E-Series Units withDirect Smart Reefer

E500e

i 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. 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: Section 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 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.
    Danger
  • Hazard of Explosion
  • Never apply heat to a sealed refrigeration system or container. Heat increases internal pressure, which might cause an explosion resulting in death or serious injury.
    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
  • Always wear goggles or safety glasses and proper PPE when working on a unit. Refrigerant liquid, oil, and battery acid can permanently damage your eyes. 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
  • Proper Equipment Condition
  • Gauge manifold hoses must be in good condition before using them. Never let them come in contact with moving belts, fans, pulleys or hot surfaces. Defective gauge equipment can damage components or cause serious injury.
    Warning
  • Equipment Damage and Risk of Injury
  • Never drill holes into the unit unless instructed by Thermo King. Holes drilled into high voltage cables could cause an electrical fire, severe personal injury, or even death.
    Caution
  • Sharp Edges
  • Use extreme care when working with exposed coil fins. Contact with fins can cause painful lacerations. Use gloves while handling coils.
    Notice
  • Equipment Damage
  • All unit mounting bolts must be installed, be the correct length for their application, and torqued to specifications. Missing bolts, incorrect bolt lengths and improper torque specifications can damage equipment and void the warranty.

    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.
    Warning
  • Personal Protective Equipment (PPE) Required
  • Always wear goggles or safety glasses and proper PPE when working on a unit. Refrigerant liquid, oil, and battery acid can permanently damage your eyes. 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
  • Hazard of Explosion
  • Never close the compressor discharge service valve when the unit is operating. Never operate the unit with the discharge valve closed (front seated). This condition increases internal pressure, which can cause an explosion.
    Warning
  • Equipment Damage and Risk of Injury
  • Never drill holes into the unit unless instructed by Thermo King. Holes drilled into high voltage cables could cause an electrical fire, severe personal injury, or even 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: Refrigerant Hazards

    Danger
  • Hazardous Pressures
  • Always store refrigerant in proper containers, out of direct sunlight and away from intense heat. Heat increases pressure inside storage containers, which can cause them to burst and could result in severe personal injury.
    Danger
  • Combustible Hazard
  • Do not use oxygen (O2 ) or compressed air for leak testing. Oxygen mixed with refrigerant is combustible.
    Warning
  • Hazardous Gases
  • Do not use a Halide torch. When a flame comes in contact with refrigerant, toxic gases are produced. These gases can cause suffocation, even death.
    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.
    Notice
  • Equipment Damage
  • When being transferred, refrigerant must be in liquid state to avoid possible equipment damage.
    Caution
  • Risk of Injury OR Equipment Damage!
  • The host unit is shipped with the refrigerant on the high side and the remote evaporators with the nitrogen on the low side.

1.4: Refrigerant Oil Hazards

    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.
    Notice
  • Equipment Damage
  • Use the correct oil in Thermo King systems to avoid damaging equipment and nullifying its warranty.
    Notice
  • Equipment Damage
  • Do not mix refrigerant oils. Mixing incompatible oils will damage the system.
    Notice
  • Equipment Damage
  • Use dedicated refrigeration equipment to prevent contaminating refrigeration systems with the wrong type of oil or refrigerant.
    Notice
  • System Contamination
  • Do not expose the refrigerant oil to the air any longer than necessary. Store refrigerant oil in an approved sealed container to avoid moisture contamination. The oil will absorb moisture, which results in much longer evacuation times and possible system contamination.
    Notice
  • Material Damage
  • Wipe up spills immediately. Refrigerant oil can damage paints and rubber materials.

1.5: Electrical Hazards

High Voltage

Important Do not move the vehicle if the power cable or the electric standby icon is illuminated.
Important Stop the vehicle and ensure no HoldOver function is active.
Important Disconnect the PDU from the EV before any maintenance activity in the condenser or the evaporators.
Important Verify NO LED in CPM (installed in condenser) before any maintenance activity.

    Danger
  • Hazardous Voltage
  • Lethal amounts of voltage are present in some electrical circuits. Use extreme care when working on the refrigeration unit. If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

    Warning
  • Hazardous Voltage
  • Treat all wires and connections as if they were high voltage until a meter and wiring diagram indicate otherwise. Only use tools with insulated handles. Never hold uninsulated metal tools near exposed, energized conductors. If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

    Warning
  • Hazardous Voltage
  • Never work alone on high voltage circuits in the refrigeration unit. Another person should be nearby to shut off the unit and provide aid in the event of an accident. If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

    Warning
  • Personal Protective Equipment (PPE) Required
  • In the event of an electrical accident, all required PPE should be near the work area in accordance with OSHA, NFPE 70E, or other local, state, or country-specific requirements for a Category 3 risk.

