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Thermo King SR-2 SmartReefer2, Diagnostic Manual

The Thermo King SR-2 SmartReefer2 is a cutting-edge refrigeration unit for temperature-controlled transport. Ensure optimal performance with the Diagnostic Manual available for free download at manualshive.com. This comprehensive manual provides detailed information on troubleshooting and maintenance, ensuring smooth operation of your SmartReefer2 unit.

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Section 6 – SR-2 Service Procedure A03A 

 

 

Step Action 

Result 

Comments 

8 

Place the microprocessor and 

interface board assembly on a 

clean bench for further 

disassembly. 

 

 

 

9 

To remove the interface board 

from the microprocessor, remove 

the interface board screws and 

pull the interface board straight 

back from the microprocessor. 

 

 

 

10 

Reassembly the components in 

the reverse order, using the 

replacement part.  Be sure to 

use the correct hardware, as 

some screw lengths may vary. 

 

 

When installing an interface 

board on a microprocessor, 

use care to line up the guide 

pins. 

11 

Reconnect all harness 

connectors to the 

microprocessor and interface 

board assembly. 

 

 

Be sure all connectors are 

securely mated and secure 

the harnesses with cable ties 

as required. 

12 

Reconnect the unit battery. 

 

 

 

13 

Reconnect the standby power if 

needed. 

 

 

 

14 

Turn the unit on. 

 

 

The real time clock settings 

will be loaded from the HMI 

Control Panel when the unit is 

turned on. 

 

 

Page 3 

P41RA03A 02 February 2005

 

Summary of Contents for SR-2 SmartReefer2

Page 1: ...inted in USA THERMO KING SR 2 SmartReefer2 Microprocessor Control System TK 51727 2 OD 02 01 05 DIAGNOSTIC MANUAL Used on SB 110 SB 210 SB 310 SL 400e SR 2 Microprocessor Software Revision B002 HMI Co...

Page 2: ...itions are available upon request Thermo King s warranty will not apply to any equipment which has been so repaired or altered outside the manufacturer s plants as in the manufacturer s judgment to af...

Page 3: ...and processes covered by the following SR2 software revisions Microprocessor Software Revision B002 and HMI Control Panel Software Revision 6502 6503 or 6602 6603 Earlier versions of software are simi...

Page 4: ......

Page 5: ...ow they are used Section 4 Operation This section explains how to operate the microprocessor control system This information is referenced by material in Section 5 Diagnostics Section 5 Diagnostics Th...

Page 6: ...urn Air or Discharge Air sensor is replaced Service Procedure D01A must be followed If a graded sensor is replaced it must be calibrated as shown in Service Procedure A15A Any time the Microprocessor...

Page 7: ...Tab goes here and the next page should be GREEN Section 1 Safety...

Page 8: ......

Page 9: ...1 1 General Practices 3 Auto Start Stop 3 Refrigerant 3 Refrigerant First Aid 4 Refrigeration Oil 4 Refrigeration Oil First Aid 4 Electrical Considerations 4 Microprocessor Service 4 Welding 4 Electri...

Page 10: ...Section 1 SR 2 Safety Information 1 2 18 January 2005...

Page 11: ...aution when working around exposed coil fins These fins can cause painful lacerations 10 Use caution when working with refrigerant in a closed or confined area with a limited air supply such as a trai...

Page 12: ...possible REFRIGERATION OIL Avoid contact with the eyes Avoid prolonged contact with the skin or clothing To prevent skin irritation wash hands thoroughly after handling refrigeration oil Refrigeratio...

Page 13: ...ction must be taken after a person has received an electrical shock Medical attention should be summoned as soon as possible The source of electricity must be immediately removed either by shutting do...

Page 14: ...Section 1 SR 2 Safety Information 1 6 18 January 2005...

Page 15: ...Tab goes here and the next page should be GREEN Section 2 Hardware Description...

Page 16: ......

Page 17: ...or Sensor arranged by use 10 Interface Board 11 Interface Board Fuse Size Function 12 Interface Board Relay Functions 12 Interface Board LED Functions 13 Smart FET Outputs 13 Power Side Logic 14 Inter...

Page 18: ...4 Suction Pressure Transducer SPT 24 High Pressure Cutout Switch HPCO 24 Pilot Solenoid PS 24 Electronic Throttling Valve ETV 24 Hot Gas Solenoid HG 25 Damper Solenoid DS 25 Damper Motor 25 Engine Con...

Page 19: ...Ambient Air Sensor Spare Sensor 1 Coolant Temp Sensor Suction Pressure Sensor Discharge Pressure Sensor Fuel Level Sensor Compressor Temp Sensor ELECTRIC STANDBY OPTION Phase Select Module Motor Cont...

Page 20: ...e unit CONTROL SYSTEM The SR2 Microprocessor Control System consists of the following main components Microprocessor On Off Switch HMI Human Machine Interface Control Panel Microprocessor Interface Bo...

Page 21: ...ng the engine compartment doors MICRO PROCESSOR OFF ON SL Series Units The Microprocessor On Off Switch is located on the control panel between the data ports SmartReefer2 OFF ON MENU 2 C 2 CYCLE SENT...

Page 22: ...of 11 languages The HMI also contains the Cargo Watch Data Logger The HMI and microprocessor communicate via a CAN Controller Area Network connection If the HMI Control Panel is disconnected from the...

Page 23: ...r 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...

Page 24: ...09 DPD1 01 CargoWatch Data Pak Detect 20 RXD2 01 Printer port receive 31 TXD2 01 Printer port transmit 19 COM2 01 Printer port chassis ground 29 D14 01 Printer port print 12 2P Printer port printer p...

Page 25: ...e memory inputs and outputs The software provides the required operating and control functions and supports the Service Watch Data Logger Inputs are used to supply power and system information to the...

Page 26: ...ir temperature sensor positive blue sensor wire 33 DTRN 01 Display discharge air temperature sensor negative brown sensor wire 25 CTP 01 Coil temperature sensor positive blue sensor wire 14 CTN 01 Coi...

Page 27: ...n the relay coil is energized and the relay contacts have transferred to the energized position The interface board is plugged directly into the microprocessor and secured with mounting hardware The m...

Page 28: ...e HMI control panel energize and de energize the K9 On Off Relay When the K9 On Off Relay is energized power is supplied through the normally open K9 contacts to turn the unit on When fuse F10 is inst...

Page 29: ...ng Is on without flashing during reboot and when under test LED22 K8 Electric Circuit LED23 K9 On Off Circuit LED24 K6 Fuel Solenoid Pull In Circuit LED25 K7 Starter Circuit LED26 Future Use Smart FET...

Page 30: ...g output circuits be sure to consider if the output is supplying battery voltage or chassis ground Interface Board Jumpers Four sets of jumper pins are located on the interface board Each set consists...

Page 31: ...om pins Place the Microprocessor Power Switch in the on position and turn the unit on by pressing the HMI Control Panel On key A cold start has been performed and all sensor grades and unit programmab...

Page 32: ...e CLS 16 CLS 01 Signal from coolant level sensor white wire CLS 17 PHPCO 01 To high pressure cutout switch HPCO 18 HPCO 01 To high pressure cutout switch HPCO 20 DSP 01 Power to the optional door swit...

Page 33: ...le PSM 4 CHHV To chassis ground 5 ER 01 To ER terminal on phase select module PSM 6 26E 01 Power to heater contactor HC J8 Remote Light Connector arranged by pin number Pin Wire Description 1 ALM 01 T...

Page 34: ...SL Interface Board 8 29 01 Power to energize damper solenoid DS J14 HMI Connector arranged by pin number Pin Number Wire Number Description 1 CANL BLK1 01 To HMI Control Panel 2 CANH RED1 01 To HMI Co...

Page 35: ...r Pin Number Wire Number Description 1 CANL BLK1 08 To Remote Controller Panel 2 CANH RED1 07 To Remote Controller Panel 3 DRAIN WHT 02 To Remote Controller Panel 4 ON_OFF RED2 03 To Remote Controller...

Page 36: ...1 F10 F2 F3 F6 ON OFF SWITCH LED22 J4 2A F7 3A F9 3A F12 3A F8 CAN 2 CAN 1 J103 RS232 2 J102 J101 J27 10A F11 K4 K3 H 2A 2 60A F5 40A 8D 8DP 8S 8 DG 7D 29 LED17 LED18 LED20 LED19 LED8 LED9 LED10 LED11...

Page 37: ...tor coil temperature and ambient temperature since these temperatures are not as critical as the return and discharge air temperatures Do not replace a graded sensor with an un graded sensor Dual Sens...

Page 38: ...tive grade of the installed sensor in order to operate properly The Control Discharge Air Sensor is marked with one red cable tie and is connected to the microprocessor via the DTP and DTN wires The D...

Page 39: ...rgoWatch sensors are connected directly to the HMI Control Panel IMPORTANT The CargoWatch sensors ARE NOT inter changeable with the unit temperature sensors These thermistor sensors change resistance...

Page 40: ...ifold of four cylinder compressors The switch is closed with normal pressures and opens with excessive pressures to shut the unit down and prevent damage Pilot Solenoid PS The microprocessor energizes...

Page 41: ...t US domestic units The interface board for units with damper solenoids is different than the one used with defrost damper motors See the information in Section 7 Hardware Features and Interchange for...

Page 42: ...or is immersed in coolant and open when coolant level is below the sensor Magnetic Reed Switch The magnetic reed switch consists of a press in miniature reed switch and a captive magnetic float inside...

Page 43: ...energized in Diesel Mode when the microprocessor energizes the K1 Run Relay LED 6 is lit when the Run Relay is energized and the contacts have transferred The K1 Run Relay normally open contacts supp...

Page 44: ...ontrol Panel It is located on the control panel next to the ServiceWatch port ServiceWatch Port The ServiceWatch port is used to download the ServiceWatch data logger and to flash load software to the...

Page 45: ...off or fails The HMI control panel will prompt for electric or diesel switchover if the respective autoswitch feature is not enabled Note The unit will automatically switch to Cycle Sentry when the un...

Page 46: ...nergized and LED 7 is lit when the microprocessor requests Electric Mode operation The K5 Diesel Electric Relay normally open contacts supply power to the 7E circuit to enable Electric Mode operation...

Page 47: ...NC SB Unit Electric Standby Components These components are located in separate control box on compressor side of the unit 5 L3 3 L2 1 L1 4 T2 2 T1 6 T3 98 97 95 96 NO NC MCB MCA OVL HC PSM THERMO KIN...

Page 48: ...Section 2 SR 2 Hardware Description 2 32 31 January 2005...

Page 49: ...Tab goes here and the next 2 pages should be GREEN Section 3 Software Description...

Page 50: ......

