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Thermo King SB-210+, Operator'S Manual

The Thermo King SB-210+ Operator's Manual is a comprehensive guide that provides step-by-step instructions on how to operate and maintain your Thermo King SB-210+ unit. This essential manual is available for free download at manualshive.com, ensuring you have easy access to vital information for optimizing the performance and longevity of your product.

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Alarm Codes

152

25

Alternator Check

If unit is shutdown repair immediately. Otherwise, report 
alarm at end of day.

X

26

Refrigeration Capacity Check

Manually monitor load temperature with independent 
thermometer. Report alarm at end of day.

X

28

Pretrip or Self Check Abort

Report alarm at end of day.

X

29

Defrost Damper Circuit 

If unit is shutdown, repair immediately. Otherwise, report 
alarm at end of day.

X

30

Defrost Damper Stuck Closed

The unit is no longer able to operate and has been shut 
down. Repair immediately.

X

31

Oil Pressure Switch

If unit is shutdown repair immediately. Otherwise, report 
alarm at end of day.

X

32

Refrigeration Capacity Low

The unit is not able to operate and has been shutdown. 
Repair immediately.

X

Table of Alarm Codes

NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.

Code Description

Corrective Action 

Level Of 

Action

Ok T

o

 

Run

Check

Shut

 

Down

Alarm Codes

152

25

Alternator Check

If unit is shutdown repair immediately. Otherwise, report 
alarm at end of day.

X

26

Refrigeration Capacity Check

Manually monitor load temperature with independent 
thermometer. Report alarm at end of day.

X

28

Pretrip or Self Check Abort

Report alarm at end of day.

X

29

Defrost Damper Circuit 

If unit is shutdown, repair immediately. Otherwise, report 
alarm at end of day.

X

30

Defrost Damper Stuck Closed

The unit is no longer able to operate and has been shut 
down. Repair immediately.

X

31

Oil Pressure Switch

If unit is shutdown repair immediately. Otherwise, report 
alarm at end of day.

X

32

Refrigeration Capacity Low

The unit is not able to operate and has been shutdown. 
Repair immediately.

X

Table of Alarm Codes

NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.

Code Description

Corrective Action 

Level Of 

Action

Ok T

o

 

Run

Check

Shut

 

Down

Summary of Contents for SB-210+

Page 1: ...Operator s Manual SB 210 SB 310 Operator s Manual SB 210 SB 310 TK 53942 2 OP Rev 1 11 09 ...

Page 2: ...Copyright 2009 Thermo King Corp Minneapolis MN USA Printed in USA Copyright 2009 Thermo King Corp Minneapolis MN USA Printed in USA SB 210 SB 310 TK 53942 2 OP Rev 1 11 09 ...

Page 3: ... recommendations and descriptions contained in this manual and such information recommendations and descriptions should not be regarded as all inclusive or covering all contingencies If you have questions or require further information please contact your local Thermo King dealer The procedures described herein should be undertaken only by qualified personnel Failure to implement these procedures ...

Page 4: ... List of Figures 7 Introduction 11 Safety Precautions 13 General Safety Practices 13 Automatic Start Stop Operation 14 Electrical Hazard 14 Refrigerant 14 Refrigerant Oil 15 First Aid 15 First Aid Refrigerant 15 First Aid Refrigerant Oil 15 Safety Decals and Locations 16 EPA Emission Control System Warranty Statement 19 Responsibilities 20 Thermo King Corporation Responsibilities 20 Owner Responsi...

Page 5: ...rting the Unit 45 Operating Instructions 47 SMART REEFER 2 SR 2 Controller Overview 47 HMI Control Panel 49 Control Panel Display 49 Control Panel Keys 50 Turning Unit On 51 Turning Unit Off 53 Standard Display 54 Standard Display Variations 55 Temperature Watch Display 56 Alarm Display 57 Starting the Diesel Engine 58 Unit Fails To Start 58 After Start Inspection 59 Electric Standby Operation 60 ...

Page 6: ...ptiSet Plus 115 Selecting a Named Product 117 Changing the Setpoint for a Named Product 122 Selecting a Setpoint 125 Optional Rear Remote Control Panel 129 Rear Remote Control Panel Functions 130 Run 130 Stand By 131 Keypad 133 Display 134 Reading a Typical Remote Standard Display 135 Remote Control Panel Lockout 135 Turning the Unit On or Off Configured for STAND BY Operation 136 Turning the Unit...

Page 7: ...Contents 6 Electrical Control System 179 Electric Standby Model 50 Units Only 180 Electric Fuel Heater Optional 181 Refrigeration System 182 Maintenance Inspection Schedule 183 Warranty 189 Glossary 191 Index 197 Serial Number Locations 201 Emergency Cold Line 205 Recover Refrigerant 206 CALIFORNIA Proposition 65 Warning 207 ...

Page 8: ...gure 4 Automatic Start Caution Locations vary depending on model Decals are located near areas that contain moving parts which can cause severe injuries if hands or clothing become tangled when unit automatically starts 17 Figure 5 Fan Caution Locations vary depending on model Decals are located near areas that contain fans which can cause severe injuries when unit automatically starts 17 Figure 6...

Page 9: ...38 Programming Electric Standby Screen 63 Figure 39 Electric Standby Undetected Screen 64 Figure 40 Programming Diesel Mode Screen 64 Figure 41 Changing Setpoint 65 Figure 42 Changing the Setpoint Screen Sequence 67 Figure 43 Changing Mode 69 Figure 44 Screen Sequence for Changing from CYCLE SENTRY Mode to Continuous Mode 70 Figure 45 Screen Sequence for Changing from Continuous Mode to CYCLE SENT...

Page 10: ...Programming Electric Standby Mode 111 Figure 81 Standard Display 112 Figure 82 Adjusting Display Brightness Screen Sequence 113 Figure 83 Time and Date Screens 114 Figure 84 Standard Display with Product Soft Key 115 Figure 85 Standard Display with Product Setpoint Soft Key 116 Figure 86 Selecting Named Product 117 Figure 87 Selecting or Changing Named Product Screen Sequence 119 Figure 88 Selecti...

Page 11: ...Logo Key 142 Figure 116 Press Enter Key 142 Figure 117 Press Pretrip Key 143 Figure 118 Press Enter Key 143 Figure 119 Pretrip Display 144 Figure 120 Pass Pretrip Display 144 Figure 121 Log Alarms Screen 145 Figure 122 Alarm Display 146 Figure 123 Shutdown Alarm Display 147 Figure 124 Loading Considerations 166 Figure 125 Unit Battery 172 Figure 126 Sequence for Connecting Jumper Cables 172 Figure...

Page 12: ...r 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 ...

Page 13: ...12 Introduction 12 ...

Page 14: ...hermo King units and describes the safety stickers on your unit that you should be familiar with General Safety Practices DANGER NEVER operate the unit with the compressor discharge valve closed Doing so could cause the compressor to explode causing death or serious injury WARNING Always wear goggles or safety glasses when working with or around the refrigeration system or battery Refrigerant or b...

Page 15: ...igerants or in areas where they are being used CAUTION Use extreme caution when drilling holes in the unit Drilling into electrical wiring or refrigerant lines could cause a fire Do not drill into structural components WARNING 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...

Page 16: ... of warm water Do not apply heat Wrap burns with dry sterile bulky dressing to protect from infection or injury Get prompt medical attention Inhalation Move victim to fresh air and restore breathing if necessary Stay with victim until emergency personnel arrive First Aid Refrigerant Oil Eyes Immediately flush eyes with large amounts of water for at least 15 minutes while holding the eyelids open G...

Page 17: ...ution Located on condenser housing AJA1947 AKB66 Safety Precautions 16 Safety Decals and Locations Figure 1 ELC Extended Life Coolant Nameplate Located on expansion tank in units equipped with ELC Figure 2 Belt Warning Located on condenser housing Figure 3 Belt Replacement Caution Located on condenser housing AJA1947 AKB65 AKB66 ...

Page 18: ...hat contain fans which can cause severe injuries when unit automatically starts AKB67 AKB68 Safety Precautions 17 Figure 4 Automatic Start Caution Locations vary depending on model Decals are located near areas that contain moving parts which can cause severe injuries if hands or clothing become tangled when unit automatically starts Figure 5 Fan Caution Locations vary depending on model Decals ar...

Page 19: ...ecautions 18 Figure 6 Door Latch Warning Located on curbside door WARNING ATENCIÓN NEW DOOR LATCH DESIGN REQUIRES DOOR TO BE SLAMMED SHUT BEFORE MOVING TRAILER FAILURE TO CLOSE DOOR FIRMLY CAN ALLOW WIND TO TEAR DOOR FROM REFRIGERATION UNIT AND CAUSE INJURY TO OTHERS NUEVO DESEÑO DE CERRADURA REQUIERE ASOTAR LA PUERTA ANTES DE CONDUCIR EL TRAILER AL NO CERRAR LA PUERTA CON FIRMEZA EL VIENTO PODRÍA...

