56869–18

i Preface For None

     
Note

ii Introduction

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

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.

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.

Assistance/Feedback

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® 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 Practices

    Danger
  • Risk of Injury
  • Keep your hands, clothing, and tools clear of fans and/or belts when working on a unit that is running or when opening or closing compressor service valves. Loose clothing might entangle moving pulleys or belts, causing serious injury or possible death.
    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: Auto Start/Stop

    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
  • Some vehicles may be equipped with an Auto Start-Stop feature allowing the engine to restart automatically if required by the system. Refer to your vehicle’s operator’s manual regarding the Auto Start-Stop safety warnings before accessing the engine compartment. Failure to do so may result in serious injuries due to automatic engine restart.

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.

    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
  • 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: Electrical Hazards

    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.

1.6: Refrigerant Hazards

Although fluorocarbon refrigerants (R-404A/R-452A and R-134a) are classified as safe, observe caution when working with refrigerants or around areas where they are being used in the servicing of your unit.

    Danger
  • 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
  • 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.

1.7: Refrigerant Oil Hazards

Observe the following when working with or around refrigerant oil.

    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.

1.8: 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

  • 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.

1.9: Safety Decals

Safety decals and locations vary depending on model.

Fan Caution
Automatic Start Caution

Chapter 2: Unit Description

Thermo King B-Series are electric powered two-piece units (condenser and evaporator) designed for fresh, frozen, and deep frozen applications for small trucks and vans.

The system is powered by the vehicle’s battery during mobile operation. Optional SmartPower© units operate when the unit is connected to an AC power source during stationary operation.

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

B-Series Units Include:

  • B-100, B-100 ECO: for fresh temperature applications above 32°F (0°C).

  • B-100 MAX: for frozen temperature applications below 32°F (0°C) and down to -26°F (-32°C).

There are four basic models:

  • Model 10: Cool and Defrost with battery operation.

  • Model 20: Cool and Defrost with both battery or electric standby operation.

  • Model 30: Hot gas heat, Cool, and Defrost with battery operation.

  • Model 50: Hot gas heat, Cool, and Defrost with both battery or electric standby 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.

  • Controls - User friendly Direct Smart Reefer (DSR) In-Cab controller.

  • Refrigerant - R-134a, R-452A or R-404A (depending on unit model).

2.2: Options

  • SmartPower™(Electric Standby)

  • Hot Gas, Electric or Coolant Heating

  • Door Switch Kit

  • Discharge Muffler Kit

  • Snow Covers

  • Refrigeration Hose / Harness Covers

  • Roof Top Mounting Kit

  • TracKing®

  • 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:

  • Electric DC motor

  • Electric AC motor (SmartPower units only)

  • Reciprocating compressor (belt driven)

  • Condenser

  • Evaporator

  • In-cab controller

2.3.1: DC Electric Motor

The DC electric motor located inside the condenser operates the reciprocating compressor. The system is powered by the vehicle’s battery (minimum 250 amp alternator recommended) during mobile operation.

DC Motor

2.3.2: AC Electric Motor

SmartPower units have an additional AC electric motor located inside the condenser that operates the reciprocating compressor. Power for the motor is supplied when unit is connected to an AC power source during stationary operation.

AC Motor

2.3.3: Compressor(s)

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.

2.3.4: 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.

2.3.5: Evaporator

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

Evaporator

2.3.6: In-Cab Controller

DSR In-Cab Controller

Chapter 3: Electrical System

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

The unit’s controls and refrigeration components operate on 12 Vdc or 24 Vdc (must match the voltage of the vehicle alternator)

SmartPower units have a standby motor that operates on 230 Vac, 400 Vac 3 ph when connected to a remote power source. A transformer in the condenser unit converts the (NOT 115 V) 230 Vac 1 ph 1 ph to 12 or 24 Vdc to operate the unit’s controls and refrigeration components.

3.1: 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.
This in-line fuse is non-serviceable and must only be replaced by an authorized Thermo King Dealer.

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 used.

Fuse Location (condenser cover removed)

Chapter 4: Operating Instructions

4.1: Introduction

In vehicle powered units, temperature control is based on two values: The setting (Setpoint) of the controller and the evaporator return air temperature. The difference between these two temperatures will determine the mode of operation: cool, heat, or null.

Cool: When the temperature in the compartment is 3°F (2°C) higher than the setpoint, the unit runs in cool mode to reduce the evaporator return temperature to achieve the setpoint.

Heat: When the temperature in the compartment is 3°F (2°C) lower than the setpoint, the unit changes to heat mode to raise the evaporator return temperature to achieve the setpoint.

Null: Once the Setpoint Temperature has been reached, and the temperature remains at or within the temperature differential, (there is no demand for heat or cool), the unit stops operating and goes into the Null mode.

