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Operator’s Manual
Precedent
™
Single Temperature Units
C-600, S-600, and S-700
June 2019
Revision A
2
Introduction
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.
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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 operating problems. A regular maintenance program will also help to keep your unit in top operating condition. If factory recommended procedures are followed, you will find that you have purchased the most efficient and dependable temperature control system available.
All service requirements, major and minor, should be handled by a Thermo
King dealer for four very important reasons:
• They are equipped with the factory recommended tools to perform all service functions
• They have factory trained and certified technicians
• They have genuine Thermo King replacement parts
• The warranty on your new unit is valid only when the repair and replacement of component parts is performed by an authorized Thermo
King dealer
TK 56218-2-OP-EN
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TK 56218-2-OP-EN 3
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Table of Contents
Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . 10
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Automatic Start/Stop Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condenser and Evaporator Fans. . . . . . . . . . . . . . . . . . . . . . . . . 16
High Voltage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
California Proposition 65 Warning Nameplate . . . . . . . . . . . . 19
Extended Life Coolant (ELC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Thermo King X430 Series Reciprocating Compressor . . . . . . . . . 22
Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SMART REEFER 4 (SR-4) Control System . . . . . . . . . . . . . . . . . . . . 22
Diesel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electric Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CYCLE-SENTRY ™ Start-Stop Controls . . . . . . . . . . . . . . . . . . . . . . . 24
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Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine Compartment Components. . . . . . . . . . . . . . . . . . . . . . . . . . 28
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SMART REEFER 4 (SR-4) Control System . . . . . . . . . . . . . . . . . . . . 32
Microprocessor On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SR-4 HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hard Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
If a Flash Drive is Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Configurable Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Display Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
If a Language is Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
If Log Alarms are Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
The TemperatureWatch ™ Display. . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Changing The Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Numerical Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Named Products - OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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6
Both Numerical Setpoints and Named Products . . . . . . . . . . 45
Changing the Setpoint - Numerical Setpoint. . . . . . . . . . . . . . 46
Changing the Setpoint - Named Product . . . . . . . . . . . . . . . . . 49
Changing the Setpoint - Both Numerical Setpoint and
Named Product Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Starting the Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Switching from Diesel to Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Switching from Electric to Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Terminating a Defrost Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Selecting Cycle Sentry or Continuous Mode . . . . . . . . . . . . . . . . . 59
Using the Gauges Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Gauges Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Using the Sensors Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Sensors Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Using the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Main Menu Choices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Pretrip Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Conditions Where Pretrip Tests Are Not Allowed . . . . . . . . . . . . 67
Pretrip Test Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pretrip Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Flashload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Flash Drive Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Selecting the Flash Drive Menu from the Main Menu (If
Already Connected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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Flash Drive (If Connected While the Unit is Turned On) . . . . . . . 74
Removing the Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Available Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Selecting an Alternate Language . . . . . . . . . . . . . . . . . . . . . . . . . 75
Language Menu Quick Access . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Log Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Check Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Prevent Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Shutdown Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Pretrip Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Alarm Codes When Switching Between Diesel and
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Displaying and Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . 83
Important Alarm Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Displaying Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Displaying Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Data Logger (CargoWatch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Sending Start of Trip Marker to CargoWatch and
ServiceWatch Data Loggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Printing CargoWatch Data Logger Reports . . . . . . . . . . . . . . . . . 91
Hourmeters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Viewing Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Hourmeter Names and Definitions . . . . . . . . . . . . . . . . . . . . . . . . 95
Using the Change Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Turn Cycle Sentry On or Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Select Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Fresh Air Exchange Open or Closed . . . . . . . . . . . . . . . . . . . . . . 100
Keypad Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Start Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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8
SmartPower ™ Electric Standby Option . . . . . . . . . . . . . . . . . 103
Electric Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Diesel Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Switching from Diesel to Electric . . . . . . . . . . . . . . . . . . . . . . . . 104
Electric Standby Power Fails or is Disconnected. . . . . . . . . . . . 105
Switching from Electric to Diesel . . . . . . . . . . . . . . . . . . . . . . . . 105
Adjust Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Clear All ECU Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Log Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Check Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Prevent Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Pretrip Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Pre-Loading Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Post-Loading Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Enroute Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Inspection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Electrical Standby (SmartPower Unit Only) . . . . . . . . . . . . . . . . . 136
Electric Motor and Overload Relay. . . . . . . . . . . . . . . . . . . . . . 136
Standby Power Cord Requirements (SmartPower Units
EPA and ARB Supplemental Emissions Warranty
TK 56218-2-OP-EN 9
Safety Precautions
Danger, Warning, Caution, and Notice
Thermo King ® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices.
Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions.
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury and unsafe practices.
Indicates a situation that could result in equipment or propertydamage only accidents.
General Safety Practices
Keep hands and loose clothing clear of fans and belts at all times when the unit is operating with the doors open.
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.
10 TK 56218-2-OP-EN
Exposed coil fins can cause lacerations. Service work on the evaporator or condenser coils is best left to a certified Thermo King technician.
Automatic Start/Stop Operation
The unit can start and run automatically any time the unit is turned on. Turn the Microprocessor On/Off switch Off before doing inspections or working on any part of the unit. Please note that only Qualified and Certified personnel should attempt to service your Thermo King unit.
Electrical Hazard
Dangerous three phase AC electric power is present whenever the unit is operating in either Diesel Mode or Electric Mode and whenever the unit is connected to a source of external standby power. Voltages of this magnitude can be lethal. Exercise extreme caution when working on the unit.
Battery Installation and Cable Routing
An improperly installed battery could result in a fire, explosion, or injury. A
Thermo King approved battery must be installed and properly secured to the battery tray.
Improperly installed battery cables could result in a fire, explosion, or injury. Battery cables must be installed, routed, and secured properly to prevent them from rubbing, chaffing, or making contact with hot, sharp, or rotating components.
TK 56218-2-OP-EN 11
Do not attach fuel lines to battery cables or electrical harnesses. This has the potential to cause a fire and could cause serious injury or death.
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.
Always cover battery terminals to prevent them from making contact with metal components during battery installation. Battery terminals grounding against metal could cause the battery to explode.
Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury.
Do not connect other manufacturer’s equipment or accessories to the unit unless approved by Thermo King. Failure to do so can result in severe damage to equipment and void the warranty.
Refrigerant
Although fluorocarbon refrigerants are classified as safe, use caution when working with refrigerants or in areas where they are being used.
12 TK 56218-2-OP-EN
Refrigerant in the presence of an open flame, spark, or electrical short produces toxic gases that are severe respiratory irritants which can cause serious injury or possible death.
Do not inhale refrigerant. Use caution when working with refrigerant or a refrigeration system in any confined area with a limited air supply.
Refrigerant displaces air and can cause oxygen depletion, resulting in suffocation and possible death.
Refrigerant in a liquid state evaporates rapidly when exposed to the atmosphere, freezing anything it contacts. Wear butyl lined gloves and other clothing and eye wear when handling refrigerant to help prevent frostbite.
Refrigerant Oil
Observe the following precautions when working with or around refrigerant oil:
Protect your eyes from contact with refrigerant oil. The oil can cause serious eye injuries. Protect skin and clothing from prolonged or repeated contact with refrigerant oil. To prevent irritation, wash your hands and clothing thoroughly after handling the oil. Rubber gloves are recommended.
TK 56218-2-OP-EN 13
First Aid
RA T
• E of water and get prompt medical attention.
• S n:: Flush area with large amounts of warm water. Do not apply heat.
Remove contaminated clothing and shoes. Wrap burns with dry, sterile, bulky dressing to protect from infection. Get prompt medical attention.
Wash contaminated clothing before reuse.
• IIn
Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
• F protect the frozen area from further injury, warm the affected area rapidly, and to maintain respiration.
RA NT
• E minutes. Get prompt medical attention.
• S n:: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.
• IIn
Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
• IIn control center or physician.
EN GIIN E C OO
• E minutes. Get prompt medical attention.
• S n:: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.
• IIn control center or physician.
BA TT
• E minutes. Get prompt medical attention. Wash skin with soap and water.
EL EC SH OC
14 TK 56218-2-OP-EN
Take IMMEDIATE action after a person has received an electrical shock. Get quick medical assistance, if possible.
The source of the shock must be quickly stopped, by either shutting off the power or removing the victim. If the power cannot be shut off, the wire should be cut with an non-conductive tool, such as a wood-handle axe or thickly insulated cable cutters. Rescuers should wear insulated gloves and safety glasses, and avoid looking at wires being cut. The ensuing flash can cause burns and blindness.
If the victim must be removed from a live circuit, pull the victim away with a non-conductive material. Use wood, rope, a belt or coat to pull or push the victim away from the current. DO NOT TOUCH the victim. You will receive a shock from current flowing through the victim’s body. After separating the victim from power source, immediately check for signs of a pulse and respiration. If no pulse is present, start Cardio Pulmonary Resuscitation
(CPR). If a pulse is present, respiration might be restored by using mouth-tomouth resuscitation. Call for emergency medical assistance.
AS HY
Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
TK 56218-2-OP-EN 15
Safety Decals and Locations
Condenser and Evaporator Fans
Be aware of the warning nameplates near the condenser fans and evaporator fans.
Figure 1. Fan Warning Nameplate
High Voltage Components
Various components on the Precedent unit operate using 220/3/60 or 460/3/
60 high voltage and are identified by warning nameplates. All high voltage wiring is identified by ORANGE conduit. Be aware of the locations of these components. Only certified, trained technicians can service them.
Figure 2. High Voltage Nameplates
16 TK 56218-2-OP-EN
Figure 3. High Voltage Component Locations (Front)
1.
2.
3.
Condenser Motors
Evaporator Motor
High Voltage Distribution Box
4.
5.
6.
High Voltage Control Box
AC Generator
Electric Standby Motor and Power
Receptacle (SmartPower Option)
TK 56218-2-OP-EN 17
Figure 4. High Voltage Component Locations (Rear)
18
7.
8.
Evaporator Motor
High Voltage Heater Strips
9.
High Voltage Junction Box
All ORANGE conduit contains High Voltage
Figure 5. Ether Starting Aids Warning Nameplate (located near engine)
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California Proposition 65 Warning Nameplate
Figure 6. P65 Warning Nameplate
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Unit Description
Unit Overview
The Thermo King Precedent units are one piece, self-contained, diesel powered, air cooling/heating units operating under the control of the SMART
REEFER ™ 4 (SR-4) programmable microprocessor controller. The unit mounts on the front of the trailer with the evaporator extending through an opening in the front wall.
The units feature all-new DDE (Diesel Direct Electric) architecture, the quiet running Thermo King engine, and the Thermo King X430L/X430P reciprocating compressor.
Precedent units are available in the following models:
Stta nd
Sm arrttP we ™ O pttiio and electric standby operation.
See the following Features and Options.
Figure 7.
Front View
20 TK 56218-2-OP-EN
Diesel Engine
The unit uses a 4-cylinder, water cooled, direct injection diesel engine.
The engine is coupled directly to the compressor on Standard Units. A centrifugal clutch transfers power from the engine to the compressor on
SmartPower Units. Belts transmit power to the AC generator, water pump, and the optional accessory alternator.
Extended Life Coolant (ELC)
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. The new engine coolant, Chevron
Extended Life Coolant, is RED in color instead of the previous GREEN or
BLUE-GREEN colored conventional coolants.
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.
recommended to assure that de-ionized water is being used. If 100 percent full strength concentrate is used, de-ionized or distilled water is recommended over tap water to insure the integrity of the cooling system is maintained.
EMI 3000
EMI 3000 is an extended maintenance interval package. The EMI 3000 package consists of the following key components:
• EMI 3000-Hour Cyclonic Air Cleaner Assembly and Air Cleaner Element
• EMI 3000-Hour 5-Micron Fuel Filter
• EMI 3000-Hour Dual Element Oil Filter (blue with white lettering)
• API Rating CJ-4 or CK-4 Oil
• Five Year or 12,000 Hour Extended Life Coolant (ELC)
The EMI package allows standard maintenance intervals to be extended to
3,000 hours, or 2 years, whichever occurs first.
TK 56218-2-OP-EN 21
inspection in accordance with Thermo King's maintenance recommendations.
Thermo King X430 Series Reciprocating
Compressor
The unit is equipped with a Thermo King X430 Series four cylinder reciprocating compressor with 30.0 cu. in. (492 cm 3 ) displacement.
Electronic Throttling Valve
The ETV provides enhanced control of the refrigeration system as follows:
• Allows the refrigeration system to fully utilize the power capabilities of the engine under varying conditions
• Provides an additional measure of protection against high discharge pressures
• Protects the engine from high coolant temperature shutdowns
• Provides a means of precise temperature control.
SMART REEFER 4 (SR-4) Control System
Do not operate the SR-4 Controller until you are completely familiar with its function.
The SR-4 is a microprocessor control system designed for a transport refrigeration system. The SR-4 integrates the following functions:
• Changing setpoint and operating mode
• Viewing gauge, sensor, and hourmeter readings
• Initiating Defrost cycles
• Viewing and clearing alarms
The microprocessor components are located inside the control box, which is located inside the lower roadside service door. The microprocessor is connected to a Human Machine Interface (HMI) Control Panel. It is used to operate the unit. The HMI control panel is mounted on the face of the control
22 TK 56218-2-OP-EN
box. It is clearly visible through an opening in the lower roadside service door.
See Operating Instructions for more information about the SR-4 Controller.
Depending on the air temperature in the trailer, as sensed by the microprocessor Base Controller, the unit will typically operate in one of the following modes:
Diesel Operation
In diesel operation, the microprocessor will select the operating mode from the following:
• High Speed Cool
• Low Speed Cool
• Low Speed Modulated Cool
• Null (CYCLE-SENTRY operation only)
• Low Speed Modulated Heat
• Low Speed Heat
• High Speed Heat
• Defrost
Electric Operation
In electric operation, the microprocessor will select the operating mode from the following:
• Cool
• Modulated Cool
• Null (CYCLE-SENTRY operation only)
• Modulated Heat (Hot Gas only)
• Hot Gas Heat
• Full Heat (Hot Gas and Electric Heat)
• Defrost (Hot Gas and Electric Heat)
Defrost
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
TK 56218-2-OP-EN 23
through collection drain tubes onto the ground. The methods of Defrost initiation are Automatic and Manual.
defrost cycles. The SR-4 microprocessor can be programmed to initiate timed defrost cycles at intervals of 2, 4, 6, 8, or 12 hours. Demand defrost cycles occur if the differences between the return air temperature, discharge air temperature, and coil temperature exceed certain limits. The unit can enter defrost cycles as often as every 30 minutes if required.
cycle. See “Initiating a Manual Defrost Cycle”.
been turned on with the ON key, the unit is running in Continuous or
CYCLE-SENTRY mode (or shut down in CYCLE-SENTRY Null mode), and the coil temperature is below 45 F (7 C).
