Thermo King V Series, Spectrum, V-100, V-200, V-200s Operator's Manual

Operator’s Manual

V-Series Units with
Direct Smart Reefer

V-100, V-200, V-200s, V-300, V-500, V-600, V-800 and
Spectrum units

December 2018

Revision A

TTKK 6611665511--1188--OOPP--EENN

Introduction

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

TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippmmeenntt wwhhiicchh hhaass
bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd oorr aalltteerreedd aass,, iinn tthhee
mmaannuuffaaccttuurreerr’’ss jjuuddggmmeenntt,, ttoo aaffffeecctt iittss iinntteeggrriittyy..””

MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy
ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,,
oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss
mmaannuuaall oorr aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss
ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd oonnllyy bbee
uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee
pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr
ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..

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

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

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

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

• They have factory trained and certified technicians

• They have genuine Thermo King replacement parts

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

Software License

The product includes software that is licensed under a non-exclusive, non­sublicensable, terminable and limited license to use the software as installed

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on the product for its intended purpose. Any removal, reproduction, reverse
engineering, or other unauthorized use of the software is strictly prohibited.
Hacking the product or installing unapproved software may void the
warranty. The owner or operator shall not reverse engineer, decompile, or
disassemble the software, except and only to the extent that such activity is
expressly permitted by applicable law notwithstanding this limitation. The
product may include third party software separately licensed as specified in
any documentation accompanying the product or in an about screen on a
mobile application or website that interfaces with the product.

Emergency Assistance

Thermo Assistance is a multi-lingual communication tool designed to put
you in direct contact with an authorized Thermo King dealer.

TThheerrmmoo AAssssiissttaannccee sshhoouulldd oonnllyy bbee ccoonnttaacctteedd ffoorr bbrreeaakkddoowwnn aanndd rreeppaaiirr
aassssiissttaannccee..

To use this system, you need the following information before you call:
(phone charges will apply)

• Contact Phone Number

• Type of TK Unit

• Thermostat Setting

• Present Load Temperature

• Probable Cause of Fault

• Warranty Details of the Unit

• Payment Details for the Repair

Leave your name and contact number and a Thermo Assistance Operator
will call you back. At this point you can give details of the service required
and the repair will be organized.

Please note that Thermo Assistance cannot guarantee payments and the
service is designed for the exclusive use of refrigerated transporters with
products manufactured by Thermo King Corporation.

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General Inquires and Unit Maintenance

For general inquiries please contact your local Thermo King dealer.

Go to www.europe.thermoking.com and select dealer locator for your local
Thermo King dealer.

Or refer to the Thermo King Service Directory for contact information.

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Customer Satisfaction Survey

Let your voice be heard!

Your feedback will help improve our manuals. The survey is accessible
through any internet-connected device with a web browser.

Scan the Quick Response (QR) code or click or type the web address http://

irco.az1.qualtrics.com/SE/?SID=SV_2octfSHoUJxsk6x to complete the

survey.

TK 61651-18-OP-EN

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Table of Contents

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . 9

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

Automatic Start/Stop Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Refrigerant Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

High Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Condenser and Evaporator Fans. . . . . . . . . . . . . . . . . . . . . . . . . 18

Remote Start of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Type Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Standard Unit Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Compressor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Standby Operation (Models 20 and 50 Only) . . . . . . . . . . . . . . . . . 27

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Pharma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Electric Standby Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Single Temperature Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Multi-Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Entering Setpoint Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Single Temperature Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Multi-Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Compartment Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Initiating the Evaporator Manual Defrost Cycle . . . . . . . . . . . . . . . 37

Initiating the Condenser Manual Defrost Cycle (reverse cycle

units only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Manual Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Auto Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Buzzers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Alarm Code Descriptions DSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Viewing Information Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Hourmeter Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Loading and Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Post-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Loading Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Electric Motor (Model 50). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

TracKing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Inspection and Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Weekly Pre-Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Weekly Pretrip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Weekly Post-Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Inspection and Service Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Service Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Warranty Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Safety Precautions

Danger, Warning, Caution, and Notice

Thermo King® recommends that all service be performed by a Thermo King
dealer and to be aware of several general safety practices.

