E-Series Units withDirect Smart Reefer

ESeries DSR

i Preface For None


		Note

ii Introduction

This manual is published for informational purposes only. Thermo King® makes no representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King Service Department should be consulted.

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.

Thermo King’s warranty shall not apply to any equipment which has been so installed, maintained, repaired or altered as, in the manufacturer’s judgment, to affect its integrity.

Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect, special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or descriptions contained herein. 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.

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

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

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

They are equipped with the factory recommended tools to perform all service functions.
They have factory trained and certified technicians.
They have genuine Thermo King replacement parts.
The warranty on your new unit is valid only when the repair and replacement of component parts is performed by an authorized Thermo King dealer.

Copies of the approved Thermo King documentation can be found on the Thermo King iService Portal: http://iservice.thermoking.com/esa.

Software License

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

EMEA: The product includes software that is licensed under a non‐exclusive, non-sublicensable, terminable and limited license to use the software as installed on the product for its intended purpose. Any removal, reproduction, reverse engineering, or other unauthorized use of the software is strictly prohibited. Hacking the product or installing unapproved software may void the warranty. The owner or operator shall not reverse engineer, decompile, or disassemble the software, except and only to the extent that such activity is expressly permitted by applicable law notwithstanding this limitation. The product may include third party software separately licensed as specified in any documentation accompanying the product or in an about screen on a mobile application or website that interfaces with the product. You are obliged to complete the declaration for “THERMO KING EQUIPMENT SOFTWARE LICENSE AGREEMENT” before you put your unit in operation.

This is located in your language at the following location: https://www.emea-user-manuals.thermoking.com “THERMO KING EQUIPMENT SOFTWARE LICENSE AGREEMENT”.

Emergency Assistance

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

Thermo Assistance should only be contacted for breakdown and repair assistance.

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

Contact Phone Number
Unit Type
Thermostat Temperature Setting
Ambient temperature
Present Load Temperature
Probable Cause of Fault
Warranty Details of the Unit
Payment Details for the Repair

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

No payment at point of repair for customers with a ThermoKare service contract or with a guaranty of payment from their Thermo King or FRIGOBLOCK home-dealer

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

General Inquires and Unit Maintenance

For general inquiries please contact your local Thermo King and/or FRIGOBLOCK dealer.

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

Or refer to the Service Directory for contact information.

Or use a Application for mobile devices, download TK Tek-Marine or TK Controller.

Customer Satisfaction Survey Assistance/Feedback

Let your voice be heard!

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

Scan the Quick Response (QR) code or click Technical Publications EMEA Feedback to complete the survey.

Need assistance finding technical literature, to report missing content, or to provide feedback on our technical literature? Email Thermo King Americas Publications at thermokingamericaspublications@thermoking.com.

Chapter 1: Safety Precautions

1.1: Danger, Warning, Caution, and Notice

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

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

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions. The four types of advisories are defined as follows:

Danger

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

Warning

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

Caution

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

Notice

Hazard
Indicates a situation that could result in equipment or property-damage only accidents.

1.2: General Safety Practices

Danger

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

Warning

Personal Protective Equipment (PPE) Required
A battery can be dangerous. Lithium-ion batteries are potentially hazardous. The combustion gas from these batteries is toxic and can present a serious FIRE HAZARD if damaged, defective, or improperly used. A battery stores enough electricity to burn you if it discharges quickly. Always wear goggles or safety glasses and personal protective equipment when working with a battery. Do not replace the battery with any type other than the one approved by Thermo King for this unit.

Warning

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

Warning

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

Warning

Risk of Injury
This unit operates with 48 volts dc. While this voltage is not considered dangerous, the large amount of amperage available can cause severe burns if shorted or grounded. Do not wear jewelry, watches, or rings when working in on this unit because they increase the risk of shorting out electrical circuits, damaging equipment, or causing severe burns.

Caution

Sharp Edges
Exposed coil fins can cause lacerations. Service work on the evaporator or condenser coils should only be accomplished by a certified Thermo King technician.

1.3: Automatic Start/Stop Operation

Caution

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

Caution

Risk of Injury
The unit can start and run automatically any time the unit is turned on. Disconnect the Hard Stop/Disable Auto Start switch before doing inspections or working on any part of the unit. Please note that only Qualified and Certified personnel should attempt to service your Thermo King unit.

Caution

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

1.4: Battery Installation and Cable Routing

Warning

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

Warning

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

Warning

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

Conventional Batteries

Warning

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

Warning

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

AGM Batteries

Warning

Personal Protective Equipment (PPE) Required
Overcharging or over-discharging of an AGM Battery. There is a very real possibility of inducing enough heat into an AGM battery to initiate thermal runaway if the battery is charged at too high a voltage. This could cause your AGM battery to get very hot. Always wear personal protective equipment when working with a battery.

Lithium Ion Batteries

Warning

Personal Protective Equipment (PPE) Required
A battery can be dangerous. Lithium-ion batteries are potentially hazardous. The combustion gas from these batteries is toxic and can present a serious FIRE HAZARD if damaged, defective, or improperly used. A battery stores enough electricity to burn you if it discharges quickly. Always wear goggles or safety glasses and personal protective equipment when working with a battery. Do not replace the battery with any type other than the one approved by Thermo King for this unit.

Warning

Hazard of Explosion
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.

Caution

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

Notice

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

1.5: Refrigerant

Danger

Hazardous Gases - Personal Protective Equipment (PPE) Required
Refrigerant in the presence of an open flame, spark, or electrical short produces toxic gases that are severe respiratory irritants which can cause serious injury or possible death. When working with or around hazardous chemicals, ALWAYS refer to the applicable Material Data Safety Sheets (MSDS) and OSHA/GHS (Global Harmonized System of Classification and Labelling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection, and handling instructions.

Danger

Hazardous Gases
The refrigeration system is regulated by EU regulation known as "F-Gas" and /or local laws. All regulated refrigeration service procedures must be performed by a certified technician, using approved equipment and complying with all EU and local laws.

Danger

Hazardous Gases - Personal Protective Equipment (PPE) Required!
Refrigerant in the presence of an open flame, spark, or electrical short produces toxic gases that are severe respiratory irritants which can cause serious injury or possible death. When working with or around hazardous chemicals, ALWAYS refer to the applicable Material Data Safety Sheets (MSDS) and F–Gas guidelines for information on allowable personal exposure levels, proper respiratory protection, and handling instructions.

Danger

Refrigerant Vapor Hazard
Do not inhale refrigerant. Use caution when working with refrigerant or a refrigeration system in any confined area with a limited air supply. Refrigerant displaces air and can cause oxygen depletion, resulting in suffocation and possible death. When working with or around hazardous chemicals, ALWAYS refer to the applicable Material Data Safety Sheets (MSDS) and OSHA/GHS (Global Harmonized System of Classification and Labelling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection, and handling instructions.

Warning

Personal Protective Equipment (PPE) Required
Refrigerant in a liquid state evaporates rapidly when exposed to the atmosphere, freezing anything it contacts. Wear butyl lined gloves and other clothing and eye wear when handling refrigerant to help prevent frostbite. When working with or around hazardous chemicals, ALWAYS refer to the applicable Material Data Safety Sheets (MSDS) and OSHA/GHS (Global Harmonized System of Classification and Labelling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection, and handling instructions.

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

Note These hazard statements refer to servicing of the unit.

1.6: Refrigerant Oil

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

Warning

Personal Protective Equipment (PPE) Required
Protect your eyes from contact with refrigerant oil. The oil can cause serious eye injuries. Protect skin and clothing from prolonged or repeated contact with refrigerant oil. To prevent irritation, wash your hands and clothing thoroughly after handling the oil. Rubber gloves are recommended. When working with or around hazardous chemicals, ALWAYS refer to the applicable Material Data Safety Sheets (MSDS) and OSHA/GHS (Global Harmonized System of Classification and Labelling of Chemicals) guidelines for information on allowable personal exposure levels, proper respiratory protection, and handling instructions.

Important Please note that it is recommended to evacuate all passengers if a refrigerant leak is suspected. Please use your own specific company evacuation procedure.

1.7: First Aid

REFRIGERANT

Eyes: For contact with liquid, immediately flush eyes with large amounts of water and get prompt medical attention.
Skin: Flush area with large amounts of warm water. Do not apply heat. Remove contaminated clothing and shoes. Wrap burns with dry, sterile, bulky dressing to protect from infection. Get prompt medical attention. Wash contaminated clothing before reuse.
Inhalation: Move victim to fresh air and use Cardiopulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
Frost Bite: In the event of frost bite, the objectives of First Aid are to protect the frozen area from further injury, warm the affected area rapidly, and to maintain respiration.

REFRIGERANT OIL

Eyes: Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and use Cardiopulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
Ingestion: Do not induce vomiting. Immediately contact local poison control center or physician.

ENGINE COOLANT

Eyes: Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.
Ingestion: Do not induce vomiting. Immediately contact local poison control center or physician.

BATTERY ACID
Under normal usage, the Ni-MH batteries are hermetically sealed. In case of accident, perform the following instructions:

Eyes: Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention. Wash skin with soap and water.
Skin: Immediately remove contaminated clothing. Wash skin with large volumes of water, for at least 15 minutes. Wash skin with soap and water. Do not apply fatty compounds. Seek immediate medical assistance.
Inhalation: Provide fresh air. Rinse mouth and nose with water. Seek immediate medical assistance.
Ingestion: If the injured person is fully conscious: make the person drink extensive amounts of milk. Do not induce vomiting. Take the injured person immediately to a hospital.

ELECTRICAL SHOCK

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

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

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

ASPHYXIATION

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

1.8: Safety Decals

Service

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

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

Service Decal

Operation

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

Operation Decal

High Voltage

In the control box.

Located on the Compressor Drive Module - Condenser fan area

High Temperature

This decal used in evaporators ES100 with AC heaters

High Temperature Warning

Condenser and Evaporator Fans

Be aware of the warning nameplates in the following locations:

On belt guard
On rear of evaporator housing

Fan Warning

Remote Start of the Unit

Caution

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

Decals located behind service door. Decals located on the cover of the electrical box, condenser section.

Unit Auto-start Warning

Refrigerant

Refrigerant Decal is located adjacent to the service ports for charging or recovering the gas, as per the F-Gas regulation.

Refrigerant Decal is located adjacent to the service ports for charging or recovering the gas.

F Gas decal indicates that this equipment Contains fluorinated greenhouse gases.

Type Certification

UNECE R10 decal sample.

Chapter 2: Unit Description

Thermo King Vehicle Powered Truck Units are two-piece units comprised of a condenser and evaporator designed for fresh, frozen, and deep-frozen applications on small trucks and vans.

E-Series: Operated by a variable speed semi-hermetic compressor. During road operation, energy is provided by the vehicle (if available) or by TK batteries (See Options) holdover batteries. Standby mode is powered from the mains supply through AC/DC converters included in the condenser section. Defrost is accomplished by hot gas reverse cycle heating. Heat is provided by the hot gas system reverse cycle system and by the forced-convection airflow created by the fans.

V-Series: A belt driven compressor running off the vehicle’s engine operates the refrigeration system during mobile operation. Electric Standby models have a second compressor located inside the condenser. This compressor is belt driven off an electric motor when connected to an AC power source during stationary operation.