    Warning
  • Risk of Injury
  • Do not make rapid moves when working on high voltage circuits in the refrigeration unit. Do not grab for falling tools because you might accidentally touch a high voltage source.

    Warning
  • Hazardous Voltage w/Capacitors
  • Be careful when working with electrical circuits that contain capacitors. Some capacitors hold a significant electrical charge that might cause burns or shocks if accidentally discharged. Capacitors must be discharged before working on electrical circuits. If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

Low Voltage

    Warning
  • Live Electrical Components
  • Control circuits used in refrigeration units are low voltage (12 to 48 Vdc). However, the large amount of amperage available can cause severe burns if accidentally shorted to ground with metal objects, such as tools. Do not wear jewelry, watches, or rings because they increase the risk of shorting out electrical circuits and damaging equipment or causing severe burns. If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

1.6: Other Electrical Considerations

    Danger
  • Hazardous Voltage and Risk of Injury
  • Always switch off the high voltage energy supply and disconnect the orange electric cable in the PDU before working on the unit.

Controller Service

Precautions must be taken to prevent electrostatic discharge when servicing the Controller and related components. A potential difference less than that required to create a small spark between a finger and a doorknob can cause severe damage to solid state components.

LV Battery

Always disconnect the negative battery terminal (-) first when removing a battery. Connect the positive terminal (+) first when installing a battery. This is important because the frame is grounded to the negative battery terminal. If the negative terminal is still connected, a complete circuit exists from the positive terminal of the battery to the frame. Metal objects contacting the positive side and the frame simultaneously will cause sparks or arcing. If there are sufficient hydrogen gases emitted from the battery, an explosion might occur, causing equipment damage, serious injury, even death.

Always cover battery terminals to prevent them from making contact with metal components.

HV Battery

Always switch off the high voltage energy supply and disconnect the electric cable before working on the unit.

    Danger
  • Hazardous Voltage and Risk of Injury
  • This unit is equipped with high voltage electrical components capable of causing serious injury or death. Turning the unit’s Service Switch to the Off position ONLY prevents the unit from operating. 400/800 VDC, 230 VAC, and 12 VDC voltage is still present in the electrical power system components any time the unit is connected to the Battery Electric Vehicle (BEV) battery bank, Battery Management System (BMS), and unit 12 VDC battery. ONLY qualified individuals should service, repair, or replace any of the electrical power system components, including fuses.

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.

UNECE R10 decal sample.

UNECE R10 decal sample.

UNECE R10 decal sample.

Chapter 2: Unit Description

2.1: Introduction

The Thermo King Vehicle Powered Single Temperature and Multi-Temperature (Spectrum) truck refrigeration systems are designed for transporting cold, frozen and deep frozen products on medium-sized trucks with one or more compartments.

The unit is operated by a variable speed hermetic compressor powered by an inverter (CPM) connected to the HV vehicle batteries using a connection box (PDU).

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-400e : Hot gas heat, Cool and Defrost modes

  • E-500e : Hot gas heat, Cool and Defrost modes

  • E–600e Spectrum: Multi-Temperature versions of the models above with the cargo area split into zones of different temperature combination settings.

Condenser is installed on the front section or on top of the truck, with the evaporator(s) (1 for Single–Temperature, 2 or 3 for Spectrum applications) on the ceiling of the cargo box.

PDU is installed in the motor compartment as per the vehicle installation guide.

2.1.1: Unit Features

Standard Features

  • In-Cab Controls with Digital LCD Thermometer

  • Hot Gas Defrost

  • Defrost Termination Switch

  • Oil Separator

  • Evaporator Drain Line Heaters

  • Liquid Injection

  • Hot Gas Heat

Optional Features

  • Door Switch Kit

  • Snow Covers

Door Switch Kit

A door switch is typically installed to stop unit operation when the cargo compartment door is opened to improve temperature control.

Snow Covers
A snow cover is available to keep snow from collecting on the condenser fan and keep it from operating properly.

