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Sharp R-880S Operator`s manual

1. Suction Pressure Regulator Valve Setting T 680R T 880R T 1080R 28 to 31 psig 193 to 214 kPa 35 to 37 psig 241 to 255 kPa 21 to 23 psig 145 to 159 kPa High Pressure Cutout Switch Open Close 470 7 psig 3241 48 kPa 375 38 psig 2586 262 kPa When the compressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured This is to be sure that the same amount of oil can be added before placing the replacement compressor in the unit Scroll Compressor T 680S and T 880S T 1080S Unit Model Compressor Model TK04 Scroll 4 HP TKO6 Scroll 6 HP Refrigerant Charge T 680S and T 880S T 1080S 7 0 Ib 3 2 kg R 404A 7 5 Ib 3 4 kg R 404A Compressor Oil Charge 82 2 0 quarts 1 9 liters Specifications Refrigeration System Compressor Oil Type Ester base P N 203 516 required for Scroll compressor Discharge Pressure Regulator Valve Setting 350 5 psig 2413 34 kPa High Pressure Cutout Switch Open 470 7 psig 3241 48 kPa Close 375 38 psig 2586 262 kPa When the compressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured This is to be sure that the same amount of oil can be added before placing the replacement compressor in the unit Electrical Control System Control System Voltage 12 5 Vdc Battery Charging System 12 volt
2. THERMO KING Figure 14 T 1080S Front View T 1080R is similar 34 ARA2021 Unit Description 5 a feme e Compressor renprocaing shon a eearewoor WOR SWeN Figure 15 Main Components 35 Unit Operation SR 3 Truck HMI Controller The SR 3 Standard Truck HMI Human Machine Interface Control Panel is supplied as standard equipment on SR 3 Single Temperature Truck applications It is used to operate the unit and display some unit information The SR 3 Standard Truck HMI Control Panel communicates with the base controller via the CAN Controller Area Network bus It is connected to the base controller via CAN Connector J14 on the interface board The SR 3 Standard Truck HMI Control Panel is typically located in the vehicle driver s compartment It may be located in the truck dashboard using a DIN mounting ring or under the dashboard using an under dash mounting kit Ei THERMO KING Ao Figure 16 SR 3 Truck HMI Controller 36 e The SR 3 Standard Truck HMI Control Panel consists of a display and nine touch sensitive keys e The display is capable of showing numbers and lighting several icons It does not display text thereby making it suitable for use with any language e Amber indicator LED s are located next to each of the four function keys below the display The LED will light when that function is active e A red indicator LED is located between the ON Key and OFF Key This indicator will g
3. 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 arrival of emergency medical personnel 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 10 Inhalation Move victim to fresh air and restore breathing if necessary Stay with victim until arrival of emergency personnel Ingestion Do not induce vomiting Immediately contact local poison control center or physician Safety Decals and Locations Fi A i SS KIZ CAUTION Cc ODRA AQAO34 Figure 1 Antifreeze Caution Attached near radiator fill cap Safety Precautions Figure 2 Belt Caution Locations vary depending on model Decals are located near areas that contain belts and fans which can cause severe injuries if hands or clothing become tangled Safety Precautions AKA99 XR CAUTION FAN ATTENTION VENTILATEUR ACHTUNG VENTILATOR ATTENZIONE VENTILATORE CUIDADO VENTILADOR 91 4815 Figure 3 Automatic Start Caution Locations vary depending on model Decals are located near areas that contain moving pa
4. If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day 7 Check Engine Report alarm at end of Coolant Level the day 35 8 Electric Phase Reversed Check Water Valve Circuit If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day 59 Unit Operation Operator Help If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise day Unit Forced to Low Report alarm at end of 42 the day 3 Report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day 4 Unit Forced to Low Speed Modulation Hot Gas or Hot Gas Bypass Circuit 60 Operator Help If unit is shut down repair immediately Otherwise i Check AI EOW report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day Service Test or Interface Board Test timed out after 15 minutes Report alarm at end of the day Operator Help If unit is shut d
5. Also establishes a maximum defrost duration if normal circuits malfunction 97 Glossary dehydrator A device used to remove moisture from refrigerant Also called a drier discharge air temperature The temperature of air leaving the evaporator drier See dehydrator ERC Extended Remote Unit Control Door switches An option on Thermo King multi temperature units to improve temperature control when doors are opened during delivery When a compartment door is opened the refrigeration unit for that compartment may be forced to NULL defrost or some other mode Opening a compartment door may also affect the operating mode of other compartments ERC systems are connected in a variety of ways to meet customer needs ETV Electronic Throttling Valve A device used with a microprocessor to precisely control the refrigeration system evaporator The part of the refrigeration system that absorbs heat during the cooling cycle F See Fahrenheit Fahrenheit A unit of temperature measurement used in the United States Abbreviated F 98 freeze up 1 Failure of a refrigeration system to operate normally due to moisture in the refrigerant and the formation of ice at the expansion valve The expansion valve may be frozen shut or open causing improper unit operation in either case 2 The formation of a solid ice mass over the evaporator coil reducing air flow fuse An electrical safety device typically a cartridge
6. Auto Switching Unit Description Engine Compartment Components Coolant Expansion Tank The coolant level and temperature are monitored by the base controller If the coolant temperature becomes too high or the level becomes too low an alarm will occur The engine must have antifreeze protection to 30 F 34 C Check and add coolant in the expansion tank as needed CAUTION Do not remove expansion tank cap EN while the coolant is hot CAUTION Do not add Green or Blue Green coolants to cooling systems that use Red Extended Life Coolants Engine Oil Dipstick Use the engine oil dipstick to check the engine oil level 31 Unit Description Receiver Tank Sight Glass The receiver tank sight glass is used to assist in checking the amount of refrigerant in the system Compressor Oil Sight Glass The compressor oil sight glass is used to check the relative level of compressor oil in the compressor sump Unit Protection Devices High Pressure Cutout Switch HPCO This normally closed switch monitors the discharge pressure at the compressor It opens on high discharge pressure to shut the unit down to prevent damage Suction Pressure Regulator SPR This component is a mechanical control device used to limit the suction pressure to the compressor The valve controls suction pressure based on the actual system pressure Scroll compressor units The SPR is not used if the unit is equipped with an ETV Electronic Thro
7. Life Coolant except in an emergency If conventional coolant is added to Extended Life Coolant the coolant must be changed after 2 years instead of 5 years 79 Specifications Engine Continued Coolant System Capacity T 680R T 680S T 880R T 880S 4 5 quarts 4 3 liters with coolant expansion tank T 1080R T 1080S 6 5 quarts 6 2 liters with coolant expansion tank Coolant Expansion Tank Cap Pressure 15 psig 103 kPa Belt Tension Tension No on TK Gauge Frequency Gauge P N 204 1903 P N 204 427 Setting Where Applicable New Belt Field Reset New Belt Field Reset Water Pump Belt 40 40 55 Hz Engine Electric Motor Jackshaft 81 77 62 Hz Static Belt Tensioner Electric Motor Jackshaft Compressor Automatically tensioned by tensioner position See Belts in appropriate Maintenance Manual Chapter 80 Specifications Engine Clutch Engagement 600 100 RPM Dynamic Torque 66 ft lb 89 5 Nem minimum 1600 RPM Refrigeration System Reciprocating Compressor Compressor Model Unit Model T 680R and T 880R Thermo King X214 T 1080R Thermo King X426 Refrigerant Charge T 680R 8 0 Ib 3 6 kg R 404A 8 5 Ib 3 9 kg R 404A 9 0 Ib 4 1 kg R 404A Compressor Oil Charge X214 in T 680R and T 880R 3 2 quarts 3 0 liters X426 in T 1080R 4 3 quarts 4 1 liters Compressor Oil Type Ester base P N 203 513 required 81 Specifications Refrigeration System
8. Options 0 0 0 0 eee eee eee eee 26 ENQING suc otecoue taba tawes gue hels bbe d ents 1B 27 ELC Extended Life Coolant 27 GIUTCH ecto ea 2 Qe neha wate Gear idee staan ads ane 28 Reciprocating Compressor 2 28 Scroll Compressor 2002000e eee eee 28 Standard HMI Control Panel 28 CYCLE SENTRY Start Stop System 28 Defrost hcni cee aE r iE e Sed a e gets 29 Table of Contents DAS Data Acquisition System Optional 29 CargoLink Optional 00 30 Electric Standby Model 50 Units Only 30 Standard Model 50 Features 31 Optional Model 50 Features 31 Engine Compartment Components 31 Unit Protection Devices 2 32 Unit Operation 2 cece eee eee eee 36 SR 3 Truck HMI Controller 36 Controller Features 002000000e 36 Display cassis meea ets Dia grind ate a nae ree asia aces 37 Keys and LED Indicators 2 38 Turning the Unit On and Off 44 The Standard Display 000 46 Changing the Setpoint 24 46 Starting the Diesel Engine 48 Starting the Electric Motor 48 Switching from Diesel to Electric 49 Switching from Electric to Diesel 50
9. Selecting CYCLE SENTRY or Continuous Mode 52 Selecting the High Speed Lock Out Feature 53 Initiating a Manual Defrost Cycle 54 Terminating a Defrost Cycle 54 Alarm o pararet t ede Po ee ee ears 55 Alarm Code Notification 55 Displaying Alarm Codes 00 0055 55 Clearing Alarm Codes 22020005 55 Important Alarm Notes 00 0000 56 SR 3 Alarm Codes 2 20002000e eee 56 Sending a Servicewatch Data Logger Start of Trip 66 Pretrip TeSt vic exude thee det aene any eae ee 66 Pretrip Test Conditions Conditions where Pretrip Tests are not allowed 66 Pretrip Test Sequence 66 Fullk Pretrip TeSt 2 icccuege ewww eae wale ee ee 67 Engine Running Pretrip Test 67 Pretrip Test Considerations 67 Performing a Pretrip Test 004 68 Starting a Pretrip Test 68 Starting a Engine Running Pretrip Test 69 Pretrip Test Results 2 70 Pass Pretrip Test iire pii a A ee eee 70 Fail Pretrip Test with Check Alarms 70 Fail Pretrip Test with Shutdown Alarms 70 Display Brightness 0 0000 71 Checking HMI Software Revision and Serial Number 71 Electric Standby Operation 72 Electric Power Receptacle 72 Loading and Enroute In
10. The unit can be run with the doors open if the truck is backed into a refrigerated warehouse with tight door seals Perform a final check of the load temperature If the load is too hot or too cold make a final notation on the manifest CAUTION Make sure cargo is pre cooled to the proper temperature before loading The unit is designed to maintain temperature not cool an above temperature load While inspecting to see that the cargo is loaded properly make sure the evaporator inlets and outlets are not blocked Close or supervise the closing of the cargo compartment doors Make sure they are securely locked Check to make sure the unit setpoint is set at the desired temperature as listed on the manifest If the unit was stopped restart using the appropriate starting procedure outlined in this manual Repeat the after start inspection Defrost the unit 30 minutes after loading by starting a manual defrost cycle Enroute Inspections NOTE Enroute inspections are recommended every four hours for the prevention of damage to the cargo 1 Note the setpoint to make certain no one has altered the setting since picking up the load 2 Note the return air temperature reading It should be within the desired temperature range If the return air temperature reading is not within the desired temperature range it indicates one of the following a The unit has not had sufficient time to pull down the temperature Refer to lo
11. WARNING Never use starting fluid 48 When the engine is preparing to start the SR 3 Standard Truck HMI Control Panel will continue to display the Standard Display as shown in Figure 27 The preheat buzzer at the unit located on the unit Interface Board sounds during the engine pre heat and crank sequence unr Jur KOE CEOL ol C Lm 9D oY Figure 27 Standard Display Starting the Electric Motor Units equipped with the Electric Standby option only Electric motor starting is automatic in both Continuous Mode and CYCLE SENTRY Mode The motor will start as required when the unit is turned on in Standby Mode and standby power is connected CAUTION The motor may start automatically any time the unit is turned on When the motor is preparing to start the SR 3 Standard Truck HMI Control Panel will continue to show the Standard Display as shown in Figure 28 The preheat buzzer at the unit located on the unit Interface Board sounds for 20 seconds before the electric motor starts Figure 28 Standard Display Unit Operation Switching from Diesel to Electric IMPORTANT Applies to units with the Electric Standby Option only The operation of this feature can be changed using the Guarded Access Menu See the Guarded Access Unit Configuration Menu Diesel to Electric Auto Switch Enabled feature in Section 3 of this manual for details The Diesel to Electric Auto Switch Enabled feat
