51585Book
51585Book
51585Book
SB-210/SB-310
TK 51585-2-OP (Rev. 0, 10/03)
The procedures described herein should be undertaken only by qualified personnel. Failure to implement
these procedures correctly may cause damage to the Thermo King unit or other property or personal
injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or any
other direct, indirect, special or consequential damage or liability whatsoever, arising out of or resulting
from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo King
unit.
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 EPA Emission Control System
Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . .19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Thermo King Corporation Responsibilities . . . . . .20
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Owner Responsibilities . . . . . . . . . . . . . . . . . . . . .21
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . 13 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . 14
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 15 Thermo King X430L Reciprocating Compressor . . . . .25
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 15
Safety Decals And Locations . . . . . . . . . . . . . . . . . . . 16
3
Unit Description (continued) Remote Status Light (Optional) . . . . . . . . . . . . . . . 45
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . 26
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Manual Pretrip Inspection
Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . . 27 (Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . . 47
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . 29 SB-210/310 Operating Instructions . . . . . . . . . . . . . 49
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Standard and Optional Temperature/Data Manage- Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . 51
ment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Turn Unit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Turn Unit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine Compartment Components . . . . . . . . . . . . . . . 32 Selection Of Operating Modes . . . . . . . . . . . . . . . . . . 55
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . 33 Selecting CYCLE SENTRY or Continuous Mode . . . . 56
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 58
SMART REEFER 2 (SR-2) Restart Unit-Continuous Run Operation . . . . . . . 59
Microprocessor Control Panel Description . . . . . . 39 Unit Fails To Start-Continuous Run Operation . . 59
SMART REEFER 2 (SR-2) Microprocessor Overview 39 Restart Unit—CYCLE-SENTRY Operation . . . . . 60
SR-2 Control Panel Overview . . . . . . . . . . . . . . . . 40 Unit Fails To Start-CYCLE-SENTRY Operation . 61
Control Panel Display Screen . . . . . . . . . . . . . . . . 40 Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control Panel Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 “Temperature Watch” Standard Display . . . . . . . . . . . 62
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Standard Display Variations . . . . . . . . . . . . . . . . . . . . 63
“Temperature Watch” Display . . . . . . . . . . . . . . . . . . . 42 Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . 64
Standard Display Variations . . . . . . . . . . . . . . . . . . . . 43 View Gauge Readings . . . . . . . . . . . . . . . . . . . . . . . . 66
4
SB-210/310 Operating Instructions (continued) Electric Standby Operation . . . . . . . . . . . . . . . . . . .119
View Sensor Readings . . . . . . . . . . . . . . . . . . . . . . . . 68 Starting the Unit on Electric Standby Operation . . . .120
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . 72 Unit fails to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Terminating a Defrost Cycle . . . . . . . . . . . . . . . . . . . . 73
Navigating SR-2 Operator Menu . . . . . . . . . . . . . . . . . 74 Loading and Enroute Inspections . . . . . . . . . . . . .123
Operator Menu Choices . . . . . . . . . . . . . . . . . . . . 75 Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . .123
Change Language . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . .125
Viewing and Clearing Alarm Codes . . . . . . . . . . . 78 Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . .126
Viewing Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Selecting CYCLE SENTRY or Continuous Mode . . . . 82 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Select Economy Mode . . . . . . . . . . . . . . . . . . . . . . . . 84
Selecting Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . 86 SB-210/310 Specifications . . . . . . . . . . . . . . . . . . .135
Selecting Diesel or Electric Operation . . . . . . . . . . . . 90 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Pretrip Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
View Time and Date . . . . . . . . . . . . . . . . . . . . . . . 96 Electrical Control System . . . . . . . . . . . . . . . . . . . . . .138
Datalogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Electric Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Printing a Trip Report . . . . . . . . . . . . . . . . . . . . . . 98 Standby Power Cord Requirements . . . . . . . . . . . . .138
Initiating a Start of Trip . . . . . . . . . . . . . . . . . . . . . 98 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . .139
Adjusting Display Brightness . . . . . . . . . . . . . . . . . . 100
Maintenance Inspection Schedule . . . . . . . . . . . . .141
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Viewing and Clearing Alarm Codes . . . . . . . . . . 103
5
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . 163
6
List of Figures
Figure 1:ELC (Extended Life Coolant) Nameplate Figure 9:Control Box With Service Door Open . . . . . .28
(Located on expansion tank in units Figure 10:Engine Compartment Components . . . . . . .34
equipped with ELC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Figure 11:Engine Compartment Components . . . . . . .35
Figure 2:Belt Warning Figure 12:Controller Interface Board (shown rotated 90
(Located on condenser housing) . . . . . . . . . . . . . . . . 16 degrees clockwise) . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 3:Belt Replacement Caution Figure 13:Control Panel . . . . . . . . . . . . . . . . . . . . . . . .39
(Located on condenser housing) . . . . . . . . . . . . . . . . 16 Figure 14:Dedicated And Soft Keys . . . . . . . . . . . . . . .40
Figure 4:Automatic Start Caution Figure 15:Standard Display . . . . . . . . . . . . . . . . . . . . .42
(Locations vary depending on model. Decals are located Figure 16:“Temperature Watch” Display . . . . . . . . . . .42
near areas that contain moving parts which can cause se- Figure 17: Standard Display Screen Variations. . . . . .43
vere injuries if hands or clothing become tangled when Figure 18:Remote Status Light . . . . . . . . . . . . . . . . . .45
unit automatically starts.) . . . . . . . . . . . . . . . . . . . . . . 17 Figure 19:SMART REEFER 2 Microprocessor Controller
Figure 5:Fan Caution 49
(Locations vary depending on model. Decals are located Figure 20:Control Box With Service Door Open . . . . .50
near areas that contain fans which can cause severe inju- Figure 21:ON Key . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
ries when unit automatically starts.) . . . . . . . . . . . . . . 17 Figure 22:“Turning Unit On” Screen Sequence . . . . . .53
Figure 6:Commodity Caution Figure 23:OFF Key . . . . . . . . . . . . . . . . . . . . . . . . . . .54
(Located on control box) . . . . . . . . . . . . . . . . . . . . . . . 18 Figure 24:“Turning Unit Off” Screen Sequence . . . . . .54
Figure 7:Door Latch Warning Figure 25:Standard Display . . . . . . . . . . . . . . . . . . . . .56
(Located on curbside door) . . . . . . . . . . . . . . . . . . . . . 18 Figure 26:Screen Sequence for Changing from CYCLE
Figure 8:SB-210/310 Front View . . . . . . . . . . . . . . . . . 23 SENTRY Mode to Continuous Mode . . . . . . . . . . . . . .56
7
List of Figures
8
List of Figures
9
List of Figures
10
Introduction
There is nothing complicated about operating and maintaining IMPORTANT: This manual is published for informational
your Thermo King unit, but a few minutes studying this purposes only and the information furnished herein should
manual will be time well spent. not be considered as all-inclusive or meant to cover all
contingencies. If more information is required, consult your
Performing pre-trip checks and enroute inspections on a
Thermo King Service Directory for the location and
regular basis will minimize on-the-road operating problems. A
telephone number of the local dealer.
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.
001 11
Introduction
12
Safety Precautions
Thermo King recommends that servicing be done only by a
WARNING: Keep hands and loose clothing clear of
Thermo King dealer. However, you should be aware of several
fans and belts at all times when the unit is operating
safety practices. This chapter gives basic safety precautions for
or when opening or closing compressor service
working with Thermo King units and describes the safety
valves.
stickers on your unit that you should be familiar with.
WARNING: Exposed coil fins can cause painful
General Safety Practices lacerations. Service work on the evaporator or
condenser coils should be done by a certified Thermo
DANGER: NEVER operate the unit with the King technician.
compressor discharge valve closed. Doing so could
cause the compressor to explode, causing death or CAUTION: Use extreme caution when drilling holes
serious injury. in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Do not drill into
WARNING: Always wear goggles or safety glasses structural components.
when working with or around the refrigeration system
or battery. Refrigerant or battery acid can cause
permanent damage if it comes in contact with your
eyes.