CYCLE-SENTRY
™
Start-Stop Controls
The CYCLE-SENTRY Start-Stop fuel saving system provides optimum operating economy.
The unit can start at any time without warning. Press the OFF key on the
HMI control panel and place the microprocessor On/Off switch in the Off position before inspecting or servicing any part of the unit.
When CYCLE-SENTRY Mode is selected, the unit will start and stop automatically to maintain setpoint, keep the engine warm, and the battery charged. When Continuous Mode is selected, the unit starts automatically and runs continuously to maintain setpoint and provide constant airflow.
Features of the CYCLE-SENTRY system are:
• Offers either CYCLE-SENTRY or Continuous Run operation.
• Controller regulated all season temperature control.
• Maintains minimum engine temperature in low ambient conditions.
• Battery Sentry keeps batteries fully charged during unit operation.
• Variable preheat time.
• Preheat indicator buzzer.
24 TK 56218-2-OP-EN
Data Logging
There are two separate data loggers. The data is downloaded through the
Flash Drive Only USB port on the front of the control box using a flash drive and ThermoServ ™ software.
Figure 8.
HMI Controller and USB Ports
1.
2.
PC Only USB Port (Removed from later units)
Flash Drive Only USB Port programmed with ThermoServ can be used in the Flash Drive Only USB
Port. Use of a USB drive eliminates the need for an on-site computer and does not require cables.
to a PC with a standard USB cable. On later units, this port was removed from the front of the control panel.
attcch ™ :: ServiceWatch is standard equipment. It records operating events, alarm codes, and compartment temperatures as they occur and at preset intervals. This information is typically used to analyze unit performance. Use a USB port to download the ServiceWatch data.
attcch ™ :: CargoWatch data logging requires the installation of optional sensors. Up to six temperature sensor/probes and four door
TK 56218-2-OP-EN 25
switches can be installed. CargoWatch also logs the setpoint. Use a USB Port to download the CargoWatch data. If optional temperature sensors are installed, the readings are displayed as Datalogger Sensor (1-6) Temperature in the sensor readings. See “Using the Sensors Key” in the Operating
Instructions Chapter.
OptiSet Plus
™
OptiSet Plus is a group of programmable functions that control how the unit will operate with specific setpoints or named products. This assures that when a particular setpoint or named product is selected, the unit will always operate the same way. This allows an entire fleet to be configured to match customers’ needs. Contact your Thermo King dealer for information about programming OptiSet Plus.
FreshSet
™
FreshSet is included in OptiSet Plus. FreshSet is a demand base temperature control for fresh products. FreshSet modifies and adjusts unit airflow operation to control temperature and to maximize protection of cargo, while keeping operating costs to a minimum. Contact your Thermo King dealer for information about programming FreshSet.
Defrost
Frost gradually builds-up on evaporator coils as a result of normal operation.
The unit uses hot refrigerant to defrost the evaporator coil. Hot refrigerant gas passes through the evaporator coil and melts the frost. The water flows through collection drain tubes onto the ground. The methods of defrost initiation are Automatic and Manual.
defrost cycles. The SR-4 microprocessor can be programmed to initiate timed defrost cycles at intervals of 2, 4, 6, 8, or 12 hours. Demand defrost cycles occur if the differences between the return air temperature, discharge air temperature, and coil temperature exceed certain limits. The unit can enter defrost cycles as often as every 30 minutes if required.
cycle. Refer to “Initiating a Manual Defrost Cycle.” been turned on with the ON key, the unit is running in Continuous or
CYCLE-SENTRY Mode (or shut down in CYCLE-SENTRY Null Mode), and the coil temperature is below 45°F (7°C).
26 TK 56218-2-OP-EN
Opening the Front Doors
To open the doors and access the engine compartment, pull the right door latch handle out at a 45 degree angle and turn it down (clockwise) 90 degrees
(
Figure 9, p. 27 ). To close the door, push the door closed while holding the
door latch handle open and then turn it up (counterclockwise) 90 degrees.
Figure 9.
Door Latch Location
1.
Door Latch
Figure 10.
Door Latch Nameplate
TK 56218-2-OP-EN 27
Engine Compartment Components
The following maintenance items can be checked visually.
The unit can start at any time without warning. Press the OFF key on the
HMI control panel and place the microprocessor On/Off switch in the Off position before inspecting or servicing any part of the unit.
Turn the unit off before attempting to check the engine oil.
Unit Protection Devices
drops below an acceptable level. If it stays closed for a specified time, the microprocessor records Alarm Code 37.
coolant temperature sensor to monitor the engine coolant temperature. If the engine coolant temperature rises above an acceptable level, the microprocessor records Alarm Code 41 and possibly 18. The microprocessor might also shut the unit down.
F5
F6
F7
Fuse
F1
F2
F3
F4
Size
5A
15A
40A
None
2A
60A
15A
2A
Function
2A Power for REB
On/Off Switch Circuit
Fuel Solenoid/Starter Circuit
No Fuse - All Bosch and Thermo King Alternators
2A Fuse - All Prestolite Alternators
Preheat Circuit (See Note)
High Speed Solenoid Circuit
8X Power for CAN bus
28 TK 56218-2-OP-EN
F8
F10
F12
F13
F15
F20
F22
F25
5A
15A
5A
2A
2A
2A
10A
7.5A
2A Power for CAN bus J12
On/Off Relay Circuit
2A Power for CAN bus J13
Status Light Circuit
SR-4 Power Supply Circuit
Alternator Sense Circuit
Fresh Air Door Circuit
High Pressure Cutout Circuit with the Yanmar trailer engine air pre-heater. Always replace the fuse with the TK specified fuse.
Sm arrtt F Tss:: Smart FETs in the base controller protect circuits and components.
utt S h:: The high pressure cutout switch 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.
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.
Lo w O an acceptable level. If it stays closed for a specified time, the microprocessor shuts the unit down and records Alarm Code 66.
Lo w O 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.
Prre he the preheat relay. This warns anyone near the unit that the controller is about to start the engine.
d R ella Sm arrttP protects the standby electric motor. The overload relay opens the circuit to the electric motor if the motor overloads for any reason (e.g., low line voltage or improper power supply) while the unit is on electric standby operation. The microprocessor will record Alarm Code 90.
TK 56218-2-OP-EN 29
Manual Pretrip Inspection and
Loading Procedures
The following Manual Pretrip Inspection should be completed before starting the unit and loading the trailer. While the pretrip inspection is not a substitute for regularly scheduled maintenance inspections, it is an important part of the preventive maintenance program designed to head off operating problems and breakdowns before they happen.
Fu ell:: The diesel fuel supply must be adequate to guarantee engine operation to the next check point.
turned (threaded) into oil pan. Never overfill.
Do not remove expansion tank cap while coolant is hot.
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.
Alarm Code 37 indicates low coolant. Add coolant in the expansion tank.
tensions.
and terminals should be free of corrosion, cracks, or moisture.
other damage. The condenser and evaporator coils should be clean and free of debris. Check the defrost drain hoses and fittings to make sure they are open. Verify all the doors are latched securely.
30 TK 56218-2-OP-EN
o B x:: Check the interior and exterior of the cargo box for damage. Any damage to the walls or insulation must be repaired.
condition. The doors should latch securely and the weather seals should fit tightly.
TK 56218-2-OP-EN 31
Operating Instructions
SMART REEFER 4 (SR-4) Control System
Thermo King has applied the latest advances in computer technology to develop a device that controls temperature and unit function, and displays operating information quickly and accurately.
There is nothing complicated about learning to operate the SR-4 Controller, but you will find that a few minutes studying the contents of this manual will be time well spent.
Do not operate the SR-4 Controller until you are completely familiar with its function.
The microprocessor components are located inside the control box, which is located inside the lower roadside service door. The microprocessor is connected to a Human Machine Interface (HMI) Control Panel. It is used to operate the unit. The USB port is used to retrieve data from the data logging system.
32 TK 56218-2-OP-EN
Figure 11.
Control Box With Service Door Open
1.
Control Box
2.
Microprocessor On/
Off Switch
3.
4.
Flash Drive Only USB
Port
HMI Control Panel
Microprocessor On/Off Switch
This switch supplies or removes electrical power to the microprocessor. It is located above the HMI Control Panel. It is hidden when the lower roadside body panel surrounding the Control Box is closed.
TK 56218-2-OP-EN 33
SR-4 HMI Control Panel
The unit can start at any time without warning. Press the OFF key on the
HMI control panel and place the microprocessor On/Off switch in the Off position before inspecting or servicing any part of the unit.
Use the HMI control panel to operate the unit. for more information.
The HMI control panel has a display and eight touch sensitive keys. The display is capable of showing both text and graphics. The four keys on the left and right sides of the display are “hard” (dedicated) keys. The four keys under the display are “soft” keys. The function of soft keys change depending on the operation being performed. If a soft key is active, its function will be shown in the display directly above the key.
Control Panel Display
The display is used to supply unit information to the operator. This information includes setpoint, current box temperature, operating information, unit gauge readings, system temperatures, and other information as selected by the operator.
The default display is called the Standard Display (). It is described in detail later in this section.
Display Icons
Display symbols or icons are used to present additional unit information.
Down-Pointing Arrow: (At the left side of the display) Shows the unit is cooling. If the arrow were pointing upward the unit would be heating.
CYCLE SENTRY/Continuous Mode Key: The unit is running in Cycle
Sentry Mode as shown by the Cycle Sentry Icon in the upper right corner of the display. If the Cycle Sentry icon is not present, the unit is running in
Continuous Mode.
USB: The USB Icon in the upper left corner of the display will appear when a USB device is connected to any of the USB Ports on the Unit Control
Panel or inside the unit control box.
34 TK 56218-2-OP-EN
Hard Keys
The keys on either side of the display are dedicated or hard keys. Their function always remains the same.
On Key: Used to turn the unit on. First the display will briefly show the
Thermo King Logo and then the statement “Configuring System - Please
Wait”. When the power-up sequence is complete the display shows the
Standard Display of box temperature and setpoint.
Off Key: Used to turn the unit off. First, the display will briefly show
“System is Powering Down - Please Wait. Press On to Resume” and then
“Off” will appear momentarily. When the power-down sequence is complete the display will be blank.
Defrost Key: Press this key to initiate a Manual Defrost cycle.
CYCLE SENTRY: Used to select Cycle Sentry Mode or Continuous Mode operation if allowed by OptiSet Plus. For more information, refer to
( “Selecting Cycle Sentry or Continuous Mode,” p. 59 ).
Soft Keys
The four soft keys under the display are multi-purpose keys. Their function changes depending on the operation being performed. If a soft key is active the key function is shown in the display directly above the key. The keys are numbered from left to right, with Key 1 on the far left and Key 4 on the far right.
Typical soft key applications:
• MENU
• NEXT
• + OR —
• SELECT
• CLEAR
• HOURMETERS
•
•
GAUGES
BACK
• NO
• SENSORS
•
•
EXIT
HELP
TK 56218-2-OP-EN 35
Turning Unit On
The unit is turned on by pressing the ON Key (
pressing the OFF Key. When the On Key is pressed the display briefly shows the THERMO KING Logo as the display initializes.
appears. If the ON Key is not held down long enough
(approximately ½ second), the display may flicker but the unit will not start up. If this occurs, hold the ON Key down until the
Thermo King logo appears.
seconds for the display to appear on initial startup.
Figure 12.
ON Key
The startup screen ( Figure 13, p. 36
) appears while communications are established and the unit prepares for operation.
Figure 13.
Startup Screen
If a Flash Drive is Connected
If a properly configured USB Flash Drive is inserted in the Flash Drive Only
USB Port on the Control Panel when the unit is turned on, the display ( Figure
) will briefly show FLASH DRIVE.
36 TK 56218-2-OP-EN
Figure 14.
Flash Drive
The FLASH DRIVE DETECTED and the Flash Drive Menu will appear on the
). The display will be shown for about 30 seconds and then the Standard Display will appear. To go to the Standard Display, immediately press the EXIT Soft Key.
Figure 15.
Flash Drive Menu above. The engine start prompt will appear and the engine will start. After the engine is started the display will return to the
Flash Drive Menu or the Standard Display.
If a properly configured USB Flash Drive is connected to the USB Flash Drive connector, this feature allows the operator to select the desired Flash Drive function. If enabled when the Flash Drive was configured, the following functions may be available:
• DOWNLOAD
– Download the ServiceWatch Data Logger
– Download the CargoWatch Data Logger
• FLASHLOAD
– Flash load Base Controller Software
– Flash load HMI Control Panel Software
TK 56218-2-OP-EN 37
• OPTISET PLUS
– SEND
• Send OptiSet Plus files
– RETRIEVE
• Retrieve OptiSet Plus files
The Flash Drive is also available from the Main Menu.
The Flash Drive Menu will time out about 30 seconds after the engine starts.
When the Flash Drive Menu times out, the Standard Display will appear. To go to the Standard Display, immediately press the EXIT Key.
Configurable Soft Keys
When the Standard Display is shown, the default functions of the two center
soft keys are GAUGES and SENSORS ( Figure 16, p. 38
).
Figure 16.
Soft Keys
The functions of these two keys can be changed as required for customer convenience. The functions of these two soft keys on the Standard Display can be re-assigned to any of the following functions using the Guarded
Access > Main Menu Configuration menu:
• Gauges
• Sensors
• Pretrip
• Data Logger
• SOT (start of trip)
• Hourmeters
The GAUGES and SENSORS functions are always available from the
Maintenance Menu.
In the example shown ( Figure 17, p. 39
), the soft key functions from the
Standard Display have been changed to PRETRIP and SOT (Start of Trip marker). The GAUGES and SENSORS functions are always available from the Maintenance Menu.
38 TK 56218-2-OP-EN
Figure 17.
PRETRIP and SOT
Display Heater
The HMI Control Panel is equipped with a display heater. This heater is needed to make the display visible in very cold ambient temperatures.
The HMI has its own internal temperature sensor for the display heater. The heater is energized when the unit is turned on and the ambient temperature is below 29.4°F (-2°C). The heater turns off when the temperature sensed by the internal sensor rises above 37.4°F (3°C). The heater draws from 1.4 to 1.7
amps when energized.
The colder the ambient temperature, the longer it will take for the heater to make the display visible on a cold startup. It may take 10-15 seconds for the display to appear with extremely cold temperatures.
If a Language is Enabled
If more than one language has been enabled from the Guarded Access
Language Menu, a prompt will appear to allow the desired language to be chosen as shown below. Only languages specifically enabled from the
Guarded Access Menu are available. If a different language is desired, press the NO Key (
).
below. The prompt will appear for 10 seconds and then the engine will start. After the engine is started the display will return to the prompt shown.
TK 56218-2-OP-EN 39
Figure 18.