Page 51: ...wchart 7 Operator Features 8 Standard Display 8 Temperature Watch 8 Setpoint Change 8 Gauges 8 Sensors 8 Main Menu Features 8 Language 8 Alarms 8 Datalogger 8 Hourmeters 8 Mode 8 Pretrip 8 Diesel Mode...

Page 52: ...int 17 Limited Alarm Resets 17 Remote Device 18 Alarm Display Menu 19 Hourmeter Setup Menu 19 Programmable Hourmeter Sub menu 19 Viewable Hourmeter Setup Sub menu 19 Sensor Calibration Menu 20 Sensor...

Page 53: ...Forces 32 Cycle Sentry Door Open Timeout 32 Continuous Mode OptiSet Features Frozen Ranges and Fresh Ranges without ETV or with Modulation Off 33 Continuous High Speed Pulldown 33 Continuous Fuel Sav...

Page 54: ...Watch digital input 1 2 3 or 4 43 Unit Configuration Setup Menu 44 Unit Configuration Setup Menu 44 Engine Type Is 44 Compressor Type Is 44 ETV Configured 44 Electric Standby Equipped 44 Electric Moto...

Page 55: ...existing conditions As an example if a 35 F 2 C setpoint is selected and the box temperature as indicated by the return air sensor is 60 F 16 C the unit should operate in Cool mode when turned on The...

Page 56: ...Soft Key Press Any Soft Key 2 5 Minute Time out Maintenance Menu Hourmeters Gauges Sensors Alarms Service Test Interface Board Test Display Self Test Evacuation Test Software Revision Set Time and Da...

Page 57: ...de Adjust Brightness Off Low Medium High Time TIme Date Display Only Setpoint Press Any Soft Key 2 5 Min Soft Key Gauges Soft Key Coolant Temperature Coolant Level Engine Oil Pressure Amps Battery Vol...

Page 58: ...operation This menu allows a Pretrip Test to be initiated by the operator If the test is started with the engine off a full test including amp checks is performed If the test is started with the engi...

Page 59: ...rator Coil Temperature Ambient Air Temperature Spare 1 Temperature Datalogger Sensor 1 Temperature Datalogger Sensor 2 Temperature Datalogger Sensor 3 Temperature Datalogger Sensor 4 Temperature Datal...

Page 60: ...de is available Maintenance Menu Features A brief explanation of each menu is shown here For complete operating details see Section 4 Hourmeters Display Self Test The Hourmeters menu allows the techni...

Page 61: ...urs Electric Run Time Reminder 1 Hours Electric Run Time Reminder 2 Hours Sensor Calibration Control Return Air Sensor Grade Control Discharge Air Sensor Grade Display Return Air Sensor Grade Display...

Page 62: ...ntenance Menu Press the NEXT key until the Set Time and Date Menu appears From the Set Time and Date Menu press and hold both the EXIT key and the key with no label above it for 5 seconds After 5 seco...

Page 63: ...to display pressures in PSIG kPa or BARS Restart Unit After Shutdown Micro Rev All HMI Rev All Choices ENABLED DISABLED or CONTINUOUS Factory Set ENABLED Exceptions Use continuous option for rail appl...

Page 64: ...e Setpoint Low Limit the display will show Setpoint Limit indicating that the selected Setpoint Low Limit has been reached Setting the Setpoint High Limit and the Setpoint Low Limit to the same temper...

Page 65: ...n Fresh and Frozen range to be set to either 24 F 4 C or 15 F 9 C Door Open Forces Micro Rev All HMI Rev All Choices OFF or LOG ONLY Factory Set LOG ONLY Exceptions The optional door switch must be in...

Page 66: ...led Description The Air Chute Detect feature is designed to detect a blocked or improperly installed trailer air chute Spare sensor 1 is located at the rear of the trailer and directly in the air flow...

Page 67: ...d to do so Water Temperature Setpoint Micro Rev All HMI Rev All Choices 180 F to 210 F 82 C to 99 C Factory Set 210 F 99 C Exceptions Description This feature allows the water temperature setpoint to...

Page 68: ...quires optional device see below Description This feature replaces the Satellite Enable Disable switch on units equipped with the remote device option Setting this feature to ENABLED allows an externa...

Page 69: ...Time Reminder 1 Hours Total Run Time Reminder 2 Hours Controller Power On Hours Pretrip Reminder Hours Engine Run Time Reminder 1 Hours Engine Run Time Reminder 2 Hours Electric Run Time Reminder 1 H...

Page 70: ...splay Return Air Sensor Alarm Code 04 RTRP RTRN 2 Yellow Display Discharge Air Sensor Alarm Code 204 DTRP DTRN 2 Red The Sensor Calibration Menu allows the operator to select the correct grade for all...

Page 71: ...8 or 12 Hours Factory Set 6 Hours Exceptions Description This feature selects the timed interval between defrost cycles with Frozen range setpoints when the temperature is in range Defrost Interval N...

Page 72: ...rned on There is an Enable Language screen for each language included in the installed software revision English is included in both language sets and is factory set as Enabled Only enabled languages...

Page 73: ...n There is one set of control point values for frozen range setpoints and a second set of control points for fresh range setpoints Programming OptiSet Features The OptiSet features are programmed usin...

Page 74: ...ntinuous Heat Cool Switchpoint Continuous Door Open Forces Continuous Door Open Timeout Continuous Low Speed Switchpoint Cycle Sentry Fresh and Frozen Continuous Frozen ranges and Fresh ranges on unit...

Page 75: ...return all settings to the default values If this OptiSet Reset feature is used all OptiSet settings are returned to factory defaults If any of the four OptiSet global features Temperature Setpoint Lo...

Page 76: ...only be used when absolutely required by the load Setpoint High Limit Micro Rev HMI Rev All Choices From 90 F 32 C to the setting of Setpoint Low Limit Factory Set 80 F 27 C Exceptions Description Th...

Page 77: ...Choices Up to 10 ranges from 0 through 9 Factory Set Range 0 is from 20 F 29 C to 24 F 4 C Range 1 is from 25 F 3 C to 80 F 27 C Exceptions Description Up to 10 ranges numbered from 0 to 9 can be prog...

Page 78: ...Economy Mode is turned off These features are the same for both Frozen and Fresh ranges Continuous Mode A number of Continuous Mode features can be customized if Continuous Mode is allowed and Economy...

Page 79: ...e is set Off the Cycle Sentry OptiSet custom features are available The Cycle Sentry OptiSet custom features are the same for Fresh and Frozen ranges These features are shown on the following pages Co...

Page 80: ...ents If set Off the unit will remain off until the door is closed If a time period is selected the unit will restart and run 4 seconds after the time period elapses It will continue to run even if the...

Page 81: ...Factory Set On Exceptions Description This feature allows Fuel Saver II for the selected range to be turned On or Off If Fuel Saver II is On and the box temperature changes a predetermined amount from...

Page 82: ...it can be no greater than 29 F 1 6 C This prevents melt damage with frozen cargo The Null Restart Temperature below setpoint is a fixed value and cannot be changed Cycle Sentry Door Open Forces Micro...

Page 83: ...l HMI Rev All Choices Off or On Factory Set On Exceptions Not active if modulation is enabled Description This feature allows Fuel Saver II for the selected range to be turned On or Off If Fuel Saver...

Page 84: ...eration is allowed when Fuel Saver II is active Continuous Heat Cool Switch Point Micro Rev All HMI Rev All Choices 0 5 F 0 2 C to 2 5 F 1 5 C Factory Set 1 7 F 0 9 C Exceptions Not active if modulati...

Page 85: ...eature allows the unit to restart if the door open time exceeds the set limit Door Open Timeout for the selected range can be set to Off or for a time limit from 1 to 4 hours in 10 minute increments I...

Page 86: ...ratures poor trailer insulation and product loaded warm are potential causes that could force the unit to run in high speed for a period of time Modulation Control Micro Rev All HMI Rev All Choices Of...

Page 87: ...mit Factory Set Maximum Exceptions Only appears if Controlling Sensor Return Description This feature determines the modulation pull down control algorithm used This feature is only available with ret...

Page 88: ...of the programmed floor limit with setpoints of 30 F 1 1 C and higher FreshSet Freeze Protection Revision All Revision All Choices Off or On Factory Set Off Exceptions Only appears if Controlling Sens...

Page 89: ...Set High Speed Modulation Ceiling Micro Rev All HMI Rev All Choices 2 0 F 1 0 C to 10 0 F 5 5 C Factory Set 3 0 F 1 7 C Exceptions Only appears if High Speed Mod ulation On Description This switch poi...

Page 90: ...oor openings are logged in both the CargoWatch and ServiceWatch data loggers The door switch must be open or closed for 4 seconds before the event is logged to prevent false readings Door Open Timeout...

Page 91: ...tory Set Sensors 1 2 ON sensors 3 6 OFF Exceptions Description This feature allows the desired sensors to be logged or ignored Independent Sensor Name for CargoWatch sensor 1 2 3 4 5 or 6 Micro Rev Al...

Page 92: ...AUGES POINT 8 Low Micro Rev All HMI Rev All Choices From 1 0 to 20 0 in 0 1 degree increments in either Fahrenheit or Celsius Factory Set 10 8 F 6 0 C Exceptions Description This feature allows the lo...

Page 93: ...input 1 2 3 or 4 Micro Rev All HMI Rev All Choices Digital Input 1 2 3 or 4 Factory Set Exceptions Description This feature allows the digital input to be programmed to be selected Door Open Logging...

Page 94: ...ion This feature allows the unit to be configured with an Electronic Throttling Valve ETV Units with ETV valve should be set YES All other units should be set NO Electric Standby Equipped Micro Rev Al...

Page 95: ...xceptions Available only if the high capacity option is selected Description If the unit was built as a high capacity unit this setting should be set to YES to allow the engine to run at higher rpm 17...

Page 96: ...Section 3 SR 2 Software Description 3 46 31 January 2005...

Page 97: ...Tab goes here and the next page should be GREEN Section 4 Operation...

Page 98: ......

Page 99: ...nu Choices 23 Languages 25 Alarms 27 Log Alarms 27 Check Alarms 27 Prevent Alarms 27 Shutdown Alarms 27 Pretrip Alarm Codes 28 Alarm Codes When Switching Between Diesel and Electric 28 Clearing Alarm...

Page 100: ...essor Electric Mode 70 Interface Board Test 71 Interface Board Test Modes and Current Draw 72 Display Self Test 73 Evacuation Test 73 Software Revision 74 Set Time and Date 74 Guarded Access Menu Over...

Page 101: ...h data logger It is located on the control box door The HMI control panel consists of a display and 8 touch sensitive keys The display is capable of showing both text and graphics The keys on the left...

