SB-200TG - Thermo King

SB-200TG - Thermo King
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.
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)
©2011 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.
©2011 Ingersoll-Rand Company
Printed in U.S.A.
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)
Copyright© 2007 Thermo King Corp., Minneapolis, MN, USA
Printed in USA
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)
Copyright© 2007 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. If you have questions or require further
information, please contact your local Thermo King dealer.
The procedures described herein should be undertaken only by 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.
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. If you have questions or require further
information, please contact your local Thermo King dealer.
The procedures described herein should be undertaken only by qualified personnel. Failure to implement
these procedures correctly may cause damage to the Thermo King unit or other property or personal
injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or any
other direct, indirect, special or consequential damage or liability whatsoever, arising out of or resulting
from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo King
unit.
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . 11
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . 12
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 13
Safety Decals And Locations . . . . . . . . . . . . . . . . . . . 14
EPA Emission Control System
Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . .17
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Thermo King Corporation Responsibilities . . . . . .18
Owner Responsibilities . . . . . . . . . . . . . . . . . . . . .19
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .23
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Thermo King X430L Compressor . . . . . . . . . . . . . . . .24
3
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . 11
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . 12
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 13
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 13
Safety Decals And Locations . . . . . . . . . . . . . . . . . . . 14
EPA Emission Control System
Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . .17
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Thermo King Corporation Responsibilities . . . . . .18
Owner Responsibilities . . . . . . . . . . . . . . . . . . . . .19
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .23
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Thermo King X430L Compressor . . . . . . . . . . . . . . . .24
3
Table of Contents
TG-VI Microprocessor Controller . . . . . . . . . . . . . . . . . 25
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . 27
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DAS (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . . 29
Opening the Secondary Door Latch . . . . . . . . . . . 29
Closing the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine Compartment Components . . . . . . . . . . . . . . . 31
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . 32
TG-VI Controller Description . . . . . . . . . . . . . . . . . . 35
TG-VI Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Upper and Lower Display . . . . . . . . . . . . . . . . . . . 37
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Remote Status Light (Optional) . . . . . . . . . . . . . . . . 43
Manual Pretrip Inspection
(Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . . 45
Unit Operation with TG-VI Controller . . . . . . . . . . .
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . .
Starting the Unit with a Unit Self Check Test . . . . . . .
Displaying Operating Data During Normal Operation
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . .
Selection of Operating Modes . . . . . . . . . . . . . . . . . .
Selecting CYCLE-SENTRY or Continuous Mode . . .
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . .
Checking Software Revision . . . . . . . . . . . . . . . . . . .
Printing a Trip Report . . . . . . . . . . . . . . . . . . . . . . . . .
Initiating a Start of Trip . . . . . . . . . . . . . . . . . . . . . . . .
Displaying and Clearing Alarm Codes . . . . . . . . . . . .
47
48
48
49
50
52
53
54
55
56
57
58
60
61
Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Code 84 (Restart Null) . . . . . . . . . . . . . . . . . . .
Alarm Code 85 (Forced Unit Operation) . . . . . . . . . . .
Table of Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . .
63
63
63
64
64
65
65
66
Unit Operation with TG-VI Controller . . . . . . . . . . .
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . .
Starting the Unit with a Unit Self Check Test . . . . . . .
Displaying Operating Data During Normal Operation
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . .
Selection of Operating Modes . . . . . . . . . . . . . . . . . .
Selecting CYCLE-SENTRY or Continuous Mode . . .
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . .
Checking Software Revision . . . . . . . . . . . . . . . . . . .
Printing a Trip Report . . . . . . . . . . . . . . . . . . . . . . . . .
Initiating a Start of Trip . . . . . . . . . . . . . . . . . . . . . . . .
Displaying and Clearing Alarm Codes . . . . . . . . . . . .
47
48
48
49
50
52
53
54
55
56
57
58
60
61
Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Code 84 (Restart Null) . . . . . . . . . . . . . . . . . . .
Alarm Code 85 (Forced Unit Operation) . . . . . . . . . . .
Table of Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . .
63
63
63
64
64
65
65
66
4
Table of Contents
TG-VI Microprocessor Controller . . . . . . . . . . . . . . . . . 25
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . 27
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DAS (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . . 29
Opening the Secondary Door Latch . . . . . . . . . . . 29
Closing the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine Compartment Components . . . . . . . . . . . . . . . 31
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . 32
TG-VI Controller Description . . . . . . . . . . . . . . . . . . 35
TG-VI Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Upper and Lower Display . . . . . . . . . . . . . . . . . . . 37
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Remote Status Light (Optional) . . . . . . . . . . . . . . . . 43
Manual Pretrip Inspection
(Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . . 45
4
Table of Contents
Loading and Enroute Inspections . . . . . . . . . . . . . .
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . .
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . .
83
83
85
86
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Serial Number Locations . . . . . . . . . . . . . . . . . . . . .113
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Control System . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . .
93
93
95
95
96
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . .117
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . .118
California Proposition 65 Warning . . . . . . . . . . . . .119
Maintenance Inspection Schedule . . . . . . . . . . . . . 97
5
Table of Contents
Loading and Enroute Inspections . . . . . . . . . . . . . .
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . .
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . .
83
83
85
86
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Serial Number Locations . . . . . . . . . . . . . . . . . . . . .113
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Control System . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . .
93
93
95
95
96
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . .117
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . .118
California Proposition 65 Warning . . . . . . . . . . . . .119
Maintenance Inspection Schedule . . . . . . . . . . . . . 97
5
Table of Contents
6
Table of Contents
6
List of Figures
Figure 1:Belt Warning
(Located on condenser housing) . . . . . . . . . . . . . . . . 14
Figure 2:Belt Replacement Caution
(Located on condenser housing) . . . . . . . . . . . . . . . . 14
Figure 3:Automatic Start Caution. . . . . . . . . . . . . . . . . 15
Figure 4:Fan Caution . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 5:Door Latch Warning
(Located on curbside door) . . . . . . . . . . . . . . . . . . . . . 16
Figure 6:Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 7:TK486V (Tier 2) . . . . . . . . . . . . . . . . . . . . . . 23
Figure 8:Control and Switch Panels . . . . . . . . . . . . . . 25
Figure 9:Door Latch Location . . . . . . . . . . . . . . . . . . . 29
Figure 10:Opening Secondary Door Latch . . . . . . . . . 29
Figure 11:Engine Compartment . . . . . . . . . . . . . . . . . 31
Figure 12:Relay Board . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 13:TG-VI Control Panel With all Possible
Icons and Characters Displayed . . . . . . . . . . . . . . . . . 35
Figure 14:Display Screen With all Possible Icons and
Characters Displayed . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 15:Upper and Lower Displays . . . . . . . . . . . . . .37
Figure 16:Standard Display . . . . . . . . . . . . . . . . . . . . .39
Figure 17:Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 18:Remote Status Light . . . . . . . . . . . . . . . . . .43
Figure 19:TG-VI Microprocessor Controller . . . . . . . . .47
Figure 20:Control and Switch Panels . . . . . . . . . . . . . .48
Figure 21:Unit Self Check . . . . . . . . . . . . . . . . . . . . . .50
Figure 22:Standard Display . . . . . . . . . . . . . . . . . . . . .52
Figure 23:Changing the Setpoint . . . . . . . . . . . . . . . . .53
Figure 24:Selecting CYCLE-SENTRY
or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Figure 25:Initiating a Manual Defrost Cycle . . . . . . . . .56
Figure 26:Checking Software Revision . . . . . . . . . . . .57
Figure 27:Printing a Trip Report . . . . . . . . . . . . . . . . . .58
Figure 28:Initiating a Start of Trip . . . . . . . . . . . . . . . . .60
7
List of Figures
Figure 1:Belt Warning
(Located on condenser housing) . . . . . . . . . . . . . . . . 14
Figure 2:Belt Replacement Caution
(Located on condenser housing) . . . . . . . . . . . . . . . . 14
Figure 3:Automatic Start Caution. . . . . . . . . . . . . . . . . 15
Figure 4:Fan Caution . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 5:Door Latch Warning
(Located on curbside door) . . . . . . . . . . . . . . . . . . . . . 16
Figure 6:Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 7:TK486V (Tier 2) . . . . . . . . . . . . . . . . . . . . . . 23
Figure 8:Control and Switch Panels . . . . . . . . . . . . . . 25
Figure 9:Door Latch Location . . . . . . . . . . . . . . . . . . . 29
Figure 10:Opening Secondary Door Latch . . . . . . . . . 29
Figure 11:Engine Compartment . . . . . . . . . . . . . . . . . 31
Figure 12:Relay Board . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 13:TG-VI Control Panel With all Possible
Icons and Characters Displayed . . . . . . . . . . . . . . . . . 35
Figure 14:Display Screen With all Possible Icons and
Characters Displayed . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 15:Upper and Lower Displays . . . . . . . . . . . . . .37
Figure 16:Standard Display . . . . . . . . . . . . . . . . . . . . .39
Figure 17:Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 18:Remote Status Light . . . . . . . . . . . . . . . . . .43
Figure 19:TG-VI Microprocessor Controller . . . . . . . . .47
Figure 20:Control and Switch Panels . . . . . . . . . . . . . .48
Figure 21:Unit Self Check . . . . . . . . . . . . . . . . . . . . . .50
Figure 22:Standard Display . . . . . . . . . . . . . . . . . . . . .52
Figure 23:Changing the Setpoint . . . . . . . . . . . . . . . . .53
Figure 24:Selecting CYCLE-SENTRY
or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Figure 25:Initiating a Manual Defrost Cycle . . . . . . . . .56
Figure 26:Checking Software Revision . . . . . . . . . . . .57
Figure 27:Printing a Trip Report . . . . . . . . . . . . . . . . . .58
Figure 28:Initiating a Start of Trip . . . . . . . . . . . . . . . . .60
7
List of Figures
Figure 29:Alarm Symbol Location . . . . . . . . . . . . . . . . 61
Figure 30:Loading Considerations . . . . . . . . . . . . . . . . 84
Figure 31:Unit Battery . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 32:Sequence for Connecting Jumper Cables . . 90
Figure 33:Unit Engine . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 34:Sequence for Disconnecting
Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 35:Compressor Serial Number Location . . . .
Figure 36:Engine Serial Number Location . . . . . . . .
Figure 37:Unit Serial Number Plate Locations . . . . .
Figure 38:Unit Serial Number Plate . . . . . . . . . . . . .
113
114
114
115
Figure 35:Compressor Serial Number Location . . . .
Figure 36:Engine Serial Number Location . . . . . . . .
Figure 37:Unit Serial Number Plate Locations . . . . .
Figure 38:Unit Serial Number Plate . . . . . . . . . . . . .
113
114
114
115
8
List of Figures
Figure 29:Alarm Symbol Location . . . . . . . . . . . . . . . . 61
Figure 30:Loading Considerations . . . . . . . . . . . . . . . . 84
Figure 31:Unit Battery . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 32:Sequence for Connecting Jumper Cables . . 90
Figure 33:Unit Engine . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 34:Sequence for Disconnecting
Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8
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.
9
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.
9
Introduction
10
Introduction
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
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: CYCLE-SENTRY Operation. The unit
can start at any time when the unit On/Off switch is
in the on position and the unit is operating in
CYCLE-SENTRY.
WARNING: Turn the unit On/Off switch to the Off
position before inspecting any part of the unit.
Electrical Hazard
CAUTION: Turn off the high voltage power supply
and disconnect the electric cable before working on
the unit. Units with electric standby present a
potential electrical hazard.
Refrigerant
Although fluorocarbon refrigerants are classified as safe, 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.
12
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: CYCLE-SENTRY Operation. The unit
can start at any time when the unit On/Off switch is
in the on position and the unit is operating in
CYCLE-SENTRY.
WARNING: Turn the unit On/Off switch to the Off
position before inspecting any part of the unit.
Electrical Hazard
CAUTION: Turn off the high voltage power supply
and disconnect the electric cable before working on
the unit. Units with electric standby present a
potential electrical hazard.
Refrigerant
Although fluorocarbon refrigerants are classified as safe, 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.
12
Safety Precautions
WARNING: Fluorocarbon refrigerants evaporate
rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.
Refrigerant Oil
Observe the following precautions when working with or
around refrigerant oil:
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact.
WARNING: Protect skin and clothing from
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended.
WARNING: Wash thoroughly immediately after
handling refrigerant oil to prevent irritation.
First Aid
First Aid–Refrigerant
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
First Aid–Refrigerant Oil
Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
13
Safety Precautions
WARNING: Fluorocarbon refrigerants evaporate
rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.
Refrigerant Oil
Observe the following precautions when working with or
around refrigerant oil:
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact.
WARNING: Protect skin and clothing from
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended.
WARNING: Wash thoroughly immediately after
handling refrigerant oil to prevent irritation.
First Aid
First Aid–Refrigerant
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
First Aid–Refrigerant Oil
Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
13
Safety Precautions
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
Safety Decals And Locations
AKB65
Figure 1: Belt Warning
(Located on condenser housing)
AKB66
Figure 2: Belt Replacement Caution
(Located on condenser housing)
14
Safety Precautions
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
Safety Decals And Locations
AKB65
Figure 1: Belt Warning
(Located on condenser housing)
AKB66
Figure 2: Belt Replacement Caution
(Located on condenser housing)
14
Safety Precautions
AKB67
Figure 3: Automatic Start Caution
(Locations vary depending on model. Decals are
located near areas that contain moving parts which
can cause severe injuries if hands or clothing become
tangled when unit automatically starts.)
AKB68
Figure 4: Fan Caution
(Locations vary depending on model. Decals are
located near areas that contain fans which can cause
severe injuries when unit automatically starts.)
15
Safety Precautions
AKB67
Figure 3: Automatic Start Caution
(Locations vary depending on model. Decals are
located near areas that contain moving parts which
can cause severe injuries if hands or clothing become
tangled when unit automatically starts.)
AKB68
Figure 4: Fan Caution
(Locations vary depending on model. Decals are
located near areas that contain fans which can cause
severe injuries when unit automatically starts.)
15
Safety Precautions
WARNING
NEW DOOR LATCH DESIGN
REQUIRES DOOR TO BE SLAMMED
SHUT BEFORE MOVING TRAILER.
FAILURE TO CLOSE DOOR FIRMLY
CAN ALLOW WIND TO TEAR DOOR
FROM REFRIGERATION UNIT AND
CAUSE INJURY TO OTHERS.
ATENCIÓN
NUEVO DESEÑO DE CERRADURA
REQUIERE ASOTAR LA PUERTA ANTES
DE CONDUCIR EL TRAILER.
AL NO CERRAR LA PUERTA CON
FIRMEZA EL VIENTO PODRÍA
DESPRENDER LA PUERTA DE LA
UNIDAD DE REFRIGERACIÓN Y
CAUSAR DAÑOS A OTROS.
AEA2422
Figure 5: Door Latch Warning
(Located on curbside door)
16
Safety Precautions
WARNING
NEW DOOR LATCH DESIGN
REQUIRES DOOR TO BE SLAMMED
SHUT BEFORE MOVING TRAILER.
FAILURE TO CLOSE DOOR FIRMLY
CAN ALLOW WIND TO TEAR DOOR
FROM REFRIGERATION UNIT AND
CAUSE INJURY TO OTHERS.
ATENCIÓN
NUEVO DESEÑO DE CERRADURA
REQUIERE ASOTAR LA PUERTA ANTES
DE CONDUCIR EL TRAILER.
AL NO CERRAR LA PUERTA CON
FIRMEZA EL VIENTO PODRÍA
DESPRENDER LA PUERTA DE LA
UNIDAD DE REFRIGERACIÓN Y
CAUSAR DAÑOS A OTROS.
Figure 5: Door Latch Warning
(Located on curbside door)
16
AEA2422
EPA Emission Control System Warranty
Statement
Thermo King warrants to the initial owner and each subsequent
owner that the certified, non-road diesel engine in your unit is:
1.
Designed, built and equipped so as to conform, at the time
of sale, with all applicable regulations adopted by the
United States Environmental Protection Agency (EPA).
2.
Free from defects in materials and workmanship in
specific emission related parts for a period of five years or
3,000 hours of operation, whichever comes first, after date
of delivery to the initial owner.
If an emission-related part or component fails during the
warranty period, it will be repaired or replaced. Any such part
or component repaired or replaced under warranty is warranted
for the warranty period.
During the term of this warranty, Thermo King will provide,
through a Thermo King authorized service dealer or other
establishment authorized by Thermo King, repair or
replacement of any warranted part at no charge to the non-road
engine owner.
In emergency, repairs may be performed at any service
establishment, or by the owner, using any replacement part.
Thermo King will reimburse the owner for their expenses,
including diagnostic charges for such emergency repair. These
expenses shall not exceed Thermo King’s suggested retail price
for all warranted parts replaced, and labor changes based on
Thermo King’s recommended time allowance for the warranty
repair and the geographically appropriate hourly labor rate.
17
EPA Emission Control System Warranty
Statement
Thermo King warrants to the initial owner and each subsequent
owner that the certified, non-road diesel engine in your unit is:
1.
Designed, built and equipped so as to conform, at the time
of sale, with all applicable regulations adopted by the
United States Environmental Protection Agency (EPA).
2.
Free from defects in materials and workmanship in
specific emission related parts for a period of five years or
3,000 hours of operation, whichever comes first, after date
of delivery to the initial owner.
If an emission-related part or component fails during the
warranty period, it will be repaired or replaced. Any such part
or component repaired or replaced under warranty is warranted
for the warranty period.
During the term of this warranty, Thermo King will provide,
through a Thermo King authorized service dealer or other
establishment authorized by Thermo King, repair or
replacement of any warranted part at no charge to the non-road
engine owner.
In emergency, repairs may be performed at any service
establishment, or by the owner, using any replacement part.
Thermo King will reimburse the owner for their expenses,
including diagnostic charges for such emergency repair. These
expenses shall not exceed Thermo King’s suggested retail price
for all warranted parts replaced, and labor changes based on
Thermo King’s recommended time allowance for the warranty
repair and the geographically appropriate hourly labor rate.
17
EPA Emission Control System Warranty Statement
Any replacement part can be used for maintenance or repairs.
The owner should ensure that such parts are equivalent in
design and durability to genuine Thermo King parts. However,
Thermo King is not liable for parts that are not genuine
Thermo King parts.
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency.
As a condition of reimbursement, replaced parts and received
invoices must be presented at a place of business of a Thermo
King authorized service dealer or other establishment
authorized by Thermo King.
If failure of one of these parts or components results in failure
of another part or component, both will be covered by this
warranty.
Responsibilities
This warranty is subject to the following:
Thermo King Corporation
Responsibilities
This warranty covers the following emission-related parts and
components:
During the emission warranty period, if a defect in material or
workmanship of a warranted part or component is found,
Thermo King will provide:
•
Fuel Injection System
•
•
Intake Manifold
•
Exhaust Manifold
•
Miscellaneous hoses, clamps, connectors and sealing
devices used in the above systems.