Page 20: ...le with all applicable regulations adopted by the United States Environmental Protection Agency EPA 2 Free from defects in materials and workmanship in specific emission related parts for a period of five years or 3 000 hours of operation whichever comes first after date of delivery to the initial owner If an emission related part or component fails during the warranty period it will be repaired o...

Page 21: ... not being completed within 30 days constitutes an emergency As a condition of reimbursement replaced parts and received invoices must be presented at a place of business of a Thermo King authorized service dealer or other establishment authorized by Thermo King This warranty covers the following emission related parts and components Fuel Injection System Intake Manifold Exhaust Manifold Miscellan...

Page 22: ...l be denied Premium of overtime cost Cost to investigate complaints that are not caused by defects in Thermo King material or workmanship Providing timely notice of a warrantable failure and promptly making the product available for repair Limitations Thermo King is not responsible for resultant damages to an emission related part or component resulting from Any application or installation Thermo ...

Page 23: ...22 EPA Emission Control System Warranty Statement 22 ...

Page 24: ... unit mounts on the front of the trailer with the evaporator extending through an opening in the front wall The SB 210 310 features cooling and heating using a quiet running engine from the Thermo King TK486 engine family The SB 210 and SB 310 are available in the following three models SB 210 30 Cooling and heating on diesel engine operation SB 210 50 Cooling and heating on diesel engine operatio...

Page 25: ... proof insulation special door gaskets and sound absorbing doors See the Design Features list below Design Features The following chart lists key design features and options Standard Features Option Factory installed Option Dealer Installed SB 210 310 Key Features Options SB 210 Model 30 SB 210 Model 50 SB 310 Model 30 SMART REEFER SR 2 Controller OptiSet Plus with FreshSet Programmable Modes ETV ...

Page 26: ...s Display with Fuel Level and Temperature Standard Unit Color White Standard Grille Color Black Directional Air Delivery Vibration Isolation System Aluminum Undermount Fuel Tank 50 Gal 186 Liter Fuel Level Sensor Fuel Heater SB 210 310 Key Features Options SB 210 Model 30 SB 210 Model 50 SB 310 Model 30 Frost Plug Heater Alternator 65 Amp 12 Vdc 24 Horsepower Electric Motor Special Color Grills Fr...

Page 27: ...ne is coupled directly to the compressor on the Model 30 A centrifugal clutch transfers power from the engine to the compressor on the Model 50 Belts transmit power to the unit fans alternator and water pump The SB 210 uses a TK486V Tier2 which is designed to run with a high speed of 2200 rpm The SB 310 uses a TK486VH Tier2 which is designed to run with a high speed of 2600 rpm Figure 8 TK486V TK4...

Page 28: ...fe Coolant is RED in color instead of the previous GREEN or BLUE GREEN colored conventional coolants NOTE The use of 50 50 pre mixed ELC is recommended to assure that de ionized water is being used If 100 full strength concentrate is used de ionized or distilled water is recommended instead of tap water to insure the integrity of the cooling system is maintained EMI 3000 EMI 3000 is an extended ma...

Page 29: ...isplacement Electronic Throttling Valve The Electronic Throttling Valve ETV is optional on the SB 210 and standard on the SB 310 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 ...

Page 30: ...ting mode viewing gauge sensor and hourmeter readings initiating defrost cycles and viewing and clearing alarms The microprocessor components are located inside the control box which is located inside the lower roadside service door The microprocessor is connected to an HMI Human Machine Interface Control Panel It is used to operate the unit The HMI control panel is mounted on the face of the cont...

Page 31: ...intains the compartment temperature engine block temperature and battery charge levels at a condition where quick easy starts are possible WARNING 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 Your Thermo King unit provides a wide range of c...

Page 32: ...compatible laptop or desktop computer and Thermo King WinTrac 4 6 or higher software ServiceWatch ServiceWatch is standard equipment It records operating events alarm codes and compartment temperatures as they occur and at preset intervals This information is typically used to analyze unit performance Use the ServiceWatch Port to downloaded the ServiceWatch data CargoWatch CargoWatch data logging ...

Page 33: ... 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...

Page 34: ... unit will not perform a Manual Defrost Cycle unless the unit has been turned on with the ON key the unit is running in Continuous or CYCLE SENTRY Mode or shut down in CYCLE SENTRY Null Mode and the coil temperature is below 45 F 7 C ...

Page 35: ...engine compartment Opening the Secondary Door Latch These units are also equipped with a secondary door latch A secondary door latch nameplate is located below the front doors After opening the door latch reach between the front doors and lift the spring latch over the spring catch while opening the door 1 Door Latch 2 Secondary Door Latch Nameplate Figure 11 Door Latch Location 1 2 1 Spring Latch...

Page 36: ...35 Unit Description 35 Closing the Front Doors Slam the door to close it Do not push the door closed while holding the door latch handle open or the door will not close properly ...

Page 37: ... attached to the engine intake manifold When the diaphragm indicates 25 service the air filter Press the button on the bottom of the restriction indicator to reset after servicing the air cleaner Compressor Oil Sight Glass Use this sight glass to check the compressor oil level Check the compressor oil when there is evidence of oil loss leaks Refer to the unit Maintenance Manual for the correct pro...

Page 38: ...ontains a full charge or an overcharge of refrigerant Unit Protection Devices Fuse Link Current Limiter The fuse link is located in the positive battery cable The fuse link protects the electric system from a short If the fuse link burns out replace it by replacing the positive battery cable High Pressure Cutout Switch The high pressure cutout switch HPCO is located on the compressor discharge man...

Page 39: ...ress the reset button on the high voltage tray to reset the overload relay The high voltage tray is located behind the lower access panel on the compressor side of the unit Smart FETs Smart FETs in the controller interface board protect some circuits and components from an overcurrent condition Fuses A number of fuses located on the interface board protect various circuits and components The inter...

Page 40: ...its with Prestolite Alternator F5 The F5 preheat fuse is a slow blow type It is designed for use with the Yanmar engine air heater Always replace the fuse with the TK specified fuse F10 When fuse F10 is installed in the upper position the On Off keys on the HMI turn the unit on and off When fuse F10 is installed in the lower position the unit will start and run without the HMI control panel F15 Th...

Page 41: ...igure 16 Interface Board 1 Interface Board Figure 15 Control Box With Control Box Door Open Unit Description 40 Figure 16 Interface Board 1 Interface Board Figure 15 Control Box With Control Box Door Open 1 ...

Page 42: ...atus display mounts on the cargo box for easy viewing of the unit s mode Figure 17 Remote Status Display All LEDs Shown The remote status display indicates operating status as follows White Status LEDs Illuminate the T portion of the TK logo when the unit is functioning properly with no alarm codes Figure 18 Normal Operation No Alarms ...

Page 43: ...t is still functioning properly Check the unit as soon as possible to correct the alarm condition Figure 19 Check Alarm White and Amber Status LEDs The two bottom LEDs in the T in white and the four bottom LEDs in the K in amber are illuminated when the unit has a shutdown alarm code and the load integrity is at risk Correct the alarm condition immediately Figure 20 Shutdown Alarm ...

Page 44: ...mber of white LEDs illuminated in the fuel level indicator show the fuel level When the fuel level falls below 10 only the two amber LEDs at the top and bottom of the fuel level indicator are illuminated to indicate the low fuel level The temperature display shows the box temperature except when the unit is in defrost in which case it displays dF 1 Status Indicator 2 Fuel Level Indicator Figure 21...

Page 45: ...44 Remote Status Display Optional 44 ...

Page 46: ...m this pretrip inspection before every trip involving refrigerated cargo NOTE Pretrip inspections are not intended to take the place of regular maintenance inspections Fuel Make sure the diesel fuel supply is adequate to guarantee engine operation to the next check point Allow for maximum fuel consumption of one gallon per hour of engine operation Engine Oil Check the engine oil level It should be...

Page 47: ...ils Make sure the condenser and evaporator coils are clean and free of debris Cargo Box Check the interior and exterior of the cargo box for damage Any damage to the walls or insulation must be repaired Cargo Doors Make sure that the cargo doors and weather seals are in good condition The doors should latch securely and the weather seals should fit tightly Defrost Drains Check the defrost drain ho...

Page 48: ...anel SMART REEFER 2 SR 2 Controller Overview Thermo King has applied the latest advances in computer technology to develop a device that controls temperature and unit function and displays operating information quickly and accurately There is nothing complicated about learning to operate the SR 2 Controller but you will find that a few minutes studying the contents of this manual will be time well...

Page 49: ...ace Control Panel It is used to operate the unit The CargoWatch and ServiceWatch ports are used to retrieve data from the data logging system Microprocessor On Off Switch This switch supplies or removes electrical power to the microprocessor It is located on the left side of the control box See Figure 24 1 Control Box 4 CargoWatch Port 2 Microprocessor On Off Switch 5 HMI Control Panel 3 ServiceWa...