2.2: System Components

The system consists of the following main components:

2.2.1: 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

2.2.2: 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

2.2.3: Evaporator

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

Evaporator

Evaporator

2.2.4: 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

HMI

HMI

2.2.5: 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.

2.2.6: 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).
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. Combined Compartment Symbol Indicates that the multi-temperature unit is working as a single temperature unit.

2.3: Electrical System

The unit’s controls and refrigeration components operate on 24 Vdc. The low voltage interface of the unit to the vehicle is 12V.

2.3.1: Fuses

The electrical components are protected by various fuses.

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.Refer to (Electrical Control System).

PDU Fuses – The PDU fuses is located inside the PDU. These 25 amp fuses are non-serviceable and must only be replaced by an authorized Thermo King Dealer.

Low Voltage e-PTO Jumper Harness- These fuses are located in the LV e-PTO section.

Fuse Location (condenser cover removed)
Note Make sure that the battery is not connected before the removal of the cover.

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: e-PTO Activation

The e-Pto button is located in the vehicle cabin on the dashboard. This button has to be pushed to engage the ePto and allow the unit get power from the vehicle battery and to start the refrigeration unit.

Important Refer to the bodybuilder manual for the activating the e-PTO in your vehicle.

Below procedure in an example for activating the e-PTO functionality.

  1. Press the e-PTO button on the dashboard.

    Important For Holdover activation, press and hold the e-PTO button for 3 seconds.

  2. The e-PTO button will start blinking, indicating waiting mode.

  3. The LED on the e-PTO button will be stable once the e-PTO is activated.

  4. Once the e-PTO is active, the dashboard will display ‘ePTO ACTIVE’ for standard activation and ‘ePTO+ ACTIVE’ for Holdover activation on the screen.

Standard Activation

Holdover Activation

3.3: Starting the Unit

  1. Start the vehicle.

  2. Press the ON/OFF Key located in the HMI. The HMI display will be activated.

  3. 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.

3.4: The Standard Display

The Standard Display appears when the unit is turned on and no other functions have been selected. The return air temperature appears in the display. In Figure below, the display shows a load compartment temperature of 38 degrees F, and that the unit is cooling the load compartment.

Note The unit undergoes a 20-second system check when the On/Off switch is turned On. During this time, the Standard Display shows the word CHEck.
The Standard Display

3.5: 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.

  4. Press and release the Enter key to enter the setpoint, or press and release the Select key to enter the setpoint and return to the Standard Display.

    Important If the Enter or 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

Setpoint Temperature Display

3.5.1: Changing the Setpoint in Multi-Temperature Units

For the Main Load Compartment of a Multi-Temperature Unit

  1. From the Standard Display, press the Select key twice to choose the setpoint display. The setpoint icon SP and the current setpoint temperature appear. See (Entering the Setpoint Temperature)

  2. Press the Up Arrow key or Down Arrow key to select a higher or lower setpoint. Each time an arrow key is pressed, the temperature changes by 1 degree.

  3. Press and release the ENTER key to enter the setpoint.

    Note If the Select or Enter key is not pressed within 20 seconds to select a new setpoint temperature, the unit continues to operate at the original Setpoint temperature.

For the Remote Load Compartment of a Multi-Temperature Unit

Setpoint Display on a Multi-Temperature Unit

  1. From the Standard Display, press the Select key twice to choose the setpoint display. The setpoint icon SP and the current setpoint temperature appear.

  2. From the Setpoint Display, press and release the SELECT key to go to the remote compartment temperature setting screen. The current setpoint temperature for the remote compartment and the letters SP2 appear on the display

  3. Press the Up Arrow key or Down Arrow key to select a higher or lower setpoint. Each time an arrow key is pressed, the temperature changes by 1 degree.

  4. Press and release the ENTER key to enter the setpoint, or press and release the SELECT key to enter the setpoint and return to the standard display.

    Note If the Select or Enter key is not pressed within 20 seconds to select a new setpoint temperature, the unit continues to operate at the original Setpoint temperature.

For the Compartment Selection (544.xx only)

  1. From the Standard Display, press the Select key twice to choose the setpoint display. The setpoint icon SP and the current setpoint temperature appear.

  2. From the Setpoint Display, press and release the SELECT key to go to the remote compartment temperature setting screen. The current setpoint temperature for the remote compartment and the letters SP2 appear on the display

  3. press and release the SELECT key to move to the CSE (Compartment Selection) screen.

