Thermo King C-600, S-600, S-700 User Manual

Operator’s Manual

Precedent

C-600, S-600 and S-700

Single Temperature Units

TK 56218-2-OP (Rev. 1, 12/15)

Precedent

C-600, S-600 and S-700

Single Temperature Units

TK 56218-2-OP (Rev. 1, 12/15)

Printed in USA

Disclaimer

This manual is published for informational purposes only. Thermo King Corporation makes no representations or warranties, express or implied, with respect to t he information, recommendations and descriptions contained in this manual and such information, recommendations and description s should not be regarded as all-inclusive or covering all contingencies. In the event you have any questions or require further information, please contact your local Thermo King dealer.

The procedures described herein should only be undertaken by suitably qualified personnel. Failure to implement these procedures correctly may cause dam age to the Th ermo King unit or o ther property or personal injury.

Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence and/or strict liability) or otherwise, to any person or entity fo r any personal injury, property damage or any other direct, indirect, special or consequential damage or liability whatsoever, arising out of or resulting from any actions by any person that are contrary to this manual or any of the information , recommendations or descriptions contained herein or the failure of any person to implement the procedures described herein correctly or to follow caution and safety decals located on the Thermo King unit.

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

EPA Emission Control System Warranty Statement 7

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Thermo King Corporation Responsibilities . . . . . . . 8

Owner Responsibilities . . . . . . . . . . . . . . . . . . . . . . 8

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Safety Practices . . . . . . . . . . . . . . . . . . . . . . 10

Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . 10

Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Battery Installation and Cable Routing . . . . . . . . . . . . 11

Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 13

First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 13

Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 13

Condenser and Evaporator Fans . . . . . . . . . . . . . 13

High Voltage Components . . . . . . . . . . . . . . . . . . 14

Do Not Use Ether Starting Aids . . . . . . . . . . . . . . 15

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .17

EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Thermo King Reciprocating Compressor . . . . . . . . . . .18

Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . .18

SMART REEFER 4 (SR-4) Control System . . . . . . . . .18

Diesel Operation . . . . . . . . . . . . . . . . . . . . . . . . . .19

Electric Operation . . . . . . . . . . . . . . . . . . . . . . . . .19

CYCLE-SENTRYTM Start-Stop Controls . . . . . . . . . .20

Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

FreshSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . .22

Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . .23

Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . .23

Manual Pretrip Inspection . . . . . . . . . . . . . . . . . . . . .25

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . 27

SMART REEFER 4 (SR-4) Controller Overview . . . . .27

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Control Panel Display . . . . . . . . . . . . . . . . . . . . . .28

Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Hard Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Turning Unit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

If a Flash Drive is Connected: . . . . . . . . . . . . . . . .32

Configurable Soft Keys . . . . . . . . . . . . . . . . . . . . . 33

Display Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

If a Language is Enabled . . . . . . . . . . . . . . . . . . .34

If Log Alarms are Present . . . . . . . . . . . . . . . . . . . 36

Turning The Unit Off . . . . . . . . . . . . . . . . . . . . . . . . . . 37

The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . 37

The TemperatureWatch Display . . . . . . . . . . . . . . . . .38

Changing The Setpoint . . . . . . . . . . . . . . . . . . . . . . . . 39

Numerical Setpoints . . . . . . . . . . . . . . . . . . . . . . .39

Named Products - OptiSet Plus . . . . . . . . . . . . . . 40

Both Numerical Setpoints and Named Products . . 40

Changing the Setpoint - Numerical Setpoint . . . . .41

Changing the Setpoint - Named Product . . . . . . . 45

Changing the Setpoint - Both Numerical Setpoint

and Named Product Available . . . . . . . . . . . . . . .49

Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . 50

Starting the Electric Motor . . . . . . . . . . . . . . . . . . . . . 50

Switching from Diesel to Electric . . . . . . . . . . . . . . . . 51

Switching from Electric to Diesel . . . . . . . . . . . . . . . . 52

Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . 53

Terminating a Defrost Cycle . . . . . . . . . . . . . . . . 56

Selecting Cycle Sentry or Continuous Mode . . . . . . . 56

Using the Gauges Key . . . . . . . . . . . . . . . . . . . . . 60

Using The Sensors Key . . . . . . . . . . . . . . . . . . . . . . . 62

Using the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . 64

Pretrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Performing a Pretrip Test . . . . . . . . . . . . . . . . . . . 67

Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Languages (If Enabled) . . . . . . . . . . . . . . . . . . . . 75

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Data Logger (CargoWatch) . . . . . . . . . . . . . . . . . 89

Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

SmartPower Electric Standby Option . . . . . . . . . 102

Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Clear All ECU Faults . . . . . . . . . . . . . . . . . . . . . 107

Loading and Enroute Inspections . . . . . . . . . . . . . 110

Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . 110

Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . 112

Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . 113

Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . 119

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

Maintenance Inspection Schedule . . . . . . . . . . . . .153

Serial Number Locations . . . . . . . . . . . . . . . . . . . . .159

Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . .160

Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . .161

Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . 148

Electrical Control System . . . . . . . . . . . . . . . . . . . . . 149

Electrical Standby (Smart Power Units Only) . . . . . . 150

Electric Motor and Overload Relay . . . . . . . . . . . 150

Standby Power Cord Requirements (Smart Power

Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

CALIFORNIA

Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . .161

Introduction

There is nothing complicated about operating and maintaining your Thermo King unit, but a few minutes studying this manual will be time well spent.

Performing pre-trip checks and enroute inspections on a regular basis will minimize on-the-road operating problems. A regular maintenance program will also help to keep your unit in top operating condition. If factory recommended procedures are followed, you will find that you have purchased the most efficient and dependable temperature control system available.

All service requirements, major and minor, should be handled by a Thermo King dealer for four very important reasons:

• They are equipped with the factory recommended tools to perform all service functions

• They have factory trained and certified technicians

• They have genuine Thermo King replacement parts

• The warranty on your new unit is valid only when the repair and replacement of component parts is performed by an authorized Thermo King dealer.

IMPORTANT: This manual is published for informational purposes only and the information furnished herein should not be considered as all-inclusive or meant to cover all contingencies. If more information is required, consult your Thermo King Service Directory for the location and telephone number of the local dealer.

EPA Emission Control System Warranty Statement

Thermo King warrants to the initial owner and each subsequent owner that the certified, non-road diesel engine in your unit is:

1. Designed, built and equipped so as to conform, at the time of sale, with all applicable regulations adopted by the United States Environmental Protection Agency (EPA).

2. Free from defects in materials and workmanship in specific emission related parts for a period of five years or 3,000 hours of opera tion , wh ich ever com es fi rst , af ter date of delivery to the initial owner.

If an emission-related part or component fails during the warranty period, it will be repaired or replaced. Any such part or component repaired or replaced under warranty is warranted for the warranty period.

During the term of this warranty, Thermo King will provide, through a Thermo King authorized service dealer or other establishment authorized by Thermo King, repair or replacement of any warranted part at no charge to the non-road engine owner.

In emergency, repairs may be performed at any service establishment, or by the owner, using any replacement part. Thermo King will reimburse the owner for their expenses, including diagnostic charges for such emergency repair. These expenses shall not exceed Thermo King’s suggested retail price for all warranted parts replaced, and labor changes based on Thermo King’s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate.

EPA Emission Control System Warranty Statement

Any replacement part can be used for maintenance or repairs. The owner should ensure that such parts are equivalent in design and durability to genuine Thermo King parts. However, Thermo King is not liable for parts that are not genuine Thermo King parts.

A part not being available within 30 days or repair not being completed within 30 days constitutes an emergency.

As a condition of reimbursement, replaced parts and received invoices must be presented at a place of business of a Thermo King authorized service dealer or other establishment authorized by Thermo King.

This warranty covers the following emission-related parts and components:

• Fuel Injection System

• Intake Manifold

• Exhaust Manifold

• Miscellaneous hoses, clamps, connectors and sealing devices used in the above systems.

If failure of one of these parts or components results in failure of another part or component, both will be covered by this warranty.

Responsibilities

This warranty is subject to the following:

Thermo King Corporation Responsibilities

During the emission warranty period, if a defect in material or workmanship of a warranted part or component is found, Thermo King will provide:

• New, remanufactured, or repaired parts or components required to correct the defect.

NOTE: Items replaced under this warranty become the property of Thermo King.

• Labor, dur ing n ormal worki ng ho urs, r equi red to make the warranty repair. This includes diagnosis and labor to remove and install the engine, if necessary.