Page 50: ...ng both text and graphics The four keys on the left and right sides of the display are 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 Th...

Page 51: ...ppear briefly The display will then show the Standard Display of box temperature and setpoint when the unit is ready to run Off Key Press this key to turn the unit off The engine will stop immediately Then the HMI control panel will enter the power down sequence Defrost Key Press this key to initiate a Manual Defrost cycle Mode Key Press this key to switch back and forth between the CYCLE SENTRY m...

Page 52: ... the ON key See Figure 26 2 The display briefly shows a Thermo King Logo See Figure 27 NOTE With extremely cold ambient temperatures it may take up to 15 seconds for the first display to appear 3 The Configuring System Screen briefly appears while communications are established between the microprocessor and the HMI control panel 4 The Standard Display showing box temperature and setpoint briefly ...

Page 53: ...52 Figure 27 Turning Unit On Screen Sequence Operating Instructions 52 Figure 27 Turning Unit On Screen Sequence ...

Page 54: ...omplete the following steps to turn unit off 1 Press the OFF key 2 The engine will immediately shut off 3 The System is Powering Down Screen will briefly appear 4 The Off Screen will briefly appear 5 The screen goes blank when the unit power is off Figure 29 Turning Unit Off Screen Sequence 1 Off Key 2 Display Figure 28 Press Off Key 1 2 ...

Page 55: ...ntrolling sensor The return air sensor is the controlling sensor except when the controller is programmed to use the discharge air sensor as the controlling sensor during modulation The box temperature shown below in Figure 30 is 35 5 F The setpoint shown is 35 F The CYCLE SENTRY Icon in the upper right corner of the display shows the unit is operating in the CYCLE SENTRY mode The arrow pointing d...

Page 56: ...p of the display may show a named product if the controller has been programmed with OptiSet Plus temperature profiles The far left soft key may display PRODUCT or PRODUCT SETPOINT if the controller has been programmed with OptiSet Plus temperature profiles See OptiSet Plus on page 115 for information about selecting or changing the named product or the setpoint if the controller has been programm...

Page 57: ...same box temperature and setpoint but in larger fonts This creates easy operator viewing from a distance To return to the Standard Display press the MENU soft key or any of the other three soft keys that are not assigned NOTE A named product may appear above the temperature reading if the controller has been programmed with OptiSet Plus temperature profiles and a named product has been selected NO...

Page 58: ...n below in Figure 33 NOTE A shutdown alarm will also cause the display and backlight to flash on and off and the display will switch from normal video to reverse video and back to normal video light areas become dark and dark areas become light See Alarms Menu on page 85 for information about displaying and clearing alarms 1 Alarm Icon 2 Named Product If Selected Figure 33 Alarm Display 1 2 ...

Page 59: ...e of keys are pressed on the controller before the engine starts the engine will preheat and start approximately 10 seconds after pressing the last key See Turning Unit On on page 51 NOTE Run a pretrip test if the unit has not been used recently See Pretrip Tests on page 104 Unit Fails To Start If the engine does not start and the Alarm Icon appears on the display take the following steps 1 Check ...

Page 60: ... amperage rate to the battery A negative number indicates a discharge condition Compressor Oil The compressor oil level should be visible in the compressor sight glass after 15 minutes of operation If not check the compressor oil level using the procedure in the appropriate maintenance manual Pre Cooling Make sure that the setpoint is at the desired temperature See Changing the Setpoint on page 65...

Page 61: ...ge power source The required voltage is shown on a decal on the unit s electric power receptacle Electric Power Receptacle The electric power receptacle is used to connect the unit to an appropriate electric power source for electric standby operation The electric power receptacle is located next to the HMI Control Panel Make sure the unit and the power supply are turned off before connecting or d...

Page 62: ...tor start the motor start will be delayed until 10 seconds after the last key is pressed Start the unit on Electric Standby operation as follows 1 Press the controller OFF key to make sure the unit is turned off 2 Connect the unit electric power receptacle to an appropriate electric power supply 3 Press the controller ON key 4 If a screen asking if you wish to switch to Electric Standby appears pr...

Page 63: ... setpoint The electric motor cycles on and off in CYCLE SENTRY Mode and runs continuously in Continuous Mode Figure 36 Electric Motor Starting Screen 6 Complete an After Start Inspection see page 59 Unit Fails to Start If the electric motor does not start and the Alarm Icon appears on the display take the following steps 1 Check for and correct any alarm conditions See Viewing and Clearing Alarms ...

Page 64: ...operation when standby power is connected and available If the Diesel to Electric Autoswitch Enabled feature in Guarded Access is set NO then the prompt screen shown below will appear when standby power is connected and available Figure 37 Electric Standby Detected Screen If YES is selected then the display will briefly show the screen below Figure 38 Programming Electric Standby Screen Electric M...

Page 65: ...y power is turned off or is no longer available If the Electric to Diesel Autoswitch Enabled feature in Guarded Access is set NO then the prompt screen shown below will appear when standby power is turned off or is no longer available Figure 39 Electric Standby Undetected Screen If YES is selected then the display will briefly show the screen below Figure 40 Programming Diesel Mode Screen Diesel M...

Page 66: ...SETPOINT the controller has been programmed with OptiSet Plus temperature profiles See OptiSet Plus on page 115 for information about selecting or changing the named product or the setpoint 1 Begin at the Standard Display If the Temperature Watch Display is showing press the MENU soft key once to return to the Standard Display 2 Press the SETPOINT soft key on the Standard Display See Figure 41 The...

Page 67: ...d to change the setpoint but the YES or NO soft keys are not used to accept or decline the new setpoint 5 The Programming New Setpoint Screen will appear See Figure 42 6 The New Setpoint Is XX Screen briefly appears See Figure 42 7 The Standard Display appears with setpoint changed to the new setpoint See Figure 42 ...

Page 68: ...2 Changing the Setpoint Screen Sequence or Key YES or NO Key Operating Instructions 67 Figure 42 Changing the Setpoint Screen Sequence If YES Key was pressed If NO Key was pressed SETPOINT Key or Key YES or NO Key ...

Page 69: ...ollowing guidelines to select the proper operating mode to protect the commodity you are transporting Examples of products normally acceptable for CYCLE SENTRY Operation Frozen foods in adequately insulated trailers Boxed or processed meats Poultry Fish Dairy products Candy Chemicals Film All non edible products Examples of products normally requiring Continuous Run Operation for air flow Fresh fr...

Page 70: ...nd run continuously to maintain setpoint and provide constant airflow CYCLE SENTRY or Continuous may not be available if OptiSet Plus is in use If allowed by OptiSet Plus complete the following steps to change modes NOTE The mode can also be changed using the Mode Menu Screen in the Main Menu See Turning CYCLE SENTRY On or Off on page 97 1 Press the MODE key See Figure 43 2 The Programming Continu...

Page 71: ...ous Mode Figure 45 Screen Sequence for Changing from Continuous Mode to CYCLE SENTRY Mode Operating Instructions 70 Figure 44 Screen Sequence for Changing from CYCLE SENTRY Mode to Continuous Mode Figure 45 Screen Sequence for Changing from Continuous Mode to CYCLE SENTRY Mode ...

Page 72: ... Defrost is also available if the unit is running and the coil temperature is less than 45 F 7 C Other features such as door switch settings may not allow Manual Defrost to be initiated Use the following steps to initiate a Manual Defrost 1 Press the DEFROST key See Figure 46 2 The Defrost Screen briefly appears See Figure 47 3 The Programming Defrost Screen briefly appears See Figure 47 4 The Def...

Page 73: ...n the figure shows that the Defrost cycle is 50 complete When the Defrost cycle is complete the display returns to the Standard Display See Figure 47 If the unit is prevented from going into a Manual Defrost IE Coil temperature more than 45 F 7 C or on economy mode etc A Defrost Unavailable Screen briefly appears The display returns to the Standard Display See Figure 47 Terminating a Defrost Cycle...

Page 74: ...he Standard Display 2 Press the GAUGES soft key to enter the Gauges Menu See Figure 48 3 Press BACK or NEXT soft keys to scroll through following gauges Coolant Temperature Coolant Level Oil Pressure Oil Level Amps Battery Voltage Engine RPM Fuel Level Sensor Discharge Pressure Suction Pressure ETV Position and I O Selecting I O enters a group of screens that are used only by technicians See Figur...

Page 75: ...BACK Key NEXT Key BACK Key Operating Instructions 74 Figure 49 Viewing Gauges Screen Sequence NEXT Key BACK Key NEXT Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key ...

Page 76: ...lay 2 Press the SENSOR soft key to enter the Sensor Menu See Figure 50 3 Press the BACK or NEXT soft keys to scroll through the following sensor screens Control Return Air Temperature Display Return Air Temperature Control Discharge Air Temperature Display Discharge Air Temperature Temperature Differential The Temperature Differential is the difference between the Control Return Air Temperature an...