Page 102: ...eys The keys on either side of the display are dedicated or hard keys Their function always remains the same They are described below ON This key is used to turn the unit on The Thermo King Logo scree...

Page 103: ...This heater is needed to make the display visible in cold ambient temperatures The HMI has its own internal temperature sensor for the display heater The heater is energized when the unit is turned o...

Page 104: ...ntil the Thermo King Logo appears If the ON key is not held down long enough approximately second the display may flicker but the unit will not start up If this occurs hold the ON key down until the T...

Page 105: ...5 CYCLE SENTRY SET SENSORS GAUGES POINT 8 Pressing the OFF key stops unit operation The unit shuts down immediately and the display briefly shows the power down message OFF ON SYSTEM IS POWERING DOWN...

Page 106: ...NTRY SET SENSORS GAUGES POINT 8 THE TEMPERATUREWATCH DISPLAY If there is no key activity or alarms present the TemperatureWatch Display appears 2 minutes after the Standard Display appears and will re...

Page 107: ...soft key OFF ON MENU 35 F 35 CYCLE SENTRY SET SENSORS GAUGES POINT 8 The setpoint display appears as shown below OFF ON EXIT CURRENT SETPOINT 35 F TO CHANGE The and soft keys are used to increase or d...

Page 108: ...anging the setpoint A warning beep will sound for 5 seconds as a reminder Failure to confirm the new setpoint by pressing Yes or No within 10 seconds of changing the setpoint will result in no setpoin...

Page 109: ...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...

Page 110: ...pressed on the HMI control panel the engine will not preheat and start until 10 seconds after the last key is pressed CAUTION The engine may start automatically any time the unit is turned on WARNING...

Page 111: ...C NOTE If Rail Alternate is set YES defrost is allowed with an evaporator coil temperature less than or equal to 50 F 10 C Other features such as door switch settings may not allow manual defrost und...

Page 112: ...t the defrost cycle is about 25 complete OFF ON 35 CYCLE SENTRY MENU SET SENSORS GAUGES POINT Terminating a Defrost Cycle The defrost cycle terminates automatically when the coil temperature is greate...

Page 113: ...irflow Cycle Sentry or Continuous may not be available if OptiSet is in use If allowed by OptiSet Cycle Sentry or Continuous Mode is selected by pressing the Cycle Sentry Continuous key Note that Cycl...

Page 114: ...ning in Continuous mode as shown at the top of the display OFF ON MENU 35 F 40 CONTINUOUS SET SENSORS GAUGES POINT 8 Pressing the Cycle Sentry Continuous key again allows the operator to change back t...

Page 115: ...35 CYCLE SENTRY SET SENSORS GAUGES POINT 8 The first gauge display will appear Press the NEXT and BACK keys to scroll thru the gauges Pressing the LOCK key will lock the gauges on the display OFF ON...

Page 116: ...it battery Engine RPM Displays the engine speed in RPMs Discharge Pressure Displays the unit discharge pressure ETV units only Suction Pressure Displays the unit suction pressure ETV units only ETV Po...

Page 117: ...F ON MENU 35 F 35 CYCLE SENTRY SET SENSORS GAUGES POINT 8 The first sensor display will appear Press the NEXT and BACK keys to scroll thru the sensors Pressing the LOCK key will lock the gauges on the...

Page 118: ...Air Temperature Displays the temperature of the ambient air sensor Spare 1 Temperature Displays the temperature of the spare 1 temperature sensor Datalogger Sensor 1 Temperature Displays the temperatu...

Page 119: ...t Brightness Off Low Medium High Time TIme Date Display Only Setpoint Press Any Soft Key 2 5 Min Soft Key Gauges Soft Key Coolant Temperature Coolant Level Engine Oil Pressure Amps Battery Voltage Eng...

Page 120: ...Main Menu choice will appear Press the NEXT and BACK keys to scroll thru the menu choices When the desired selection is shown on the display press the SELECT key to access it The Pretrip submenu is sh...

Page 121: ...If the view feature for a particular hourmeter is not turned on or the hourmeter does not apply that hourmeter cannot be viewed Possible Hourmeters Total Hours Total Run Time Hours Engine Hours Electr...

Page 122: ...ture allows the operator to select electric mode operation This feature does not appear if the unit does not feature Electric Standby Diesel Mode If Electric Standby unit is running in electric this f...

Page 123: ...rrently supported by software revision 65xx are English Spanish French German Italian Dutch Portuguese Greek Turkish Hebrew and Arabic Languages currently supported by software revision 66xx are Engli...

Page 124: ...ay will then return to the Language Menu but will show the new language German is shown below OFF ON HAUPTMENU SPRACHE BEENDEN WEITER AUSWHAL Exercise care when changing languages as once changed all...

Page 125: ...wait a timed restart interval or until conditions allow and then restart If the unit is in a restart interval Alarm Code 84 Restart Null will be present along with the Prevent Alarm In most cases the...

Page 126: ...allow diesel mode operation If the unit is switched back to electric mode the alarm reverts to an electric mode shutdown alarm and prevents unit operation If the unit is configured for electric to die...

Page 127: ...09 High Evaporator Temperature Manually monitor load temperature Report alarm at end of the day 10 High Discharge Pressure If unit is shut down repair immediately Otherwise report alarm at end of the...

Page 128: ...g Cycle Fault The indicated zone is not longer able to operate and has been shut down Repair immediately 25 Alternator Check If unit is shut down repair immediately Otherwise report alarm at end of th...

Page 129: ...shut down repair immediately Otherwise report alarm at end of the day 42 Unit Forced to Low Speed Report alarm at end of the day 43 Unit Forced to Low Speed Modulation Report alarm at end of the day...

Page 130: ...immediately Otherwise report alarm at end of the day 68 Internal Controller Fault Code Report alarm at end of the day 70 Hourmeter Failure Report alarm at end of the day 74 Controller Reset to Default...

Page 131: ...the day 94 Check Loader 1 Circuit If unit is shut down repair immediately Otherwise report alarm at end of the day 95 Check Loader 2 Circuit If unit is shut down repair immediately Otherwise report a...

Page 132: ...down repair immediately Otherwise report alarm at end of the day 115 Check High Pressure Cut Out Switch If unit is shut down repair immediately Otherwise report alarm at end of the day 116 Check High...

Page 133: ...larm at end of the day 133 Total Unit Run Time Reminder 2 Report alarm at end of the day 134 Controller Power On Hours Report alarm at end of the day 136 Check Spare Digital Outputs Report alarm at en...

Page 134: ...SET SENSORS GAUGES POINT Alarms are displayed and cleared using the Alarm Menu From the Standard Display press the MENU key OFF ON 35 F 35 SERVICE REQUIRED WITHIN 24 HOURS 8 MENU SET SENSORS GAUGES P...

Page 135: ...ere are two alarms present The most recent is Alarm Code 6 It indicates a problem with the coolant temperature sensor OFF ON ALARM 6 2 OF 2 ALARMS COOLANT TEMP SENSOR NEXT EXIT HELP CLEAR After the al...

Page 136: ...p message will appear For the alarm shown above the message CHECK OIL LEVEL IF UNIT IS SHUT DOWN REPAIR IMMEDIATELY OTHERWISE REPORT ALARM AT END OF THE DAY will be shown on the display Check the oil...

Page 137: ...ch Data Logger contents can be printed The CargoWatch Data Logger is accessed using the Data Logger Menu From the Standard Display press the MENU key OFF ON 35 F 35 CYCLE SENTRY 8 MENU SET SENSORS GAU...

Page 138: ...as set in the data logger OFF ON START OF TRIP START OF TRIP NEXT EXIT SELECT Press the NEXT key to select the PRINT VIEW feature The PRINT VIEW screen will appear OFF ON DATALOGGER PRINT VIEW NEXT EX...

Page 139: ...T key will print a Trip Ticket The Trip Ticket shows details for the current trip OFF ON PRINT DATA TRIP TICKET NEXT EXIT BACK SELECT Pressing the EXIT key returns the display to the Main Menu For add...

Page 140: ...Menu When the Hourmeter Menu is shown press the SELECT key The Hourmeter Display will appear OFF ON MAIN MENU HOURMETERS NEXT EXIT BACK SELECT Press the NEXT or PREVIOUS key to scroll through the hou...

Page 141: ...re a Total Unit Run Time Maintenance Reminder 2 occurs Controller Power On Total hours the controller and HMI control panel have been turned on Pretrip Reminder User Programmable number of hours befor...

Page 142: ...en if the unit is turned off and back on If Keypad Lockout is active press and hold any soft key for 5 seconds to deactivate the feature Start Sleep Mode Sleep Mode is used to keep the engine warm and...

Page 143: ...Menu When the Mode Menu is shown press the SELECT key OFF ON MAIN MENU MODE NEXT EXIT BACK SELECT The first mode change screen will appear To chose that function press the SELECT key To Scroll thru th...

Page 144: ...Check and Log alarms The unit is in Sleep Mode Unit is in Service Test Mode Interface Board Test Mode or Evacuation Mode Pretrip Test Sequence Pretrip tests proceed in the order shown below A Full Pr...

Page 145: ...st 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 Performing a Pretrip Test If a P...

Page 146: ...f 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...

Page 147: ...IL If the results are CHECK or FAIL the accompanying alarm codes will direct the technician to the cause of the problem OFF ON EXIT PRETRIP PASS If the Pretrip Test results are CHECK or FAIL the probl...

Page 148: ...to electric mode is enabled the unit is switched using the Electric Standby Menu From the Standard Display press the MENU key OFF ON 35 F 35 CYCLE SENTRY 8 MENU SET SENSORS GAUGES POINT The Language M...

Page 149: ...LECTRIC STANDBY UNDETECTED DO YOU WISH TO SWITCH TO DIESEL NO YES Switching from Electric to Diesel If the unit is running in electric and manual switching to diesel mode is enabled the unit is switch...

Page 150: ...operation The unit can be programmed to automatically switch to electric mode operation when standby power is available It can also be programmed to automatically switch to diesel mode operation if th...

Page 151: ...screen suitable for low light conditions Display brightness is adjusted using the Adjust Brightness Menu From the Standard Display press the MENU key OFF ON MENU SETPOINT TEMPERATURE 35 8 F 35 CYCLE S...

Page 152: ...elect the desired display brightness When the desired brightness is shown press the YES key to confirm the choice OFF ON YES NO DISPLAY BRIGHTNESS WILL BE MEDIUM USE TO CHANGE OK The display will brie...

Page 153: ...ed using the Main Menu From the Standard Display press the MENU key OFF ON 35 F 35 CYCLE SENTRY 8 MENU SET SENSORS GAUGES POINT The Language Menu or Alarm Menu will appear Press the NEXT key as requir...