Owner Responsibilities

During the emission warranty period, the owner is responsible for:

EPA Emission Control System Warranty Statement

• The performance of all required maintenance. A warranty claim will not be denied because the scheduled maintenance was not performed. However, if the lack of required maintenance was the reason for the repair, then the claim will be denied.

• Premium of overtime cost.

• Cost to investigate complaints that are not caused by defects in Thermo K ing 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 King deems improper as explained in this Operator’s Manual, or any other manuals provided for the unit.

• Attachments, accessory items, or parts not authorized for use by Thermo King.

• Improper off-road engine maintenance, repair or abuse.

• Owner’s unreasonable delay in making the product available after being notified of a potential product problem.

This warranty is in addition to Thermo King’s standard warranty applicable to the off-road engine product involved.

Remedies under this warranty are limited to the provision of material and services as specified herein. Thermo King is not responsible for inc i dental or consequential dam age s suc h as downtime or loss of engine powered equipment.

Safety Precautions

Thermo King recommends that se rvicing be done onl y by a Thermo King dealer. However, you should be aware of several safety practices. This chapter gives basic safety precautions for working with Thermo King units and describes the safety stickers on your unit that you should be familiar with.

General Safety Practices

WARNING: Keep hands and loose clothing clear of fans and belts at all times when the unit is operating with the doors open.

WARNING: Exposed coil fins can cause painful lacerations. Service work on the evaporator or condenser coils should be done by a certified Thermo King technician.

WARNING: Do not apply heat to a closed cooling system. Before applying heat to a cooling system, drain it. Then flush it with water and drain the water. Antifreeze contains water and ethylene glycol. The ethylene glycol is flammable and can ignite if the antifreeze is heated enough to boil off the water.

Automatic Start/Stop Operation

This unit is capable of automatic operation and could start at any time without warning.

WARNING: The unit can start at any time without warning. Press the O place the microprocessor On/Off switch in the Off position before inspecting or servicing any part of the unit.

FF key on the control panel and

Electrical Hazard

DANGER: Dangerous three phase AC electric power is present whenever the unit is operating in either Diesel Mode or Electric Mode and whenever the unit is connected to a source of external standby power. Voltages of this magnitude can be lethal. Exercise extreme caution when working on the unit.

Safety Precautions

Battery Installation and Cable Routing

W ARNING: Improperly installed battery could result in a fire or explosion. A Thermo Kin g approved battery must be installed and properly secured to the battery tray.

W ARNING: Improperly installed battery cables could result in fire or explosion. Battery cables must be installed, routed and secured properly to prevent them from rubbing, chaffing or making contact with hot, sharp or rotating components.

CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit. This could result in severe damage to equipment and void the warranty.

CAUTION: Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury.

CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries. Battery acid can cause serious burns when exposed to eyes or skin. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.

CAUTION: Always cover battery terminals to prevent them from making contact with metal components during battery installation. Battery terminals grounding against metal could cause the battery to explode.

Safety Precautions

Refrigerant

Although fluorocarbon refrigerants are classified as safe, use caution when working with refrigerants or in areas where they are being used.

DANGER: Fluorocarbon refrigerants can produce toxic gases. In the presence of an open flame or electrical short, these gases are severe respiratory irritants CAPABLE OF CAUSING DEATH.

DANGER: Fluorocarbon refrigerants tend to displace air and can cause oxygen depletion which could result in DEATH BY SUFFOCATION. Provide adequate ventilation in enclosed or confined areas.

WARNING: Fluorocarbon refrigerants evaporate rapidly, freezing anything they contact if accidentally released into the atmosphere from the liquid state.

Refrigerant Oil

Observe the following precautions when working with or around refrigerant oil:

WARNING: Always wear goggles or safety gla sse s to protect eyes from refrigerant oil contact.

WARNING: Protect skin and clothing from prolonged or repeated contact wi th refrigerant oil. Rubber gloves are recommended.

WARNING: Wash thoroughly immediately after handling refrigerant oil to prevent irritation.

Safety Precautions

First Aid

First Aid–Refrigerant

Eyes: For contact with liquid, immediately flush eyes with

large amounts of water. Get prompt medical attention. Skin: Flush areas with large amounts of warm water. Do not

apply heat. Wrap burns with dry, sterile, bulky dressing to protect from infection or injury. Get prompt medical attention.