Page 77: ...y heater on if this temperature goes below a certain point in extremely cold ambient temperatures See Figure 51 and Figure 52 If no keys are pressed within 30 seconds the screen will return to the Standard Display 4 Press the LOCK soft key to display any sensor screen for an indefinite period Press the key again to unlock the screen 5 Press the EXIT soft key to return to the Standard Display ...

Page 78: ...n next page NEXT Key NEXT Key NEXT Key BACK Key NEXT Key Operating Instructions 77 Figure 51 Viewing Sensors Screen Sequence continued on next page NEXT Key BACK Key NEXT Key BACK Key Continued on next page SENSORS Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key ...

Page 79: ...ACK Key NEXT Key NEXT Key BACK Key Operating Instructions 78 Figure 52 Viewing Sensors Screen Sequence continued from previous page NEXT Key BACK Key Continued from previous page NEXT Key BACK Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key ...

Page 80: ...y unit operation Use the following steps to access these menu areas 1 Begin at the Standard Display If the Temperature Watch Display is showing press the MENU soft key once to return to the Standard Display 2 Press the MENU soft key See Figure 53 3 Press NEXT and BACK soft keys to scroll up or down through the main menu areas See Figure 53 and Figure 54 4 Press the SELECT soft key to access a spec...

Page 81: ...s the operator to select which language is used All other subsequent displays are shown in the selected language English is the default language See page 82 2 Alarms Menu Shows any active alarms and allows alarms to be cleared See page 85 3 Datalogger Menu Allows the operator to view the datalogger displays See page 88 4 Hourmeters Menu If enabled allows the operator to view the hourmeter displays...

Page 82: ... It allows the operator to manually select Electric Standby or Diesel operation See page 109 8 Adjust Brightness Allows the operator to adjust the display intensity as required by conditions See page 111 9 Time Allows the operator to view the Time and Date The Time is displayed in 24 hour military time See page 114 ...

Page 83: ...pear The languages available are dependant on the HMI control panel software revision Languages currently supported by software revision 65xx are English Spanish French German Italian Dutch Portuguese Greek Turkish Arabic and Hebrew Languages currently supported by software revision 66xx are English Russian Polish Hungarian Romanian Bulgarian Czech Danish Swedish Norwegian and Finnish Other than l...

Page 84: ...ired language is shown press the YES soft key to confirm the choice 7 The PROGRAMMING LANGUAGE PLEASE WAIT Screen briefly appears 8 The LANGUAGE SELECTED IS XXX Screen briefly appears 9 The display returns to Language Menu Screen but will show the new language German is shown in Figure 57 NOTE Exercise care when changing languages as once changed all HMI Control panel displays will be in the new l...

Page 85: ...E WILL BE DEUTSCH YES NO USE TO CHANGE OK ARA819 YES Key or Key Operating Instructions 84 Figure 57 Change Language Screen Sequence HAUPTMENU SPRACHE BEENDEN WEITER AUSWHAL ARA820 NEW LANGUAGE WILL BE DEUTSCH YES NO USE TO CHANGE OK ARA819 SELECT Key YES Key or Key ...

Page 86: ...ENU soft key on the Standard Display 3 The Language Menu or Alarm Menu will appear If the Language Menu appears press the NEXT soft key until the Alarm Menu appears 4 Press the SELECT soft key The Alarm Display will appear See Figure 59 5 If no alarms are present the No Alarm Screen is shown Press the EXIT soft key to return to the Standard Display 6 If alarms are present the quantity of alarms if...

Page 87: ...ed it will not clear If an alarm cannot be cleared from the Main menu the CLEAR key will not appear These alarms must be cleared from the Guarded Access Menus All alarms must be viewed before any of the alarms can be cleared Check Alarm Code 96 Low Fuel Level is set when the fuel level falls to 15 The controller can be programmed to set a shutdown Alarm Code 44 Out of Fuel when the fuel level fall...

Page 88: ...LEAR Key Operating Instructions 87 Figure 59 Viewing and Clearing Alarms Screen Sequence ALARM 6 2 OF 2 ALARMS COOLANT TEMP SENSOR NEXT EXIT HELP CLEAR ARA823 ALARM 5 1 OF 2 ALARMS AMBIENT TEMP SENSOR NEXT EXIT HELP CLEAR ARA824 MENU Key SELECT Key SELECT Key NEXT Key CLEAR Key ...

Page 89: ... The Start Of Trip marker then shows when the trip started in the data that is downloaded or printed from the datalogger A Start Of Trip can be initiated through the use of WinTrac datalogging software or manually in the field The following procedure covers manual initiation For more information on datalogging see the WinTrac User Manual included with the WinTrac software 1 Begin at the Standard D...

Page 90: ...89 Figure 61 Start of Trip Screen Sequence SELECT Key Operating Instructions 89 Figure 61 Start of Trip Screen Sequence SELECT Key SELECT Key SELECT Key ...

Page 91: ... record shows things such as the unit and controller identification numbers dates and times the setpoint and the data from the optional sensors connected to the CargoWatch datalogger If no sensors are connected the printed record shows the same things without the sensor data 1 Connect the printer to the 6 pin printer port located inside the control box NOTE The printer port can be mounted so it is...

Page 92: ...the Datalogger Menu The Start Trip Screen will appear 6 Press the NEXT soft key The Print View Screen will appear 7 Press the SELECT soft key The Delivery Ticket Screen will appear Press the SELECT soft key to print a delivery report 8 Press the NEXT soft key to go to the Trip Ticket Screen Press the SELECT soft key to print a trip report 1 Menu Soft Key Figure 63 Standard Display 1 ...

Page 93: ...92 Figure 64 Print Report Screen Sequence NEXT Key SELECT Key Operating Instructions 92 Figure 64 Print Report Screen Sequence SELECT Key NEXT Key SELECT Key NEXT Key SELECT Key SELECT Key ...

Page 94: ...he default setting for Model 30 units is to display only the Engine Hours The default setting for Model 50 units is to display Total Run Time Hours Engine Hours and Electric Run Hours The Hourmeters Menu will not appear if all hourmeters are hidden Contact your Thermo King dealer for information about programming the controller Hourmeters can be viewed in the Hourmeters Menu as follows 1 Begin at ...

Page 95: ...ey NEXT Key BACK Key NEXT Key NEXT Key NEXT Key BACK Key Operating Instructions 94 Figure 66 Viewing Hourmeters Screen Sequence continued on next page NEXT Key BACK Key NEXT Key BACK Key Continued on next page SELECT Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key ...

Page 96: ... continued from previous page NEXT Key NEXT Key BACK Key Operating Instructions 95 Figure 67 Viewing Hourmeters Screen Sequence continued from previous page NEXT Key BACK Key NEXT Key BACK Key NEXT Key BACK Key Continued from previous page BACK Key ...

Page 97: ...NTRY is turned off the unit runs in Continuous mode Either CYCLE SENTRY or Continuous operation may be disabled via OptiSet Plus See Turning CYCLE SENTRY On or Off on page 97 Keypad Lockout If enabled in Guarded Access the keypad can be locked to prevent unauthorized use If the keypad is locked only the On and Off keys function The keypad will remain locked even if the unit is turned off and back ...

Page 98: ...e Mode Menu as follows 1 Begin at the Standard Display If the Temperature Watch Display is showing press the MENU soft key once to return to the Standard Display 2 Press the MENU soft key on the Standard Display 3 Press the NEXT soft key until the Mode Menu appears 4 Press SELECT soft key to enter the Mode Menu See Figure 69 5 Press the SELECT soft key to switch between modes 6 The new mode is the...

Page 99: ...98 Figure 69 Selecting Mode Screen Sequence SELECT Key SELECT Key Operating Instructions 98 Figure 69 Selecting Mode Screen Sequence SELECT Key SELECT Key SELECT Key ...

Page 100: ...ps to select Keypad Lockout 1 Begin at the Standard Display If the Temperature Watch Display is showing press any soft key to return to the Standard Display 2 Press the MENU soft key on the Standard Display 3 Press the NEXT soft key until the Mode Menu appears 4 Press the SELECT soft key to enter the Mode Menu The Turn CYCLE SENTRY On Off Screen will appear 5 Press the NEXT soft key until the Keyp...

Page 101: ...ad Lockout Display Operating Instructions 100 6 Press the SELECT soft key to select Keypad Lockout 7 The new mode is then confirmed for 10 seconds 8 The display then returns to the Mode Menu 9 Press the Exit soft key to return to the Standard Display If no keys are pressed within 30 seconds the screen will return to the Standard Display NOTE If Keypad Lockout is active press and hold any soft key ...

Page 102: ...int it keeps the compartment temperature near the ambient temperature when the unit is running This is useful in extremely cold weather or when the unit is to be out of service for an extended time Sleep mode operates in both Diesel mode and Electric mode In Diesel mode the unit will start and stop as required to maintain engine temperature and battery charge In Electric mode the unit starts and s...