13
Safety Precautions
14
Safety Precautions
Refrigerant Oil Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
Observe the following precautions when working with or protect from infection or injury. Get prompt medical attention.
around refrigerant oil:
Inhalation: Move victim to fresh air and restore breathing if
WARNING: Always wear goggles or safety glasses to necessary. Stay with victim until emergency personnel arrive.
protect eyes from refrigerant oil contact.
First Aid–Refrigerant Oil
WARNING: Protect skin and clothing from Eyes: Immediately flush eyes with large amounts of water for
prolonged or repeated contact with refrigerant oil. at least 15 minutes while holding the eyelids open. Get prompt
Rubber gloves are recommended. medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with
WARNING: Wash thoroughly immediately after soap and water. Get medical attention if irritation persists.
handling refrigerant oil to prevent irritation.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
First Aid Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
First Aid–Refrigerant
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
15
Safety Precautions
AKB65
AKB66
AJA1947
16
Safety Precautions
AKB67 AKB68
17
Safety Precautions
WARNING
NEW DOOR LATCH DESIGN
REQUIRES DOOR TO BE SLAMMED
SHUT BEFORE MOVING TRAILER.
FAILURE TO CLOSE DOOR FIRMLY
CAN ALLOW WIND TO TEAR DOOR
FROM REFRIGERATION UNIT AND
CAUSE INJURY TO OTHERS.
ATENCIÓN
AKB69
NUEVO DESEÑO DE CERRADURA
REQUIERE ASOTAR LA PUERTA ANTES
DE CONDUCIR EL TRAILER.
AL NO CERRAR LA PUERTA CON
Figure 6: Commodity Caution FIRMEZA EL VIENTO PODRÍA
(Located on control box) DESPRENDER LA PUERTA DE LA
UNIDAD DE REFRIGERACIÓN Y
CAUSAR DAÑOS A OTROS.
AEA2422
18
EPA Emission Control System Warranty
Statement
Thermo King warrants to the initial owner and each subsequent During the term of this warranty, Thermo King will provide,
owner that the certified, non-road diesel engine in your unit is: through a Thermo King authorized service dealer or other
1. Designed, built and equipped so as to conform, at the time establishment authorized by Thermo King, repair or
of sale, with all applicable regulations adopted by the replacement of any warranted part at no charge to the non-road
United States Environmental Protection Agency (EPA). engine owner.
In emergency, repairs may be performed at any service
2. Free from defects in materials and workmanship in
establishment, or by the owner, using any replacement part.
specific emission related parts for a period of five years or
Thermo King will reimburse the owner for their expenses,
3,000 hours of operation, whichever comes first, after date
including diagnostic charges for such emergency repair. These
of delivery to the initial owner.
expenses shall not exceed Thermo King’s suggested retail price
If an emission-related part or component fails during the for all warranted parts replaced, and labor changes based on
warranty period, it will be repaired or replaced. Any such part Thermo King’s recommended time allowance for the warranty
or component repaired or replaced under warranty is warranted repair and the geographically appropriate hourly labor rate.
for the warranty period.
19
EPA Emission Control System Warranty Statement
Any replacement part can be used for maintenance or repairs. If failure of one of these parts or components results in failure
The owner should ensure that such parts are equivalent in of another part or component, both will be covered by this
design and durability to genuine Thermo King parts. However, warranty.
Thermo King is not liable for parts that are not genuine
Thermo King parts.
Responsibilities
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency. This warranty is subject to the following:
20
EPA Emission Control System Warranty Statement
Limitations
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
• Any application or installation Thermo King deems
improper as explained in this Operator’s Manual or any
other manuals provided with the unit.
21
EPA Emission Control System Warranty Statement
22
Unit Description The Electronic Throttling Valve (ETV) provides enhanced
control of the refrigeration system. The ETV is optional on the
SB-210 30 and standard on the SB-210 50 and SB-310 30.
In addition to the quiet TK 486 engine, the SB-210/310
Unit Overview includes other sound deadening components as standard and
The Thermo King SB-210/310 is a one piece, self-contained, optional equipment. Among them are a special exhaust system,
diesel powered, air cooling/heating unit operating under the sound-proof insulation, special door gaskets and
control of a programmable microprocessor controller. The unit sound-absorbing doors. Refer to the Design Features list on the
mounts on the front of the trailer with the evaporator extending following pages.
through an opening in the front wall.
The SB-210/310 features air cooling and heating using a quiet
running Thermo King TK 486, 4-cylinder, water cooled, direct
injection diesel engine.
The SB-210 and SB-310 are available in the following three
models:
SB-210 30: Cooling and heating on diesel engine operation.
SB-210 50: Cooling and heating on diesel engine operations
and electric standby operation.
SB-310 30: Cooling and heating on diesel engine operation.
Figure 8: SB-210/310 Front View
23
Unit Description
24
Unit Description
25
Unit Description
ELC (Extended Life Coolant) CAUTION: Do not add “RED” Extended Life
ELC (Extended Life Coolant) is standard on all SB-210 and Coolants to cooling systems using “GREEN” or
SB-310 units. The maintenance interval for ELC is five years “BLUE-GREEN” coolants. Do not add “GREEN” or
or 12,000 hours. A nameplate on the coolant expansion tank “BLUE-GREEN” coolants to cooling systems using
identifies units with ELC (see “Safety Decals and Locations”). “RED” Extended Life Coolants.
The new engine coolant, Chevron Extended Life Coolant, is NOTE: The use of 50/50% pre-mixed ELC is recommended
RED in color instead of the previous GREEN or to assure that de-ionized water is being used. If 100% full
BLUE-GREEN colored conventional coolants. strength concentrate is used, de-ionized or distilled water is
ELC cannot be used in older units. The water pump seal recommended instead of tap water to insure the integrity of
bellows and O-rings used in older units are not compatible with the cooling system is maintained.
ELC.
26
Unit Description
27
Unit Description
Control System
1 WARNING: Do not operate the unit until you are
completely familiar with the location and function of
2 each control.
The SB-210/310 units operate under the control of an SR-2
Microprocessor. The Microprocessor components are located
3 inside the Electrical Control Box that is located inside the
lower roadside service door. See Figure 9. The Microprocessor
4 has a Control Panel, also referred to as the “Controller.” The
Controller is mounted on the face of the Electrical Control
Box. It is clearly visible through an opening in the lower
5 roadside service door. See Figure 9. The Controller operates
the SB-210/310 units. Some basic controller functions are
6 changing setpoint and operating mode, viewing gauge, sensor
AJA1950
and hourmeter readings, initiating defrost cycles and viewing
and clearing alarms. The controller completes other functions
1. Electrical Control Box 4. Controller that will be described in detail through out the operating
2. Microprocessor On/Off 5. Controller On Key instructions.
Switch
3. Computer Download Ports 6. Controller Off Key
Figure 9: Control Box With Service Door Open
28
Unit Description
The unit will operate in one of the following modes, depending Continuous Run Operation
on the air temperature in the trailer, as sensed by the
• High Speed Cool
microprocessor controller:
• Low Speed Cool
CYCLE-SENTRY Operation • Low Speed Modulated Cool (Optional Model 210 50)
• High Speed Cool • Low Speed Modulated Heat (Optional Model 210 50
• Low Speed Cool • Low Speed Heat
• Null (Engine Off) • High Speed Heat
• Low Speed Heat • Defrost
• High Speed Heat
• Defrost CYCLE-SENTRY Start-Stop Controls
The CYCLE-SENTRY Start-Stop fuel saving system provides
optimum operating economy.
29
Unit Description
30
Unit Description
31
Unit Description
32
Unit Description
Unit Protection Devices Low Oil Level Switch: The low oil level switch closes if the
oil drops below an acceptable level. If it stays closed for a
Fuse Link (Current Limiter): The fuse link is located in the specified time, the microprocessor shuts the unit down and
positive battery cable. The fuse link protects the electric records alarm code 66.
system from a short.
Preheat Buzzer: The preheat buzzer sounds when the
High Pressure Cutout Switch: The high pressure cutout CYCLE-SENTRY system energizes the preheat relay. This
switch is located on the compressor discharge manifold. If the warns anyone near the unit that the CYCLE-SENTRY systems
compressor discharge pressure becomes excessive, the switch is about to start the engine.
opens the circuit to the fuel solenoid to stop the engine.