Inhalation: Move victim to fresh air and restore breathing if necessary. Stay with victim until emergency personnel arrive.

First Aid–Refrigerant Oil

Eyes: Immediately flush eyes with large amounts of water for

at least 15 minutes while holding the eyelids open. Get prompt medical attention.

Skin: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.

Inhalation: Move victim t o fresh air and restore breathing if necessary. Stay with victim until emergency personnel arrive.

Ingestion: Do not induce vomiting. Immediately contact local poison control center or physician.

Safety Decals and Locations

Condenser and Evaporator Fans

Be aware of the warning nameplates near the condenser fans and evaporator fans (example in Figure 1).

AMA1581

Figure 1: Fan Warning

Safety Precautions

AMA1580

AMA1579

High Voltage Components

Var ious components on the Precedent unit operate using 220/3/60 or 460/3/60 high voltage and are identified by warning nameplates (examples in Figure 2). All high voltage wiring is identified by ORANGE conduiting. Be aware of the locations of these components. Only certified, trained technicians can service them.

Figure 2: High Voltage Warning

NOTE: See Figure 3 and Figure 4 for high voltage component locations.

1. Condenser Motors 4. High Voltage Control Box

2. Evaporator Motor 5. AC Generator

3. High Voltage Distribution Box

6. Electric Standby Motor & Power Receptacle (SmartPower Option)

Figure 3: High Voltage Component Locations (Front)

Safety Precautions

Do Not Use Ether Starting Aids

Figure 5: Do Not Use Ether Starting Aids

(Near Engine)

7. Evaporator Motor 9. High Voltage Junction

8. High Voltage Heater Strips

Figure 4: High Voltage Component Locations (Rear)

Box All ORANGE conduiting contains High Voltage

Unit Description

Unit Overview

Thermo King Precedent C-600, S-600 and S-700 are one piece, self-contained, diesel powered, air cooling/heating units operating under the control of the SMART REEFER™ 4 (SR-4) programmable microprocessor controller. These units mount on the front of the trailer with the evaporator extending through an opening in the front wall. These single temperature models are designed to maintain temperature in one compartment or zone.

These units feature all-new DDE (Diesel Direct Electric) architecture, quiet running Thermo King diesel engine and a Thermo King reciprocating compressor.

The C-600, S-600 and S-700 are available in the following models:

Standard : Cooling and heating on die sel engine operation. SmartPower

engine operation and electric standby operation.

Option: Cooli ng and heating on die sel

Figure 6: Front View

Unit Description

Diesel Engine

Precedent C-600, S-600 and S-700 use a 4-cylinder, water cooled, direct injection diesel engine. The engine is coupled directly to the compressor on standard units. SmartPower units are equipped with a centrifugal clutch which transfers power from the engine to the compressor. Belts transmit power to the AC generator, water pump, and alternator on all models.

ELC (Extended Life Coolant)

ELC (Extended Life Coolant) is standard equipment. The maintenance interval for ELC is five years or 12,000 hours. A nameplate on the coolant expansion tank identifies units with ELC. The new engine coolant, Chevron Extended Life Coolant, is RED in color instead of the previous GREEN or BLUE-GREEN colored conventional coolants.

CAUTION: Do not add “GREEN” or “BLUE-GREEN” conventional coolant to cooling systems using “RED” Extended Life Coolant, except in an emergency. If conventional coolant is added to Extended Life Coolant, the coolant must be ch anged after 2 years instead of 5 years.

NOTE: The use of 50/50% pre-mixed ELC is recommended to assure that de-ionized water is being used. If 100% full strength concentrate is used, de-ionized or distilled water is recommended instead of tap water to insure the integrity of the cooling system is maintained.

EMI 3000

EMI 3000 is an extended maintenance interval package. It is standard equipment. The EMI 3000 package consists of the following key components:

• EMI 3000-Hour Cyclonic Air Cleaner Assembly and Air Cleaner Element

• EMI 5-Micron 3000-Hour Fuel Filter

• EMI 3000-Hour Dual Element Oil Filter

• API Rating CI-4 Mineral Oil

• Five Year or 12,000 Hour ELC (Extended Life Coolant)

The EMI package allows standard maintenance intervals to be extended to 3,000 hours, or 2 years, whichever occurs first.