Page 103: ...nit will resume normal operation and control to setpoint 8 To enter a Wake up Time verify that the unit clock is set properly see Time Display on page 114 Then press the YES soft key at the Program A Wake Up Time Screen 9 Press the or soft keys to select the day the unit is to restart in normal operation In this example Monday has been chosen Press the YES soft key to confirm the day 10 The displa...

Page 104: ...ng Sleep Mode Screen Sequence YES Key YES Key YES Key or NO Key Operating Instructions 103 Figure 74 Selecting Sleep Mode Screen Sequence SELECT Key then NEXT Key SELECT Key YES Key YES Key YES Key YES Key YES Key or NO Key ...

Page 105: ...e not allowed if Any alarms are present The unit is in Sleep mode Unit is in Service Test Mode Interface Board Test Mode or Evacuation Mode Full Pretrip A Full Pretrip occurs when Pretrip is initiated before the engine or electric motor starts running The Full Pretrip test proceeds in the order shown below Amp Checks Each electrical control component is energized and the current drawn is confirmed...

Page 106: ...Diesel Mode only If the unit is running in the Diesel Mode the engine RPM in high and low speed is checked during the Cool Check Heat Check The ability of the unit to heat in low speed is checked Report Test Results The test results are reported as PASS CHECK or FAILED when the Pretrip is completed If test results are Check or Failed alarm codes will exist to direct the technician to the source of...

Page 107: ... key to stop the unit 2 Press the ON key to turn the unit on 3 To initiate a Full Pretrip press the MENU soft key as soon as the Standard Display appears and before the unit starts To initiate a Running Pretrip let the unit start before pressing the MENU soft key on the Standard Display 4 Press the NEXT soft key until the Pretrip Screen appears See Figure 77 5 Press the SELECT soft key to start a ...

Page 108: ...nsor menus In a Full Pretrip when the non running tests are complete the unit will start automatically and continue with the running tests 7 When all tests are complete the results are reported as PASS CHECK or FAILED If FAILED appears the unit will shut down If the results are Check or Failed the accompanying alarm codes will direct the technician to the cause of the problem 8 If the Pretrip Test...

Page 109: ...108 Figure 77 Pretrip Test Screen Sequence Operating Instructions 108 Figure 77 Pretrip Test Screen Sequence SELECT Key ...

Page 110: ... is available and Diesel Mode operation if standby power fails or is removed Contact your Thermo King dealer for information about programming the controller NOTE Manual selection is the default setting for both Electric Standby and Diesel Mode A screen asking if you wish to switch to Electric Standby will appear if the unit is connected to standby power when in the Diesel Mode A screen asking if ...

Page 111: ...Screen appears See Figure 79 and Figure 80 NOTE The Electric Standby Screen will not appear if diesel to electric switchover is enabled The Diesel Mode Screen will not appear if electric to diesel switchover is enabled 4 Press the SELECT soft key to select the mode shown on the display Figure 79 Programming Diesel Mode SELECT Key ...

Page 112: ...acklight 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 backlight suitable for low light conditions IMPORTANT Before replacing an HMI with no backlight check the Adjust Backlight feature to be sure the backlight is turned on Adjust the display brightness as follows 1 Begin at the St...

Page 113: ...t key until the Adjust Brightness Menu appears See Figure 82 4 Press the SELECT soft key to enter the Adjust Brightness Menu See Figure 82 5 Press the or soft keys to select the desired brightness See Figure 82 This example shows changing screen brightness from low to medium 6 Press the YES soft key to enter the new brightness level 7 The ADJUSTING BRIGHTNESS PLEASE WAIT Screen briefly appears 8 T...

Page 114: ...113 Figure 82 Adjusting Display Brightness Screen Sequence YES Key Key Operating Instructions 113 Figure 82 Adjusting Display Brightness Screen Sequence SELECT Key YES Key Key ...

Page 115: ...anged from the Main Menu The time and date are changed by programming the HMI Contact your Thermo King dealer for information about programming the HMI View the time and date as follows 1 Begin at the Standard Display If the Temperature Watch Display is showing press the MENU soft key once to return to the Standard Display 2 Press the MENU soft key on the Standard Display 3 Press the NEXT soft key...

Page 116: ...s can have a single setpoint or they can have a setpoint range that allows the user to select a setpoint within that range The controller can be programmed to allow only named products to be selected In which case the far left soft key will display PRODUCT See Figure 84 The controller can be programmed to allow named products or numeric setpoints to be selected In which case the far left soft key ...

Page 117: ...116 Operating Instructions 116 1 Product Setpoint Soft Key Figure 85 Standard Display with Product Setpoint Soft Key 1 ...

Page 118: ...CT SETPOINT soft key Using the Standard Display with the PRODUCT soft key is basically the same but some of the screens differ slightly 1 Begin at the Standard Display If the Temperature Watch Display is showing press the MENU soft key once to return to the Standard Display 2 Press the PRODUCT SETPOINT or PRODUCT soft key on the Standard Display See Figure 86 3 The Named Product Numeric Setpoint o...

Page 119: ...ys are not used to accept or decline the new named product 8 The Programming Named Product Screen will briefly appear See Figure 87 NOTE If the Change Setpoint for XXXXX Screen appears the named product has been programmed with a setpoint range See Selecting the Setpoint for a Named Product on page 120 9 The New Named Product Is XXXXX Screen briefly appears See Figure 87 10 The Standard Display ap...

Page 120: ...Key NAMED Key or Key Operating Instructions 119 Figure 87 Selecting or Changing Named Product Screen Sequence PRODUCT SETPOINT Key YES Key NAMED Key or Key NOTE If Change Setpoint for XXXXX Screen appears instead see Selecting the Setpoint for a Named Product on page 120 ...

Page 121: ...ars then the Current Setpoint of XXXXX Setpoint Range Is XX to XX Screen will appear See Figure 88 2 Press the or EXIT soft keys accordingly as described below See Figure 88 Press the or soft keys to change the current setpoint for the named product and then go to step 3 Press the EXIT soft key to accept the current setpoint for the named product The Standard Display will appear with the named pro...

Page 122: ...21 Figure 88 Selecting Setpoint for Named Product Screen Sequence or Key YES Key EXIT Key Operating Instructions 121 Figure 88 Selecting Setpoint for Named Product Screen Sequence or Key YES Key EXIT Key ...

Page 123: ...ete the following steps to change the setpoint for a named product This example shows the Standard Display with the PRODUCT SETPOINT soft key Using the Standard Display with the PRODUCT soft key is basically the same but some of the screens differ slightly 1 Begin at the Standard Display If the Temperature Watch Display is showing press the MENU soft key once to return to the Standard Display 2 Pr...

Page 124: ...e with the or soft keys will not be accepted the named product setpoint will not be changed and the display will return to the Standard Display If the YES soft key is pressed the named product setpoint change made with the or soft keys will be accepted and the following screens will appear 8 The Programming New Setpoint for XXXXX Screen will briefly appear See Figure 90 9 The New Setpoint Is XX Sc...

Page 125: ...0 Changing Setpoint for Named Product Screen Sequence YES Key CHANGE SP Key Operating Instructions 124 Figure 90 Changing Setpoint for Named Product Screen Sequence YES Key or Key PRODUCT SETPOINT Key CHANGE SP Key ...

Page 126: ...ETPOINT soft key on the Standard Display See Figure 91 3 The Named Product Numeric Setpoint Screen briefly appears then the Named Product or Numeric Setpoint Screen will appear See Figure 92 4 Press the NUMERIC soft key See Figure 92 5 The Setpoint Screen briefly appears then the Current Setpoint Is Screen will appear See Figure 92 6 Press the or soft keys to change the setpoint See Figure 92 7 Pr...

Page 127: ... The Standard Display appears with setpoint changed to the new setpoint See Figure 92 NOTE Pressing the EXIT soft key at any point will return to the Standard Display NOTE If no keys are pressed for 30 seconds while in the Named Product Changer Screens the HMI will return to the Standard Display ...

Page 128: ...ecting or Changing Numeric Setpoint Screen Sequence YES Key NUMERIC Key or Key Operating Instructions 127 Figure 92 Selecting or Changing Numeric Setpoint Screen Sequence PRODUCT SETPOINT Key YES Key NUMERIC Key or Key ...

Page 129: ...128 Operating Instructions 128 ...

Page 130: ...location typically at the rear of the trailer In the illustration below all display segments are turned on Figure 93 Rear Remote Control Panel IMPORTANT The SR 2 Rear Remote Control Panel is capable of turning the control system on from a fully powered down condition It is not necessary to turn the control system on using the unit HMI Control Panel before the Rear Remote Control Panel will operate...

Page 131: ...ear Remote Control Panel either the Standard Display or STAnd by will appear on the display Run If the Rear Remote Control Action is set to RUN the unit will automatically start and run as required when the remote control ON key is pressed Pressing the Rear Remote Control Panel OFF key will power down the control system If the control system is powered up from the Rear Remote Control Panel the Sta...