NO Key
The Language Menu will appear as shown (
Figure 19, p. 40 ). Press the + or -
Keys to select the desired language. When the desired language is shown, press the YES Key to confirm the choice.
Figure 19.
+ or -, then YES Key
The display will briefly show PROGRAMMING LANGUAGE - PLEASE WAIT in the new language as shown (
).
Figure 20.
New Language
The new language is confirmed, and the Standard Display will appear in the new language as shown (
Figure 21, p. 41 ). The unit is ready to run.
40 TK 56218-2-OP-EN
Figure 21.
Standard Display, New Language
If Log Alarms are Present
Log Alarms are indicated for 30 seconds each time the unit is turned on. This level of alarm serves as a notice to take corrective action before a problem becomes severe. Maintenance items such as maintenance hourmeter timeouts are log alarms. The TemperatureWatch screen is not disabled if only log alarm(s) are active.
If log alarm(s) are present, the Log Alarm notice shown (
appear on the display for 30 seconds. The remote indicator alarm light (if installed) will also be on during this period. After 30 seconds the Standard
Display will appear and the remote indicator alarm light will go off. Pressing the EXIT soft key (
) will return to the Standard Display immediately.
Figure 22.
Log Alarms Active
When the unit is ready to run, the Standard Display appears ( Figure 23, p.
TK 56218-2-OP-EN 41
Figure 23.
Standard Display
Turning The Unit Off
Pressing the OFF Key stops unit operation. The unit shuts down immediately
and the display briefly shows the power down message ( Figure 24, p. 42 ).
Figure 24.
Power Down Message
The display briefly shows OFF (
Figure 25, p. 42 ) and then goes blank. To
start the unit again, press the ON Key.
Figure 25.
Display Shows OFF
42 TK 56218-2-OP-EN
The Standard Display
The Standard Display is the default display that appears if no other display function is selected. The Standard Display shows the box temperature and setpoint. The box temperature is measured by the controlling sensor, usually
the return air sensor. The box temperature ( Figure 26, p. 43
) is 35.8°F (2.1°C) with a 35°F (1.7°C) setpoint.
Figure 26.
Standard Display
The down-pointing arrow at the left side of the display shows the unit is cooling. If the arrow were pointing upward the unit would be heating.
The unit is running in Cycle Sentry Mode as shown by the Cycle Sentry Icon in the upper right corner of the display. If the
Cycle Sentry icon is not present, the unit would be running in Continuous Mode.
The USB Icon in the upper left corner of the display will appear when a USB Flash
Drive is connected to the Flash Drive Only
USB Port or a computer is connected to the PC Only USB Port on the Unit Control
Panel or inside the unit control box.
Pressing the left soft key allows the user to change the SETPOINT, and pressing the right soft key accesses the MAIN MENU. The other two soft keys access the GAUGES menu and the SENSORS menu.
assigned to better suit customer requirements. The GAUGES and
SENSORS functions are always available from the Maintenance Menu.
TK 56218-2-OP-EN 43
The TemperatureWatch
™
Display
The TemperatureWatch Display appears 2 ½ minutes after the Standard
Display appears so long as there is no key activity and no Check, Prevent, or
Shutdown alarms present. The TemperatureWatch Display will remain on until any key is pressed or a Check, Prevent, or Shutdown alarm occurs.
The TemperatureWatch Display shows the box temperature and setpoint.
The large numbers allow unit conditions to be checked from a distance. The box temperature is that measured by the controlling sensor, usually the return air sensor. The box temperature (
Figure 27, p. 44 ) is 35.8°F (2.1°C)
with a 35°F (1.7°C) setpoint. The Cycle Sentry icon in the upper right corner of the display shows that the unit is operating in Cycle Sentry mode. If the
Cycle Sentry icon is not present, the unit is running in Continuous Mode. The down-pointing arrow indicates that the unit is cooling. Pressing any soft key returns the display to the Standard Display.
Figure 27.
TemperatureWatch Display
If an alarm condition (other than a Log Alarm) is present, the
TemperatureWatch Display will not appear. If an alarm condition occurs while the TemperatureWatch Display is present, the display will return to the
Standard Display.
If the Defrost Key or Cycle Sentry Key is pressed, the display will return to the TemperatureWatch Display immediately after the defrost cycle is initiated or the operating mode is changed.
Changing The Setpoint
The Setpoint is changed from the Standard Display. If the
TemperatureWatch display is present, press any key to return to the
Standard Display.
changing the setpoint.
44 TK 56218-2-OP-EN
Numerical Setpoints
If OptiSet Plus is not in use or if only Numerical Setpoints are enabled, the left soft key will be labeled SETPOINT (
Figure 28.
SETPOINT
Named Products - OptiSet Plus
OptiSet Plus allows the use of Named Products such as APPLES or
BANANAS in place of a numerical setpoint. If only named products are enabled, the left soft key will be labeled PRODUCT (
• A single setpoint temperature may be allowed for the specific named product.
• A numerical setpoint range may be allowed for the specific named product.
Figure 29.
Left Soft Key Labeled “PRODUCT”
Both Numerical Setpoints and Named Products
OptiSet Plus can allow the use of both Numerical Setpoints and Named
Products. If both numerical setpoints and named products are enabled, the
left soft key will be labeled PRODUCT/SETPOINT ( Figure 30, p. 46
).
TK 56218-2-OP-EN 45
Figure 30.
Left Soft Key Labeled “PRODUCT/SETPOINT”
Changing the Setpoint - Numerical Setpoint
If the TemperatureWatch display is shown, press any soft key to return to the
Standard Display. From the Standard Display, press the SETPOINT Key
(
).
Figure 31.
Setpoint Key
The setpoint display appears (
Figure 32.
Setpoint Display
The “-” and “+” Keys are used to increase or decrease the setpoint until the desired setpoint is shown. The setpoint has been changed to 40 F using the
“+” Key (
46 TK 56218-2-OP-EN
Figure 33.
Setpoint Changed Using “+” Key
The YES and NO Keys (
Figure 34, p. 47 ) confirm the setpoint change. When
the desired setpoint has been selected using the “+” and/or “-” Keys, press the YES Key to confirm and load the new setpoint. If the setpoint is changed using the “+” or “-” Keys, the change must be confirmed or rejected by pressing the YES or NO Key within 10 seconds of changing the setpoint. A warning beep will sound for five seconds as a reminder.
Failure to confirm the new setpoint by pressing Yes or No within 10 seconds of changing the setpoint will result in no setpoint change. In addition, Alarm
Code 127 Setpoint Not Entered is set, to indicate that a setpoint change was initiated but not completed.
Figure 34.
Yes and No Keys
After the YES Key has been pressed, the display briefly shows
PROGRAMMING NEW SETPOINT - PLEASE WAIT. The display then confirms
the new setpoint for several seconds ( Figure 35, p. 48 ).
TK 56218-2-OP-EN 47
Figure 35.
New Setpoint
If the NO Key is pressed the display will briefly show SETPOINT NOT
CHANGED and return to the Standard Display. The Standard Display will show the old setpoint.
The display then returns to the Standard Display showing the new setpoint.
Notice that the arrow now points up to indicate that the unit is heating
(
).
Figure 36.
Up Arrow must be confirmed or rejected by pressing the YES or NO Key within 10 seconds of changing the setpoint.
• If the YES Key is pressed, the setpoint change made with the “+” or “-”
Key is accepted, the setpoint changes, and the display returns to the
Standard Display.
• If the NO Key is pressed the setpoint change made with the “+” or “-”
Key is not accepted, the setpoint is not changed, and the display returns to the Standard Display.
• If the YES or NO Key is not pressed within 10 seconds of making a change with the “+” or “-” Key, the setpoint is not changed and the display returns to the Standard Display. The display briefly shows
48 TK 56218-2-OP-EN
[SETPOINT NOT CHANGED] and Alarm Code 127 Setpoint Not Entered is set, to indicate that a setpoint change was initiated but not completed.
procedure.
Changing the Setpoint - Named Product
If the TemperatureWatch display is shown, press any soft key to return to the
Standard Display. From the Standard Display, press the PRODUCT Key. Note that PRODUCT is displayed in place of SETPOINT (
Figure 37.
Product Displayed
The display briefly shows PRODUCT and then the setpoint display appears
(
).
Figure 38.
Setpoint Display
The “-” and “+” Keys are used to change the Named Product until the desired product is shown. The product has been changed to Potato, Late
).
TK 56218-2-OP-EN 49
Figure 39.
Named Product
The YES and NO Keys confirm the product change ( Figure 40, p. 50
). When the desired product has been selected using the “+” and/or “-” Keys, press the YES Key to confirm and load the new product. If the product is changed using the “+” or “-” Keys, the change must be confirmed or rejected by pressing the YES or NO Key within 10 seconds of changing the product. A warning beep will sound for five seconds as a reminder.
Failure to confirm the new product by pressing Yes or No within 10 seconds of changing the product will result in no product change. In addition, Alarm
Code 127 Setpoint Not Entered is set, to indicate that the product change was initiated but not completed.
Figure 40.
Yes and No Keys
After the YES Key has been pressed, the display briefly shows
PROGRAMMING NAMED PRODUCT - PLEASE WAIT. The display then
confirms the new setpoint for several seconds ( Figure 41, p. 51
).
50 TK 56218-2-OP-EN
Figure 41.
New Named Product
If the NO Key is pressed the display will briefly show SETPOINT NOT
CHANGED and return to the Standard Display. The Standard Display will show the old setpoint.
The display then returns to the Standard Display showing the new named product. Notice that the arrow points down, to indicate that the unit is cooling (
Figure 42.
Standard Display change must be confirmed or rejected by pressing the YES or
NO Key within 10 seconds of changing the named product.
• If the YES Key is pressed, the product change made with the “+” or “-”
Key is accepted, the product changes, and the display returns to the
Standard Display.
• If the NO Key is pressed the product change made with the “+” or “-”
Key is not accepted, the product is not changed, and the display returns to the Standard Display.
• If the YES or NO Key is not pressed within 10 seconds of making a change with the “+” or “-” Key, the product is not changed and the display returns to the Standard Display. The display briefly shows
TK 56218-2-OP-EN 51
[SETPOINT NOT CHANGED] and Alarm Code 127 Setpoint Not Entered is set, to indicate that the product change was initiated but not completed.
procedure.
Changing the Setpoint - Both Numerical Setpoint and
Named Product Available
If the TemperatureWatch display is shown, press any soft key to return to the
Standard Display. From the Standard Display, press the SETPOINT Key. Note
that both PRODUCT and SETPOINT are displayed as shown ( Figure 43, p.
Figure 43.
PRODUCT and SETPOINT are Displayed
The NAMED PRODUCT / NUMERIC SETPOINT prompt will appear (
).
Figure 44.
NAMED PRODUCT / NUMERIC SETPOINT Prompt
• Press the NUMERIC Soft Key to proceed with Changing the Setpoint -
Numeric Setpoint change as previously shown.
• Press the NAMED Soft Key to proceed with Changing the Setpoint -
Named Product change as previously shown.
• Press the EXIT Soft Key to return to the Standard Display.
52 TK 56218-2-OP-EN
Starting the Diesel Engine
Diesel engine preheats and starts are automatic in both Continuous Mode and Cycle Sentry Mode. The engine will preheat and start as required when the unit is turned on. The engine preheat and start will be delayed in Cycle
Sentry mode if there is no current need for the engine to run. If any keys are being pressed on the HMI Control Panel, the engine will not preheat and start until 10 seconds after the last key is pressed.
some additional prompts before the engine will start. Refer to
“Starting the Electric Motor ”for details.
The engine may start automatically any time the unit is turned on.
Never use starting fluid. Damage to the engine can occur.
When the engine is preparing to start, the HMI Control Panel will display the engine start screen as shown (
Figure 45, p. 53 ). The preheat buzzer sounds
during the engine preheat and crank sequence.
Figure 45.
Engine Start Screen
After the engine is started, the display returns to the Standard Display of temperature and setpoint.
TK 56218-2-OP-EN 53
Starting the Electric Motor
The motor may start automatically any time the unit is turned on.
the unit to an appropriate electric power source for electric standby
operation ( Figure 46, p. 54 ). The electric power receptacle is located next to
the HMI Control Panel. Verify the unit and the power supply are turned off before connecting or disconnecting a power cord.
Figure 46.
Electric Power Receptacle
Electric motor starting is automatic in both Continuous Mode and Cycle
Sentry Mode. The motor will start as required when the unit is turned on. If any keys are being pressed on the HMI Control Panel prior to the motor start, the motor start will be delayed until 10 seconds after the last key is pressed.
When the motor is preparing to start, the HMI Control Panel will display the motor start screen (
Figure 47, p. 54 ). The preheat buzzer sounds for 20
seconds before the electric motor starts.
Figure 47.
Motor Start Screen
54 TK 56218-2-OP-EN
After the motor is started the display returns to the Standard Display of temperature and setpoint.
Switching from Diesel to Electric
If the Diesel to Electric Auto-Switch Enabled feature in Guarded Access is set
YES, the unit will automatically switch to Electric Mode operation when standby power is connected and available.
If the Diesel to Electric Auto-Switch Enabled feature in Guarded Access is set
NO, the prompt screen (
Figure 48, p. 55 ) will appear when standby power is
connected and available.
Figure 48.
Standby Power Connected
If NO is selected, the unit will continue to operate in Diesel Mode. If YES is
selected, the display will briefly show the screen ( Figure 49, p. 55
).
Figure 49.
YES Selected
Electric Mode operation will briefly be confirmed. If unit operation is required the electric motor will start as shown previously under STARTING
THE ELECTRIC MOTOR.
If the Diesel to Electric Auto-Switch Enabled feature in Guarded Access is set
NO, the unit can also be switched from Diesel mode to Electric mode
TK 56218-2-OP-EN 55
operation using the Electric Standby Selection from the Main Menu as shown later in this section.
Switching from Electric to Diesel
If the Electric to Diesel Auto-Switch Enabled feature in Guarded Access is set
YES, the unit will automatically switch to Diesel Mode operation when standby power is turned off or is no longer available.
If the Electric to Diesel Auto-Switch Enabled feature in Guarded Access is set
NO and standby power is disconnected or fails, the unit will not automatically switch to Diesel mode. This is primarily designed to prevent unauthorized diesel engine starts when the truck is indoors or on a ferry where engine operation is strictly prohibited. If the Electric to Diesel Auto-
Switch Enabled feature in Guarded Access is set NO, the prompt screen
(
) will appear when standby power is turned off or is no longer available.
Figure 50.
Standby Power is Off
If YES is selected, the display will briefly show the screen ( Figure 51, p. 56
).
Figure 51.
Yes Selected
56 TK 56218-2-OP-EN
Diesel Mode operation will briefly be confirmed. If unit operation is required, the diesel engine will start as shown previously under “Starting the Diesel
Engine”.