  4. Press the key UP or DOWN to change options between the four different options available:

    1. 1-2: This is the standard multi-temperature setting where both compartments (zones) are active. This option shows the temperature in both compartments (zones) on the Standard Display.

      Standard Multi-Temperature Compartment Selection
      The Standard Display, showing the temperature in both compartments

    2. 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.

      C1 Multi-Temperature Compartment Selection
      The Standard Display, showing the temperature only in compartment 1

    3. 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.

      C2 Multi-Temperature Compartment Selection
      The Standard Display, showing the temperature only in compartment 2

    4. 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 is shown like that of a single temperature unit but with the triangle symbol activated to indicate that it is actually a Multi-Temperature unit operating as a single temperature unit.

      1 - 1 multi-temperature compartment selection
      The Standard Display, showing the temperature for Compartment 1 and the Combined Compartment Icon

  5. Press and release the ENTER key to select an option or press and release the SELECT key to select an option and return to the Standard Display.

3.6: 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.

  1. 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

  2. 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

  4. 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

  5. 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.

  6. 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.

3.7: DSR-III/DSR-3.1 Alarms

There are three alarm categories:

Manual Start

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

Manual Start

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.

Auto Start

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

P1E Alarm

For multi-temperature units, when a Return Air Sensor alarm [P2E] occurs in the remote compartment, the return air temperature reading for the remote compartment is replaced by the - - - icon. The temperature reading for the main compartment continues to be displayed. The Alarm icon also appears.

P2E Alarm

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.

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.

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
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   Thermal Protection Alarm - If the problem persists when the unit is restarted, contact your Thermo King Dealer.
tP4   CPM error - See CPM LED for alarm and/or Diagnostic tool.
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.

3.9: To View Alarm Codes

DSR-III/DSR-3.1 Alarms

Note Refer to the table on the following pages for a list of Gateway Control Module alarm codes.

If the Alarm icon is present, press the Select key once to show the Alarm screen. The most recent alarm code is shown on the display.

  • If no alarm conditions have occurred, the Alarm icon does not appear. If the Select key is pressed, the Alarm screen does not appear.

  • If more than one alarm code exists, each is displayed for several seconds.

Gateway Control Module Alarms

Note See the table on the following pages for a list of Gateway Control Module alarm codes.

  • If the Alarm icon is present, press the Select key once. GCx will appear (where x is the number of alarms present).

    Display showing Originator as Gateway Control Module and Quantity of Alarms Present is 1

  • Press the Up arrow to view the Alarm screen. The most recent alarm code is shown on the display.

  • If no alarm conditions have occurred, the Alarm icon does not appear. (If the Select key is pressed, the Alarm screen does not appear).

  • If more than one alarm code exists, each is displayed for several seconds.

The alarm code shown is for alarm code H0C (Power derating shutdown).

Compressor Drive Module Alarms

Note See the table on the following page for a list of CDM alarm codes.

  • If the Alarm icon is present, press the Select key once. CDN1 will appear.

    Display showing Originator as Compressor Drive Module and Quantity of Alarms Present is 1

  • Press the Up arrow to view the Alarm screen. The most recent alarm code is shown on the display.

  • If no alarm conditions have occurred, the Alarm icon does not appear. (If the Select key is pressed, the Alarm screen does not appear).

  • If more than one alarm code exists, each is displayed for several seconds.

The alarm code shown is for alarm code H30 (Compressor temperature protection).

3.10: 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:

  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.

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

3.11: Viewing Information Screens

Main Menu

From the Standard Display use the Select key to display:

  1. Alarms (if any active).

  2. Evaporator Manual Defrost.

  3. Condenser Manual Defrost (reverse cycle units only).

  4. 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.

  1. HC: Hours remaining to maintenance notice.

  2. tH: The total amount of time the unit has been switched on protecting the load.

  3. CC: Engine driven compressor operating hours.

  4. EC: Electric standby compressor operating hours.

  5. 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

  1. 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).

  2. Carefully check and record the load temperature when loading the truck. Note whether any products are out of temperature range.

  3. 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.