Page 132: ...d run Pressing the Rear Remote Control Panel OFF key will power down the control system The HMI Control Panel on the unit must be used to start and stop unit operation Only the setpoint can be changed from the Rear Remote Control panel Other than On and Off and changing setpoint no other functions are available from the Rear Remote Control Panel The unit will not start and run If the control syste...

Page 133: ...order to change the setpoint press the Select Key to show the Remote Standard Display The setpoint can now be changed in the usual manner After the setpoint is changed the display will return to the StAnd bY display shown below in about 10 seconds Figure 96 Press Select Key ...

Page 134: ...etpoint to be changed and control other functions Figure 97 Rear Remote Control Panel ON Key Turns the unit on as determined by the setting of Rear Remote Control Action OFF Key Turns the unit off Up Arrow Key Increases setpoint or changes other setting Down Arrow Key Decreases setpoint or changes other setting Select Key Allows Cycle Sentry to be turned on and off displays the discharge air tempe...

Page 135: ... possible segments lighted The display icons are defined below Figure 98 Rear Remote Control Panel Cool Icon This icon appears when the unit is cooling Heat Icon This icon appears when the unit is heating Modulation Icon This icon appears when the unit is in modulation Defrost Icon This icon appears when the unit is defrosting Cycle Sentry Icon This icon appears when the unit is operating in Cycle...

Page 136: ...mote Standard Display The Remote Standard Display above shows the following information The temperature typically return air temperature is 35 8 F The setpoint is 35 F The unit is cooling as shown by the icon at the upper left side of the display The unit is operating in Cycle Sentry mode as shown by the icon at the upper right side of the display Remote Control Panel Lockout The remote control pa...

Page 137: ...etpoint can be changed but the unit will not start and run Only the Select Key Enter Key and Up and Down Arrow Keys are functional The unit can be started and run by pressing the unit HMI Control Panel ON key Figure 101 Stand By Display IMPORTANT To change the setpoint press the Select Key to show the Remote Standard Display The setpoint can now be changed as shown on the next page Turning the Uni...

Page 138: ...isplay is shown 1 When the Remote Standard Display is shown press the Up or Down Arrow Keys to select the desired setpoint Figure 103 Press Up or Down Arrow Keys 2 When the desired setpoint is shown on the display immediately press the Enter Key to load the new setpoint The display will briefly show Lod and then the new setpoint will reappear in the display Figure 104 Press Enter Key IMPORTANT The...

Page 139: ...peration can be changed using the Select Key 1 Press the Select key once to display the Cycle Sentry prompt Figure 105 Press Select Key 2 Use the Up and Down Arrow Keys to chose either YES or nO Yes Cycle Sentry Mode nO Continuous Mode Figure 106 Press Up or Down Arrow Keys 3 When the desired selection is shown press the Enter Key to load the setting The display will briefly show Lod and then the ...

Page 140: ...ntrol Panel 139 Displaying the Discharge Air Temperature The discharge air temperature can be shown using the Select Key 1 Press the Select Key twice The discharge air temperature will be shown in the display for about 10 seconds Figure 108 Press Select Key Twice 2 The display will then return to the Remote Standard Display ...

Page 141: ...ress the Select Key three times Any alarm codes present will be shown in the display with the most recent alarm code shown first If no alarm codes are present the display will show 00 Figure 109 Press Select Key Three Times 2 To clear a displayed alarm code press the Enter Key The display will briefly show CLEAr ALm Figure 110 Press Enter Key 3 If any additional alarms are present the next alarm w...

Page 142: ...itions allow a manual defrost cycle can be initiated using the Defrost Key 1 Press the Defrost Key The defrost prompt EnTEr dEF will appear in the display Figure 112 Press Defrost Key 2 When the defrost prompt is shown press the Enter Key to start a manual defrost The display will briefly show LOAd dEF and then a defrost cycle will begin if conditions allow Figure 113 Press Enter Key 3 The display...

Page 143: ...t to the data loggers using the TK Logo Key 1 Press the TK Logo Key The Start of Trip EnTEr SOt prompt will appear in the display Figure 115 Press TK Logo Key 2 When the Start of Trip prompt is shown press the Enter Key to send a Start of Trip marker to the CargoWatch and ServiceWatch data loggers The display will briefly show LOAd SOt Figure 116 Press Enter Key 3 The display will then return to t...

Page 144: ...en the Pretrip Test is started a Running Pretrip Test will be performed 1 Clear any alarm codes as shown previously 2 Press the Pretrip Key The Pretrip EntEr PrE prompt will appear in the display Figure 117 Press Pretrip Key 3 When the Pretrip prompt is shown press the Enter Key to start a Pretrip Test The display will briefly show LOAd PrE If the unit is not running a Full Pretrip Test will be pe...

Page 145: ...isplay will show PrE trP The HMI Control Panel will show the Pretrip Test progress Figure 119 Pretrip Display 5 When the Pretrip Test is complete the display will show PASS CHEC or FAIL Pressing the Select Key will return to the Remote Standard Display Figure 120 Pass Pretrip Display ...

Page 146: ...ill 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 Operation Instructions Chapter for information about viewing and clearing alarms NOTE Some alarms 3 4 74 203 and 204 cannot be cleared in the Alarms Menu they must be cleared in the Maintenance Menu or the Guarded Access Menu Contact your supervisor ...

Page 147: ...vent Alarms Prevent Alarms are also indicated by the Alarm Display as shown in Figure 122 The Alarm Menu must be used to view the existing alarms The unit may stop running and wait a timed interval or until conditions allow and then restart If the unit is waiting to restart Alarm Code 84 Restart Null will be present along with the Prevent Alarm In other cases the unit may restart or run with reduc...

Page 148: ... and will not restart until the shutdown alarm is cleared Exceptions are some engine and electric shutdown alarms become that log alarms when switched to the alternate operating mode diesel to electric or electric to diesel If a shutdown alarm occurs that affects only diesel mode operation and the unit is switched to electric either manually or automatically the diesel mode shutdown alarm becomes ...

Page 149: ...hermo King dealer about clearing those alarms Refer to the table on the following pages for the proper corrective action NOTE Document all alarm faults and report them to the service technician There are three levels of corrective action that can be taken when an alarm condition occurs OK To Run An alarm condition exists but does not affect unit operation Corrective action can occur at a later dat...

Page 150: ...ll microprocessor controllers or all revisions of software Code Description Corrective Action Level Of Action Ok To Run Check Shut Down 00 No Alarms Exist None required X 2 Evaporator Coil Sensor Manually monitor load temperature with independent thermometer Report alarm at end of day X 3 Control Return Air Sensor Manually monitor load temperature with independent thermometer Report alarm at end o...

Page 151: ...alarm at end of day X 10 High Discharge Pressure If unit is shut down repair immediately Otherwise report alarm at end of day X 11 Unit Controlling on Alternate Sensor Manually monitor load temperature with independent thermometer Report alarm at end of day X 12 Sensor Shutdown The unit is no longer able to operate and has been shut down Repair immediately X 13 Sensor Check Manually monitor load t...

Page 152: ...t alarm at end of day X 19 Low Engine Oil Pressure It unit is shutdown repair immediately Otherwise report alarm at end of day X 20 Engine Failed to Start If unit is shutdown repair immediately Otherwise report alarm at end of day X 21 Cooling Cycle Check Manually monitor load temperature with independent thermometer Report alarm at end of day X 22 Heating Cycle Check Manually monitor load tempera...

Page 153: ... at end of day X 26 Refrigeration Capacity Check Manually monitor load temperature with independent thermometer Report alarm at end of day X 28 Pretrip or Self Check Abort Report alarm at end of day X 29 Defrost Damper Circuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 30 Defrost Damper Stuck Closed The unit is no longer able to operate and has been shut down Rep...

Page 154: ...rcuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 36 Electric Motor Failed to Run If unit is shutdown repair immediately Otherwise report alarm at end of day X 37 Engine Coolant Level Check coolant level add as needed Report alarm at end of day X 38 Electric Phase Reversed If unit is shutdown repair immediately Otherwise report alarm at end of day X 39 Water Valve...

Page 155: ...Otherwise report alarm at end of day X 42 Unit Forced to Low Speed Report alarm at end of day X 43 Unit Forced to Low Speed Modulation Report alarm at end of day X 44 Out of Fuel Unit has been shut down Refill fuel tank X X 45 Hot Gas Bypass or Hot Gas Bypass Circuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 46 Check Air Flow Cargo may be restricting air flow ch...

Page 156: ...therwise report alarm at end of day X 50 Reset Clock Report alarm at end of day X 52 Heat Circuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 53 Economizer Valve Circuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 54 Test Mode Time out Service Test or Interface Board Test time out after 15 minutes Report alarm at end of day X 55 C...