B-Series: A belt driven compressor powered by the vehicle battery. It provides constant cooling and heating capacity independent of the vehicle engine. Where electric stand-by is required, an AC motor is fitted in the condenser. The aerodynamic condenser can be roof or front mounted, depending on the vehicle body shape.

The user-friendly Direct Smart Reefer (DSR) controller makes operating your unit simple, while its modular design allows for ease of service.

E-Series Units Include:

E-200: for fresh temperature applications above or close to 0°C (32°F).
E-200 MAX: for frozen temperature applications below 0°C (32°F) and down to -25°C (-13°F).

There are three basic models for your E-Series unit:

Model 20: Cool and Defrost with both vehicle and electric standby compressor operation.
Model 50: Hot gas heat, Cool and Defrost with both vehicle and electric standby compressor operation.
MAX Spectrum: Multi-Temperature versions of the models above with the cargo area split into zones of different temperature combination settings.

E-Series Units Include:

E-100e ECO, E-100e, and E-200e: For fresh temperature applications above or close to 0°C (32°F).
E-100e MAX, E-200e MAX, and E-200e MAX Spectrum: For frozen temperature applications below 0°C (32°F) and down to -25°C (-13°F). It also supports fresh temperature conditions when flexibility is needed.

There are five basic models for your E-Series unit:

Model 10:
Cool and Defrost vehicle only.
Model 20: Cool and Defrost with both vehicle and electric standby compressor operation.
Model 30: Cool, Defrost and Heat vehicle only.
Model 50: Cool, Defrost and Heat with both vehicle and electric standby compressor operation.
MAX Spectrum 10, 20, 30, 50: Multi-Temperature versions of the models above with the cargo area split into zones of different temperature combination settings.

V-Series Units Include:

V-100, V-200, V-300, V-500, V-600,, V-800, V-1000: for fresh temperature applications above 0°C.
V-100, V-200, V-300, V-500, V-600, V-800, V-1000 MAX: for frozen temperature applications below 0°C and down to -32°C.

VX-Series Units Include:

V-400X, V-500X, V-600X: for fresh temperature applications above 0°C.
V-400X, V-500X, V-600X MAX: for frozen temperature applications below 0°C and down to -32°C.

B-Series Units Include:

B-100. B-100 ECO: for fresh temperature applications above 0°C.
B-100 MAX: for frozen temperature applications below 0°C and down to -32°C.

There are five basic models for your B-Series or V-Series unit:

Model 10: Cool and Defrost with only vehicle powered engine driven compressor operation.
Model 20: Cool and Defrost with both vehicle powered engine driven compressor operation and electric standby compressor operation.
Model 30: Hot gas heat, Cool, and Defrost with only vehicle powered engine driven compressor operation.
Model 50: Hot gas heat, Cool and Defrost with both vehicle powered engine driven compressor operation and electric standby compressor operation.
Spectrum: Multi-Temperature versions of the models above with the cargo area split into zones of different temperature combination settings.

There are five basic models for your B-Series or V-Series unit:

Model 10: Cool and Defrost with only vehicle powered engine driven compressor operation.
Model 20: Cool and Defrost with both battery or electric standby compressor operation
Model 30: Electric heat, Cool, and Defrost with only vehicle powered engine driven compressor operation.
Model 50: Electric heat, Cool, and Defrost with both battery or electric standby compressor operation.

Two add-on heat options are available:

Coolant Heat (Models 10 and 20 only).
Coolant and Electric Heat (Model 20 only).

2.1: Standard Unit Features

Condenser - Lightweight design, easy to service with automotive grade polypropylene cover.
Evaporator - Ultra slim design, aluminum construction automotive grade Acrylonitrile Butadiene Styrene (ABS) cover.
Compressor(s) - Industry-standard reciprocating compressor that delivers excellent performance in a compact size. For increased reliability and performance.
Compressor(s) - Industry-standard swash plate compressor that delivers excellent performance in a compact size. For increased reliability and performance, reciprocating compressors are also available.
Controls - User friendly Direct Smart Reefer (DSR) In-Cab controller.
Refrigerant - R-134a, R-452A or R-404A (depending on unit model).
Electric Standby
Start/Stop and Increased Idle Speed Functionality - improves the refrigeration performance during long periods of engine stops due to vehicle START/STOP activation/vehicle running in idle (eg. Traffic jam, urban distribution with high density of traffic lights,…). Needs Dealer activation and installation according to each chassis OEM's conversion manual.
TK BlueBox Lite - Requires dealer activation. It is mounted inside the condenser section.

2.2: Options

SmartPower™(Electric Standby)

Electric Standby
Hot Gas, Electric or Coolant Heating
Hot Gas
Door Switch Kit
Note Installing door switch(es) is strongly recommended if the application will use holdover mode.
DIN Adapter
Rear Cover for Roof Mount
Rear Pod Mounting (Carenage)
Discharge Muffler Kit
Snow Covers
Refrigeration Hose / Harness Covers
Roof Top Mounting Kit
TracKing®
Hold-over functionality - using extended vehicle battery to allow the user to maintain the temperature control of the compartment for a certain period when there is no alternator or stand-by power sources available. Needs Dealer activation.
TK Batteries - This option allows to get up to 2 x 1.8kWh Li-ion batteries mounted in the driver’s cabin. This will keep the refrigeration unit in operation while the vehicle is stopped and cannot be connected to shore power. This is useful to hold the cargo box temperature during the following circumstances for example: deliveries to customers, lunch breaks etc. without the need to return to base. Each battery can support the refrigeration unit operating more than 1 hour in standard conditions. This option is not compatible with using extended vehicle battery for short holdover times.
Electric Standby Plug (115 Vac, 230 Vac 1phase NOT in V800/V1000, 230 Vac 3 phase, 400 Vac 3 phase)
Electric Standby Plug (230V single phase 50Hz/60Hz or 115V single phase 60Hz options)

Note Some options are available factory installed or as a retrofit option to suit individual customer needs.

2.3: System Components

The system consists of the following main components:

2.3.1: Compressor(s)

With E-Series units, mobile operation and electric standby modes operate with a compressor driven by an DC/AC inverter a 12Vdc power intake. Power is taken from vehicle battery or auxiliary batteries in mobile operation or from shore power in electric standby.

All V-Series systems utilize an engine driven compressor and a swash plate or reciprocating compressor depending on model. Electric standby models also have an electric motor that operates a second compressor located inside the condenser.

All V-Series systems utilize an engine driven compressor and a swash plate compressor. Electric standby models also have an electric motor that operates a second compressor located inside the condenser.

All VX-Series systems utilize an engine driven compressor and a swash plate compressor. Electric standby models also have an electric motor that operates a second compressor located inside the condenser.

All B-Series units are battery driven, and therefore there is no need for a compressor in the engine department. Electric standby models however, have an electric motor that operates a reciprocating compressor located inside the condenser.

The compressor is mounted to the trucks engine and driven by the engine by a belt-drive system. The evaporator, condenser and engine driven compressor are connected with refrigeration hoses that are assembled during the installation process

E-Series units are battery driven, and therefore there is no need for a compressor in the engine section. The hermetic compressor is driven by an inverter. Power is taken from vehicle HV battery and auxiliary batteries during startup of the unit.

Compressors

1.	Swash Plate
2.	Reciprocating

Swash Plate Compressor

2.3.2: Condenser

The condenser is located on the roof of the vehicle or on the front of the cargo box. The cover can easily be removed to access the fuses or service the unit.

Condenser

Condensers, V-Series

Condensers, VX-Series

Condensers, E-Series

2.3.3: Evaporator

The evaporator is mounted on the ceiling inside the cargo box. The cover can easily be removed for service.

Evaporator

2.3.4: TK Lithium Ion Batteries (if equipped)

When TK Battery option is present, some additional components are installed in the condenser:

Smart Charger Module (SCM): converter for battery charging and discharging. The SCM has the ability to intelligently manage different power sources. It has also a Smart (dis)charging system to use with the additional battery pack.
Two DC relays (K2 and K3): for battery connection to E-200 internal DC bus.
Battery Management System (BMS): Lithium battery protection and diagnostics.

The TK battery system has two main purposes:

Gives power to the E-200 refrigeration system when the vehicle is off and the shore power is not connected. The batteries will connect automatically and will be able to run the unit for 1 hour with 1 TK battery is installed, or 2 hours with 2 TK batteries (time estimated depending the application).
Gives support to the vehicle alternator (via the SCM) when there is not enough power to charge the batteries and when a voltage drop in main vehicle battery is present.

The TK battery is charged when the unit is connected to shore power, or when the unit is running in road mode and there is enough power to charge the batteries when the unit is running.

2.3.5: Electronic Control System

Thermo King direct drive refrigeration units are composed of a condenser unit, an evaporator unit (two evaporators in multi-temperature units), a vehicle compressor (in models with electric standby there is a second compressor which is driven by an electric motor) and a control panel (HMI) witch operates the unit.

The Electronic Control System is composed of an Electronic Control Module (located inside the condenser unit), an interface Board Module, and the HMI. This HMI allows the user to operate the Thermo King refrigeration unit.

The Electronic Control System is composed of an Electronic Control Module (DSR-IV controller - located inside the condenser unit) and the HMI. This HMI allows the truck driver to operate the Thermo King refrigeration unit.

The Electronic Control System is composed of an Electronic Control Module (located inside the condenser unit) and the HMI. This HMI allows the truck driver to operate the Thermo King refrigeration unit.

HMI

2.3.6: Description

The Electronic Control System has the following characteristics:

Auto Start
Soft Start
Active Display
Lit Keypad
Total Hourmeter
Vehicle Compressor Hourmeter
Vehicle Compressor frequency depending on power available
Electric Standby Compressor Hourmeter
Low Battery Voltage Alarm
Buzzer
Unit Control without HMI
Manual or Automatic Defrost
Maintenance Warning
Return Air Temperature Sensor
Setpoint Temperature Reading
Electric Power Warning
Independent connection/disconnection of compartments in multi-temperature units

Auto Start: Should the unit stop due to a failure in the power supply, whether during on-the-road or electric standby operation, it will start up again as soon as the power supply is re-established.

Soft Start: All operation modes remain inactive for a few seconds after an Auto Start.

Active Display: The HMI display is always active and backlit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the HMI (when there is no active alarm).

Lit Keypad: The HMI keys are always lit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the HMI (when there is no active alarm). The On/Off key is always lit except when the unit is disconnected (no power), and thus indicates the presence of power in the unit.

Total Hourmeter: Total number of hours the unit is in operation.

Vehicle Compressor Hourmeter: Compressor hours in road mode.

Variable compressor frequency depending on power available: the controller will determine the optimal compressor speed in each situation depending on set-point, vehicle voltage and other parameters.

Electric Standby Compressor Hourmeter: Compressor hours in electrical standby mode.

Low Battery Voltage Alarm: Disconnects the unit when the battery voltage falls below 10.5V in 12VDC systems or below 21V in 24VDC systems.

Buzzer: It is energised when the vehicle battery and the electric power supply are connected at the same time. It is also energised if the doors are opened while the refrigeration unit is running.

Unit Control without HMI: The unit can also be operated by the Electronic Control System without the HMI, under conditions selected by the HMI before it is disconnected.

Manual or Automatic Defrost: It is possible to choose between manual or automatic defrost.