While in the Null mode, the unit is still monitoring the compartment temperature and will resume operation only if the temperature increases or decrease by 3°F (2°C) above or below the setpoint.

Defrost: After a period of time in cool mode, (time is setup during installation between 0 and 8 hours), the unit checks the coil temperature. If the temperature is cold enough to form ice, the unit runs in automatic Defrost Mode to eliminate ice that has accumulated in the evaporator coil. Defrost can also be initiated manually by selecting the defrost mode on the DSR controller. The unit will run in defrost until one of the two events occurs: 1) the coil temperature is back within range, or 2) the defrost termination timer has expired. (time is setup during installation).

Note The return air temperature will increase slightly while in defrost, however it will quickly return to the desired setpoint after completion of the defrost cycle.

4.2: Unit Controls

    Warning
  • Risk of Injury
  • Never operate the unit unless you completely understand the controls; otherwise serious injury may occur.
1. Main Display Always active and back-lit except when the unit has been manually switched off from the In-Cab Controller. It normally displays the evaporator return air temperature but also displays setpoint temperature, hours, etc. depending on the selection chosen.
2. C/F Symbol Indicates temperature reading is in degrees Celsius (C) or degrees Fahrenheit (F).
3. Heat Symbol The unit is heating (Thermometer with an arrow pointing upward).
4. Up Key Is used to increase the setpoint temperature.
5. Select Key Is used to scroll through prompt displays and information displays.
6. On/Off Key This key is used to start/stop the unit.
7. Buzzer Alerts when vehicle battery and electric power supply are connected simultaneously (Models 20/50 only). Alerts if doors are opened while the refrigeration unit is running (Door Switch Option Only). Can be configured by Thermo King dealer to suit individual customer needs.
8. Enter Key Is used to enter a new command such as manual defrost, etc.
9. Down Key Is used to reduce the setpoint temperature.
10. Cool Symbol The unit is cooling (Thermometer with an arrow pointing downward).
11. Alarm Symbol Indicates there is an alarm in the system.
12. Maintenance Symbol Indicates the need to carry out maintenance to the unit. Refer to (Maintenance Inspection Schedule).
13. Defrost Symbol Indicates the unit is in Defrost Mode.
14. Electrical Symbol Indicates the unit is connected to electric standby AC power (Models 20/50 only).

4.3: Operating the Unit

4.3.1: Vehicle Engine Operation

  1. Start the vehicle’s engine.

  2. Press the On/Off Key on the DSR controller. The Standard Display will appear.

    The Standard Display normally displays the return air temperature and the current operating mode with the appropriate symbol. The example below shows: 38 F temperature and cool mode with an alarm present.

    If an alarm is present, the Alarm symbol will also appear on the display. Refer to (Alarm Code Descriptions).

  3. Check the setpoint, and adjust if necessary. Refer to (Entering the Setpoint Temperature).

Standard Display

4.3.2: Standby Operation (Models 20 and 50 Only)

    Warning
  • Hazardous Voltage
  • A certified electrician should verify that the proper standby power requirements are being supplied 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 shut off.
Standby Power Receptacle

  1. Connect the external power supply to the electric power receptacle. Verify the power supply is the correct voltage, phase and frequency for unit.

  2. Press the On/Off Key on DSR controller. The display will be activated. The electric symbol will appear on the display.

  3. Check the setpoint, and adjust if necessary. Refer to (Entering the Setpoint Temperature).

Standard Display with Standby Symbol

4.3.3: Entering the Setpoint Temperature

The Setpoint Temperature can be quickly and easily changed.

  1. 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.

  2. 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.

  3. Press and release the Select key, and the Standard Display will reappear on display.

    Important If the Select key is not pressed within 20 seconds to select the new Setpoint Temperature, the unit will continue to run at the original Setpoint Temperature.

Setpoint Temperature Display

4.3.4: Initiating Manual Defrost Cycle

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

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

    Defrost Off

  2. To activate manual defrost, press the Enter key and then the Up or Down key and the defrost will change to ON.

    Defrost On

  3. Press the Select key twice to return to the Standard Display where the Defrost symbol will appear when the defrost cycle begins.

    Note Manual defrost will be aborted if there is no ice on the coil.

    Important The evaporator coil must be below 36°F (2.26°C) for a defrost to be enabled.
Defrost Cycle in Process

4.4: Alarms

When the unit is not operating properly, the microprocessor records the alarm code, alerts the operator by displaying the Alarm symbol, and shuts the unit down. Press and release the Select key to display the current alarm code. 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. Refer to (Alarm Code Descriptions).

Auto Start (after an alarm)

When an alarm stops unit operation, the Alarm icon appears on the Standard Display. After the condition that caused the alarm is corrected and the alarm has been cleared, the unit will start automatically. Refer to (Alarm Code Descriptions).