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.
18
EPA Emission Control System Warranty Statement
Any replacement part can be used for maintenance or repairs.
The owner should ensure that such parts are equivalent in
design and durability to genuine Thermo King parts. However,
Thermo King is not liable for parts that are not genuine
Thermo King parts.
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency.
As a condition of reimbursement, replaced parts and received
invoices must be presented at a place of business of a Thermo
King authorized service dealer or other establishment
authorized by Thermo King.
If failure of one of these parts or components results in failure
of another part or component, both will be covered by this
warranty.
Responsibilities
This warranty is subject to the following:
Thermo King Corporation
Responsibilities
This warranty covers the following emission-related parts and
components:
During the emission warranty period, if a defect in material or
workmanship of a warranted part or component is found,
Thermo King will provide:
•
Fuel Injection System
•
•
Intake Manifold
•
Exhaust Manifold
•
Miscellaneous hoses, clamps, connectors and sealing
devices used in the above systems.
18
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.
EPA Emission Control System Warranty Statement
Owner Responsibilities
•
During the emission warranty period, the owner is responsible
for:
Attachments, accessory items, or parts not authorized for
use by Thermo King.
•
Improper off-road engine maintenance, repair or abuse.
•
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.
•
Owner’s unreasonable delay in making the product
available after being notified of a potential product
problem.
•
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.
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.
This warranty is in addition to Thermo King’s standard
warranty applicable to the off-road engine product involved.
Limitations
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
•
Any application or installation Thermo King deems
improper as explained in this Operator’s Manual, or any
other manuals provided for the unit.
19
EPA Emission Control System Warranty Statement
Owner Responsibilities
•
During the emission warranty period, the owner is responsible
for:
Attachments, accessory items, or parts not authorized for
use by Thermo King.
•
Improper off-road engine maintenance, repair or abuse.
•
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.
•
Owner’s unreasonable delay in making the product
available after being notified of a potential product
problem.
•
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.
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.
This warranty is in addition to Thermo King’s standard
warranty applicable to the off-road engine product involved.
Limitations
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
•
Any application or installation Thermo King deems
improper as explained in this Operator’s Manual, or any
other manuals provided for the unit.
19
EPA Emission Control System Warranty Statement
20
EPA Emission Control System Warranty Statement
20
Unit Description
Unit Overview
The Thermo King SB-200TG is a one piece, self-contained,
diesel powered, air cooling/heating unit operating under the
control of a TG-VI programmable microprocessor controller.
The unit mounts on the front of the trailer with the evaporator
extending through an opening in the front wall.
The unit is available as a Model 30 and features cooling and
heating using a quiet running Thermo King TK486V engine.
Figure 6: Front View
21
Unit Description
Unit Overview
The Thermo King SB-200TG is a one piece, self-contained,
diesel powered, air cooling/heating unit operating under the
control of a TG-VI programmable microprocessor controller.
The unit mounts on the front of the trailer with the evaporator
extending through an opening in the front wall.
The unit is available as a Model 30 and features cooling and
heating using a quiet running Thermo King TK486V engine.
Figure 6: Front View
21
Unit Description
Design Features
Key Features & Options
The following chart lists key design features and options.
EMI-3000
●
●
High-Capacity Condenser Coil
●
❍ Option/Factory installed
Easy-Access Door Design
●
❏ Option/Dealer Installed
Composite Exterior Panels
●
Long-Life Coolant/Silicone Hoses
●
Standard Unit Color White
●
Standard Grille Color Black
●
Directional Air Delivery
●
Vibration Isolation System
●
Aluminum Undermount Fuel Tank 50 Gal.
(186 Liter)
●
Standard Features
DAS Data Logger
Remote Status Light
SB-200TG
❍ /❏
❏
22
Unit Description
Design Features
Key Features & Options
The following chart lists key design features and options.
EMI-3000
●
●
High-Capacity Condenser Coil
●
❍ Option/Factory installed
Easy-Access Door Design
●
❏ Option/Dealer Installed
Composite Exterior Panels
●
Long-Life Coolant/Silicone Hoses
●
Standard Unit Color White
●
Standard Grille Color Black
●
Directional Air Delivery
●
Vibration Isolation System
●
Aluminum Undermount Fuel Tank 50 Gal.
(186 Liter)
●
Standard Features
DAS Data Logger
Remote Status Light
22
SB-200TG
❍ /❏
❏
Unit Description
Diesel Engine
ELC (Extended Life Coolant)
The unit uses a quiet running TK486V (Tier 2), which is a
4-cylinder, water cooled, direct injection diesel engine. The
engine is coupled directly to the compressor. Belts transmit
power to the unit fans, alternator and water pump.
ELC (Extended Life Coolant) is standard equipment. The
maintenance interval for ELC is five years or 12,000 hours. A
nameplate on the coolant expansion tank identifies units with
ELC (see “Safety Decals and Locations”). The new engine
coolant, Chevron Extended Life Coolant, is RED in color
instead of the previous GREEN or BLUE-GREEN colored
conventional coolants.
CAUTION: Do not add “GREEN” or
“BLUE-GREEN” conventional coolant to cooling
systems using “RED” Extended Life Coolant, except
in an emergency. If conventional coolant is added to
Extended Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to assure that de-ionized water is being used. If 100% full
strength concentrate is used, de-ionized or distilled water is
recommended instead of tap water to insure the integrity of
the cooling system is maintained.
Figure 7: TK486V (Tier 2)
23
Unit Description
Diesel Engine
ELC (Extended Life Coolant)
The unit uses a quiet running TK486V (Tier 2), which is a
4-cylinder, water cooled, direct injection diesel engine. The
engine is coupled directly to the compressor. Belts transmit
power to the unit fans, alternator and water pump.
ELC (Extended Life Coolant) is standard equipment. The
maintenance interval for ELC is five years or 12,000 hours. A
nameplate on the coolant expansion tank identifies units with
ELC (see “Safety Decals and Locations”). The new engine
coolant, Chevron Extended Life Coolant, is RED in color
instead of the previous GREEN or BLUE-GREEN colored
conventional coolants.
CAUTION: Do not add “GREEN” or
“BLUE-GREEN” conventional coolant to cooling
systems using “RED” Extended Life Coolant, except
in an emergency. If conventional coolant is added to
Extended Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to assure that de-ionized water is being used. If 100% full
strength concentrate is used, de-ionized or distilled water is
recommended instead of tap water to insure the integrity of
the cooling system is maintained.
Figure 7: TK486V (Tier 2)
23
Unit Description
EMI 3000
Thermo King X430L Compressor
EMI 3000 is an extended maintenance interval package. It is
standard equipment. The EMI 3000 package consists of the
following key components:
The unit is equipped with a Thermo King X430L, four-cylinder
compressor with 30 cu. in. (492 cm3) displacement. The unit is
also equipped with a compressor oil filter.
•
New EMI 3000-Hour Cyclonic Air Cleaner Assembly and
Air Cleaner Element
•
New EMI 3000-Hour Fuel Filter (black with gold
lettering)
•
New EMI 3000-Hour Dual Element Oil Filter (black with
gold lettering)
•
API Rating CI-4 Mineral Oil
•
Five Year or 12,000 Hour ELC (Extended Life Coolant)
The EMI package allows standard maintenance intervals to be
extended to 3,000 hours, or 2 years, whichever occurs first.
NOTE: Units equipped with the EMI 3000 package do
require regular inspection in accordance with Thermo King's
maintenance recommendations.
NOTE: The new EMI 3000 oil filters and new EMI 3000 air
cleaners are NOT interchangeable with the older style oil
filters and air cleaners.
24
Unit Description
EMI 3000
Thermo King X430L Compressor
EMI 3000 is an extended maintenance interval package. It is
standard equipment. The EMI 3000 package consists of the
following key components:
The unit is equipped with a Thermo King X430L, four-cylinder
compressor with 30 cu. in. (492 cm3) displacement. The unit is
also equipped with a compressor oil filter.
•
New EMI 3000-Hour Cyclonic Air Cleaner Assembly and
Air Cleaner Element
•
New EMI 3000-Hour Fuel Filter (black with gold
lettering)
•
New EMI 3000-Hour Dual Element Oil Filter (black with
gold lettering)
•
API Rating CI-4 Mineral Oil
•
Five Year or 12,000 Hour ELC (Extended Life Coolant)
The EMI package allows standard maintenance intervals to be
extended to 3,000 hours, or 2 years, whichever occurs first.
NOTE: Units equipped with the EMI 3000 package do
require regular inspection in accordance with Thermo King's
maintenance recommendations.
NOTE: The new EMI 3000 oil filters and new EMI 3000 air
cleaners are NOT interchangeable with the older style oil
filters and air cleaners.
24
Unit Description
TG-VI Microprocessor Controller
1
2
Thermo King has applied the newest technological advances to
develop a programmable microprocessor controller that
controls unit functioning and displays operating information
quickly and accurately.
ANA03
Features include:
3
Thermometer: Displays return air temperature with 0.1
degree accuracy.
4
Thermostat: Provides temperature control from -20 to 80 F
(- 28 to 27 C) in 1.0 degree increments.
6
Defrost Control: The controller is programmed to
automatically initiate timed or demand defrost cycles. The
operator can also manually initiate a defrost cycle. See
“Defrost” on page 27.
Alarm: Can detect and display alarm conditions. Refer to the
Operating and Alarm Codes Sections later in this manual.
COMPUTER
PRINTER
5
AJA1070
1.
Control Panel
4.
Computer Port (Optional)
2.
Display
5.
Printer Port (Optional)
3.
Keypad
6.
On/Off Switch
Figure 8: Control and Switch Panels
25
Unit Description
TG-VI Microprocessor Controller
1
2
Thermo King has applied the newest technological advances to
develop a programmable microprocessor controller that
controls unit functioning and displays operating information
quickly and accurately.
ANA03
Features include:
3
Thermometer: Displays return air temperature with 0.1
degree accuracy.
4
Thermostat: Provides temperature control from -20 to 80 F
(- 28 to 27 C) in 1.0 degree increments.
6
Defrost Control: The controller is programmed to
automatically initiate timed or demand defrost cycles. The
operator can also manually initiate a defrost cycle. See
“Defrost” on page 27.
Alarm: Can detect and display alarm conditions. Refer to the
Operating and Alarm Codes Sections later in this manual.
COMPUTER
PRINTER
5
AJA1070
1.
Control Panel
4.
Computer Port (Optional)
2.
Display
5.
Printer Port (Optional)
3.
Keypad
6.
On/Off Switch
Figure 8: Control and Switch Panels
25
Unit Description
CAUTION: Firmly close the controller access door
after operating the microprocessor controller or
before starting a trip. The control panel might be
damaged in transit if the door is not firmly closed.
In CYCLE-SENTRY Operation Mode:
•
High Speed Cool
•
Low Speed Cool
•
Null (Engine Off)
Depending on the air temperature in the trailer sensed by the
TG-VI Microprocessor Controller, the unit will operate in one
of the following modes:
•
Low Speed Heat
•
High Speed Heat
In Continuous Run Operation Mode:
•
Defrost.
•
High Speed Cool
•
Low Speed Cool
Generally, the unit will operate in low speed switching back
and forth from cooling to heating as necessary, thus controlling
the temperature in the trailer.
•
Low Speed Heat
•
High Speed Heat
•
Defrost.
On very hot days, with the setpoint at a low temperature, the
unit may cycle between high speed cool and low speed cool
without switching into a heating cycle.
On very cold days, the unit may cycle between high speed heat
and low speed heat. The unit may switch into cooling for short
periods of time.
26
Unit Description
CAUTION: Firmly close the controller access door
after operating the microprocessor controller or
before starting a trip. The control panel might be
damaged in transit if the door is not firmly closed.
In CYCLE-SENTRY Operation Mode:
•
High Speed Cool
•
Low Speed Cool
•
Null (Engine Off)
Depending on the air temperature in the trailer sensed by the
TG-VI Microprocessor Controller, the unit will operate in one
of the following modes:
•
Low Speed Heat
•
High Speed Heat
In Continuous Run Operation Mode:
•
Defrost.
•
High Speed Cool
•
Low Speed Cool
Generally, the unit will operate in low speed switching back
and forth from cooling to heating as necessary, thus controlling
the temperature in the trailer.
•
Low Speed Heat
•
High Speed Heat
•
Defrost.
On very hot days, with the setpoint at a low temperature, the
unit may cycle between high speed cool and low speed cool
without switching into a heating cycle.
On very cold days, the unit may cycle between high speed heat
and low speed heat. The unit may switch into cooling for short
periods of time.
26
Unit Description
CYCLE-SENTRY Start-Stop Controls
Defrost
The CYCLE-SENTRY Start-Stop fuel saving system provides
optimum operating economy.
Frost gradually builds-up on evaporator coils as a result of
normal operation. The unit uses hot refrigerant to defrost the
evaporator coils. 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 Manual and Automatic.
CYCLE-SENTRY automatically starts the unit on
microprocessor demand, and shuts down the unit when all
demands are satisfied.
The system automatically monitors and maintains
compartment temperatures, the engine block temperature and
battery charge levels at a point where quick, easy starts are
possible.
WARNING: Set the unit ON/OFF switch to OFF
before opening doors or inspecting any part of the
unit. With the unit ON/OFF switch in the ON position,
the unit may start at any time without warning.
Automatic Defrost: The controller is programmed to
automatically initiate timed or demand defrost cycles. Defrost
intervals are set at the factory at 2, 4 6, 8, 10, or 12 hours. The
unit can enter a demand defrost cycle as often as every 30
minutes if required.
Manual Defrost: The operator manually initiates a defrost
cycle.
NOTE: The unit will not perform a Manual Defrost cycle
unless the ON/OFF switch is set to ON, 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 (7.2 C).
27
Unit Description
CYCLE-SENTRY Start-Stop Controls
Defrost
The CYCLE-SENTRY Start-Stop fuel saving system provides
optimum operating economy.
Frost gradually builds-up on evaporator coils as a result of
normal operation. The unit uses hot refrigerant to defrost the
evaporator coils. 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 Manual and Automatic.
CYCLE-SENTRY automatically starts the unit on
microprocessor demand, and shuts down the unit when all
demands are satisfied.
The system automatically monitors and maintains
compartment temperatures, the engine block temperature and
battery charge levels at a point where quick, easy starts are
possible.
WARNING: Set the unit ON/OFF switch to OFF
before opening doors or inspecting any part of the
unit. With the unit ON/OFF switch in the ON position,
the unit may start at any time without warning.
Automatic Defrost: The controller is programmed to
automatically initiate timed or demand defrost cycles. Defrost
intervals are set at the factory at 2, 4 6, 8, 10, or 12 hours. The
unit can enter a demand defrost cycle as often as every 30
minutes if required.
Manual Defrost: The operator manually initiates a defrost
cycle.
NOTE: The unit will not perform a Manual Defrost cycle
unless the ON/OFF switch is set to ON, 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 (7.2 C).
27
Unit Description
DAS (Optional)
The DAS (Data Acquisition System) is an independent data
logger that logs information from dedicated external DAS
sensors and inputs. The DAS features (up to six) directly
connected sensors. The DAS is also connected through a serial
port to the unit microprocessor. Sensor readings can be viewed
on the microprocessor keyboard panel using the SELECT key.
See “Figure 8: Control and Switch Panels,” on page 25. The
DAS allows unit operating information, operating events,
alarm codes and compartment temperatures to be logged as
well. The data can be retrieved using an IBM® PC compatible
laptop or desktop computer and Thermo King WinTrac 4.1 (or
higher) software. The computer is connected to the computer
port on the front of the control box. See “Figure 8: Control and
Switch Panels,” on page 25. Detailed graph or table trip reports
can then be created.
A hand-held printer can be connected to the printer port on the
front of the control box to print out the DAS sensor readings.
Refer to the DAS Data Acquisition System Manual TK 50565
for more information.
28
Unit Description
DAS (Optional)
The DAS (Data Acquisition System) is an independent data
logger that logs information from dedicated external DAS
sensors and inputs. The DAS features (up to six) directly
connected sensors. The DAS is also connected through a serial
port to the unit microprocessor. Sensor readings can be viewed
on the microprocessor keyboard panel using the SELECT key.
See “Figure 8: Control and Switch Panels,” on page 25. The
DAS allows unit operating information, operating events,
alarm codes and compartment temperatures to be logged as
well. The data can be retrieved using an IBM® PC compatible
laptop or desktop computer and Thermo King WinTrac 4.1 (or
higher) software. The computer is connected to the computer
port on the front of the control box. See “Figure 8: Control and
Switch Panels,” on page 25. Detailed graph or table trip reports
can then be created.
A hand-held printer can be connected to the printer port on the
front of the control box to print out the DAS sensor readings.
Refer to the DAS Data Acquisition System Manual TK 50565
for more information.
28
Unit Description
Opening the Front Doors
Opening the Secondary Door Latch
Pull the door latch handle to open the door and access the
engine compartment.
These units are also equipped with a secondary door latch. A
secondary door latch nameplate is located below the front
doors. After opening the door latch, reach between the front
doors and lift the spring latch over the spring catch while
opening the door.
1
1
2
2
1.
Door Latch
2.
Secondary Door Latch Nameplate
Figure 9: Door Latch Location
1.
Spring Latch
2.
Spring Catch
Figure 10: Opening Secondary Door Latch
29
Unit Description
Opening the Front Doors
Opening the Secondary Door Latch
Pull the door latch handle to open the door and access the
engine compartment.
These units are also equipped with a secondary door latch. A
secondary door latch nameplate is located below the front
doors. After opening the door latch, reach between the front
doors and lift the spring latch over the spring catch while
opening the door.
1
1
2
2
1.
Door Latch
2.
Secondary Door Latch Nameplate
Figure 9: Door Latch Location
1.
Spring Latch
2.
Spring Catch
Figure 10: Opening Secondary Door Latch
29
Unit Description
Closing the Front Doors
Slam the door to close it. Do not push the door closed while
holding the door latch handle open or the door will not close
properly.
30
Unit Description
Closing the Front Doors
Slam the door to close it. Do not push the door closed while
holding the door latch handle open or the door will not close
properly.
30
Unit Description
Engine Compartment Components
1
2
The following maintenance items can be checked visually.
WARNING: The unit can start at any time without
warning. Place the On/Off switch in the Off position
before inspecting any part of the unit.
Air Filter Restriction Indicator: The air filter restriction
indicator is attached to the engine intake manifold. When the
diaphragm indicates 25, service the air filter. Press the button
on the top of the restriction indicator to reset after servicing the
air cleaner.
4
1.
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.
3
Engine Oil Dipstick: Use the engine oil dipstick to check
the engine oil level.
Air Filter Restriction Indicator
2.