Maintenance Warning: On-screen warning of the need to carry out maintenance on the unit.

Return Air Temperature Sensor: On-screen reading of the temperature in the load compartment. In bi-temperature units, the temperature in both compartments can be read on the same screen.

Setpoint Temperature Reading: On-Screen Setpoint Temperature Reading. In bi-temperature units, the setpoint temperature of both compartments can be read on the same screen.

Electric Power Warning: On-screen warning that the unit is connected to an electric power supply.

2.3.7: Unit Controls

Warning

Risk of Injury
Never operate the unit unless you completely understand the controls; otherwise serious injury may occur.

In-cab Control Panel (HMI) Display, Keys, Symbols

1. Display	It is always active and backlit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the HMI. It normally displays the return air temperature (of both load compartments in multi-temperature units).
2. On/Off Key	This key is used to start/stop the unit. It is always lit except when the unit is disconnected (no power) and thus acts as an indicator of the presence of power in the unit.
3. Select Key	Selects prompt screens and information screens.
4. Up Key	Is used to increase the setpoint temperature.
5. Down Key	Is used to reduce the setpoint temperature.
6. Enter Key	Is used to enter a new command such as manual defrost, etc.
7. Buzzer	It is energised when the vehicle battery and the electric power supply are connected simultaneously. It is also energized if the doors are opened while the refrigeration unit is running.
8. Cool Symbol	(Thermometer with an arrow pointing downward). The unit is cooling.
9. Heat Symbol	(Thermometer with an arrow pointing upward). The unit is heating.
10. °C/°F Symbol	Indicates whether the on-screen temperature reading is in degrees Celsius (C) or degrees Fahrenheit (F). Note This icon will appear like a % sign in TK Battery charging. See (TK Batteries HMI Menu)
11. Alarm Symbol	Indicates that there is an alarm in the system.
12. Maintenance Symbol	Warns of the need to carry out maintenance to the unit.
13. Defrost Symbol	Indicates the unit is in Defrost Mode.
14. Electrical Symbol	Indicates that the unit is in Electric Standby.
15. Condenser Defrost Symbol	Indicates the condenser unit is in defrost mode (turns on at the same time as defrost symbol 13).
15. Battery Status	If the unit is connected to shorepower and this symbol is solid, this means that the TK Batteries are charged. if this symbol is blinking, this means that the E-200 is charging the TK batteries.
16. Combined Compartment Symbol	Indicates that the multi-temperature unit is working as a single temperature unit.
17. Unit Derating mode.	Indicates the compressor is running in derating mode. This means that the controller is reducing the power delivered due to a particular battery voltage. When the battery voltage rises sufficiently, this mode is disabled, and this icon will no longer appear.

2.4: Standby Operation (Models 20 and 50 Only)

Warning

Hazardous Voltage
A certified electrician should verify that the proper standby power requirements are being met before connecting to a new power source.

These units may be operated in electric standby mode by connecting the proper voltage power cable to the unit’s power receptacle mounted on the vehicle. Standby operation is used while the vehicle is stationary with the engine shutoff.

Standby Power Receptacle

2.5: Electrical System

The unit’s controls and refrigeration components operate on 12 Vdc.

Electric Standby units have a standby motor that operates on 230 Vac, taking power from vehicle battery. A transformer in the condenser unit converts the 230 Vac to 12 Vdc to operate the unit’s controls and refrigeration components.

These units have a hermetic motor-compressor. This compressor is powered from the Compressor Drive Module (CDM), which is a 12/230 VAC inverter, taking power from either or all of the following battery sources (depending on the options supplied in the unit):

Vehicle Battery
Auxiliary Battery (option)
Extended Battery in hold-over functionality (if activated)

Two AC/DC converters in the condenser unit converts the shore power supply to 12 Vdc to operate the unit’s controls and refrigeration components in stand-by mode. The unit also features START/STOP and Increased Idle Speed functionalities to enhance refrigeration performance during extended engine stops due to vehicle START/STOP activation (e.g., traffic jams, urban areas with many traffic lights). These functionalities require external vehicle support for START/STOP control and Increased idle speed adjustment. For further details, consult your Thermo King Dealer Representative.

These units have a semi-hermetic motor-compressor taking power from either of the following sources (depending on the options supplied in the unit):

Vehicle Battery
Auxiliary Battery (if installed by the vehicle manufacturer/dealer)

2.5.1: Fuses

The electrical components are protected by various fuses.

Main Power Fuse - The main power fuse is located in the vehicle’s engine compartment and is connected directly to the vehicle’s battery.
For B-Series and V-Series: This in-line fuse is non-serviceable and must only be replaced by an authorized Thermo King Dealer.
Main Power Fuse - The main power fuse is located in the vehicle’s engine compartment and is connected directly to the vehicle’s battery (or extended hold-over battery if fitted).
For E-Series: This 150 amp in-line fuse is non-serviceable and must only be replaced by an authorized Thermo King Dealer.

TK Battery Fuses - Each Battery is protected by a fuse installed inside the metal battery enclosure. If one battery is installed, the fuse must be 150A DC MEGA type. If two batteries an 80A DC MEGA type must be installed inside the metal battery enclosure. These fuses are non-serviceable and must only be replaced by an authorized Thermo King Dealer.

Smart Charger Module Fuses - Inside the electrical cabinet there are two fuses (F71 and F72) for the SCM protection, one in the input and one in the output (60A MIDI type).

BMS Supply Fuses - Two non-serviceable fuses (F84 and F8) are installed inline with the harness and located inside the electrical cabinet, protecting the BMS supply. These fuses have a 10A DC rating.

Ignition Power Fuse - The ignition power fuse is connected to the vehicle’s fused ignition system. Depending on the vehicle, the location of the fuse panel could be located inside the cab or under the hood of the vehicle.

Unit Component Fuses - These fuses are located in the condenser unit. Remove the condenser cover to access them. Depending on your model, some fuses may not be present Refer to (Electrical Control System).

V-200 V–300 Condenser, Fuses Location

V-200 V–300 SPECTRUM Condenser, Fuses Location

V-500 V–600 Condenser, Fuses Location

Note Remove the cover to access the fuses.

V-800 V–1000 Condenser, Fuses Location

Note Remove the cover to access the fuses.

VX–Series Condenser, Fuses Location

Note Make sure that the standby is not connected before the removal of the cover.

Fuse Location (condenser cover and electric box cover removed)

Fuse Location (condenser cover removed)

Chapter 3: Operating Instructions

3.1: General Operation

In truck-driven units, temperature control is based on two values: The setting (Setpoint) of the electronic thermostat and the evaporator return temperature. The difference between these two temperatures will determine the mode of operation: cool, heat, or null.

Cool: When the temperature in the load compartment is higher than the setpoint, the unit runs in cool mode to reduce the evaporator return temperature.
Heat: When the temperature in the load compartment is lower than the setpoint, the unit changes to heat mode to raise the evaporator return temperature.
Null: Once the Setpoint Temperature has been reached, and while the temperature remains between XºC/F above or below the setpoint, there is no demand for transfer of heat or cold, and the unit runs in null mode.
Defrost: After a scheduled period of time in cool mode, between 1 and 8 hours, the unit runs in this fourth mode of operation to eliminate ice that has accumulated in the evaporator or condenser coil. Defrost can be initiated automatically or manually.

Factory setting for X is 3ºC (5ºF). During unit installation, this value can be adjusted by between 1 and 5ºC (2 and 9ºF) in increments of 1ºC/F.

Units with R-134a refrigerant: Units Recommended for Fresh Cargo applications. Temperatures can be controlled from -20ºC to +22ºC (-4ºF to +71ºF) -10ºC to +22ºC (14ºF to +71ºF).

Units with R-404A /R-452A refrigerant: Temperatures can be controlled from -20ºC to +22ºC (-4ºF to +71ºF).

Address:

Sant Josep, 140-142 P.I. “El Pla”,

Sant Feliu de Llobregat,

Barcelona, Spain.

Year of manufacture: Reference Serial Plate.

Installation and commissioning are to be carried out by an authorised Thermo King Dealer in accordance with Thermo King procedures and drawings. Exceptions to this with the written authorisation of the manufacturer only.

3.2: Starting the Unit

Engine Operation

Start the vehicle.
Press the On/Off Key located in the HMI. The HMI display will be activated.
Check the setpoint and adjust if necessary.

Electric Standby Operation

Connect the external power supply to the electric power receptacle. Verify the power supply is of the correct voltage and phase for the unit.
- Hazardous Voltage
- In case of outdoor conditions, ensure that the connection is made under safe conditions.
Press the On/Off Key located in the HMI. The HMI display will be activated. The electric symbol will appear on the screen.
Check the setpoint and adjust if necessary.

Note

Regular monitoring of the unit is recommended, the frequency of this monitoring will depend on the type of cargo.
The operating mode, whether engine-driven or electric standby, is selected automatically. When the unit is connected to an electric power source, engine-driven operation is automatically blocked. If the truck engine is started up while the power cable is still connected to the electrical power source, the unit will continue to operate in electric standby mode and the buzzer will be activated.

3.3: Standard Display

This is the display that appears when the On/Off key is pressed and the unit started. It normally displays the return air temperature (of both load compartments in bi-temperature units) and the current operating mode with the appropriate symbol.

Should there be an alarm, the alarm symbol will also appear on screen.

Single Temperature Units

The example below shows 10.8ºC temperature, cool mode, and standby operation.

Multi-Temperature Units

The example below shows -10ºC temperature and cool mode in the main compartment, and 2ºC temperature and heat mode in the remote compartment. Unit running in on-the-road mode.

3.4: Entering Setpoint Temperature

The Setpoint Temperature can be quickly and easily changed.

Single Temperature Units

Press and release the Select key twice (three times for reverse cycle units), and the current Setpoint Temperature and the letters SP will appear on screen.
Press the Up or Down arrow keys to select the desired Setpoint Temperature. Each time either of these buttons is pressed and released, the Setpoint Temperature will change one degree.
Press and release the Enter key to set the setpoint or press and release the Select key to set the setpoint and return to the Standard Display.
Important If the Select key or the Enter key is not pressed within 20 seconds to select the new Setpoint Temperature, the unit will continue to run at the original Setpoint Temperature.

Multi-Temperature Units

Note Since software MSK 544.03, Thermo King has introduced a Zone Priority function which allows Spectrum units to provide cooling or heating priority for a specific zone to satisfy setpoint as soon as possible. Contact your local dealer for detailed information.

Main Load Compartment: Press and release the SELECT key twice, and the current Setpoint Temperature in the main compartment and the letters SP will appear on screen.
Press the UP or DOWN arrow keys to select the desired Setpoint Temperature. Each time either of these buttons is pressed and released, the Setpoint Temperature will change one degree.
Press and release the ENTER key to set the setpoint or press and release the SELECT key to set the setpoint and to change to the Remote Compartment Setpoint Temperature Setting Screen.
Important If the Select key or the Enter key is not pressed within 20 seconds to select the new Setpoint Temperature, the unit will continue to run at the original Setpoint Temperature.
Remote Load Compartment: The present Setpoint Temperature in the remote compartment and the letters SP2 will appear on screen.
Press the UP or DOWN arrow keys to select the desired Setpoint Temperature. Each time either of these buttons is pressed and released, the Setpoint Temperature will change one degree.
Press and release the Enter key to set the set point value or press and release the SELECTION key to set the set point and move to the CSE (Compartment Selection) screen.
Important If the Select key or the Enter key is not pressed within 20 seconds to select the new Setpoint Temperature, the unit will continue to run at the original Setpoint Temperature.