Fuses: Various fuses are located on the controller interface
High Pressure Relief Valve: This valve is designed to board to protect circuits and components. Refer to the
relieve excessive pressure in the refrigeration system. following table. See Figure 12 on page 36.
33
Unit Description
1
9
2
3 10
4 11
12
5
6 13
14
7
15
16
8 17
AJA1921
34
Unit Description
35
Unit Description
AJA1942
36
Unit Description
37
Unit Description
38
SMART REEFER 2 (SR-2)
Microprocessor Control Panel Description
SMART REEFER 2 (SR-2)
Microprocessor Overview
This unit operates under the control of a Microprocessor. The
microprocessor has a control panel that is connected to the
microprocessor and used to operate the unit. The control panel
is located on the roadside control box door. See Figure 13.
The control panel is used to monitor unit operation and change
miscellaneous settings. Complete functions are described in
detail in the Operators Section.
AJA1956
39
SMART REEFER 2 (SR-2) Microprocessor Control Panel Description
40
SMART REEFER 2 (SR-2) Microprocessor Control Panel Description
Control Panel Keys The four “soft” keys under the display are
multi-purpose keys. See Figure 14. Their
The four keys on the left and right sides of the display screen function changes depending on the operation
are “dedicated keys”. See Figure 14” Their functions are listed being performed. If a soft key is active, it’s
below. function will be shown in the display directly
On Key: This key is used to turn the unit on. The above the key. For more information, see the
Thermo King Logo screen will appear briefly. Operators Section.
The display will then show the Standard Display Typical soft key applications:
of box temperature and setpoint when the unit is
•Set Point
ready to run. For more information see the
Operators Section. •Gauges
Off Key: This key is used to turn the unit off. •Sensors
The unit will enter the power-down sequence •Menu
when this key is pressed. For more information
see the Operators Section. •Next/Back
41
SMART REEFER 2 (SR-2) Microprocessor Control Panel Description
Standard Display 1
The Standard Display is the default display on the display
screen. It appears if no other display function is selected. See
Figure 15. The Standard Display shows the box temperature
and setpoint. The box temperature is measured by the 2
controlling sensor. This is usually the return air sensor. The box
temperature shown in the figure is 42.5F. The setpoint shown is AJA1907
38F. See Figure 15.
AJA1850
“Temperature Watch” Display
The Standard Display defaults to the “Temperature Watch”
Figure 15: Standard Display Display after 2-1/2 minutes of non-use. The “Temperature
Watch” screen displays the same box temperature and setpoint
1. On Key 3. Standard Display but in larger fonts. This creates easy operator viewing from a
2. Off Key distance. To return to the Standard Display press the menu soft
key. See Figure 16.
42
SMART REEFER 2 (SR-2) Microprocessor Control Panel Description
43
SMART REEFER 2 (SR-2) Microprocessor Control Panel Description
44
Remote Status Light (Optional)
The Remote Status Light mounts on the cargo box for easy
viewing of the unit’s mode. The remote light indicates
operating status as follows:
Green status light: Illuminates the “T” portion of the TK
logo when the unit is functioning properly with no alarm
codes.
Amber status light: Illuminates the “K” portion of the TK
logo when the unit has a check alarm code, but is still
functioning properly. Check the unit as soon as possible to
correct the alarm condition.
ANA23
Flashing status lights: The “T” (in green) and the “K” (in
amber) are illuminated and blinking when the unit has a
shutdown alarm code and the load integrity is at risk. Correct Figure 18: Remote Status Light
the alarm condition immediately.
45
Remote Status Light (Optional)
46
Manual Pretrip Inspection
(Before Starting the Unit)
Pretrip inspections are an important part of a preventative Engine Coolant: The engine coolant must have antifreeze
maintenance program designed to minimize operating protection to -30 F (-34 C). Check and add coolant to the
problems and breakdowns. Perform this pre-trip inspection expansion tank.
before every trip involving refrigerated cargo.
WARNING: Do not remove the expansion tank cap
NOTE: Pretrip inspections are not intended to take the place while the coolant is hot.
of regular maintenance inspections.
Fuel: Make sure the diesel fuel supply is adequate to Battery: Make sure the battery terminals are tight and free of
guarantee engine operation to the next check point. Allow for corrosion.
maximum fuel consumption of one gallon per hour of engine
operation. Belts: Make sure belts are in good condition and adjusted to
the proper tension. For more information about belt tension,
Engine Oil: Check the engine oil level. It should be at the see the Specifications chapter.
Full mark when the dipstick is threaded all the way into the oil
pan. Do not overfill. Electrical: Check the electrical connections to make sure they
are securely fastened. Wires and terminals should be free of
CAUTION: Turn the engine off before checking the corrosion, cracks, and moisture.
engine oil level. Structural: Visually inspect the unit for leaks, loose or
broken parts, and other damage.
001 47
Manual Pretrip Inspection (Before Starting the Unit)
48
SB-210/310 Operating Instructions
Thermo King has applied the latest advances in computer
technology to develop a device that controls temperature and
unit functioning, and displays operating information quickly
and accurately.
There is nothing complicated about learning to operate the
SB-210/310, but you will find that a few minutes studying the
contents of this manual will be time well spent.
The following pages are general instructions for operating the
SB-210/310 and SMART REEFER 2 Microprocessor
Controller. It is recommended that you become completely
familiar with controller operation before attempting to start or
operate the unit.
AJA1956
Figure 19: SMART REEFER 2 Microprocessor
Controller
49
SB-210/310 Operating Instructions
Control System
1 The SB-210/310 units operate under the control of an SR-2
WARNING: Do not operate the unit until you are
2 completely familiar with the location and function of
each control.
Microprocessor. The Microprocessor components are located
3 inside the Electrical Control Box that is located inside the
lower roadside service door. See Figure 20. The
4 Microprocessor has a Control Panel, also referred to as the
“Controller.” The Controller is mounted on the face of the
Electrical Control Box. It is clearly visible through an opening
5 in the lower roadside service door. See Figure 20. The
Controller operates the SB-210/310 units. Some basic
6 controller functions are changing setpoint and operating mode,
AJA1950 viewing gauge, sensor and hourmeter readings, initiating
defrost cycles and viewing and clearing alarms. The controller
1. Electrical Control Box 4. Controller completes other functions that will be described in detail
through out the operating instructions.
2. Microprocessor On/Off 5. Controller On Key
Switch
3. Computer Download Ports 6. Controller Off Key
Figure 20: Control Box With Service Door Open
50
SB-210/310 Operating Instructions
Microprocessor ON/OFF Switch: This switch supplies or Starting the Diesel Engine
removes electrical power to the Microprocessor. It is located
on the left side of the control box. See “Figure 20: Control Diesel engine preheats and starts are automatic in both
Box With Service Door Open,”. Continuous Mode and CYCLE SENTRY Mode. The engine
will preheat and start if necessary when the unit is turned on.
Controller ON Key: Pressing this key supplies electrical The engine preheat and start will be delayed in CYCLE
power to the controller. It is located on the face of the display. SENTRY mode if there is no current need for the engine to run.
See Figure 20. Once a key or sequence of keys are pressed on the controller,
Controller OFF Key: Pressing this key removes electrical the engine will preheat and start 10 seconds after pressing the
power to the controller. See Figure 20. last key.
Refer to the Turn Unit On/Off instructions on the following
CAUTION: The Microprocessor and Controller must pages.
be turned off before connecting or disconnecting the
CAUTION: The engine may start automatically any
battery or servicing the microprocessor system.
time the unit is turned on.
CAUTION: The microprocessor is vulnerable to
damage from Electro Static Discharge (ESD). This
damage is not always immediately apparent. As a WARNING: Never use starting fluid.
result of ESD, a circuit can be damaged but may
continue to operate temporarily, only to fail later.
51
SB-210/310 Operating Instructions
Turn Unit On 3
52
SB-210/310 Operating Instructions
53
SB-210/310 Operating Instructions
AJA1850
Figure 23: OFF Key Figure 24: “Turning Unit Off” Screen Sequence
54
SB-210/310 Operating Instructions
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SB-210/310 Operating Instructions
Selecting CYCLE SENTRY or 5. The Standard Display screen appears and the bar on top of
screen reads the new mode. See Figure 26 and Figure 27.