Receiver Tank Sight Glass
3.
Engine Oil Dipstick
4.
Compressor Oil Sight Glass
CAUTION: Make sure the engine is turned off before
attempting to check the engine oil.
Figure 11: Engine Compartment
31
Unit Description
Engine Compartment Components
1
2
The following maintenance items can be checked visually.
WARNING: The unit can start at any time without
warning. Place the On/Off switch in the Off position
before inspecting any part of the unit.
Air Filter Restriction Indicator: The air filter restriction
indicator is attached to the engine intake manifold. When the
diaphragm indicates 25, service the air filter. Press the button
on the top of the restriction indicator to reset after servicing the
air cleaner.
4
1.
3
Air Filter Restriction Indicator
2.
Receiver Tank Sight Glass
3.
Engine Oil Dipstick
4.
Compressor Oil Sight Glass
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.
Figure 11: Engine Compartment
31
Unit Description
Receiver Tank Sight Glass: This sight glass indicates the
level of refrigerant in the receiver tank.
Operate the unit in high speed cool for approximately 15
minutes to stabilize operating conditions and temperature
before attempting to check the refrigerant.
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.
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.
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.
Unit Protection Devices
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.
Fuse Link (Current Limiter): The fuse link is located in the
positive battery cable. The fuse link protects the electric
system from a short. If the fuse link burns out, replace it by
replacing the positive battery cable.
Preheat Buzzer: The preheat buzzer sounds when the
controller energizes the preheat relay. This warns anyone near
the unit that the controller is about to start the engine.
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.
32
Unit Description
Receiver Tank Sight Glass: This sight glass indicates the
level of refrigerant in the receiver tank.
Operate the unit in high speed cool for approximately 15
minutes to stabilize operating conditions and temperature
before attempting to check the refrigerant.
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.
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.
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.
Unit Protection Devices
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.
Fuse Link (Current Limiter): The fuse link is located in the
positive battery cable. The fuse link protects the electric
system from a short. If the fuse link burns out, replace it by
replacing the positive battery cable.
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.
32
Preheat Buzzer: The preheat buzzer sounds when the
controller energizes the preheat relay. This warns anyone near
the unit that the controller is about to start the engine.
Unit Description
Fuses: A number of fuses, located on the relay board, protect
various circuits and components. Not all of the fused circuits
and components are used in this system. The relay board (see
Figure 12 on page 34) is located inside the control box. Refer
to TK 53687 the TG-VIc Diagnostic Manual for more
information about the fuses.
Fuse
Size
Function
F1
2A
High Speed Relay
F2
2A
Defrost Relay
F3
15A
Damper Solenoid/Motor
F4
2A
Run Relay
F5
2A
Hot Gas Solenoid
F6
2A
Pilot Solenoid
F7
2A
Starter Relay
F8
2A
Preheat Relay
F9
40A
#2 Circuit
F10
2A
Cool Light/Damper Motor Heater
F11
2A
VHN (Ammeter Shunt)
Fuse
Size
F12
2A
Data Logger
F13
2A
VHP (Ammeter Shunt)
F14
2A
High Speed Light
F15
Function
None No Fuse - All Thermo King and Bosch
Alternators
2A 2A Fuse - All Prestolite Alternators
F16
2A
Electric Motor Contactor
F17
2A
Defrost Light
F18
15A
High Speed Solenoid
F21
15A
#8F Circuit
F22
2A
Electric Heater Contactor
F25
2A
Cycle-Sentry Light
F26
2A
Emergency Heat
F27
2A
Spare Fuse
F28
15A
Spare Fuse
F29
30A
Spare Fuse
F30
40A
Spare Fuse
33
Unit Description
Fuses: A number of fuses, located on the relay board, protect
various circuits and components. Not all of the fused circuits
and components are used in this system. The relay board (see
Figure 12 on page 34) is located inside the control box. Refer
to TK 53687 the TG-VIc Diagnostic Manual for more
information about the fuses.
Fuse
Size
Function
F1
2A
High Speed Relay
F2
2A
Defrost Relay
F3
15A
Damper Solenoid/Motor
F4
2A
Run Relay
F5
2A
Hot Gas Solenoid
F6
2A
Pilot Solenoid
F7
2A
Starter Relay
F8
2A
Preheat Relay
F9
40A
#2 Circuit
F10
2A
Cool Light/Damper Motor Heater
F11
2A
VHN (Ammeter Shunt)
Fuse
Size
F12
2A
Data Logger
F13
2A
VHP (Ammeter Shunt)
F14
2A
High Speed Light
F15
Function
None No Fuse - All Thermo King and Bosch
Alternators
2A 2A Fuse - All Prestolite Alternators
F16
2A
Electric Motor Contactor
F17
2A
Defrost Light
F18
15A
High Speed Solenoid
F21
15A
#8F Circuit
F22
2A
Electric Heater Contactor
F25
2A
Cycle-Sentry Light
F26
2A
Emergency Heat
F27
2A
Spare Fuse
F28
15A
Spare Fuse
F29
30A
Spare Fuse
F30
40A
Spare Fuse
33
Unit Description
Fuse
Size
Function
F31
2A
Modulation
F32
2A
Remote Lights
F33
2A
Oil Level Switch/ Door Switch
F34
2A
Emergency Run
F35
2A
Pilot Solenoid
F36
30A
Main Power Fuse
F37
30A
Main Power Fuse
AJA1069
Figure 12: Relay Board
34
Unit Description
Fuse
Size
Function
F31
2A
Modulation
F32
2A
Remote Lights
F33
2A
Oil Level Switch/ Door Switch
F34
2A
Emergency Run
F35
2A
Pilot Solenoid
F36
30A
Main Power Fuse
F37
30A
Main Power Fuse
AJA1069
Figure 12: Relay Board
34
TG-VI Controller Description
TG-VI Overview
1
2
ANA03
1.
2.
Display Screen
Keypad
Figure 13: TG-VI Control Panel With all Possible Icons
and Characters Displayed
This unit is controlled by a ThermoGuard TG-VI
microprocessor. The TG-VI control panel consists of a display
screen and a keypad. The TG-VI control panel is shown in
Figure 13. This display shows all possible icons and characters.
Not all icons and characters will be displayed at the same time
in normal operation.
Unit operation is as simple as turning it on and entering a
setpoint. You can also:
•
Initiate a manual defrost cycle
•
Change the thermostat setpoint
•
Change operating modes
•
Check gauges, hourmeters, and alarm codes
•
Run a unit self check.
Several other functions are also available. This chapter
describes the TG-VI control panel. For operating procedures,
see “Unit Operation” in this manual.
35
001
TG-VI Controller Description
TG-VI Overview
1
2
ANA03
1.
2.
Display Screen
Keypad
Figure 13: TG-VI Control Panel With all Possible Icons
and Characters Displayed
001
This unit is controlled by a ThermoGuard TG-VI
microprocessor. The TG-VI control panel consists of a display
screen and a keypad. The TG-VI control panel is shown in
Figure 13. This display shows all possible icons and characters.
Not all icons and characters will be displayed at the same time
in normal operation.
Unit operation is as simple as turning it on and entering a
setpoint. You can also:
•
Initiate a manual defrost cycle
•
Change the thermostat setpoint
•
Change operating modes
•
Check gauges, hourmeters, and alarm codes
•
Run a unit self check.
Several other functions are also available. This chapter
describes the TG-VI control panel. For operating procedures,
see “Unit Operation” in this manual.
35
TG-VI Controller Description
IMPORTANT: To prevent damage to the controller, always
push the controller access door firmly closed.
1
Display Screen
The display screen indicates operating status, including
temperature, setpoint, mode, alarm codes, and other
information depending on the unit status. The display consists
of an upper and lower display in the center and icons around
the edges. The display shown here is displaying all possible
icons and characters. Not all icons and characters will be
displayed at the same time in normal operation.
The default display is called the Standard Display. See “Figure
16: Standard Display,” on page 39. The upper and lower
displays, the icons, the Standard Display, and other display
screens are described later in this section.
2
9
8
3
7
4
6
5
ANA03
1.
2.
3.
4.
5.
Upper Display
CYCLE-SENTRY Icon
Alarm Icon
Electric Icon
Setpoint Icon
6.
7.
8.
9.
Lower Display
Defrost Icon
Heat Icon
Cool Icon
Figure 14: Display Screen With all Possible Icons and
Characters Displayed
36
TG-VI Controller Description
IMPORTANT: To prevent damage to the controller, always
push the controller access door firmly closed.
1
Display Screen
The display screen indicates operating status, including
temperature, setpoint, mode, alarm codes, and other
information depending on the unit status. The display consists
of an upper and lower display in the center and icons around
the edges. The display shown here is displaying all possible
icons and characters. Not all icons and characters will be
displayed at the same time in normal operation.
The default display is called the Standard Display. See “Figure
16: Standard Display,” on page 39. The upper and lower
displays, the icons, the Standard Display, and other display
screens are described later in this section.
2
9
8
3
7
4
6
5
ANA03
1.
2.
3.
4.
5.
Upper Display
CYCLE-SENTRY Icon
Alarm Icon
Electric Icon
Setpoint Icon
6.
7.
8.
9.
Lower Display
Defrost Icon
Heat Icon
Cool Icon
Figure 14: Display Screen With all Possible Icons and
Characters Displayed
36
TG-VI Controller Description
Upper and Lower Display
The center of the display screen has a five character row of
large digits called the upper display and a four character row of
small digits called the lower display.
1
The upper and lower displays show operating data for the
screen you are viewing.
An example of operating data would be return temperature
(upper display) and setpoint (lower display) on the Standard
Display screen. See “Figure 15: Upper and Lower Displays,”
on page 37.
2
AJA1077
1.
2.
Upper Display
Lower Display
Figure 15: Upper and Lower Displays
37
TG-VI Controller Description
Upper and Lower Display
The center of the display screen has a five character row of
large digits called the upper display and a four character row of
small digits called the lower display.
1
The upper and lower displays show operating data for the
screen you are viewing.
An example of operating data would be return temperature
(upper display) and setpoint (lower display) on the Standard
Display screen. See “Figure 15: Upper and Lower Displays,”
on page 37.
2
AJA1077
1.
2.
Upper Display
Lower Display
Figure 15: Upper and Lower Displays
37
TG-VI Controller Description
Display Icons
Lit icons indicate the operating modes of the unit and show if
alarm codes are present. They appear around the left, right, and
bottom edges of the display, and are listed here in that order.
NOTE: Not all units are equipped with all functions.
Optional functions are noted. However, all icons light up
when the unit is powered on, regardless of whether the unit
has that function.
Cool Icon: Indicates that the unit is cooling.
Heat Icon: Indicates that the unit is heating.
Defrost Icon: Indicates that the unit is
defrosting.
CYCLE-SENTRY Icon: Indicates that the
unit is in CYCLE-SENTRY mode. This
feature may be optional on some units.
Alarm Icon: Indicates that one or more
alarm conditions are present.
Setpoint Icon: Indicates that the lower
display is the setpoint temperature.
Electric Standby Icon: Indicates that the
unit is running in electric standby mode.
Model 50 unit only.
38
TG-VI Controller Description
Display Icons
Lit icons indicate the operating modes of the unit and show if
alarm codes are present. They appear around the left, right, and
bottom edges of the display, and are listed here in that order.
NOTE: Not all units are equipped with all functions.
Optional functions are noted. However, all icons light up
when the unit is powered on, regardless of whether the unit
has that function.
Cool Icon: Indicates that the unit is cooling.
Heat Icon: Indicates that the unit is heating.
Defrost Icon: Indicates that the unit is
defrosting.
CYCLE-SENTRY Icon: Indicates that the
unit is in CYCLE-SENTRY mode. This
feature may be optional on some units.
Alarm Icon: Indicates that one or more
alarm conditions are present.
Setpoint Icon: Indicates that the lower
display is the setpoint temperature.
Electric Standby Icon: Indicates that the
unit is running in electric standby mode.
Model 50 unit only.
38
TG-VI Controller Description
Standard Display
The Standard Display is the default display screen showing
setpoint temperature and return air temperature. See “Figure
16: Standard Display,” on page 39.
On the Standard Display screen:
•
The upper display shows the return air temperature in
Fahrenheit or Celsius depending on the unit’s
programming.
•
The lower display shows the setpoint temperature.
•
The setpoint icon shows to the right of the lower display,
indicating that the lower display shown is the setpoint.
5
1
4
2
3
AJA1077
•
The cool icon is displayed in the upper left corner of the
display.
1.
CYCLE-SENTRY Icon
•
The CYCLE-SENTRY icon will also show if the unit is in
CYCLE-SENTRY.
2.
Setpoint Icon
3.
Setpoint Temperature (Lower Display)
4.
Cool Icon
5.
Return Air Temperature (Upper Display)
Figure 16: Standard Display
39
TG-VI Controller Description
Standard Display
The Standard Display is the default display screen showing
setpoint temperature and return air temperature. See “Figure
16: Standard Display,” on page 39.
On the Standard Display screen:
•
The upper display shows the return air temperature in
Fahrenheit or Celsius depending on the unit’s
programming.
•
The lower display shows the setpoint temperature.
•
The setpoint icon shows to the right of the lower display,
indicating that the lower display shown is the setpoint.
5
1
4
2
3
AJA1077
•
The cool icon is displayed in the upper left corner of the
display.
1.
CYCLE-SENTRY Icon
•
The CYCLE-SENTRY icon will also show if the unit is in
CYCLE-SENTRY.
2.
Setpoint Icon
3.
Setpoint Temperature (Lower Display)
4.
Cool Icon
5.
Return Air Temperature (Upper Display)
Figure 16: Standard Display
39
TG-VI Controller Description
Keypad
This section describes the keypad keys that control the
operating system.
SELECT Key: Scrolls through the following
screens in the Standard Display mode:
[Pnt]: Print latest trip report. Displays only if
DAS is connected and Print Shortcut is
enabled.
[Alr]: Alarm codes, if any.
[DEF]: Defrost prompt.
3
2
4
1
5
[CYCLS]: CYCLE-SENTRY mode. Upper
display shows [CYCLS], lower display shows
[YES] if on, [no] if off.
[dIS]: Discharge air temperature.
[tLH]: Total unit hours.
[EnH]: Diesel engine hours.
ANA03
1.
2.
3.
SELECT Key
UP Key
DOWN Key
4.
5.
ENTER Key
TK LOGO Key
Hr4]: : Hourmeter 4 hours. Displays only if
hourmeter 4 is enabled.
Hr5]: : Hourmeter 5 hours. Displays only if
hourmeter 5 is enabled.
Figure 17: Keypad
40
TG-VI Controller Description
Keypad
This section describes the keypad keys that control the
operating system.
SELECT Key: Scrolls through the following
screens in the Standard Display mode:
[Pnt]: Print latest trip report. Displays only if
DAS is connected and Print Shortcut is
enabled.
[Alr]: Alarm codes, if any.
[DEF]: Defrost prompt.
3
2
4
1
5
[CYCLS]: CYCLE-SENTRY mode. Upper
display shows [CYCLS], lower display shows
[YES] if on, [no] if off.
[dIS]: Discharge air temperature.
[tLH]: Total unit hours.
[EnH]: Diesel engine hours.
ANA03
1.
2.
3.
SELECT Key
UP Key
DOWN Key
4.
5.
ENTER Key
TK LOGO Key
Figure 17: Keypad
40
Hr4]: : Hourmeter 4 hours. Displays only if
hourmeter 4 is enabled.
Hr5]: : Hourmeter 5 hours. Displays only if
hourmeter 5 is enabled.
TG-VI Controller Description
SELECT Key (Continued)
[Hr6]: : Hourmeter 6 hours. Displays only if
hourmeter 6 is enabled.
UP Key: On the Standard Display screen, it
increases the setpoint. On other screens, it
changes the displayed prompt or other setting.
[oIL]: Engine oil pressure.
[EnT]: Engine coolant temp.
[rPn]: Engine revolutions per minute.
[bAt]: Battery voltage.
DOWN Key: On the Standard Display screen,
it decreases the setpoint. On other screens, it
changes the displayed prompt or other setting.
[coL]: Coil temperature.
[dS1]-[dS6]: Up to six DAS sensors.
Displays only if DAS is connected.
ENTER Key: Enters new temperature
setpoints and initiates or enters other settings.
[dFI]: Defrost interval in range.
[dFn]: Defrost interval not in range
[ddr]: Defrost duration.
NOTE: If a DAS is installed, the unit must be on for
approximately 15 seconds with no keypad keys pressed for the
microprocessor to confirm the presence of the DAS.
TK LOGO Key: Initiates unit self check and
displays software revision. Also used to print
a trip report and initiate a start of trip on units
equipped with a DAS.
41
TG-VI Controller Description
SELECT Key (Continued)
[Hr6]: : Hourmeter 6 hours. Displays only if
hourmeter 6 is enabled.
UP Key: On the Standard Display screen, it
increases the setpoint. On other screens, it
changes the displayed prompt or other setting.
[oIL]: Engine oil pressure.
[EnT]: Engine coolant temp.
[rPn]: Engine revolutions per minute.
[bAt]: Battery voltage.
DOWN Key: On the Standard Display screen,
it decreases the setpoint. On other screens, it
changes the displayed prompt or other setting.
[coL]: Coil temperature.
[dS1]-[dS6]: Up to six DAS sensors.
Displays only if DAS is connected.
ENTER Key: Enters new temperature
setpoints and initiates or enters other settings.
[dFI]: Defrost interval in range.
[dFn]: Defrost interval not in range
[ddr]: Defrost duration.
NOTE: If a DAS is installed, the unit must be on for
approximately 15 seconds with no keypad keys pressed for the
microprocessor to confirm the presence of the DAS.
TK LOGO Key: Initiates unit self check and
displays software revision. Also used to print
a trip report and initiate a start of trip on units
equipped with a DAS.
41
TG-VI Controller Description
42
TG-VI Controller Description
42
Remote Status Light (Optional)
The Remote Status Light mounts on the cargo box for easy
viewing of the unit’s mode. The remote light indicates
operating status as follows:
Green status light: Illuminates the “T” portion of the TK
logo when the unit is functioning properly with no alarm
codes.
Amber status light: Illuminates 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.
ANA23
Flashing status lights: The “T” (in green) and the “K” (in
amber) are illuminated and blinking when the unit has a
shutdown alarm code and the load integrity is at risk. Correct
the alarm condition immediately.
Figure 18: Remote Status Light
43
Remote Status Light (Optional)
The Remote Status Light mounts on the cargo box for easy
viewing of the unit’s mode. The remote light indicates
operating status as follows:
Green status light: Illuminates the “T” portion of the TK
logo when the unit is functioning properly with no alarm
codes.
Amber status light: Illuminates 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.
ANA23
Flashing status lights: The “T” (in green) and the “K” (in
amber) are illuminated and blinking when the unit has a
shutdown alarm code and the load integrity is at risk. Correct
the alarm condition immediately.