If the Electric to Diesel Auto-Switch Enabled feature in Guarded Access is set
NO, the unit can also be switched from Diesel mode to Electric mode operation using the Diesel Selection from the Main Menu as shown later in this section.
Initiating a Manual Defrost Cycle
Defrost cycles are usually initiated automatically based on time or demand.
Manual defrost is also available.
Manual defrost is available if the unit is running and the evaporator coil temperature is less than or equal to 45 F (7 C).
evaporator coil temperature less than or equal to 55 F (13 C).
Other features such as door switch settings may not allow manual defrost under some conditions. To initiate a manual defrost cycle, press the Defrost
Key (
Figure 52.
Press Defrost Key
The display briefly shows [DEFROST], [PROGRAMMING DEFROST - PLEASE
WAIT] and then [DEFROST STARTED] ( Figure 53, p. 58
).
TK 56218-2-OP-EN 57
Figure 53.
Defrost Started
The display then shows the Defrost display. The bar indicator shows approximately how much time remains to complete the defrost cycle. The
bar indicator shows that the defrost cycle is about 25% complete ( Figure 54, p. 58
).
Figure 54.
Bar Indicator
If conditions do not allow a defrost cycle, the display shown ( Figure 55, p.
58 ) will briefly appear. The display will then return to the Standard Display.
Figure 55.
Defrost Not Available
58 TK 56218-2-OP-EN
Terminating a Defrost Cycle
The defrost cycle terminates automatically when the coil temperature is greater than or equal to 58°F (14°C) or the defrost timer expires. Defrost can also be terminated by turning the unit off and back on.
or if the defrost timer expires.
Selecting Cycle Sentry or Continuous Mode
When Cycle Sentry Mode is selected, the unit will start and stop automatically to maintain setpoint, keep the engine warm, and the battery charged. When Continuous Mode is selected, the unit starts automatically and runs continuously to maintain setpoint and provide constant airflow.
OptiSet Plus is in use.
procedure.
If the unit is operating in Cycle Sentry Mode, the Cycle Sentry Icon will be present in the upper right corner of the display as shown below. If the Cycle
Sentry Icon ( Figure 56, p. 59 ) is not present the unit is operating in
Continuous Mode.
Figure 56.
Cycle Sentry Icon
If allowed by OptiSet Plus, Cycle Sentry Mode or Continuous Mode is
selected by pressing the Cycle Sentry/Continuous Key as shown ( Figure 57, p. 60
).
TK 56218-2-OP-EN 59
Figure 57.
Cycle Sentry/Continuous Key
Main Menu > Mode Submenu.
If the unit is in Cycle Sentry Mode, pressing the Cycle Sentry/Continuous Key changes the mode from Cycle Sentry Mode to Continuous Mode. The
display confirms the change ( Figure 58, p. 60
).
Figure 58.
Continuous Mode
The new mode is confirmed for three seconds ( Figure 59, p. 60
).
Figure 59.
New Mode Confirmed
The display then returns to the Standard Display. In the example shown
(
), the absence of the Cycle Sentry Icon indicates that the unit is running in Continuous Mode.
60 TK 56218-2-OP-EN
Figure 60.
Cycle Sentry Icon Not Shown = Continuous Mode
Pressing the Cycle Sentry/Continuous Key again allows the operator to change back to Cycle Sentry Mode operation.
Continuous Mode, the unit will start automatically.
OptiSet Plus is in use.
Using the Gauges Key
The GAUGES Key allows the operator to view the unit gauges. If the function of this key has been reassigned, the GAUGES Menu is also available in the
Maintenance Menu.
To access the GAUGES Menu, press the GAUGES Key (
Figure 61.
Gauges Key
The first gauge display will appear. Press the NEXT and BACK Keys to scroll through the gauges. Pressing the LOCK Key will lock the current gauge on the display (
TK 56218-2-OP-EN 61
Figure 62.
Gauge Display Locked
The gauges and I/O conditions available are shown on the next page. Not all gauges or I/O conditions may appear depending on unit configuration and software revision.
To return to the Standard Display press the EXIT Key.
Gauges Available
Fu ell L
Exchange Door.
an e:: Displays the current position of the optional Fresh Air devices listed here:
• High Speed Relay/Electric Heat
• Run Relay
• Spare Analog Input 2
• Spare Output 1
62 TK 56218-2-OP-EN
• Run Relay Feedback
• Alternator Excite Output
• Defrost Damper
• Heat Output
• Motor RPM
• Spare Digital Input 1
• Spare Digital Input 2
• Spare Digital Input 3
• Spare Digital Input 4
• Spare Output 2
• Spare Output 3
• Spare Output 4
• Spare Output 5
• Fresh Air Exchange Output
• Fresh Air Exchange Feedback
• Diesel/Electric Relay (SmartPower ™ units only)
• Electric Ready Input (SmartPower ™ units only)
• Electric overload (SmartPower ™ units only)
• Hot Gas Bypass • Spare Analog Input 1
Using the Sensors Key
The SENSORS Key allows the operator to view the unit gauges. If the function of this key has been reassigned, the SENSORS Menu is also available in the Maintenance Menu.
To access the SENSORS Menu, press the SENSORS Key:
Figure 63.
Sensors Key
TK 56218-2-OP-EN 63
The first sensor display will appear. Press the NEXT and BACK Keys to scroll through the sensors. Pressing the LOCK Key will lock the current sensor on the display (
Figure 64.
Next, Back, Lock Keys
The sensors available are shown below.
To return to the Standard Display, press the EXIT Key.
Sensors Available
return air sensor.
return air sensor.
control discharge air sensor.
display discharge air sensor.
Te mp control return air sensor and the control discharge air sensor.
Ev po coil sensor.
sensor.
temperature sensor.
temperature sensor 1.
temperature sensor 2.
64 TK 56218-2-OP-EN
temperature sensor 3.
temperature sensor 4.
temperature sensor 5.
temperature sensor 6.
Control Panel pc board.
* If sensors have been added.
Using the Main Menu
The Main Menu contains several additional submenus that allow the operator to view information and modify unit operation. To access the Main
Menu press the MENU Key ( Figure 65, p. 65
).
Figure 65.
Menu Key
The first Main Menu choice will appear. Press and hold the UP or DOWN
Keys to scroll through the menu choices. When the desired selection is shown on the display, press the SELECT Key to access it. The Pretrip
submenu is displayed ( Figure 66, p. 66
).
To return to the Standard Display press the EXIT Key.
TK 56218-2-OP-EN 65
Figure 66.
Pretrip Submenu
Main Menu Choices
Each of these Main Menu choices will be explained later in this section: to the USB Port on the unit Control Panel, the Flash Drive Menu will appear as a Main Menu selection.
an gu
> Language Menu, this menu item will appear.
allows most alarms to be cleared.
au ess:: The Gauges Menu allows the operator to view the unit gauges and
I/O conditions.
CargoWatch Data Logger temperature sensors.
located in the HMI Control Panel. It can support up to 6 optional temperature sensors.
hourmeters that have the view feature enabled in the Guarded Access menu.
modes that have been enabled in Guarded Access.
the keypad can be locked to prevent unauthorized use.
Configuration, the operator can select and set Sleep Mode from the Mode
Menu.
66 TK 56218-2-OP-EN
Sm arrttP we ™ E selection from the Main Menu allows the operator to manually select diesel or electric mode operation on units equipped with the electric standby
SmartPower option.
adjusted to allow for changing ambient light conditions.
Time and Date cannot be changed from the Main Menu.
Clle arr A
Unit (ECU) Fault Codes on applicable units with an ECU.
Pretrip
Pretrip Test verifies unit operation. This display allows a Pretrip Test to be selected and initiated by the operator. If the Pretrip Test is entered with the unit not running, a Full Pretrip Test with device amp checks will be performed. If the Pretrip Test is entered with the unit running in either diesel or electric mode, a Running Pretrip Test is performed. Test results are reported as PASS, CHECK, or FAIL when the Pretrip Test is completed.
Pretrip Test Conditions
• Current unit settings are saved and restored at the end of the Pretrip Test or if the unit is turned off and back on.
• Pretrip Test can be run in either Diesel or Electric Mode.
• The unit will auto switch from Diesel Mode to Electric Mode or from
Electric Mode to Diesel Mode during a Pretrip Test if these features are enabled and the auto switch conditions occur.
Conditions Where Pretrip Tests Are Not Allowed
• If any shutdown alarms are present. Pretrip tests are allowed with some
Check and Log alarms.
• If the unit is in Sleep Mode.
• If the unit is in Service Test Mode, Output Test Mode, or Evacuation
Mode.
Pretrip Test Considerations
When performing a Pretrip Test, the following issues should be considered:
• If running a Pretrip Test on a trailer loaded with dry cargo, verify that proper airflow can occur around the load. If the load restricts airflow, false test results may occur. Also, these units have high refrigeration
TK 56218-2-OP-EN 67
capacity which results in rapid temperature changes. Sensitive dry cargo may be damaged as a result.
• If running a Pretrip Test on a trailer that has just been washed down, the extremely high humidity inside the trailer may result in false test results.
• If running a Pretrip Test on a trailer loaded with sensitive cargo, monitor the load temperature during the test as normal temperature control is suspended during pre-trip operation.
• Always perform Pretrip Tests with the trailer cargo doors closed to prevent false test failures.
Pretrip Test Sequence
Pretrip tests proceed in the order shown below. A Full Pretrip Test is started with the engine or electric motor not running and includes all tests. A
Running Pretrip Test is started with the engine or electric motor running and does not include the Amp Checks or Engine Start Check.
• A p C ecckkss:: Each electrical control component is energized and the current drawn is confirmed as within specification.
• E giin e S
• D initiated.
• R the Cool Check.
• C
• H
• R ep orrtt T
FAIL when the Pretrip Test is completed. If test results are CHECK or FAIL alarm codes will exist to direct the technician to the source of the problem.
Performing a Pretrip Test
If a Pretrip Test is initiated with the engine or electric motor not running, a
Full Pretrip Test will be performed. If a Pretrip Test is initiated with the engine or electric motor running, a Running Pretrip Test is performed.
• Before initiating a Pretrip Test, clear all alarm codes.
• To stop a Pretrip Test at any time, turn the unit off.
Pretrip Tests are initiated using the Pretrip Menu. From the Standard
Display, press the MENU Key ( Figure 67, p. 69
).
68 TK 56218-2-OP-EN
Figure 67.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Pretrip Menu. When the Pretrip Menu is shown, press the
SELECT Key to start a Pretrip Test ( Figure 68, p. 69
).
Figure 68.
Select Key
The display will briefly show PROGRAMMING PRETRIP MODE (
69 ). If the unit is not running, a Full Pretrip Test will be initiated. If the unit is
running in either diesel or electric mode, a Running Pretrip Test will be performed.
Figure 69.
Programming Trip Mode
If all alarms were not cleared, a prompt appears ( Figure 70, p. 70 ). Exit the
Pretrip Test, clear all alarms, and repeat the Pretrip Test.
TK 56218-2-OP-EN 69
Figure 70.
Alarms Not Cleared
If all alarms were cleared, the Pretrip Test display appears ( Figure 71, p. 70
).
Figure 71.
Pretrip Test
• The top line of the display indicates the unit is performing the nonrunning portion of the Pretrip Test.
• The second line measures test progress. The number of tests completed of the total number of tests to be performed is shown. In the example above the unit is performing Test 1 of 26, Sensor Check.
• The soft keys may be used during the Pretrip Test to select the
Hourmeter, Gauge or Sensor menus.
• To stop a Pretrip Test at any time turn the unit off. This will generate
Alarm Code 28 Pretrip Abort. Other alarm codes may also be generated.
This is normal when the Pretrip Test is halted before completion.
When the non-running tests are complete, the unit will start automatically and continue with the Running Pretrip Test. In the example shown (
), the unit is in the Running Pretrip and is performing Test 21 of 26,
Cool Test.
70 TK 56218-2-OP-EN
Figure 72.
Cool Test
When all tests are complete, the results are reported as PASS, CHECK or
). If the results are CHECK or FAIL, the accompanying alarm codes will direct the technician to the cause of the problem.
Figure 73.
Pretrip Pass
If the Pretrip Test results are CHECK or FAIL, the problem should be diagnosed and corrected by a Thermo King service technician before the unit is released for service.
To return to the Main Menu, press the EXIT Key. To return to the Standard display press the EXIT Key again.
TK 56218-2-OP-EN 71
Flash Drive
If a properly configured USB Flash Drive is currently connected to the USB
Port on the unit Control Panel, the Flash Drive Menu will appear as a Main
Menu selection. If a properly configured USB Flash Drive is connected to the
USB Flash Drive connector, this feature allows the operator to select the desired Flash Drive function. If enabled when the Flash Drive was configured, the following functions may be available:
Download
• Download the ServiceWatch Data Logger
• Download the CargoWatch Data Logger
Flashload
• Flash load Base Controller Software
• Flash load HMI Control Panel Software
OptiSet Plus
• SEND
– Send OptiSet Plus files
• RETRIEVE
– Retrieve OptiSet Plus files appear in the Main Menu.
Flash Drive Icon
•
•
The USB Icon (
appear in the upper left corner of the display as shown below when a USB Flash
Drive is inserted in the USB Flash Drive
USB Port on the Unit Control Panel.
The USB Icon will also appear if a computer is connected to the USB PC
USB Port on the Unit Control Panel or inside the control box.
72 TK 56218-2-OP-EN
Figure 74.
Flash Drive Icon
Selecting the Flash Drive Menu from the Main Menu (If
Already Connected)
To select the Flash Drive Menu, press the MENU Key ( Figure 75, p. 73
). The
Main Menu will appear.
Figure 75.
Menu Key
If a properly configured USB Flash Drive is connected to the Flash Drive Only
USB Port on the Control Panel, the Flash Drive Menu will appear as a Main
Menu selection. Press the UP or DOWN Key as required to choose the Flash
Drive Menu. When the Flash Drive Menu is shown, press the SELECT Key to select the Flash Drive Menu (
Figure 76.
Flash Drive Menu
TK 56218-2-OP-EN 73
Flash Drive (If Connected While the Unit is Turned On)
If a properly configured USB Flash Drive is connected to the USB Port on the unit Control Panel while the unit is turned on, a Flash Drive indication will
appear for several seconds and the Flash Drive Menu will be shown ( Figure
).
Figure 77.
Flash Drive
Removing the Flash Drive
If the Flash Drive is disconnected, the display shown ( Figure 78, p. 74
) will appear for 30 seconds and the display will return to the Standard Display. To return to the Standard Display, immediately press the EXIT Soft Key.
Figure 78.
Flash Drive Removed
If the HELP Soft Key is pressed, the display shown (
appear.
74 TK 56218-2-OP-EN
Figure 79.
