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Operator's Manual: T-680R / T-880R / T-1080R T-680S / T-880S / T-1080S Series With Premium SR-3 HMI
Operator's Manual: T-680R / T-880R / T-1080R T-680S / T-880S / T-1080S Series With Premium SR-3 HMI
The procedures described herein should only be undertaken by suitably qualified personnel. Failure to
implement these procedures correctly may cause damage to the Thermo King unit or other property or
personal injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or
any other direct, indirect, special or consequential damage or liability whatsoever, arising out of or
resulting from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo
King unit.
2
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Manufacturer’s Warranty Coverage . . . . . . . . . . .19
Owner’s Warranty Responsibilities . . . . . . . . . . . .19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Manufacturer Explanation Of Emission Control System
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 EPA Emission Control System Warranty Statement . .22
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . . 8 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Battery Installation and Cable Routing . . . . . . . . . . . . . 9 Thermo King Corporation Responsibilities . . . . . . . . . .23
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Owner Responsibilities . . . . . . . . . . . . . . . . . . . . . . . .23
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 11 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . .25
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 11 Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 11 Unit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Model 50 Units (Electric Standby) . . . . . . . . . . . . 14 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .28
Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
California Emission Control System Warranty Reciprocating Compressor . . . . . . . . . . . . . . . . . . . . .29
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Your Warranty Rights And Obligations . . . . . . . . . 18 Premium HMI Control Panel . . . . . . . . . . . . . . . . . . . .29
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Table of Contents
4
Table of Contents
Displaying and Clearing Alarm Codes . . . . . . . . . . . . 67 Loading and Enroute Inspections . . . . . . . . . . . . . .98
SR-3 Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . .98
Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Inspecting the Load . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . .100
Hourmeter Names and Definitions . . . . . . . . . . . . . . . 80
Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Turn CYCLE-SENTRY On or Off . . . . . . . . . . . . . . . . 81 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Keypad Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Start Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Engine Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Selecting CYCLE-SENTRY or Continuous Mode . . . . 83 Reciprocating Compressor . . . . . . . . . . . . . . . . .106
Selecting Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . 85 Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . .107
Pretrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Electrical Control System . . . . . . . . . . . . . . . . . . . . . .108
Pretrip Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . 89 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Conditions where Pretrip Tests are not allowed . . . . . 89 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . .110
Pretrip Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . 90 SmartPower Electrical Standby
Pretrip Test Considerations . . . . . . . . . . . . . . . . . . . . 90 (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . .112
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . 91 T-680R, T-680S, T-880R, T-880S Electric Motor
Diesel/Electric Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 93 and Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . .112
Switching from Diesel to Electric - Units equipped with the T-1080R & T-1080S Electric Motor and Overload
Electric Standby option only. . . . . . . . . . . . . . . . . . . . 93 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Switching from Electric to Diesel - Units equipped with the Electric Heater Strips (Optional) . . . . . . . . . . . . . . . .113
Electric Standby option only . . . . . . . . . . . . . . . . . . . . 94 SmartPower Standby Power Requirements . . . . . . .113
Adjust Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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Table of Contents
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
CALIFORNIA
Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . 126
6
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
regular basis will minimize on-the-road operating problems. A Thermo King Service Directory for the location and
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.
7
Safety Precautions
Thermo King recommends that all services be performed by a
CAUTION: Use extreme caution when drilling holes
Thermo King dealer. However, there are several general safety
in the unit. Drilling into electrical wiring or
practices which you should be aware of:
refrigerant lines could cause a fire. Never drill into
structural components.
WARNING: Always wear goggles or safety glasses
when working with or around the refrigeration
system or battery. Refrigerant or battery acid can Automatic Start/Stop Operation
cause permanent damage if it comes in contact with This unit is capable of automatic operation and may start at any
your eyes. time without prior warning.
WARNING: Keep hands and loose clothing clear of WARNING: The unit may start at any time when the
fans and belts at all times when the unit is operating controller is turned on. The controller display lights
or when opening or closing compressor service up when the controller is turned on.
valves.
WARNING: Units equipped with electric standby may
WARNING: Exposed coil fins can cause painful start at any time when the unit is connected to live
lacerations. Service work on the evaporator or electric power and the controller is turned on.
condenser coils is best left to a certified Thermo King
technician. WARNING: Be sure to press the OFF key to turn the
controller off before opening doors or inspecting any
part of the unit.