Compartment Selection

Press the key UP or DOWN to change option between the four different options available:
- 1-2: This is the standard multi-temperature setting where both compartments (zones) are active.
  - The screen shows the temperature in both compartments (zones).
- C1: Compartment 1 is active while Compartment 2 is disabled.
  - Only the temperature for compartment 1 appears on the screen, while no reading is shown for compartment 2.
- C2: Compartment 2 is active while Compartment 1 is disabled.
  - Only the temperature for compartment 2 appears on the screen, while no reading is shown for compartment 1.
- 1-1: Compartments 1 and 2 are combined to operate as a single-temperature unit; only the temperature for Compartment 1 is displayed.
  - The screen shown as that of a single-temperature unit but with the triangle symbol activated to indicate that it is a bi-temperature unit operating as a single-temperature unit.
Press and release the ENTER key to select an option or press and release the SELECTION key to select an option and return to the standard screen.
Important If the Select key or the Enter key is not pressed within 20 seconds to select the new Setpoint Temperature, the unit will continue to run at the original Setpoint Temperature.

3.5: Initiating the Evaporator Manual Defrost Cycle

Important Before initiating a manual defrost, ensure that the unit is not already in a defrost cycle. When the unit is in a defrost cycle the defrost symbol appears on screen.

Note If the unit is not running, or if the coil temperature is not below 37°F, the request for a manual defrost is ignored.

Press and release the Select key once, and the letters dEF will appear (flashing) on screen along with the present defrost condition OFF.

Display Showing Defrost Off
To activate manual defrost, press the Enter key and then the Up or Down key and the defrost condition will change to On.

Display Showing Defrost ON
Press the Select key twice to return to the Standard Display where the Defrost (dEF) symbol along with the DEFROST icons will appear when the defrost cycle begins.
Note In 380.xx software, the compartment temperature appears instead of the Defrost (dEF) symbol.

Note The defrost termination switch must be closed.

Note Press the Select key three times for multi-temperature or reverse cycle units.

Display Showing Defrost Icon
Press the Select key twice to return to the Standard Display (three times in bi-temperature units and in reverse cycle units), where the letters dEF and the DEFROST symbol will appear when the defrost cycle starts (the load compartment temperature must be lower than 0ºC).

Note The letters dEF will remain on screen for a while after returning to cool mode.
A defrost cycle terminates automatically, in accordance with the [dtt] time set at the Parameters screen. See Section 3 for a description of the [dtt] parameter.

Note The letters dEF will remain on screen for a while after returning to cool mode.

3.6: TK Batteries HMI Menu

Battery Life Display Screen showing Battery 1 @ 70.1%

This Icon represents a Percentage symbol %

HMI in Shorepower operation

When the unit is connected to shore power and is off (HMI – OFF), in the HMI appears information regarding the status of the battery, showing the messages:

UntOFF (unit Off)
bL1, bL2 (Battery life: a parameter from 0 to 100% showing the battery charge)
top right of the display an additional icon appears - The Battery Status icon:: when is flashing, the battery is charging, when is solid, the battery is fully charged.

When the unit is connected to shore power and is ON (HMI-ON), the Standard E-200 HMI display (temperatures) is shown, however in the top right of the display an additional icon appears - The Battery Status icon: when this is flashing, the battery is charging, when is solid, the battery is fully charged.

Road Mode

When the unit is OFF (HMI-OFF), and Ignition is OFF, the battery charging is not enabled.

When the unit is ON (HMI-ON), Ignition is ON, no messages regarding the battery status appear in the HMI, but the battery could be charging or discharging.

When unit is OFF (HMI-OFF), but the vehicle Ingnition is ON, the following status messages will now appear in the HMI:

UntOFF (unit Off)
bL1, bL2 (Battery life: a parameter from 0 to 100% showing the battery charge)
In this mode however, there is no Battery Status arrow like in Shorepower.

TK Hold-Over Mode

When the IGNITION is OFF and in is NOT connected to Shore Power, is possible to start the unit in HoldOver Mode, this means the power to run the E-200 will come from the TK battery.

If we press HMI –ON, a message bAThOL is shown in HMI. If we don’t do anything, the message will disappear. If we press UP arrow, the BATon message will be shown and the unit will start operation.

The HMI will show this sequence:

bAT On
Battery Life (bL1, bL2)
The standard HMI temperature menu
Automatic battery configuration shall be requested to a dealer representative for activation.

3.7: Alarms

When the unit is not operating properly, the microprocessor records the alarm code, alerts the operator by displaying the Alarm symbol and, depending on the type of alarm, shuts the unit down.

There are three alarm categories:

Manual Start

The alarm stops the unit, and only the Alarm symbol appears on screen.

Once the alarm condition has been rectified, the On/Off key must be pressed to start up again.

Press and release the Select key to display the current alarm code on screen. If there is more than one active alarm, all the alarm codes on the unit can be viewed in sequence by pressing and releasing the Select key.

Auto Start

The alarm stops the unit, the Alarm symbol appears on screen and the unit starts up automatically once the alarm condition has been rectified.

Should a P1E alarm occur (return air temperature read error alarm code) appear, --- will appear on screen together with the alarm symbol, instead of the return air temperature reading.

If it is a multi-temperature unit, the --- will appear on the screen together with the alarm symbol, instead of the main compartment return air temperature reading.

In multi-temperature units, should a P2E - return air temperature read error in the remote compartment alarm code - appear, --- will also appear on screen together with the alarm symbol, instead of the remote compartment return air temperature reading.

Buzzers

The buzzers are energized when the vehicle battery and the electrical supply are connected simultaneously (the unit continues running in Standby mode). The buzzers are also energized if the doors open, if this option is selected.

3.8: Alarm Code Descriptions

Color Code Definitions

OK TO RUN

CHECK AS SPECIFIED

TAKE IMMEDIATE ACTION

Alarm		Description
Manual Start
OL		Electric Motor Overload (Electric standby models only) - The electric motor overload relay has tripped due to excessive current draw. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
bAt		Low Battery Voltage - Check vehicle battery.
Auto Start
HP		High Pressure Alarm - The system has detected excessively high discharge pressure. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
LP		Low Pressure Alarm - The system has detected excessively low suction pressure. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
PSE		High Pressure Sensor Failure - The high pressure sensor has become faulty or disconnected. Contact your Thermo King Dealer.
tEP, tP4		Thermal Protection Alarm - If the problem persists when the unit is restarted, contact your Thermo King Dealer.
dr1, dr2		Cargo Doors Are Open (Units with door switch option only) - Check if the Doors are open. if not, then the door switches are faulty, or improper door switch configuration. Contact your Thermo King Dealer.
tCO		Control Module Overheating If the problem persists when the unit is restarted, contact your Thermo King Dealer.
SOF		Software Failure Contact your Thermo King Dealer.
P1E		Faulty Cargo Box Return Air Temperature Sensor - Faulty or disconnected return air temperature sensor. Contact your Thermo King Dealer.
P2E		Remote Cargo Box Return Air Temperature Reading Error (open circuit or short-circuit) Contact your Thermo King Dealer.
C		Communications Failure Contact your Thermo King Dealer.
H01		DSR communication lost - Communication lost to the other Electronic Control Module.
H02		HMI communication lost - Communication lost to the HMI.
H03		SCM communication lost - Communication lost to Smart Charger Module.
H04		CDM communication lost - Communication lost to Compressor Drive Module.
H0A		Low Power Mode Activation - ignition key of the vehicle is disconnected and the unit is not connected to the shore power. Operation of the unit may be inhibited but remains operational.
H0B		Sleep Mode Activation - While the unit OFF, the vehicle battery voltage dropped below a threshold. Normal operation of the controller will resume as soon as the power is restored.
H0C		Power Derating Shutdown - Low Voltage Shutdown alarm - your battery voltage has dropped below a defined level. The shutdown alarm is automatically cleared once the voltage rises over this limit once more.
H10		Internal flash erase error - Internal, System reset needed
H12		Default parameters in use - This will typically happen after a new firmware version has been loaded.
H15		eMMC erase error - An error occurred while loading parameters to the DSR-IV Controller.
H16		eMMC write error - An error occurred while loading parameters to the DSR-IV Controller or performing the datalogging process.
H17		eMMC read error - An error during powering-up when reading configuration paramenters.
H18		Flash Loading Failed - An error occurred while loading firmware to the DSR-IV Controller.
H1A		Non-Compatible SW - Indicates that one of the Electronic components contains an incorrect or out-of-date Software version.

Compressor Drive Module Alarms

H21		Phase overcurrent- Shutdown alarm
H2A		Overcurrent of DC/DC converter- Shutdown alarm
H22		Input overvoltage - Shutdown alarm
H23		Input undervoltage - Consider let the engine run to allow the alternator to charge the vehicle battery.
H24		Motor Endstage temperature too high - Shutdown alarm
H25		Motor controller communication error - Critical, Motor controller alarm
H26		Locked Rotor - Critical, Motor controller alarm
H27		Compressor start-up failure - Critical, Motor controller alarm
H28		Phase Loss - One of the phases carrying current to the Compressor Drive Module (CDM) is disconnected.
H40		CFLT activated

Battery Management Alarms

H50 to H5D		Battery internal alarm (Thermal or Voltage problem) - Shutdown alarm
H5E		Battery communications lost - Shutdown alarm
H5F		Low Battery warning. - Please connect your unit to shore power to charge the TK Battery.
H60 to H63		Battery internal alarm (internal sensors) - Shutdown alarm
H6B, H6C		Battery deeply discharged. - Please connect your unit to shore power to charge the TK Battery
H6D		BMS communication lost. - Restart the E-200.
H70 to H77		SCM Charging Condition. - Restart the E-200.
H78, H79		Over Temperature in the Power Supply Unit (Main Unit) - Let the unit cool down, then restart the E-200.
H7A. H7B		Relay Malfunction - Shutdown alarm
H7C, H7D		Batteries current imbalance warning (2 Battery Application ONLY) - Please connect E-200 to shore power to charge the TK battery.

Note Refer to the Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096 for more information about Alarm Codes and diagnosis.

Note For further information, please refer to the DSR–IV Controller Control System Operator and Diagnostic Manuals for more information about Alarm Codes and diagnosis.

Alarm	Description
Manual Start
OL	Electric Motor Overload. Unit protection system during electric standby operation.
bAt	Low Battery Voltage. Unit and battery protection system.
Auto Start
HP	High Pressure Alarm. Indicates that the refrigeration system will shut down in the event of excessively high pressure in the refrigerant circuit.
LP	Low Pressure Alarm. Indicates that the refrigeration system will shut down in the event of excessively low pressure in the refrigerant circuit.
PSE	High Pressure Sensor Failure. The high pressure sensor has become faulty or disconnected.
tEP	Electric standby motor thermal protection alarm
tP4	Power supply thermal protection alarm. Indicates that the power source thermal protection circuit has opened due to overheating of the power source or circuit failure.
dr1, dr2	Doors Open. This option must be activated.
tCO (Hot)	Electronic Control Module Overheating.
SOF	Software failure. The software in the microprocessor is corrupted.
P1E	Main or Single Cargo Box Return Air Temperature Reading Error (open circuit or short-circuit).
P2E	Remote Cargo Box Return Air Temperature Reading Error (open circuit or short-circuit).
C	Communication error between the cab control box and the ECM Electronic Control Module.