Page 154: ...oil Temperature Ambient Air Temperature Spare 1 Temperature Datalogger Sensor 1 Temperature Datalogger Sensor 2 Temperature Datalogger Sensor 3 Temperature Datalogger Sensor 4 Temperature Datalogger S...

Page 155: ...uation Mode Software revisions can be checked and the time and date can be set To access the Maintenance Menu press the MENU key OFF ON MENU 35 F 35 CYCLE SENTRY SET SENSORS GAUGES POINT 8 The Mainten...

Page 156: ...key to access it OFF ON MAINTENANCE MENU HOURMETERS NEXT EXIT SELECT The Maintenance Menu choices are shown on the next page For detailed information see the individual explanations of each item late...

Page 157: ...s with a programmed time limit Choose Hourmeters by pressing the SELECT key when HOURMETERS is shown in the Maintenance Menu The hourmeter screen appears as shown below OFF ON TOTAL RUN TIME HOURS 87...

Page 158: ...ammable The number of hours before a Total Unit Run Time Maintenance Reminder 2 occurs Controller Power On Total hours the controller and HMI control panel have been turned on Pretrip Reminder User Pr...

Page 159: ...EXT EXIT BACK LOCK v The NEXT and BACK keys are used to scroll through the gauges The LOCK key allows a gauge display to be locked on the display for 15 minutes at the operator s discretion The EXIT k...

Page 160: ...t Level Engine Oil Pressure Amps Battery Voltage Engine RPM Discharge Pressure Suction Pressure ETV Position I O Input Output State High Speed Relay Run Relay Defrost Damper Heat Output Diesel Electri...

Page 161: ...rs as shown below OFF ON DISPLAY RETURN AIR TEMPERATURE 44 8 NEXT EXIT BACK LOCK F The NEXT and BACK keys are used to scroll through the sensors The LOCK key allows a sensor display to be locked on th...

Page 162: ...emperature Temperature Differential Evaporator Coil Temperature Ambient Air Temperature Spare 1 Temperature Datalogger Sensor 1 Temperature Datalogger Sensor 2 Temperature Datalogger Sensor 3 Temperat...

Page 163: ...URS 8 MENU SET SENSORS GAUGES POINT If a prevent alarm condition occurs a prevent alarm message will appear in place of the mode indication in the display as shown below OFF ON 35 F 35 UNIT IN PREVENT...

Page 164: ...n below OFF ON ALARM 10 1 OF 2 ALARMS NEXT EXIT HELP CLEAR HIGH DISCHARGE PRESSURE The NEXT key is used to scroll through the alarms The HELP key accesses an Operator level help screen The CLEAR key c...

Page 165: ...Return Air Sensor Alarm Code 04 Check Control Discharge Air Sensor Alarm Code 203 Check Display Return Air Sensor Alarm Code 204 Check Display Discharge Air Sensor The following alarm codes clear aut...

Page 166: ...own is the High Speed Cool test OFF ON HIGH COOL TEST EXIT GAUGES TEST TIME REMAINING 12 32 MINS RET ECOIL DIS DIFF 45 F 35 F 30 F 10 F Return Discharge and Evaporator Coil temperatures are shown The...

Page 167: ...100 ETV units only Devices Energized Reciprocating Compressor Diesel Mode Service Test Mode Test Run Relay High Speed Heat D E Relay Hot Gas Bypass ETV Damper Null High Speed Cool ON ON Enabled Low Sp...

Page 168: ...c Heat Heat D E Relay Hot Gas Bypass ETV Damper Null Cool ON ON Enabled Hot Gas Heat ON ON ON Enabled Hot Gas Elec Heat ON ON ON ON Enabled Defrost ON ON ON ON Enabled ON Cool Bypass ON ON ON Enabled...

Page 169: ...ey when INTERFACE BOARD TEST is shown in the Maintenance Menu The Interface Board Test screen appears as shown below The test shown is the Heat Output test OFF ON HEAT OUTPUT EXIT LOCK ON TEMP ON HEAD...

Page 170: ...ter shows the time remaining for the test If the test times out Alarm Code 54 Test Mode Timeout is set The UNLOCK key unlocks the display and returns to the Interface Board Test Interface Board Test M...

Page 171: ...on and off to verify operation Heater Output This test allows the technician to turn the HMI display heater on and off Unit On Off Output Test This test allows the technician to turn the Unit On Off o...

Page 172: ...on This menu allows the technician to view the software revision for the HMI control panel and the microprocessor Set Time and Date This menu allows the technician to view and change the HMI control p...

Page 173: ...ectric Run Time Reminder 1 Hours Electric Run Time Reminder 2 Hours Sensor Calibration Control Return Air Sensor Grade Control Discharge Air Sensor Grade Display Return Air Sensor Grade Display Discha...

Page 174: ...d Access Menu NOTE If the unit is running select Interface Board Test from the Maintenance Menu This will shut the unit down Press the EXIT key to return to the Maintenance Menu and continue scrolling...

Page 175: ...cess to the Guarded Access Menu If access is required by a technician and the code is not known enter 4444 If an Access Code is not enabled or when the correct security code is entered 4444 always wor...

Page 176: ...Section 4 SR 2 Operation To return to the Standard Display press the EXIT key Note A warm restart is performed when guarded access is exited 4 78 31 January 2005...

Page 177: ...ures some features not available if OptiSet has been programmed Temperature Units Pressure Units Restart Unit After Shutdown Setpoint High Limit Setpoint Low Limit Fuel Saver II High Speed Pulldown Fr...

Page 178: ...er 1 Hours Electric Run Time Reminder 2 Hours Viewable Hourmeter Setup Total Hours Viewing Total Run Hours Viewing Total Run Time Reminder 1 Viewing Total Run Time Reminder 2 Viewing Controller Power...

Page 179: ...Defrost Setup Defrost Interval In Range with Fresh Setpoint Defrost Interval Not In Range with Fresh Setpoint Defrost Interval In Range with Frozen Setpoint Defrost Interval Not In Range with Frozen...

Page 180: ...ere are six sensors and four digital inputs that can be utilized See Service Procedure A49A for complete details Unit Configuration Engine Type Is Compressor Type Is ETV Configured Electric Standby Eq...

Page 181: ...Tab goes here and the next 2 pages should be GREEN Section 5 Diagnostics...

Page 182: ......

Page 183: ...Exist 9 02 Check Evaporator Coil Sensor 9 03 Check Control Return Air Sensor 11 04 Check Control Discharge Air Sensor 13 05 Check Ambient Temperature Sensor 15 06 Check Coolant Temperature Sensor 17 0...

Page 184: ...eed Circuit 47 41 Check Engine Coolant Temperature 48 42 Unit Forced to Low Speed 49 43 Unit Forced to Low Speed Modulation 49 44 Check Fuel System 50 45 Check Hot Gas or Hot Gas Bypass Circuit 51 46...

Page 185: ...pressor Pressure Ratio 73 108 Door Open Timeout 74 111 Unit Not Configured Correctly 74 113 Check Electric Heat Circuit 75 115 Check High Pressure Cut Out Switch 75 116 Check High Pressure Cut In Swit...

Page 186: ...ction 5 SR 2 Diagnostics 136 Check Spare Digital Outputs 79 137 Check Damper Motor Heater Output 79 203 Check Display Return Air Sensor 80 204 Check Display Discharge Air Sensor 82 5 4 02 February 200...

Page 187: ...helpful Every effort should be made to perform a Pretrip Test on a suspect unit In almost all cases the Pretrip Test will result in one or more alarm codes that will lead you directly to the problem O...

Page 188: ...laced these Service Procedures must be used A02A Recording Existing Microprocessor Setup A03A Microprocessor Removal and Replacement A04A Microprocessor Setup Any time welding is necessary Service Pro...

Page 189: ...event Alarms are indicated by a steady alarm indication at the top of the display and the message Unit in Prevent Mode The unit will wait a timed restart interval or until conditions allow and then re...

Page 190: ...de log alarm to allow diesel mode operation If the unit is switched back to electric mode the alarm reverts to an electric mode shutdown alarm and prevents unit operation If the unit is configured for...

Page 191: ...res enter the sensor shell Mount sensors with the barrel up and the wires down wherever possible How Alarm is Set 1 The sensor is over or under range for a specified time interval The sensor reading m...

Page 192: ...If the display is normal proceed as shown below Alarm Code 02 and Alarm Code 13 Sensor was reading erratically 1 Review the ServiceWatch data logger and check the senor reading at the time the alarm w...

Page 193: ...ode 11 Unit Controlling on Alternate Sensor will be set 2 Sensor codes must be cleared from the Maintenance Menu before Alarm Code 11 will clear 3 Sensor grades must be correctly set to the actual gra...

Page 194: ...reading erratically 1 Review the ServiceWatch data logger and check the senor reading at the time the alarm was set Also review the history to see if previous alarm codes exist that would indicate an...

Page 195: ...Alarm Code 11 Unit Controlling on Alternate Sensor will be set 2 Sensor codes must be cleared from the Maintenance Menu before Alarm Code 11 will clear 3 Sensor grades must be correctly set to the act...

Page 196: ...g erratically 1 Review the ServiceWatch data logger and check the sensor reading at the time the alarm was set Also review the history to see if previous alarm codes exist that would indicate an inter...

Page 197: ...Harness The sensor is connected to the sensor harness with a Deutsch connector Considerations 1 Sensors should be positioned to minimize the potential for moisture entry where the wires enter the sen...

Page 198: ...2 If the display is normal proceed as shown below Alarm Code 05 and Alarm Code 13 Sensor was reading erratically 1 Review the ServiceWatch data logger and check the senor reading at the time the alarm...

Page 199: ...nnector J3 pin 26 to the blue sensor wire The WTN 01 wire connects the microprocessor 35 pin sensor connector J3 pin 15 to the brown sensor wire The sensor wires are routed in the Sensor Harness The s...

Page 200: ...croprocessor using Service Procedure A01A 2 Review the ServiceWatch data logger and check the senor reading at the time the alarm was set Also review the history to see if previous alarm codes exist t...

Page 201: ...nd positive battery charge current indicate the engine is running but RPM is less than 300 RPM for 4 seconds How Alarm is Cleared This alarm is cleared manually Diagnostic Procedure 1 Disconnect the s...

Page 202: ...il Sensor How Alarm is Set The temperature of the evaporator coil was excessive over a period of time How Alarm is Cleared This alarm is cleared manually Diagnostic Procedure 1 Check refrigeration sys...

Page 203: ...ossible the alarm is set as a Shutdown alarm If continuous restarts are enabled a shutdown alarm is not set after 3 attempts If restarts are disabled the alarm will be set as a shutdown on the first o...