Figure 18: Remote Status Light
43
Remote Status Light (Optional)
44
Remote Status Light (Optional)
44
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 pre-trip inspection
before every trip involving refrigerated cargo.
NOTE: Pretrip inspections are not intended to take the place
of regular maintenance inspections.
Fuel: Make sure the diesel fuel supply is adequate to
guarantee engine operation to the next check point. Allow for
maximum fuel consumption of one gallon per hour of engine
operation.
Engine Oil: Check the engine oil level. It should be at the
Full mark when the dipstick is threaded all the way into the oil
pan. Do not overfill.
CAUTION: Turn the engine off before checking the
engine oil level.
Engine Coolant: Check the engine coolant level. The engine
coolant must have antifreeze protection to –30 F (–34 C).
Maintain a minumum of 50% Ethylene Glycol based coolant
and 50% water mixture. Do not mix solution any stronger than
68% Ethylene Glycol based coolant and 32% water for use in
extreme temperatures.
WARNING: Do not remove the expansion tank cap
while the coolant is hot.
The engine is designed to operate on Ethylene Glycol based
coolant. This is the only recommended coolant type. Failure to
use the proper antifreeze mixture could cause plugging or
engine overheating. Do not mix brands, use water alone or mix
rust inhibitors.
Do not overfill the coolant.
45
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 pre-trip inspection
before every trip involving refrigerated cargo.
NOTE: Pretrip inspections are not intended to take the place
of regular maintenance inspections.
Fuel: Make sure the diesel fuel supply is adequate to
guarantee engine operation to the next check point. Allow for
maximum fuel consumption of one gallon per hour of engine
operation.
Engine Oil: Check the engine oil level. It should be at the
Full mark when the dipstick is threaded all the way into the oil
pan. Do not overfill.
CAUTION: Turn the engine off before checking the
engine oil level.
Engine Coolant: Check the engine coolant level. The engine
coolant must have antifreeze protection to –30 F (–34 C).
Maintain a minumum of 50% Ethylene Glycol based coolant
and 50% water mixture. Do not mix solution any stronger than
68% Ethylene Glycol based coolant and 32% water for use in
extreme temperatures.
WARNING: Do not remove the expansion tank cap
while the coolant is hot.
The engine is designed to operate on Ethylene Glycol based
coolant. This is the only recommended coolant type. Failure to
use the proper antifreeze mixture could cause plugging or
engine overheating. Do not mix brands, use water alone or mix
rust inhibitors.
Do not overfill the coolant.
45
Manual Pretrip Inspection (Before Starting the Unit)
Keep the radiator clean and clear of debris by gently spraying
with water.
Damper: Make sure the damper in the evaporator air outlets
move freely, with no sticking or binding.
NOTE: Used Ethylene Glycol based coolant is a regulated
substance requiring proper disposal. Check for local disposal
regulations. Do not store in open containers. Keep away from
children and animals.
Coils: Make sure the condenser and evaporator coils are clean
and free of debris.
CAUTION: If air is suspected to be trapped in the
system, it must be bled out. If the engine runs with air
trapped in the block, the engine may be damaged.
Battery: Make sure the battery terminals are tight and free of
corrosion. Electrolyte should be at the Full mark.
Belts: Make sure belts are in good condition and adjusted to
the proper tension. For more information about belt tension,
see the Specifications chapter.
Cargo Box: Check the interior and exterior of the trailer for
damage. Any damage to the walls or insulation must be
repaired.
Defrost Drains: Check the defrost drain hoses and fittings to
make sure they are open.
Doors: Make sure that the doors and weather seals are in good
condition. The doors should latch securely and the weather
seals should fit tightly.
IMPORTANT: To prevent damage to the controller, always
push the controller access door firmly closed.
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.
46
Manual Pretrip Inspection (Before Starting the Unit)
Keep the radiator clean and clear of debris by gently spraying
with water.
Damper: Make sure the damper in the evaporator air outlets
move freely, with no sticking or binding.
NOTE: Used Ethylene Glycol based coolant is a regulated
substance requiring proper disposal. Check for local disposal
regulations. Do not store in open containers. Keep away from
children and animals.
Coils: Make sure the condenser and evaporator coils are clean
and free of debris.
CAUTION: If air is suspected to be trapped in the
system, it must be bled out. If the engine runs with air
trapped in the block, the engine may be damaged.
Battery: Make sure the battery terminals are tight and free of
corrosion. Electrolyte should be at the Full mark.
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.
46
Cargo Box: Check the interior and exterior of the trailer for
damage. Any damage to the walls or insulation must be
repaired.
Defrost Drains: Check the defrost drain hoses and fittings to
make sure they are open.
Doors: Make sure that the doors and weather seals are in good
condition. The doors should latch securely and the weather
seals should fit tightly.
IMPORTANT: To prevent damage to the controller, always
push the controller access door firmly closed.
Unit Operation with TG-VI Controller
Thermo King has applied the latest advances in computer
technology to develop a device that controls temperature and
unit functioning, and displays operating information quickly
and accurately.
There is nothing complicated about learning to operate the
TG-VI Microprocessor Controller, but you will find that a few
minutes studying the contents of this manual will be time well
spent.
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.
The following are general instructions for operating the TG-VI
Microprocessor Controller. It is recommended that you become
completely familiar with its operation before attempting to
start or operate the unit.
ANA03
Figure 19: TG-VI Microprocessor Controller
47
Unit Operation with TG-VI Controller
Thermo King has applied the latest advances in computer
technology to develop a device that controls temperature and
unit functioning, and displays operating information quickly
and accurately.
There is nothing complicated about learning to operate the
TG-VI Microprocessor Controller, but you will find that a few
minutes studying the contents of this manual will be time well
spent.
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.
The following are general instructions for operating the TG-VI
Microprocessor Controller. It is recommended that you become
completely familiar with its operation before attempting to
start or operate the unit.
ANA03
Figure 19: TG-VI Microprocessor Controller
47
Unit Operation with TG-VI Controller
Control Panel
1
2
WARNING: Do not operate the unit until you are
completely familiar with the location and function of
each control.
ANA03
Two sets of controls are used to operate a unit that has a TG-VI
Microprocessor Controller. The Microprocessor control panel
contains the Display Screen (2) and Keypad (3) used to control
microprocessor operations.
3
4
Basic operation of the unit is controlled with the On/Off
switch (6) located on the Switch Panel.
6
On/Off Switch
COMPUTER
The On/Off switch energizes the electrical control system for
the unit. In the On position, the unit will operate under the
control of the microprocessor. In the Off position, the electric
control system is de-energized and the unit will not operate.
WARNING: When the On/Off switch is in the On
position, the unit may start at any time without prior
warning.
PRINTER
5
AJA1070
1.
Control Panel
4.
Computer Port (Optional)
2.
Display
5.
Printer Port (Optional)
3.
Keypad
6.
On/Off Switch
Figure 20: Control and Switch Panels
48
Unit Operation with TG-VI Controller
Control Panel
1
2
WARNING: Do not operate the unit until you are
completely familiar with the location and function of
each control.
ANA03
Two sets of controls are used to operate a unit that has a TG-VI
Microprocessor Controller. The Microprocessor control panel
contains the Display Screen (2) and Keypad (3) used to control
microprocessor operations.
3
4
Basic operation of the unit is controlled with the On/Off
switch (6) located on the Switch Panel.
6
On/Off Switch
COMPUTER
The On/Off switch energizes the electrical control system for
the unit. In the On position, the unit will operate under the
control of the microprocessor. In the Off position, the electric
control system is de-energized and the unit will not operate.
WARNING: When the On/Off switch is in the On
position, the unit may start at any time without prior
warning.
48
PRINTER
5
AJA1070
1.
Control Panel
4.
Computer Port (Optional)
2.
Display
5.
Printer Port (Optional)
3.
Keypad
6.
On/Off Switch
Figure 20: Control and Switch Panels
Unit Operation with TG-VI Controller
Starting the Diesel Engine
Turn the On/Off switch to the On position. If no key is pressed,
the engine will automatically preheat and start in about 10
seconds. If a key is pressed (to change setpoint or view display
screens), the engine will automatically preheat and start about
10 seconds after the last key is pressed.
If the unit is in CYCLE-SENTRY mode and cooling, heating
or defrosting is required, the engine will automatically preheat
and start.
WARNING: When the On/Off switch is in the On
position, the unit may start at any time without prior
warning.
WARNING: Never use starting fluid.
49
Unit Operation with TG-VI Controller
Starting the Diesel Engine
Turn the On/Off switch to the On position. If no key is pressed,
the engine will automatically preheat and start in about 10
seconds. If a key is pressed (to change setpoint or view display
screens), the engine will automatically preheat and start about
10 seconds after the last key is pressed.
If the unit is in CYCLE-SENTRY mode and cooling, heating
or defrosting is required, the engine will automatically preheat
and start.
WARNING: When the On/Off switch is in the On
position, the unit may start at any time without prior
warning.
WARNING: Never use starting fluid.
49
Unit Operation with TG-VI Controller
Starting the Unit with a Unit Self
Check Test
This procedure is used for a complete check of the trailer, unit,
and unit control circuits. It should be used when first starting
the unit for a trip before the cargo is loaded.
1.
Perform a Pretrip Inspection. See the manual Pretrip
Inspection in the previous chapter.
2.
This procedure is automatic and can be performed on the
way to the loading area or while waiting to load.
3.
Place the On/Off switch in the On position.
4.
Clear any alarms.
5.
Press and hold the TK key for at least 3 seconds. USC
(Unit Self Check) will appear on the display.
6.
Press the ENTER key while USC is displayed.
7.
Lod (load) will appear on the display and the Unit Self
Check will start.
1
AMA61
2
1.
TK Logo Key
2.
Enter Key
Figure 21: Unit Self Check
50
Unit Operation with TG-VI Controller
Starting the Unit with a Unit Self
Check Test
This procedure is used for a complete check of the trailer, unit,
and unit control circuits. It should be used when first starting
the unit for a trip before the cargo is loaded.
1.
Perform a Pretrip Inspection. See the manual Pretrip
Inspection in the previous chapter.
2.
This procedure is automatic and can be performed on the
way to the loading area or while waiting to load.
3.
Place the On/Off switch in the On position.
4.
Clear any alarms.
5.
Press and hold the TK key for at least 3 seconds. USC
(Unit Self Check) will appear on the display.
6.
Press the ENTER key while USC is displayed.
7.
Lod (load) will appear on the display and the Unit Self
Check will start.
1
AMA61
2
1.
TK Logo Key
2.
Enter Key
Figure 21: Unit Self Check
50
Unit Operation with TG-VI Controller
8.
If any alarms were not cleared before starting the Unit Self
Check, they will be displayed at this time. They can be
cleared by pressing the ENTER key.
9.
The controller will now automatically preheat and start the
diesel engine.
10. All segments of the display will be lighted at the same
time.
11. All programmable settings will be sequentially displayed.
These settings may be verified by the operator if
necessary.
12. The diesel engine RPM is checked in both high and low
speed.
17. At the completion of the Unit Self Check, the check results
will appear on the display. They will remain until any key
on the controller is pressed. Check results are shown as
either PASS, CHEC or FAIL:
[PASS]—The unit is running and no alarms have been
recorded. The unit has passed the USC.
[CHEC]—The unit is running but Check Alarms have
been recorded.
[FAIL]—The unit has shut down. View and correct any
alarms. See “Figure 29: Alarm Symbol Location,” on
page 61.
13. The operation of the defrost damper is checked.
14. The ability of the unit to cool in low speed is checked.
15. The ability of the unit to heat is checked.
16. A second low speed cooling capacity check is performed
to insure that the unit can switch from cool to heat and
back to cool.
51
Unit Operation with TG-VI Controller
8.
If any alarms were not cleared before starting the Unit Self
Check, they will be displayed at this time. They can be
cleared by pressing the ENTER key.
9.
The controller will now automatically preheat and start the
diesel engine.
10. All segments of the display will be lighted at the same
time.
11. All programmable settings will be sequentially displayed.
These settings may be verified by the operator if
necessary.
12. The diesel engine RPM is checked in both high and low
speed.
17. At the completion of the Unit Self Check, the check results
will appear on the display. They will remain until any key
on the controller is pressed. Check results are shown as
either PASS, CHEC or FAIL:
[PASS]—The unit is running and no alarms have been
recorded. The unit has passed the USC.
[CHEC]—The unit is running but Check Alarms have
been recorded.
[FAIL]—The unit has shut down. View and correct any
alarms. See “Figure 29: Alarm Symbol Location,” on
page 61.
13. The operation of the defrost damper is checked.
14. The ability of the unit to cool in low speed is checked.
15. The ability of the unit to heat is checked.
16. A second low speed cooling capacity check is performed
to insure that the unit can switch from cool to heat and
back to cool.
51
Unit Operation with TG-VI Controller
Displaying Operating Data
During Normal Operation
During normal operation, the standard display appears on the
screen. Return air temperature is displayed in the upper
readout, and the setpoint is displayed in the lower readout. In
this example, the return air temperature is 50.8 F and the
setpoint temperature is 35 F.
NOTE: If the unit is turned off by the optional remote
control, the display will read [Standby].
NOTE: The TG-VI can be programmed by a service
technician to display the setpoint to a tenth of a degree.
Press the SELECT key to display the prompt and display
screens. See “SELECT Key” on page 40 for list of these screens.
1
AJA1077
1.
Select Key
Figure 22: Standard Display
52
Unit Operation with TG-VI Controller
Displaying Operating Data
During Normal Operation
During normal operation, the standard display appears on the
screen. Return air temperature is displayed in the upper
readout, and the setpoint is displayed in the lower readout. In
this example, the return air temperature is 50.8 F and the
setpoint temperature is 35 F.
NOTE: If the unit is turned off by the optional remote
control, the display will read [Standby].
NOTE: The TG-VI can be programmed by a service
technician to display the setpoint to a tenth of a degree.
Press the SELECT key to display the prompt and display
screens. See “SELECT Key” on page 40 for list of these screens.
1
AJA1077
1.
Select Key
Figure 22: Standard Display
52
Unit Operation with TG-VI Controller
Changing the Setpoint
The setpoint temperature of the Thermo King unit can be
quickly and easily changed.
1.
3
With the standard display on the screen, press the UP or
DOWN key until the setpoint is at the desired temperature
setting.
Press and release either key repeatedly to cause the
temperature to change by 1 (or 0.1 degrees if programmed
to do so).
2
1
4
Hold either key down to cause the temperature to scroll
automatically. The longer the key is depressed, the faster
the scrolling speed.
2.
Press and release the ENTER key within 10 seconds to
enter the new setpoint into memory.
The display will briefly show Lod (load) in the lower
readout.The new setpoint will appear on the display. The unit
now operates with the new setpoint.
AJA1077
CAUTION: Make sure the ENTER key was pressed in
the first 10 seconds, or the original setpoint will
return to the screen and control the unit.
1.
Up Key
3.
Setpoint
2.
Down Key
4.
Enter Key
Figure 23: Changing the Setpoint
53
Unit Operation with TG-VI Controller
Changing the Setpoint
The setpoint temperature of the Thermo King unit can be
quickly and easily changed.
1.
3
With the standard display on the screen, press the UP or
DOWN key until the setpoint is at the desired temperature
setting.
Press and release either key repeatedly to cause the
temperature to change by 1 (or 0.1 degrees if programmed
to do so).
2
1
4
Hold either key down to cause the temperature to scroll
automatically. The longer the key is depressed, the faster
the scrolling speed.
2.
Press and release the ENTER key within 10 seconds to
enter the new setpoint into memory.
The display will briefly show Lod (load) in the lower
readout.The new setpoint will appear on the display. The unit
now operates with the new setpoint.
CAUTION: Make sure the ENTER key was pressed in
the first 10 seconds, or the original setpoint will
return to the screen and control the unit.
AJA1077
1.
Up Key
3.
Setpoint
2.
Down Key
4.
Enter Key
Figure 23: Changing the Setpoint
53
Unit Operation with TG-VI Controller
Selection of Operating Modes
•
Film
The Thermo King CYCLE-SENTRY system is designed to
save refrigeration fuel costs. The savings vary with the
commodity, ambient temperatures and trailer insulation.
However, not all temperature controlled products can be
properly transported using CYCLE-SENTRY operation.
Certain highly sensitive products normally require continuous
air circulation. Use the following guidelines to select the
proper operating mode to protect the commodity you are
transporting.
•
All non-edible products.
Examples of products normally acceptable for
CYCLE-SENTRY Operation:
•
Frozen foods (in adequately insulated trailers)
•
Boxed or processed meats
•
Poultry
•
Fish
•
Dairy products
•
Candy
•
Chemicals
Examples of products normally requiring Continuous Run
Operation for air flow:
•
Fresh fruits and vegetables, especially asparagus,
bananas, broccoli, carrots, citrus, green peas, lettuce,
peaches, spinach, strawberries, sweet corn, etc.
•
Non-processed meat products (unless pre-cooled to
recommended temperature)
•
Fresh flowers and foliage.
The above listings are not all inclusive. Consult your grower or
shipper if you have any questions about the operating mode
selection of your type of load.
54
Unit Operation with TG-VI Controller
Selection of Operating Modes
•
Film
The Thermo King CYCLE-SENTRY system is designed to
save refrigeration fuel costs. The savings vary with the
commodity, ambient temperatures and trailer insulation.
However, not all temperature controlled products can be
properly transported using CYCLE-SENTRY operation.
Certain highly sensitive products normally require continuous
air circulation. Use the following guidelines to select the
proper operating mode to protect the commodity you are
transporting.
•
All non-edible products.
Examples of products normally acceptable for
CYCLE-SENTRY Operation:
54
•
Frozen foods (in adequately insulated trailers)
•
Boxed or processed meats
•
Poultry
•
Fish
•
Dairy products
•
Candy
•
Chemicals
Examples of products normally requiring Continuous Run
Operation for air flow:
•
Fresh fruits and vegetables, especially asparagus,
bananas, broccoli, carrots, citrus, green peas, lettuce,
peaches, spinach, strawberries, sweet corn, etc.
•
Non-processed meat products (unless pre-cooled to
recommended temperature)
•
Fresh flowers and foliage.
The above listings are not all inclusive. Consult your grower or
shipper if you have any questions about the operating mode
selection of your type of load.
Unit Operation with TG-VI Controller
Selecting CYCLE-SENTRY or
Continuous Mode
NOTE: The CYCLE-SENTRY icon will appear when the
CYCLE-SENTRY mode is selected and the ON/OFF switch is
in the ON position.
Continuous Mode: When Continuous mode is selected, the
unit will run continuously to maintain the setpoint and provide
constant airflow.