Auto Start Alarm

Manual Start (after an alarm)

When a Manual Start alarm stops unit operation, the Alarm icon appears on the Standard Display with no other icons present.

Note This information applies only to the OL (Electric Standby overload) alarm and bAt (low battery voltage) alarm.

After the condition that caused the alarm is corrected, the On/Off key on the In-cab Control Box must be pressed, in order to start unit operations. Once the unit is powered back up, the alarm must be cleared. Refer to (Clearing Alarm Codes).

Alarm Symbol

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

P1E Alarm

Press and release the Select key to display the current alarm code. 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.

4.5: Clearing Alarm Codes

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:

  1. Press the Select key once to show the Alarm screen. You will now see the bAt Alarm code.

  2. 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.

4.6: Buzzers (Optional)

A buzzer sounds when the vehicle battery and the electrical supply are connected simultaneously (the unit continues running in standby mode). It can also sound if the door(s) is open or the return air temperature is out of range. Buzzers are configurable to different parameters to suit individual customer needs. Contact your Thermo King Dealer for assistance.

4.7: 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 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.

C  

Communications Failure

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.

4.8: Viewing Information Displays

4.8.1: Main Menu

From the Standard Display use the Select key to display:

  • Alarms (if any active)

  • Defrost Status

  • Temperature Setpoint

4.8.2: Hourmeter Menu

To open the Hourmeter Menu from the Standard Display, press the Select key for three seconds and release, then press the Select key to display:

  • HC: Hours remaining to maintenance notice.

  • tH: The total amount of time unit has been switched on.

  • CC: Engine-driven compressor operating hours.

  • EC: Electric standby compressor operating hours.

Chapter 5: Unit Operation and Loading Procedures

This chapter describes unit operation and proper loading procedures. Thermo King refrigeration units are designed to maintain the required product load temperature during transit. Transport refrigeration units are not designed to reduce the load temperature. Follow these recommended procedures to help prevent cargo spoilage.

5.1: Unit Operation (Before Loading Refrigerated Cargo)

Start Unit: Adjust the thermostat setting to above and below the compartment temperature to check thermostat operation.

Pre-Cooling: With the thermostat set at the desired temperature, run the unit for half-an-hour to one hour (or until the desired setpoint is reached) before loading the refrigerated cargo. Pre-cooling eliminates residual heat and acts as a good test of the refrigeration system.

Defrost: When the unit has finished pre-cooling the cargo box the evaporator temperature should have dropped below 36°F (2.2°C). Initiate a manual defrost cycle with the In-Cab Controller. The defrost cycle will stop automatically.

5.2: Loading Procedure

Important 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.
Note To minimize frost accumulation in the evaporator coil and a heat increase inside the load compartment, ensure that the unit is OFF before opening the doors.

  1. Carefully check and record the load temperature when loading the refrigerated cargo. Note whether any products are out of temperature range.

  2. Load the product to verify sufficient air space is maintained around and through the load in compartment. Airflow around the cargo must not be restricted. DO NOT block the evaporator inlet or outlet. Refer to the Air Circulation Diagram on the following page.

  3. Minimize door opening times and close door(s) in between loading to preserve box temperature.

Air Circulation Diagram

1. Evaporator air outlet not blocked by cargo.
2. Sufficient air space is maintained above cargo.
3. Good air circulation around and between cargo.
4. Cargo separated from bulkhead and walls a minimum of 4.00 inch (100 mm).
5. Evaporator air inlet not blocked by cargo.

5.3: Enroute Inspections

To help prevent damage to the cargo, complete the following enroute inspection every four hours.

Inspection Procedure

  1. Verify the setpoint is correct.

  2. Check the return air temperature readings. The temperature readings should be within the desired temperature range. If the readings are not within this range, refer to ( Inspection Troubleshooting).

Inspection Troubleshooting

  1. If a return air temperature reading is not within the desired temperature range, refer to ( Inspection Troubleshooting). Correct the problem as needed.

  2. Repeat the Enroute Inspection every 30 minutes until the compartment temperature is within the desired temperature range. Stop the unit if the compartment temperature is not within desired temperature range on two consecutive 30 minute inspections, especially if the compartment temperature appears to be moving away from the setpoint.