  4. 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

  1. Verify all doors are closed and locked.

  2. Adjust the thermostat to the desired temperature setpoint.

  3. Start the unit.

  4. 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-400e/E-500e/E–600e
Compressor Type Electrical hermetic compressor, rotary type
Oil Type PVE

Electrical Control System

  24 Vdc
Fuses
Common Fuses
Fuse 3: Evaporator Fan Motor (EFM1) 10 amps
Fuse 4: Evaporator Fan Motor (EFM2) 10 amps

Fuse 5: Liquid Injection Switch (LIS), Liquid Injection Valve Roadside compressor (LIV1), EVAP1 Defrost Hot Gas Solenoid Valve (PS1), Heat Pilot Solenoid (PS5), Bypass valve (PS7)

 10 amps
Fuse 6: Condenser fan for Series / Parallel operation 7.5 amps
Fuse 1: Condenser Fan Motor (CFM1) (located in CF1 wire, in an inline fuseholder, type ATO 32V) 10 amps
Fuse 2: Condenser Fan Motor (CFM2) (located in CF1 wire, in an inline fuseholder, type ATO 32V) 10 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 10 amps
Fuse 9: (Spectrum Only) Evaporator Fan 3 10 amps
Fuse 10: (Spectrum Only) Evaporator Fan 4 15 amps
Fuse 11: Drain Heaters (H1 and H2) 2 amps
Fuse 17: Drain Heaters (H3 and H4) (type MINI 32V) 2 amps
Fuse 23: Extra Activation Condenser Fan Motor (CFM2) (type MINI 32V) 10 amps
Fuse 13: Fuse in ePTO OEM connection 5 amps
Fuse 14: Fuse in ePTO OEM connection 5 amps
Fuse 15: Fuse in ePTO OEM connection 5 amps
 
Condenser Fan Motor
Voltage 26 Vdc
Full Load Current 4.7 Amps
Power Rating 122 W
RPM with Full Load 3,300
     
Evaporator Fan Motors (Each)
Voltage 26 Vdc
Full Load Current 4 Amps
Power Rating 104 W
RPM with Full Load 3,300
     
Coil for Hot Gas Solenoid (PS1, PS2, PS3, PS4)
Voltage 24 Vdc
Current 0.6 Adc
     
Coil for Liquid Injection Solenoid (LIS) – MAX Only
Voltage 24 Vdc
Current 0.6 Adc
     
Coil for Heat Pilot Solenoid (PS5) - Truck Engine Coolant Heat Option Only
Voltage 24 Vdc
Current 0.6 Adc
Resistance 8.0 ohms
     
Coil for Bypass (PS7)
Voltage 24 Vdc
Current 0.9 Adc
     
Drain Line Heaters (Each) - MAX Only
Voltage 24 Vdc
Contacts 0.9 amps ± 5% at 68 F (20 C)
Coil Resistance   13.8 ohms ± 5% at 68 F (20 C)
     
Power Distribution Unit (PDU)    
Voltage   24 Vdc
Current   24 Amps
     
Core Power Module (CPM)    
Voltage   12 VDC/24 VDC
Current   24 Amps

TracKing

Platform LTE Cat 1, GSM, Dual Sim ,128MB Flash, IP41
GSM/GPRS  
GPS  
Bluetooth Version 4.0 + LE
Serial Ports 1 External Serial Ports for TracKing extensions or Third-Party Connect
Input Power 10 - 30 V DC with overvoltage protection
Backup Battery 170 mAh Li-Ion battery 3.7 V (0.63 Wh)
Environmental Storage Temperature -20 °C to +85 °C (without battery)
-20 °C to +40 °C (with battery)
Certification & Approvals CE-RED, E-mark, Anatel, RCM

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

  1. Visually inspect belt.

  2. Listen for unusual noises, vibrations, etc.

  3. Visually inspect unit for fluid leaks (coolant, oil, refrigerant).

  4. Visually inspect unit for damaged, loose or broken parts (including air ducts and bulkheads, if so equipped).

  5. 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.

  1. Clean the outside cover of the unit. Use a damp cloth and neutral detergents. Do not use harsh cleaning products or solvents.

  2. Check for leaks.

  3. Check for loose or missing hardware.

  4. 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

V-100 Condenser, Serial Number Location

V-200 V–300 Condenser and Standby Compressor, Serial Number Locations

V-200 V–300 SPECTRUM Condenser and Standby Compressor, Serial Number Locations

V-500 V–600 Condenser, Serial Number Location

V-800 V–1000 Condenser, Serial Number Location

V-400X V-500X V–600X E-400e E-500e E600e Condenser, Serial Number Location

Engine Driven Compressor Serial Number Location

Standby Compressor Serial Number Location
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.