3
2
1
CYCLE-SENTRY Mode: : When the CYCLE-SENTRY
Mode is selected, the unit starts and stops automatically as
required to maintain the setpoint and to keep the engine warm
and the battery charged.
ANA11
1.
The unit must be turned on. Clear all alarms.
1.
Select Key
2.
Press the SELECT key (cycling arrows) until the display
shows CYCLS and YES or NO.
2.
Up Key
3.
4.
3.
Down Key
Figure 24: Selecting CYCLE-SENTRY
or Continuous Mode
Press the UP or DOWN keys to choose YES or NO. YES
operates the unit in CYCLE-SENTRY. NO operates the
unit in Continuous Run.
NOTE: The ENTER key must be pressed within 10 seconds to
load the new mode.
Press the ENTER key (equals sign) when the desired mode
is shown in the display.
The display will briefly show Lod (load) and then the new
mode will appear.
55
Unit Operation with TG-VI Controller
Selecting CYCLE-SENTRY or
Continuous Mode
NOTE: The CYCLE-SENTRY icon will appear when the
CYCLE-SENTRY mode is selected and the ON/OFF switch is
in the ON position.
Continuous Mode: When Continuous mode is selected, the
unit will run continuously to maintain the setpoint and provide
constant airflow.
3
2
1
CYCLE-SENTRY Mode: : When the CYCLE-SENTRY
Mode is selected, the unit starts and stops automatically as
required to maintain the setpoint and to keep the engine warm
and the battery charged.
ANA11
1.
The unit must be turned on. Clear all alarms.
1.
Select Key
2.
Press the SELECT key (cycling arrows) until the display
shows CYCLS and YES or NO.
2.
Up Key
3.
4.
3.
Down Key
Figure 24: Selecting CYCLE-SENTRY
or Continuous Mode
Press the UP or DOWN keys to choose YES or NO. YES
operates the unit in CYCLE-SENTRY. NO operates the
unit in Continuous Run.
NOTE: The ENTER key must be pressed within 10 seconds to
load the new mode.
Press the ENTER key (equals sign) when the desired mode
is shown in the display.
The display will briefly show Lod (load) and then the new
mode will appear.
55
Unit Operation with TG-VI Controller
Initiating a Manual Defrost Cycle
1.
The unit must be running in Continuous or
CYCLE-SENTRY mode or be in CYCLE-SENTRY Null
mode and the coil temperature must be below 45 F (7 C).
2.
Press the SELECT key until the dEF (defrost) prompt
appears in the display.
3.
Press the ENTER key to enter a Defrost cycle. The display
will briefly show Lod (load). The unit will then enter a
Defrost cycle. The Defrost cycle will terminate
automatically.
2
1
NOTE: The ENTER key must be pressed to enter a Defrost
cycle. The display will return to the Standard Display in
about 10 seconds and the defrost mode will not be entered
unless the ENTER key is pressed.
AMA60
1.
Select Key
2.
Enter Key
Figure 25: Initiating a Manual Defrost Cycle
56
Unit Operation with TG-VI Controller
Initiating a Manual Defrost Cycle
1.
The unit must be running in Continuous or
CYCLE-SENTRY mode or be in CYCLE-SENTRY Null
mode and the coil temperature must be below 45 F (7 C).
2.
Press the SELECT key until the dEF (defrost) prompt
appears in the display.
3.
Press the ENTER key to enter a Defrost cycle. The display
will briefly show Lod (load). The unit will then enter a
Defrost cycle. The Defrost cycle will terminate
automatically.
2
1
NOTE: The ENTER key must be pressed to enter a Defrost
cycle. The display will return to the Standard Display in
about 10 seconds and the defrost mode will not be entered
unless the ENTER key is pressed.
AMA60
1.
Select Key
2.
Enter Key
Figure 25: Initiating a Manual Defrost Cycle
56
Unit Operation with TG-VI Controller
Checking Software Revision
There are currently several different software revisions in use.
This information may be requested in the event that service is
required. To determine the software revision installed in your
unit, perform the following steps.
1.
Place the On/Off switch in the ON position.
2.
Press and hold the TK LOGO key for at least three seconds.
The Unit Self Check [USC] prompt screen will appear.
3.
Press the SELECT key (cycling arrows) until rEU
(revision) appears in the lower part of the display.
2
1
The number shown in the upper part of the display is the
software revision number.
ARA914
1.
Select Key
2.
TK Logo Key
Figure 26: Checking Software Revision
57
Unit Operation with TG-VI Controller
Checking Software Revision
There are currently several different software revisions in use.
This information may be requested in the event that service is
required. To determine the software revision installed in your
unit, perform the following steps.
1.
Place the On/Off switch in the ON position.
2.
Press and hold the TK LOGO key for at least three seconds.
The Unit Self Check [USC] prompt screen will appear.
3.
Press the SELECT key (cycling arrows) until rEU
(revision) appears in the lower part of the display.
2
1
The number shown in the upper part of the display is the
software revision number.
ARA914
1.
Select Key
2.
TK Logo Key
Figure 26: Checking Software Revision
57
Unit Operation with TG-VI Controller
Printing a Trip Report
This procedure is only available on units equipped with an
optional DAS datalogger. It prints the current DAS record
directly to an handheld printer. Only data from the directly
connected DAS sensors can be printed. Graphs are not
available with a handheld printer.
1.
2.
Connect the printer to the Printer Port on the front of
control panel.
2
1
Place the On/Off switch in the On position. The standard
display should appear on the screen. Wait for 15 seconds
before pressing any keys to allow the microprocessor to
confirm the presence of the DAS.
NOTE: If the Print Shortcut is enabled, pressing the
SELECT key at the standard display will take you directly
to the print screen.
3
COMPUTER
3.
Press and hold the TK LOGO key for at least three seconds.
The Unit Self Check [USC] prompt screen will appear.
4.
Press the SELECT key (cycling arrows) until Pnt (print)
appears in the lower part of the display.
PRINTER
ARA915
1.
Select Key
3.
Printer Port
2.
TK Logo Key
Figure 27: Printing a Trip Report
58
Unit Operation with TG-VI Controller
Printing a Trip Report
This procedure is only available on units equipped with an
optional DAS datalogger. It prints the current DAS record
directly to an handheld printer. Only data from the directly
connected DAS sensors can be printed. Graphs are not
available with a handheld printer.
1.
2.
Connect the printer to the Printer Port on the front of
control panel.
2
1
Place the On/Off switch in the On position. The standard
display should appear on the screen. Wait for 15 seconds
before pressing any keys to allow the microprocessor to
confirm the presence of the DAS.
NOTE: If the Print Shortcut is enabled, pressing the
SELECT key at the standard display will take you directly
to the print screen.
3
COMPUTER
3.
Press and hold the TK LOGO key for at least three seconds.
The Unit Self Check [USC] prompt screen will appear.
4.
Press the SELECT key (cycling arrows) until Pnt (print)
appears in the lower part of the display.
PRINTER
ARA915
1.
Select Key
3.
Printer Port
2.
TK Logo Key
Figure 27: Printing a Trip Report
58
Unit Operation with TG-VI Controller
5.
Press the ENTER key. The display will briefly show Lod
(load) and the printing process will begin.
6.
Place the On/Off switch in the Off position to stop
printing.
NOTE: If printing is initiated without a printer connected, or
if the printer cable is not connected properly, printing will be
aborted after 30 seconds and the standard display will appear.
59
Unit Operation with TG-VI Controller
5.
Press the ENTER key. The display will briefly show Lod
(load) and the printing process will begin.
6.
Place the On/Off switch in the Off position to stop
printing.
NOTE: If printing is initiated without a printer connected, or
if the printer cable is not connected properly, printing will be
aborted after 30 seconds and the standard display will appear.
59
Unit Operation with TG-VI Controller
Initiating a Start of Trip
This procedure is only available on units equipped with an
optional DAS datalogger. A “Start Of Trip” places a marker in
the datalogger memory. It is typically initiated when the cargo
is being loaded. The Start Of Trip marker then shows when the
trip started in the data that is downloaded or printed from the
DAS datalogger. A Start Of Trip can be initiated through the
use of WinTrac datalogging software, or manually in the field.
The following procedure covers manual initiation. For more
information on datalogging, see the WinTrac User Manual
included with the WinTrac software. The WinTrac User
Manual is also available on the Internet at
HTTP://WWW.BLUETREE.IE.
7.
Place the On/Off switch in the On position. The standard
display should appear on the screen. Wait for 15 seconds
before pressing any keys to allow the microprocessor to
confirm the presence of the DAS.
8.
Press and hold the TK LOGO key for at least three seconds.
The Unit Self Check [USC] prompt screen will appear.
9.
Press the SELECT key (cycling arrows) until Pnt (print)
appears in the lower part of the display.
10. Press the ENTER key. The display will briefly show Lod
(load). A Start Of Trip Marker has been inserted.
If no keys are pressed for 30 seconds, the standard display will
automatically reappear on the display.
2
1
ARA916
1.
Select Key
2.
TK Logo Key
Figure 28: Initiating a Start of Trip
60
Unit Operation with TG-VI Controller
Initiating a Start of Trip
This procedure is only available on units equipped with an
optional DAS datalogger. A “Start Of Trip” places a marker in
the datalogger memory. It is typically initiated when the cargo
is being loaded. The Start Of Trip marker then shows when the
trip started in the data that is downloaded or printed from the
DAS datalogger. A Start Of Trip can be initiated through the
use of WinTrac datalogging software, or manually in the field.
The following procedure covers manual initiation. For more
information on datalogging, see the WinTrac User Manual
included with the WinTrac software. The WinTrac User
Manual is also available on the Internet at
HTTP://WWW.BLUETREE.IE.
7.
Place the On/Off switch in the On position. The standard
display should appear on the screen. Wait for 15 seconds
before pressing any keys to allow the microprocessor to
confirm the presence of the DAS.
8.
Press and hold the TK LOGO key for at least three seconds.
The Unit Self Check [USC] prompt screen will appear.
9.
Press the SELECT key (cycling arrows) until Pnt (print)
appears in the lower part of the display.
10. Press the ENTER key. The display will briefly show Lod
(load). A Start Of Trip Marker has been inserted.
If no keys are pressed for 30 seconds, the standard display will
automatically reappear on the display.
2
1
ARA916
1.
Select Key
2.
TK Logo Key
Figure 28: Initiating a Start of Trip
60
Unit Operation with TG-VI Controller
Displaying and Clearing Alarm
Codes
1
For detailed alarm code information refer to the “Alarm
Codes” chapter in this manual.
NOTE: Alarms are indicated by the appearance of an alarm
symbol (exclamation point within a triangle) in the
upper-right on the screen. Check alarms and stored alarms
are indicated by a steady alarm symbol. Shutdown alarms are
indicated by a flashing alarm symbol.
1.
The unit On/Off switch must be On. If the alarm symbol is
displayed on the screen, press the SELECT key.
2.
If more than one alarm is present, each will be displayed
for several seconds.
2
3
NOTE: Some of the codes will only be meaningful to an
authorized TK service technician. If you are unable to clear
an alarm code, carefully record the number of the code and
refer the matter to an authorized dealer.
ANA12
NOTE: Do not reset the alarm system until all the alarm
codes have been recorded, the alarm information has been
checked.
1.
Alarm Symbol
2.
Enter Key
3.
Select Key
Figure 29: Alarm Symbol Location
61
Unit Operation with TG-VI Controller
Displaying and Clearing Alarm
Codes
1
For detailed alarm code information refer to the “Alarm
Codes” chapter in this manual.
NOTE: Alarms are indicated by the appearance of an alarm
symbol (exclamation point within a triangle) in the
upper-right on the screen. Check alarms and stored alarms
are indicated by a steady alarm symbol. Shutdown alarms are
indicated by a flashing alarm symbol.
1.
The unit On/Off switch must be On. If the alarm symbol is
displayed on the screen, press the SELECT key.
2.
If more than one alarm is present, each will be displayed
for several seconds.
NOTE: Some of the codes will only be meaningful to an
authorized TK service technician. If you are unable to clear
an alarm code, carefully record the number of the code and
refer the matter to an authorized dealer.
NOTE: Do not reset the alarm system until all the alarm
codes have been recorded, the alarm information has been
checked.
2
3
ANA12
1.
Alarm Symbol
2.
Enter Key
3.
Select Key
Figure 29: Alarm Symbol Location
61
Unit Operation with TG-VI Controller
3.
To reset the alarm system.
a.
Press the SELECT KEY to display the alarm screen.
b.
Press the ENTER KEY to clear the alarm. Enter must be
pushed to clear each alarm if more than one alarm is
present
After all alarms are cleared, the alarm symbol will
disappear. After about ten seconds, the standard display
will appear on the screen.
NOTE: If the alarm condition is not corrected, alarms may
continue to appear.
Alarm code 74 requires an authorized service technician to
reprogram the TG-VI.
62
Unit Operation with TG-VI Controller
3.
To reset the alarm system.
a.
Press the SELECT KEY to display the alarm screen.
b.
Press the ENTER KEY to clear the alarm. Enter must be
pushed to clear each alarm if more than one alarm is
present
After all alarms are cleared, the alarm symbol will
disappear. After about ten seconds, the standard display
will appear on the screen.
NOTE: If the alarm condition is not corrected, alarms may
continue to appear.
Alarm code 74 requires an authorized service technician to
reprogram the TG-VI.
62
Alarm Codes
Introduction
Repair
An alarm is generated when the microprocessor senses an
abnormal condition. Alarms direct an operator or service
technician to the source of a problem.
The operator can repair certain faults, other faults can only be
repaired by your Thermo King Dealer. Refer to the table on the
following pages for the proper corrective action.
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: Document all alarm faults and report them to the
service technician.
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.
NOTE: Alarms with an asterisk (*) can exist with Alarm
Code 84. The alarm can clear automatically if the condition
does not reoccur.
NOTE: The corrective actions listed on the “Table of Alarm
Codes” are suggestions only. Always consult your company
for final decisions.
63
Alarm Codes
Introduction
Repair
An alarm is generated when the microprocessor senses an
abnormal condition. Alarms direct an operator or service
technician to the source of a problem.
The operator can repair certain faults, other faults can only be
repaired by your Thermo King Dealer. Refer to the table on the
following pages for the proper corrective action.
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: Document all alarm faults and report them to the
service technician.
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.
NOTE: Alarms with an asterisk (*) can exist with Alarm
Code 84. The alarm can clear automatically if the condition
does not reoccur.
NOTE: The corrective actions listed on the “Table of Alarm
Codes” are suggestions only. Always consult your company
for final decisions.
63
Alarm Codes
Alarm Types
Corrective Action
The three types of alarms are described below. They can occur
individually or with other alarms. More than one alarm can be
present at one time.
There are three levels of corrective action that can be taken
when an alarm condition occurs.
Stored Alarm: Indicates a condition exists that should be
investigated, but does not affect unit operation. The alarm icon
will appear for 30 seconds when the unit On/Off switch is
turned on, then it disappears.
Check Alarm: Notice to take corrective action before an
abnormal condition becomes severe. The alarm icon will
appear and remain on.
Shutdown Alarm: Indicates conditions that could damage
the unit. The unit will automatically shut down, the alarm icon
will appear, and the entire display will flash on and off.
OK To Run: An alarm condition exists but does not affect
unit operation. Corrective action can occur at a later date.
Check As Specified: An alarm condition exists that could
affect unit operation. Follow directions in the Corrective
Action column on the following chart.
Take Immediate Action: An alarm condition exists that
will damage the unit or load. Take immediate action to correct
the problem.
NOTE: The corrective actions listed above and on the
following chart are suggestions only. Always consult your
company for final decisions.
NOTE: Alarms that occurred during a unit pre-trip or self
check will be preceded by a dash (-). Refer to the Alarm Type
column on the following chart.
NOTE: Some alarms are self-clearing. These alarms will
clear automatically when the operating condition causing the
alarm returns to normal.
64
Alarm Codes
Alarm Types
Corrective Action
The three types of alarms are described below. They can occur
individually or with other alarms. More than one alarm can be
present at one time.
There are three levels of corrective action that can be taken
when an alarm condition occurs.
Stored Alarm: Indicates a condition exists that should be
investigated, but does not affect unit operation. The alarm icon
will appear for 30 seconds when the unit On/Off switch is
turned on, then it disappears.
Check Alarm: Notice to take corrective action before an
abnormal condition becomes severe. The alarm icon will
appear and remain on.
Shutdown Alarm: Indicates conditions that could damage
the unit. The unit will automatically shut down, the alarm icon
will appear, and the entire display will flash on and off.
NOTE: Alarms that occurred during a unit pre-trip or self
check will be preceded by a dash (-). Refer to the Alarm Type
column on the following chart.
NOTE: Some alarms are self-clearing. These alarms will
clear automatically when the operating condition causing the
alarm returns to normal.
64
OK To Run: An alarm condition exists but does not affect
unit operation. Corrective action can occur at a later date.
Check As Specified: An alarm condition exists that could
affect unit operation. Follow directions in the Corrective
Action column on the following chart.
Take Immediate Action: An alarm condition exists that
will damage the unit or load. Take immediate action to correct
the problem.
NOTE: The corrective actions listed above and on the
following chart are suggestions only. Always consult your
company for final decisions.
Alarm Codes
Alarm Code 84 (Restart Null)
Alarm Code 84 is a temporary abnormal condition resulting
from other alarms. The unit shuts down for approximately 15
minutes. The unit will restart after approximately 15 minutes,
or after the condition has reset, and in most cases the other
alarm(s) will have been cleared. If after 3 attempts, the
condition continues to occur, the alarm that caused the
shutdown will appear on the display and the unit will shut
down until the alarm is cleared. Code 84 will automatically
clear after the final attempt at restarting has occurred.
Alarm Code 85
(Forced Unit Operation)
Alarm Code 85 is also a temporary abnormal condition
resulting from other alarm(s). The unit goes into an abnormal
mode which allows the unit to continue to run without shutting
down, the unit may however run with reduced capacity. When
the alarm that caused 85 is no longer active, Alarm Code 85
will be reset.
65
Alarm Codes
Alarm Code 84 (Restart Null)
Alarm Code 84 is a temporary abnormal condition resulting
from other alarms. The unit shuts down for approximately 15
minutes. The unit will restart after approximately 15 minutes,
or after the condition has reset, and in most cases the other
alarm(s) will have been cleared. If after 3 attempts, the
condition continues to occur, the alarm that caused the
shutdown will appear on the display and the unit will shut
down until the alarm is cleared. Code 84 will automatically
clear after the final attempt at restarting has occurred.
Alarm Code 85
(Forced Unit Operation)
Alarm Code 85 is also a temporary abnormal condition
resulting from other alarm(s). The unit goes into an abnormal
mode which allows the unit to continue to run without shutting
down, the unit may however run with reduced capacity. When
the alarm that caused 85 is no longer active, Alarm Code 85
will be reset.