Help Soft Key Pressed
Languages
If more than one language is enabled from the Guarded Access > Language
Menu, this menu item will appear. If only one language is enabled, this menu will not appear. The Language Menu allows the operator to select a language from a list of up to four enabled languages. All subsequent displays are shown in the selected language. English is the default language.
Refer to the Language Setup Menu in Section 3 of the SR-4 Trailer S/T
Diagnostic Manual (TK 55533-2) for details.
If Languages are not enabled from the Guarded Access Menu, this feature will not appear in the Main Menu.
Control Panel displays will be in the new language.
Available Languages
The following languages are available:
English French Spanish Portuguese
Selecting an Alternate Language
To select an alternate language, press the MENU Key (
TK 56218-2-OP-EN 75
Figure 80.
Menu Key
The Main Menu will appear. If more than one language is enabled, the
Language Menu will appear as a Main Menu selection (
Press the UP or DOWN Key as required to choose the Language Menu. When the Language Menu is shown press the SELECT Key to select the Language
Menu.
Figure 81.
Main Menu
The Language Menu will appear as shown (
Figure 82, p. 76 ). Press the + or -
Keys to select the desired language. Only languages enabled from the
Guarded Access Menu are available. When the desired language is shown
(example is Español [Spanish]) press the YES Key to confirm the choice.
Figure 82.
Language Menu
76 TK 56218-2-OP-EN
The display will briefly show PROGRAMMING LANGUAGE - PLEASE WAIT in the new language. The display will then return to the Language Menu, but will show the new language. Español (Spanish) is shown (
Figure 83.
New Language (Example: Spanish)
Repeat the process to select a different language. To select a different Main
Menu item, press the NEXT (SIGUIENTE) Key. To return to the Standard
Display, press the EXIT (SALIDA) Key.
All displays will now be in the new language. Español (Spanish) is shown
(
).
Figure 84.
New Language (Example: Spanish)
To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.
ua ess (
Figure 85, p. 78 ) for an overview of the selection
procedure.
TK 56218-2-OP-EN 77
Figure 85.
Languages
Language Menu Quick Access
Should it be necessary at any time to change to English or any other installed language, return to the Standard Display and then press and hold the first and last soft keys for five seconds as shown below. The Standard
Display shown (
Figure 86, p. 78 ) is Español (Spanish).
Figure 86.
Standard Display in Español
After five seconds, the Language Menu will appear in the current language as shown below. Press the + or - Keys to select the desired language. When the desired language is shown, press the SI (YES) Key to confirm the choice
(
).
78 TK 56218-2-OP-EN
Figure 87.
Select Desired Language method.
Alarms
The Alarm Menu allows the operator to view any active alarms, and allows most alarms to be cleared.
Log Alarm
Log Alarms are indicated for 30 seconds each time the unit is turned on. This level of alarm serves as a notice to take corrective action before a problem becomes severe. Maintenance items such as maintenance hourmeter timeouts are Log Alarms. The TemperatureWatch ™ screen is not disabled if only
Log Alarm(s) are active.
When the unit is turned on, the display will show the Thermo King Logo and then the “Configuring System” message. If Log Alarm(s) are present, the
Log Alarm notice will appear on the display for 30 seconds. The remote indicator alarm light (if installed) will also be on during this period. After 30 seconds, the Standard Display will appear and the remote indicator alarm light will go off.
Figure 88.
Log Alarms Exist
TK 56218-2-OP-EN 79
Check Alarm
Check Alarms are indicated by a steady alarm indication at the top of the display and the message “Service Required within 24 Hours”. The Alarm
Icon will appear. This level of alarm serves as a notice to take corrective action before a problem becomes severe. The unit will run with Check
Alarms but some features and functions may be inhibited. The
TemperatureWatch screen is disabled if a Check Alarm is active.
If a Check Alarm condition occurs while the unit is running, the alarm icon
will appear in the display as shown ( Figure 89, p. 80 ).
Figure 89.
Alarm Icon
Prevent Alarm
Prevent Alarms are indicated by a steady alarm indication at the top of the display and the message “Service Required within 24 Hours”. The Alarm
Icon will appear. The unit will be temporarily shut down if a Prevent Alarm is active. The unit will remain shut down for a timed restart interval or until the fault conditions are corrected and then restart. If the unit is in a temporary shutdown, Alarm Code 84 Restart Null will be present along with the associated Prevent Alarm. In most cases, the unit will restart with reduced performance to determine if continued operation is possible. If the alarm does not reoccur with reduced performance, the unit will return to full performance. If the unit is operating with reduced performance, Alarm Code
85 Forced Unit Operation will also be present under some conditions. In general, if the alarm condition reoccurs a defined number of times, the alarm is set as a Shutdown Alarm and no further restarts are possible. The
Temperature Watch screen is disabled if a prevent alarm is active.
set for CONTINUOUS, an unlimited number of restart attempts are allowed.
80 TK 56218-2-OP-EN
Shutdown Alarm
If a Shutdown Alarm occurs while the unit is running, it will be indicated by all of the following (
):
• The Alarm Icon will appear.
• The display, backlight and optional remote alarm light will flash on and off.
• The display will switch from normal to inverted and back (light areas become dark and dark areas become light.)
Shutdown Alarms will force the unit into shutdown. The unit will remain in shutdown until the Shutdown Alarm is manually cleared. Exceptions are some engine and electric Shutdown Alarms that become Log Alarms when switched to the alternate operating mode (diesel to electric or electric to diesel). The TemperatureWatch screen is disabled if a unit level Shutdown
Alarm is active.
Figure 90.
Reverse/Normal Video
Pretrip Alarm
If an alarm occurs during a Pretrip Test, the alarm code will be displayed as
Pretrip Alarm XX, where XX is the alarm code.
Alarm Codes When Switching Between Diesel and Electric
If a shutdown alarm occurs that affects only diesel mode operation and the unit is switched to electric, the diesel mode shutdown alarm becomes an electric mode log alarm. This allows the unit to run in electric mode without clearing the shutdown alarm that is preventing diesel mode operation. If the unit is switched back to diesel mode, the alarm again become a diesel mode shutdown alarm and prevents unit operation.
In the same manner, if a shutdown alarm occurs that affects only electric mode operation and the unit is switched to diesel, the electric mode shutdown alarm becomes a diesel mode log alarm to allow diesel mode
TK 56218-2-OP-EN 81
operation. If the unit is switched back to electric mode, the alarm reverts to an electric mode shutdown alarm and prevents unit operation. If the unit is configured for electric to diesel Auto-Switch, it automatically starts and runs in diesel mode if an electric shutdown occurs.
Clearing Alarm Codes
Most alarm codes can be cleared conventionally from the Alarm Menu using the CLEAR Key.
The following control and display sensor alarm codes can only be cleared from the Maintenance Menu or Guarded Access Menu:
• Alarm Code 03 Check Control Return Air Sensor
• Alarm Code 04 Check Control Discharge Air Sensor
• Alarm Code 203 Check Display Return Air Sensor
• Alarm Code 204 Check Display Discharge Air Sensor
• Alarm Code 74 Controller Reset to Defaults.
The following alarm codes clear automatically:
• Alarm Code 64 Pretrip Reminder - Clears when a Pretrip Test is performed.
• Alarm Code 84 Restart Null - Clears when the unit is no longer in a restart null due to a Prevent Alarm.
• Alarm Code 85 Forced Unit Operation - Clears when the unit is no longer running in a forced mode due to a Prevent Alarm.
• Alarm Code 91 Check Electric Ready Input - Clears automatically when electric power is restored.
• Alarm Code 92 Sensor Grades Not Set - Clears when the sensor grade is changed from 5H.
If the Limited Alarm Restarts feature is enabled, the following additional alarm codes may only be cleared from the Guarded Access Menu. If this is the case, the CLEAR soft key will not appear if the alarms are displayed from the Main Menu or the Maintenance Menu.
• Alarm Code 10 High Discharge Pressure
• Alarm Code 23 Cooling Cycle Fault
• Alarm Code 24 Heating Cycle Fault
• Alarm Code 32 Refrigeration Capacity Low
82 TK 56218-2-OP-EN
Displaying and Clearing Alarm Codes
Alarms are displayed and cleared using the Alarm Menu. From the Standard
Display, press the MENU Key ( Figure 91, p. 83
).
Figure 91.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Alarms Menu (
Figure 92, p. 83 ). When the Alarms Menu is
shown, press the SELECT Key to select the Alarms Menu.
Figure 92.
Up/Down, Select Keys
The number of alarms (if more than one) and a list of the alarms with the
most recent alarm first will be shown. In the example shown ( Figure 93, p.
84 ), there are two alarms. The most recent is Alarm Code 5 Check Ambient
Temp Sensor.
TK 56218-2-OP-EN 83
Figure 93.
Alarms Menu
If necessary to view all alarms, scroll down using the DOWN Key (
).
Figure 94.
Down Key
If the alarm situation has been resolved, press the CLEAR Key to clear the
).
Figure 95.
Clear Key
The display will briefly show CLEARING ALARM 5 – PLEASE WAIT and the
Alarm Menu will reappear (
Alarm Code 64 Pretrip Reminder cannot be cleared using the CLEAR Key.
This alarm will clear automatically when a Pretrip Test is run.
84 TK 56218-2-OP-EN
Figure 96.
Pretrip Reminder
If a serious condition occurs, the unit will be shut down to prevent damage to the unit or the load. If this occurs, the Alarm Icon will appear, the display
and backlight will flash on and off ( Figure 97, p. 85 ).
Figure 97.
Unit Shutdown
The Alarm Menu display will display the Shutdown Alarm Code. For additional information regarding the alarm shown on the display, press the
HELP Key (
Figure 98.
Help Key
TK 56218-2-OP-EN 85
A help message will appear. Press the EXIT Key to return to the Alarms
). Check the oil level and add oil as required, clear the alarm and restart the engine.
Figure 99.
Exit Key
To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.
Important Alarm Notes
• If an alarm will not clear, it may still exist. If the alarm is not corrected, it will not clear or may be immediately set again.
• If an alarm cannot be cleared from the Main menu, the Clear Key will not appear. These alarms must be cleared from the Maintenance or Guarded
Access Menus.
procedure.
86 TK 56218-2-OP-EN
Gauges
The Gauges Menu allows the operator to view the unit gauges and I/O conditions. The unit gauges can always be viewed from the Main Menu. This is necessary if the GAUGES Soft Key on the Standard Display has been reassigned to a different function.
Displaying Gauges
Gauges are displayed using the Gauges Menu. From the Standard Display,
press the MENU Key ( Figure 100, p. 87 ).
Figure 100.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Gauges Menu. When the Gauges Menu is selected, press the
SELECT Key to choose the Gauges Menu (
).
Figure 101.
Up, Down, Select Keys
The first gauge display will appear. Press the NEXT and BACK Keys to scroll through the gauges and I/O conditions. Pressing the LOCK Key will lock the current gauge on the display (
).
TK 56218-2-OP-EN 87
Figure 102.
Next, Back, Lock Keys
The gauges and I/O conditions available are described in “Using the Gauges
Key”. Not all gauges or I/O conditions may appear depending on unit configuration and software revision.
To return to the Main Menu, press the EXIT Key. To return to the Standard
Display, press the EXIT Key again.
Sensors
The Sensors Menu allows the operator to view the unit and CargoWatch
Data Logger temperature sensors. The sensors can always be viewed from the Main Menu. This is necessary if the SENSORS Soft Key on the Standard
Display has been reassigned to a different function.
Displaying Sensors
Sensors are displayed using the Sensors Menu. From the Standard Display,
press the MENU Key ( Figure 103, p. 88 ).
Figure 103.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Sensors Menu. When the Sensors Menu is selected, press the
SELECT Key to choose the Sensors Menu (
).
88 TK 56218-2-OP-EN
Figure 104.
Up, Down, Select Keys
The first sensors display will appear. Press the NEXT and BACK Keys to scroll through the sensors and I/O conditions. Pressing the LOCK Key will lock the current sensor on the display (
).
Figure 105.
Next, Back, Lock Keys
The sensors available are described in
“Using the Sensors Key,” p. 63 .
To return to the Main Menu, press the EXIT Key. To return to the Standard
Display, press the EXIT Key again.
Data Logger (CargoWatch)
The CargoWatch Data Logger is physically located in the HMI Control Panel.
It can support up to 6 optional temperature sensors.
When shipped from the factory, CargoWatch sensors 1 and 2 are turned on to be logged and CargoWatch sensors 3 through 6 are turned off. Also, digital input 1 is turned on to be logged and digital inputs 2 through 4 are turned off. Sensors and digital inputs can be turned on, off and configured using the CargoWatch menu in Guarded Access or with WinTrac. The
CargoWatch Data Logger can also be configured using the USB Flash Drive
OptiSet Plus Feature.
TK 56218-2-OP-EN 89
A Start of Trip can be sent to the unit ServiceWatch and CargoWatch Data
Loggers. In addition, the CargoWatch Data Logger contents can be printed with a hand-held printer.
The ServiceWatch and CargoWatch Data Logger are accessed using the Data
Logger Menu. From the Standard Display, press the MENU Key ( Figure 106, p. 90
).
Figure 106.
Standard Screen, Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Data Logger Menu. When the Data Logger Menu is selected, press the SELECT Key to choose the Data Logger Menu (
).
Figure 107.
Up, Down, Select Keys
The Data Logger Menu will appear.
Sending Start of Trip Marker to CargoWatch and
ServiceWatch Data Loggers
To send a Start of Trip marker to the CargoWatch and ServiceWatch Data
Loggers, press the SELECT Key. The display will briefly show START OF TRIP
COMPLETE to confirm that a Start of Trip marker was set in the CargoWatch
Data Logger ( Figure 108, p. 91 ).
90 TK 56218-2-OP-EN
Figure 108.
Select Key, Start of Trip Complete
ServiceWatch data loggers.
Printing CargoWatch Data Logger Reports
Press the DOWN Key to select the PRINT / VIEW feature and press the
SELECT Key to choose Print/View (
Figure 109.
Select Key, Print/View
The Print Data Menu will appear. The first Print Data Menu allows the operator to print a Delivery Ticket using a hand held printer. Pressing the
SELECT Key will print the ticket (
). The Delivery Ticket is a short ticket that shows delivery specific details including the current
temperature. A Sample Delivery Ticket is shown ( Figure 111, p. 92 ).
TK 56218-2-OP-EN 91
Figure 110.
Select Key, Print Delivery Ticket
Figure 111.
Sample Delivery Ticket
Pressing the DOWN Key allows the operator to print a Trip Ticket using a
hand held printer. Press the SELECT Key to print the ticket ( Figure 112, p.
92 ). The Trip Ticket is a long ticket that shows details for the current trip
including a temperature history. The Trip Ticket is also called a Journey
Ticket. A sample Trip Ticket is shown (
).
Figure 112.