12. be warranted for the period of time up to the first scheduled replacement point for that part Emission Control 5 Maintenance Schedule To maintain optimum engine performance and compliance with the California ULG Rules the maintenance schedule must be adhered to Regular scheduled maintenance is the major key to engine service life and emission regulation compliance Scheduled maintenance requirements must be performed regularly See the Maintenance Schedule provided in this Operator s Manual California Emission Control System Warranty Statement Your Warranty Rights And Obligations The California Air Resources Board and Thermo King are pleased to explain the California emission control system warranty on your 1996 and later utility equipment ULG engine In California new utility equipment ULG engines must be designed built and equipped to meet the state s stringent anti smog standards Thermo King must warrant the California emission control system on your utility equipment 17 Emission Control ULG engine for the time listed below provided there has been no abuse neglect or improper maintenance of your utility equipment ULG engine Your California emission control system includes parts such as the fuel injection pump the fuel injection nozzle and the high pressure fuel line Also included are the air filter element and the fuel filter element which are covered under this California emission control syste
13. completed e The Pretrip Test will take about 20 30 minutes depending on conditions IMPORTANT The box temperature will vary during the Pretrip Test This is normal operation e When the Pretrip Test is complete or if a Shutdown Alarm occurs the amber Pretrip LED will turn off e Stopping a Pretrip Test To stop a Pretrip Test at any time press the POWER OFF Key to turn the unit off This will generate Alarm Code 28 Pretrip Abort Other alarm codes may also be generated This is normal when the Pretrip Test is halted before completion Starting a Engine Running Pretrip Test The Engine Running Pretrip Test must be started with the unit running Turn the unit on and clear all alarm codes Allow the unit to start With the unit running press and hold the PRETRIP Key for 5 seconds Unit Operation Figure 42 PRETRIP Key e A flashing Pretrip LED indicates that the Pretrip Test is being initialized When the Pretrip Test starts the Pretrip LED will glow steady amber to indicate the test is in progress The display will show the Standard Display e The Pretrip Test will take about 20 25 minutes depending on conditions IMPORTANT The box temperature will vary during the Pretrip Test This is normal operation When the Pretrip Test is complete or if a Shutdown Alarm occurs the amber Pretrip LED will turn off 69 Unit Operation Stopping a Pretrip Test To stop a Pretrip Test at any time e The amber P
14. for replacement as required maintenance or that is scheduled only for regular inspection to the effect of repair or replacement as necessary shall be warranted for the warranty period Any warranted part that is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement point for that part or component Diagnosis The owner shall not be charged for diagnostic labor which leads to the determination that a California emission control system warranted part or component is defective if the diagnostic work is performed at a Thermo King authorized service dealer Consequential Damages Thermo King is liable for damages to other engine parts or components caused by the failure of an emission control system part or component within the above stated California emission control system warranty period 19 Emission Control D What is Not Covered 1 Failures caused by abuse neglect or improper maintenance 2 Add On or Modified Parts The use of add on or modified parts can be grounds for disallowing a warranty claim Thermo King is not liable for failures of emission control system parts or components caused by the use of add on or modified parts 3 Use of fuel other than the California Title 13 CCR Section 2282 g 3 low sulfur low aromatic with a cetane number of 48 minimum will nullify this warranty E How to File a Claim Warranty claims for California em
15. has lighted indicating that Alarm Code 127 Setpoint Not Entered is set IMPORTANT If the setpoint is changed using the UP ARROW Key or DOWN ARROW Key the change must be confirmed by pressing the ENTER Key within 20 seconds of changing the setpoint e If the ENTER Key is pressed the setpoint change made with the UP ARROW Key and or DOWN ARROW Key is accepted the setpoint is changed and the display returns to the Standard Display showing the new setpoint 47 Unit Operation e Ifthe ENTER Key is not pressed within 20seconds of making a change with the UP ARROW Key and or DOWN ARROW Key the setpoint is not changed and the display returns to the Setpoint Display showing the old setpoint Alarm Code 127 Setpoint Not Entered is set and the Alarm Icon will appear on the display to indicate that the setpoint change was started but not completed Starting the Diesel Engine Diesel engine preheats and starts are automatic in both Continuous Mode and CYCLE SENTRY Mode The engine will preheat and start as required when the unit is turned on The engine pre heat and start sequence will be delayed in Cycle Sentry mode if there is no current need for the engine to run NOTE If the unit is equipped with optional Electric Standby there may be some additional prompts before the engine will start See STARTING THE ELECTRIC MOTOR on the following pages for details CAUTION The engine may start automatically any time the unit is turned on
16. 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 e They are equipped with the factory recommended tools to perform all service functions e They have factory trained and certified technicians e They have genuine Thermo King replacement parts e 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 Safety Precautions Thermo King recommends that all services be performed by a Thermo King dealer However there are several general safety practices which you should be aware of CAUTION Use extreme caution wh
17. may also be present Alarm occurs e View and record the alarm s correct as necessary clear the alarm s and repeat the Pretrip Test 70 Display Brightness The brightness of the SR 3 Standard Truck HMI Control Panel display can be adjusted to allow for changing ambient light conditions The choices available to the operator are HIGH MEDIUM and LOW To change the display brightness press and hold the ON key then press the UP ARROW Key to increase display brightness and the DOWN ARROW Key to decrease display brightness Figure 43 ON Key UP DOWN Arrow Keys Checking HMI Software Revision and Serial Number The Standard Truck HMI Control Panel serial number and software revision can be displayed if necessary Unit Operation To display the serial number and software revision press and hold the PRETRIP key for 5 seconds when the unit is turned off Figure 44 PRETRIP Key The serial number is shown at the top of the display and the software revision is shown at the bottom of the display The HMI Control Panel Serial Number shown in Figure 45 is 00212 The software revision shown below is Revision 2200 NNI I UUC A 02200 d S m A Figure 45 Software Revision and Serial Number 71 Electric Standby Operation SmartPower Model 50 units are equipped with Electric Standby This feature allows the unit to operate on electric
18. power as well as be powered by the standard diesel engine During Electric Standby operation power to the unit is supplied by an electric motor connected to a high voltage power source Check the unit for proper power source ratings WARNING Units equipped with electric standby can start at any time when the unit is connected to live electric power and the controller is turned on CAUTION Always turn the electric power supply off when handling connecting or disconnecting high voltage power cords 72 Electric Power Receptacle The electric power receptacle is used to connect the unit to an appropriate electric power source for electric standby operation Turn the unit OFF before connecting or disconnecting the power cord Figure 46 Model 50 Power Receptacle Box NOTE The Model 50 control system automatically determines if diesel or electric power is desired See Starting the Electric Motor in the Unit Operation chapter of this manual Loading and Enroute Inspections Thermo King refrigeration units are designed to maintain the required temperature for the product being carried during its time in transit Because of the unit s unique design special care is required during loading to prevent cargo spoilage Pre Loading Inspection 1 Inspect all door seals including vent doors for condition and a tight seal with no air leakage Inspect the cargo compartment inside and out for damaged or loose skin and in
19. reaches a predetermined maximum kPa Kilopascals A metric unit of pressure 1 kPa 0 01 bar 0 145 psi load 1 The product being refrigerated and transported 2 The amount of heat being removed by the refrigeration system For example a compressor is under a heavy heat load when expected to cool a very warm box Glossary LPCO Low Pressure Cut Out Switch A pressure operated switch that opens to stop unit operation when suction pressure reaches a predetermined minimum modulation An optional system that reduces load product dehydration and avoids top freeze movable bulkhead A thick insulated portable wall like device used to compartmentalize a temperature controlled truck or trailer See bulkhead Multi Temp A Thermo King truck or trailer unit capable of maintaining different set points in multiple compartments no 1 diesel fuel A grade of diesel fuel formulated to prevent jelling in low ambient temperatures no 2 diesel fuel A grade of diesel fuel formulated for moderate to warm ambient temperatures ohm An electrical unit measuring the amount of resistance opposition to the current flow in an electrical circuit pre cooling 1 To cool down an empty box temperature controlled area to the desired load temperature prior to loading 2 To cool cargo to a desired temperature before loading 99 Glossary pre heat The heating of diesel engine glow plugs prior to start up Some eng
20. set The red LED between the ON key and OFF 50 Key will glow the Alarm Icon will glow and the box temperature and setpoint displays will disappear as shown in Figure 29 Figure 29 Alarm Icon Alarm Code 91 Check Electric Ready Input will be cleared and the unit will restart automatically if power is restored Pressing the ON Key will clear Alarm Code 91 Check Electric Ready Input and turn the unit back on in Diesel Mode If unit operation is required the diesel engine will start as shown previously in STARTING THE DIESEL ENGINE THERMO KING Unit Operation Cee Cor C CY Figure 30 Press ON Key Preferred Method for Manually Switching from Electric Mode to Diesel Mode 1 Press the Standard Truck HMI Control Panel OFF Key to turn the unit off Turn off the standby power and disconnect the cord Press the Standard Truck HMI Control Panel ON Key to turn the unit on The Hourmeters display will briefly appear and then the screen will appear as shown in Figure 31 Figure 31 Display Preferred Method for Manually Switching from Electric Mode to Diesel Mode 4 Press the Standard Truck HMI Control Panel ON Key again to clear Alarm Code 91 Check Electric Ready Input and turn the unit back on in Diesel Mode IMPORTANT When the display shown in Figure 31 is present do not press the Standard Truck HMI Control Panel OFF Key to turn the unit off Press the Stan
21. the State of California to cause cancer 107 am Ingersoll Rand Ingersoll Rand s Climate Solutions sector delivers energy efficient HVACR solutions for customers globally Its world class brands include Thermo King the leader in transport temperature control and Trane a provider of energy efficient heating ventilating and air conditioning systems building and contracting services parts support and advanced controls for commercial buildings and homes 2013 Ingersoll Rand Company Printed in U S A