65
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
00
No Fault
None required.
01
Microprocessor Power Up Reset Will not affect unit operation, data log only - clear alarm.
02
Evaporator Coil Sensor
Monitor box temp, repair as required.
X
03
Return Air Sensor
Unit controls on discharge air sensor, monitor box temp,
repair as required.
X
04
Discharge Air Sensor
Unit controls on return air sensor, monitor box temp, repair
as required.
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
X
05
Ambient Air Sensor
Unit operating with reduced features, repair as required.
X
06
Engine Water Temp Sensor
Unit operating with reduced features, repair as required.
X
07
Engine RPM Sensor
Unit operating with reduced features, repair as required.
X
66
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
66
00
No Fault
None required.
X
01
Microprocessor Power Up Reset Will not affect unit operation, data log only - clear alarm.
02
Evaporator Coil Sensor
Monitor box temp, repair as required.
X
03
Return Air Sensor
Unit controls on discharge air sensor, monitor box temp,
repair as required.
X
04
Discharge Air Sensor
Unit controls on return air sensor, monitor box temp, repair
as required.
X
X
05
Ambient Air Sensor
Unit operating with reduced features, repair as required.
X
06
Engine Water Temp Sensor
Unit operating with reduced features, repair as required.
X
07
Engine RPM Sensor
Unit operating with reduced features, repair as required.
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
08
Remote Return Air Sensor
09* High Evaporator Temperature
Remote zone controls on coil sensor, monitor box temp,
repair as required.
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
Unit shut down to prevent damage, repair immediately.
X
X
10*
High Discharge Pressure or
Temp
Unit shut down to prevent damage, clear and retry, if
reoccurs repair immediately.
11
Unit Controlling on Alternate
Sensor
Secondary alarm related to Alarm Code 3 or 4, monitor box
temp, repair as required.
12
Sensor Shutdown
Unit shut down to prevent damage, repair immediately.
13
Check Sensor Calibration
Monitor box temp with independent thermometer, repair as
required.
14
Defrost Terminated by Time
Clear alarm, repair after delivery.
X
X
X
X
67
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
08
Remote Return Air Sensor
09* High Evaporator Temperature
Remote zone controls on coil sensor, monitor box temp,
repair as required.
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
Unit shut down to prevent damage, repair immediately.
X
X
10*
High Discharge Pressure or
Temp
Unit shut down to prevent damage, clear and retry, if
reoccurs repair immediately.
11
Unit Controlling on Alternate
Sensor
Secondary alarm related to Alarm Code 3 or 4, monitor box
temp, repair as required.
12
Sensor Shutdown
Unit shut down to prevent damage, repair immediately.
13
Check Sensor Calibration
Monitor box temp with independent thermometer, repair as
required.
14
Defrost Terminated by Time
Clear alarm, repair after delivery.
X
X
X
X
67
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
15
Glow Plug/Intake Air Heater
Check
Repair after delivery.
X
16
Manual Start Not Completed
Engine was not manually started, clear alarm and manually
start engine.
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
17* Engine Failed to Crank
Attempt to start in Continuous mode, repair as required.
X
18* High Engine Water Temperature
Check belts and coolant level, repair as required.
X
19* Low Engine Oil Pressure
Check engine oil level, add oil as needed, repair as
required.
X
20* Engine Failed to Start
Check fuel level, attempt to start in Continuous mode, repair
as required.
X
21
Cooling Cycle Check
Monitor box temp, repair as required.
X
22
Heating Cycle Check
Monitor box temp, repair as required.
X
68
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
15
Glow Plug/Intake Air Heater
Check
Repair after delivery.
X
16
Manual Start Not Completed
Engine was not manually started, clear alarm and manually
start engine.
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
17* Engine Failed to Crank
Attempt to start in Continuous mode, repair as required.
X
18* High Engine Water Temperature
Check belts and coolant level, repair as required.
X
19* Low Engine Oil Pressure
Check engine oil level, add oil as needed, repair as
required.
X
20* Engine Failed to Start
Check fuel level, attempt to start in Continuous mode, repair
as required.
X
21
Cooling Cycle Check
Monitor box temp, repair as required.
X
22
Heating Cycle Check
Monitor box temp, repair as required.
X
68
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
23* Cooling Cycle Fault
Unit shut down to prevent damage, repair immediately.
X
24* Heating Cycle Fault
Unit shut down to prevent damage, repair immediately.
X
25
Alternator Check
Check alternator charging rate, repair immediately.
X
26
Check Refrigeration Capacity
Monitor box temp, repair as required.
X
27
Unassigned
28
Pretrip or Self-check Abort
Pretrip or self-check was terminated, check for other alarms
and repeat.
X
29
Damper Circuit
Unit or zone may not defrost, monitor box temp, repair as
required.
X
30
Damper Stuck Closed
Damper is stuck closed, repair immediately.
X
31
Oil Pressure Switch
Oil pressure switch is not functioning.
X
X
69
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
23* Cooling Cycle Fault
Unit shut down to prevent damage, repair immediately.
X
24* Heating Cycle Fault
Unit shut down to prevent damage, repair immediately.
X
25
Alternator Check
Check alternator charging rate, repair immediately.
X
26
Check Refrigeration Capacity
Monitor box temp, repair as required.
X
27
Unassigned
28
Pretrip or Self-check Abort
Pretrip or self-check was terminated, check for other alarms
and repeat.
X
29
Damper Circuit
Unit or zone may not defrost, monitor box temp, repair as
required.
X
30
Damper Stuck Closed
Damper is stuck closed, repair immediately.
X
31
Oil Pressure Switch
Oil pressure switch is not functioning.
X
X
69
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
32
Refrigeration Capacity Low
Unit shut down to prevent damage, repair immediately.
X
33
Check Engine RPM
Check and note RPM, repair as required.
X
34
Modulation Circuit
Check modulation circuit breaker or fuse, monitor box temp,
repair as required.
X
35
Run Relay Circuit
Check run relay circuit, repair immediately.
X
36*
Electric Motor Failed to
Run/Loose Belt
Check standby source of power and motor drive belt, repair
immediately.
X
37
Check Engine Water Level
Check coolant level, add as needed.
38
Phase Reversed /Overload
Tripped
Standby power phased wrong or motor overload tripped,
repair immediately.
39
Water Valve Circuit
Unit operating with reduced heating, monitor box temp,
repair as required.
X
X
X
70
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
32
Refrigeration Capacity Low
Unit shut down to prevent damage, repair immediately.
33
Check Engine RPM
Check and note RPM, repair as required.
X
34
Modulation Circuit
Check modulation circuit breaker or fuse, monitor box temp,
repair as required.
X
35
Run Relay Circuit
Check run relay circuit, repair immediately.
X
36*
Electric Motor Failed to
Run/Loose Belt
Check standby source of power and motor drive belt, repair
immediately.
X
37
Check Engine Water Level
Check coolant level, add as needed.
38
Phase Reversed /Overload
Tripped
Standby power phased wrong or motor overload tripped,
repair immediately.
39
Water Valve Circuit
Unit operating with reduced heating, monitor box temp,
repair as required.
70
X
X
X
X
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
40
High Speed Circuit
Check high speed operation, monitor box temp, repair as
required.
X
41
Engine Water Temp Check
Check belts and coolant level, repair as required.
X
42
Unit Forced to Low Speed
Temporary overheat condition, if condition persists repair as
required.
X
43
Unit Forced to Low Speed Mod
Temporary overheat condition, if condition persists repair as
required.
X
44*
Fuel System
Check fuel level in unit fuel tank, add fuel, purge fuel lines
and restart as required.
45
Hot Gas Circuit
Unit operating with reduced modulation control, repair as
required.
X
46
Air Flow Check
Cargo may be restricting air flow, check load.
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
71
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
40
High Speed Circuit
Check high speed operation, monitor box temp, repair as
required.
X
41
Engine Water Temp Check
Check belts and coolant level, repair as required.
X
42
Unit Forced to Low Speed
Temporary overheat condition, if condition persists repair as
required.
X
43
Unit Forced to Low Speed Mod
Temporary overheat condition, if condition persists repair as
required.
X
44*
Fuel System
Check fuel level in unit fuel tank, add fuel, purge fuel lines
and restart as required.
45
Hot Gas Circuit
Unit operating with reduced modulation control, repair as
required.
X
46
Air Flow Check
Cargo may be restricting air flow, check load.
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
71
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
47
Remote Sensor Shutdown
Multi-temp zone sensor failed, zone shut down, monitor
temp and repair as required.
X
48
Check Belts or Clutch
Drive clutch or belts slipping, repair immediately
X
49
RF Tag Communications Error
Data Tag disconnected or inoperative, affects data tag only,
repair as required.
X
50
Reset Clock
Unit will operate normally, set date and time to clear alarm.
(see the “Unit Operation” chapter for procedures).
X
51
Shutdown Circuit
Secondary protection circuit failed, repair as required.
X
52
Heat Circuit
May have no heat, monitor box temperature, repair as
required.
X
53
Economizer Valve Circuit
Unit operating with reduced heat performance, monitor box
temp, repair as required.
X
72
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
72
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
47
Remote Sensor Shutdown
Multi-temp zone sensor failed, zone shut down, monitor
temp and repair as required.
X
48
Check Belts or Clutch
Drive clutch or belts slipping, repair immediately
X
49
RF Tag Communications Error
Data Tag disconnected or inoperative, affects data tag only,
repair as required.
X
50
Reset Clock
Unit will operate normally, set date and time to clear alarm.
(see the “Unit Operation” chapter for procedures).
X
51
Shutdown Circuit
Secondary protection circuit failed, repair as required.
X
52
Heat Circuit
May have no heat, monitor box temperature, repair as
required.
X
53
Economizer Valve Circuit
Unit operating with reduced heat performance, monitor box
temp, repair as required.
X
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
54
Test Mode Time-out
A diagnostic mode timed out, does not affect unit
performance.
55
Check Engine Speeds
Engine speed out of spec, check RPM, monitor box temp,
repair as required.
X
56
Evap Fan Low Speed
Unit operating with no low speed evaporator fan, repair as
required (RC units only).
X
57
Evap Fan High Speed
Unit operating with no high speed evaporator fan, repair as
required (RC units only).
X
58
Cond Fan Low Speed
Unit operating with no low speed condenser fan, repair as
required (RC units only).
X
59
Cond Fan High Speed
Unit operating with no high speed condenser fan, repair as
required (RC units only).
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
73
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
54
Test Mode Time-out
A diagnostic mode timed out, does not affect unit
performance.
55
Check Engine Speeds
Engine speed out of spec, check RPM, monitor box temp,
repair as required.
X
56
Evap Fan Low Speed
Unit operating with no low speed evaporator fan, repair as
required (RC units only).
X
57
Evap Fan High Speed
Unit operating with no high speed evaporator fan, repair as
required (RC units only).
X
58
Cond Fan Low Speed
Unit operating with no low speed condenser fan, repair as
required (RC units only).
X
59
Cond Fan High Speed
Unit operating with no high speed condenser fan, repair as
required (RC units only).
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
73
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
60
Boost Circuit
Unit operating without boost capacitors, repair as required
(RC units only).
X
61
Low Battery Volts
Check charge rate and battery voltage, repair as required.
X
62
Ammeter Out of Cal Range
Ammeter inaccurate, repair as required.
X
63*
Engine Stopped
Engine should be running, try restart, repair as required.
X
64
Pretrip Reminder
Does not affect unit operation, perform Pretrip or Unit Self
Check to clear alarm.
65
Abnormal Temp Differential
If unit is shutdown, repair immediately. Otherwise, monitor
box temp and repair as required.
66
Low Engine Oil Level
Check engine oil level, add as needed.
67
Liquid Line Solenoid Circuit
Unit operating with reduced performance, monitor box temp,
repair as required.
X
X
X
X
X
74
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
60
Boost Circuit
Unit operating without boost capacitors, repair as required
(RC units only).
X
61
Low Battery Volts
Check charge rate and battery voltage, repair as required.
X
62
Ammeter Out of Cal Range
Ammeter inaccurate, repair as required.
X
63*
Engine Stopped
Engine should be running, try restart, repair as required.
X
64
Pretrip Reminder
Does not affect unit operation, perform Pretrip or Unit Self
Check to clear alarm.
65
Abnormal Temp Differential
If unit is shutdown, repair immediately. Otherwise, monitor
box temp and repair as required.
66
Low Engine Oil Level
Check engine oil level, add as needed.
67
Liquid Line Solenoid Circuit
Unit operating with reduced performance, monitor box temp,
repair as required.
74
X
X
X
X
X
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
68
µP Internal Fault Code
Clear and retry, monitor box temp, repair as required.
X
69
Remagnetization Circuit
Clear and retry, if alarm reoccurs or is shutdown repair as
required (RC units only).
X
70
Hourmeter Failure
Will not affect unit operation, repair after delivery.
X
71
Hourmeter 4 Exceeds Set Limit
Maintenance alarm dependent on customer selection, will
not affect unit operation.
X
72
Hourmeter 5 Exceeds Set Limit
Maintenance alarm dependent on customer selection, will
not affect unit operation.
X
73
Hourmeter 6 Exceeds Set Limit
Maintenance alarm dependent on customer selection, will
not affect unit operation.
74
µP Reverted to Default Settings
Unit has reset, control parameters. May be inaccurate,
repair immediately.
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
X
75
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
68
µP Internal Fault Code
Clear and retry, monitor box temp, repair as required.
X
69
Remagnetization Circuit
Clear and retry, if alarm reoccurs or is shutdown repair as
required (RC units only).
X
70
Hourmeter Failure
Will not affect unit operation, repair after delivery.
X
71
Hourmeter 4 Exceeds Set Limit
Maintenance alarm dependent on customer selection, will
not affect unit operation.
X
72
Hourmeter 5 Exceeds Set Limit
Maintenance alarm dependent on customer selection, will
not affect unit operation.
X
73
Hourmeter 6 Exceeds Set Limit
Maintenance alarm dependent on customer selection, will
not affect unit operation.
74
µP Reverted to Default Settings
Unit has reset, control parameters. May be inaccurate,
repair immediately.
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
X
75
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
75
µP Internal Fault Code
Controller may be defective, repair immediately.
X
76
µP Internal Fault Code
Controller may be defective, repair immediately.
X
77
µP Internal Fault Code
Controller may be defective, repair immediately.
X
78
µP Internal Fault Code
Controller may be defective, repair immediately.
X
79
Data Log Overflow
Data logger missed logging one event, no action required,
clear alarm.
80
Compressor Temp Sensor
Compressor protection reduced, repair as required.
X
81
High Comp Temp
Compressor operating above temp limits, repair as required.
X
82
High Comp Temp Shutdown
Compressor shut down to prevent damage, repair
immediately.
83
Low Coolant Temp
Reduced heating capacity, monitor box temp and engine
temp, repair as required.
X
X
X
76
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
76
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
75
µP Internal Fault Code
Controller may be defective, repair immediately.
X
76
µP Internal Fault Code
Controller may be defective, repair immediately.
X
77
µP Internal Fault Code
Controller may be defective, repair immediately.
X
78
µP Internal Fault Code
Controller may be defective, repair immediately.
X
79
Data Log Overflow
Data logger missed logging one event, no action required,
clear alarm.
80
Compressor Temp Sensor
Compressor protection reduced, repair as required.
X
81
High Comp Temp
Compressor operating above temp limits, repair as required.
X
82
High Comp Temp Shutdown
Compressor shut down to prevent damage, repair
immediately.
83
Low Coolant Temp
Reduced heating capacity, monitor box temp and engine
temp, repair as required.
X
X
X
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
84
Restart Null
Temporary shutdown resulting from other alarm codes.
Refer to detailed explanation at start of chapter.
X
85
Forced Unit Operation
Temporary forced operation resulting from other alarm
codes. Refer to detailed explanation at start of chapter.
X
86
Discharge Press Transducer
Unit operating with reduced performance, monitor box temp,
repair as required.
X
87
Suction Press Transducer
Unit operating with reduced performance, monitor box temp,
repair as required.
X
88
Unassigned
89
If Check Alarm, unit operating with reduced performance,
Electronic Throttling Valve Circuit monitor box temp, repair as required. If Shutdown Alarm,
ETV or refrigeration system failure, repair immediately.
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
77
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
84
Restart Null
Temporary shutdown resulting from other alarm codes.
Refer to detailed explanation at start of chapter.
X
85
Forced Unit Operation
Temporary forced operation resulting from other alarm
codes. Refer to detailed explanation at start of chapter.
X
86
Discharge Press Transducer
Unit operating with reduced performance, monitor box temp,
repair as required.
X
87
Suction Press Transducer
Unit operating with reduced performance, monitor box temp,
repair as required.
X
88
Unassigned
89
If Check Alarm, unit operating with reduced performance,
Electronic Throttling Valve Circuit monitor box temp, repair as required. If Shutdown Alarm,
ETV or refrigeration system failure, repair immediately.
X
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
77
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
9092
Unassigned
93
Low Compressor Suction
Pressure
Suction pressure lower than expected for current conditions,
repair as required.
94
Loader Valve #1
Suction pressure drops less than specified when Loader
Valve #1 is energized during unit start up, repair as required.
X
95
Loader Valve #2
Suction pressure drops less than specified when Loader
Valve #2 is energized during unit start up, repair as required.
X
96
Low Fuel Level
Check fuel level, add as needed.
X
97
Unassigned
98
Check Fuel Level Sensor
Low fuel level or defective fuel level sensor.
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
X
78
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
9092
Unassigned
93
Low Compressor Suction
Pressure
Suction pressure lower than expected for current conditions,
repair as required.
94
Loader Valve #1
Suction pressure drops less than specified when Loader
Valve #1 is energized during unit start up, repair as required.
X
95
Loader Valve #2
Suction pressure drops less than specified when Loader
Valve #2 is energized during unit start up, repair as required.
X
96
Low Fuel Level
Check fuel level, add as needed.
X
97
Unassigned
98
Check Fuel Level Sensor
78
Low fuel level or defective fuel level sensor.
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
X
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
99
High Compressor Pressure Ratio
Level Of
Action
Compression ratio of discharge to suction pressure has
risen above specification, repair as required.
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
100Unassigned
104
Unit operating with reduced heat performance, monitor box
temp, repair as required.
X
106 Purge Valve Circuit
Unit operating with reduced heat performance, monitor box
temp, repair as required.
X
107 Condenser Inlet Solenoid Circuit
Unit operating with reduced performance, monitor box temp,
repair as required.
X
108 Door Open Timeout
Door open for extended time, close door and clear alarm.
X
105
Receiver Tank Press Solenoid
Circuit
79
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
High Compressor Pressure Ratio
Level Of
Action
Compression ratio of discharge to suction pressure has
risen above specification, repair as required.
Shut
Down
99
Corrective Action
Check
Description
Ok To
Run
Code
X
100Unassigned
104
Unit operating with reduced heat performance, monitor box
temp, repair as required.