Safety advisories appear throughout this manual as required. Your personal
safety and the proper operation of this unit depend upon the strict
observance of these precautions.

Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
could result in minor or moderate injury and unsafe practices.

Indicates a situation that could result in equipment or property­damage only accidents.

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General Safety Practices

DDAANNGGEERR

RRiisskk ooff IInnjjuurryy!!

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

WWAARRNNIINNGG

RRiisskk ooff IInnjjuurryy!!

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.

WWAARRNNIINNGG

RRiisskk ooff IInnjjuurryy!!

Temperatures above 120 degrees F (50 degrees C) can cause serious burns.
Use an infrared thermometer or other temperature measuring device
before touching any potentially hot surfaces.

CCAAUUTTIIOONN

SShhaarrpp EEddggeess!!

Exposed coil fins can cause lacerations. Service work on the evaporator or
condenser coils is best left to a certified Thermo King technician.

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Automatic Start/Stop Operation

CCAAUUTTIIOONN

RRiisskk ooff IInnjjuurryy!!

The unit can start and run automatically any time the unit is turned on. Turn
the Microprocessor On/Off switch Off before doing inspections or working
on any part of the unit. Please note that only Qualified and Certified
personnel should attempt to service your Thermo King unit.

Battery Installation and Cable Routing

WWAARRNNIINNGG

HHaazzaarrdd ooff EExxpplloossiioonn!!

An improperly installed battery could result in a fire, explosion, or injury. A
Thermo King approved battery must be installed and properly secured to
the battery tray.

WWAARRNNIINNGG

HHaazzaarrdd ooff EExxpplloossiioonn!!

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

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WWAARRNNIINNGG

FFiirree HHaazzaarrdd!!

Do not attach fuel lines to battery cables or electrical harnesses. This has
the potential to cause a fire and could cause serious injury or death.

WWAARRNNIINNGG

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!

A battery can be dangerous. A battery contains a flammable gas that can
ignite or explode. A battery stores enough electricity to burn you if it
discharges quickly. A battery contains battery acid that can burn you.
Always wear goggles or safety glasses and personal protective equipment
when working with a battery. If you get battery acid on you, immediately
flush it with water and get medical attention.

WWAARRNNIINNGG

HHaazzaarrdd ooff EExxpplloossiioonn!!

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.

CCAAUUTTIIOONN

HHaazzaarrddoouuss SSeerrvviiccee PPrroocceedduurreess!!

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.

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

Do not connect other manufacturer’s equipment or accessories to the unit
unless approved by Thermo King. Failure to do so can result in severe
damage to equipment and void the warranty.

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Refrigerant

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

DDAANNGGEERR

HHaazzaarrddoouuss GGaasseess!!

Refrigerant in the presence of an open flame, spark, or electrical short
produces toxic gases that are severe respiratory irritants which can cause
serious injury or possible death.

DDAANNGGEERR

RReeffrriiggeerraanntt VVaappoorr HHaazzaarrdd!!

Do not inhale refrigerant. Use caution when working with refrigerant or a
refrigeration system in any confined area with a limited air supply.
Refrigerant displaces air and can cause oxygen depletion, resulting in
suffocation and possible death.

WWAARRNNIINNGG

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!

Refrigerant in a liquid state evaporates rapidly when exposed to the
atmosphere, freezing anything it contacts. Wear butyl lined gloves and
other clothing and eye wear when handling refrigerant to help prevent
frostbite.

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Refrigerant Oil

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

WWAARRNNIINNGG

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!

Protect your eyes from contact with refrigerant oil. The oil can cause serious
eye injuries. Protect skin and clothing from prolonged or repeated contact
with refrigerant oil. To prevent irritation, wash your hands and clothing
thoroughly after handling the oil. Rubber gloves are recommended.