NOTE: Units equipped with the EMI 3000 package do require regular inspection in accordance with Thermo King's maintenance recommendations.

Unit Description

Thermo King Reciprocating Compressor

The Precedent C-600, S-600 and S-700 are equipped with a 4-cylinder 30.0 cu. in. (492 cm3) displacement Thermo King X430 reciprocati n g compressor .

Electronic Throttling Valve

The ETV provides enhanced control of the refrigeration system as follows:

• Allows the refrigeration system to fully utilize the power capabilities of the engine under varying conditions

• Provides an additional measure of protection against high discharge pressures

• Protects the engine from high coolant temperature shutdowns

• Provides a means of precise temperature control.

SMART REEF ER 4 (SR-4) Control System

The SR-4 is a microprocessor control system designed for transport refrigeration. The SR-4 integrates the following functions: changing setpoint and operating mode, viewing gauge, sensor and hourmeter readings, initiating defrost cycles, and viewing and clearing alarms.

The microprocessor components are located inside the control box, which is located inside the lower roadside service door. It is used to operate the unit. The control panel is mounted on the face of the control box. It is clearly visible through an opening in the lower roadside service door.

See “Operating Instructions” for mo re information about the SR-4 Controller.

Depending on the air temperature in the trailer, as sensed by the microprocessor Base Controller, the unit will typically operate in on e of the following modes:

Unit Description

Diesel Operation

In diesel operation the microprocessor will select the operating mode from the following:

• High Speed C ool

• Low Speed Cool

• Low Speed Modulated Cool

• Null (CYCLE-SENTRY operation only)

• Low Speed Modulated Heat

• Low Speed Heat

• High Speed Heat

• Defrost

Electric Operation

In electric operation the microprocessor will select the operating mode from the following:

• Cool

• Modulated Cool

• Null (CYCLE-SENTRY operation only)

• Modulated Heat (Hot Gas only)

• Hot Gas Heat

• Full Heat (Hot Gas and Electric Heat)

• Defrost (Hot Gas and Electric Heat)

Unit Description

CYCLE-SENTRYTM Start-Stop Controls

WARNING: The unit can start at any time without warning. Press the O place the microprocessor On/Off switch in the Off position before inspecting or servicing any part of the unit.

The CYCLE-SENTRY Start-Stop fuel saving system provides optimum operating economy.

When CYCLE-SENTRY Mode is selected the unit will start and stop automatically to maintain setpoint, keep the engine warm and the battery charged. When Continuous Mode is selected, the unit starts automatically and runs continuously to maintain setpoint and provide constant airflow.

FF key on the control panel and

Data Logging

There are two separate data loggers. The data is downloaded through the Flash Drive Only USB port on the front of the control box using a flash drive and ThermoServ™ software.

ServiceWatch™: ServiceWatch is standard equipment. It records operating events, alarm codes and compartment temperatures as they occur and at preset intervals. This information is typically used to analyze unit performance.

CargoWatch™: CargoWatch data logging requires the installation of optional sensors. Up to six temperature sensor/probes and four door switches can be installed. CargoWatch also logs the setpoint. If optional temperature sensors are installed, their readings are displayed as Datalogger Sensor (1-6) Temperature in the sensor readings.

USB Ports: :

• The Flash Drive Only USB Port allows a USB Flash Drive that has been pr operly conf igured us ing the T hermoServ ™ Service Tool to be connected to the unit.

• The optional PC Computer Only USB Port allows a PC Computer to be connected to the unit via a standard USB Cable.

MICRO

PROCESSOR

OFF

THERMO KING

OFF

POINT

SET SENSORSGAUGES

SR4

Smart Reefer 4

°F

USB PORT

FLASH DRIVE ONLY

USB PORT

PC COMPUTER ONLY

1. Flash Drive Only USB Port

2. PC Computer Only USB Port (option)

Unit Description

OptiSet Plus

OptiSet Plus is a grou p o f progr amm able funct io ns tha t cont ro l how the unit will operate with specific setpoints or named products. Thi s ass ur es tha t wh en a p art icu lar s etp oin t or n ame d product is selected, the unit will always operate the same way. This allows an entire fleet to be configured to match the

customers’ needs. Contact your Thermo King dealer for information about programming OptiSet Plus.