X
106 Purge Valve Circuit
Unit operating with reduced heat performance, monitor box
temp, repair as required.
X
107 Condenser Inlet Solenoid Circuit
Unit operating with reduced performance, monitor box temp,
repair as required.
X
108 Door Open Timeout
Door open for extended time, close door and clear alarm.
X
105
Receiver Tank Press Solenoid
Circuit
79
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
109 High Discharge Pressure/Sensor
High discharge press or defective discharge press sensor,
high speed prevented.
X
110
Suction Line Solenoid CIrcuit
Unit operating with reduced performance, monitor box temp,
repair as required.
X
111
Unit Not Configured Correctly
Controller not set properly for unit type, repair immediately.
112
Remote Fan Zone 2-3 Circuit
Remote fan failure in indicated zone, repair as required.
X
113
Electric Heat Circuit
Electric heating problem, repair as required.
X
114
Multiple Alarms, Can Not Run
Multiple problems prevent unit operation, check alarm
codes, repair immediately.
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
X
80
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
109 High Discharge Pressure/Sensor
High discharge press or defective discharge press sensor,
high speed prevented.
X
110
Suction Line Solenoid CIrcuit
Unit operating with reduced performance, monitor box temp,
repair as required.
X
111
Unit Not Configured Correctly
Controller not set properly for unit type, repair immediately.
112
Remote Fan Zone 2-3 Circuit
Remote fan failure in indicated zone, repair as required.
X
113
Electric Heat Circuit
Electric heating problem, repair as required.
X
114
Multiple Alarms, Can Not Run
Multiple problems prevent unit operation, check alarm
codes, repair immediately.
80
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
X
X
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
115Unassigned
120
121 Liquid Injection Valve
Unit operating with reduced performance, monitor box temp,
repair as required.
X
81
Alarm Codes
Table of Alarm Codes
*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Action
Shut
Down
Corrective Action
Check
Description
Ok To
Run
Code
115Unassigned
120
121 Liquid Injection Valve
Unit operating with reduced performance, monitor box temp,
repair as required.
X
81
Alarm Codes
82
Alarm Codes
82
Loading and Enroute Inspections
This chapter describes pre-loading, post loading, and enroute
inspection procedures. Thermo King refrigeration units are
designed to maintain the required product load temperature
during transit. Follow these recommended loading and enroute
procedures to help minimize temperature related problems.
4.
Verify that the setpoint temperature is correct for your
cargo. Pre-cool the trailer as required.
5.
Push the microprocessor controller access door firmly
closed after setting temperature setpoint
CAUTION: Push the controller access door firmly
closed after each use. Damage can occur in transit if
the door is not properly closed.
Pre-Loading Inspection
1.
Pre-cool products before loading. Note any variances on
the manifest.
2.
Inspect door seals and vent doors for condition and a tight
seal with no air leakage.
3.
Inspect the trailer inside and out. Look for:
•
Damaged or loose trailer skin and insulation
•
Damaged walls, air ducts, floor channels or “T”
flooring
•
Clogged defrost drain tubes
•
Blocked return air bulkhead
6.
Supervise product loading to ensure sufficient air space
around and through the load. Airflow around the cargo
must not be restricted.
NOTE: If the warehouse is not refrigerated, operate the
unit with doors closed until cargo is ready to be loaded.
Then turn off the unit, open cargo doors and load cargo.
When cargo is loaded, close trailer doors and restart the
unit.
The unit can be operated with the cargo box doors open
if the truck is backed into a refrigerated warehouse and
the dock door seals fit tightly around the trailer.
83
001
Loading and Enroute Inspections
This chapter describes pre-loading, post loading, and enroute
inspection procedures. Thermo King refrigeration units are
designed to maintain the required product load temperature
during transit. Follow these recommended loading and enroute
procedures to help minimize temperature related problems.
4.
Verify that the setpoint temperature is correct for your
cargo. Pre-cool the trailer as required.
5.
Push the microprocessor controller access door firmly
closed after setting temperature setpoint
CAUTION: Push the controller access door firmly
closed after each use. Damage can occur in transit if
the door is not properly closed.
Pre-Loading Inspection
1.
Pre-cool products before loading. Note any variances on
the manifest.
2.
Inspect door seals and vent doors for condition and a tight
seal with no air leakage.
3.
Inspect the trailer inside and out. Look for:
001
•
Damaged or loose trailer skin and insulation
•
Damaged walls, air ducts, floor channels or “T”
flooring
•
Clogged defrost drain tubes
•
Blocked return air bulkhead
6.
Supervise product loading to ensure sufficient air space
around and through the load. Airflow around the cargo
must not be restricted.
NOTE: If the warehouse is not refrigerated, operate the
unit with doors closed until cargo is ready to be loaded.
Then turn off the unit, open cargo doors and load cargo.
When cargo is loaded, close trailer doors and restart the
unit.
The unit can be operated with the cargo box doors open
if the truck is backed into a refrigerated warehouse and
the dock door seals fit tightly around the trailer.
83
Loading and Enroute Inspections
1
2
9
3
8
4
1.
2.
3.
4.
5.
7
6
6.
7.
8.
9.
5
Correct load height (trailers without chutes)
Tight doors and gaskets
Good air circulation around load
Proper cargo temperature (prior to loading)
Interior/exterior walls and insulation in good
condition
Clear defrost drains
Good outside air circulation
Unit inspection
Tight seals
ADZ30
Figure 30: Loading Considerations
84
Loading and Enroute Inspections
1
2
9
3
8
4
1.
2.
3.
4.
5.
7
6
5
6.
7.
8.
9.
Correct load height (trailers without chutes)
Tight doors and gaskets
Good air circulation around load
Proper cargo temperature (prior to loading)
Interior/exterior walls and insulation in good
condition
Clear defrost drains
Good outside air circulation
Unit inspection
Tight seals
ADZ30
Figure 30: Loading Considerations
84
Loading and Enroute Inspections
Post-Loading Inspection
4.
Close or supervise the closing of the cargo box doors.
Make sure they are securely locked.
Post-loading inspections ensure the cargo has been loaded
properly. To perform a post-load inspection:
5.
Make sure the setpoint is at the temperature listed on the
manifest.
6.
If the unit was stopped, restart using the correct starting
procedure. See the Operating Instruction chapter in this
manual.
7.
Start a manual defrost cycle 30 minutes after loading. See
the Manual Defrost procedure in this manual.
8.
Push the microprocessor controller access door firmly
closed.
1.
Inspect the evaporator outlets for blockage.
2.
Turn the unit off before opening the cargo box doors to
maintain efficient operation.
NOTE: The unit can be operated with the cargo box
doors open if the truck is backed into a refrigerated
warehouse and the dock door seals fit tightly around the
trailer.
3.
Perform a final check of the load temperature. If the load
is above or below temperature, make a final notation on
the manifest.
CAUTION: Push the controller access door firmly
closed after each use. Unit damage can occur in
transit if the door is not properly closed.
CAUTION: Cargo must be pre-cooled to the proper
temperature before loading. The unit is designed to
maintain temperature, not cool an above-temperature
load.
85
Loading and Enroute Inspections
Post-Loading Inspection
4.
Close or supervise the closing of the cargo box doors.
Make sure they are securely locked.
Post-loading inspections ensure the cargo has been loaded
properly. To perform a post-load inspection:
5.
Make sure the setpoint is at the temperature listed on the
manifest.
6.
If the unit was stopped, restart using the correct starting
procedure. See the Operating Instruction chapter in this
manual.
7.
Start a manual defrost cycle 30 minutes after loading. See
the Manual Defrost procedure in this manual.
8.
Push the microprocessor controller access door firmly
closed.
1.
Inspect the evaporator outlets for blockage.
2.
Turn the unit off before opening the cargo box doors to
maintain efficient operation.
NOTE: The unit can be operated with the cargo box
doors open if the truck is backed into a refrigerated
warehouse and the dock door seals fit tightly around the
trailer.
3.
Perform a final check of the load temperature. If the load
is above or below temperature, make a final notation on
the manifest.
CAUTION: Push the controller access door firmly
closed after each use. Unit damage can occur in
transit if the door is not properly closed.
CAUTION: Cargo must be pre-cooled to the proper
temperature before loading. The unit is designed to
maintain temperature, not cool an above-temperature
load.
85
Loading and Enroute Inspections
Enroute Inspections
2.
Repeat the Enroute Inspection every 30 minutes until the
compartment temperature is within the desired
temperature range. Stop the unit if the compartment
temperature is not within the desired temperature range on
two consecutive 30 minute inspections, especially if the
compartment temperature appears to be moving away
from the setpoint.
Complete the following enroute inspection every four hours.
This will help minimize temperature related problems.
Inspection Procedure
1.
Verify setpoint is correct.
2.
Check the return air temperature reading. It should be
within the desired temperature range.
3.
Immediately contact the nearest Thermo King Service
Center or your company office.
3.
Initiate a manual defrost cycle after each enroute
inspection.
4.
Take all necessary steps to protect and maintain proper
load temperature.
CAUTION: Stop the unit if the compartment
temperature remains higher than the desired
temperature range from the setpoint on two
consecutive 30 minute inspections. Contact the
nearest Thermo King Service Center or your
company office immediately. Take all necessary steps
to protect and maintain proper load temperature.
Inspection Troubleshooting
1.
If a temperature reading is not within the desired
temperature range, refer to the troubleshooting table on the
following pages. Correct problem as required.
86
Loading and Enroute Inspections
Enroute Inspections
2.
Repeat the Enroute Inspection every 30 minutes until the
compartment temperature is within the desired
temperature range. Stop the unit if the compartment
temperature is not within the desired temperature range on
two consecutive 30 minute inspections, especially if the
compartment temperature appears to be moving away
from the setpoint.
Complete the following enroute inspection every four hours.
This will help minimize temperature related problems.
Inspection Procedure
1.
Verify setpoint is correct.
2.
Check the return air temperature reading. It should be
within the desired temperature range.
3.
Immediately contact the nearest Thermo King Service
Center or your company office.
3.
Initiate a manual defrost cycle after each enroute
inspection.
4.
Take all necessary steps to protect and maintain proper
load temperature.
Inspection Troubleshooting
1.
86
If a temperature reading is not within the desired
temperature range, refer to the troubleshooting table on the
following pages. Correct problem as required.
CAUTION: Stop the unit if the compartment
temperature remains higher than the desired
temperature range from the setpoint on two
consecutive 30 minute inspections. Contact the
nearest Thermo King Service Center or your
company office immediately. Take all necessary steps
to protect and maintain proper load temperature.
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 the reading is
within the desired temperature range of the setpoint.
The unit may have
a low refrigerant
charge.
Check the receiver tank sight glass for refrigerant level. If liquid is not
showing in the receiver tank sight glass, the refrigerant charge may be low.
A competent refrigeration technician is required to add refrigerant or repair
the system. Contact the nearest Thermo King dealer, authorized Service
Center, or call the Thermo King Cold Line for referral. Consult the Table of
Contents for Cold Line information.
The unit is in defrost 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 the return air temperature until the
reading is within the desired temperature range of the setpoint.
87
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 the reading is
within the desired temperature range of the setpoint.
The unit may have
a low refrigerant
charge.
Check the receiver tank sight glass for refrigerant level. If liquid is not
showing in the receiver tank sight glass, the refrigerant charge may be low.
A competent refrigeration technician is required to add refrigerant or repair
the system. Contact the nearest Thermo King dealer, authorized Service
Center, or call the Thermo King Cold Line for referral. Consult the Table of
Contents for Cold Line information.
The unit is in defrost 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 the return air temperature until the
reading is within the desired temperature range of the setpoint.
87
Loading and Enroute Inspections
Problem
Cause
Remedy
Improper air
Inspect the unit and cargo compartment to determine if the evaporator fan(s)
circulation in the
are working and properly circulating the air. Poor air circulation may be due
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.
The unit did not
start automatically.
Determine the cause for not starting. Correct as required. Continue
monitoring the return air temperature until the reading is within the desired
temperature range of the setpoint.
88
Loading and Enroute Inspections
Problem
Cause
Remedy
Improper air
Inspect the unit and cargo compartment to determine if the evaporator fan(s)
circulation in the
are working and properly circulating the air. Poor air circulation may be due
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.
The unit did not
start automatically.
88
Determine the cause for not starting. Correct as required. Continue
monitoring the return air temperature until the reading is within the desired
temperature range of the setpoint.
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.
89
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.
89
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
1.
Red Cover on Positive (+) Battery Terminal
Figure 31: Unit Battery
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 32: Sequence for Connecting Jumper Cables
90
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
1.
Red Cover on Positive (+) Battery Terminal
Figure 31: Unit Battery
90
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 32: Sequence for Connecting Jumper Cables
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.
1
1.
Lower Starter Mounting Bolt
Figure 33: Unit Engine
91
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.
1
1.
Lower Starter Mounting Bolt
Figure 33: Unit Engine
91
Jump Starting
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.
4
3
Unit
(Discharged)
12-Volt
Battery
CAUTION: Be careful around fans and belts.
Keep your hands away from moving parts when an
engine is running.
Good
12-Volt
Battery
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).
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 34: Sequence for Disconnecting Jumper Cables
92
Jump Starting
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.
4
3
Unit
(Discharged)
12-Volt
Battery
CAUTION: Be careful around fans and belts.
Keep your hands away from moving parts when an
engine is running.
Good
12-Volt
Battery
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).
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 34: Sequence for Disconnecting Jumper Cables
92
Specifications
Engine
Engine
TK486V (Tier 2)
Fuel Type
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity:
Crankcase
13 quarts (12.3 liters)
Fill to full mark on dipstick
Oil Type
API Classification CI-4 or better
Oil Viscosity
5 to 122 F (-15 to 50 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 32 F (-30 to 0 C): SAE 5W-30
Engine Oil Pressure
The microprocessor will display OK if the oil pressure is within an
acceptable range and LOW if the oil pressure is below this range.
Low Oil Pressure Switch (Normally Closed)
17 ± 3 psi (117 ± 21 kPa)
Engine rpm:
1450 + 25 rpm
2200 ± 25 rpm
Low Speed Operation
High Speed Operation
93
Specifications
Engine
Engine
TK486V (Tier 2)
Fuel Type
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity:
Crankcase
13 quarts (12.3 liters)
Fill to full mark on dipstick
Oil Type
API Classification CI-4 or better
Oil Viscosity
5 to 122 F (-15 to 50 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 32 F (-30 to 0 C): SAE 5W-30
Engine Oil Pressure
The microprocessor will display OK if the oil pressure is within an
acceptable range and LOW if the oil pressure is below this range.
Low Oil Pressure Switch (Normally Closed)
17 ± 3 psi (117 ± 21 kPa)
Engine rpm:
1450 + 25 rpm
2200 ± 25 rpm
Low Speed Operation
High Speed Operation
93
Specifications
Engine (Continued)
Engine Thermostat
160 F (71 C)
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
7 psi (48 kPa)
Drive
Direct to compressor; belts to fans, alternator and water pump
94
Specifications
Engine (Continued)
Engine Thermostat
160 F (71 C)
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
7 psi (48 kPa)
Drive
Direct to compressor; belts to fans, alternator and water pump
94
Specifications
Belt Tension
Belt
Tension No. on TK Gauge 204-427
Alternator Belt
61
Lower Fan Belt (Engine to Idler)
67
Upper Fan Belt (Fan to Idler)
74
NOTE: These are the field reset settings. Because it is sometimes difficult to use the TK Gauge 204-427 in the
field, adjust each belt to allow 1/2 inch (13mm) deflection at the center of the longest span.
Electrical Control System
Voltage
12.5 Vdc
Battery
One, Group C31, 12 volt, (950 CCA recommended for operation
below -15 F [-26 C])
Battery Charging Alternator
12 V, 37 Amp (brush type)
Voltage Regulator Setting
13.8 to 14.2 Vdc at 77 F (25 C)
Fuses
2 to 40 Amp (see “Fuses” on page 33)
95
Specifications
Belt Tension
Belt
Tension No. on TK Gauge 204-427
Alternator Belt
61
Lower Fan Belt (Engine to Idler)
67
Upper Fan Belt (Fan to Idler)
74
NOTE: These are the field reset settings. Because it is sometimes difficult to use the TK Gauge 204-427 in the
field, adjust each belt to allow 1/2 inch (13mm) deflection at the center of the longest span.
Electrical Control System
Voltage
12.5 Vdc
Battery
One, Group C31, 12 volt, (950 CCA recommended for operation
below -15 F [-26 C])
Battery Charging Alternator
12 V, 37 Amp (brush type)
Voltage Regulator Setting
13.8 to 14.2 Vdc at 77 F (25 C)
Fuses
2 to 40 Amp (see “Fuses” on page 33)
95
Specifications
Refrigeration System
Compressor
Thermo King X430L
Compressor Oil Charge
4.3 quarts (4.1 liters)
Compressor Oil Type
Polyol Ester Type P/N 203-413
Refrigerant Charge - Type
13 lb (5.9 kg) - R404A
Heat/Defrost Method
Hot gas
High Pressure Cutout Switch
Opens 470 +7/-35 psi (3241 +48/-241 kPa)
Automatic Reset @ 375 ± 38 psi (2586 ± 262 kPa)
96
Specifications
Refrigeration System
Compressor
Thermo King X430L
Compressor Oil Charge
4.3 quarts (4.1 liters)
Compressor Oil Type
Polyol Ester Type P/N 203-413
Refrigerant Charge - Type
13 lb (5.9 kg) - R404A
Heat/Defrost Method
Hot gas
High Pressure Cutout Switch
Opens 470 +7/-35 psi (3241 +48/-241 kPa)
Automatic Reset @ 375 ± 38 psi (2586 ± 262 kPa)
96
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep
your Thermo King unit in top operating condition. The
following general schedule is provided to assist in monitoring
that maintenance.
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
For more details, refer to the appropriate maintenance manual
and to the “Manual Pretrip Inspection” in this manual.
Inspect/Service These Items
Engine
•
Check fuel supply and engine oil level.
•
Inspect belts for condition and proper tension (belt tension tool No. 204-427).
•
•
•
•
Check engine oil pressure hot, on high speed (should display “OK”).
•
•
•
•
Listen for unusual noises, vibrations, etc.
*3,000 hours or two years, whichever occurs first.
97
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep
your Thermo King unit in top operating condition. The
following general schedule is provided to assist in monitoring
that maintenance.
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
For more details, refer to the appropriate maintenance manual
and to the “Manual Pretrip Inspection” in this manual.
Inspect/Service These Items
Engine
•
Check fuel supply and engine oil level.
•
Inspect belts for condition and proper tension (belt tension tool No. 204-427).
•
•
•
•
Check engine oil pressure hot, on high speed (should display “OK”).