First Aid

RREEFFRRIIGGEERRAANNTT

• EEyyeess:: For contact with liquid, immediately flush eyes with large amounts
of water and get prompt medical attention.

• SSkkiinn:: Flush area with large amounts of warm water. Do not apply heat.
Remove contaminated clothing and shoes. Wrap burns with dry, sterile,
bulky dressing to protect from infection. Get prompt medical attention.
Wash contaminated clothing before reuse.

• IInnhhaallaattiioonn:: Move victim to fresh air and use Cardio Pulmonary
Resuscitation (CPR) or mouth-to-mouth resuscitation to restore
breathing, if necessary. Stay with victim until emergency personnel
arrive.

• FFrroosstt BBiittee:: In the event of frost bite , the objectives of First Aid are to
protect the frozen area from further injury, warm the affected area
rapidly, and to maintain respiration.

RREEFFRRIIGGEERRAANNTT OOIILL

• EEyyeess:: Immediately flush with large amounts of water for at least 15
minutes. Get prompt medical attention.

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

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• IInnhhaallaattiioonn:: Move victim to fresh air and use Cardio Pulmonary
Resuscitation (CPR) or mouth-to-mouth resuscitation to restore
breathing, if necessary. Stay with victim until emergency personnel
arrive.

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

EENNGGIINNEE CCOOOOLLAANNTT

• EEyyeess:: Immediately flush with large amounts of water for at least 15
minutes. Get prompt medical attention.

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

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

BBAATTTTEERRYY AACCIIDD

• EEyyeess:: Immediately flush with large amounts of water for at least 15
minutes. Get prompt medical attention. Wash skin with soap and water.

EELLEECCTTRRIICCAALL SSHHOOCCKK

Take IMMEDIATE action after a person has received an electrical shock. Get
quick medical assistance, if possible.

The source of the shock must be quickly stopped, by either shutting off the
power or removing the victim. If the power cannot be shut off, the wire
should be cut with an non-conductive tool, such as a wood-handle axe or
thickly insulated cable cutters. Rescuers should wear insulated gloves and
safety glasses, and avoid looking at wires being cut. The ensuing flash can
cause burns and blindness.

If the victim must be removed from a live circuit, pull the victim away with a
non-conductive material. Use wood, rope, a belt or coat to pull or push the
victim away from the current. DO NOT TOUCH the victim. You will receive a
shock from current flowing through the victim’s body. After separating the
victim from power source, immediately check for signs of a pulse and
respiration. If no pulse is present, start Cardio Pulmonary Resuscitation
(CPR). If a pulse is present, respiration might be restored by using mouth-to­mouth resuscitation. Call for emergency medical assistance.

AASSPPHHYYXXIIAATTIIOONN

Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or
mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with
victim until emergency personnel arrive.

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Safety Decals

Service

The Service decal is located in an appropriate location internally. This decal
gives you the information to access/download your unit operator manual,
but also the safety icons associated with your unit. These safety icons are
directly associated with the information within this chapter. You can see the
explanations for these icons starting from the beginning of this chapter.

NNoottee:: This decal only contains symbols of warning for the service of the unit.

Figure 1. Service Decal

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Operation

The Operation decal is located in an appropriate position near your in-cab
controller (HMI). This decal gives you the information to access/download
your unit operator manual and other supporting documentation and in many
supported languages.

Figure 2. Operation Decal

High Voltage

• In the control box.

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Condenser and Evaporator Fans

Be aware of the warning nameplates () in the following locations:

• On belt guard

• On rear of evaporator housing

Figure 3. Fan Warning

Remote Start of the Unit

CCAAUUTTIIOONN

RRiisskk ooff IInnjjuurryy!!

The unit can start and run automatically any time the unit is turned on. Turn
the Microprocessor On/Off switch Off before doing inspections or working
on any part of the unit. Please note that only Qualified and Certified
personnel should attempt to service your Thermo King unit.

Decals located behind service door.

18

TK 61651-18-OP-EN