  3. Immediately contact the nearest Thermo King Dealer.

  4. Take the necessary steps to protect and maintain proper load temperature.

Inspection Troubleshooting
Problem Cause Remedy
Return air temperature reading is not within desired temperature range of the setpoint. Unit has not had time to cool cargo to correct temperature. Refer to load log history. Look for above temperature load records, properly pre-cooled cargo compartment, length of time on road, etc. Correct as required. Continue monitoring return air temperature until reading is within desired temperature range of the setpoint.
  Unit may have a low refrigerant charge Contact nearest Thermo King dealer, or call the Thermo King Cold Line for referral.
  Unit is in defrost or has just completed a defrost cycle. Monitor return air temperature after defrost cycle is completed to see if temperature returns to desired temperature range of the setpoint.
Note Temperature will increase slightly during defrost cycle.
  Evaporator is plugged with frost. Initiate a manual defrost cycle. Defrost cycle will automatically terminate when complete. Continue monitoring return air temperature until reading is within desired temperature range of the setpoint.
Return air temperature reading is not within desired temperature range of the setpoint. Improper air circulation in the cargo compartment. Inspect unit and cargo compartment to determine if evaporator fans are working and properly circulating the air. Poor air circulation may be due to improper loading of the cargo or shifting of the load. Correct as required. Continue monitoring return air temperature until problem is corrected.
    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.
  The unit did not start automatically. Contact nearest Thermo King dealer, or call the Thermo King Cold Line for referral.
  Air leaks in cargo box. Inspect cargo box for air leaks such as doors that are not fully closed or bad/missing door seals. Repair as necessary.

Chapter 6: Specifications

6.1: Fuses

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

* Refer to (Fuses) for important information regarding replacing main power fuse F1.

** Only if coolant heat option is installed.

*** Only if electric heat option is installed.

6.2: Electric Standby Power Supply Requirements (Models 20 and 50 Only)

 

Power Cord Size (AWG)

Power Cord Length

Voltage Phase Hz Power Supply Circuit Breaker 25 ft. 50 ft. 75 ft.
230 (Vac) 1 50/60 16 amp AWG16/ 1.5mm2 AWG16/ 1.5mm2 AWG16/ 1.5mm2
115 (Vac) 1 50/60 20 amp AWG14/ 2.5mm2 AWG14/ 2.5mm2 AWG14/ 2.5mm2
Important Failure to use properly sized power cord may result in improper unit operation, or unit failure.

Chapter 7: Maintenance Inspection Schedule

A closely followed maintenance program will help to keep your Thermo King unit in top operating condition. The following general schedule is provided to assist in monitoring that maintenance.

Note All service requirements, major and minor, should be handled by a Thermo King dealer.

Daily Weekly 12 Months or 2000 Hours 24 Months or 4000 Hours Inspect/Check/Service These Items
•       Check unit for any active alarms.
•       Inspect exterior of evaporator and condenser.
•       *Inspect evaporator air inlet and outlet for blockage (dirt, debris, cargo, etc.).
•       *Inspect condenser air inlet and outlet for blockage (dirt, debris, etc.).
•       Adequate air space above and around cargo.
  •     Inspect evaporator drain hoses (Verify water is not collecting in drain pan).
  •     Check unit for proper defrost operation.
    •   *Clean evaporator drain hoses.
    •   *Clean evaporator and condenser coils.
    •   Inspect moisture indicator and refrigerant level.
    •   Inspect wiring harnesses and connectors.
    •   Inspect refrigerant hoses.
    •   Inspect refrigerant hose connections for leaks.
    •   Inspect roadside compressor drive belt condition and tension.
    •   Inspect standby compressor drive belt condition and tension (20 and 50 Models Only).
    •   Check return air temperature sensor calibration.
      • Check suction pressure regulator setting (20, 30, 50 MAX Models Only).
      • Inspect evaporator and condenser mounting hardware.
      • Inspect ground terminals.
      • Replace filter dryer.

*More frequent cleaning may be required based on operating environment (dusty conditions, etc.).

Chapter 8: Warranty

Terms of the Thermo King North American Vehicle Powered Truck Unit Limited Warranty are available on request from your Thermo King Dealer. Please reference document TK 51350.

8.1: Serial Number Locations

  1. CONDENSER: Nameplate located on the front inside edge of condenser frame (Cover needs to be removed).

  2. STANDBY COMPRESSOR: 20 and 50 Models only. Nameplate located on standby compressor body. Standby compressor is located inside the Condenser.

Condenser and Standby Compressor Serial Number Locations

Chapter 9: Recover Refrigerant

At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere.

We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.

In addition, service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians. For additional information on regulations and technician certification programs, contact your local THERMO KING dealer.

Chapter 10: Emergency Cold Line

If you can’t get your unit operating and need assistance, you can locate a Thermo King Dealer anywhere in the United States by going to thermoking.com or by using the Thermo King North American Service Directory (available from any Thermo King Dealer). If you are unable to reach a Dealer, call the Toll Free Emergency Cold Line Number (888) 887-2202. The answering service will assist you in reaching a Dealer to get the help you need. The Cold Line is answered 24 hours a day by personnel who will do their best to get you quick service at an authorized Thermo King Dealer.