Page 204: ...controlling on the alternate sensor If the unit is operating with return air sensor control and either of the dual return air sensors fails the unit will control using the discharge air sensor If the...

Page 205: ...al sensor alarm control With a fresh range setpoint the alarm is set as a shutdown alarm Frozen Setpoints Both return and discharge sensors have failed or have been disabled by the dual sensor alarm c...

Page 206: ...not read within a specified number of degrees of each other Alarm Code 02 will also be set 2 The alarm is set if immediately after clearing Alarm Codes 02 03 203 04 or 204 all return discharge and co...

Page 207: ...d on an engine start the alarm is set as a check alarm Maximum current on Yanmar 2 1 engines is 80 amps 3 If the current draw is less than specified during a Pretrip Test the alarm is set as a check a...

Page 208: ...e 17 that follows an Alarm Code 20 84 Failed to Start will be set as a shutdown alarm If Alarm Code 17 follows an Alarm Code 63 alarm clear only one crank attempt will be made Diagnostic Procedure 1 C...

Page 209: ...coolant temperature is high as determined by the coolant temperature sensor and the coolant level sensor is indicating low coolant level Alarm Code 18 High Engine Coolant Temperature is set as a Shut...

Page 210: ...e of the low oil pressure switch The switch is not polarity sensitive and closes on low oil pressure The switch wires are routed in the Main Harness The switch screw terminal is connected to the senso...

Page 211: ...the Gauge menu The oil pressure should be OK If not the switch may be stuck closed or the switch circuit may be shorted 6 The oil pressure switch should be closed when the engine is not running and o...

Page 212: ...arm Code 20 follows an Alarm Code 63 alarm clear only one crank attempt will be made How Alarm is Cleared The alarm is cleared manually Considerations This alarm become a log alarm if the unit is swit...

Page 213: ...rm Diagnostic Procedure Download and review the ServiceWatch data logger using Technician Level to determine the conditions at the time the alarm was set 1 Check temperature differential by displaying...

Page 214: ...f the alarm Diagnostic Procedure Download and review the ServiceWatch data logger using Technician Level to determine the conditions at the time the alarm was set 1 Check temperature differential by d...

Page 215: ...Download and review the ServiceWatch data logger using Technician Level to determine the conditions at the time the alarm was set 1 Check temperature differential by displaying the temperature differe...

Page 216: ...de 24 will be set as a shutdown alarm on the first occurrence of the alarm Diagnostic Procedure Download and review the ServiceWatch data logger using Technician Level to determine the conditions at t...

Page 217: ...during a Pretrip Test and as a Shutdown alarm in Sleep mode How Alarm is Cleared This alarm is cleared manually Diagnostic Procedure 1 Check and adjust the alternator drive belt 2 Start the engine an...

Page 218: ...because of a Prevent alarm and Alarm Code 26 is set Alarm Code 85 Forced Unit Operation alarm is also set Alarm Code 85 indicates the unit was forced into a reduced capacity mode Diagnostic Procedure...

Page 219: ...ow Alarm is Cleared This alarm is cleared manually Diagnostic Procedure 1 This is a normal alarm any time the Pretrip Test is halted and does not finish with a PASS CHECK or FAIL screen display 2 Proc...

Page 220: ...g non running pre trip Current is measured with the output on and off 2 The alarm is set as a Check alarm if the current is not within specifications when the solenoid is energized 3 The alarm is set...

Page 221: ...a Check alarm if the damper gear motor draws excessive current for a specified time This indicates that the damper is frozen or stalled How Alarm is Cleared This alarm is cleared manually Considerati...

Page 222: ...is set as a Log alarm 2 If unit is in diesel mode but not running the oil level is not good and the oil pressure switch is not indicating low oil pressure Alarm Code 31 Check Oil Pressure Switch is s...

Page 223: ...ually Considerations Alarm code 32 is typically preceded by an alarm code 26 Diagnostic Procedure Download and review the ServiceWatch data logger using Technician Level to determine the conditions at...

Page 224: ...This alarm is cleared manually Considerations Only checked during a Pretrip Test Diagnostic Procedure 1 Check and adjust high speed as shown in the Maintenance Manual for the unit 2 Check and adjust...

Page 225: ...digital input is not present when the run relay should be energized How Alarm is Set Run relay output does not match feedback circuit 7K The Run Relay fails the Pretrip Test How Alarm is Cleared This...

Page 226: ...uits in the contactor may be defective requiring replacement of contactor 2 Check the voltages at the phase detect module Battery voltage should be present on the ER wire and the 8 wire 3 Check the st...

Page 227: ...el rises above the sensor location The wiring is located in the Main Harness via the CLS 01 and CLP 01 circuits How Alarm is Set 1 If the engine coolant level input indicates low coolant level for 3 m...

Page 228: ...cleared manually Diagnostic Procedure 1 Check motor wiring to be sure phase rotation is correct 2 Confirm that the 7EC 01 wire is connected to the MCB motor contactor and the 7EB 01 wire is connected...

Page 229: ...nt current is incorrect during a non running Pretrip Test Current is measured with the output on and off 2 The alarm is set as a Check alarm if the current is not within specifications when the soleno...

Page 230: ...ation How Alarm is Set The engine coolant temperature rose above 210 F and remained above 205 F for 60 seconds How Alarm is Cleared This alarm is cleared manually Diagnostic Procedure 1 Check the engi...

Page 231: ...engine load How Alarm is Cleared Alarm will self clear if unit returns to normal operation Diagnostic Procedure Troubleshoot as shown for the associated alarm code 43 UNIT FORCED TO LOW SPEED MODULATI...

Page 232: ...vate condition 2 and return to normal operation Condition 2 This condition does not apply if condition 1 is active If the engine is running and the fuel pressure switch was indicating good fuel pressu...

Page 233: ...measured shunt current is incorrect during non running Pretrip Test Current is measured with the output on and off 2 The alarm is set as a Check alarm if the current is not within specifications when...

Page 234: ...chute mounted sensor Spare 1 exceeds the programmed limits See Blocked Air Chute Detect feature is Section 3 for details How Alarm is Cleared This alarm is cleared manually Programmable Features See...

Page 235: ...cuit including resistor for continuity 4 Check unit configuration if this alarm occurs on a Model 30 diesel only unit 50 RESET CLOCK Page 1 of 2 Alarm Type Log Alarm How Alarm is Set This alarm indica...

Page 236: ...is incorrect during non running Pretrip Test Current is measured with the output on and off 2 The alarm is set as a Check alarm if the current is not within specifications when the solenoid is energiz...

Page 237: ...his alarm is set if the unit has been in the same Interface Board Test Mode function for 15 minutes How Alarm is Cleared This alarm is manually cleared Diagnostic Procedure 1 While the unit is in Serv...

Page 238: ...is greater than 16 0 volts for 3 minutes Alarm Code 61 is set as a Shutdown alarm 6 If the ambient temperature is more than 10 0 F from setpoint or if the ambient sensor is failed and three consecutiv...

Page 239: ...nly Associated Alarm Codes How Alarm is Set Shunt calibration check in Pretrip Test shows shunt circuit is out of calibration with all outputs de energized How Alarm is Cleared This alarm is cleared m...

Page 240: ...l performance is not possible the alarm is set as a Shutdown alarm If continuous restarts are enabled a Shutdown alarm is not set after 3 attempts If restarts are disabled the alarm will be set as a S...

Page 241: ...ate are secure 10 Check for a seized compressor or engine 11 If a Model 50 electric standby unit check for a failed clutch or seized electric motor 64 PRETRIP REMINDER Page 1 of 1 Alarm Type Log Alarm...

Page 242: ...hutdown alarm 2 If Alarm Code 66 is manually cleared and the engine oil level is still low Alarm Code 66 is reset as a Shutdown Alarm How Alarm is Cleared Alarm self clears if the oil level input is g...

Page 243: ...1 Alarm Type Log Alarm Associated Alarm Codes How Alarm is Set One or more hourmeters exceeds 499 999 hours How Alarm is Cleared This alarm is cleared manually Diagnostic Procedure 1 If the hourmeter...

Page 244: ...tart will occur every time the unit is turned on 2 Complete the microprocessor setup using Service Procedure A04A 3 Alarm code 74 will be cleared during the microprocessor setup using Service Procedur...

Page 245: ...HIGH COMPRESSOR TEMP Page 1 of 1 Alarm Type Log Alarm Considerations Not implemented future use 82 HIGH COMPRESSOR TEMP SHUTDOWN Page 1 of 1 Alarm Type Prevent Alarm Considerations Not implemented fut...

Page 246: ...ction and that a restart will be attempted when conditions permit 4 If the corrective action is successful the original alarm code as well as Alarm Code 84 are cleared automatically If the original al...

Page 247: ...s a secondary alarm that is set along with the associated primary alarm 2 This alarm indicates that the unit was forced to a different operating mode than would normally be implemented under the exist...

Page 248: ...he discharge pressure did not rise or fall during an ETV test How Alarm is Cleared This alarm is cleared manually Clearing the code will cause the unit to shut down and restart to check the transducer...

Page 249: ...did not rise or fall during an ETV test How Alarm is Cleared This alarm is cleared manually Clearing the code will cause the unit to shut down and restart to check the transducer for proper operation...

Page 250: ...operation is confirmed by a rise in suction pressure The electrical test is performed before every engine or motor start The running test is only performed when the unit restarts after a shutdown or...

Page 251: ...unit is switched from electric mode to diesel mode Diagnostic Procedure CAUTION High voltage is present any time the unit is connected to standby power Exercise extreme care 1 Check the electric motor...

Page 252: ...o diesel mode Diagnostic Procedure CAUTION High voltage is present any time the unit is connected to standby power Exercise extreme care 1 Check the ER 01 Circuit from the phase detect module for 12 v...

Page 253: ...ade is set to other than 5H Considerations The sensor grade must be set using the Sensor Calibration feature in the Guarded Access Menu If the sensor grade is not properly set the sensor reading will...

Page 254: ...ck Alarm or Shutdown Alarm Considerations Not implemented future use 96 LOW FUEL LEVEL Page 1 of 1 Alarm Type Log Alarm Associated Alarm Codes Alarm Code 98 Check Fuel Level Sensor How Alarm is Set A...

Page 255: ...is determined to be out of range How Alarm is Cleared This alarm is cleared manually Diagnostic Procedure 1 Check fuel level sensor harness to be sure it is connected and secure 2 Check fuel level sen...

Page 256: ...then re opened Diagnostic Procedure Check the operation of the door switches 111 UNIT NOT CONFIGURED CORRECTLY Page 1 of 1 Alarm Type Log or Check Alarm Pretrip Test Only Associated Alarm Codes Alarm...