Select Key, Print Trip Ticket
92 TK 56218-2-OP-EN
Figure 113.
Sample Trip Ticket
To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.
Hourmeters
The Hourmeters Menu allows the operator to view the unit hourmeters that have the view feature enabled in the Guarded Access Menu. If the view feature for a particular hourmeter is not enabled, that hourmeter will continue to accumulate time but cannot be viewed from the Main Menu.
However, all hourmeters can be viewed from the Maintenance Menu, even if they are not enabled. The hourmeters shown below are implemented.
Viewing Hourmeters
Only Hourmeters that have been enabled in Guarded Access are shown from the Main Menu. The Hourmeters can be viewed only.
Hourmeters are displayed using the Hourmeter Display. From the Standard
Display, press the MENU Key ( Figure 114, p. 94 ).
TK 56218-2-OP-EN 93
Figure 114.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Hourmeter Menu. When the Hourmeter Menu is selected, press
the SELECT Key to choose the Hourmeter Menu ( Figure 115, p. 94 ).
Figure 115.
Select Key
Press the NEXT or PREVIOUS Key to scroll through the hourmeters ( Figure
Figure 116.
Up/Down Keys
Hourmeter names and definitions are shown below in the order they appear.
Only hourmeters enabled in the Guarded Access Menu will be shown. To return to the Standard Display, press the EXIT Key.
94 TK 56218-2-OP-EN
When shipped from the factory, only these hourmeters are enabled for viewing from the Main Menu:
• Total Unit Run Hours
• Total Engine Run Hours
• Total Electric Run Hours
To return to the Main Menu, press the EXIT Key. To return to the Standard
Display, press the EXIT Key again.
Hourmeter Names and Definitions
Only configured hourmeters that have been enabled in the Viewable
Hourmeter Setup Menu will be shown:
Hourmeter Name
Total Hours
Total Run Time Hours
Engine Hours
Electric Run Hours
Total Run Reminder 1
Total Run Reminder 2
Controller Power On
Pretrip Reminder
Engine Reminder 1
Engine Reminder 2
Definition
Total number of hours the unit has been turned on (protection hours).
Total number of hours the unit has run in both diesel and electric mode.
Total number of hours the unit has run in diesel mode.
Total number of hours the unit has run in electric mode.
User Programmable - The number of hours before a Total Unit Run Time
Maintenance Reminder 1 occurs.
User Programmable - The number of hours before a Total Unit Run Time
Maintenance Reminder 2 occurs.
Total hours the controller and HMI
Control Panel have been turned on.
User Programmable - number of hours before a Pretrip Reminder occurs.
User Programmable - The number of hours before an Engine Run Time
Maintenance Reminder 1 occurs.
User Programmable - The number of hours before an Engine Run Time
Maintenance Reminder 2 occurs.
TK 56218-2-OP-EN 95
Hourmeter Name
Electric Reminder 1
Electric Reminder 2
Definition
User Programmable - The number of hours before an Electric Run Time
Maintenance Reminder 1 occurs.
User Programmable - The number of hours before an Electric Run Time
Maintenance Reminder 2 occurs.
hourmeter is not turned on it will not appear in the display sequence.
Mode
The Mode Menu allows the operator to change the unit operating modes that have been enabled in Guarded Access. Only Operating Modes that have been enabled from the Guarded Access > Main Menu Configuration Menu will be shown.
• Turns Off Cycle Sentry Mode/Turns On Cycle Sentry Mode (If Cycle
Sentry is turned Off unit runs in Continuous). Note that selecting Cycle
Sentry Mode or Continuous Mode can also be accomplished using the
Cycle Sentry Key to the right of the display.
• Allows temperature to be displayed in either Fahrenheit or Celsius degrees (if enabled from the Guarded Access > Main Menu Configuration
Menu).
• Allows the optional Fresh Air Exchange door to be opened or closed (if enabled from the Guarded Access > Hardware Configuration Menu).
• Allows Keypad Lockout to be selected (if enabled from the Guarded
Access > Main Menu Configuration Menu).
• Allows Sleep Mode to be set up and started (if enabled from the
Guarded Access > Main Menu Configuration Menu).
When shipped from the factory, only the Cycle Sentry/Continuous Mode is enabled.
If OptiSet Plus is in use, some modes may not be available.
To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.
Using the Change Mode Menu
Mode changes are made using the Mode Menu. From the Standard Display,
press the MENU Key ( Figure 117, p. 97 ).
96 TK 56218-2-OP-EN
Figure 117.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Mode Menu. When the Mode Menu is selected, press the SELECT
Key to choose the Mode Menu ( Figure 118, p. 97 ).
Figure 118.
Up, Down, Select Keys
The first enabled Change Mode Menu selection will appear. To choose that function, press the SELECT Soft Key. To Scroll through the enabled features in the Change Mode Menu, press the UP and DOWN Soft Keys (
).
Figure 119.
Select, Up, Down Keys
Possible mode selections are shown later in this section.
TK 56218-2-OP-EN 97
• Only those modes that have been enabled will appear. Only the Cycle
Sentry Menu is enabled on factory units.
• Not all modes may be available, depending on OptiSet Plus usage and the settings of other programmable features.
• To return to the Standard Display press the EXIT Key.
• The modes shown below may be available.
Turn Cycle Sentry On or Off
Cycle Sentry Mode can be turned On or Off if Cycle Sentry Mode is allowed by OptiSet Plus. If Cycle Sentry is turned off, the unit runs in Continuous mode, unless Continuous Mode is not allowed by OptiSet Plus. Either Cycle
Sentry or Continuous operation can be disabled via OptiSet Plus. From the
Main Menu > Change Mode menu choose Turn On/Off Cycle Sentry Mode
and press the SELECT Soft Key ( Figure 120, p. 98 ).
Figure 120.
Select Key
If the unit is running in Cycle Sentry Mode, press the SELECT Soft Key
(
Figure 121, p. 98 ) to turn off Cycle Sentry Mode as shown.
Figure 121.
Select Key
Confirmation screens will appear briefly, the unit will switch to Continuous
Mode operation and the Cycle Sentry Icon will disappear.
98 TK 56218-2-OP-EN
To turn Cycle Sentry back on, press the SELECT Key again.
To leave this menu without changing the setting, press the EXIT Soft Key. To return to the Standard Display, press the EXIT Soft Key again.
Sentry Key on the HMI Control Panel.
Select Temperature Units
If this feature enabled in Guarded Access > Main Menu Configuration, the operator can select temperature units to be displayed as either degrees
Fahrenheit or degrees Celsius. From the Main Menu > Change Mode menu
choose Fahrenheit or Celsius and press the SELECT Soft Key ( Figure 122, p.
Figure 122.
Fahrenheit or Celsius, Select Key
Choose the desired Temperature Units using the UP and DOWN Soft Keys
and press the SELECT Soft Key to select the choice ( Figure 123, p. 99 ).
Figure 123.
Up, Down, Select Keys
Temperatures will be displayed in the selected units.
• To leave this menu without changing the setting, press the EXIT Soft
Key. To return to the Standard Display, press the EXIT Soft Key again.
TK 56218-2-OP-EN 99
Fresh Air Exchange Open or Closed
If installed and enabled in Guarded Access > Main Menu Configuration, the
Fresh Air Exchange option allows fresh outside air to be drawn into the trailer and the interior air to be exhausted by opening the Fresh Air
Exchange door. This feature is beneficial when hauling loads that release gas as they ripen, such as potatoes. The Fresh Air Exchange feature is only available with setpoints above 32°F (0°C). The feature is disabled with setpoints of 32°F (0°C) and below. This feature may not be available if
OptiSet Plus is in use.
specified by the customer.
The Fresh Air Exchange door will only be open when the unit engine is running. The door will close when the engine shuts down to preserve unit battery life.
The setting of the Fresh Air Exchange door will survive power off/power on cycles, if the door is set to “Open” by the operator, it will continue to open any time the engine is running until it is set to “Close” by the operator.
From the Change Mode menu choose Open Fresh Air Exchange and press
the SELECT Soft Key ( Figure 124, p. 100
).
Figure 124.
Select Key
To open the Fresh Air Exchange door press the SELECT Key as shown below.
100 TK 56218-2-OP-EN
Figure 125.
Select Key
The Fresh Air Exchange door will open. To close the Fresh Air Exchange door press the SELECT Key again.
To leave this menu without changing the setting, press the EXIT Soft Key. To return to the Standard Display, press the EXIT Soft Key again.
Keypad Lockout
If enabled in Guarded Access > Main Menu Configuration, the keypad can be locked to prevent unauthorized use. If the keypad is locked, only the On Key and Off Key function. The keypad will remain locked even if the unit is turned off and back on. If Keypad Lockout is active, press and hold any soft key for five seconds to deactivate the feature. To turn the feature on, from the
Change Mode menu choose Keypad Lockout and press the SELECT Soft Key
(
).
Figure 126.
Select Key
A Confirmation Request will appear. To activate Keypad Lockout press the
YES Soft Key. To leave this menu without turning the Keypad Lockout feature on, press the NO Soft Key (
).
TK 56218-2-OP-EN 101
Figure 127.
Yes, No Soft Keys
If the YES Soft Key was pressed, Keypad Lockout is active. Repeat the process to turn the Keypad Lockout feature off.
• If the keypad is locked, only the On Key and Off Key function. The keypad will remain locked even if the unit is turned off and back on.
• If Keypad Lockout is active, press and hold any soft key for five seconds to deactivate the feature.
• To return to the Standard Display, press the EXIT Soft Key again.
Start Sleep Mode
If this feature enabled in Guarded Access > Main Menu Configuration, the operator can select and set Sleep Mode from the Mode Menu. Sleep Mode is used to keep the engine warm and the battery charged when the unit is not in use. When the unit is Sleep Mode the display will show “SLEEP” and the current time. To turn the feature on, from the Change Mode menu choose
Start Sleep Mode and press the SELECT Soft Key (
).
Figure 128.
Select Soft Key
The following features are available in Sleep Mode. Follow the display prompts to select and set the features.
• P og specified. When the selected time is reached, the unit will start and
102 TK 56218-2-OP-EN
resume normal operation. If a Wakeup Time is selected, the following features are available:
– Day to Wake Up: This feature allows the day the unit is to wake up to be specified.
– Hour to Wake Up: This feature allows the hour the unit is to wake up to be specified.
– Minute to Wake Up: This feature allows the minute the unit is to wake up to be specified.
– Run Pretrip on Wakeup: This feature allows a Pretrip Test to be automatically run when the unit wakes up.
SmartPower ™ Electric Standby Option
The Diesel/Electric Standby selection from the Main Menu allows the operator to manually select diesel or electric mode operation on units equipped with the electric standby SmartPower option. The unit can also be programmed to automatically switch to Electric Mode operation when standby power is available and to automatically switch to Diesel Mode operation if standby power fails or is removed. If the unit is programmed to automatically switch from diesel to electric and/or electric to diesel, the associated screens do not appear.
• If the unit is currently operating in Diesel Mode, the ELECTRIC STANDBY selection will appear in the Main Menu.
• If the unit is currently operating in Electric Mode, the DIESEL MODE selection will appear in the Main Menu.
Electric Mode Operation
If a unit equipped with the electric standby SmartPower option is running in
Diesel Mode, the Diesel to Electric Auto-Switch feature is set NO and the unit is connected to a source of standby power, this feature allows the operator to manually select electric mode operation. This feature does not appear if the electric standby SmartPower option is not installed or if the Diesel to
Electric Auto-Switch feature is set YES.
Diesel Mode Operation
If a unit equipped with the electric standby SmartPower option is running in
Electric Mode and the Electric to Diesel Auto-Switch feature is set NO, this feature allows the operator to manually select diesel mode operation. This feature does not appear if the electric standby SmartPower option is not installed or if the Electric to Diesel Auto-Switch feature is set YES.
TK 56218-2-OP-EN 103
Switching from Diesel to Electric
If the unit is running in Diesel Mode and the Diesel to Electric Auto-Switch
Enabled feature in Guarded Access is set YES, the unit will automatically switch to Electric Mode operation when standby power is connected and available. The screens shown will not appear.
If the unit is running in Diesel Mode and the Diesel to Electric Auto-Switch
Enabled feature in Guarded Access is set NO, the unit can be switched to
Electric Mode using the Electric Standby selection from the Main Menu.
From the Standard Display, press the MENU Key (
).
Figure 129.
Menu Key
From the Main Menu choose Electric Standby and press the SELECT Soft
Key (
Figure 130.
Select Key
If the unit has standby power available and is turned on, the electric standby run screen will appear. The new mode is confirmed for 10 seconds. The unit will start and run in Electric Mode.
Any engine related Shutdown Alarms become Log Alarms when the unit is switched to Electric Mode operation. If the unit is switched back to Diesel
Mode, these alarms again become Shutdown Alarms.
104 TK 56218-2-OP-EN
Electric Standby Power Fails or is Disconnected
If the electric standby power source fails or is disconnected and manual switching to Diesel Mode is selected, the unit will prompt for a switch to
Diesel Mode (
Figure 131.
Diesel Mode Prompt
• Pressing the YES Soft Key will switch unit operation back to Diesel
Mode.
• Pressing the NO Soft Key will allow the unit to remain in Electric Mode even though standby power is not available.
The unit will not run and Alarm Code 91 Check Electric Ready Input will be set as a Prevent Alarm.
Switching from Electric to Diesel
If the unit is running in Electric Mode and the Electric to Diesel Auto-Switch
Enabled feature in Guarded Access is set YES, the unit will automatically switch to Diesel Mode operation when standby power is no longer available.
The screens shown will not appear.
If the Diesel to Electric Auto-Switch Enabled feature in Guarded Access is set
NO and standby power is disconnected or fails, the unit will not automatically switch to Diesel mode. This is primarily designed to prevent unauthorized diesel engine starts when the truck is indoors or on a ferry where engine operation is strictly prohibited.
From the Standard Display, press the MENU Key (
).
TK 56218-2-OP-EN 105
Figure 132.
Menu Key
From the Main Menu choose Diesel Mode and press the SELECT Soft Key
(
).
Figure 133.
Select Key
The new mode is confirmed for 10 seconds. The unit will start and run in
Diesel Mode.
Any electric standby related Shutdown Alarms become Log Alarms when the unit is switched to Diesel Mode operation. If the unit is switched back to
Electric Mode, these alarms again become Shutdown Alarms.
Adjust Brightness
The brightness of the HMI Control Panel display can be adjusted to allow for changing ambient light conditions. The choices available to the operator are
HIGH, MEDIUM, LOW, and OFF. OFF actually results in a very dim screen suitable for low light conditions.
Display brightness is adjusted using the Adjust Brightness Menu. From the
Standard Display, press the MENU Key ( Figure 134, p. 107 ).