Color Code Definitions

OK TO RUN

CHECK AS SPECIFIED

TAKE IMMEDIATE ACTION

Alarm		Description
Manual Start
OL		Electric Motor Overload (Electric standby models only) - The electric motor overload relay has tripped due to excessive current draw. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
bAt		Low Battery Voltage - Check vehicle battery.
Auto Start
HP		High Pressure Alarm - The system has detected excessively high discharge pressure. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
LP		Low pressure alarm – The system has detected excessively low suction pressure and has protected the compressor from an abnormal condition. Unit operation will resume automatically once the normal suction pressure is restored, and the alarm can be cleared (see Clearing Alarm Codes). Among other reasons, this could be due to: Dirty evaporator coil – excessive ice formation. Load stacked in front of the evaporator does not allow proper air recirculation through the box. If the problem persists when the unit is restarted, contact your Thermo King dealer.
PSE		High Pressure Sensor Failure - The high pressure sensor has become faulty or disconnected. Contact your Thermo King Dealer.
tEP, tP4		Thermal Protection Alarm - If the problem persists when the unit is restarted, contect your Thermo King Dealer
dr1, dr2		Cargo Doors Are Open (Units with door switch option only) - Check if the Doors are open. if not, then the door switches are faulty, or improper door switch configuration. Contact your Thermo King Dealer.
tCO		Control Module Overheating If the problem persists when the unit is restarted, contact your Thermo King Dealer.
SOF		Software Failure Contact your Thermo King Dealer.
P1E		Faulty Cargo Box Return Air Temperature Sensor - Faulty or disconnected return air temperature sensor. Contact your Thermo King Dealer.
P2E		Remote Cargo Box Return Air Temperature Reading Error (open circuit or short-circuit) Contact your Thermo King Dealer.
C		Communications Failure Contact your Thermo King Dealer.
H01		DSR communication lost - Communication lost to the other Electronic Control Module. Contact your Thermo King Dealer.
H02		HMI communication lost - Communication lost to the HMI. Contact your Thermo King Dealer.
H03		SCM communication lost - Communication lost to Smart Charger Module. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
H04		CDM communication lost - Communication lost to Compressor Drive Module. Contact your Thermo King Dealer.
H0A		Low Power Mode Activation - ignition key of the vehicle is disconnected, and the unit is not connected to the shore power. Operation of the unit may be inhibited but remains operational. Report Alarm at the end of the day.
H0B		Sleep Mode Activation - While the unit OFF, the vehicle battery voltage dropped below a threshold. Normal operation of the controller will resume as soon as the power is restored. Report Alarm at the end of the day.
H0C		Power Derating Shutdown - Low Voltage Shutdown alarm - your battery voltage has dropped below a defined level. The shutdown alarm is automatically cleared once the voltage rises over this limit once more. Contact your Thermo King Dealer.
H10		Internal flash erase error - Internal, System reset needed Report Alarm at the end of the day.
H12		Default parameters in use - This will typically happen after a new firmware version has been loaded. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
H15		eMMC erase error - An error occurred while loading parameters to the DSR-IV Controller. Internal, System reset needed, contact your Thermo King Dealer.
H16		eMMC write error - An error occurred while loading parameters to the DSR-IV Controller or performing the datalogging process. Internal, System reset needed, contact your Thermo King Dealer.
H17		eMMC read error - An error during powering-up when reading configuration paramenters. Internal, System reset needed, contact your Thermo King Dealer.
H18		Flash Loading Failed - An error occurred while loading firmware to the DSR-IV Controller. Internal, System reset needed, contact your Thermo King Dealer.
H1A		Non-Compatible SW - Indicates that one of the electronic components contain an incorrect or out-of-date Software version. Contact your Thermo King Dealer.

Compressor Drive Module Alarms

H21		Phase overcurrent- Shutdown alarm Contact your Thermo King Dealer.
H2A		Overcurrent of DC/DC converter- Shutdown alarm Contact your Thermo King Dealer.
H22		Input overvoltage - Shutdown alarm Contact your Thermo King Dealer.
H23		Input undervoltage - Consider let the engine run to allow the alternator to charge the vehicle battery. Contact your Thermo King Dealer.
H24		Motor Endstage temperature too high - Shutdown alarm Contact your Thermo King Dealer.
H25		Motor controller communication error - Critical, Motor controller alarm Contact your Thermo King Dealer.
H26		Locked Rotor - Critical, Motor controller alarm Contact your Thermo King Dealer.
H27		Compressor start-up failure - Critical, Motor controller alarm Contact your Thermo King Dealer.
H28		Phase Loss - One of the phases carrying current to the Compressor Drive Module (CDM) is disconnected. Contact your Thermo King Dealer.
H40		CFLT activated - Repeating non-critical alarms or a threshold of Active Alarms is reached which forces the unit to shutdown for maintenance. Contact your Thermo King Dealer.

Battery Management Alarms

H50 to H5D		Battery internal alarm (Thermal or Voltage problem) - Shutdown alarm Contact your Thermo King Dealer.
H5E		Battery communications lost - Shutdown alarm Contact your Thermo King Dealer.
H5F		Low Battery warning. - Please connect your unit to shore power to charge the TK Battery. If problem persists, Contact your Thermo King Dealer.
H60 to H63		Battery internal alarm (internal sensors) - Shutdown alarm Contact your Thermo King Dealer.
H6B, H6C		Battery deeply discharged. - Please connect your unit to shore power to charge the TK Battery If problem persists, Contact your Thermo King Dealer.
H6D		BMS communication lost. - Restart the E-200. If problem persists, Contact your Thermo King Dealer.
H70 to H77		SCM Charging Condition. - Restart the E-200. If problem persists, Contact your Thermo King Dealer.
H78, H79		Over Temperature in the Power Supply Unit (Main Unit) - Let the unit cool down, then restart the unit. If problem persists, Contact your Thermo King Dealer.
H7A. H7B		Relay Malfunction - Shutdown alarm Contact your Thermo King Dealer.
H7C, H7D		Batteries current imbalance warning (2 Battery Application ONLY) - Connect the unit to shore power to charge the TK battery. If problem persists, Contact your Thermo King Dealer.

Color Code Definitions

OK TO RUN

CHECK AS SPECIFIED

TAKE IMMEDIATE ACTION

DSR Alarms

Alarm		Description
P1E		Temperature Probe 1 Fault - Shutdown alarm - Faulty or disconnected return air temperature sensor. Contact your Thermo King Dealer.
P2E		Temperature Probe 2 Fault - Shutdown alarm - Remote Cargo Box Return Air Temperature Reading Error (open circuit or short-circuit) Contact your Thermo King Dealer.
bAt		Low Battery Voltage - Shutdown alarm – Manual Start Contact your Thermo King Dealer.
HP		High Pressure Cut-out- Shutdown alarm - The system has detected excessively high discharge pressure. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
LP		Low Pressure Cut-out- Shutdown alarm The system has detected excessively low suction pressure and has protected the compressor from an abnormal condition. Unit operation will resume automatically once the normal suction pressure is restored, and the alarm can be cleared (see Clearing Alarm Codes). Among other reasons, this could be due to: Dirty evaporator coil – excessive ice formation. Load stacked in front of the evaporator does not allow proper air recirculation through the box. Contact your Thermo King Dealer.
PSE		High Pressure Sensor Failure- Shutdown alarm The high pressure sensor has become faulty or disconnected. Contact your Thermo King Dealer.
dr1		Door 1 Open- Shutdown alarm - Check if the door 1 open. if not, then the door switches are faulty, or improper door switch configuration. Contact your Thermo King Dealer.
dr2		Door 2 Open- Shutdown alarm - Check if the door 2 is open. if not, then the door switches are faulty, or improper door switch configuration. Contact your Thermo King Dealer.
SOF		Software Failure- Shutdown alarm Contact your Thermo King Dealer.
bAL		Shutdown alarm Contact your Thermo King Dealer.
tEP		Thermal Protection Alarm If the problem persists when the unit is restarted, contect your Thermo King Dealer
tP4		Thermal Protection Alarm – Indicates that the power source thermal protection circuit has opened due to overheating of the power source or circuit failure. If the problem persists when the unit is restarted, contact your Thermo King Dealer
P3E		Shutdown alarm Contact your Thermo King Dealer.
P4E		Shutdown alarm Contact your Thermo King Dealer.

Gateway Internal Alarms

Alarm		Description
Auto Start
H01		DSR3 Communication Lost - Communication lost to the other Electronic Control Module. Contact your Thermo King Dealer.
H02		HMI Communication Lost - Communication lost to the HMI. Contact your Thermo King Dealer.
H0A		Low Power Mode Activation - Ignition key of the vehicle is disconnected, and the unit is not connected to the shore power. Operation of the unit may be inhibited but remains operational. Report Alarm at the end of the day.
H0B		Sleep Mode Activation - While the unit OFF, the vehicle battery voltage dropped below a threshold. Normal operation of the controller will resume as soon as the power is restored. Report Alarm at the end of the day.
H0C		Power Derating Shutdown - Low Voltage Shutdown alarm - your battery voltage has dropped below a defined level. The shutdown alarm is automatically cleared once the voltage rises over this limit once more. Give voltage to the system.
H0D		Power Source Issue - The output voltage of the power source is lower than expected Contact your Thermo King Dealer.
H0E		RTC Lost Contact your Thermo King Dealer.
H10		Internal Flash Erase Error - Internal, System reset needed Report Alarm at the end of the day.
H11		Internal Flash write Error - Internal, System reset needed Report Alarm at the end of the day.
H12		Default Parameters in Use - This will typically happen after a new firmware version has been loaded. If the problem persists when the unit is restarted, contact your Thermo King Dealer.
H15		eMMC Erase Error - An error occurred while loading parameters to the DSR-III Controller. Internal, System reset needed, contact your Thermo King Dealer.
H16		eMMC Write Error - An error occurred while loading parameters to the DSR-III Controller or performing the datalogging process. Internal, System reset needed, contact your Thermo King Dealer.
H17		eMMC Read Error - An error during powering-up when reading configuration paramenters. Internal, System reset needed, contact your Thermo King Dealer.
H18		Flash Loading Failed - An error occurred while loading firmware to the DSR-III Controller. Internal, System reset needed, contact your Thermo King Dealer.
H19		eMMC NearlyFull Contact your Thermo King Dealer.
H1A		Non-Compatible SW - Indicates that one of the electronic components contain an incorrect or out-of-date Software version. Contact your Thermo King Dealer.
H1B		Testing Software Contact your Thermo King Dealer.

Parameters Alarms

Alarm		Description
H60		ParEr0 - Shutdown alarm - Refrigerant type does not match between GC and Ecomp. Contact your Thermo King Dealer.
H61		ParEr1 - Shutdown alarm - Displacement does not match between GC and Ecomp. Contact your Thermo King Dealer.
H62		ParEr2 - Shutdown alarm - Voltage does not match between GC and Ecomp. Contact your Thermo King Dealer.
H63		ParEr3 - Shutdown alarm - Refrigerant type does not match between GC and DSR. Contact your Thermo King Dealer.