•
•
•
•
Listen for unusual noises, vibrations, etc.
*3,000 hours or two years, whichever occurs first.
97
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
Engine (Continued)
•
•
•
Check air cleaner restriction indicator (change when indicator reaches 25
in.). Replace EMI 3000 air cleaner element at 3,000 hours or two years
(whichever occurs first) if air cleaner restriction indicator has not reached 25
in. The EMI 3000 air cleaner element has a nameplate that reads “EMI
3000.”
•
•
•
•
Check engine coolant level and antifreeze protection (-30 F [-34 C]).
•
•
•
Drain water from fuel tank and check vent.
•
•
•
Inspect/clean fuel transfer pump inlet strainer (pre-filter).
•
•
•
Check and adjust engine speeds (high and low speed).
•
Replace fuel filter/water separator.
•
Change engine oil and oil filter (hot). Requires oil with API Rating CI-4 or
better.
•
Check condition of engine mounts.
•
Check condition of drive coupling bushings per Service Bulletin T&T 171.
*3,000 hours or two years, whichever occurs first.
98
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
Engine (Continued)
•
•
•
Check air cleaner restriction indicator (change when indicator reaches 25
in.). Replace EMI 3000 air cleaner element at 3,000 hours or two years
(whichever occurs first) if air cleaner restriction indicator has not reached 25
in. The EMI 3000 air cleaner element has a nameplate that reads “EMI
3000.”
•
•
•
•
Check engine coolant level and antifreeze protection (-30 F [-34 C]).
•
•
•
Drain water from fuel tank and check vent.
•
•
•
Inspect/clean fuel transfer pump inlet strainer (pre-filter).
•
•
•
Check and adjust engine speeds (high and low speed).
•
Replace fuel filter/water separator.
•
Change engine oil and oil filter (hot). Requires oil with API Rating CI-4 or
better.
•
Check condition of engine mounts.
•
Check condition of drive coupling bushings per Service Bulletin T&T 171.
*3,000 hours or two years, whichever occurs first.
98
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
Engine (Continued)
—
Change ELC (red) engine coolant every 5 years or 12,000 hours.
—
Test fuel injection nozzles at least every 10,000 hours.
—
Replace fuel return lines between fuel injection nozzles every 10,000 hours.
Electrical
•
•
•
•
Check damper door operation
(closes on defrost initiation, opens on defrost termination).
•
•
•
Inspect battery terminals and electrolyte level.
•
•
•
Inspect wire harness for damaged wires or connections.
•
Inspect alternator wire connections for tightness.
Microprocessor
•
Run Unit Self Check Test (see “Starting the Unit with a Unit Self Check Test”
on page 50).
*3,000 hours or two years, whichever occurs first.
99
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
Engine (Continued)
—
Change ELC (red) engine coolant every 5 years or 12,000 hours.
—
Test fuel injection nozzles at least every 10,000 hours.
—
Replace fuel return lines between fuel injection nozzles every 10,000 hours.
Electrical
•
•
•
•
Check damper door operation
(closes on defrost initiation, opens on defrost termination).
•
•
•
Inspect battery terminals and electrolyte level.
•
•
•
Inspect wire harness for damaged wires or connections.
•
Inspect alternator wire connections for tightness.
Microprocessor
•
Run Unit Self Check Test (see “Starting the Unit with a Unit Self Check Test”
on page 50).
*3,000 hours or two years, whichever occurs first.
99
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
Refrigeration
•
•
•
•
Check refrigerant level.
•
•
•
Check compressor oil level.
•
Check compressor efficiency and pump down refrigeration system.
—
Replace dehydrator and check discharge and suction pressure every 2 years.
Structural
•
•
•
•
Visually inspect unit for fluid leaks.
•
•
•
•
Visually inspect unit for damaged, loose or broken parts (includes air ducts).
•
•
•
Inspect tapered roller bearing fanshaft and idler for leakage and bearing
wear.
•
•
•
Clean entire unit including condenser and evaporator coils and defrost
drains.
•
•
•
Check all unit, fuel tank and electric motor mounting bolts, brackets, lines,
hoses, etc.
•
•
•
Check evaporator damper door adjustment and operation.
*3,000 hours or two years, whichever occurs first.
100
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
Refrigeration
•
•
•
•
Check refrigerant level.
•
•
•
Check compressor oil level.
•
Check compressor efficiency and pump down refrigeration system.
—
Replace dehydrator and check discharge and suction pressure every 2 years.
Structural
•
•
•
•
Visually inspect unit for fluid leaks.
•
•
•
•
Visually inspect unit for damaged, loose or broken parts (includes air ducts).
•
•
•
Inspect tapered roller bearing fanshaft and idler for leakage and bearing
wear.
•
•
•
Clean entire unit including condenser and evaporator coils and defrost
drains.
•
•
•
Check all unit, fuel tank and electric motor mounting bolts, brackets, lines,
hoses, etc.
•
•
•
Check evaporator damper door adjustment and operation.
*3,000 hours or two years, whichever occurs first.
100
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.
101
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.
101
Warranty
102
Warranty
102
Glossary
This glossary is published for informational purposes only and
the information being furnished herein should not be
considered as all-inclusive or meant to cover all contingencies.
NOTE: Additional terms not found in the glossary may be
located in the index section of this manual.
accumulator: A device located in the suction line to collect
liquid refrigerant and meter it safety back to the compressor as
gas.
ambient air temperature: Temperature of the air
surrounding an object.
amp: Abbreviation for ampere. The basic measuring unit of
electrical current.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Battery Sentry: Part of the CYCLE-SENTRY™ system. The
Battery Sentry module monitors alternator charge rate and will
keep the unit running until the battery is adequately charged.
box temperature: The temperature within a
temperature-controlled compartment.
Btu (british thermal unit): The quantity of heat required to
raise the temperature of one pound of water by one degree
Fahrenheit. 1 Btu = 252 calories.
bulkhead: 1) return air bulkhead. A metal or plastic “wall”
placed at the front of the box to prevent loading of product
tightly against the Thermo King unit. (Loading too close to the
unit restricts air flow and system efficiency.) 2) bulkhead
divider. A thick, insulated “wall” used to separate
compartments of a multi-temperature truck or trailer.
calorie: The amount of heat required to raise temperature of
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
Celsius: The metric unit of temperature measurement. The
preferred alternate to the term centigrade. Abbreviated “C.”
centigrade. See Celsius.
103
001
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.
001
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.
103
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.
104
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.
104
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.
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.
ECT: A ceiling-mounted Thermo King remote evaporator. See
EW and TLE.
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.
evaporator: The part of the refrigeration system that absorbs
heat during the cooling cycle.
EW: A wall-mounted Thermo King remote evaporator. See
ECT and TLE.
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.
ETV (Electronic Throttling Valve) : A device used with a
microprocessor to precisely control the refrigeration system.
105
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.
ECT: A ceiling-mounted Thermo King remote evaporator. See
EW and TLE.
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.
evaporator: The part of the refrigeration system that absorbs
heat during the cooling cycle.
EW: A wall-mounted Thermo King remote evaporator. See
ECT and TLE.
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.
ETV (Electronic Throttling Valve) : A device used with a
microprocessor to precisely control the refrigeration system.
105
Glossary
fusible link: An electrical safety device (typically a short
piece of wire) inserted into an electrical circuit. The wire melts
or breaks when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
HCFC: Hydrochlorofluorocarbon. A chlorine-based
refrigerant containing hydrogen, chlorine, fluorine and carbon.
Example: R22. Because chlorine damages the earth’s
atmosphere, in many countries, it is illegal to release this type
of refrigerant to the atmosphere. HCFC refrigerants are not
used in modern Thermo King units.
Hertz: A unit of frequency equal to one cycle per second.
Abbreviated “Hz.”
HFC: A refrigerant consisting of hydrogen, fluorine and
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered “safe” for the
environment.
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the
system if pressure exceeds a predetermined value.
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
HPCO (High Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when discharge pressure reaches a predetermined maximum.
invertible: A multi-temperature truck or trailer unit designed
to allow the placement of deep-frozen cargo in any
compartment. See Multi-Temp.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
load: 1) The product being refrigerated and transported.
2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
when expected to cool a very warm box.)
LPCO (Low Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
modulation: An optional system that reduces load (product)
dehydration and avoids “top freeze.”
106
Glossary
fusible link: An electrical safety device (typically a short
piece of wire) inserted into an electrical circuit. The wire melts
or breaks when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
HCFC: Hydrochlorofluorocarbon. A chlorine-based
refrigerant containing hydrogen, chlorine, fluorine and carbon.
Example: R22. Because chlorine damages the earth’s
atmosphere, in many countries, it is illegal to release this type
of refrigerant to the atmosphere. HCFC refrigerants are not
used in modern Thermo King units.
Hertz: A unit of frequency equal to one cycle per second.
Abbreviated “Hz.”
HFC: A refrigerant consisting of hydrogen, fluorine and
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered “safe” for the
environment.
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the
system if pressure exceeds a predetermined value.
106
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
HPCO (High Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when discharge pressure reaches a predetermined maximum.
invertible: A multi-temperature truck or trailer unit designed
to allow the placement of deep-frozen cargo in any
compartment. See Multi-Temp.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
load: 1) The product being refrigerated and transported.
2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
when expected to cool a very warm box.)
LPCO (Low Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
modulation: An optional system that reduces load (product)
dehydration and avoids “top freeze.”
Glossary
movable bulkhead: A thick, insulated, portable wall-like
device used to compartmentalize a temperature-controlled
truck or trailer. See bulkhead.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
Multi-Temp: A Thermo King truck or trailer unit capable of
maintaining different set-points in multiple compartments.
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.
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.
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.
107
Glossary
movable bulkhead: A thick, insulated, portable wall-like
device used to compartmentalize a temperature-controlled
truck or trailer. See bulkhead.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
Multi-Temp: A Thermo King truck or trailer unit capable of
maintaining different set-points in multiple compartments.
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.
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.
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.
107
Glossary
return air temperature: The temperature of the air
returning to the evaporator. See box temperature.
Vac (volts alternating current): An electric current that
reverses direction at regularly recurring intervals.
rpm: Revolutions per minute.
Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
volts: The basic measuring unit of electrical potential.
watt: The basic measuring unit of electrical power.
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.
TLE: Thin-line evaporator. A Thermo King remote evaporator
designed to be compact (thin) while supplying superior air
flow. See ECT and EW.
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.
108
Glossary
return air temperature: The temperature of the air
returning to the evaporator. See box temperature.
Vac (volts alternating current): An electric current that
reverses direction at regularly recurring intervals.
rpm: Revolutions per minute.
Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
short cycling: When a refrigeration unit cycles between the
heat and cool modes more often than normal.
sight glass: A system component that permits visual
inspection of oil or refrigerant level and condition.
thermostat: A device that controls unit modes of operation to
maintain a selected box temperature.
TLE: Thin-line evaporator. A Thermo King remote evaporator
designed to be compact (thin) while supplying superior air
flow. See ECT and EW.
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.
108
volts: The basic measuring unit of electrical potential.
watt: The basic measuring unit of electrical power.
Index
A
air cleaner restriction indicator 31
alarm 25
alarm codes
Code 84 (restart null) 65
Code 85 (forced unit operation) 65
corrective action 64
displaying and clearing 61
repair 63
types 64
alarm icon 38
amber status light 43
automatic start/stop safety precautions 12
B
battery inspection 46
belt tension 95
belts inspection 46
C
changing setpoint 53
coils inspection 46
compressor 24
compressor oil sight glass 31
continuous mode 55
control panel 48
cool icon 38
CYCLE-SENTRY
start-stop controls 27
CYCLE-SENTRY icon 38
CYCLE-SENTRY mode 55
D
damper inspection 46
DAS (Data Acquisition System) 28
defrost 27
control 25
defrost drain inspection 46
defrost icon 38
109
Index
A
air cleaner restriction indicator 31
alarm 25
alarm codes
Code 84 (restart null) 65
Code 85 (forced unit operation) 65
corrective action 64
displaying and clearing 61
repair 63
types 64
alarm icon 38
amber status light 43
automatic start/stop safety precautions 12
B
battery inspection 46
belt tension 95
belts inspection 46
C
changing setpoint 53
coils inspection 46
compressor 24
compressor oil sight glass 31
continuous mode 55
control panel 48
cool icon 38
CYCLE-SENTRY
start-stop controls 27
CYCLE-SENTRY icon 38
CYCLE-SENTRY mode 55
D
damper inspection 46
DAS (Data Acquisition System) 28
defrost 27
control 25
defrost drain inspection 46
defrost icon 38
109
Index
display 36
alarm icon 38
cool icon 38
CYCLE-SENTRY 38
defrost icon 38
electric standby 38
heat icon 38
icons 38
setpoint 38
displaying operating data during normal operation 52
door inspection 46
down key 41
E
ELC (extended life coolant) 23
electric standby icon 38
electrical control system specifications 95
electrical hazards 12
electrical inspection 46
Emergency Cold Line 117
EMI 3000 24
engine compartment components 31
engine coolant level 45
engine oil dipstick 31
engine oil level 45
engine specifications 93
enroute inspections 86
enter key 41
extended life coolant (ELC) 23
F
first aid for refrigerant 13
first aid for refrigerant oil 13
flashing amber status light 43
forced unit operation alarm code 65
front doors
closing 30
opening 29
fuel level 45
fuse link 32
fuses 33
G
green status light 43
H
heat icon 38
high pressure cutout switch 32
110
Index
display 36
alarm icon 38
cool icon 38
CYCLE-SENTRY 38
defrost icon 38
electric standby 38
heat icon 38
icons 38
setpoint 38
displaying operating data during normal operation 52
door inspection 46
down key 41
E
ELC (extended life coolant) 23
electric standby icon 38
electrical control system specifications 95
electrical hazards 12
electrical inspection 46
Emergency Cold Line 117
EMI 3000 24
engine compartment components 31
engine coolant level 45
engine oil dipstick 31
110
engine oil level 45
engine specifications 93
enroute inspections 86
enter key 41
extended life coolant (ELC) 23
F
first aid for refrigerant 13
first aid for refrigerant oil 13
flashing amber status light 43
forced unit operation alarm code 65
front doors
closing 30
opening 29
fuel level 45
fuse link 32
fuses 33
G
green status light 43
H
heat icon 38
high pressure cutout switch 32
Index
high pressure relief valve 32
I
icons 38
introduction 9
J
jump starting 89
K
keypad 40
down key 41
enter 41
select 40
TK logo 41
up key 41
L
loading procedures
enroute inspections 86
post-loading inspection 85
pre-loading inspection 83
low oil level switch 32
low oil pressure switch 32
M
maintenance inspection schedule 97
manual defrost cycle, initiating 56
manual pretrip inspection 45
microprocessor controller TG-VI 25
O
oil type
compressor 96
engine 93
On/Off switch 48
P
post-loading inspection 85
preheat buzzer 32
pre-loading inspection 83
pretrip inspection, manual 45
printing a trip report 58
protection devices 32
R
receiver tank sight glass 32
refrigerant oil safety 13
refrigerant safety 12
111
Index
high pressure relief valve 32
I
icons 38
introduction 9
J
jump starting 89
K
keypad 40
down key 41
enter 41
select 40
TK logo 41
up key 41
L
loading procedures
enroute inspections 86
post-loading inspection 85
pre-loading inspection 83
low oil level switch 32
low oil pressure switch 32
M
maintenance inspection schedule 97
manual defrost cycle, initiating 56
manual pretrip inspection 45
microprocessor controller TG-VI 25
O
oil type
compressor 96
engine 93
On/Off switch 48
P
post-loading inspection 85
preheat buzzer 32
pre-loading inspection 83
pretrip inspection, manual 45
printing a trip report 58
protection devices 32
R
receiver tank sight glass 32
refrigerant oil safety 13
refrigerant safety 12
111
Index
refrigeration system specifications 96
remote status light 43
restart null alarm code 65
S
safety precautions 11
automatic start/stop operation 12
decal locations 14
electrical hazards 12
first aid for refrigerant 13
first aid for refrigerant oil 13
general safety practices 11
refrigerant 12
refrigerant oil 13
select key 40
selecting CYCLE-SENTRY or continuous mode 55
selection of operating modes 54
serial number locations 113
setpoint icon 38
setpoint, changing 53
software revision, checking 57
specifications 93
standard display 39
starting diesel engine 49
starting unit with unit self check test 50
status light, remote 43
structural inspection 46
switch panel and controls 25
T
TG-VI
controller 25, 35
thermometer 25
thermostat 25
TK logo key 41
trip report, printing 58
U
unit description 21
unit self check test 50
up key 41
W
warranty 101
112
Index
refrigeration system specifications 96
remote status light 43
restart null alarm code 65
S
safety precautions 11
automatic start/stop operation 12
decal locations 14
electrical hazards 12
first aid for refrigerant 13
first aid for refrigerant oil 13
general safety practices 11
refrigerant 12
refrigerant oil 13
select key 40
selecting CYCLE-SENTRY or continuous mode 55
selection of operating modes 54
serial number locations 113
setpoint icon 38
setpoint, changing 53
software revision, checking 57
specifications 93
standard display 39
starting diesel engine 49
112
starting unit with unit self check test 50
status light, remote 43
structural inspection 46
switch panel and controls 25
T
TG-VI
controller 25, 35
thermometer 25
thermostat 25
TK logo key 41
trip report, printing 58
U
unit description 21
unit self check test 50
up key 41
W
warranty 101
Serial Number Locations
Compressor: Stamped between the cylinders on the front
end above the oil pump.
Engine: See the engine identification plate located on the
engine valve cover.
Unit: Nameplates on the bulkhead above the compressor
inside the curbside door and on the roadside of the evaporator.
Figure 35: Compressor Serial Number Location
113
Serial Number Locations
Compressor: Stamped between the cylinders on the front
end above the oil pump.
Engine: See the engine identification plate located on the
engine valve cover.
Unit: Nameplates on the bulkhead above the compressor
inside the curbside door and on the roadside of the evaporator.
Figure 35: Compressor Serial Number Location
113
Serial Number Locations
Figure 36: Engine Serial Number Location
Figure 37: Unit Serial Number Plate Locations
(on the bulkhead above compressor inside
curbside door and on roadside of evaporator)
114
Serial Number Locations
Figure 36: Engine Serial Number Location
114
Figure 37: Unit Serial Number Plate Locations
(on the bulkhead above compressor inside
curbside door and on roadside of evaporator)
Serial Number Locations
Figure 38: Unit Serial Number Plate
115
Serial Number Locations
Figure 38: Unit Serial Number Plate
115
Serial Number Locations
116
Serial Number Locations
116
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.
AKB12
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.
117
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.
AKB12
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.
117
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.
118
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.
118
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
119
001
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
001
119
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.
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)
©2011 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.
©2011 Ingersoll-Rand Company
Printed in U.S.A.
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)
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