Continuous Mode
6. Press the MODE Selection Key again to change the unit
When CYCLE SENTRY Mode is selected the unit will start back to the previous mode.
and stop automatically to maintain the setpoint, keep the 3
engine warm and the battery charged. When Continuous Mode
is selected, the unit will start automatically and run
continuously to maintain setpoint and provide constant airflow. 2
56
SB-210/310 Operating Instructions
57
SB-210/310 Operating Instructions
After Start Inspection Pre-Cooling: Make sure that the setpoint is at the desired
temperature. ‘Changing the Setpoint Screen Sequence” on
After the unit is running, check the following items to confirm page 65. Allow the unit to run for a minimum of 30 minutes
that the unit is running properly. (longer if possible) before loading the trailer.
Oil Pressure: Check the engine oil pressure by pressing the This provides a good test of the refrigeration system while
Gauges Soft Key. ‘Viewing Gauges Screen Sequence” on page removing residual heat and the moisture from the trailer
67. The Engine Oil Display will indicate OK or LOW. interior to prepare it for a refrigerated load.
Ammeter: Check the ammeter reading by pressing the Defrost: When the unit has finished pre-cooling the trailer
Gauges Soft Key. ‘Viewing Gauges Screen Sequence” on page interior, manually initiate a defrost cycle. ‘Initiating A Manual
67.The Amps Display should indicate a positive charge Defrost Screen Sequence” on page 73. This will remove the
amperage rate to the battery. A negative (-) number indicates a frost that builds up while running the unit to pre-cool the
discharge condition. trailer.
Compressor Oil: The compressor oil level should be visible
in the compressor sight glass after 15 minutes of operation.
58
SB-210/310 Operating Instructions
59
SB-210/310 Operating Instructions
60
SB-210/310 Operating Instructions
61
SB-210/310 Operating Instructions
Standard Display 1
1
2. Menu Soft Key
Figure 29: “Temperature Watch” Standard Display
2
3
62
SB-210/310 Operating Instructions
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SB-210/310 Operating Instructions
Changing the Setpoint • If the YES Key was pressed, the setpoint change made with
the “+” or “-” keys will be accepted, and the following
To change the setpoint complete the following steps. screens will appear.
1. Press the EXIT Soft Key to return to the Standard Display 5. The “Programming New Setpoint” Screen will appear. See
Screen (several times may be required). If the Figure 32.
“Temperature Watch” Standard Display Screen is
showing, press the MENU Soft Key once to return to the 6. The “New Setpoint Is XX” Screen briefly appears. See
Standard Display Screen. Figure 32.
2. Press the SETPOINT Soft Key on the Standard Display. See 7. The Standard Display Screen appears with setpoint
Figure 31. The “Current Setpoint” screen appears. See changed to the new setpoint. See Figure 32.
1
Figure 32.
3. Press the + or - Soft Keys to change the setpoint reading.
See Figure 32.
4. Press the YES OR NO Soft Key accordingly as described AJA1850
below. See Figure 32. 2
• If the NO Key is pressed the setpoint change made with
the “+” or “-” keys will not be accepted, the setpoint will 1. Standard Display
not be changed and the display will return to the Standard 2. Setpoint Soft Key
Display.
Figure 31: Standard Display
NOTE: This generates an alarm code 127 “Setpoint Not
Entered”. See Figure 32.
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SB-210/310 Operating Instructions
If “YES” soft key was pressed If “NO” soft key was pressed
65
SB-210/310 Operating Instructions
66
SB-210/310 Operating Instructions
67
SB-210/310 Operating Instructions
68
SB-210/310 Operating Instructions
69
SB-210/310 Operating Instructions
70
SB-210/310 Operating Instructions
Figure 38: Viewing Sensors Screen Sequence (continued from previous page)
71
SB-210/310 Operating Instructions
72
SB-210/310 Operating Instructions
73
SB-210/310 Operating Instructions
74
SB-210/310 Operating Instructions
75
SB-210/310 Operating Instructions
Change Language 5. Press the + or - Keys to select the desired language. See
Figure 44.
If the Language feature is enabled an alternate language can be
selected from the Language Menu. After a new language is 6. When the desired language is shown press the YES Key to
chosen all displays will appear in that language. confirm the choice.
Languages currently supported are English, German, Spanish, 7. The “PROGRAMMING LANGUAGE-PLEASE WAIT”
French Italian, Dutch, Danish, Portuguese, Russian, Japanese Screen briefly appears.
and Norwegian. The default language is English. Only 8. The “LANGUAGE SELECTED IS XXX” Screen briefly
languages that have been enabled will appear on this menu. appears.
To select an alternate language: 9. The display returns to language menu screen. The display
1. Press the EXIT Soft Key to return to the Standard Display will return to the standard display if no keys are pressed.
Screen (several times may be required). If the Press the NEXT Key to select a different main menu item.
“Temperature Watch” Standard Display Screen is Press the EXIT Key to return to the Standard Display.
showing, press the MENU Soft Key once to return to the
Standard Display Screen.
2. Press the MENU Key on the Standard Display Screen.
1
3. The Language Menu Screen appears. Press the SELECT
Key to choose the language menu Screen. See Figure 44. AJA1850
4. The “NEW LANGUAGE WILL BE” Screen will appear 1. Menu Key
as shown below. See Figure 44.
Figure 43: Standard Display
76
SB-210/310 Operating Instructions
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SB-210/310 Operating Instructions
Viewing and Clearing Alarm Codes 7. If a serious alarm occurs, the unit will be shut down to
prevent damage to the unit or the load. If this occurs, the
Alarms are viewed and cleared using the Alarm Menu as
display will show that the unit is shut down and display
follows.
the alarm code that caused the shutdown.
1. Press the EXIT Soft Key to return to the Standard Display
8. To clear an alarm press the CLEAR Soft Key.
Screen (several times may be required). If the
“Temperature Watch” Standard Display Screen is 9. For additional information regarding the alarm shown on
showing, press the MENU Soft Key once to return to the the display press the HELP Soft Key. A help message will
Standard Display Screen. appear. Also refer to the complete alarm code list in the
alarm code section.
2. From the Standard Display Screen, press the MENU Soft
Key. 1
3. Press the Next Soft Key until the Alarm Menu appears.
4. Press the Select Soft Key. The Alarm Display will appear.
2
5. If no alarms are present, the “No Alarm” Screen is shown.
Press the Exit Soft Key to return to the Standard Display.
AJA1626
6. If alarms are present, the quantity of alarms and the most 1. Standard Display
recent alarm code number will be shown. If there is more
than one alarm, press the NEXT Key to view each alarm. 2. Menu Key
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SB-210/310 Operating Instructions
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SB-210/310 Operating Instructions
Viewing Hourmeters
Hourmeters can be viewed in the Hourmeters Menu as follows: 1
3. Press the NEXT and BACK Soft Keys repeatedly and Scroll 1. Standard Display
through the Main Menu until the Hourmeters Main Menu
Screen appears. 2. Menu Key
4. Press the SELECT Key to enter the Hourmeters Menu. See Figure 47: Standard Display
Figure 48.
5. Press the NEXT and BACK keys to view the hourmeter
displays.
80
SB-210/310 Operating Instructions
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SB-210/310 Operating Instructions
Selecting CYCLE SENTRY or 7. The display then returns to the Mode Menu. Press the
SELECT Key again to change the mode again.
Continuous Mode
When CYCLE SENTRY mode is selected the unit will start CAUTION: If the unit is in CYCLE SENTRY null
and stop automatically to maintain the setpoint, keep engine and the mode is switched to Continuous Mode, the
warm and the battery charged. When Continuous Mode is unit will start automatically.
selected, the unit will start automatically and run continuously
to maintain setpoint and provide constant airflow. NOTE: Mode selection can also be changed by pressing the
Mode Selection Key. See Figure 49 on page 82.