Electric Compressor Alarms

Alarm		Description
H80		Communication Error- CEN active but no communication for more than 2 seconds Contact your Thermo King Dealer.
H81		Input Over Voltage - Shutdown alarm Contact your Thermo King Dealer.
H82		Input Under Voltage Contact your Thermo King Dealer.
H83		Over Temperature- Shutdown alarm Contact your Thermo King Dealer.
H84		Over Current- Shutdown alarm Contact your Thermo King Dealer.
H85		Phase Loss - One of the phases carrying current to the Compressor. Contact your Thermo King Dealer.
H86		Low Frequency - Running under minimum frequency for longer than 30 seconds or minimum frequency not reached in 45 seconds during the start-up. Contact your Thermo King Dealer.
H87		Start Blocked - Motor temperature higher than 70°C. Prevents the start. Contact your Thermo King Dealer.

3.9: Clearing Alarm Codes

The alarm condition in the unit must first be corrected.
After correcting the alarm condition, press and release the Select key to remove existing Alarm Codes.
If more than one alarm code is present, press the Select key to clear each alarm code individually.
The standard display will appear once the Alarm Codes have been cleared.

The alarm condition in the unit must first be corrected. See important note below. After resolving the alarm condition, press and release the Select key to remove existing Alarm codes. The Standard Display will appear once the Alarm codes have been cleared.

To Clear Alarm Codes:

Correct the cause of the alarm code.
Press the Select key to remove the alarm code.
If more than one alarm code is present, press the Select key to clear each alarm code individually.

Important Continually clearing alarm codes without resolving the problem will result in damage to the unit and compressor.

Note The bAt alarm is the unique DSR-III/DSR-3.1 alarm that requires manual confirmation. The DSR-III/DSR-3.1 will keep in OFF condition until the operator acknowledges and the voltage is above the BCH value (factory setting 10.5v).
The way to acknowledge this alarm is as follows:

Press the Select key once to show the Alarm screen. You will now see the bAt Alarm code.
Press the Select key again to acknowledge the alarm and Press the select key again and again until the screen returns to the standard Display.

Note After Clearing all active Compressor Drive Module Alarms, Cdn0 will appear after Acknowledging the Alarm.

3.10: Viewing Information Screens

Main Menu

From the Standard Display use the Select key to display:

Alarms (if any active).
Evaporator Manual Defrost.
Condenser Manual Defrost (reverse cycle units only).
Temperature Setpoint.

Hourmeter Menu

From the Standard Display press the Select key for three seconds to open the Hourmeter Menu, then use the Select key to display:

Note For units with firmware version 380.03 and earlier: The unit of measurement is tens of hours (e.g., 150 = 1500 hours). For units with firmware version 380.06 and later: The unit of measurement is hours.

HC: Hours remaining to maintenance notice.
tH: The total amount of time the unit has been switched on protecting the load.
CC: Engine driven compressor operating hours.
EC: Electric standby compressor operating hours.
Return to Main Menu.

Chapter 4: Loading and Inspection Procedures

This chapter describes pre-loading inspections, loading procedures, post-loading procedures, post-loading inspections, and enroute inspections. Thermo King FRIGOBLOCK refrigeration units are designed to maintain the required product load temperature during transit. Follow these recommended loading and enroute procedures to help minimize temperature related problems.

Note When in doubt as to the correct refrigeration requirements and/or loading procedures, call your company office for instructions.

4.1: Post-Start Inspection

Thermostat: Adjust the thermostat setting to above and below the compartment temperature to check thermostat operation (see Operating Modes).

Pre-cooling: With the thermostat set at the desired temperature, run the unit for half-an-hour to one hour (or longer if possible) before loading the truck. Pre-cooling eliminates residual heat and acts as a good test of the refrigeration system.

Defrost: When the unit has finished pre-cooling the truck interior - the evaporator temperature should have dropped below 2ºC (35.6ºF) - initiate a defrost cycle with the manual defrost switch. The defrost cycle should stop automatically.

4.2: Loading Procedure

To minimise frost accumulation in the evaporator coil and a heat increase inside the load compartment, ensure that the unit is OFF before opening the doors (The unit may continue to run when the truck is being loaded in a warehouse with the doors closed).
Carefully check and record the load temperature when loading the truck. Note whether any products are out of temperature range.
Load the product in such a way that there is sufficient space for the air to circulate throughout the load. DO NOT block the evaporator inlet or outlet.
Product should be pre-cooled before loading. Thermo King units are designed to maintain the load at the temperature at which it is loaded. Transport refrigeration units are not designed to reduce the load temperature.

4.3: Post Load Procedure

Verify all doors are closed and locked.
Adjust the thermostat to the desired temperature setpoint.
Start the unit.
Half an hour after loading the truck, defrost the unit for a moment by pressing the Manual Defrost switch. If the coil temperature drops to below 2ºC (35.6ºF), the unit will defrost. The defrost cycle should stop automatically.

Chapter 5: Specifications

Refrigeration System

Contact your Thermo King dealer for refrigeration system service or maintenance.

Compressor

	E-200
Compressor Type	Electrical hermetic compressor, rotary type
Oil Type	PVE

	E-100e and E-200e Series
Compressor Type	Electrical Semi-hermetic Compressor, Scroll type
Oil Type	Polyolester Oil (POE)
Voltage	12V

	V-100/ V-200s	V-200	V-300	V-500/V-600	V-800	V-1000
Compressor Model	TK08N	QP13	QP15	QP16	QP21	QP25
Displacement (cc)	82	131	146.7	163	215	249
Number of cylinders	6	6	6	6	10	10

	V-400X/V-500X/V-600X
Compressor Model	QP16
Displacement (cc)	163
Number of cylinders	6

Displacement (cc)	47.7
Number of cylinders	6

Electrical Control System

Fuses
	12 Vdc	24 Vdc
Fuse 1: Main Fuse	100 amps	60 amps
Fuse 3: Evaporator Fan Motor (EFM1)	15 amps	10 amps
Fuse 5: Signals	20 amps	10 amps
Fuse 6: Drain Heaters (H3 and H4)	2 amps	2 amps
Fuse 7: Transformer AC Power Supply 2	10 amps	10 amps
Fuse 14: Vehicle Ignition Switch	5 amps	5 amps
Fuse 20: Transformer AC Power Supply (located at compressor motor contactor in condenser section)	4 amps	4 amps
Fuse 25: Battery Fuse	5 amps	5 amps
Fuse 30: Condenser Fan Motor (CFM) (located in CF1 wire near terminal strip in condenser section)	16 amps	10 amps
Fuse 31: Fuse - Heater 1	20 amps	20 amps
Fuse 32: Fuse - Heater 2	20 amps	20 amps
Fuse 33: Fuse - Heater 3	20 amps	20 amps
Fuse 34: Fuse - Heater 4	20 amps	20 amps


Evaporator Fan Motors (Each)
Voltage	13 Vdc	26 Vdc
Full Load Current	7.5 Amps	4 Amps
Power Rating	97.5 W	104 W
RPM with Full Load	2,800	2,800

AC Electrical Power Supply Motor
Voltage/Phase/Frequency	230/1/50
Output Power	0.75 kW
Nominal Current Drawn	5.2 amps
OL Relay Adjustment	5.2 amps

DC Electrical Power Supply Motor
Voltage	12 Vdc	24 Vdc
Output Power	600 W	600 W
Nominal Current Drawn	65 amps	30 amps

			12 Vdc
Fuses
E-200
Fuse 1: Main Fuse			150 amps
Fuse 3: Evaporator Fan			15 amps
Fuse 4: Evaporator second Fan			15 amps
Fuse 5: Distribution fuse			20 amps
Fuse 6: Drain Heaters			2 amps
Fuse 9: Evaporator Fan second compartment			15 amps
Fuse 11: Drain Heaters second compartment			2 amps
Fuse 14: ACC1 Ignition Fuse			5 amps
Fuse 25: Vehicle Battery			5 amps
Fuse 63:	TK Battery	1 Battery	150 amps
Fuse 83:		2 Battery	80 amps
Fuse 71: SCM Fuse			60 amps
Fuse 72: SCM Fuse			60 amps
Fuse 8:	BMS Fuses		10 amps
Fuse 84:

Condenser Fan Motor
Voltage			13 Vdc
Full Load Current			10 Amps
Power Rating			130 W
RPM with Full Load			2,800

Condenser Fan Motor
Voltage			13 Vdc
Full Load Current			11 Amps
Power Rating			145 W
RPM with Full Load			2,670

Evaporator Fan Motors (Each)
Voltage			13 Vdc
Full Load Current			7.5 Amps
Power Rating			97.5 W
RPM with Full Load			2,800

Compressor driver module
Battery Input			11.5 to 14.5 VDC
Isolated, balanced three-phase output:			240 VAC Maximum
			30–300 Hz (speed controlled)
Electrical output power:			1150 W continuous, 1400 W for 30 sec

Smart Charger module
Bidirectional battery Charger / Discharger
Voltage			13 Vdc
Maximum Charge Current			40 A dc
Maximum Discharge Current			40 A dc

Electrical Specifications Battery
Voltage			12.8 Vdc
Capacity @ C/5, 25 C (typical)			144 Ah
Energy			1.84 kWh
Discharge Temperature			-10 C to 50 C
Charge Temperature			0 C to 45 C
Self Discharge @ 25 C			< 2% per month
Battery weight			19.2 Kg
Thermo King Part Number			3E73431H01

		12 Vdc
Fuses
E-100e and E-200e Series
Fuse 1: Main Fuse		150 amps
Fuse 3: Evaporator Fan		15 amps
Fuse 4: Evaporator second Fan		15 amps
Fuse 5: Distribution fuse		20 amps
Fuse 6: Drain Heaters		2 amps
Fuse 9: Evaporator Fan second compartment		15 amps
Fuse 11: Drain Heaters second compartment		2 amps
Fuse 14: ACC1 Ignition Fuse		5 amps
Fuse 25: Vehicle Battery		5 amps
Fuse 71: SCM Fuse		60 amps
Fuse 72: SCM Fuse		60 amps
Fuse 8:	BMS Fuses	10 amps
Fuse 84:

Condenser Fan Motor — E-100e
Voltage			13 Vdc
Max. Load Current			9.2 Amps
Power Rating			119.60 W
Max. Airflow			1360 m³/h

Condenser Fan Motor — E-200e
Voltage			13 Vdc
Max. Load Current			10.8 Amps
Power Rating			140.4 W
Max. Airflow			1505 m³/h

Evaporator Fan Motors (Each)
Voltage			13 Vdc
Max. Load Current			7.9 Amps
Power Rating			102.7 W
Max. Airflow			1166 m³/h

	12 Vdc	24 Vdc
Fuses
Common Fuses
Fuse 3: Evaporator Fan Motor (EFM1)	15 amps	10 amps
Fuse 4: Evaporator Fan Motor (EFM2)	15 amps	10 amps
Fuse 5: Roadside (Engine) Compressor Clutch (CCL1), Liquid Injection Switch (LIS), Liquid Injection Valve (LIV), EVAP1 Defrost Hot Gas Solenoid Valve (PS1), Compressor Motor Contactor (CMC), Heat Pilot Solenoid (PS5)	20 amps	10 amps
Fuse 14: Vehicle Ignition Switch	5 amps	5 amps
Fuse 30: Condenser Fan Motor (CFM) (located in CF1 wire near terminal strip in condenser section)	16 amps	10 amps