22. the day 65 Unit Operation Sending a ServiceWatch Data Logger Start of Trip When the unit is turned on press and hold the ENTER Key for 5 seconds to send a Start of Trip SOT marker to the unit ServiceWatch Data Logger and the optional DAS Data Logger if equipped Ej THERMO KING EC m O aN Figure 40 ENTER Key Pretrip Test A Pretrip Test verifies unit operation The PRETRIP Key allows either a Full Pretrip Test or an Engine Running Pretrip Test to be initiated by the operator 66 Pretrip Test Conditions e The current unit settings are saved and restored at the end of the Pretrip Test or if the unit is turned off and back on e The Pretrip Test can be run in either Diesel or Electric Mode e The unit will auto switch from Diesel Mode to Electric Mode or from Electric Mode to Diesel Mode during a Pretrip Test if these features are enabled and the auto switch conditions occur Conditions where Pretrip Tests are not allowed e Pretrip Tests are not allowed if any shutdown alarms are present e Pretrip tests are allowed with some Check and Log alarms present Pretrip Test Sequence Pretrip tests proceed in the order shown below Full Pretrip Test Full Pretrip Tests include all of the tests shown below Amp Checks Each electrical control component is energized and the current drawn is confirmed as within specification Engine Start The Engine will start automatically
23. 37 amp brush type Thermo King alternator Voltage Regulator Setting 13 8 to 14 4 volts 77 F 25 C NOTE Fuse F4 Bypass resistor for Prestolite Alternator must be removed for the Thermo King Alternator 83 Specifications Fuses Function Power to On Off Switch Fuel Sol Pull In Starter Circuit No Fuse All Bosch and Thermo King Alternators 2A Fuse All Prestolite Alternators Preheat Circuit Damper and High Speed Circuits 8XP Circuit Controller On Feedback to HMI 2A Power to CAN Connector J12 2A Power to CAN Connector J14 8X Power Install fuse in right position 2A Power to CAN Connector J13 8FC Circuit Remote Status Light Optional Power Alternator Sense 84 Main Fuse 2 Circuit Specifications Fuses Continued Fuse Function F25 HPCO Switch Circuit F26 Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators Install fuse F4 for units with Prestolite Alternator F10 When fuse F10 is installed in the right position the On Off keys on the HMI turn the unit on and off When fuse F10 is installed in the left position the unit will start and run without the HMI control panel Electrical Components Component Current Draw Amps Resistance at 12 5 Vdc Ohms Glow Plugs 3 Each 4 3 2 3 40 2 Fuel Solenoid Pull In Coil 35 to 45 0 2 to 0 3 Hold In Coil 0 5 24
24. Defrost If the coil temperature is below 45 F 7 C a defrost cycle is initiated RPM Check The engine RPM in high and low speed is checked during the Cool Check Cool Check The ability of the unit to cool in low speed is checked Heat Check The ability of the unit to heat in low speed is checked Report Test Results The test results are reported when the Pretrip Test is completed If the Pretrip Test fails alarm codes will exist to direct the technician to the source of the problem Unit Operation Engine Running Pretrip Test Engine Running Pretrip Tests include all of the tests shown below They do not include the Amps Check or the Engine Start tests e Defrost If the coil temperature is below 45 F 7 C a defrost cycle is initiated RPM Check The engine RPM in high and low speed is checked during the Cool Check Cool Check The ability of the unit to cool in low speed is checked e Heat Check The ability of the unit to heat in low speed is checked e Report Test Results The test results are reported when the Pretrip Test is completed If the Pretrip Test fails alarm codes will exist to direct the technician to the source of the problem Pretrip Test Considerations When performing a Pretrip Test the following issues should be considered 67 Unit Operation 68 Whenever possible run the Pretrip Test with an empty truck box If running a Pretrip Test on a truck loaded with dry car
25. F 25 to 40 C SAE 10W 40 13 to 86 F 25 to 30 C SAE 10W 30 22 to 122 F 30 to 50 C SAE 5W 40 Synthetic Below 22 F 30 C SAE OW 30 Synthetic 77 Specifications Engine Continued Engine rpm Low Speed Operation High Speed Operation 1625 25 rpm Reciprocating Compressor 2200 25 rom Scroll Compressor 2200 25 rom Engine Oil Pressure 20 to 50 psig 138 to 345 kPa in low speed 40 to 60 psig 276 to 414 kPa in high speed Intake Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Exhaust Valve Clearance 0 006 to 0 010 in 0 15 to 0 25 mm Valve Setting Temperature 70 F 21 C Fuel Injection Timing 16 1 degrees BTDC Injection Nozzle Pressure 1784 to 1929 psig 12 300 to 13 300 kPa Low Oil Pressure Switch Sensor 10 2 psig 69 14 kPa shutdown High Coolant Temperature Sensor 220 5 F 104 3 C shutdown Engine Thermostat 78 160 F 71 C Engine Continued Engine Coolant Type Specifications ELC Extended Life Coolant which is RED Use a 50 50 concentration of any of the following equivalents Chevron Dex Cool Texaco ELC Havoline Dex Cool Havoline XLC for Europe Shell Dexcool Shell Rotella Saturn General Motors Dex Cool Caterpillar ELC Detroit Diesel POWERCOOL Plus CAUTION Do not add GREEN or BLUE GREEN conventional coolant to cooling systems using RED Extended
26. REF 888888888888888888888 VOLTS 888 AMPS 888 PHASE 888 CYC 888 THERMO KING CORPORATION AQA011 Figure 52 Laminated Unit Serial Number Plate AMA833 R404A Refrigerant Type ro Figure 51 Label Locations Figure 53 Refrigerant Type Label 104 Recover Refrigerant At Thermo King we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians For additional information on regulations and technician certification programs contact your local THERMO KING dealer Emergency Cold Line If you can t get your rig rolling and you have tried the Thermo King North American Service Directory available from any Thermo King dealer to reach a dealer without success then call the Toll Free Emergency Cold Line Number 888 887 2202 The answering service at the factory will assist you in reaching a dealer to get the help you need The Cold Line is answered 24 hours a day by personnel who will do their best to get you quick service at an authorized Thermo King Dealer AMA1585 106 CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to
27. a defrost cycle The amber LED will flash while the defrost cycle is initialized and will glow during the defrost cycle The defrost cycle will terminate automatically and the amber LED will turn off when the evaporator coil temperature is greater than 52 F 11 C To manually terminate a defrost cycle turn the unit off and back on Unit Operation PRETRIP TEST Key Pressing and holding the PRETRIP TEST Key for 5 seconds will initiate either a Full Pretrip Test or Engine Running Pretrip Test so long as no alarm conditions exist If the Alarm Icon is glowing record and clear the alarms before starting the Pretrip Test Press and hold the PRETRIP TEST Key for 5 seconds If the unit is not running when the PRETRIP TEST Key is pressed the unit will perform a Full Pretrip that includes circuit amps and running system checks If the unit is running when the PRETRIP TEST Key is pressed the unit will perform the running system checks only The amber LED may flash while the Pretrip Test is initialized and will glow steady while the Pretrip Test is running When the Pretrip Test is complete the amber LED will turn off e If there are no alarm codes set when the Pretrip Test is complete the unit passed e Ifthere are alarm codes set when the Pretrip Test is complete the unit failed Check and correct the alarm conditions and repeat the test e If a shutdown alarm occurred Alarm Code 28 Pretrip Abort will be set and the unit will be shut down Check an
28. aker See amp coil A cooling or heating element made of pipe or tube formed into a helical or serpentine shape that may be equipped with thin metal fins to aid heat transfer cold curtains Flexible vinyl curtains used to reduce air exchange between the refrigerated compartment and the outside during door openings compound gauge A gauge calibrated in psig or kPa to measure pressure and in inches of mercury Kg cm2 to measure vacuum compressor The refrigeration component that compresses refrigerant vapor and creates refrigerant flow Glossary condenser An arrangement of tubing in which the vaporized and compressed refrigerant is liquefied as heat is removed cycles per second See Hertz damper door A door on the evaporator section that closes during defrost to prevent hot air from entering the refrigerated cargo compartment data logger An electronic device that monitors and stores unit operating and temperature data for later review Examples DMS DAS DRS and AccuTrac defrost The removal of accumulated ice from an evaporator coil Periodic defrost is necessary when the evaporator coil is operating below freezing Defrost is required more frequently when the air passing through the evaporator has a high moisture content defrost termination switch A component that terminates defrost operation at a specific temperature defrost timer A solid state module that initiates defrost at selected intervals
29. artPower Electric Standby Operation Model 50 Engine Block Heater Fuel Tank Hand held SR 3 Electronic Diagnostic Tool Hose Management System Quick Oil Drain Kit Rear Remote Control flushmount Remote Indicator Light Snow Cover Telematics Whisper Plus Sound Kit Top Cover System Engine Engine power for the T 680R T 680S T 880R and T 880S is provided by the TK374F a three cylinder EPA Tier 4 special clean and quiet diesel engine rated at 11 7 continuous horsepower 8 7 kW at 2200 RPM A belt drive system transfers energy to the compressor unit fans and alternator Engine power for the T 1080R and T 1080S is provided by the TK380F a three cylinder EPA Tier 4 special clean and quiet diesel engine rated at 16 2 continuous horsepower 12 1 kW at 2200 RPM A belt drive system transfers energy to the compressor unit fans and alternator ELC Extended Life Coolant The maintenance interval for ELC is five years or 12 000 hours A nameplate on the coolant expansion tank identifies units with ELC see Safety Decals and Locations The new engine coolant Texaco Extended Life Coolant is Red instead of the previous Green or Blue Green coolants Unit Description fy TEXACO e Filled with Texaco Extended Life Coolant Anti Freeze ELC Top Off with Texaco ELC or any listed below equivalents in a 50 50 concentration Havoline Extended Life Anitfreeze DEXCOOL Shell Dexcool 94040 She
30. ature inside the truck box 37 Unit Operation 38 When this icon is present the lower display is showing the current setpoint When this icon is present the upper display is showing the diesel engine run time When this icon is present the lower display is showing the electric motor run time if the unit equipped with optional ELECTRIC STANDBY When this Alarm Icon is present one or more alarm conditions have occurred If the display is not flashing any alarms are Check Alarms If the display is A N flashing on and off a shutdown alarm has occurred and the unit has been shut down Immediate action must be taken Keys and LED Indicators There are nine touch sensitive keys Some of these keys have more than one function as shown in Figure 18 OEEO ESING _ ee a r a7 Figure 18 Keys and LED Indicators Unit Operation There are amber indicator LED s located next to each of the The primary and secondary key uses are shown in the table four function keys below the display The LED will glow below If the key has more than one use the primary use is amber when that function is active shown first A red indicator LED is located between the ON Key and OFF Key at the left side of the display This indicator will glow if Alarm Code 91 Check Electric Ready Input occurs It will also light if a 15 pin Thermo King data cable is connected to the serial port on the back of the controlle
31. cted the High Speed Inhibit Timeout feature may be enabled to return the unit to normal operation after a set time period has expired This prevents unintended extended operation with high speed operation locked out The time period may be set from 15 minutes to 2 hours If a time period is set and exceeded the unit will return to normal operation with high speed operation allowed and the amber LED indicator will turn off If necessary to return to High Speed Lockout Mode press the HIGH SPEED LOCKOUT Key again The unit shown in Figure 33 has High Speed Lockout turned on Figure 33 HIGH SPEED LOCKOUT Key 53 Unit Operation Initiating a Manual Defrost Cycle Defrost cycles are usually initiated automatically based on time or demand Manual defrost may also be available Defrost is only available if the unit is running and the evaporator coil temperature is less than 45 F 7 C Other features such as door switch settings may not allow manual defrost under some conditions To initiate a manual defrost cycle press the DEFROST Key as shown in Figure 34 If conditions allow the unit will enter a defrost cycle and the amber LED next to the DEFROST Key will glow Figure 34 DEFROST Key 54 IMPORTANT During the defrost cycle the box temperature will rise toward 50 F 10 C This is normal and is caused by the defrost cycle warming the evaporator coil Since the damper door is closed during the de