8
Safety Precautions
Battery Installation and Cable CAUTION: Set all unit electrical controls to the
Routing OFF position before connecting battery cables to
the battery to prevent unit from starting
WARNING: Improperly installed battery could unexpectedly and causing personal injury.
result in a fire or explosion! A Thermo King
approved battery must be installed and properly CAUTION: Always wear protective clothing,
secured to the battery tray. gloves and eye wear when handling and installing
batteries. Battery acid can cause serious burns
WARNING: Improperly installed battery cables when exposed to eyes or skin. If battery acid
could result in fire or explosion! Battery cables contacts skin or clothing, wash immediately with
must be installed, routed and secured properly to soap and water. If acid enters your eye,
prevent them from rubbing, chaffing or making immediately flood it with running cold water for at
contact with hot, sharp or rotating components. least twenty minutes and get medical attention
immediately.
WARNING: Do not attach fuel lines or any
additional wiring harnesses to the battery cables as CAUTION: Always cover battery terminals to
this could cause an electrical fire! prevent them from making contact with metal
components during battery installation. Battery
CAUTION: Do not connect other manufacturer’s terminals grounding against metal could cause the
equipment or accessories to the Thermo King unit. battery to explode.
This could result in severe damage to equipment
and void the warranty!
9
Safety Precautions
DANGER: Fluorocarbon refrigerants may produce WARNING: Protect skin and clothing from
toxic gases. In the presence of an open flame or prolonged or repeated contact with refrigerant oil.
electrical short, these gases are severe respiratory Rubber gloves are recommended.
irritants CAPABLE OF CAUSING DEATH.
WARNING: Wash thoroughly immediately after
DANGER: Fluorocarbon refrigerants tend to handling refrigerant oil to prevent irritation.
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
10
Safety Precautions
Figure 2: Clearing Alarms Caution Figure 3: Belt Caution (Locations vary depending on
(Typically located near the HMI Controller) model. Decals are located near areas that contain
belts and fans which can cause severe injuries if
hands or clothing become tangled.)
12
Safety Precautions
CAUTION FAN
ATTENTION VENTILATEUR
91-4815
ACHTUNG VENTILATOR
ATTENZIONE VENTILATORE
CUIDADO VENTILADOR
Figure 4: Automatic Start Caution (Locations vary Figure 5: Fan Caution (Locations vary depending on
depending on model. Decals are located near areas model. Decals are located near areas that contain
that contain moving parts which can cause severe fans which can cause severe injuries if hands or
injuries if hands or clothing become tangled when the clothing become tangled.)
unit automatically starts.)
13
Safety Precautions
14
Emission Control
In compliance with the California ULG (Utility, Lawn and 2-4. Fuel Oil System: Fuel oil system must remain intact
Garden) Rules, the following information is provided: and receive regular prescribed maintenance. Example: Fuel
filter replacement at required operation hour interval.
1. Selection Of Fuel Oil: Use diesel fuel only.
3. Engine Identification: Engines must be identified in a
2-1. Modification To Any Engine Component:
manner that will determine when they were built and what
Modifications to any engine component which many cause regulations they comply with. The engine must be labeled with
engine exhaust emission output changes are not allowed. an emission control label and the engine family name, both
Any engine modification not in compliance with regulation described below.
will be the responsibility of the engine manufacturer, dealer or
customer who made the modification.
2-2. Air Induction System: Air induction system must
remain intact and receive regular prescribed maintenance.
Example: Air cleaner element replacement at required
operation hour interval.
2-3. Exhaust System: Exhaust system must remain intact
and cannot be modified in any manner that will further restrict
exhaust flow.
15
Emission Control
a. Emission control label: a new label, shown in b. Engine Family Name, as assigned by the California
Figure 8, contains important engine information. Air Resources Board, identifies engine family group,
by largest displacement, within an engine family, and
is shown in Figure 9.
AMA04
AMA06
16
Emission Control
3-1 Emission Control Labels: Emission control labels are All engine labels and supplementary labels will contain the
a requirement of the California ULG Rules. In the event the following information:
emission control label provided on the engine is inaccessible, • Engine Family Name
there will be a supplemental label containing the same
information, provided by the equipment manufacturer, located • Displacement
in a readily accessible location, shown in Figure 10: • Manufacturer
The above information, along with the engine serial number,
will be required to obtain proper service information and
correct service repair parts. An example list which identifies
the exhaust control system is shown in Figure 11.