Page 257: ...specifications when the solenoid is energized 3 The alarm is set as a Shutdown alarm if the current does not return to 0 when the device is de energized How Alarm is Cleared This alarm is cleared man...

Page 258: ...on only No action is required 118 AUTO SWITCH FROM ELECTRIC TO DIESEL Page 1 of 1 Alarm Type Log Alarm Associated Alarm Codes Alarm Code 117 Auto Switch from diesel to electric How Alarm is Set Alarm...

Page 259: ...re 1 Check the operation of the diesel electric relay using Interface Board Test Mode in the Maintenance Menu Be sure the hot gas LED 5 lights 2 Use the HMI control panel amps gauge to check the curre...

Page 260: ...ow Alarm is Set The indicated hourmeter has exceeded the programmed time limit How Alarm is Cleared This alarm is cleared manually Diagnostic Procedure Perform required maintenance as dictated by owne...

Page 261: ...OUTPUT Page 1 of 1 Alarm Type Check Alarm Associated Alarm Codes Alarm Code 30 Defrost Damper Stuck Component Description and Location Circuit Description On units equipped with a damper gear motor t...

Page 262: ...scharge Air Control and Alarm Code 11 Unit Controlling on Alternate Sensor will be set 2 Sensor codes must be cleared from the Maintenance Menu before Alarm Code 11 will clear 3 Sensor grades must be...

Page 263: ...r was reading erratically 1 Review the ServiceWatch data logger and check the sensor reading at the time the alarm was set Also review the history to see if previous alarm codes exist that would indic...

Page 264: ...Return Air Control and Alarm Code 11 Unit Controlling on Alternate Sensor will be set 2 Sensor codes must be cleared from the Maintenance Menu before Alarm Code 11 will clear 3 Sensor grades must be c...

Page 265: ...or was reading erratically 1 Review the ServiceWatch data logger and check the sensor reading at the time the alarm was set Also review the history to see if previous alarm codes exist that would indi...

Page 266: ...Section 5 SR 2 Diagnostics 5 84 02 February 2005...

Page 267: ...Tab goes here and the next page should be GREEN Section 6 Service Procedures...

Page 268: ......

Page 269: ...on Units Equipped with Microprocessors A28A Setting Unit Running Time Hourmeters A34A Operating Service Test Mode See Section 4 A44A Operating Interface Board Test Mode See Section 4 A46A Flash Loadin...

Page 270: ...Section 6 SR 2 Service Procedure Index Page 2 01 February 2005...

Page 271: ...e 1 Table of Contents 1 Materials Required 1 Operation 1 Important Notes 2 Important PC Notes 2 Diagnostic Procedure 3 Materials Required Thermo King SR 2 Diagnostic Tool Service Part Number 204 1102...

Page 272: ...harnesses Never accept an initial failure Always retest to confirm If component fails the test be sure wiring is connected correctly Important PC Notes The following notes apply to the pc computer us...

Page 273: ...r the J4 Microprocessor On Off Switch connector and the heavy power wires at J23 J24 and J25 The Microprocessor On Off Switch and the heavy power wires will be used to apply test power to the assembly...

Page 274: ...eft clicking RUN TEST 9 Follow the prompts as shown below to connect the tester to the unit microprocessor interface board assembly under test Press any key to step thru the connection prompts shown o...

Page 275: ...r CAN Harnesses to the J12 J13 and J14 connectors of the assembly under test 14 Connect the Tester RS232 Serial Harnesses to the J9 and J10 connectors of the assembly under test 15 Turn the Microproce...

Page 276: ...d 20 Retest the assembly if necessary to confirm the test results 21 Turn the Microprocessor On Off switch off 22 Record the data requested in the fields on the test report 23 Print the test report fo...

Page 277: ...Contents 1 Materials Required 1 Operation 1 Important Notes 2 Important PC Notes 2 Diagnostic Procedure 3 Materials Required Thermo King SR 2 Diagnostic Tool Service Part Number 204 1102 The Thermo Ki...

Page 278: ...st to confirm If component fails the test be sure wiring is connected correctly There is a Display Self Test included in the Maintenance Menu See Section 4 and Service Procedure A01C for details Impor...

Page 279: ...cables and the serial cable to the tester 3 Connect a serial cable from the right side Tester Serial Connector to a pc computer The serial cable must be connected to the right side Tester Serial Conn...

Page 280: ...ts shown on the pc 9 Connect the blue Tester HMI Harness connector to the HMI Control Panel under test Do not connect the black Tester J3 Sensor Harness connector to the microprocessor interface board...

Page 281: ...test check the test results for possible causes and correct as directed The test results will indicate if a problem exists with the HMI Control Panel 18 Retest the assembly if necessary to confirm the...

Page 282: ...Section 6 SR 2 Service Procedure A01B Page 6 P41RA01B 31 January 2005...

Page 283: ...Where Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Operation 1 Important Notes 1 Diagnostic Procedure 2 Materials Required None Operation The following procedure allows the technician to...

Page 284: ...Display Press and hold both the unlabelled soft key and the Exit key for 5 seconds 3 The first Maintenance Menu feature will appear Press the NEXT and BACK keys to scroll thru the Maintenance Menu cho...

Page 285: ...ISPLAY SELF TEST is shown on the display press the SELECT key to access it 8 When the individual test is complete another test can be selected 9 When testing is finished press EXIT to return to the Ma...

Page 286: ...HMI buzzer on and off to verify operation Heater Output This test allows the technician to turn the HMI display heater on and off Unit On Off Output Test This test allows the technician to turn the Un...

Page 287: ...rvice Procedure Operation The settings of all programmable features must be retrieved before replacing a microprocessor or performing a Cold Start These settings will then be duplicated in the replace...

Page 288: ...ectric Run Time Reminder 1 Hours Electric Run Time Reminder 2 Hours Sensor Calibration Control Return Air Sensor Grade Control Discharge Air Sensor Grade Display Return Air Sensor Grade Display Discha...

Page 289: ...hold both the EXIT and unlabelled key for 5 seconds The Maintenance Menu appears 4 Press the NEXT key as required to display the Software Revision Menu 5 Use the NEXT and or BACK keys to scroll throug...

Page 290: ...ked and set if necessary 8 Check the Time to determine the time zone used by the customer Record the time zone on the Setup Sheet Compare local time to unit time to determine time zone 9 Press and hol...

Page 291: ...its Setup Menu The Hourmeter Limits Setup Menu appears 15 Use the NEXT and or BACK keys to scroll through all Hourmeter Limits Record all Hourmeter Limits on the Setup Sheet 16 When all Hourmeter Limi...

Page 292: ...The Guarded Access Menu appears 22 Press the NEXT key as required to display the Sensor Calibration Menu The Sensor Calibration Menu appears 23 When the Sensor Calibration Menu is shown press the SELE...

Page 293: ...features Record the setting of each Cycle Sentry feature on the Setup Sheet 29 When all Cycle Sentry features have been recorded press the EXIT key to return to the Guarded Access Menu 30 When the Gu...

Page 294: ...s the Language Setup Menu The Language Setup Menu will appear 36 Use the NEXT and or BACK keys to scroll through the Language features Record the setting of each Language feature on the Setup Sheet 37...

Page 295: ...setting of each Sensor Configuration feature on the Setup Sheet 42 When all Sensor Configuration features have been recorded press the EXIT key to return to the Guarded Access Menu 43 Press the NEXT...

Page 296: ...dard Display 48 Connect a serial cable from the unit Service Watch connector to a pc equipped with Wintrac 4 4 and OptiSet Setup Guide 49 Turn the unit on 50 From the Wintrac 4 4 Tools Menu choose Ret...

Page 297: ...Use OptiSet Setup Guide to save the XXXX opt file as an Upload file This will create the XXXX csv file required by Wintrac 4 4 to perform an upload Make note of the location of this file It will be us...

Page 298: ...Section 6 SR 2 Service Procedure A02A Page 12 P41RA02A 02 February 2005...

Page 299: ...upplied to the microprocessor each time the unit is turned on If the microprocessor is changed the clock setting will be supplied to the microprocessor when the unit is turned on If the HMI Control Pa...

Page 300: ...r Open Forces LOG ONLY Door Open Timeout HRS MIN OFF Sleep Mode After Pretrip DISABLED Rail Option DISABLED Rail Alternate If Rail Option ENABLED DISABLED Blocked Air Chute Detect DISABLED Temperature...

Page 301: ...Time Viewing ENABLED Total Run Time Reminder 1 Viewing DISABLED Total Run Time Reminder 2 Viewing DISABLED Controller Power On Hours Viewing DISABLED Pretrip Reminder Viewing DISABLED Engine Run Time...

Page 302: ...TUP First language 65xx second language 66xx Function Default Setting Recorded Setting Default Language ENGLISH Enable Language English DISABLED Enable Language Spanish or Russian DISABLED Enable Lang...

Page 303: ...d Setting Log Interval 15 minutes Up to 6 sensors may be configured Function Default 1 2 3 4 5 6 Sensor Logging 1 2 On 3 6 Off Sensor Name Log Sensor X Out of Range Checking ON Low Limit 6 High Limit...

Page 304: ...Connect a serial cable from the unit Service Watch connector to a pc equipped with Wintrac 4 4 and OptiSet Setup Guide 2 Turn the unit on 3 From the Wintrac 4 4 Tools Menu choose Retreive OptiSet Conf...

Page 305: ...upplied to the microprocessor each time the unit is turned on If the microprocessor is changed the clock setting will be supplied to the microprocessor when the unit is turned on If the HMI Control Pa...

Page 306: ...r Open Forces LOG ONLY Door Open Timeout HRS MIN OFF Sleep Mode After Pretrip DISABLED Rail Option DISABLED Rail Alternate If Rail Option ENABLED DISABLED Blocked Air Chute Detect DISABLED Temperature...

Page 307: ...Time Viewing ENABLED Total Run Time Reminder 1 Viewing DISABLED Total Run Time Reminder 2 Viewing DISABLED Controller Power On Hours Viewing DISABLED Pretrip Reminder Viewing DISABLED Engine Run Time...

Page 308: ...TUP First language 65xx second language 66xx Function Default Setting Recorded Setting Default Language ENGLISH Enable Language English DISABLED Enable Language Spanish or Russian DISABLED Enable Lang...

Page 309: ...ed Setting Log Interval 5 minutes Up to 6 sensors may be configured Function Default 1 2 3 4 5 6 Sensor Logging 1 2 On 3 6 Off Sensor Name Log Sensor X Out of Range Checking ON Low Limit 6 High Limit...

Page 310: ...Connect a serial cable from the unit Service Watch connector to a pc equipped with Wintrac 4 4 and OptiSet Setup Guide 2 Turn the unit on 3 From the Wintrac 4 4 Tools Menu choose Retreive OptiSet Con...