To select/change the mode, complete the following steps:
1. Press the EXIT Soft Key to return to the Standard Display
1
Screen (several times may be required). If the
“Temperature Watch” Standard Display Screen is
showing, press the MENU Soft Key once to return to the 3
Standard Display Screen. 2
4. Press SELECT Key to enter the Mode Menu. See Figure 50. 2. Menu Soft Key
5. Press the SELECT Key, to switch between modes,. 3. Mode Selection Key
6. The new mode is then confirmed for 10 seconds. Figure 49: Standard Display
82
SB-210/310 Operating Instructions
83
SB-210/310 Operating Instructions
Select Economy Mode 5. Press the NEXT Key as required to display Economy
Mode. The current state of Economy mode, either enabled
Economy Mode is used on selected loads that do not require or disabled will appear in the display.
critical temperature control. The temperature control points are
relaxed and other features are optimized for maximum fuel 6. Press the SELECT Key to turn the Economy Mode on. The
economy. Economy Mode will be enabled or disabled per your display will confirm the change.The new mode is then
company policy. If it is disabled, the economy screens will not confirmed for 10 seconds.
appear on your display. 1
If enabled, select Economy Mode as follows:
1. Press the EXIT Soft Key to return to the Standard Display
Screen (several times may be required). If the 2
84
SB-210/310 Operating Instructions
Figure 52: Turning On Economy Mode Figure 53: Turning Off Economy Mode
85
SB-210/310 Operating Instructions
86
SB-210/310 Operating Instructions
When Sleep mode is entered, the operator can program an 2. Press the MENU Key.
automatic Wake-up Time up to a week away. Using this
3. Press the BACK and NEXT Key as required to show the
feature, the unit will automatically restart and run normally at
Mode Menu. Press the SELECT Key on the Mode Menu.
the determined time. If a Wake-up Time is programmed, the
Press the NEXT Key as required to display the Sleep Mode
operator can also program an automatic Pretrip Test when the
screen.
unit restarts.
4. Press the SELECT Key to start the Sleep Mode.
Select Sleep Mode as follows:
5. The operator can now choose to program a Sleep Mode
1. Press the EXIT Soft Key to return to the Standard Display
Wake-up Time or simply enter Sleep Mode immediately.
Screen (several times may be required). If the
If the NO Soft Key is pressed, the unit will immediately
“Temperature Watch” Standard Display Screen is
enter Sleep Mode.
showing, press the MENU Soft Key once to return to the
Standard Display Screen.
87
SB-210/310 Operating Instructions
6. The display will show SLEEP and the unit will start and 11. The Display will now prompt the operator to “Run A
stop as required to keep engine warm and/or the battery Pretrip On Wake Up?” Press YES soft key or the NO soft
charged. Sleep mode does not maintain the compartment Key accordingly and the display will show the unit is
temperature. programming the sleep mode.
7. Press the EXIT key to exit Sleep Mode or turn the unit off 12. The display will show SLEEP and the unit will start and
and back on. The unit will resume normal operation and stop as required to keep the engine warm and/or the
control to setpoint. battery charged. Sleep mode does not maintain
8. To enter a Wake-up Time verify that the unit clock is set compartment temperatures.
properly. Then press the YES Key at the Sleep Mode menu. 13. The unit will restart at the programmed time (in this
example 18:37 hours) and perform a Pretrip (if selected).
Press the + or - keys to select the day the unit is to restart
After the Pretrip is complete the test results will be
in normal operation. In this example Monday has been
displayed and the unit will resume normal operation and
chosen. Press the YES key to confirm the day.
control to setpoint.
9. The display will now prompt the operator for the Hour the
14. To exit Sleep Mode before the selected Wake-up time
unit is to restart in normal operation. In this example 18:00
press the EXIT key or turn the unit off and back on. The
hours has been chosen. Note that 24 hour “military time”
unit will resume normal operation and control to setpoint.
is used. Press the YES key to confirm the hour.
10. The display will now prompt the operator for the minute
the unit is to restart in normal operation. In this example
18:37 hours has been chosen. Press the YES key to confirm
the minute.
88
SB-210/310 Operating Instructions
89
SB-210/310 Operating Instructions
90
SB-210/310 Operating Instructions
Figure 57: Programming Diesel Mode Figure 58: Programming Electric Standby Mode
91
SB-210/310 Operating Instructions
A Pretrip test verifies unit operation. The pretrip menu allows Pretrip tests proceed in the order shown below. A Full Pretrip
the operator to select and initiate a pretrip test. If the Pretrip is Test includes all tests. A Running Pretrip Test is started with
entered with the unit not running a Full Pretrip with device the engine or motor running and does not include the Amp
amp checks will be performed. If the Pretrip is entered with the Checks or Engine Start Check.
unit running in either diesel or electric mode a Partial Pretrip is • Amp Checks – Each electrical control component is
performed. Results are reported as PASS, CHECK or FAIL energized and the current drawn is confirmed as within
when the Pretrip Test is completed. specification.
Pretrip Test Conditions • Engine Start – The Engine will start automatically.
• Pretrip Test can be run in either Diesel or Electric Mode. • Defrost – If the coil temperature is below 45°F (7°C), a
• The unit will autoswitch from Diesel Mode to Electric defrost is cycle is initiated.
Mode or from Electric Mode to Diesel Mode during a • Cool Check – The ability of the unit to cool in low speed is
Pretrip Test if these features are enabled. checked.
Pretrip Tests are not allowed if: • RPM Check – The engine RPM in high and low speed is
• Any alarms are present. checked during the Cool Check.
• The unit is in Sleep Mode. • Heat Check - The ability of the unit to heat in low speed is
checked.
92
SB-210/310 Operating Instructions
• Report Test Results – The test results are reported as 3. Press the BACK and NEXT Keys as required to show the
PASS, CHECK or FAIL when the Pretrip is completed. If Pretrip Menu.
test results are CHECK or FAIL alarm codes will exist to
4. Press the SELECT Key to start a Pretrip.
direct the technician to the source of the problem.
5. A Full Pretrip will be initiated if the unit is not running,. If
If a Pretrip is initiated with the engine shut down a Full Pretrip the unit is running in either diesel or electric mode a
will be performed. If a Pretrip is initiated with the engine or Running Pretrip will be performed.
motor running a Running Pretrip is performed.
6. The Pretrip display appears. The top line of the display
Before initiating a Pretrip, clear all alarm codes.
indicates the unit is performing the non-running Pretrip.
Start a Pretrip as follows: Test progress is measured by the number of tests
completed out of a total of 26. The soft keys may be used
1. Press the EXIT Soft Key to return to the Standard Display
during the Pretrip Test to select the Hourmeter, Gauge or
Screen (several times may be required). If the
Sensor menus.
“Temperature Watch” Standard Display Screen is
showing, press the MENU Soft Key once to return to the 7. Turn the unit off to stop a Pretrip Test at any time. This
Standard Display Screen. will generate Alarm Code 28 Pretrip Abort. Other alarm
2. Press the MENU Key. codes may also be generated. This is normal when the
Pretrip test is halted before completion.
93
SB-210/310 Operating Instructions
94
SB-210/310 Operating Instructions
95
SB-210/310 Operating Instructions
1. Standard Display
2. Menu Key
96
SB-210/310 Operating Instructions
Datalogging
The SR-2 controller is equipped with Datalogging capability. 1
Data logging can store trip information for later use. A “Start
of Trip” is initiated to accurately store information,.
Trip data is logged as follows:
2
ServiceWatch™: ServiceWatch™ is standard with all
SB210/SB310 units. Its an integrated data logging system that
records operating events, alarm codes and compartment
AJA1850
temperatures as they occur and at preset intervals.
CargoWatch™: CargoWatch™ is an optional datalogger that
1. Standard Display
logs data of up to six temperature sensor/probes, 4 door
switches, humidity sensor data averaging and programmable 2. Menu Soft Key
temperature and out of range alarms.
Figure 62: Standard Display
97
SB-210/310 Operating Instructions
98
SB-210/310 Operating Instructions
99
SB-210/310 Operating Instructions
100
SB-210/310 Operating Instructions
101
SB-210/310 Operating Instructions
102
Alarms
Viewing and Clearing Alarm Codes Prevent Alarms: are indicated at the top of the Standard
Display with the statement [UNIT IN PREVENT MODE]. The
Alarms may be one of four types as shown. Alarm Display must be used to view the existing alarms. The
Log Alarms: Log Alarms are indicated at the top of the unit may wait a timed restart interval or until conditions allow
standard Display for 30 seconds each time the unit is turned on. and then restart. If the unit is in a restart interval Alarm Code
The alarm indication will go off after 30 seconds. The Alarm 84 Restart Null will be present along with the Prevent Alarm.