32. d correct the alarm conditions and repeat the test Secondary Use When the unit is turned off press and hold this key for 5 seconds to show the HMI Control Panel Serial Number in the upper display and the HMI Control Panel Software Revision in the lower display 43 Unit Operation Turning the Unit On and Off IMPORTANT Verify the Base Controller On Off Switch is turned on before turning on the HMI Control Panel The Base Controller On Off switch is located on the outside of the control box side of the unit If the Standard Truck HMI Control Panel is turned on and the Base Controller On Off Switch is turned off the HMI display screen will flash on and off The unit is turned on by pressing the ON Key and off by pressing the OFF Key When the ON Key is pressed the display briefly shows dashes as the display initializes IMPORTANT If the display flashes on and off continuously when the ON Key is pressed check to make sure the Base Controller On Off switch is in the ON position 44 Ke CD Figure 19 Keys and LED Indicators Then the unit running time hourmeters are shown for 30 seconds The diesel engine run time hours and Diesel Icon are shown in the upper display If the optional Electric Standby Feature is installed the electric motor run time hours and Electric Icon are shown in the lower display A Full Pretrip Test is initiated from this display by pressing and ho
33. dard Truck HMI Control Panel ON Key again to clear Alarm Code 91 Check Electric Ready Input and turn the unit back on in Diesel Mode If the Standard Truck HMI Control Panel OFF Key is pressed when the display shown in Figure 31 is present the unit will turn off and the display will be blank 51 Unit Operation To restart the unit in Diesel Mode proceed as follows e Press the Standard Truck HMI Control Panel ON Key The Hourmeters display and a blinking Alarm Icon will appear e When the Hourmeters display and a blinking Alarm Icon is shown press the Standard Truck HMI Control Panel ON Key again The display will go blank but the blinking Alarm Icon will remain on and blinking e When the display goes blank and the blinking Alarm Icon is shown press the Standard Truck HMI Control Panel ON Key again The box temperature and setpoint will appear the blinking Alarm Icon will disappear and the unit will start in Diesel Mode Selecting CYCLE SENTRY or Continuous Mode When CYCLE SENTRY mode is selected the unit will start and stop automatically to maintain setpoint keep the engine warm and the battery charged When Continuous Mode is selected the unit starts automatically and runs continuously to maintain setpoint and to provide constant airflow throughout the truck box 52 CYCLE SENTRY Mode or Continuous Mode is selected by pressing the CYCLE SENTRY CONTINUOUS Key when the unit is turned on If the unit is running in C
34. de has been set they are displayed with the most recent alarm shown first Use the UP ARROW Key to scroll through the alarms Clearing Alarm Codes After the alarm situation is resolved press the ENTER Key to clear the alarm code currently being shown When all alarms have been cleared the display will show all zeros to indicate that no alarm codes exist 55 Unit Operation a aCe eos C O EAD Figure 38 ENTER Key The display will return to the Standard Display about 30 seconds after all alarms have been cleared Ba G 4OF Lu LF Figure 39 Standard Display 56 Important Alarm Notes All alarms must be viewed before any of the alarms can be cleared If an alarm will not clear it may still exist If the alarm is not corrected it will not clear or may be immediately set again Some alarms cannot be cleared using the Standard Truck HMI Control Panel These alarms must be cleared by maintenance personnel from the Maintenance or Guarded Access Menus Alarm Code 91 Check Electric Ready Input is cleared by turning the unit off and back on See SWITCHING FROM ELECTRIC TO DIESEL in this section SR 3 Alarm Codes NOTE Not all alarm codes are used with all applications Operator Help o foams Unit Operation Code Description Operator Help Operator Help Check Evaporator Manually monitor load l l lf unit is shut
35. down repair Coil Sensor temperature Report High Discharge immediately Otherwise alarm at end of the day Pressure report alarm at end of the Manually monitor load day temperature Report Manually monitor load alarm at end of the day temperature Report alarm at end of the day Check Control Manually monitor load Discharge Air Sensor temperature Report The indicated zone is not 9 alarm at end of the day 12 Sensor or Digital longer able to operate Check Control Return Air Sensor Unit Controlling on Alternate Sensor Check Ambient Air Report alarm at end of Input Shutdown and has been shut down Sensor the day Repair immediately Check Coolant Temp Report alarm at end of Sensor the day Manually monitor load Sensor Check temperature Report Check Engine RPM Report alarm at end of Sensor the day alarm at end of the day Manually monitor load If unit is shut down repair Check Glow Plugs or immediately Otherwise Aa a temperature Report p alarm at end of the day Intake Air Heater report alarm at end of the day A i 57 Unit Operation Operator Help Engine Failed to Crank High Engine Coolant Temperature Engine Failed to Start Cooling Cycle Check e Low Engine Oil 19 Pressure 58 If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shu
36. e Digital Report alarm at end of Peel ale Report alarm at end of Inputs the day the day Check Spare Digital Report alarm at end of Reminder 1 Outputs the day Engine Run Time Report alarm at end of heck Damper Motor Report alarm at end of Maintenance 37 the day Heater Output the day Reminder 2 If unit is shut down repair 122 Check Diesel Electric immediately Otherwise Total Unit Run Time Circuit report alarmatendofthe 4 Mainten rice iP alarm at end of day Reminder 2 pce 64 Operator Help 144 Autoswitch Diesel to Report alarm at end of Electric Disabled the day Loss of Controller 145 On Feedback Signal Software Version Mismatch 49 50 If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day 148 Autoswitch Electric to Report alarm at end of Diesel Disabled the day If unit is shut down repair 1 Alarm Not Identified immediately Otherwise Out of Range Low report alarm at end of the day Manually monitor load temperature Report alarm at end of the day Unit Operation Operator Help Out of Range High Check Display Return Air Sensor Check Display Discharge Air Sensor Manually monitor load temperature Report alarm at end of the day Manually monitor load temperature Report alarm at end of the day Manually monitor load temperature Report alarm at end of
37. em component that permits visual inspection of oil or refrigerant level and condition thermostat A device that controls unit modes of operation to maintain a selected box temperature top freeze When the top portion of perishable cargo is damaged by freezing temperatures discharged from the refrigeration unit This may occur near the front of the box when product is placed too close to the cold discharge air flow Vac volts alternating current An electric current that reverses direction at regularly recurring intervals Vdc volts direct current An electric current that flows in one direction only and is constant in value volts The basic measuring unit of electrical potential watt The basic measuring unit of electrical power Glossary 101 Serial Number and Refrigerant Label Locations Write the unit model and unit serial number in the spaces provided in the following Emergency Cold Line chapter This information is needed to service the unit SS Figure 48 Scroll Compressor Serial Number Figure 47 Engine Serial Number Location Location 102 Serial Number and Refrigerant Label Locations lt ae Ls ae a HE Qi tell AQA088 Figure 49 X214 Reciprocating Compressor Serial Figure 50 X426 Reciprocating Compressor Serial Number Location Number Location AQA183 103 Serial Number and Refrigerant Label Locations MODEL NO 888888888888888 B M NO 8888888888 SERIAL NO 888888888888
38. em must remain intact and receive regular prescribed maintenance Example Fuel filter replacement at required operation hour interval 3 Engine Identification Engines must be identified in a manner that will determine when they were built and what regulations they comply with The engine must be labeled with an emission control label and the engine family name both described below a AMA04 Emission control label a new label shown in Figure 7 contains important engine information IMPORTANT ENGINE INFORMATION ENGINE FAMILY DISPLACEMENT MANUFACTURE NO THIS ENGINE MEETS 1995 CALIFORNIA EMISSION REGULATIONS FOR UTILITY AND LAWN AND GARDEN EQUIPMENT ENGINES REFER TO OWNER S MANUAL FOR MAINTE NANCE SPECIFICATIONS amp ADJUSTMENTS NAME OF MANUFACTURER OF DIESEL ENGINE Figure 7 Emission Control Label Emission Control Engine Family Name as assigned by the California Air Resources Board identifies engine family group by largest displacement within an engine family and is shown in Figure 8 L ON BOARD DIAGNOSTIC CONVERTOR CATALYTIC CLASS DIESEL CONTINUOUS FUEL INJECTION ULG DISPLACEMENT ex 212 cc or 1 0 L MANUFACTURER YEAR AMAO6 Figure 8 Engine Family Name 15 Emission Control 3 1 Emission Control Labels Emission control labels are a requirement of the California ULG Rules In the event the emission control label provided on the engine is inaccessible there wil
39. en drilling holes in the unit Drilling into electrical wiring or refrigerant lines could cause a fire Never drill into structural components Al WARNING Always wear goggles or safety glasses when working with or around the refrigeration system or battery Refrigerant or battery acid can Auto matic Sta rt Sto p Operati on cause permanent damage if it comes in contact with This unit is capable of automatic operation and may start at any your eyes time without prior warning WARNING The unit may start at any time when the controller is turned on The controller display lights fans and belts at all times when the unit is operating up when the controller is turned on or when opening or closing compressor service valves Al WARNING Keep hands and loose clothing clear of WARNING Units equipped with electric standby may start at any time when the unit is connected to live WARNING Exposed coil fins can cause painful electric power and the controller is turned on lacerations Service work on the evaporator or condenser coils is best left to a certified Thermo King technician WARNING Be sure to press the OFF key to turn the controller off before opening doors or inspecting any part of the unit Safety Precautions Battery Installation and Cable Routing WARNING Improperly installed battery could result in a fire or explosion A Thermo King approved battery must be installed and properly secured to the batt
40. ery tray WARNING 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 WARNING Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire 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 Electrical Hazard CAUTION Be sure to turn off the high voltage power supply and disconnect the electric cable before working o
41. f the day Check Loader 1 Circuit Check Loader 2 Circuit Low Fuel Level High Compressor Pressure Ratio 1 1 Unit Not Configured Report alarm at end of Correctly the day If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day Check Electric Heat Circuit Multiple Alarms Can Not Run Check High Pressure Cut Out Switch 16 Check High Pressure Report alarm at end of Cut In Switch the day Auto Switch from Report alarm at end of Diesel to Electric the day Auto Switch from Report alarm at end of Electric to Diesel the day 63 Unit Operation Operator Help Operator Help If unit is shut down repair Electric Run Time Check Alternator immediately Otherwise Maintenance Excite Circuit report alarm at end of the Reminder 1 sak Electric Run Time Report alarm at end of If unit is shut down repair 131 Maintenance p 33 Report alarm at end of the day Check Liquid immediately Otherwise Reminder 2 the day Injection Circuit report alarm at end of the Total Unit Run Time da Report alarm at end of y Maintenance the da Reminder 1 y Be sure the setpoint is Controller Power On Report alarm at end of Setpoint Not Entered set to the required 34 Hours the day l l temperature 5 Check Spar
42. fd THERMO KING Operator s Manual GY Ingersoll Rand T 680R T 880R T 1080R T 680S T 880S T 1080S Series with Standard SR 3 HMI TK 55665 1 OP Rev 1 02 2015 Copyright 2013 Thermo King Corp Minneapolis MN USA 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 the information recommendations and descriptions contained in this manual and such information recommendations and descriptions 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 damage to the Thermo King unit or other 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 for 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 t