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 protect ion of car go, whil e keepin g operati ng costs to a minimum. Contact your Thermo King dealer for information about programming FreshSet.

Figure 7: HMI Controller and USB Ports

Defrost

Frost gradually builds-up on evaporator coils as a result of normal operation. Th e unit uses hot re f r ige ra n t to def ro s t th e evaporator coil. Hot refrigerant gas passes through t he

Unit Description

evaporator coil and melts the frost. The water flows through collection drain tubes onto the ground. The methods of defrost initiation are Automatic, and Manual.

Automatic Defrost: The SR-4 automatically initiates timed or demand defrost cycles. The SR-4 microprocessor can be programmed to initiate timed defrost cycles at intervals of 2, 4, 6, 8, or 12 hours. Demand defrost cycles occur if the differences between the return air temperature, discharge air temperature, and coil temperature exceed certain limits. The unit can enter defrost cycles as often as every 30 minutes if required.

Manual Defrost: In Manual Defrost mode, the operator initiates a defrost cycle. See “Initiating a Manual Defrost Cycle.”

NOTE: The unit will not perform a Manual Defrost Cycle unless the unit has been turned on with the O is running in Continuous or CYCLE-SENTRY Mode (or s hut down in CYCLE-SENTRY Null Mode), and the coil temperature is below 45 F (7 C).

N key, the unit

Opening the Front Doors

Pull the right door latch handle out at a 45 degree angle and turn it down (clockwise) 90 degrees to open the doors and access the engine compartment. Push the door closed while holding the door latch handle open and then turn it up (counterclockwise) 90 degrees to close the door.

Figure 8: Door Latch Location

Unit Description

Engine Compartment

The following maintenance items can be checked visually.

WARNING: The unit can start at any time without warning. Press the O place the microprocessor On/Off switch in the Off position before inspecting any part of the unit.

Engine Oil Dipstick: Use the engine oil dipstick to check the engine oil level.

CAUTION: Make sure the engine is turned off before attempting to check the engine oil.

FF key on the control panel and

Unit Protection Devices

Coolant Level Switch: The coolant level switch closes if

the coolant level drops below an acceptable level. If it stays closed for a specified time, the microprocessor records alarm code 37.

Engine Coolant Temperature Sensor:

The microprocessor uses the engine coolant temperature sensor to monitor the engine coolant temperature. If the engine

coolant temperature rises above an acceptable level, the microprocessor records alarm code 41 and possibly 18. The microprocessor might also shut the unit down.

High Pressure Cutout Switch: The high pressure cutout switch (HPCO) is located on the compressor discharge manifold. If the compressor discharge pressure becomes excessive, the switch opens the circuit to the run relay to stop the unit. The microprocessor will record Alarm Code 10.

High Pressure Relief Valve: This valve is designed to relieve excessive pressure in the refrigeration system. It is located on the receiver tank. If the high pressure relief valve opens, much of the refrigerant will be lost. Take the unit to a Thermo King dealer if this occurs.

Low Oil Level Switch: The low oil level switch closes if the oil drops below an acceptable level. If it stays closed for a specified time, the microprocessor shuts the unit down and records Alarm Code 66.

Low Oil Pressure Switch: The low oil pressure switch closes if the oil pressure drops below an acceptable level. If it stays closed for a specified time, the microprocessor shuts the unit down and records alarm code 19.

Unit Description

Preheat Buzzer: The preheat buzzer sounds when the base

controller energizes the preheat relay. This warns anyone near the unit that the controller is about to start the engine.

Overload Relay—Automatic Reset (SmartPower): An overload relay protects the standby electric motor. The overload relay opens the circuit to the electric motor if the motor overloads for any reason (e.g., low line voltage or improper power supply) while the unit is on electric standby operation. The microprocessor will record Alarm Code 90.

Smart FETs: Smart FETs in the microprocessor protect some circuits and components from an overcurrent condition.

Fuses: A number of fuses, located on the microprocessor, protect various circuits and components. The microprocessor is located inside the control box.