Page 311: ...red 1 Operation 1 Important Notes 1 Diagnostic Procedure 2 Materials Required Cable ties Operation The interface board can be changed without removing the microprocessor from the control box If the mi...

Page 312: ...roprocessor Power switch off 3 Disconnect standby power if connected 4 Disconnect the unit battery 5 Disconnect all harness connectors from the microprocessor and interface board assembly 6 If the mic...

Page 313: ...replacement part Be sure to use the correct hardware as some screw lengths may vary When installing an interface board on a microprocessor use care to line up the guide pins 11 Reconnect all harness...

Page 314: ...ents 15 Clear any alarm codes as shown in Section 4 16 If the microprocessor was replaced set up all programmable features using Service Procedure A04A 17 Run a Pretrip Test as shown in Section 4 to v...

Page 315: ...1 Purpose 1 Table of Contents 1 Materials Required 1 Operation 1 Important Notes 1 Diagnostic Procedure 2 Materials Required Cable ties Operation The HMI Control Panel is removed from the control box...

Page 316: ...5 Remove the four screws securing the HMI Control Panel to the control box and remove the HMI Control Panel from the control box 6 Install the new HMI Control Panel in the control box 7 Reconnect all...

Page 317: ...ngs will be loaded from the microprocessor when the unit is turned on 11 Clear any alarm codes as shown in Section 4 12 Check the setting of the real time clock as shown in Section 4 and correct if ne...

Page 318: ...Section 6 SR 2 Service Procedure A03B Page 4 P41RA03B 30 January 2005...

Page 319: ...ecording Existing Microprocessor Settings Operation The settings of the programmable features must be programmed after replacing a microprocessor or performing a Cold Start The Programming Menu Overvi...

Page 320: ...ctric Run Time Reminder 1 Hours Electric Run Time Reminder 2 Hours Sensor Calibration Control Return Air Sensor Grade Control Discharge Air Sensor Grade Display Return Air Sensor Grade Display Dischar...

Page 321: ...for 5 seconds The Maintenance Menu appears 4 Press the NEXT key as required to display the Software Revision Menu 5 Use the NEXT BACK and SELECT keys to scroll through the HMI Control Panel and Micro...

Page 322: ...and date must be checked and set if necessary 9 Press and hold both the EXIT and unlabelled key for 5 seconds The Guarded Access Menu appears If a Security Code is requested enter the Security Code or...

Page 323: ...imits Set all Hourmeter Limits to those shown on the Setup Sheet 16 When all Hourmeter Limits have been set press the EXIT key to return to the Hourmeter Setup Menu The Hourmeter Setup Menu appears 17...

Page 324: ...ration Menu appears 23 When the Sensor Calibration Menu is shown press the SELECT key to access the Sensor Calibration Menu Control Return Air Sensor Grade and the current grade appear Set the grade t...

Page 325: ...entry features have been set press the EXIT key to return to the Guarded Access Menu 30 When the Guarded Access Menu is shown press the NEXT key to access the Defrost Setup Menu 31 When the Defrost Me...

Page 326: ...at shown on the Setup Sheet 37 When all Language features have been set press the EXIT key to return to the Guarded Access Menu 38 Press the NEXT key again to access the OptiSet Setup Menu The OptiSet...

Page 327: ...to access the Unit Configuration Setup Menu 44 When the Unit Configuration Setup Menu is shown press the Select key to access the Unit Configuration Setup Menu The Unit Configuration Setup Menu will a...

Page 328: ...Guide 49 Turn the unit on 50 From the Wintrac 4 4 Tools Menu choose Send Optiset Configuration 51 Select the XXXX csv OptiSet configuration file created when the setup sheet was completed 52 Double c...

Page 329: ...This procedure will perform a Cold Start on the microprocessor All programmable features are reset except hourmeters and Service Watch data logger The Cold Start can be performed by means of an Inter...

Page 330: ...be used 2 Turn off the Microprocessor On Off switch 3 Locate the J101 jumper on the relay board It is located in the upper center of the interface board See the illustration on the next page 4 Remove...

Page 331: ...1 CAN 3 F1 F10 F2 F3 F6 ON OFF SWITCH LED22 J4 2A F7 3A F9 3A F12 3A F8 CAN 2 CAN 1 J103 RS232 2 J102 J101 J27 10A F11 K4 K3 H 2A 2 60A F5 40A 8D 8DP 8S 8 DG 7D 29 LED17 LED18 LED20 LED19 LED8 LED9 LE...

Page 332: ...74 indicates the Cold Start was successful The other alarm codes exist because the sensor grades have been set to 5H These codes will clear when the sensor grades are properly set 10 Set up all progra...

Page 333: ...nnot be retrieved the customer specified settings must be used 2 Connect the download cable to the ServiceWatch port on the unit 3 Turn unit on 4 Start Wintrac 4 4 The Wintrac Display will appear 5 Fr...

Page 334: ...s successful The other alarm codes exist because the sensor grades have been set to 5H These codes will clear when the sensor grades are properly set 10 Set up all programmable features using Service...

Page 335: ...re sensors and the control and display discharge air temperature sensors are graded sensors Any time these sensors are replaced the grade of the new sensor must be correctly entered to insure optimum...

Page 336: ...r 5 seconds The Maintenance Menu appears 5 Press the NEXT key as required to display the Set Time and Date Menu The Set Time and Date Menu appears 6 Press and hold both the EXIT and unlabelled key for...

Page 337: ...nu for the selected sensor will appear 11 Use the and keys to change the sensor grade to match the grade stamped on the sensor 12 When the correct grade is shown press the YES key to confirm the choic...

Page 338: ...Section 6 SR 2 Service Procedure A15A Page 4 P41RA15A 30 January 2005...

Page 339: ...Units Equipped with SR 2 Microprocessors 1 Where Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Operation 1 Before Welding 2 After Welding 2 Materials Required None Operation Electric weldi...

Page 340: ...y cables 4 Connect the welder ground cable as close as possible to the area where the welding is to be performed Move the welder ground cable as required After Welding Step Action Result Comments 1 Re...

Page 341: ...ourmeters 1 Where Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Procedure 2 Materials Required None IMPORTANT Time can only be added if all hourmeters have less than 100 hours accumulated...

Page 342: ...ess and hold both the EXIT and unlabelled key for 5 seconds The Maintenance Menu appears 5 Press the NEXT key as required to display the Set Time and Date Menu 6 Press and hold both the EXIT and unlab...

Page 343: ...NEXT key to scroll to the last item in the Program Hourmeter Menu The NEXT key will disappear 11 Press and hold both the EXIT and unlabelled key for 5 seconds This will add the non programmable hourm...

Page 344: ...s can no longer be changed Exercise care when changing hourmeter settings 15 Repeat Steps 12 14 as necessary to change the remaining hourmeters 16 When all hourmeters are set press the EXIT key to ret...

Page 345: ...ash load files for use by Wintrac 2 Connecting the Cables 3 Flash Load Details 3 Flash Load Procedure 4 Flash Load Failure During a Flash Load 7 Flash Loading a Microprocessor Already in Flash Load Mo...

Page 346: ...r download the necessary file or files The files must then be prepared for use Preparing flash load files for use by Wintrac Flash load files must be prepared for use before the Wintrac flash load pro...

Page 347: ...the other end The 15 pin D connector is attached to the 15 pin D connector on the data cable and the 5 pin Deutsch connector is attached to the Service Watch connector above the HMI Control Panel Do...

Page 348: ...t a power source to the PC computer Do not rely on a laptop battery as low power may cause communications to be lost and the flash load to fail See Flash Load Recovery on the previous page 4 Start Win...

Page 349: ...be changed as shown by the readme txt file supplied with Wintrac 8 Left click Tools The TOOLS menu will appear 9 From the Tools menu left click Flash Load A download data warning menu appears 10 Left...

Page 350: ...oad will take several minutes The unit must remain on and connections must not be disturbed during the flash load process Several status screens are shown as the flash load proceeds 14 When the flash...

Page 351: ...oad process The Retry flash load differs from the Full flash load as follows Since the microprocessor is already in flash load mode it does not respond to the full set of Datapac commands Therefore du...

Page 352: ...t will be a Full flash load Since the microprocessor is already in flash load mode it will not respond to the first flash load command Searching for Device on COM 1 If the search continues for more th...

Page 353: ...ents 1 Materials Required 1 Obtaining Flash Load Files and Preparing Them for Use 2 Preparing flash load files for use by Wintrac 3 Connecting the Cables 3 Flash Load Recovery 4 Flash Load Procedure 5...

Page 354: ...ge support as shown below 65xx 66xx English English Spanish Russian French Polish German Hungarian Italian Romanian Dutch Bulgarian Portuguese Czech Greek Danish Turkish Swedish Hebrew Norwegian Arabi...

Page 355: ...ftware files are now ready for flash loading using Wintrac Connecting the Cables The same cables used for downloading are required to perform a flash load Typically two cables are used to connect the...

Page 356: ...re the flash load can be completed This can be accomplished by removing the connector at the back of the HMI or by disconnecting the unit battery If the power was turned off during flash load the next...

Page 357: ...a power source to the PC computer Do not rely on a laptop battery as low power may cause communications to be lost and the flash load to fail See Flash Load Recovery on the previous page 4 Start Wintr...

Page 358: ...s menu left click Flash Load A download data warning menu appears 10 Left click Yes to continue A directory containing the flash load files appears 11 Double click the flash load directory and locate...

Page 359: ...is complete a message appears confirming a successful flash load 15 Left click OK to complete the flash load The unit will automatically restart and run 16 Clear any alarm codes 17 Run a Pretrip Test...

Page 360: ...Section 6 SR 2 Service Procedure A46B Page 8 P41RA46B 30 January 2005...

Page 361: ...stic procedures Table of Contents Phase Detect Module Operation and Diagnostics 1 Where Used 1 Purpose 1 Table of Contents 1 Description 1 Operation 2 Connections 2 Removal and Replacement 4 Diagnosti...

Page 362: ...4 seconds after the voltage rises above 180 volts AC and all three phases are present If phase rotation is L1 L2 L3 the 7EB wire will supply 12 to 24 VDC to energize the appropriate phase rotation con...

Page 363: ...ase contactors from being energized at once ER This wire will output 12 24 VDC 2 to 4 seconds after the voltage rises above 180 volts AC and all three phases are present If the voltage drops below 160...

Page 364: ...new phase detect module wires to the upper contactor as follows 9 Connect the brown wire to L1 on the contactor 10 Connect the blue wire to L2 on the contactor 11 Connect the black wire to L3 on the...

Page 365: ...Off switch 4 If correct power is present in the test above then the ER circuit on the interface board should have 12 24 VDC present If power is not present replace the phase detect module Removal and...