43. frost cycle this warm air is not allowed to pass into the truck box JU amp 4YOF i THERMO KING Cee Cr C C1 Figure 35 Box temperature will rise toward 50 F 10 C Terminating a Defrost Cycle The defrost cycle terminates automatically when the coil temperature is greater than or equal to 52 F 11 C or the maximum defrost timer expires Alarm code 14 Defrost Terminated by Time will generate if the maximum defrost time is exceeded When the defrost cycle is completed the amber LED next to the DEFROST Key will turn off Defrost can also be terminated by turning the unit off and back on Alarms Alarm Code Notification If an alarm condition occurs the Alarm Icon will appear on the display If the alarm is a Check Alarm the Alarm Icon will turn on but the unit will continue to run If the alarm is a Shutdown Alarm the Alarm Icon and the display will flash on and off and the unit will shut down m THERMO KING fal Figure 36 Alarm Icon Displaying Alarm Codes Alarms are displayed by simultaneously pressing and holding the ON Key and PRETRIP TEST Key The alarm display will appear as shown below The upper display shown in Figure 37 Unit Operation indicates that Alarm Code 127 Setpoint Not Entered has been set The lower display indicates that only one alarm code exists Figure 37 ON and PRETRIP TEST Keys If more than one alarm co
44. g if possible for history of load for example above temperature load properly pre cooled cargo compartment length of time on road b The unit is in defrost or has just completed defrost NOTE You can cancel defrost by turning the unit off then restarting the unit e Loading and Enroute Inspections The evaporator is plugged with frost Initiate a manual defrost cycle The defrost cycle will be automatically terminated Improper air circulation within the cargo compartment Inspect the cargo compartment if possible to determine if the evaporator fans are working and properly circulating the air Poor air circulation can be due to improper loading of the cargo or shifting of the load or the fan belt slipping WARNING The unit may START automatically AT ANY TIME while it is turned ON Make sure to turn the unit OFF before opening unit doors or inspecting any part of the unit The unit did not start automatically If the unit cranked without starting determine and correct the cause for not starting 75 Loading and Enroute Inspections 76 f The unit may have a low refrigerant charge If liquid is not showing in the unit receiver tank sight glass the refrigerant charge may be low Adding refrigerant or repairing the refrigeration system requires a competent mechanic Refer such problems to the nearest Thermo King dealer or authorized Service Center or call the Thermo King Cold Line telephone number show
45. gned 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 operation whichever comes first after date of delivery to the initial owner If an emission related part or component fails during the warranty period it will be repaired 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 Emission Control In an emergency repairs can 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 Any replacement part can be used for maintenance or repairs The owner should ensure that such parts are equivalent in design and du
46. go insure that proper airflow can occur around the load If the load restricts airflow false test results may occur Also units have high refrigeration capacity which results in rapid temperature change Sensitive dry cargo may be damaged as a result If running a Pretrip Test on a truck that has just been washed down the extremely high humidity inside the truck box may result in false test results If running a Pretrip Test on a truck loaded with sensitive cargo monitor the load temperature during the test as normal temperature control is suspended during pre trip operation Always perform Pretrip Tests with the cargo doors closed to prevent false test results Performing a Pretrip Test Starting a Pretrip Test The Full Pretrip Test must be started with the unit not running Turn the unit on and clear all alarm codes Turn the unit off Turn the unit on and wait for the unit running time hourmeters to be shown on the display When the unit running time hourmeters are shown on the display press and hold the PRETRIP Key for 5 seconds CH G83 8 ON G am a bd ane a Ga CLO E Figure 41 Pretrip Test e A flashing Pretrip LED indicates that the Pretrip Test is being initialized When the Pretrip Test starts the Pretrip LED will glow steady amber The display will show the Standard Display e The Amps Check Test will be preformed and then the unit will start automatically The balance of the tests will be
47. he procedures described herein correctly or to follow caution and safety decals located on the Thermo King unit Table of Contents Introduction 00 eee eee eee eee 6 Safety Precautions 2000 eee seen eee 7 Automatic Start Stop Operation 7 Battery Installation and Cable Routing 8 Electrical Hazard 200200 cece eee 9 Refrigerant 0 eee eee ees 9 Refrigerant Oil 2 eee eee 9 First Aid ea ei ee ke a ee i 10 First Aid Refrigerant 004 10 First Aid Refrigerant Oil 10 Safety Decals and Locations 11 SmartPower Units Electric Standby 13 Emission Control 00cee eee eens 14 California Emission Control System Warranty Statement 2202005 17 Your Warranty Rights And Obligations 17 Manufacturer s Warranty Coverage 18 Owner s Warranty Responsibilities 18 Manufacturer Explanation Of Emission Control System Warranty Coverage 19 EPA Emission Control System Warranty Statement 21 Responsibilities 0 0 0 0 00000 22 Thermo King Corporation Responsibilities 22 Owner Responsibilities 22 Limitations 25 a0 he a Re 23 Unit Description cee eee eee 24 General Description 00 0000 a ee 24 Design Features 00 0000 cece eeeee 25 Unit
48. he cargo area The optional electric heater strips are also energized in defrost during electric standby operation Defrost can be initiated at any time the evaporator coil temperature is below 42 F 5 5 C There are two methods of defrost initiation SR 3 Microprocessor Controller The Microprocessor Controller is programmed to automatically initiate timed and forced defrost cycles The SR 3 uses temperature sensors to determine if forced defrost is required Manual Defrost Manual Defrost allows the operator to initiate a defrost cycle by pressing the DEFROST key See Initiating a Manual Defrost Cycle DAS Data Acquisition System Optional The DAS Data Acquisition System monitors and records the temperatures of up to six additional sensors The sensors are independent from the microprocessor controller and are normally located in the truck box to monitor load temperatures 29 Unit Description DAS data can be downloaded through a serial port to an IBM PC compatible computer WinTrac 4 0 or higher software is used to view and analyze the data Brief reports can be printed on a microprinter connected to the serial port CargoLink Optional CargoLink is a wireless sensor system The main components are the coordinator module interconnect harness antenna and wireless sensors The coordinator module receives information from the wireless sensors through the antenna and communicates with the contro
49. ines use an intake manifold heater rather than glow plugs pre trip inspection Checking the operation of a refrigeration system before loading psi Pounds per square inch A unit of pressure 1 psi 0 069 bar 6 89 kPa psig Pounds per Square Inch Gauge Pressure in pounds per square inch as displayed by a gauge calibrated to zero when open to the atmosphere receiver tank A refrigerant storage device included in nearly all Thermo King units refrigerant The medium of heat transfer in a refrigeration system which absorbs heat by evaporating at a low temperature and releases heat by condensing at a higher temperature refrigerant oil A special oil used to lubricate compressors in refrigeration systems remote evaporator A separate evaporator unit located in a second or third compartment of a multi temperature truck or trailer unit 100 return air bulkhead A structure metal or plastic mounted in the front of a trailer and designed to prevent restriction of return air flow to the Thermo King unit due to improper loading See bulkhead return air temperature The temperature of the air returning to the evaporator See box temperature rpm Revolutions per minute setpoint The temperature selected on a thermostat or microprocessor controller This is normally the desired box temperature short cycling When a refrigeration unit cycles between the heat and cool modes more often than normal sight glass A syst
50. ing dealer as soon as a problem exists The emission control system parts or component repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities contact a Thermo King service representative at 952 887 2337 Manufacturer Explanation Of Emission Control System Warranty Coverage A Warranty Commencement Date The California emission control system warranty period begins on the date the engine or equipment is delivered to the original retail purchaser B Length Of Coverage Thermo King warrants to the original purchaser and each subsequent purchaser that the engine emission control system is free from defects in material and workmanship that cause the failure of the warranted California emission control system part or component for a period of two years 24 months beginning on the day the utility equipment ULG engine is delivered to the original purchaser C What Is Covered 1 Repair or Replacement of Parts Repair or replacement of any California emission control system warranted part or component will be performed at no charge to the owner Emission Control at a Thermo King authorized service dealer To obtain the phone number of your nearest Thermo King authorized service dealer call the Cold Line at 952 887 2202 Warranty Period Any warranted California emission control system part or component that is not scheduled
51. ing mount snubber pre load adjustment Drain water from fuel tank and check vent Check and adjust engine speeds high and low speed Maintenance Inspection Schedule Inspect Service These Items Check condition of engine mounts Maintain year round antifreeze protection at 30 F 34 Test fuel injection nozzles at least every 3 000 hours Replace fuel return lines between fuel injection nozzles every 10 000 hours or sooner as required Change ELC red engine coolant every 5 years or 12 000 hours Units equipped with ELC have an ELC nameplate on the expansion tank Based on EPA 40 CFR Part 89 91 Maintenance Inspection Schedule Annual Inspect Service These Items 3 000 Check controller for alarms Run pretrip test Check battery voltage Inspect battery terminals and electrolyte level Inspect wire harness for damaged wires or connections Inspect alternator bearings and brushes Inspect electric motor bearings Model 50 With belt removed spin bearings by hand Listen for noise bearings roll freely 92 Maintenance Inspection Schedule 2 000 Inspect Service These Items Hours a eoo Check refrigerant level Check compressor oil level Check discharge and suction pressures Check compressor efficiency Replace dehydrator and compressor oil filter every two 2 years 93 Maintenance Inspection Schedule Annual Inspect Service These Items 3 000 Visuall
52. inserted into an electrical circuit It contains material that will melt or break when the current is increased beyond a specific value When this occurs the circuit is opened and electrical current flow is stopped fusible link An electrical safety device typically a short piece of wire inserted into an electrical circuit The wire melts or breaks when the current is increased beyond a specific value When this occurs the circuit is opened and electrical current flow is stopped HCFC Hydrochlorofluorocarbon A chlorine based refrigerant containing hydrogen chlorine fluorine and carbon Example R22 Because chlorine damages the earth s atmosphere in many countries it is illegal to release this type of refrigerant to the atmosphere HCFC refrigerants are not used in modern Thermo King units Hertz A unit of frequency equal to one cycle per second Abbreviated Hz HFC A refrigerant consisting of hydrogen fluorine and carbon Examples R134a and 404A HFC refrigerants contain no chlorine and are therefore considered safe for the environment high pressure relief valve A safety valve on the refrigeration system that allows refrigerant to escape from the system if pressure exceeds a predetermined value hp horsepower A unit of power equivalent to 746 watts or 550 foot pounds per second HPCO High Pressure Cut Out Switch A pressure operated switch that opens to stop unit operation when discharge pressure
53. ission control system parts or components are to be filed by the Thermo King authorized servicing dealer on behalf of the engine owner F Where to Get Warranty Service Warranty service or repairs shall be provided at all Thermo King authorized service dealers You can generally find dealers in the Yellow Pages of your regional telephone directory or call the customer service representative at 888 887 2202 for the location of the nearest Thermo King authorized service dealer 20 G Maintenance Replacement and Repair of Emission Control System Related Parts Any Thermo King approved replacement part can be used in the performance of any warranty maintenance or repairs on emission control system parts or components and must be provided without charge to the owner if the part is still under the California emission control system warranty e Emission Control System Warranty Parts List e Part Name e Fuel Injection Pump e Fuel injection Nozzle e High Pressure Fuel Oil Line e Air Cleaner Element e Fuel Filter Element e Air Cleaner Gasket e Air Intake Pipe Manifold e Gasket Muffler Gasket H Maintenance Statements The owner is responsible for the performance of the required maintenance as defined by Thermo King within this Operator s Manual 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 Desi