Page 157: ...ort alarm at end of day X 63 Engine Stopped If unit is shutdown repair immediately Otherwise report alarm at end of day X 64 Pretrip Reminder Report alarm at end of day X 66 Low Engine Oil Level Check engine oil level If unit is shutdown repair immediately Otherwise report alarm at end of day X 67 Liquid Line Solenoid Circuit If unit is shutdown repair immediately Otherwise report alarm at end of ...

Page 158: ...end of day X 73 Hourmeter 6 Exceeds Set Time Limit Report alarm at end of day X 74 Controller Reset to Defaults Report alarm at end of day X 75 Controller RAM Failure If unit is shutdown repair immediately Otherwise report alarm at end of day X 76 Controller EPROM Failure If unit is shutdown repair immediately Otherwise report alarm at end of day X 77 Controller EPROM Checksum Failure If unit is s...

Page 159: ...mp Sensor Report alarm at end of day X 81 High Comp Temp Report alarm at end of day X 82 High Compressor Temperature Shutdown If unit is shutdown repair immediately Otherwise report alarm at end of day X 83 Low Engine Coolant Temperature Manually monitor load temperature with independent thermometer Report alarm at end of day X 84 Restart Null Report alarm at end of day X 85 Forced Unit Operation ...

Page 160: ...rm at end of day X 91 Electric Ready Input If unit is shutdown repair immediately Otherwise report alarm at end of day X 92 Sensor Grades Not Set Report alarm at end of day X 93 Low Compressor Suction Pressure If unit is shutdown repair immediately Otherwise report alarm at end of day X 94 Loader 1 If unit is shutdown repair immediately Otherwise report alarm at end of day X 95 Loader 2 If unit is...

Page 161: ...essure Ratio If unit is shutdown repair immediately Otherwise report alarm at end of day X 104 Check Remote Fan Speed Not Currently Used Report alarm at end of day X 105 Receiver Tank Pressure Solenoid Circuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 106 Purge Valve Circuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 107 Conden...

Page 162: ... Otherwise report alarm at end of day X 111 Unit Configuration Report alarm at end of day X 112 Check Remote Fans If unit is shutdown repair immediately Otherwise report alarm at end of day X 113 Electric Heat Circuit Manually monitor load temperature with independent thermometer Report alarm at end of day X 114 Many Alarms Cannot Run If unit is shutdown repair immediately Otherwise report alarm a...

Page 163: ...alarm at end of day X 120 Alternator Exciter Circuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 121 Liquid Injection Circuit If unit is shutdown repair immediately Otherwise report alarm at end of day X 122 Diesel Electric Relay Circuit If unit is shutdown repair immediately Otherwise report at end of day X 123 Evaporator Coil Inlet Temp Sensor Manually monitor l...

Page 164: ... at end of day X 126 Back Pressure Regulator Manually monitor load temperature with independent thermometer Report alarm at end of day X 127 Setpoint Not Entered Be sure the setpoint is set to the required temperature X 128 Engine Run Time Maintenance Reminder 1 Report alarm at end of day X 129 Engine Run Time Maintenance Reminder 2 Report alarm at end of day X 130 Electric Run Time Maintenance Re...

Page 165: ...at end of day X 133 Total Unit Run Time Maintenance Reminder 2 Report alarm at end of day X 134 Power On Hours Report alarm at end of day X 135 Spare Digital Inputs Report alarm at end of day X 136 Spare Digital Outputs Report alarm at end of day X 203 Display Return Air Sensor Manually monitor load temperature with independent thermometer Report alarm at end of day X 204 Display Discharge Air Sen...

Page 166: ...ize temperature related problems Pre Loading Inspection 1 Pre cool products before loading Note any variances on the manifest 2 Inspect door seals and vent doors for condition and a tight seal with no air leakage 3 Inspect the trailer inside and out Look for Damaged or loose trailer skin and insulation Damaged walls air ducts floor channels or T flooring Clogged defrost drain tubes Blocked return ...

Page 167: ...tions 166 Figure 124 Loading Considerations ADZ30 6 8 9 1 2 5 4 7 1 Correct load height trailers without chutes 2 Tight doors and gaskets 3 Good air circulation around load 4 Proper cargo temperature prior to loading 5 Interior exterior walls and insulation in good condition 6 Clear defrost drains 7 Good outside air circulation 8 Unit inspection 9 Tight seals 3 ...

Page 168: ...d with the cargo box doors open if the truck is backed into a refrigerated warehouse and the dock door seals fit tightly around the trailer 3 Perform a final check of the load temperature If the load is above or below temperature make a final notation on the manifest 4 Close or supervise the closing of the cargo box doors Make sure they are securely locked 5 Make sure the setpoint is at the temper...

Page 169: ...frost cycle after each enroute inspection Inspection Troubleshooting 1 If a temperature reading is not within the desired temperature range refer to the troubleshooting table on the following pages Correct problem as required 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...

Page 170: ...oled cargo compartment length of time on road etc Correct as required Continue monitoring return air temperature until the reading is within the desired temperature range of the setpoint The unit may have a low refrigerant charge Check the receiver tank sight glass for refrigerant level If liquid is not showing in the receiver tank sight glass the refrigerant charge may be low A competent refriger...

Page 171: ...irculation 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 The unit did not start automatically Determine the cause for not starting Correct as required Continue monitoring the return air temperature until the reading is within the desired temperature range of the setpoin...

Page 172: ...e make sure it has a 12 volt battery with a negative ground system Do not use a hot shot booster device or a 24 volt source Read and understand the following procedure completely before connecting any jumper cables Use good jumper cables made with 2 gauge or larger cables 1 Make sure the unit is turned off If you are using a vehicle make sure its ignition is also turned off 2 Open the front doors ...

Page 173: ...tive battery terminal on the unit s battery CAUTION Do not use a match or lighter as a light near the battery Use a flashlight A flame or a spark can ignite the gas in the battery and cause it to explode 1 Red Cover on Positive Battery Terminal Figure 125 Unit Battery 1 1 Positive Terminal on Unit Battery 2 Positive Terminal on Good Battery 3 Negative Terminal on Good Battery 4 Starter Mounting Bo...

Page 174: ...not let the other end of the jumper cable touch anything that conducts electricity 7 Connect the other end of the red positive jumper cable to the positive battery terminal on the good battery 8 Connect the black negative jumper cable to the negative battery terminal on the good battery Do not let the other end of the jumper cable touch anything that conducts electricity 9 Connect the black negati...

Page 175: ...ed battery 11 Turn the unit on and let it start automatically or start it manually If the unit will not crank or start contact a qualified technician NOTE Some units with microprocessors will show an alarm code and will not try to start until the battery voltage is above 10 volts 12 After the unit starts remove the jumper cables in reverse order black negative from the unit starter mounting bolt b...

Page 176: ...ne Engine SB 210 SB 310 TK486V TK486VH Fuel Type No 2 diesel fuel under normal conditions No 1 diesel fuel is acceptable cold weather fuel Oil Capacity Crankcase and Oil Filter 13 quarts 12 3 liters Fill to full mark on dipstick Oil Type API Classification CI 4 or better Oil Viscosity 14 F to 122 F 10 C to 50 C SAE 15W 40 Synthetic 5 to 104 F 15 to 40 C SAE 15W 40 13 to 104 F 25 to 40 C SAE 10W 40...

Page 177: ...ange and LOW if the oil pressure is below this range Low Oil Pressure Switch Normally Closed 17 3 psi 117 21 kPa Engine Thermostat 160 F 71 C Engine Coolant Type ELC Extended Life Coolant which is red Use a 50 50 concentration of any of the following equivalents Chevron Dex Cool Texaco ELC Havoline Dex Cool Havoline XLC for Europe Shell Dexcool Shell Rotella Saturn General Motors Dex Cool Caterpil...

Page 178: ... quarts 7 1 liters Radiator Cap Pressure 7 psi 48 kPa Drive Model 30 Model 50 Direct to compressor belts to fans alternator and water pump Centrifugal clutch to compressor belts to electric standby motor fans alternator and water pump Engine Continued ...

Page 179: ... span Specifications 178 Belt Tension Belt Tension No on TK Gauge 204 427 Model 30 Alternator Belt 61 Lower Fan Belt Engine to Idler SB 210 SB 310 67 79 Upper Fan Belt Fan to Idler SB 210 SB 310 74 79 Model 50 Alternator Belt 29 Compressor Drive Belts 79 Fan Belt 74 Water Pump Belt 35 NOTE These are the field reset settings Because it is sometimes difficult to use the TK Gauge 204 427 in the field...

Page 180: ...l Control System Voltage 12 5 Vdc Battery One Group C31 12 volt 950 CCA recommended for operation below 15 F 26 C Fuses 1 to 60 Amp Battery Charging Alternator 12 V 37 Amp brush type Voltage Regulator Setting 13 8 to 14 3 at 77 F 25 C ...