106 TK 56218-2-OP-EN
Figure 134.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Adjust Brightness Menu. When the Adjust Brightness is selected, press the SELECT Key to choose the Adjust Brightness (
Figure 135.
Select Key
The Display Brightness menu will appear as shown. Press the UP or DOWN
Soft Keys to select the desired display brightness. When the desired brightness is shown, press the SELECT Soft Key to confirm the choice
(
).
Figure 136.
Select Key
To return to the Main Menu press the EXIT Key. To return to the Standard
Display, press the EXIT Key again.
TK 56218-2-OP-EN 107
Time
The Time and Date held by the HMI Control Panel can be checked. Time and
Date cannot be changed from the Main Menu. The time and date is accessed using the Main Menu. From the Standard Display, press the MENU Key
(
).
Figure 137.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Time Menu. When the Time Menu is selected, press the SELECT
Key to choose the Time Menu (
Figure 138.
Select Key
The date and time held in the HMI Control Panel will be shown on the display
(
). Time and Date cannot be changed from the Main Menu.
108 TK 56218-2-OP-EN
Figure 139.
Date and Time
To return to the Main Menu press the EXIT Key. To return to the Standard
Display, press the EXIT Key again.
Clear All ECU Faults
Pressing this key will clear all existing Engine Control Unit (ECU) Fault
Codes. This may allow continued unit operation should an ECU fault code result in engine shutdown.
• Any Thermo King Alarm Codes associated with the Engine Control Unit
(ECU) Fault Codes will also be cleared.
• The Thermo King Alarm Codes and ECU Fault Codes that were cleared can be viewed in the ServiceWatch and ECU Data Loggers.
Engine Control Unit (ECU) Fault Codes are cleared using the Clear All ECU
Faults Menu. From the Standard Display, press the MENU Key (
Figure 140.
Menu Key
The Main Menu will appear. Press the UP or DOWN Key as required to choose the Clear All ECU Faults Menu. When the Clear All ECU Faults Menu is selected, press the SELECT Key to choose the Clear All ECU Faults Menu
(
).
TK 56218-2-OP-EN 109
Figure 141.
Select Key
The Clear All ECU Faults Prompt will appear. To clear all ECU Faults and associated Thermo King Faults, press the CLEAR Soft Key (
).
Figure 142.
Clear Key
All ECU Faults and associated Thermo King Faults will be cleared.
To return to the Main Menu press the EXIT Key. To return to the Standard
Display, press the EXIT Key again.
110 TK 56218-2-OP-EN
Alarm Codes
Introduction
An alarm code is generated when the microprocessor senses an abnormal condition. Alarms direct an operator or service technician to the source of a problem.
Multiple alarms can be present at one time. All generated alarms will be stored in memory until cleared by the operator. Document all alarm occurrences and report them to the service technician.
See “Alarms Menu” in the Operator’s Instructions Chapter for information about viewing and clearing alarms.
occur – as well as any other pertinent information. This information is extremely valuable to service personnel.
1. Some alarms (3, 4, 74, 203, and 204) cannot be cleared in the
Alarms Menu, they must be cleared in the Maintenance Menu or the Guarded Access Menu. Contact your supervisor or a Thermo
King dealer about clearing those alarms.
2. In some cases alarms cannot be cleared, or cannot be cleared after they have occurred a specified number of times. If such is the case, these alarms must be cleared by a service technician.
Alarm Types
There are four types of alarms.
Log Alarms
Log Alarms are indicated for 30 seconds each time the unit is turned on. This level of alarm serves as a notice to take corrective action before a problem becomes severe. Maintenance items such as maintenance hourmeter timeouts are Log Alarms. The TemperatureWatch ™ screen is not disabled if only
Log Alarm(s) are active.
When the unit is turned on, the display will show the Thermo King Logo and then the “Configuring System” message. If Log Alarm(s) are present, the
Log Alarm notice will appear on the display for 30 seconds. The remote indicator alarm light (if installed) will also be on during this period. After 30
TK 56218-2-OP-EN 111
seconds, the Standard Display will appear and the remote indicator alarm light will go off.
Figure 143.
Log Alarms Screen
Check Alarms
Check Alarms are indicated by a steady alarm indication at the top of the display and the message “Service Required within 24 Hours”. The Alarm
Icon will appear. This level of alarm serves as a notice to take corrective action before a problem becomes severe. The unit will run with Check
Alarms but some features and functions may be inhibited. The
TemperatureWatch screen is disabled if a Check Alarm is active.
Figure 144.
Alarm Display
Prevent Alarms
Prevent Alarms are indicated by a steady alarm indication at the top of the display and the message “Service Required within 24 Hours”. The Alarm
Icon will appear. The unit will be temporarily shut down if a Prevent Alarm is active. The unit will remain shut down for a timed restart interval or until the fault conditions are corrected and then restart. If the unit is in a temporary shutdown, Alarm Code 84 Restart Null will be present along with the associated Prevent Alarm. In most cases, the unit will restart with reduced
112 TK 56218-2-OP-EN
performance to determine if continued operation is possible. If the alarm does not reoccur with reduced performance, the unit will return to full performance. If the unit is operating with reduced performance, Alarm Code
85 Forced Unit Operation will also be present under some conditions. In general, if the alarm condition reoccurs a defined number of times, the alarm is set as a Shutdown Alarm and no further restarts are possible. The
TemperatureWatch screen is disabled if a prevent alarm is active.
set for CONTINUOUS, an unlimited number of restart attempts are allowed.
Shutdown Alarms
Depending on software revisions, Shutdown Alarms may be indicated by the following:
• The Alarm Icon will appear.
• The display and backlight will flash on and off.
• The display will switch from normal to inverted and back (light areas become dark and dark areas become light).
Shutdown Alarms will force the unit into shutdown. The unit will remain in shutdown until the Shutdown Alarm is manually cleared. Exceptions are some engine and electric Shutdown Alarms that become Log Alarms when switched to the alternate operating mode (diesel to electric or electric to diesel). The TemperatureWatch screen is disabled if a unit level Shutdown
Alarm is active.
Figure 145.
Shutdown Alarm Display
Pretrip Alarm Codes
If an alarm occurs during a Pretrip Test the alarm code will be displayed as
Pretrip Alarm XX, where XX is the alarm code.
TK 56218-2-OP-EN 113
Clearing Alarm Codes
Most alarm codes can be cleared conventionally from the Alarm Menu using the CLEAR soft key. See the Operating Instructions chapter for procedures.
The operator should contact a supervisor or a Thermo King dealer about
clearing alarms using the Guarded Access Menu. Refer to ( Table 1, p. 114 )
for alarm corrective action.
There are three levels of corrective action that can be taken when an alarm condition occurs.
o R n:: An alarm condition exists but does not affect unit operation.
Corrective action can occur at a later date.
operation. Follow diections in the Corrective Action column on the following chart.
Accttiio n:: An alarm condition exists that will damage the unit or load. Take immediate action to correct the problem.
in
are suggestions only. Always consult your company for final decisions.
otte
shows all possible alarm codes for all possible applications. Not all codes will be applicable to each individual unit.
Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Table 1.
Table of Alarm Codes
Num
COLOR CODE
DEFINITIONS:
Description
OK TO
RUN
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
00
02
No Alarms Exist
Check Evaporator Coil Sensor
03
04
05
Check (Control) Return Air
Sensor
Check (Control) Discharge Air
Sensor
Check Ambient Temp Sensor
No action required.
Manually monitor load temperature.
Report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
Report alarm at end of day.
114 TK 56218-2-OP-EN
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
COLOR CODE
DEFINITIONS:
Description
06
07
(09)
Check Coolant Temp Sensor
Check Engine RPM Sensor
High Evaporator Temperature
(10)
11
12
13
(17)
(18)
(19)
(20)
(21)
(22)
(23)
High Discharge Pressure
Unit Controlling on Alternate
Sensor
Sensor or Digital Input
Shutdown
Sensor Calibration Check
Engine Failed to Crank
High Engine Coolant
Temperature
Low Engine Oil Pressure
Engine Failed to Start
Cooling Cycle Check
Heating Cycle Check
Cooling Cycle Fault
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
Report alarm at end of day.
Report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
The unit is no longer able to operate and has been shut down. Repair immediately.
Manually monitor load temperature.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
The unit is no longer able to operate and has been shut down. Repair immediately.
TK 56218-2-OP-EN 115
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
COLOR CODE
DEFINITIONS:
Description
(24) Heating Cycle Fault
25
(26)
28
31
32
33
35
(36)
37
38
39
40
Alternator/Battery Charger
Check
Check Refrigeration Capacity
Pretrip Abort
Check Oil Pressure Switch
Refrigeration Capacity Low
Check Engine RPM
Check Run Relay Circuit
Electric Motor Failed to Run
Check Engine Coolant Level
Electric Phase Reversed
Check Water Valve Circuit
Check High Speed Circuit
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
The unit is no longer able to operate and has been shut down. Repair immediately.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
The unit is no longer able to operate and has been shut down. Repair immediately.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Check engine coolant level. Do not remove the cap if the engine is hot.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
116 TK 56218-2-OP-EN
Table 1.
Table of Alarm Codes (continued)
Num
41
42
43
44
45
46
48
50
52
54
56
57
61
COLOR CODE
DEFINITIONS:
Description
OK TO
RUN
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
Check Engine Coolant
Temperature
Unit Forced to Low Speed
Unit Forced to Low Speed
Modulation
Check Fuel System
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Check Hot Gas or Hot Gas
Bypass Circuit
Add fuel as necessary, otherwise report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Check Air Flow
Check Belts or Clutch
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Reset Clock
Check Heat Circuit
Test Mode Timeout
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Service Test or Output Test timed out after 15 minutes. Report alarm at end of day.
Check Host Evap Fan Low Speed
Check Host Evap Fan High Speed If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Low Battery Voltage
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
TK 56218-2-OP-EN 117
84
85
86
68
70
74
79
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
62
(63)
64
65
66
67
87
89
90
COLOR CODE
DEFINITIONS:
Description
Ammeter Out of Calibration
Engine Stopped
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Pretrip Reminder
Abnormal Temperature
Differential
Low Engine Oil Level
Report alarm at end of day.
Check Liquid Line Solenoid
Circuit
Internal Controller Fault Code
Hourmeter Failure
Controller Reset to Defaults
Internal Data Logger Overflow
Restart Null
Forced Unit Operation
Check Discharge Pressure
Sensor
Check Suction Pressure Sensor
Check Electronic Throttling Valve
Circuit
Electric Overload
Check engine oil level. If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
118 TK 56218-2-OP-EN
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
COLOR CODE
DEFINITIONS:
Description
91 Check Electric Ready Input
92
96
98
108
111
113
114
117
118
120
Sensor Grades Not Set
Low Fuel Level
Check Fuel Level Sensor
Door Open Time-out
Unit Not Configured Correctly
Check Electric Heat Circuit
Multiple Alarms - Can Not Run
Auto Switch from Diesel to
Electric
Auto Switch from Electric to
Diesel
Check Alternator Excite Circuit
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Check engine fuel level and add fuel as required.
Report alarm at end of day.
Close doors. Report alarm at end of day.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
121
122
127
128
Check PWM/Liquid Injection
Circuit
Check Diesel/Electric Circuit
Setpoint Not Entered
Engine Run Time Maintenance
Reminder #1
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Be sure setpoint is adjusted to required temperature.
Report alarm at end of day.
TK 56218-2-OP-EN 119
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
COLOR CODE
DEFINITIONS:
Description
129
130
131
132
133
134
141
143
Engine Run Time Maintenance
Reminder #2
Electric Run Time Maintenance
Reminder #1
Electric Run Time Maintenance
Reminder #2
Total Unit Run Time Maintenance
Reminder #1
Total Unit Run Time Maintenance
Reminder #2
Controller Power On Hours
Auto-Switch Diesel to Electric
Disabled
Check Remote Zone Drain Hose
Heater Output
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
144
145
146
148
Lost Expansion Module CAN
Communication
Loss of Controller “On” 8XP
Feedback Signal
Software Version Mismatch
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
150
Auto-Switch Electric to Diesel
Disabled
Out of Range Low (HMI)
151
157
158
Out of Range High (HMI)
OptiSet File Mismatch
Primary Software Failed to Load
Manually monitor load temperature.
Report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
120 TK 56218-2-OP-EN
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
159
160
203
204
233
234
251
252
508
509
510
511
518
519
520
COLOR CODE
DEFINITIONS:
Description
Check Battery Condition
Lost Radio Expansion Board
(REB) CAN Communication
Check Display Return Air Sensor
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
Manually monitor load temperature.
Report alarm at end of day.
Report alarm at end of day.
Check Display Discharge Air
Sensor
REB Transitioning From
Conservative to Full Null
Check Relative Humidity Sensor
REB Mis-configured
Check Auto Fresh Air Exchange
Speed Request Communications
Error
Engine Control Unit (ECU) Failed to Enable
Engine Control Unit (ECU) Run
Signal Failed
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Engine Wait to Start Time Delay
Expired
Generator Ground Fault
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Check Battery Charger Input
Power
Check Battery Charger Output
Power
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
TK 56218-2-OP-EN 121
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
COLOR CODE
DEFINITIONS:
Description
521 Battery Charger External /
Environmental Faults
522
523
524
525
526
528
529
538
539
599
600
601
Battery Temperature Sensor
Alarm
Battery Charger Indicated
Conditions
Generator Operational Limit, V out to Frequency Ratio
Generator Frequency Range
Fault
Generator Operational Limit
Output Current
Controller Not Receiving
Messages From Battery Charger
Check Fuel Pump Circuit
Engine J1939 CAN Datalink
Degraded (Electronic Engine
Only)
Engine J1939 CAN Datalink
Failed (Electronic Engine Only)
Engine Service Tool Connected
Check Crankshaft Speed Sensor
Check Camshaft Speed Sensor
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Maintenance information only. Report alarm at end of the day.
Report alarm at end of day.
Report alarm at end of day.
122 TK 56218-2-OP-EN
611
612
613
614
615
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
COLOR CODE
DEFINITIONS:
Description
602
603
604
605
607
608
609
610
Check Intake Throttle Position
Sensor
Check Exhaust Pressure Sensor
Check Coolant Temperature
Sensor
Check Fresh Air Temperature
Sensor
Check Fuel Temperature Sensor
Check Rail Pressure Sensor
Check Intake Pressure Sensor
Check Atmospheric Pressure
Sensor
Check Glow Plug Circuit
Check Intake Throttle Circuit
Check Injector(s)
Check High Pressure Fuel Pump
Rail Pressure Fault
616
617
618
619
623
624
Engine Overspeed
Internal ECU Fault
Check EGR
ECU Main Relay Fault
TRU CAN Message Timeout
Check EGR Temperature Sensor
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
TK 56218-2-OP-EN 123
Table 1.