54. ission warranty period the owner is responsible for e 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 e Premium of overtime cost e Cost to investigate complaints that are not caused by defect in Thermo King material or workmanship e 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 with 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 incidental or consequential damages such as downtime or loss of engine powered equipment Emission Control 23 Unit Description Ge
55. l be a supplemental label containing the same information provided by the equipment manufacturer located in a readily accessible location shown in Figure 9 Figure 9 Emission Control Label Location 16 All engine labels and supplementary labels will contain the following information e Engine Family Name e Displacement e Manufacturer The above information along with the engine serial number will be required to obtain proper service information and correct service repair parts An example list which identifies the exhaust control system is shown in Figure 10 Engine Model Engine Family Name 3TNV70 TK 6YDXLO 85W3N 3TNV76 TK 6YDXL1 11W3N Note Design parameters to bring engine family into compliance were utilized no after treatment measures incorporated Figure 10 Exhaust Control Systems 4 Emission Control Related Parts The California ULG Rules require a manufacturing defect warranty on all emission control parts including e Fuel Injection Pump e Fuel Injection Nozzle e High Pressure Oil Line e Air Cleaner Element e Fuel Filter Element e Air Cleaner Gasket e Air Intake Pipe Manifold Gasket e Muffler Gasket The warranty period is two years and complete details are included in the section of this manual titled California Emission Control System Warranty Statement Your Warranty Rights And Obligations Tany warranted part which is scheduled for replacement as required maintenance shall
56. lding the Pretrip Key as shown later in this section Unit Operation EJ o s om 0 C7 Figure 21 Standard Display of Box temperature and Figure 20 Electric Motor Run Time Hours Setpoint and Electric Icon Pressing the OFF Key stops unit operation The unit shuts down immediately and the display goes blank To start the unit again press the ON Key When the unit is ready to run the Standard Display of box temperature and setpoint appears The box temperature and Box Temp Icon are shown in the upper display The setpoint and Setpoint Icon are shown in the lower display The box temperature shown in Figure 21 is 35 8 F 2 1 C with a 35 F 1 6 C setpoint Figure 22 ON Key 45 Unit Operation The Standard Display The Standard Display is the default display that appears if no other display function is selected The Standard Display shows the box temperature and setpoint The box temperature is that measured by the return air sensor The box temperature and Box Temperature Icon are shown in the upper display The setpoint and Setpoint Icon are shown in the lower display The box temperature in Figure 23 is 35 8 F 2 1 C with a 35 F 1 6 C setpoint Figure 23 Standard Display 46 Changing the Setpoint From the Standard Display press the UP ARROW Key and or DOWN ARROW Key until the desired setpoint is shown In Figure 24 the setp
57. ll Rotella 94041 General Motors DEXCOOL Saturn DEXCOOL Texaco Extended Life Coolant 7997 7998 16445 16447 Cat Extended Life Coolant Detroit Diesel POWERCOO Plus Do Not Mix conventional coolants and or add SCA s with Texaco ELC 91 9269 ARB108 Figure 11 ELC Extended Life Coolant Nameplate Located On Expansion ELC In Units Equipped With 27 Unit Description CAUTION Do not add Green or Blue Green coolants to cooling systems that use Red Extended Life Coolants NOTE The use of 50 50 pre mixed ELC is recommended to ensure that deionized water is being used If 100 full strength concentrate is used deionized or distilled water is recommended instead of tap water to ensure the integrity of the cooling system is maintained Clutch The centrifugal clutch engages fully at 600 100 RPM on engine operation constantly turning the compressor alternator and fans at both high and low speed The clutch isolates the engine from the belt drive system during electric standby operation on Model 50 units Reciprocating Compressor The T 680R and T 880R feature the X214 2 cylinder reciprocating compressor with 13 92 cu in 229 cc displacement The T 1080R features the X426 4 cylinder reciprocating compressor with 25 9 cu in 424 cc displacement 28 Scroll Compressor The T 680S and T 880S feature the TK04 scroll compressor The T 1080S features the TK06 scroll compressor Standard HMI Co
58. ller through the interconnect harness Currently only wireless door switches are available Other wireless sensors will be available in the future Refer to TK 55151 the Truck and Trailer Edition CargoLink Installation Manual for information about installing the CargoLink system and sensors and troubleshooting problems with the system 30 Electric Standby Model 50 Units Only The Electric Standby option allows the unit to be operated on either the diesel engine or external electric power whenever the unit is operating in the Electric mode and whenever the unit is connected to external standby power Voltages of this magnitude can be lethal Exercise extreme caution when working on the unit Al DANGER High voltage AC power is present Standard Model 50 Features The following features are standard equipment on units equipped with Electric Standby Automatic Diesel Electric Selection The unit will automatically switch to electric operation when a power cord is connected and the standby power is switched On Overload Relay The overload relay is self resetting Hot Gas Heat Hot gas heat is utilized on all units Automatic Phase Correction The control system features two motor contactors This allows correct motor rotation regardless of phase rotation on the incoming power Optional Model 50 Features The following features are available as options on units equipped with Electric Standby e Electric Heater Strips e
59. low if Alarm Code 91 Check Electric Ready Input occurs It will also glow if a 15 pin Thermo King data cable is connected to the serial port on the back of the controller DPD Controller Features e Displays Box Temperature and Setpoint in Fahrenheit or Celsius e Displays Engine Running and Motor Running Hourmeters e Changes Setpoint e Selects and Indicates CYCLE SENTRY or Continuous Mode Operation e Selects and Indicates High Speed Lock Out Operation e Initiates and Indicates a Defrost Cycle e Indicates an Alarm Condition Exists Displays and Clears Alarms e Initiates and Indicates a Pretrip Test e Sends a Start of Trip to the ServiceWatch data logger e Changes Display Brightness e Shows HMI Control Panel Serial Number and Software Revision Display The display presents information to the operator This information includes setpoint and box temperature hourmeter readings alarms and several icons as shown below All display segments and icons are shown in Figure 17 Unit Operation 2 885E ata amp GAGA amp UUES OOS Figure 17 Display The upper row of numbers can display the Box Temperature Engine Run Time Hourmeter or Alarm Code s The lower row of numbers can display the Setpoint Electric Run Time Hourmeter or Total Number of Alarms The meaning of the display icons are shown in the table below When this icon is present the upper display is showing the actual box 3 temper
60. m warranty only up to the first scheduled maintenance replacement Where a warrantable condition exists Thermo King will repair your utility equipment ULG engine with California emission control system parts or components at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage 1996 and later utility equipment ULG engines California emission control system parts and components are warranted for the period of two years 24 months If any California emission control system part or component on your utility equipment ULG engine is defective the part or component will be repaired or replaced by Thermo King 18 Owner s Warranty Responsibilities As the utility equipment ULG engine owner you are responsible for the performance of the required maintenance listed in this Operator s Manual Thermo King recommends that you retain all receipts covering maintenance on your utility equipment ULG engine but Thermo King cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance As the utility equipment ULG engine owner you should be aware that Thermo King may deny you warranty coverage if your utility equipment ULG engine or a part or component has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your utility equipment ULG engine to an authorized Thermo K
61. mp T 1080S 230 3 60 50 amps All 380 460 3 50 60 20 amps Extension Cord Size Up to 50 ft 10 gauge 75 ft 8 gauge 88 Maintenance Inspection Schedule A closely followed maintenance program will help to keep your Thermo King unit in top operating condition The following general schedule is provided to assist in monitoring that maintenance For more specific detail see the maintenance manual for your unit and to the PreTrip Inspection chapter in this manual 2 000 Annual Hours 3 000 Hours After first week of operation Check belt tension Tighten unit mounting bolts Check coolant level Check refrigerant oil level Check refrigerant level Inspect Service These Items CEN ie eee Run pretrip test see Pretrip Test in Operating Instructions Chapter eee de oC aes i Enenes Check fuel supply Check engine oil level 89 Maintenance Inspection Schedule Inspect Service These Items 90 Check condition of belts Check engine oil pressure hot on high speed Listen for unusual noises vibrations etc Check air cleaner hose for damage Inspect and clean electric fuel pump filter Dry air cleaner Replace air cleaner element at 2 000 hours or 1 year whichever occurs first Change EMI 2000 black fuel filter Change engine oil and oil filters hot Requires oil with API Rating Cl 4 or better ACEA Rating E3 for Europe and EMI 2000 bypass oil filter Check restrain
62. n on the inside back cover of this manual for referral NOTE If the temperature in the compartment is not within the desired temperature range repeat the Enroute Inspection every 30 minutes until the compartment temperature comes within the desired temperature range CAUTION Stop the unit if the compartment temperature remains outside the desired temperature range from the setpoint on two consecutive 30 minute inspections Contact the nearest Thermo King Service Center or your company office immediately Take all necessary steps to protect and maintain proper load temperature Initiate a Manual Defrost cycle after each Enroute Inspection Specifications Engine Model T 680R T 680S T 880R amp T 880S T 1080R amp T 1080S TK374F Tier 4 TK380F Tier 4 Fuel Type No 2 Diesel fuel under normal conditions No 1 Diesel fuel is acceptable cold weather fuel Oil Capacity T 680S and T 880S Crankcase amp Oil Filter T 680S and T 880S w Bypass Oil Filter T 1080R amp T 1080S Crankcase amp Oil Filter T 1080R amp T 1080S w Bypass Oil Filter 9 0 quarts 8 5 liters 10 0 quarts 9 5 liters Fill to full mark on dipstick 12 0 quarts 11 4 liters 13 0 quarts 12 3 liters Fill to full mark on dipstick Oil Type API Classification Cl 4 or better ACEA Rating E3 or better for Europe Oil Viscosity 14 F to 122 F 10 C to 50 C SAE 15W 40 Synthetic 5 to 104 F 15 to 40 C SAE 15W 40 13 to 104
63. n the unit Units with electric standby present a potential electrical hazard Refrigerant Although fluorocarbon refrigerants are classified as safe observe caution when working with refrigerants or around areas where they are being used in the servicing of your unit DANGER Fluorocarbon refrigerants may 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 Safety Precautions 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 glasses to protect eyes from refrigerant oil contact WARNING Protect skin and clothing from prolonged or repeated contact with refrigerant oil Rubber gloves are recommended WARNING Wash thoroughly immediately after FN 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