Display must be used to view the existing alarms. This level of In other cases the unit may restart or run with reduced
alarm serves as a notice to take corrective action before a performance to determine if continued operation is possible. If
problem becomes severe. Maintenance items such as the alarm does not reoccur with reduced performance the unit
maintenance hour meter time-outs are log alarms. will then return to full performance. If the unit is operating
with reduced performance Alarm Code 85 Forced Unit
Check Alarms: Check Alarms are indicated at the top of the Operation will also be present.
Standard Display with the statement [SERVICE REQUIRED
WITHIN 24 HOURS]. The Alarm Display must be used to Shutdown Alarms: Replaces the Standard Display with a
view the existing alarms. This level of alarm serves as a notice flashing Alarm Display and the statement [UNIT NOT
to take corrective action before a problem becomes severe. The RUNNING – SERVICE REQUIRED]. The flashing display
unit will run with check alarms but some features and functions shows the alarm that caused the shutdown. Shutdown alarms
may be inhibited. will force the unit into shutdown. The unit will remain in
shutdown until the shutdown alarm is cleared. Exceptions are
103
Alarms
104
Alarms
Alarms
SR2 Alarm Codes
Code Description Operator Help
00 No Alarms
2 Evaporator Coil Sensor Manually monitor load temperature. Report alarm at end
of the day.
3 Return Air Sensor Manually monitor load temperature. Report alarm at end
of the day.
4 Discharge Air Sensor Manually monitor load temperature. Report alarm at end
of the day.
5 Ambient Temp Sensor Report alarm at end of the day.
6 Coolant Temp Sensor Report alarm at end of the day.
7 Engine RPM Sensor Report alarm at end of the day.
8 Unit Running on Coil Sensor
9 High Evaporator Temperature Manually monitor load temperature. Report alarm at end
of the day.
105
Alarms
106
Alarms
107
Alarms
108
Alarms
109
Alarms
110
Alarms
111
Alarms
112
Alarms
113
Alarms
114
Alarms
115
Alarms
116
Alarms
117
Alarms
118
Electric Standby Operation
Model 50 units are equipped with Electric Standby. This
feature allows the unit to operate on electric power as well as
be powered by the standard diesel engine.
During Electric Standby operation, power to the unit is
supplied by an electric motor connected to a high voltage
power source. Check the unit for proper power source ratings.
119
Electric Standby Operation
Electric Power Receptacle: The electric power receptacle Starting the Unit on Electric
is used to connect the unit to an appropriate electric power
source for electric standby operation. (Place the Standby Operation
microprocessor On/Off Switch in the Off position before Start the unit on Electric Standby operation as follows:
connecting or disconnecting the power cord).
1. Press the controller Off key.
CAUTION: Always turn off the electric power supply 2. Turn the microprocessor On/Off switch to the “Off”
when handling, connecting, or disconnecting high position.
voltage power cords.
3. Connect the unit electric power receptacle to an
appropriate electric power supply.
CAUTION: Do not start the electric drive motor
unless the diesel engine is completely stopped. 4. Turn the Microprocessor On/Off switch to the “On”
position.
5. Press the controller On key. If the microprocessor
WARNING: When the microprocessor On/Off switch
determines that the unit should cool or heat, the
is in the On position, the unit may start at any time
appropriate screens will appear and the electric motor will
without prior warning.
start. It may not start if the return air sensor temperature is
within a few degrees of setpoint.
6. Complete an After Start Inspection.
120
Electric Standby Operation
121
Electric Standby Operation
122
Loading and Enroute Inspections
This chapter describes pre-loading, post loading, and enroute 4. Verify that the setpoint temperature is correct for your
inspection procedures. Thermo King refrigeration units are cargo. Pre-cool the trailer as required.
designed to maintain the required product load temperature
5. Supervise product loading to ensure sufficient air space
during transit. Follow these recommended loading and enroute
around and through the load. Airflow around the cargo
procedures to help minimize temperature related problems.
must not be restricted.
NOTE: If the warehouse is not refrigerated, operate the
Pre-Loading Inspection unit with doors closed until cargo is ready to be loaded.
1. Pre-cool products before loading. Note any variances on Then turn off the unit, open cargo doors and load cargo.
the manifest. When cargo is loaded, close trailer doors and restart the
unit.
2. Inspect door seals and vent doors for condition and a tight The unit can be operated with the cargo box doors open
seal with no air leakage. if the truck is backed into a refrigerated warehouse and
3. Inspect the trailer inside and out. Look for: the dock door seals fit tightly around the trailer.
• Damaged or loose trailer skin and insulation
• Damaged walls, air ducts, floor channels or “T”
flooring
• Clogged defrost drain tubes
• Blocked return air bulkhead
001 123
Loading and Enroute Inspections
1
2 1. Correct load height (trailers without chutes)
2. Tight doors and gaskets
9
3. Good air circulation around load
3
4. Proper cargo temperature (prior to loading)
8
4 5. Interior/exterior walls and insulation in good
7 condition
6. Clear defrost drains
7. Good outside air circulation
6 5 8. Unit inspection
9. Tight seals
ADZ30
124
Loading and Enroute Inspections
Post-Loading Inspection 4. Close or supervise the closing of the cargo box doors.
Make sure they are securely locked.
Post-loading inspections ensure the cargo has been loaded
properly. To perform a post-load inspection: 5. Make sure the setpoint is at the temperature listed on the
manifest.
1. Inspect the evaporator outlets for blockage.
6. If the unit was stopped, restart using the correct starting
2. Turn the unit off before opening the cargo box doors to procedure. See the Operating Instruction chapter in this
maintain efficient operation. manual.
NOTE: The unit can be operated with the cargo box 7. Start a manual defrost cycle 30 minutes after loading. See
doors open if the truck is backed into a refrigerated the Manual Defrost procedure in this manual.
warehouse and the dock door seals fit tightly around the
trailer.
3. Perform a final check of the load temperature. If the load
is above or below temperature, make a final notation on
the manifest.
125
Loading and Enroute Inspections
Enroute Inspections 2. Repeat the Enroute Inspection every 30 minutes until the
compartment temperature is within the desired
Complete the following enroute inspection every four hours.
temperature range. Stop the unit if the compartment
This will help minimize temperature related problems.
temperature is not within the desired temperature range on
two consecutive 30 minute inspections, especially if the
Inspection Procedure compartment temperature appears to be moving away
1. Verify setpoint is correct. from the setpoint.
2. Check the return air temperature reading. It should be 3. Immediately contact the nearest Thermo King Service
within the desired temperature range. Center or your company office.
3. Initiate a manual defrost cycle after each enroute 4. Take all necessary steps to protect and maintain proper
inspection. load temperature.
126
Loading and Enroute Inspections
Inspection Troubleshooting
Problem Cause Remedy
A return air The unit has not Refer to the load log history. Look for above temperature load records,
temperature had time to cool properly pre-cooled cargo compartment, length of time on road, etc. Correct
reading is not down to correct as required. Continue monitoring return air temperature until the reading is
within desired temperature. within the desired temperature range of the setpoint.
temperature The unit may have Check the receiver tank sight glass for refrigerant level. If liquid is not
range of the a low refrigerant showing in the receiver tank sight glass, the refrigerant charge may be low.
setpoint. charge. A competent refrigeration technician is required to add refrigerant or repair
the system. Contact the nearest Thermo King dealer, authorized Service
Center, or call the Thermo King Cold Line for referral. Consult the Table of
Contents for Cold Line information.
The unit is in defrost Monitor the return air temperature after the defrost cycle is completed to see
or has just if the temperature returns to the desired temperature range of the setpoint.
completed a defrost
cycle.
The evaporator is Initiate a manual defrost cycle. The defrost cycle will automatically terminate
plugged with frost. when complete. Continue monitoring the return air temperature until the
reading is within the desired temperature range of the setpoint.