V-100/V-200s
Fuse 6: Condenser Fan 1/2	2 amps	2 amps
Fuse 21: Battery Power Supply (located in 2 wire near battery)	30 amps	30 amps

V-200/V-300 and Spectrum
Fuse 6: Condenser Fan 1/2	2 amps	2 amps
Fuse 8: (Spectrum Only) EVAP2 Liquid Solenoid Valve (PS2), EVAP1 Liquid Solenoid Valve (PS3), EVAP2 Defrost Hot Gas Solenoid Valve (PS4), Drain Heaters 3 and 4 (HT3, HT4)	20 amps	10 amps
Fuse 9: (Spectrum Only) Evaporator Fan 3	15 amps	10 amps
Fuse 10: (Spectrum Only) Evaporator Fan 4	15 amps	10 amps
Fuse 11: Drain Heaters (H1 and H2)	2 amps	2 amps
Fuse 20: Transformer AC Power Supply (located at compressor motor contactor in condenser section)	4 amps	4 amps
Fuse 21: Battery Power Supply (located in 2 wire near battery)	40 amps	40 amps

V-500/V-600 and Spectrum
Fuse 6: Condenser Fan 1/2	10 amps	7.5 amps
Fuse 8: (Spectrum Only) EVAP2 Liquid Solenoid Valve (PS2), EVAP1 Liquid Solenoid Valve (PS3), EVAP2 Defrost Hot Gas Solenoid Valve (PS4), Drain Heaters 3 and 4 (HT3, HT4)	20 amps	10 amps
Fuse 9: (Spectrum Only) Evaporator Fan 3	15 amps	10 amps
Fuse 10: (Spectrum Only) Evaporator Fan 4	15 amps	10 amps
Fuse 11: Drain Heaters (H1 and H2)	2 amps	2 amps
Fuse 17: Drain Heaters (H3 and H4)	2 amps	2 amps
Fuse 20: Transformer AC Power Supply (located at compressor motor contactor in condenser section)	4 amps	4 amps
Fuse 21: Battery Power Supply (located in 2 wire near battery)	50 amps (Single Temp)	60 amps (Multi-Temp)
Fuse 31: Condenser Fan Motor 2 (CFM2) (located in CF2 wire near terminal strip in condenser section)	16 amps	10 amps


V-800, V1000 and Spectrum
Fuse 1: Condenser Fan Motor (CFM1)	15 amps	10 amps
Fuse 2: Condenser Fan Motor (CFM2)	15 amps	10 amps
Fuse 3: Evaporator Fan 1	15 amps	10 amps
Fuse 4: Evaporator Fan 2	15 amps	10 amps
Fuse 5: PS1, PS7, CMC, LIV,PS5, RCV, CCL	20 amps	10 amps
Fuse 10: (Spectrum Only) Evaporator Fan 4	15 amps	10 amps*
Fuse 6: Drain Heaters 1/2	2 amps	2 amps
Fuse 8: (Spectrum Only) EVAP2 Liquid Solenoid Valve (PS2), EVAP1 Liquid Solenoid Valve (PS3), EVAP2 Defrost Hot Gas Solenoid Valve (PS4), Drain Heaters 3 and 4 (HT3, HT4)	20 amps	10 amps
Fuse 9: (Spectrum Only) Evaporator Fan 3	15 amps	10 amps
Fuse 10: (Spectrum Only) Evaporator Fan 4	15 amps	10 amps*
Fuse 11: Drain Heaters (H3 and H4)	2 amps	2 amps
Fuse 14: Ignition	5 amps	5 amps
Fuse 17: TracKing	5 amps	5 amps
Fuse 20: Transformer AC Power Supply	5 amps (time delay fuse)	5 amps (time delay fuse)
Fuse 21: Battery Power Supply (located in 2 wire near battery)	1000 amps	60 amps
Fuse 41: Evaporator Fan 5	11 amps	10 amps
Fuse 41: Evaporator Fan 6	11 amps	10 amps
Note * 15 A in Spectrum Versions with Double Evaporator Fan 4
Condenser Fan Motor (All except V-800/V-1000)
Voltage	13 Vdc	26 Vdc
Full Load Current	10 Amps	4.7 Amps
Power Rating	130 W	122 W
RPM with Full Load	2,800	2,800

Condenser Fan Motor (V-800/V-1000)
Voltage	9–15 Vdc	16–32 Vdc
Full Load Current	11 Amps	10 Amps
Power Rating	145 W	240 W
Control Voltage Range	1–10 Vdc	6.5–10 Vdc

Evaporator Fan Motors (All except ES–800/ES–1000)
Voltage	13 Vdc	26 Vdc
Full Load Current	7.5 Amps	4 Amps
Power Rating	97.5 W	104 W
RPM with Full Load	2,800	2,800

Evaporator Fan Motors (ES–800/ES–1000)
Voltage	14 Vdc	28 Vdc
Full Load Current	5.7 Amps	3.4 Amps
RPM with Full Load	2,350	2,430
Speed control	0 to 10 Vdc	0 to 10 Vdc
Type	Brushless DC motor	Brushless DC motor

Transformer (All except V-800/V-1000)
Power	500 VA
Frequency	50/60 Hz
Primary Inputs	115-208-230 Vac
Secondary Nominal Voltage	11.7 Vac (21.4 Amps)

Transformer (V-800/V-1000)
Power	1100 VA
Frequency	50/60 Hz
Primary Inputs	230–400 Vac
Secondary Nominal Voltage	2 windings: 11.7 Vac (47 Amps) and 11.7 Vac (47 Amps)

Electric Motor (Model 50)

AC Electric Compressor Motors and Overload Relays

Voltage/Phase/Frequency	Horsepower	Kilowatts	RPM	Full Load (amps)	Overload Relay Setting (amps)
V-100/V-200s
230/1/50	2.0	1.5	1750	5.4	5.5
V-200/V-300
230/1/50	2.0	1.5	1750	8.6	8.6
230/1/60	2.0	1.5	1750	9	9
230/3/60	2.4	1.8	1750	6.9	6.9
400/3/50	2.4	1.8	1750	4	4
400/3/60	2.4	1.8	1750	4	4
V-500/V-600 (Semi hermetic Standby compressor)
115/1/60	1.5	1.1	1710	14	14
208/1/60	2.0	1.5	1740	9.5	9.5
230/1/60	2.0	1.5	1750	9	9
208/3/60	2.4	1.8	1730	7.2	7.2
230/3/60	2.4	1.8	1750	6.9	7
V-800 (Semi hermetic Standby compressor)
230/3/50	3	2.3	1450	57/16.6 amps	18
400/3/50	3	2.3	1450	32.9/9.6 amps	14
230/3/60	3	2.3	1740	68.4/19.9 amps	18
400/3/60	3	2.3	1740	39.5/11.5 amps	14
V-1000 (Semi hermetic Standby compressor)
230/3/50	5	3.7	1450	22/109 amps	24
400/3/50	5	3.7	1450	12.7/63.1 Amps	16
230/3/60	5	3.7	1740	26.5/121 Amps	24
400/3/60	5	3.7	1740	15.3/70.1 amps	16

Electrical Control System

VX-Series

	12 Vdc	24 Vdc
Fuses
Common Fuses
Fuse 3: Evaporator Fan Motor (EFM1)	15 amps	10 amps
Fuse 4: Evaporator Fan Motor (EFM2)	15 amps	10 amps
Fuse 5: Roadside (Engine) Compressor Clutch (CCL1), Liquid Injection Switch (LIS), Liquid Injection Valve Roadside compressor (LIV1), Liquid Injection Valve Standby compressor (LIV2), EVAP1 Defrost Hot Gas Solenoid Valve (PS1), Compressor Motor Contactor (CMC), Heat Pilot Solenoid (PS5), Bypass valve (PS7)	20 amps	10 amps
Fuse 14: Vehicle Ignition Switch (type MINI 32V)	5 amps	5 amps
Fuse 1: Condenser Fan Motor (CFM1) (located in CF1 wire, in an inline fuseholder, type ATO 32V)	15 amps	7.5 amps
Fuse 2: Condenser Fan Motor (CFM1) (located in CF1 wire, in an inline fuseholder, type ATO 32V)	10 amps	7.5 amps
Fuse 8: (Spectrum Only) EVAP2 Liquid Solenoid Valve (PS2), EVAP1 Liquid Solenoid Valve (PS3), EVAP2 Defrost Hot Gas Solenoid Valve (PS4), Drain Heaters 3 and 4 (HT3, HT4), UON signal	20 amps	10 amps
Fuse 9: (Spectrum Only) Evaporator Fan 3	15 amps	10 amps
Fuse 10: (Spectrum Only) Evaporator Fan 4	15 amps	10 amps
Fuse 11: Drain Heaters (H1 and H2)	2 amps	2 amps
Fuse 17: Drain Heaters (H3 and H4) (type MINI 32V)	2 amps	2 amps
Fuse 20: Transformer AC Power Supply (5A - time delay fuse (FLQ005)	5 amps	5 amps
Fuse 21: Battery Power Supply (located in 2 wire near battery)	50 amps (Single Temp)	60 amps (Multi-Temp)
Fuse 6: Condenser fan for Series / Parallel operation	15 amps	7.5 amps

Condenser Fan Motor
Voltage	13 Vdc	26 Vdc
Full Load Current	10 Amps	4.7 Amps
Power Rating	130 W	122 W
RPM with Full Load	3,300	3,300

Evaporator Fan Motors (Each)
Voltage	13 Vdc	26 Vdc
Full Load Current	7.5 Amps	4 Amps
Power Rating	97.5 W	104 W
RPM with Full Load	2,800	2,800

Coil for Hot Gas Solenoid (PS1, PS2, PS3, PS4)
Voltage	12 Vdc	24 Vdc
Current	2.3 amps	1.3 amps
Resistance	5.2 ohms	20 ohms

Coil for Liquid Injection Solenoid (LIS) – MAX Only
Voltage	12 Vdc
Current	1.2 amps
Resistance	10.0 ohms

Coil for Heat Pilot Solenoid (PS5) - Truck Engine Coolant Heat Option Only
Voltage	12 Vdc
Current	1.5 amps
Resistance	8.0 ohms

Drain Line Heaters (Each) - MAX Only
Voltage	12 Vdc
Current	0.9 amps ± 5% at 68 F (20 C)
Resistance	13.8 ohms ± 5% at 68 F (20 C)

Battery Relay (BATR)
Type		Single Pole Single Throw (SPST)
Contacts	Terminals 30 to 87	Normally Open (NO)
Coil Resistance	Terminals 85 to 86	90 ohms

Electric Standby Power Relay (STDR)
Type		Single Pole Single Throw (SPST)
Contacts	Terminals 30 to 87	Normally Open (NO)
Coil Resistance	Terminals 85 to 86	90 ohms

Capacitors
Running Capacitor (CR) (1ph units)	60 μF 475 Vac

Compressor Motor Contactor (CMC)
Contacts	Normally Open
Coil Voltage	12 Vdc
Coil Current	0.25 amps
Coil Resistance	48 ohms

Transformer
Power	700 VA
Frequency	50/60 Hz
Primary Inputs	0–230–400 Vac
Secondary Nominal Voltage	2 x 11.7 Vac (30.4 amps)

AC Electric Compressor Motors and Overload Relays

Voltage/Phase/Frequency	RPM	Full Load (amps)	Overload Relay Setting (amps)
230/1ph 50/60Hz	???	20	18
230/3ph 50/60Hz	???	16	16
400/3ph 50/60	???	9	10

TracKing

Platform	ARM Cortex-A8, 300MHz, 256MB RAM, 4GB Flash, Linux
GSM/GPRS	3G, Sierra HL8548
GPS	u-blox NEO-7M
Bluetooth	Version 4.0 Bluetooth Classic /Bluetooth Low Energy (BLE)
Serial Ports	2 External Serial Ports for TracKing extensions or Third-Party Connect
Input Power	12V Nominal
Backup Battery	Single cell Li-Ion 3.7V Nominal, > 2Ah
Environmental Storage Temperature	-40 to +85 C

Chapter 6: Warranty

Please also refer to TK 61654-18-WA Thermo King EMEA Unit Limited Warranty for Vehicle Powered Truck Units.