64. neral Description This manual covers the following Thermo King models e T 680R T 880R and T 1080R with reciprocating compressor e T 680S T 880S and T 1080S with scroll compressor All units are microprocessor based transport temperature control systems that use the Standard SR 3 Truck HMI microcontroller to manage system functions All units are one piece front mounted diesel powered cooling and heating systems designed for straight trucks The unit mounts on the front of a truck with the evaporator portion protruding into the box They are designed for use with chlorine free refrigerants 24 Units are offered as Model 30 or Model 50 Model 30 Cooling and hot gas heating on engine operation Model 50 Cooling and hot gas heating on engine operation and electric standby operation Electric evaporator heaters are optional Engine power for the unit is provided by a diesel engine Optional SmartPower electric standby power is provided by an electric motor A clutch on the diesel engine isolates the engine during electric standby operation The continuous monitoring function of the SR 3 microprocessor optimizes the unit s performance reducing fuel consumption and unit down time The unit has a self check feature that can be run before the daily distribution route to identify possible malfunctions The built in CYCLE SENTRY an exclusive Thermo King feature automatically starts and stops the unit according to tempera
65. nt immediately Otherwise Temperature report alarm at end of the day Restart Null Report alarm at end of the day Forced Unit Report alarm at end of Operation the day Check Discharge Report alarm at end of Pressure Sensor the day Check Suction Report alarm at end of Pressure Sensor the day N R 62 Desorption Operator Heip If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair Check Electric Ready immediately Otherwise report alarm at end of the day Sensor Grades Not Report alarm at end of Set the day If unit is shut down repair Low Compressor immediately Otherwise Suction Pressure report alarm at end of the day Check Electronic Throttling Valve Circuit Electric Overload Unit Operation Code Code Desorption Operator Heip Description Operator Heip If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day Check engine fuel level If unit is shut down repair immediately Otherwise report alarm at end of the day Check Fuel Level Report alarm at end of Sensor the day If unit is shut down repair immediately Otherwise report alarm at end of the day Close Doors Report Poor open lineout alarm at end o
66. ntrol Panel The Standard HMI Control Panel Human Machine Interface is used to operate the unit and display unit information The Control Panel is typically located in the vehicle driver s compartment and communicates with the base controller using a connection on the interface board Gj THERMO KING Am Figure 12 Standard HMI Control Panel CYCLE SENTRY Start Stop System The CYCLE SENTRY Start Stop fuel saving system provides optimum operating economy WARNING Turn the unit off by pressing the OFF key before opening doors or inspecting any part of the unit The unit can start at any time without warning if it has been turned on by pressing the ON key The CYCLE SENTRY system automatically starts the unit on microprocessor demand and shuts down the unit when all demands are satisfied The system monitors and maintains the compartment temperature the engine block temperature and battery charge levels at a point where quick easy starts are possible Defrost Frost will gradually build up on the evaporator coils as a result of normal operation Periodically this frost must be melted to prevent a loss of cooling and airflow Defrost is accomplished by passing hot refrigerant gas through the evaporator coil thus melting the frost or ice Melted frost drains out of the unit onto the ground through the drain tubes Unit Description The defrost damper closes during defrost to prevent warm air from entering t
67. oint has been increased to 40 F 4 4 C using the UP ARROW Key JICQ i J IL A 4OF M THERMO KING OJ 6s Ger CS C7 Figure 24 UP ARROW Key When the desired setpoint has been selected using the UP ARROW Key or DOWN ARROW Key the ENTER Key must be pressed to confirm and load the new setpoint e Ifthe setpoint is changed using the UP ARROW Key and DOWN ARROW Key the setpoint display will begin to flash 10 seconds after the last press of the UP ARROW or DOWN ARROW key as a reminder to press the ENTER Key e The setpoint display will flash for 10 additional seconds If at the end of this time the ENTER Key still has not been pressed to complete the setpoint change the setpoint will return to the old setpoint and Alarm Code 127 Setpoint Not Entered will be set The Alarm Icon will appear in the display THERMO KING Cee Cm C2 CY Figure 25 ENTER Key The new setpoint of 40 F 4 4 C will remain on the display after the ENTER Key has been pressed Failure to confirm the new setpoint by pressing the ENTER Key within 20 seconds of changing the setpoint will result in no setpoint change In addition Alarm Code 127 Setpoint Not Entered is set to indicate that the setpoint change was started but was not completed Unit Operation Ca a G ain Figure 26 Alarm Icon and Setpoint Notice that the setpoint has returned to the old setpoint of 35 F 1 6 C and the Alarm Icon
68. ontinuous Mode pressing this key will switch operation to CYCLE SENTRY Mode and the amber LED indicator will glow If the unit is running in CYCLE SENTRY Mode pressing this key will switch operation to Continuous Mode and the amber LED will turn off The unit shown in Figure 32 is running in CYCLE SENTRY Mode JB Ci Figure 32 CYCLE SENTRY Continuous Key B A CAUTION The engine may start automatically any time the unit is turned on CAUTION If the unit is in CYCLE SENTRY null and the mode is switched to Continuous Mode the unit will start automatically Selecting the High Speed Lock Out Feature If the High Speed Lock Out feature is enabled and turned on the unit will run only in low speed until the High Speed Lock Out feature is turned off or the High Speed Lockout Timer is exceeded This feature is typically used in noise sensitive areas to reduce unit engine noise High Speed Lock Out is turned on or off by pressing the HIGH SPEED LOCKOUT Key when the unit is turned on Pressing this key will turn High Speed Lock Out on pressing it again will turn High Speed Lockout off If High Speed Lockout is turned on unit will switch to low speed operation and the amber LED indicator will glow No further high speed operation is allowed until this feature is turned off or the High Speed Lockout Timer is exceeded Unit Operation IMPORTANT HIGH SPEED LOCKOUT TIMER If High Speed Lockout Mode is sele
69. own repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day Pretrip Reminder Report alarm at end of the day Check engine oil level If unit is shut down repair Low Engine Oil Level immediately Otherwise report alarm at end of the day Low Battery Voltage Ammeter Out of Calibration Engine Stopped Code 70 N N N D o N e N Unit Operation Desorption Operator Heip If unit is shut down repair immediately Otherwise report alarm at end of the day Internal Controller Report alarm at end of Fault Code the day HourmetetF il re Report alarm at end of the day Controller Resetto Report alarm at end of Defaults the day If unit is shut down repair immediately Otherwise report alarm at end of the day Internal Data Logger Report alarm at end of Overflow the day Check Compressor Report alarm at end of Temp Sensor the day Check Liquid Line Solenoid Circuit Controller EPROM Checksum Failure 61 Unit Operation Code Operator Help Code If unit is shut down repair High Compressor immediately Otherwise Temp report alarm at end of the day If unit is shut down repair High Compressor immediately Otherwise Temp Shutdown report alarm at end of the day If unit is shut down repair Low Engine Coola
70. r DPD ON Key Pressing the ON Key will turn the unit on Secondary Use When the unit is on pressing this key and the PRETRIP Key at the same time will display any alarm codes that are present 1 Secondary Use When the unit is on pressing and holding this key allows the UP ARROW Key and DOWN ARROW Key to increase or decrease the display brightness Secondary Use When the unit is on pressing this key will return to the Standard Display of box temperature and setpoint 39 Unit Operation Co cz 40 POWER OFF Key Pressing the OFF Key will turn the unit off UP ARROW Key When the unit is turned on and the Standard Display is shown pressing the UP ARROW Key will increase the setpoint Secondary Use When alarms are being displayed pressing this key will scroll thru the alarms if more than one alarm is present Secondary Use While holding ON Key down with the unit turned on pressing this key will increase the display brightness Low Medium High DOWN ARROW Key When the unit is turned on and the Standard Display is shown pressing the DOWN ARROW Key will decrease the setpoint Secondary Use While holding ON Key down with the unit turned on pressing this key will decrease the display brightness High Medium Low Unit Operation ENTER Key If the setpoint has been changed using the UP ARROW Key and or DOWN ARROW Key pressing the ENTER Key enters the setpoint into the base controllers memo
71. rability to genuine Thermo King parts However Thermo King is not liable for parts which 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 21 Emission Control This warranty covers the following emission related parts and components e Fuel Injection System e Intake Manifold e Exhaust Manifold e 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 e New remanufactured or repaired parts or components required to correct the defect 22 NOTE Items replaced under this warranty become the property of Thermo King e Labor during normal working hours required to make the warranty repair This includes diagnosis and labor to remove and install the engine if necessary Owner Responsibilities During the em
72. retrip Test LED will turn off at the completion press the POWER OFF Key to turn the unit off This will of the test but the Alarm Icon will remain lit This generate Alarm Code 28 Pretrip Abort Other alarm codes may indicates that one or more Check Alarm conditions also be generated This is normal when the Pretrip Test is occurred during the Pretrip Test More than one alarm may halted before completion be present e View and record the alarm s correct as necessary clear Pretri p Test Results the alarm s and repeat the Pretrip Test Pass Pretrip Test Fail Pretrip Test with Shutdown Alarms e If the unit passes the Pretrip Test the amber Pretrip Test e If the unit fails the Pretrip Test with a Shutdown alarm the LED will turn off at the completion of the test and the unit Alarm Icon will appear when the alarm condition occurs will continue to run as required This signifies that the unit the unit will immediately shut down and the amber Pretrip passed the Pretrip Test Test LED will turn off e The Pretrip Test will be aborted Fail Pretrip Test with Check Alarms e Alarm Code 28 Pretrip Abort will be set along with the e Tf the unit fails the Pretrip Test with Check alarms the Shutdown Alarm that was detected This signifies that a Alarm Icon will appear when the alarm condition occurs Shutdown Alarm occurred during the Pretrip Test and that The Pretrip Test will continue to run unless a Shutdown the test was aborted Other alarms
73. rts which can cause severe injuries if hands or clothing become tangled when the unit automatically starts 12 ARA183 Figure 4 Fan Caution Locations vary depending on model Decals are located near areas that contain fans which can cause severe injuries if hands or clothing become tangled SmartPower Units Electric Standby AKBO1 Figure 5 Electrical Hazard Locations vary depending on model Typically located near power receptacle high voltage tray cover and interface board Safety Precautions Figure 6 High Voltage Caution Located near high voltage box 13 Emission Control In compliance with the California ULG Utility Lawn and Garden Rules the following information is provided 1 Selection Of Fuel Oil Use diesel fuel only 2 1 Modification To Any Engine Component Modifications to any engine component which many cause engine exhaust emission output changes are not allowed Any engine modification not in compliance with regulation will be the responsibility of the engine manufacturer dealer or customer who made the modification 2 2 Air Induction System Air induction system must remain intact and receive regular prescribed maintenance Example Air cleaner element replacement at required operation hour interval 2 3 Exhaust System Exhaust system must remain intact and cannot be modified in any manner that will further restrict exhaust flow 14 2 4 Fuel Oil System Fuel oil syst