Page 366: ...Section 6 SR 2 Service Procedure A48A Page 6 P41RA48A 30 January 2005...

Page 367: ...he HMI Control Panel This datalogger conforms to European standard EN12830 The data logger supports up to 6 optional temperature sensors and 4 digital inputs These optional sensors are not the same as...

Page 368: ...arrel than unit sensors No sensor grades Thermistor CargoWatch Sensor The thermistor sensors change resistance as the temperature changes Resistance values are as shown in the table They can be measur...

Page 369: ...d The printer must be connected to the printer port connector located inside the unit control box This port may be routed to the outside of the unit as required by the individual user Programmable Fea...

Page 370: ...f Range Checking Low High Italian Option Sensor Averaging S N B N B N B N B N B B Sensor Logging Ind Sensor 6 Name Out of Range Checking Low High Italian Option Sensor Averaging S N B N B N B N B N B...

Page 371: ...ads 2 To View the Customer Level Data 3 Customer Level Data 3 To View the Technician Level Data 4 Technician Level Data 5 Description The ServiceWatch Data Logger is contained within the SR 2 micropro...

Page 372: ...er when the unit is turned off and back on Time and date can not be changed by connecting directly to the ServiceWatch datalogger with Wintrac Downloads Downloads are obtained using Wintrac 4 4 Step A...

Page 373: ...trac menu bar The Open Wintrac File Menu appears 8 Select the desired trailer number and data file and left click OK The file is opened Customer Level data is shown according to the list below Custome...

Page 374: ...Technician User Level The Technician Level is enabled and if a file is currently open the message shown below will appear 9 Left click OK 10 Left click the File Icon in the upper left corner of the W...

Page 375: ...r Setpoint Return Control Return Display Discharge Control Discharge Display Ambient Coil Spare 1 Operating Mode Suction Pressure Discharge Pressure ETV Position Engine RPM Engine Temp ETV State Batte...

Page 376: ...Section 6 SR 2 Service Procedure A50A Page 6 P41RA50A 31 January 2005...

Page 377: ...to sense return air and discharge air temperature Ungraded sensors are used to sense coil and ambient air temperature Both graded and ungraded sensors are checked in the same manner Dual Sensors Dual...

Page 378: ...charge Air Sensor is marked with one red cable tie and is connected to the microprocessor via the DTP and DTN wires The Display Discharge Air Sensor is marked with two red cable ties and is connected...

Page 379: ...sensor to be replaced from the sensor harness 2 If the sensor is a soft failure replace the sensor Steps 3 thru 6 can be omitted Go to Step 8 3 If the sensor is a hard failure turn the unit on This st...

Page 380: ...r shorts and open wires Test and repair the harness as required See Service Procedure H04A for additional information This step can be omitted if the failure is a soft failure 7 If the harness passes...

Page 381: ...rpose To confirm the proper operation of the suction or discharge pressure sensors Table of Contents Pressure Sensor Test 1 Where Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Diagnostic P...

Page 382: ...or wiring harness is defective 3 Turn the unit off and disconnect the suction or discharge pressure transducer at the transducer plug 4 Turn the unit on 5 Check the voltage at the sensor harness conne...

Page 383: ...ere Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Operation 1 Diagnostic Procedure 2 Replacing the Switch Screw In Applications 2 Materials Required Fluke Digital Multimeter Operation The...

Page 384: ...e switch should be closed This check can be performed while changing oil 4 Reconnect the Deutsch connector Replacing the Switch Screw In Applications Step Action Result Comments 1 Turn the unit off 2...

Page 385: ...R 2 units Purpose To test the oil pressure switch for proper operation Table of Contents Checking the Oil Pressure Switch 1 Where Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Diagnostic P...

Page 386: ...ch is defective 3 Start the engine and observe the meter reading Battery voltage should be present when the engine is running If the voltage is low or is 0 proceed to Step 4 4 With the unit running di...

Page 387: ...l Multimeter Operation An optical sensor is used on some units to determine the coolant level This three wire sensor is supplied with 5 VDC from the microprocessor on the CLP wire J7 Pin 15 and ground...

Page 388: ...to determine the cause 2 If 5 VDC is present at the sensor check the voltage on the white wire CLS at the sensor harness connector Less than 0 5 VDC should be present when the sensor is not immersed i...

Page 389: ...itch is supplied with 5 VDC from the microprocessor on the CLP wire J7 Pin 15 The switch outputs 5 VDC on the CLS wire J7 Pin 16 when coolant level is above the sensor and less than 0 VDC when the coo...

Page 390: ...sor harness connector Less than 0 5 VDC should be present when the coolant level is below the switch and 5 VDC should be present when the coolant level is above the switch If these voltages are not pr...

Page 391: ...oolant temperature sensor for proper operation Table of Contents Coolant Temperature Sensor Test 1 Where Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Engine Temperature Sensor 1 Diagnosti...

Page 392: ...at the plug next to the sensor 4 Turn the unit on The Standard Display will appear 5 Access the Gauge menu and display Coolant Temperature The display for the Engine Coolant Temperature sensor should...

Page 393: ...n Step 6 above is incorrect check the microprocessor as shown in Service Procedure A01A If the microprocessor fails the test it must be replaced 9 If the microprocessor passes the test the problem is...

Page 394: ...Section 6 SR 2 Service Procedure F08A Page 4 P41RF08A 30 January 2005...

Page 395: ...ust the RPM sensor Table of Contents RPM Sensor Test and Adjustment 1 Where Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Diagnostic Procedure 2 Materials Required Fluke Digital Multimeter...

Page 396: ...oved If not the sensor should be replaced 4 Loosen the lock nut turn the sensor in until it contacts the ring gear on the flywheel then back it out turn and tighten the lock nut 5 Reattach the FS1 and...

Page 397: ...ss the sensor terminals with the FS1 and FS2 wires removed The voltage in high speed should read from 1 0 to 5 0 volts ac Set the meter to read AC volts 11 If the required voltage is not present repla...

Page 398: ...Section 6 SR 2 Service Procedure F09A Page 4 P41RF09A 30 January 2005...

Page 399: ...t refrigeration system pressures did not respond as expected This may be caused by a malfunction in the electronic throttling valve circuits or a refrigeration system problem such as low refrigerant l...

Page 400: ...e EVA and EVB wires for shorts to ground Be sure the valve connector is properly attached to the valve Identify the associated pins on the ETV and check for continuity at the valve If the resistance f...

Page 401: ...red 8 Exit Evacuation Test The test ETV should close when Evacuation Test is exited 9 If the test ETV opens and closes as described in Step 6 7 replace the unit ETV If the ETV must be changed consult...

Page 402: ...Section 6 SR 2 Service Procedure G03A Page 4 P41RG03A 31 January 2005...

Page 403: ...tents Wiring Harness Continuity Test 1 Where Used 1 Purpose 1 Table of Contents 1 Materials Required 1 Important Notes 1 Diagnostic Procedure 2 Materials Required Fluke Digital Multimeter Jumper Wires...

Page 404: ...g meter with high input impedance Older analog needle type meter movement meters and some inexpensive mechanic tool box meters present a large load to the circuit being tested This can significantly a...

Page 405: ...results 6 Using jumpers as required connect each end of the circuit to a high quality multimeter The meter must show a very low resistance less than 1 0 ohm indicating circuit continuity If not the c...

Page 406: ...Section 6 SR 2 Service Procedure H04A Page 4 P41RH04A 30 January 2005...

Page 407: ...Tab goes here and the next page should be GREEN Section 7 Service Information...

Page 408: ......

Page 409: ...change 5 SR 2 Microprocessor 5 SR 2 Interface Board 5 SR 2 HMI Control Panel 5 SR 2 Microprocessor Interface Board HMI Control Panel Tester 6 SR 2 Economy Mode Settings 7 SR 2 Cycle Sentry Mode Normal...

Page 410: ...Section 7 SR 2 Information 7 2 02 February 2005...

Page 411: ...Revision CAUTION The software on a replacement microprocessor should always be checked to be certain it is current software SR 2 Microprocessor Software Software Revision Features Interchange with 92...

Page 412: ...602 Limited OptiSet software enhancements improved PRINT feature reduced startup initialization time from approx 50 seconds to approx 30 seconds R Com support Can replace all previous limited OptiSet...

Page 413: ...SR 2 Trailer Applications 45 2013 SR 2 Interface Board Features Where Used Interchange With Service Parts Number Production units with damper solenoids SB Trailer Applications 45 2014 Production unit...

Page 414: ...Microprocessor Interface Board HMI Control Panel Tester Features Where Used Interchange With Service Parts Number Tests the microprocessor interface board and HMI control panel SR 2 Trailer Applicatio...

Page 415: ...e Economy Mode settings to Standard Mode default settings for Cycle Sentry Mode and Continuous Mode operation OptiSet or user modified settings are not considered SR 2 Cycle Sentry Mode Normal Default...

Page 416: ...1 9 C Only if High Speed Pull Down Off 6 5 F 3 6 C Only if High Speed Pull Down Off 3 5 F 1 9 C Only if High Speed Pull Down Off 8 5 F 4 7 C Only if High Speed Pull Down Off High Speed Heat to Low Sp...

Page 417: ...T 347 04 02 04 SR 2 Software Revision B001 T T 348 04 02 04 SR 2 CargoWatch Downloads T T 350 04 16 04 SR 2 Software Revision B002 T T 355 04 23 04 SR 2 Hourmeter View and Dual Sensor Enhancement T T...

Page 418: ...ng on SL 400e SR 2 Units SB 730 G 04 07 23 04 SR 2 On Off Isolation Switch SB 733 G 04 08 27 04 SR 2 New Damper Door Gear Motor ESA Warranty Bulletins Bulletin Date Title WB 200 G 04 10 29 04 SR 2 ON...

Page 419: ...Tab goes here and the next page should be GREEN Section 8 Schematics and Wiring Diagrams...

Page 420: ......

Page 421: ...Diagram NAD Manuals Only 1E07692 Rev E SB 210 310 30 50 SR 2 w Yanmar Wiring Diagram NAD Manuals Only 1E07693 Rev C SL 400e SR 2 30 50 Schematic Diagram ESA Manuals Only 1E08157 Rev B SL 400e SR 2 30...

Page 422: ...Section 8 SR 2 Drawings 8 2 01 February 2005...

Page 423: ..._______________________________ __________________________________________________________________________ __________________________________________________________________________ __________________...

Page 424: ...Section 8 SR 2 Drawings 8 4 01 February 2005...

Page 425: ...8 5...

Page 426: ...8 6...

Page 427: ...8 7...

Page 428: ...8 8...

Page 429: ...8 9...

Page 430: ...8 10...

Page 431: ...8 11...

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