Chapter 7: Inspection and Service Intervals

7.1: Weekly Pre-Trip Checks

Visually inspect belt.
Listen for unusual noises, vibrations, etc.
Visually inspect unit for fluid leaks (coolant, oil, refrigerant).
Visually inspect unit for damaged, loose or broken parts (including air ducts and bulkheads, if so equipped).
In the event of excess of dirt or obstruction clean the unit, including condenser and evaporator coils.

7.1.1: Weekly Pretrip Inspection

The following Weekly Pretrip Inspection should be completed before starting the unit and loading the truck. While the weekly inspection in not a substitute for regularly scheduled maintenance inspections, it is important part of the preventive maintenance program designed to head off operating problems before they happen.

Leaks: Inspect for refrigerant leaks and worn refrigerant lines.

Battery: Terminals should be properly tightened and show no signs of corrosion.

Belts: Inspect for cracks, wear, and proper belt tension.

Mounting Bolts: Verify bolts are properly tightened.

Electrical: Electrical connections should be securely fastened. Wires and terminals should be free of corrosion, cracks, or moisture.

Structural: Visually check for physical damage.

Coils: The condenser and evaporator coils (evaporator coils in multi–temperature units) should be clean and free of debris.

Coils: The condenser and evaporator coils should be clean and free of debris.

Washing with clean water should be sufficient. The use of cleaning agents or detergents is strongly discouraged due to the possibility of degradation of the construction. If using a power washer, the nozzle pressure should not exceed 600 psi (41 bar). For the best results, spray the coil perpendicular to the face of the coil. The spray nozzle should be kept between 1 inch and 3 inches (25 to 75 millimeters) from the coil surface.
Important Models V–500 and V–800/V–1000 feature a high efficient micro channel aluminum condenser coil, in these cases the spray nozzle should be kept 300mm away from the coil and aimed perpendicularly to the coil surface to avoid damaging the aluminum fins.
If necessary to use a chemical cleaner or detergent use a cleaner that does not contain any hydrofluoric acids and is between 7 and 8 on the pH scale. Ensure dilution instructions provided by the detergent supplier are followed. In case of doubt about the compatibility of the detergent with the type of materials listed above, always ask the supplier a written confirmation of the compatibility. Should a chemical cleaner be required, it is MANDATORY that all components are thoroughly rinsed with water even if the instructions of the cleaner specify that it is a “no rinse” cleaner. Failure to comply with above mentioned guidelines will lead to a shortened life of the equipment to an indeterminable degree. The repeated transportation of meat and fish waste can cause extensive corrosion to the evaporator coils and evaporator section tubing over time due to ammonia formation and can reduce the lifespan of the coils. Appropriate additional measures should be taken to protect the coils against the aggressive corrosion that can result from transportation of such products.

Load Compartment: Inspect the interior and exterior of the truck for any damage. Any damage to the walls or insulation should be repaired.

Defrost Drains: Check the defrost drain hoses and fittings to ensure they are not blocked.

Doors: Verify doors and weather seals are in good condition and seal hermetically.

Sight glass: Check that the refrigerant charge sight glass on the running unit is totally full (the cargo compartment temperature must be approximately 0ºC).

7.2: Weekly Post-Trip Checks

Notice

Equipment Damage
Do not use pressurised water.

Clean the outside cover of the unit. Use a damp cloth and neutral detergents. Do not use harsh cleaning products or solvents.
Check for leaks.
Check for loose or missing hardware.
Check for physical damage to the unit.

7.3: Inspection and Service Schedules

To ensure that your Thermo King unit operates reliably and economically over its full life, and to avoid limiting its warranty cover, the appropriate inspection and service schedule must be followed. Inspection and Service intervals are determined by the number of unit operating hours and by the age of the unit. Examples are shown in the table below. Your Dealer will prepare a schedule to suit your specific needs.

Operating Hours per Year	1000	2000	3000
Inspection	6 months/ 500 hours
Inspection	12 months/ 1000 hours (+ preventative maintenance)	6 months/ 1000 hours	4 months/ 1000 hours
Inspection	18 months/ 1500 hours	12 months/ 2000 hours (+ preventative maintenance)	8 months/ 2000 hours
Full Service	24 months/ 2000 hours	18 months/ 3000 hours	12 months/ 3000 hours (+ preventative maintenance)
	(continue as above)	(continue as above)	(continue as above)

Operating Hours per Year	1000	2000	3000
Service	12 months/ 1000 hours (+ preventative maintenance)	6 months/ 1000 hours	4 months/ 1000 hours
Service		12 months/ 2000 hours (+ preventative maintenance)	8 months/ 2000 hours
Full Service	24 months/ 2000 hours	18 months/ 3000 hours	12 months/ 3000 hours (+ preventative maintenance)
	(continue as above)	(continue as above)	(continue as above)

Important Installation Inspection needs to be carried out on all the units at 6 months/ 500 hours (whichever occurs first).

Service Record

Each inspection and service performed should be recorded on the Service Record Sheet found at the back of this manual.

Preventative Maintenance

Refer to the previous page for checks that should be carried out daily/weekly on the unit. Please work with your Dealer in order to create a maintenance schedule which fits your needs.
Thermo King has extended the limited warranty on new units from 3,000 total hours to a maximum of 4,000 compressor run hours within the 2 year warranty period.
This limited warranty is dependent on the owner and/ or operator adhering to the preventative maintenance schedule as advised by your Thermo King Dealer.

Chapter 8: Serial Number Locations

CONDENSER: Nameplate located on the front inside edge of condenser frame.

CONDENSER: Nameplate located on the back inside wall of condenser frame.

ENGINE DRIVEN COMPRESSOR: Nameplate located on compressor body. The engine driven compressor is located in the truck engine compartment.

STANDBY COMPRESSOR: Nameplate located on compressor body. The Standby compressor is located inside the Condenser assembly.

CONDENSER: Nameplate located on the front inside edge of condenser frame (Cover needs to be removed).
STANDBY COMPRESSOR: 20 and 50 Models only. Nameplate located on standby compressor body. Standby compressor is located inside the Condenser.
ENGINE DRIVEN COMPRESSOR: Nameplate located on compressor body. Engine driven compressor is located in the vehicle’s engine compartment.
ELECTRIC MOTOR DRIVEN COMPRESSOR: Nameplate located on compressor body. The compressor is located inside the condenser assembly.

CONDENSER: Nameplate is located on the back of the condenser frame (cover needs to be removed).





		1.	Condenser Serial Number Location

COMPRESSOR: Nameplate is located on compressor body.







		1.	Compressor Serial Number Location

Condenser and Standby Compressor Serial Number Locations

Engine Driven Compressor Serial Number Location

CONDENSER: Nameplate located on the back of the condenser frame (cover needs to be removed).
INVERTER DRIVEN COMPRESSOR: Nameplate located on compressor body. Inverter driven compressor is located in the Compressor Drive Module.
SMART CHARGER MODULE (SCM) Nameplate location as shown below.
SECOND UNIT NAMEPLATE: A second unit serial number nameplate is typically located inside the vehicle’s door opening area. This nameplate provides quick and easy access to the same unit serial number found on the condenser unit.

Condenser Serial Number Locations

Hermetic Compressor Serial Number Location

Smart Charger Module

Second Unit Nameplate

CONDENSER: Nameplate located on the back inside wall of condenser frame.

Condenser Serial Number Location

STANDBY COMPRESSOR: Nameplate located on compressor body. The Standby compressor is located inside the Condenser assembly.

Standby Compressor Serial Number Location

Chapter 9: Recover Refrigerant

At Thermo King®, and FrigoBlock 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 local 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.

E-Series Units withDirect Smart Reefer

ESeries DSR

i Preface For None

ii Introduction

Software License

Emergency Assistance

General Inquires and Unit Maintenance

Customer Satisfaction Survey Assistance/Feedback

Chapter 1: Safety Precautions

1.1: Danger, Warning, Caution, and Notice

1.2: General Safety Practices

1.3: Automatic Start/Stop Operation

1.4: Battery Installation and Cable Routing

1.5: Refrigerant

1.6: Refrigerant Oil

1.7: First Aid

1.8: Safety Decals

Service

Service Decal

Operation

Operation Decal

High Voltage

High Temperature

High Temperature Warning

Condenser and Evaporator Fans

Fan Warning

Remote Start of the Unit

Unit Auto-start Warning

Refrigerant

Type Certification

Chapter 2: Unit Description

2.1: Standard Unit Features

2.2: Options

2.3: System Components

2.3.1: Compressor(s)

Compressors

Swash Plate Compressor

2.3.2: Condenser

Condenser

Condensers, V-Series

Condensers, VX-Series

Condensers, E-Series

2.3.3: Evaporator

Evaporator

Evaporator

2.3.4: TK Lithium Ion Batteries (if equipped)

2.3.5: Electronic Control System

HMI

HMI

HMI

2.3.6: Description

2.3.7: Unit Controls

In-cab Control Panel (HMI) Display, Keys, Symbols

In-cab Control Panel (HMI) Display, Keys, Symbols

2.4: Standby Operation (Models 20 and 50 Only)

Standby Power Receptacle

2.5: Electrical System

2.5.1: Fuses

V-200 V–300 Condenser, Fuses Location

V-200 V–300 SPECTRUM Condenser, Fuses Location

V-500 V–600 Condenser, Fuses Location

V-800 V–1000 Condenser, Fuses Location

VX–Series Condenser, Fuses Location

Fuse Location (condenser cover and electric box cover removed)

Fuse Location (condenser cover removed)

Chapter 3: Operating Instructions

3.1: General Operation

3.2: Starting the Unit

Engine Operation

Electric Standby Operation

3.3: Standard Display

Single Temperature Units

Multi-Temperature Units

3.4: Entering Setpoint Temperature

Single Temperature Units

Multi-Temperature Units

Compartment Selection

3.5: Initiating the Evaporator Manual Defrost Cycle

Display Showing Defrost Off

Display Showing Defrost ON