Page 181: ... Model 50 Units Only Electric Motor and Overload Relay Voltage Phase Frequency Horsepower Kilowatts rpm Full Load amps Overload Relay Setting amps 230 3 60 14 0 10 4 1755 37 8 38 460 3 60 14 0 10 4 1755 18 9 20 460 3 60 24 0 17 9 3480 29 31 Electric Heater Strips Number 3 Power Rating 1000 watts each Standby Power Cord Requirements Supply Circuit Breaker 14 HP Motor 230 3 60 14 HP Motor 460 3 60 2...

Page 182: ...r 460 3 60 24 HP Motor 460 3 60 8 AWG Power Cable 25 50 foot length 6 AWG Power Cable 75 foot length 10 AWG Power Cable up to 75 foot length 8 AWG 4 Conductor 2000V Type W Power Cable up to 75 foot length Electric Fuel Heater Resistance Current Draw at 12 5 Vdc Internal Thermostat Minimum Closing Temp Internal Thermostat Maximum Opening Temp 0 9 to 1 1 ohms 11 4 to 13 9 amps 30 F 1 C 75 F 24 C W F...

Page 183: ... liters Compressor Oil Type Polyol Ester Type P N 203 413 Refrigerant Charge Type SB 210 SB 310 13 lb 5 9 kg R404A 16 lb 7 3 kg R404A Heat Defrost Method Hot gas and electrical heater strips on Model 50 units High Pressure Cutout Switch Opens 470 7 35 psi 3241 48 241 kPa Automatic Reset 375 38 psi 2586 262 kPa ...

Page 184: ...top operating condition The following general schedule is provided to assist in monitoring that maintenance For more details refer to the appropriate maintenance manual and to the Manual Pretrip Inspection in this manual Fuel Island Pre trip Every 1 500 Hours Every 3 000 Hours Annual 4 500 Hours Inspect Service These Items Engine Check fuel supply and engine oil level Inspect belts for condition a...

Page 185: ...aner element at 3 000 hours or two years whichever occurs first if air cleaner restriction indicator has not reached 25 in The EMI 3000 air cleaner element has a nameplate that reads EMI 3000 Check engine coolant level and antifreeze protection 30 F 34 C Drain water from fuel tank and check vent Inspect clean fuel transfer pump inlet strainer pre filter Replace EMI 3000 black fuel filter water sep...

Page 186: ...ery 5 years or 12 000 hours Units equipped with ELC have an ELC nameplate on the expansion tank See Safety Decals and Locations Test fuel injection nozzles at least every 10 000 hours Replace fuel return lines between fuel injection nozzles every 10 000 hours Electrical Check damper door operation closes on defrost initiation opens on defrost termination Inspect battery terminals and electrolyte l...

Page 187: ...l Structural Visually inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts includes air ducts Inspect tapered roller bearing fanshaft and idler for leakage and bearing wear Clean entire unit including condenser and evaporator coils and defrost drains Check all unit fuel tank and electric motor mounting bolts brackets lines hoses etc Check evaporator damper door adju...

Page 188: ...ing valve regulating pressure on defrost units mechanical throttling valve only Check compressor efficiency and pump down refrigeration system Replace dehydrator and check discharge and suction pressure every 2 years Fuel Island Pre trip Every 1 500 Hours Every 3 000 Hours Annual 4 500 Hours Inspect Service These Items 3 000 hours or two years whichever occurs first ...

Page 189: ...188 Maintenance Inspection Schedule 188 ...

Page 190: ... Warranty are available on request Please reference document TK 50046 for the Thermo King Trailer Unit Warranty See the EPA Emission Control System Warranty Statement chapter earlier in this manual for the EPA Emission Control System Warranty ...

Page 191: ...190 Warranty 190 ...

Page 192: ... A device located in the suction line to collect liquid refrigerant and meter it safety back to the compressor as gas ambient air temperature Temperature of the air surrounding an object amp Abbreviation for ampere The basic measuring unit of electrical current bar A metric unit of pressure 1 bar 100 kPa 14 5 psi Battery Sentry Part of the CYCLE SENTRY system The Battery Sentry module monitors alt...

Page 193: ...al circuit when the current in the circuit exceeds the predetermined amperage rating of the breaker See amp coil A cooling or heating element made of pipe or tube formed into a helical or serpentine shape that may be equipped with thin metal fins to aid heat transfer cold curtains Flexible vinyl curtains used to reduce air exchange between the refrigerated compartment and the outside during door o...

Page 194: ...or drier See dehydrator ECT A ceiling mounted Thermo King remote evaporator See EW and TLE ERC Extended Remote Unit Control Door switches An option on Thermo King multi temperature units to improve temperature control when doors are opened during delivery When a compartment door is opened the refrigeration unit for that compartment may be forced to NULL defrost or some other mode Opening a compart...

Page 195: ...e damages the earth s atmosphere in many countries it is illegal to release this type of refrigerant to the atmosphere HCFC refrigerants are not used in modern Thermo King units Hertz A unit of frequency equal to one cycle per second Abbreviated Hz HFC A refrigerant consisting of hydrogen fluorine and carbon Examples R134a and 404A HFC refrigerants contain no chlorine and are therefore considered ...

Page 196: ... of diesel fuel formulated for moderate to warm ambient temperatures ohm An electrical unit measuring the amount of resistance opposition to the current flow in an electrical circuit pre cooling 1 To cool down an empty box temperature controlled area to the desired load temperature prior to loading 2 To cool cargo to a desired temperature before loading pre heat The heating of diesel engine glow p...

Page 197: ...geration unit cycles between the heat and cool modes more often than normal sight glass A system component that permits visual inspection of oil or refrigerant level and condition thermostat A device that controls unit modes of operation to maintain a selected box temperature TLE Thin line evaporator A Thermo King remote evaporator designed to be compact thin while supplying superior air flow See ...

Page 198: ...1 air cleaner restriction indicator 36 alarm codes 145 corrective action 148 types 145 alarms menu 85 amber status light 42 automatic start stop safety precautions 14 B battery inspection 45 belt tension 178 belts inspection 45 C coils inspection 46 compressor oil sight glass 36 continuous mode selecting 69 continuous run operation 29 control panel 49 display 49 keys 50 CYCLE SENTRY operation 29 s...

Page 199: ...ing unit on 61 electric standby specifications 180 electrical control system specifications 179 electrical hazards 14 electrical inspection 45 electronic throttling valve ETV 28 Emergency Cold Line 205 EMI 3000 27 engine compartment components 36 engine coolant level 45 engine oil dipstick 36 engine oil level 45 engine specifications 175 enroute inspections 168 ETV electronic throttling valve 28 e...

Page 200: ...ypad lockout 96 selecting 99 L language menu 82 loading procedures enroute inspections 168 post loading inspection 167 pre loading inspection 165 low oil level switch 37 low oil pressure switch 37 M main menu choices 80 navigating 79 Maintenance Inspection Schedule 183 manual defrost cycle initiating 71 manual pretrip inspection 45 microprocessor On Off switch 48 Mode key 50 mode menu 96 O Off key...

Page 201: ...16 electrical hazards 14 first aid for refrigerant 15 first aid for refrigerant oil 15 general safety practices 13 refrigerant 14 refrigerant oil 15 selection of operating modes 68 sensor readings viewing 75 Serial Number Locations 201 setpoint changing 65 sleep mode 96 sleep mode selecting 101 smart FETs 38 SMART REEFER 2 SR 2 Controller 29 47 soft keys 50 specifications 175 SR 2 Controller 29 47...

Page 202: ... the bulkhead above the compressor inside the curbside door and on the roadside of the evaporator Engine See the engine identification plate located on the engine valve cover Compressor Stamped between the cylinders on the front end above the oil pump ...

Page 203: ...02 Figure 129 Compressor Serial Number Location Figure 130 Engine Serial Number Location Serial Number Locations 202 Figure 129 Compressor Serial Number Location Figure 130 Engine Serial Number Location ...

Page 204: ...of Material Number 3 Unit Model 4 Unit ID Figure 132 Unit Serial Number Plate ARA793 Serial Number Locations 203 Figure 131 Unit Serial Number Plate Locations on the bulkhead above compressor inside curbside door and on roadside of evaporator 1 Unit Serial Number 2 Bill of Material Number 3 Unit Model 4 Unit ID Figure 132 Unit Serial Number Plate ARA793 1 2 3 4 ...

Page 205: ...204 Serial Number Locations 204 ...

Page 206: ...you can t get your rig rolling and you have tried the Thermo King North American Service Directory available from any Thermo King dealer to reach a dealer without success then call the Toll Free Emergency Cold Line Number 888 887 2202 The answering service at the factory will assist you in reaching a dealer to get the help you need The Cold Line is answered 24 hours a day by personnel who will do ...

Page 207: ...ng we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations concerning the use of refrigerants and the cert...

Page 208: ...001 207 the State of California to cause cancer 001 207 CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer ...

Page 209: ... class brands include Thermo King the leader in transport temperature control and Trane a provider of energy efficient heating ventilating and air conditioning systems building and contracting services parts support and advanced controls for commercial buildings and homes 2011 Ingersoll Rand Company Printed in U S A ...

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