Fuse Size Function

F1 5A 2A Power for REB F2 15A On/Off Switch Circuit F3 40A Fuel Solenoid/Starter Circuit F4 None2ANo Fuse - All Bosch and Thermo King

Alternators (Note 1) 2A Fuse - All Prestolite Alternators

F5 60A Preheat Circuit (Note 2) F6 15A High Speed Solenoid Circuit F7 2A 8X Power for CAN bus F8 5A 2A Power for CAN bus J12 F10 15A On/Off Relay Circuit F12 5A 2A Power for CAN bus J13 F13 2A Status Light Circuit F15 2A SR-4 Power Supply Circuit F20 2A Alternator Sense Circuit F25 10A Fresh Air Door Circuit F25 7.5A High Pressure Cutout Circuit

NOTE: The F5 preheat fuse is a “slow blow” type fuse. It is designed for use with the Ya nmar trailer engine air pre-heater. Always replace the fuse with the TK specified fuse.

Manual Pretrip Inspection

Before Starting the Unit

Pretrip inspections are an important part of a preventative maintenance program designed to minimize operating problems and breakdowns. Perform this pretrip inspection before every trip involving refrigerated cargo.

NOTE: Pretrip inspections are not intended to take the place of regular maintenance inspections.

Fuel: Make sure the diesel fuel supply is adequate to guarantee engine operation to the next check point. Allow for maximum fuel consumption of one gallon per hour of engine operation.

Engine Oil: Check the engine oil level. It should be at the Full mark when the dipstick is threaded all the way into the oil pan. Do not overfill.

CAUTION: Turn the engine off before checking the engine oil level.

Engine Coolant: The engine coolant must have antifreeze protection to -30 F (-34 C). Add coolant if Alarm Code 37 is active. Check and add coolant to the expansion tank.

WARNING: Do not remove the expansion tank cap while the coolant is hot.

Battery: Make sure the battery terminals are tight and free of corrosion.

Belts: Make sure belts are in good condition and adjusted to the proper tension. For more information about belt tension, see the Specifications chapter.

Electrical: Check the electrical connections to make sure they are securely fastened. Wires and terminals should be free of corrosion, cracks, and moisture.

Structural: Visually inspect the unit for leaks, loose or broken part s, and other damage .

Manual Pretrip Inspection

Coils: Make sure the condenser and evaporator coils are clean

and free of debris. Cargo Box: Check the interior and exterior of the cargo box

for damage. Any damage to the walls or insulation must be repaired.

Cargo Doors: Make sure that the cargo doors and weather seals are in good condition. The doors should latch securely and the weather seals should fit tightly.

Defrost Drains: Check the defrost drain hoses to make sure they are open.

Operating Instructions

MICRO

PROCESSOR

OFF

THERMO KING

OFF

Figure 9: SR-4 Control Panel

(Optional PC USB Port Shown)

SET SENSORSGAUGES

POINT

SR4

Smart Reefer 4

°F

USB PORT

FLASH DRIVE ONLY

USB PORT

PC COMPUTER ONLY

SMART REEFER 4 (SR-4) Controller Overview

Thermo King has applied the latest advances in computer technology to develop a device that controls temperature and unit function, and displays operating information quickly and accurately.

There is nothing complicated about learning to operate the SR-4 Controller, but you will find that a few minutes studying the contents of this manual will be time well spent.

WARNING: Do not operate the SR-4 until you are completely familiar with the location and function of each con t r o l.

Operating Instructions

The microprocessor components are located inside the control box, which is located inside the lower roadside service door. The microprocessor is connected to a Human Machine Interface (HMI) Control Panel. It is used to operate the unit. The USB 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. The Microprocessor Power Switch is located above HMI Control Panel. It is hidden when the lower roadside body panel surrounding the Control Box is closed.

WARNING: The unit can start at any time without warning. Press the O place the microprocessor On/Off switch in the Off position before inspecting or servicing any part of the unit.

FF key on the control panel and

Control Panel

The control panel has a display and eight touch sensitive keys. The display is capable of showing both text and graphics. The four keys on the left and right sides of the display are “hard” (dedicated) keys. The four keys under the display are “soft” keys. The function of “soft” keys change depending on the operation being performed. If a soft key is active, its function will be shown in the display directly above the key.

Control Panel Display

The display is used to supply unit information to the operator. This information includes setpoint, current box temperature operating information, unit gauge readings, system temperatures and other information as selected by the operator.

The default display is called the Standard Display. It is shown in Figure 10 and will be described in detail later in this chapter.

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