Table of Alarm Codes (continued)
OK TO
RUN
Num
COLOR CODE
DEFINITIONS:
Description
625
626
699
Check Intake Air Temperature
Sensor
Check Exhaust Temperature
Sensor
Unknown ECU Fault
CHECK AS
SPECIFIED
TAKE IMMEDIATE
Operator Action
ACTION
Report alarm at end of day.
Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
124 TK 56218-2-OP-EN
Loading and Inspection Procedures
This chapter describes pre-loading inspections, loading procedures, postloading procedures, post-loading inspections and enroute inspections.
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.
loading procedures, call your company office for instructions.
Pre-Loading Inspection
1. Inspect door seals and vent doors for condition and a tight seal with no air leakage.
2. 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
3. Verify that the setpoint temperature is correct for your cargo. Pre-cool the trailer as required.
4. Supervise product loading to ensure sufficient air space around and through the load. Airflow around cargo must not be restricted.
closed until cargo is ready to be loaded. Then turn off the unit, open the 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.
TK 56218-2-OP-EN 125
Figure 146.
Loading Considerations
3.
4.
1.
2.
5.
Correct load height (trailers without chutes)
Tight doors and seals
Good air circulation around load
Proper cargo temperature ( prior to loading)
Interior/exterior walls and insulation in good condition
8.
9.
6.
7.
10.
Clear defrost drains
Good outside air circulation
Unit inspection
Tight seals
Maximum load height followed
Post-Loading Inspection
Post-loading inspections verify the cargo has been loaded properly. To perform a post-load inspection:
1. Inspect the evaporator outlets for blockage.
2. Turn the unit off before opening the cargo box doors to maintain efficient operation.
126 TK 56218-2-OP-EN
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.
loading. The unit is designed to maintain temperature, not cool an above-temperature load.
4. Close or supervise the closing of the cargo box doors. Verify they are securely locked.
5. Verify 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 the manual.
Enroute Inspections
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. Initiate a manual defrost cycle after each enroute inspection.
Inspection Troubleshooting
1. If a temperature reading is not within the desired temperature range,
refer to the troubleshooting table ( Table 2, p. 128
). Correct problem as required.
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.
3. Immediately contact the nearest Thermo King Service Center or your company office.
TK 56218-2-OP-EN 127
4. Take all necessary steps to protect and maintain proper load temperature.
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.
Table 2.
Inspection Troubleshooting
Problem: A return air temperature reading is not within desired temperature range of the setpoint.
Cause Remedy
The unit has not had time to cool down to correct temperature.
The unit may have a low refrigerant charge.
The unit is in defrost or has just completed a defrost cycle.
The evaporator is plugged with frost.
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 witin the desired temperature range of the setpoint.
Check the receiver tank sight glass for refrigerant level. If fluid 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.
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.
Improper air circulation in the cargo compartment.
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.
Inspect the unit and cargo compartment to determine if the evaporator fan(3) are working properly circulation the air. Poor air circulation may be due 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.
128 TK 56218-2-OP-EN
Table 2.
Inspection Troubleshooting (continued)
Problem: A return air temperature reading is not within desired temperature range of the setpoint.
Remedy Cause
The unit did not start automatically.
Multi-Temp Units
Only – The unit is being used to cool/ heat a single temperature load and does not have the capacity to cool the entire trailer.
Determine the cause for not starting. Correct as required. Continue monitoring return air temperature until reading is within desired temperature range of the setpoint.
A multi-temperature unit may not have the cooling or heating capacity to maintain a specific temperature range throughout an entire trailer.
TK 56218-2-OP-EN 129
Jump Starting
If unit battery is discharged or run down, 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.
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.
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.
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 and jumper cables. Use good jumper cables made with #2 gauge (or larger) cables.
1. Verify unit is turned off. If you are using a vehicle, verify its ignition is also turned off.
2. Open front doors on unit. Battery is located on the right of engine.
3. Check discharged battery to verify it is not damaged or frozen. Do not jump start a damaged or frozen battery. Check vent caps to verify they are tight.
4. Identify positive (+) and negative (–) battery terminals.
5. Remove red cover from positive (+) battery terminal on the unit’s battery.
130 TK 56218-2-OP-EN
Figure 147.
Sequence for Connecting Jumper Cables
1.
2.
3.
4.
Positive (+) Terminal on Unit Battery
Positive (+) Terminal on Good Battery
Negative (–)Terminal on Good Battery
Starter Mounting Bolt on Unit Engine
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.
off E pllo
Allowing the positive (+) jumper cable to short to ground can produce dangerous sparks.
7. Connect the other end of the red positive (+) jumper cable to the positive
(+) battery terminal on the good battery.
TK 56218-2-OP-EN 131
8. Connect the black negative (–) jumper cable to the negative (–) battery terminal on a 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.
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.
Keep your hands, clothing, and tools clear of fans and/or belts when working on a unit that is running or when opening or closing compressor service valves. Loose clothing might entangle moving pulleys or belts, causing serious injury or possible death.
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.
not try to start the unit until 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).
132 TK 56218-2-OP-EN
Figure 148. Sequence for Disconnecting Jumper Cables
1.
2.
3.
4.
Starter Mounting Bolt on Unit Engine
Negative (–)Terminal on Good Battery
Positive (+) Terminal on Good Battery
Positive (+) Terminal on Unit Battery
TK 56218-2-OP-EN 133
Specifications
Engine
Model
Fuel Type
Oil
Capacity
Oil Type
C-600: TK486V25 (Tier 4) 4 cylinder
S-600: TK488CR (Tier 4) 4 cylinder
S-700: TK488CRH (Tier 4) 4 cylinder
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Note: The sulfur content must be less than or equal to 15 ppm, the fuel must be free of zinc, and comply with the latest release of ASTM D975, EN
590, or JIS K2204.
12 quarts (11.4 liters) crankcase and oil filter.
Fill to full mark on dipstick
C-600: Requires API Classification CI-4 or better.
Important: This oil type must be used to meet Federal Regulations based on
EPA 40 CFR Part 89.
Recommended oil viscosity based on ambient temperature
Engine
Coolant
Type
S-600 and S-700 (only): Requires API Classification CJ-4 or better.
Important: This oil type must be used together with ULSD fuel to prevent damage to the DOC.
14 to 122 F (-10 C to 50 C): SAE 15–W-40 (Synthetic)
5 to 104 F (-15 to 40 C): SAE 15W-40
5 to 104 F (-15 to 40 C): SAE 10W-30 (Synthetic or Synthetic Blend)
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-2 to 30 C): SAE 10W-30
-22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic)
Below -22 F (-30 C): SAE 0W-30 (Synthetic)
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 ®
Caterrpillar ELC
Detroit Diesel POWERCOOL ® Plus
134 TK 56218-2-OP-EN
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.
7.5 quarts (7.1 liters) Coolant
System
Capacity
Radiator
Cap
Pressure
Engine
Coolant
Thermostat
15 psig (103 kPa)
160 F (71 C)
Filters
Oil Filter
Fuel Filter
Air Filter
EMI 3000 Hour – P/N 119959
EMI 3000 Hour – P/N 119957
EMI 3000 Hour – P/N 119955
Refrigeration System
Contact your Thermo King dealer for refrigeration system service or maintenance.
TK 56218-2-OP-EN 135
Electrical Control System
Low
Voltage
12.5 Vdc
High
Voltage
200-210 Vac from AC generator at engine low speed.
345 Vac from AC generator at engine high speed.
Battery
Fuses
Battery
Charging
All inspection or service procedures of the high voltage systems should only be done by an authorized Thermo King dealer.
One, Group C31, 12 volt battery. The battery must be suitable for deep cycling, heavy duty and rated with a minimum of 95 amp/hr.
Thermo King ReliaMax 925N (925 CCA) wet cell battery is recommended for both warm and cold climates.
Thermo King EON (1150 CCA) AGM battery is recommended for extreme climates and for Rail Ready (RR), Domestic Refrigerated Container (DRC), and Trailer on Flat Car (TOFC) applications.
Note: If the unit is not going to be used for an extended period of time, turn the Microprocesor On/Off Power Switch to the OFF position to maximize battery life.
Refer to Fuses (
“Unit Protection Devices,” p. 28 ).
12 volt, 37 amp, brush type, Thermo King Alternator.
Electrical Standby (SmartPower Unit Only)
and evaporator fan motors in units configured to use electric standby input voltage of 460 Vac.
Electric Motor and Overload Relay
Kilowatts RPM Voltage/
Phase/
Frequency
Horsepower
230/3/60
460/3/60
460/3/60
12.0
12.0
19.0
9.0
9.0
14.2
1760
1760
3500
Full Load
(amps)
31.2
15.6
21.7
Overload
Relay Setting
(amps)
34
20
32
136 TK 56218-2-OP-EN
Standby Power Cord Requirements (SmartPower Units
Only)
Supply Circuit
Breaker
12 HP Motor 230/3/60 – 70 amps
12 HP Motor 460/3/60 – 40 amps
19 HP Motor 460/3/60 – 60 amps
Extension Cord
Size
12 HP Motor 230/3/60 (all 4 conductor, 2000 Vac, Type W Power Cable)
– 8 AWG Power Cable, 25 to 50 foot length
12 HP Motor 230/3/60 – 6 AWG Power Cable, 75 foot length
12 HP Motor 460/3/60 – 10 AWG Power Cable, up to 75 foot length
19 HP Motor 460/3/60 – 8 AWG Power Cable, up to 75 foot length
TK 56218-2-OP-EN 137
Maintenance Inspection Schedule
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
Inspect/Check/Service These Items
Microprocessor:
Run Pretrip Test.
Engine:
Check fuel supply.
Check engine oil level.
Inspect belts for condition and proper tension.
Check engine oil pressure hot, on high speed (should display “OK”).
Listen for unusual noises, vibrations, etc.
Check engine coolant level and antifreeze protection (-30 F [-40 C]).
Drain water from fuel tank and check vent.
Inspect/clean electric fuel pump filter.
C-600 Only – Check and adjust engine speeds (high and low speed).
Check condition of drive coupling bushings per Service Bulletin
TT171.
Check engine mounts for wear.
Replace EMI 3000 air cleaner element (see “EMI 3000 Air Cleaner”) at 3,000 hours or two years (whichever occurs first). See Note.
Replace EMI 3000 fuel filter/water separator. See Note.
138 TK 56218-2-OP-EN
•
•
•
Inspect/Check/Service These Items
Change engine oil and oil filter (hot).
C-600 Only – Requires oil with API Classification CJ-4 or CK-4
(ACEA Rating E6 for Europe).
Important: This oil type must be used to meet Federal Regulations based on EPA 40 CFR Part 89.
S-600 and S-700 Only – Requires API Classification CJ-4 or CK-4.
Important: This oil type must be used together with ULSD fuel to prevent damage to the DOC.
Adjust engine valve clearance.
C-600 Only – Test fuel injection nozzles at least every 3,000 hours.
Based on EPA 40 CFR Part 89.
— Change ELC (red) engine coolant every 5 years or 12,000 hours.
Units equipped with ELC have an ELC nameplate on the expansion tank (see “Engine Cooling System”).
— Replace fuel return lines between fuel injection nozzles every 10,000 hours.
Note: Units equipped with Severe Duty Filtration Package - Replace air cleaner element, replace fuel filter/water separator, and change engine oil and oil filter every 4,000 hours.
• • •
Electrical:
Inspect battery terminals and electrolyte level.
•
•
•
•
•
•
Inspect wire harness for damaged wires or connections.
Inspect AC generator and alternator wire connections for tightness.
•
•
Inspect electric motors.
Inspect and, if required, re-torque all electrical connections on the contactors in the Fan Control Box to 15 in-lb (1.7 N•m).
TK 56218-2-OP-EN 139
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Inspect/Check/Service These Items
•
•
•
•
• Inspect and, if required, re-torque all electrical connections on the contactors in the High Voltage Box in SmartPower units. Torque the connections on the Compressor Motor Contactor, Phase Contactors, and Overload Relay to 22 in-lb (2.5 N•m). Torque the connections on all other contactors to 15 in-lb (1.7 N•m).
Refrigeration:
Check refrigerant level.
•
• Check for proper suction pressure.
Check compressor oil level and condition.
•
• Check compressor efficiency and pump down refrigeration system.
Empty oil collection container mounted on compressor.
•
— Replace dehydrator and check discharge and suction pressure every two (2) years.
Structural:
Visually inspect unit for fluid leaks.
Visually inspect unit for damaged, loose, or broken parts (includes air ducts and bulkheads).
Inspect idlers for bearing wear (noise).
•
Clean entire unit including condenser and evaporator coils and defrost drains.
Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.
Note: * 3,000 hours or two years, whichever occurs first.
140 TK 56218-2-OP-EN
Serial Number Locations
Figure 149.
Unit Serial Number Locations
1.
2.
On Evaporator Housing
On Frame In Engine Compartment
TK 56218-2-OP-EN 141
Figure 150.
Laminated Serial Number Plate (Located Where Shown
Above)
1.
2.
3.
Unit Serial Number
Unit Model
Bill of Material Number
Figure 151.
Serial Number Plate Location
(S-3 shown, S–2 similar)
1.
Serial nameplate on right end of evaporator frame behind cover
142 TK 56218-2-OP-EN
Emergency Cold Line
If you can’t get your unit operating and need assistance, you can locate a
Thermo King Dealer anywhere in the United States by going to thermoking.
com or by using the Thermo King North American Service Directory
(available from any Thermo King dealer). If you are unable to reach a dealer, then call the Toll Free Emergency Cold Line Number (888) 887-2202. The answering service 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
TK 56218-2-OP-EN 143
Warranty
Please contact your nearest Thermo King dealer for terms of the Thermo
King North American Trailer Unit Limited Warranty.
EPA and ARB Supplemental Emissions Warranty
Statement
Your Thermo King unit is covered by the diesel engine manufacturer’s EPA and
ARB Supplemental Emissions Warranty. Complete details of this emission warranty can be found at www.thermo.com/manuals reference TK 56690-9-WA.
144 TK 56218-2-OP-EN
TK 56218-2-OP-EN 145
146 TK 56218-2-OP-EN
TK 56218-2-OP-EN 147
Ingersoll Rand (NYSE: IR) advances the quality of life by creating comfortable, sustainable and efficient environments. Our people and our family of brands — including Club Car ® , Ingersoll Rand ® , Thermo King ® and Trane ® —work together to enhance the quality and comfort of air in homes and buildings; transport and protect food and perishables; and increase industrial productivity and efficiency.
We are a global business committed to a world of sustainable progress and enduring results.
ingersollrand.com
Ingersoll Rand has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice.
We are committed to using environmentally conscious print practices.
TK 56218-2-OP-EN
01 Jun 2019
Supersedes TK 56218-2-OP-EN (December 2015) ©2019 Ingersoll Rand

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