127
Loading and Enroute Inspections
128
Jump Starting
If the battery in a unit is discharged or run down, the unit may IMPORTANT: Make sure to use a 12-volt battery to jump
be jump started using jumper cables and another battery or start the unit. If you are using a vehicle, make sure it has a
vehicle. Consider the following precautions and be careful 12-volt battery with a negative ground system. Do not use a
when jump starting a unit. “hot shot” booster device or a 24-volt source.
WARNING: A battery can be dangerous. A battery Read and understand the following procedure completely
contains a flammable gas that can ignite or before connecting any jumper cables. Use good jumper cables
explode. A battery stores enough electricity to burn made with #2 gauge (or larger) cables.
you if it discharges quickly. A battery contains 1. Make sure the unit is turned off. If you are using a vehicle,
battery acid that can burn you. Always wear make sure its ignition is also turned off.
goggles or safety glasses and personal protective
2. Open the front doors on the unit. The battery is located to
equipment when working with a battery. If you get
the right of the engine.
battery acid on you, immediately flush it with water
and get medical attention. 3. Check the discharged battery to make sure it is not
damaged or frozen. Do not jump start a damaged or frozen
CAUTION: Unhook the semi tractor from the battery. Check the vent caps to make sure they are tight.
trailer before using the tractor to jump start the 4. Identify the positive (+) and negative (–) battery terminals.
unit on the trailer. The negative ground circuit is
complete when the tractor is hooked to the trailer.
This can cause dangerous sparks when the positive
connection is made at the battery.
129
Jump Starting
Unit
Engine
3
130
Jump Starting
7. Connect the other end of the red positive (+) jumper cable
to the positive (+) battery terminal on the good battery.
8. Connect the black negative (–) jumper cable to the
negative (–) battery terminal on the good battery. Do not
let the other end of the jumper cable touch anything that
conducts electricity.
9. Connect the black negative (–) jumper cable to the lower 1
starter mounting bolt on the unit’s engine.
1. Lower Starter Mounting Bolt
Figure 70: Unit Engine
131
Jump Starting
10. If you are using a vehicle to jump start the unit, start the
4
vehicle and let it run for a few minutes. This will help
charge the discharged battery. 3
Unit
CAUTION: Be careful around fans and belts. (Discharged)
Keep your hands away from moving parts when an 12-Volt
Battery
engine is running.
11. Turn the unit on and let it start automatically or start it Good
manually. If the unit will not crank or start, contact a 12-Volt
Battery
qualified technician.
NOTE: Some units with microprocessors will show an
alarm code and will not try to start until the battery Unit
voltage is above 10 volts. Engine
12. After the unit starts, remove the jumper cables in reverse 2
order: black negative (–) from the unit starter mounting 1
bolt, black negative (–) from the good battery, red positive
(+) from the good battery, and red positive (+) from the 1. Starter Mounting Bolt on Unit Engine
unit battery (that was discharged).
2. Negative (–) Terminal on Good Battery
Figure 71: Sequence for Disconnecting Jumper
Cables
132
Jump Starting
133
Jump Starting
134
SB-210/310 Specifications
Engine
Engine TK 486
Fuel Type No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity: Crankcase 15 quarts (14.2 liters)
Fill to full mark on dipstick
Oil Type API Classification CG-4 or better
Oil Viscosity 5 to 122 F (-15 to 50 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-13 to 32 F (-30 to 0 C): SAE 5W-30
Engine rpm: SB-210 Low Speed Operation 1450 + 25 rpm
SB-210 High Speed Operation 2200 + 25 rpm
SB-310 Low Speed Operation 1720 ± 25 rpm
SB-310 High Speed Operation 2600 ± 25 rpm
Engine Oil Pressure The microprocessor will display OK if the oil pressure is within an
acceptable range and LOW if the oil pressure is below this range.
135
SB-210/310 Specifications
Engine (Continued)
Low Oil Pressure Switch (Normally Closed) 17 ± 3 psi (117 ± 21 kPa)
Engine Thermostat 180 F (82 C)
CAUTION: Make sure you know what type of coolant is in your
Engine Coolant Type:
unit. Do not mix conventional coolant and ELC.
ELC is red. Units equipped with ELC have an ELC nameplate on the
ELC (Extended Life Coolant)
expansion tank (See Safety Decals and Locations).
Use a 50/50 concentration of any of the following equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
Coolant System Capacity 7.5 quarts (7.1 liters)
Radiator Cap Pressure 7 psi (48 kPa)
Drive Direct to compressor; belts to fans, alternator and water pump
136
SB-210/310 Specifications
Belt Tension
Belt Tension No. on TK Gauge 204-427
Model 30:
Alternator Belt 35
Lower Fan Belt (Engine to Idler) 67
Upper Fan Belt (Fan to Idler) 74
Model 50:
Alternator Belt 29
Compressor Drive Belts 79
Fan Belt 74
Water Pump Belt 35
NOTE: These are the field reset settings. Because it is sometimes difficult to use the TK Gauge 204-427 in the field, adjust
each belt to allow 1/2 inch (13mm) deflection at the center of the longest span.
137
SB-210/310 Specifications
Electric Standby
Full Load Overload Relay
Voltage/Phase/Frequency Horsepower Kilowatts rpm
(amps) Setting (amps)
230/3/60 14.0 10.4 1755 37.8 40
460/3/60 14.0 10.4 1755 18.9 20
138
SB-210/310 Specifications
Refrigeration System
Compressor Thermo King X430L
Compressor Oil Charge 4.3 quarts (4.1 liters)
Compressor Oil Type Polyol Ester Type P/N 203-413
Refrigerant Charge - Type 13 lb. (5.9 kg) - R404A
Heat/Defrost Method Hot gas (and electrical heater strips on Model 50 units)
Opens 470 + 7/-35 psi (3241 +48/-241 kPa)
High Pressure Cutout Switch
Automatic Reset @ 375 ± 38 psi (2586 ± 262 kPa)
139
SB-210/310 Specifications
140
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep For more details, refer to the appropriate maintenance manual
your Thermo King unit in top operating condition. The and to the “Manual Pretrip Inspection” in this manual.
following general schedule is provided to assist in monitoring
that maintenance.
141
Maintenance Inspection Schedule
142
Maintenance Inspection Schedule
143
Maintenance Inspection Schedule
144
Maintenance Inspection Schedule
145
Maintenance Inspection Schedule
146
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50046 for the Thermo King
Trailer Unit Warranty.
147
Warranty
148
Glossary
This glossary is published for informational purposes only and box temperature: The temperature within a
the information being furnished herein should not be temperature-controlled compartment.
considered as all-inclusive or meant to cover all contingencies.
Btu (british thermal unit): The quantity of heat required to
NOTE: Additional terms not found in the glossary may be raise the temperature of one pound of water by one degree
located in the index section of this manual. Fahrenheit. 1 Btu = 252 calories.
accumulator: A device located in the suction line to collect bulkhead: 1) return air bulkhead. A metal or plastic “wall”
liquid refrigerant and meter it safety back to the compressor as placed at the front of the box to prevent loading of product
gas. tightly against the Thermo King unit. (Loading too close to the
unit restricts air flow and system efficiency.) 2) bulkhead
ambient air temperature: Temperature of the air
divider. A thick, insulated “wall” used to separate
surrounding an object.
compartments of a multi-temperature truck or trailer.
amp: Abbreviation for ampere. The basic measuring unit of
calorie: The amount of heat required to raise temperature of
electrical current.
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Celsius: The metric unit of temperature measurement. The
Battery Sentry: Part of the CYCLE-SENTRY™ system. The preferred alternate to the term centigrade. Abbreviated “C.”
Battery Sentry module monitors alternator charge rate and will
centigrade. See Celsius.
keep the unit running until the battery is adequately charged.
001 149
Glossary
150
Glossary
defrost timer: A solid state module that initiates defrost at evaporator: The part of the refrigeration system that absorbs
selected intervals. Also establishes a maximum defrost heat during the cooling cycle.
duration if normal circuits malfunction.
EW: A wall-mounted Thermo King remote evaporator. See
dehydrator: A device used to remove moisture from ECT and TLE.
refrigerant. Also called a drier.