74. ry Secondary Use When alarms are being displayed pressing this key will clear the alarm shown on the display Secondary Use When the unit is turned on press and hold this key for 5 seconds to send a Start of Trip SOT to the data logger CYCLE SENTRY Continuous Key If the unit is turned on and is in Continuous Mode pressing the CYCLE SENTRY CONTINUOUS Key will switch operation to CYCLE SENTRY Mode and the amber LED indicator will glow If the unit is running in CVCLE SENTRY Mode pressing this key will switch operation to Continuous Mode and the amber LED will turn off 41 Unit Operation 42 me HIGH SPEED LOCK OUT Key If the unit is turned on pressing the HIGH SPEED LOCK OUT Key will activate High Speed Lock Out The unit will switch to low speed operation and the amber LED indicator will glow No further high speed operation is allowed until this feature is turned off Unit may automatically return to high speed operation after a programmed time limit if timer feature is enabled This feature is typically used in noise sensitive areas to reduce unit noise NOTE The HIGH SPEED LOCK OUT Key is only used when the unit is operating in Diesel Mode The HIGH SPEED LOCK OUT Key does not have any effect in Electric Mode operation DEFROST Key If the unit is turned on pressing the DEFROST Key will initiate a manual defrost cycle if conditions allow If the evaporator coil temperature less than 45 F 7 C the unit will enter
75. ry module monitors alternator charge rate and will keep the unit running until the battery is adequately charged 96 box temperature The temperature within a temperature controlled compartment Btu british thermal unit The quantity of heat required to raise the temperature of one pound of water by one degree Fahrenheit 1 Btu 252 calories bulkhead 1 return air bulkhead A metal or plastic wall placed at the front of the box to prevent loading of product tightly against the Thermo King unit Loading too close to the unit restricts air flow and system efficiency 2 bulkhead divider A thick insulated wall used to separate compartments of a multi temperature truck or trailer calorie The amount of heat required to raise temperature of one gram of water one degree Celsius 1 calorie 0 004 Btu Celsius The metric unit of temperature measurement The preferred alternate to the term centigrade Abbreviated C centigrade See Celsius CFC Chlorofluorocarbon A chlorine based refrigerant consisting of chlorine fluorine and carbon Example R12 In many countries it is illegal to release this type of refrigerant to the atmosphere because chlorine damages the earth s atmosphere CFC refrigerants are not used in modern Thermo King units circuit breaker A thermal device that automatically interrupts an electrical circuit when the current in the circuit exceeds the predetermined amperage rating of the bre
76. spections 73 Pre Loading Inspection 0000 73 Inspecting the Load 2 2 200 005 74 Enroute Inspections 22 20 05 75 Specifications 000 cece eee 77 ENQING c04 dda eb lgetuhalog dar nak eb digeladans 77 Belt TENSION 2 h4 iandstieiaei decade ade 80 Engine Clutch 0 0 ee eee ee eee 81 Reciprocating Compressor 81 Pe esate tench a cach shone Rutt ohcich tat cud eee tice eee cet saa 82 Scroll Compressor 22 20 000 82 Electrical Control System 0004 83 FUSES jessy each eared reeled Bled eee ee eee 84 Electrical Components 2 2 05 85 T 1080R amp T 1080S Electric Motor and Overload Relay 0000s eee eee 87 Table of Contents SmartPower Electrical Standby Model 50 Units Only 87 T 680R T 680S T 880R T 880S Electric Motor and Overload Relay 00 87 Electric Heater Strips Optional 88 SmartPower Standby Power Requirements 88 Maintenance Inspection Schedule 89 Wattanty jz s c0e oseeete es deeb ep oeteee atte es 95 GlosSaly skeen S a EO A eens 96 Serial Number and Refrigerant Label Locations 102 Recover Refrigerant asuasusunnnnnnnnnn 105 Emergency Cold Line sansnnnnnnnnnn 106 CALIFORNIA Proposition 65 Warning 00e0005 107 Introduction There is nothing complicated about operating and
77. sulation Inspect the inside of the cargo compartment for damaged walls air ducts floor channels or T flooring clogged defrost drain tubes and clogged or damaged floor channels which could block the air return creating isolated areas in the load that are warmer than the desired temperature 4 Pre cool the cargo compartment Adjust the setpoint to the desired cargo temperature and allow the unit to run a minimum of 30 to 60 minutes longer if possible before loading Check to be certain the setpoint temperature is correct for the cargo Pre cooling before loading will remove residual heat and moisture from the cargo compartment and prepare it to receive the refrigerated load Pre cooling also provides a good test of the refrigeration system Make sure products are pre cooled to the proper temperature before loading Any variance should be noted on the manifest Supervise product loading to make sure that there is sufficient air space around and through the load so air flow is not restricted 73 Loading and Enroute Inspections Inspecting the Load Never assume that the product has been loaded properly Watch for and perform the following tasks It takes only a few minutes and could save you or your employer considerable time and money later on 1 74 Make sure the unit is off before opening the cargo compartment doors During operation the unit blows out refrigerated air and draws in outside air NOTE
78. t down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day Manually monitor load temperature Report alarm at end of the day Operator Help 22 23 24 25 6 Heating Cycle Check Cooling Cycle Fault Heating Cycle Fault Alternator Check Check Refrigeration Capacity Manually monitor load temperature Report alarm at end of the day The indicated zone is not longer able to operate and has been shut down The indicated zone is not longer able to operate and has been shut down If unit is shut down repair immediately Otherwise report alarm at end of the day Manually monitor load temperature Report alarm at end of the day 8 Pretrip or Self Check Report alarm at end of Abort the day Operator Help Defrost Damper Circuit Check Switch 3 Refrigeration Capacity Low Defrost Damper Stuck 29 30 31 2 Report alarm at end of Check Oil Pressure If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day If unit is shut down repair immediately Otherwise report alarm at end of the day The indicated zone is not longer able to operate and has been shut down Repair immediately Unit Operation Operator Help Check Run Relay Circuit Electric Motor Failed to Run
79. to 29 High Speed Throttle Solenoid 3 3 3 8 Damper Solenoid 5 7 2 2 85 Specifications Electrical Components Continued Component Current Draw Amps at 12 5 Vdc Resistance Ohms Condenser Inlet Solenoid CIS 1 8 6 9 Hot Gas Solenoid HGS 1 1 11 3 Purge Valve PV 1 1 11 3 Liquid Injection Solenoid LIS Scroll Compressor 1 1 only 11 3 Electronic Throttling Valve ETV if used Coil A Red EVA and Blue EVB Wires Coil B Black EVC and White EVD Wires 20 to 35 20 to 35 Starter Motor No Load Bench Test 86 Specifications SmartPower Electrical Standby Model 50 Units Only T 680R T 680S T 880R T 880S Electric Motor and Overload Relay Voltage Phase Frequency Horsepower Kilowatts Full Load Overload Relay amps Setting amps 230 3 50 6 0 4 5 17 0 19 230 3 60 7 2 5 4 19 4 22 400 3 50 6 0 4 5 9 8 11 460 3 60 7 2 5 4 9 7 11 T 1080R amp T 1080S Electric Motor and Overload Relay Voltage Phase Frequency Horsepower Kilowatts Full Load Overload Relay amps Setting amps 230 3 50 10 0 7 5 22 5 25 230 3 60 12 0 8 9 28 8 32 400 3 50 10 0 7 5 17 0 16 460 3 60 12 0 8 9 14 4 16 87 Specifications Electric Heater Strips Optional Number 3 Watts 750 watts each Resistance 71 ohms each SmartPower Standby Power Requirements Supply Circuit Breaker T 680R T 680S T 880R amp T 880S T 1080R a
80. ttling Valve ETV Scroll compressor units only This component is an electromechanical control device used to limit the suction pressure to the compressor The valve is controlled by the microprocessor controller 32 Engine Oil Pressure Switch Sensor The engine oil pressure switch sensor is located on the filter head above the bypass oil filter Engine oil pressure should rise immediately on starting If engine oil pressure drops below 10 2 psig 69 14 kPa the switch sensor signals the microprocessor to stop the engine Preheat Buzzer The preheat buzzer sounds when the CYCLE SENTRY system energizes the glow plugs This should warn anyone near the unit that the CYCLE SENTRY system is about to start the diesel engine Coolant Temperature Sensor This sensor provides an engine coolant temperature input to the microprocessor If the engine coolant temperature is too high the controller stops the unit and records an alarm Electric Motor Overload Relay Model 50 The overload relay protects the electric standby motor The overload relay opens the circuit from the contactor to the electric motor if the motor overloads for any reason and an alarm will occur The relay resets when the alarm code is cleared Fuses Sizes and functions are described in the Specifications section of this manual Unit Description ARA2022 Figure 13 T 680S Front View T 680R T 880S and T 880R are similar 33 Unit Description
81. ture demands Design Features e Microprocessor Controller SR 3 Truck e Alarm Code Display e Battery Voltage Display e Continuous System Monitoring e Coolant Temperature Display e CYCLE SENTRY Start Stop Controls e Engine and Electric Model 50 Hour Display e In Cab Remote e Smart Defrost e Symbolic Controller Interface e Unit Self Check pretrip e Aerodynamic Thermo Plastic Recyclable Injection Molded Skins with In mold Color e Air Cleaner Dry Type e Alternator 12 Volt 37 Amp e Automatic Phase Correction Model 50 Unit Description Bypass Oil Filter Coolant Expansion Tank Diesel Electric Autoswitching Model 50 Economy Mode Fahrenheit and Celsius Scales Fuel Filter Spin On Low Decibel Kit Oil Filter Full Flow Poly V Belt System with Quiet Channel Technology R 404A Chlorine free Refrigerant Robotic Welded Steel Frame with Automotive Grade 2 Coat Paint Finish X214 Compressor T 680R and T 880R X426 Compressor T 1080R TK04 Scroll 4 HP T 680S and T 880S TK06 Scroll 6 HP T 1080S ETV Electronic Throttling Valve 25 Unit Description Stainless Steel Condenser and Evaporator Hardware TK374F Tier 4 Diesel Engine T 680R T 680S T 880R and T 880S TK380F Tier 4 Diesel Engine T 1080R and T 1080S Unit Options 26 Body Mount HMI Enclosure Systems DAS Data Acquisition System Door Switch CargoLink Wireless Sensors Easy Read Thermometer Electric Evaporator Heater Sm
82. ure should be set YES on units equipped with the Standard Truck HMI Control panel Diesel to Electric Auto Switch Enabled set YES Default If this feature is set YES the unit will switch automatically from Diesel Mode to Electric Mode when standby power is connected and present Diesel to Electric Auto Switch Enabled set NO The Diesel to Electric Auto Switch Enabled feature should not be set NO on units equipped with the Standard Truck HMI Control panel 49 Unit Operation Switching from Electric to Diesel IMPORTANT Applies to units with the Electric Standby Option only The operation of this feature can be changed using the Guarded Access Menu See the Guarded Access Unit Configuration Menu Electric to Diesel Auto Switch Enabled feature Electric to Diesel Auto Switch Enabled feature set YES If this feature is set YES the unit will switch automatically from Electric Mode to Diesel Mode when standby power is removed or fails Electric to Diesel Auto Switch Enabled feature set NO Default If the unit is operating in Electric Mode and standby power is disconnected or fails the unit will not automatically switch to Diesel mode This is primarily designed to prevent unauthorized diesel engine starts when the truck is indoors or on a ferry where engine operation is strictly prohibited If the unit is operating in Electric Mode and standby power is disconnected or fails Alarm Code 91 Check Electric Ready Input will be
83. y inspect unit for fluid leaks Visually inspect unit for damaged loose or broken parts includes air ducts and bulkheads Inspect clutch for shoe and anchor bushing wear with a mirror Check bearings Inspect idlers fan shafts and jackshaft if so equipped for leakage and bearing wear Clean entire unit including condenser coils evaporator coils and defrost drains Check all unit fuel tank engine and electric motor mounting bolts brackets lines hoses etc With belt removed spin bearings by hand Listen for noise bearings roll freely 94 Warranty Terms of the Thermo King Warranty are available on request Please reference document TK 50047 for the Thermo King Self Powered Truck Unit Warranty 95 Glossary This glossary is published for informational purposes only and the information being furnished herein should not be considered as all inclusive or meant to cover all contingencies NOTE Additional terms not found in the glossary may be located in the index section of this manual accumulator A device located in the suction line to collect liquid refrigerant and meter it safety back to the compressor as gas ambient air temperature Temperature of the air surrounding an object amp Abbreviation for ampere The basic measuring unit of electrical current bar A metric unit of pressure 1 bar 100 kPa 14 5 psi Battery Sentry Part of the CYCLE SENTRY system The Battery Sent

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