F: See Fahrenheit.
discharge air temperature: The temperature of air leaving
Fahrenheit: A unit of temperature measurement used in the
the evaporator.
United States. Abbreviated “F.”
drier: See dehydrator.
freeze up: 1) Failure of a refrigeration system to operate
ECT: A ceiling-mounted Thermo King remote evaporator. See normally due to moisture in the refrigerant and the formation
EW and TLE. of ice at the expansion valve. The expansion valve may be
frozen shut or open, causing improper unit operation in either
ERC: Extended Remote Unit Control. (Door switches) An
case. 2) The formation of a solid ice mass over the evaporator
option on Thermo King multi-temperature units to improve
coil reducing air flow.
temperature control when doors are opened during delivery.
When a compartment door is opened, the refrigeration unit for fuse: An electrical safety device (typically a cartridge)
that compartment may be forced to NULL, defrost, or some inserted into an electrical circuit. It contains material that will
other mode. Opening a compartment door may also affect the melt or break when the current is increased beyond a specific
operating mode of other compartments. ERC systems are value. When this occurs, the circuit is opened and electrical
connected in a variety of ways to meet customer needs. current flow is stopped.
ETV (Electronic Throttling Valve) : A device used with a
microprocessor to precisely control the refrigeration system.
151
Glossary
fusible link: An electrical safety device (typically a short hp (horsepower): A unit of power equivalent to 746 watts
piece of wire) inserted into an electrical circuit. The wire melts or 550 foot-pounds per second.
or breaks when the current is increased beyond a specific
HPCO (High Pressure Cut Out Switch): A
value. When this occurs, the circuit is opened and electrical
pressure-operated switch that opens to stop unit operation
current flow is stopped.
when discharge pressure reaches a predetermined maximum.
HCFC: Hydrochlorofluorocarbon. A chlorine-based
invertible: A multi-temperature truck or trailer unit designed
refrigerant containing hydrogen, chlorine, fluorine and carbon.
to allow the placement of deep-frozen cargo in any
Example: R22. Because chlorine damages the earth’s
compartment. See Multi-Temp.
atmosphere, in many countries, it is illegal to release this type
of refrigerant to the atmosphere. HCFC refrigerants are not kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
used in modern Thermo King units. 0.145 psi.
Hertz: A unit of frequency equal to one cycle per second. load: 1) The product being refrigerated and transported.
Abbreviated “Hz.” 2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
HFC: A refrigerant consisting of hydrogen, fluorine and
when expected to cool a very warm box.)
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered “safe” for the LPCO (Low Pressure Cut Out Switch): A
environment. pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the modulation: An optional system that reduces load (product)
system if pressure exceeds a predetermined value. dehydration and avoids “top freeze.”
152
Glossary
movable bulkhead: A thick, insulated, portable wall-like psi: Pounds per square inch. A unit of pressure.
device used to compartmentalize a temperature-controlled 1 psi = 0.069 bar = 6.89 kPa.
truck or trailer. See bulkhead.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
Multi-Temp: A Thermo King truck or trailer unit capable of square inch as displayed by a gauge calibrated to zero when
maintaining different set-points in multiple compartments. open to the atmosphere.
no. 1 diesel fuel: A grade of diesel fuel formulated to receiver tank: A refrigerant storage device included in
prevent “jelling” in low ambient temperatures. nearly all Thermo King units.
no. 2 diesel fuel: A grade of diesel fuel formulated for refrigerant: The medium of heat transfer in a refrigeration
moderate to warm ambient temperatures. system which absorbs heat by evaporating at a low temperature
and releases heat by condensing at a higher temperature.
ohm: An electrical unit measuring the amount of resistance
(opposition to the current flow) in an electrical circuit. refrigerant oil: A special oil used to lubricate compressors in
refrigeration systems.
pre-cooling: 1) To cool down an empty box
(temperature-controlled area) to the desired load temperature remote evaporator: A separate evaporator unit located in a
prior to loading. 2) To cool cargo to a desired temperature second or third compartment of a multi-temperature truck or
before loading. trailer unit.
pre-heat: The heating of diesel engine glow plugs prior to return air bulkhead: A structure (metal or plastic) mounted
start-up. Some engines use an intake manifold heater rather in the front of a trailer and designed to prevent restriction of
than glow plugs. return air flow to the Thermo King unit due to improper
loading. See bulkhead.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
153
Glossary
return air temperature: The temperature of the air Vac (volts alternating current): An electric current that
returning to the evaporator. See box temperature. reverses direction at regularly recurring intervals.
rpm: Revolutions per minute. Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box volts: The basic measuring unit of electrical potential.
temperature.
watt: The basic measuring unit of electrical power.
short cycling: When a refrigeration unit cycles between the
heat and cool modes more often than normal.
sight glass: A system component that permits visual
inspection of oil or refrigerant level and condition.
thermostat: A device that controls unit modes of operation to
maintain a selected box temperature.
TLE: Thin-line evaporator. A Thermo King remote evaporator
designed to be compact (thin) while supplying superior air
flow. See ECT and EW.
top freeze: When the top portion of perishable cargo is
damaged by freezing temperatures discharged from the
refrigeration unit. This may occur near the front of the box
when product is placed too close to the cold, discharge air flow.
154
Index
A defrost drain inspection 48
air cleaner restriction indicator 32 Design Features 135
amber status light 45 door inspection 48
automatic start/stop safety precautions 14
E
B ELC (Extended Life Coolant) 26
battery inspection 47 electric power receptacle 120
belts inspection 47 Electric Standby 119
electrical hazards 14
C electrical inspection 47
coils inspection 48 electronic throttling valve 27
compressor oil sight glass 32 Emergency Cold Line 163
Continuous Run Operation 29 EMI 3000 27
CYCLE-SENTRY Operation 29 engine compartment components 32
CYCLE-SENTRY Start-Stop Controls 29 engine coolant level 47
engine oil level 47
D enroute inspections 126
damper inspection 48
data logging 30 F
defrost 31 first aid for refrigerant 15
155
Index
G O
green status light 45 Oil Type, Engine 135
H P
high pressure cutout 33 post-loading inspection 125
high pressure relief valve 33 preheat buzzer 33
pre-loading inspection 123
I pretrip inspection, manual 47
introduction 11 protection devices 33
J R
jump starting 129 receiver tank sight glass 32
refrigerant oil safety 15
L refrigerant safety 14
loading procedures remote control box 30
enroute inspections 126 remote status light 45
post-loading inspection 125
pre-loading inspection 123
156
Index
S U
safety precautions 13 unit description 23
automatic start/stop operation 14
decal locations 16 W
electrical hazards 14 warranty 147
first aid for refrigerant 15
first aid for refrigerant oil 15
general safety practices 13
refrigerant 14
refrigerant oil 15
Serial Number Locations 159
Specifications, Belt Tension 137
Specifications, Electric Standby 138
Specifications, Electrical Control System 138
Specifications, Engine 135
Specifications, Refrigeration System 139
Specifications, Standby Power Cord Requirements 138
status light, remote 45
structural inspection 47
T
Thermo King X430L Compressor 23
157
Index
158
Serial Number Locations
Unit: Nameplates on the bulkhead above the compressor
inside the curbside door, and on the top, roadside corner of the
evaporator.
Engine: See the engine identification plate located on the
engine valve cover.
Compressor: Stamped between the cylinders on the front
end above the oil pump.
159
Serial Number Locations
Figure 72: Compressor Serial Number Location Figure 73: Engine Serial Number Location
160
Serial Number Locations
AEA1398
ARA103
Figure 74: Unit Serial Number Plate Locations
(on the bulkhead above compressor inside
curbside door, and on the top, roadside
corner of evaporator)
161
Serial Number Locations
162
Emergency Cold Line
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer. Have the
following information available when you call:
Name ________________Title _________________
Company _____________Phone No. _____________
Address ___________________________________
Location ______________Destination ____________
Product _______________Required Temp. ________
AKB12
Present Temp. __________Time Out Of Service _____
Unit Model _______________Problem ___________
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any Serial Number_______________________________
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
163
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.
164 001
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
001 165
166
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