17
Emission Control
4. Emission Control Related Parts: The California ULG 5. Maintenance Schedule: To maintain optimum engine
Rules require a manufacturing defect warranty on all emission performance and compliance with the California ULG Rules,
control parts, including: the maintenance schedule must be adhered to.
• Fuel Injection Pump Regular scheduled maintenance is the major key to engine
service life and emission regulation compliance. Scheduled
• Fuel Injection Nozzle
maintenance requirements must be performed regularly. See
• High Pressure Oil Line the Maintenance Schedule provided in this Operator’s Manual.
• Air Cleaner Element1
• Fuel Filter Element1 California Emission Control
• Air Cleaner Gasket
System Warranty Statement
• Air Intake Pipe (Manifold) Gasket
Your Warranty Rights And
• Muffler Gasket Obligations
The warranty period is two years and complete details are The California Air Resources Board and Thermo King are
included in the section of this manual titled “California pleased to explain the California emission control system
Emission Control System Warranty Statement, Your Warranty warranty on your 1996 and later utility equipment (ULG)
Rights And Obligations.” engine. In California, new utility equipment (ULG) engines
1 must be designed, built, and equipped to meet the state’s
Any warranted part which is scheduled for replacement as
stringent anti-smog standards. Thermo King must warrant the
required maintenance shall be warranted for the period of time
California emission control system on your utility equipment
up to the first scheduled replacement point for that part.
18
Emission Control
(ULG) engine for the time listed below, provided there has Owner’s Warranty Responsibilities
been no abuse, neglect or improper maintenance of your utility
As the utility equipment (ULG) engine owner, you are
equipment (ULG) engine.
responsible for the performance of the required maintenance
Your California emission control system includes parts such as listed in this Operator’s Manual. Thermo King recommends
the fuel injection pump, the fuel injection nozzle, and the that you retain all receipts covering maintenance on your utility
high-pressure fuel line. Also included are the air filter element equipment (ULG) engine, but Thermo King cannot deny
and the fuel filter element which are covered under this warranty solely for the lack of receipts or your failure to ensure
California emission control system warranty only up to the first the performance of all scheduled maintenance.
scheduled maintenance replacement.
As the utility equipment (ULG) engine owner, you should be
Where a warrantable condition exists, Thermo King will repair aware that Thermo King may deny you warranty coverage if
your utility equipment (ULG) engine with California emission your utility equipment (ULG) engine, or a part or component,
control system parts or components at no cost to you, including has failed due to abuse, neglect, improper maintenance, or
diagnosis, parts and labor. unapproved modifications.
You are responsible for presenting your utility equipment
Manufacturer’s Warranty Coverage (ULG) engine to an authorized Thermo King dealer as soon as
1996 and later utility equipment (ULG) engines: California a problem exists. The emission control system parts or
emission control system parts and components are warranted component repairs should be completed in a reasonable
for the period of two years (24 months). If any California amount of time not to exceed 30 days.
emission control system part or component on your utility If you have any questions regarding your warranty rights and
equipment (ULG) engine is defective, the part or component responsibilities, contact a Thermo King service representative
will be repaired or replaced by Thermo King. at 952-887-2337.
19
Emission Control
20
Emission Control
21
Emission Control
EPA Emission Control System In an emergency, repairs can be performed at any service
establishment, or by the owner, using any replacement part.
Warranty Statement Thermo King will reimburse the owner for their expenses,
Thermo King warrants to the initial owner and each subsequent including diagnostic charges, for such emergency repair. These
owner that the certified non-road diesel engine in your unit is: expenses shall not exceed Thermo King’s suggested retail price
for all warranted parts replaced, and labor changes based on
1. Designed, built and equipped so as to conform, at the time
Thermo King’s recommended time allowance for the warranty
of sale, with all applicable regulations adopted by the
repair and the geographically appropriate hourly labor rate.
United States Environmental Protection Agency (EPA).
Any replacement part can be used for maintenance or repairs.
2. Free from defects in materials and workmanship in
The owner should ensure that such parts are equivalent in
specific, emission-related parts for a period of five years
design and durability to genuine Thermo King parts. However,
or 3,000 hours of operation, whichever comes first, after
Thermo King is not liable for parts which are not genuine
date of delivery to the initial owner.
Thermo King parts.
If an emission-related part or component fails during the
A part not being available within 30 days or repair not being
warranty period, it will be repaired or replaced. Any such part
completed within 30 days constitutes an emergency.
or component repaired or replaced under warranty is warranted
for the warranty period. As a condition of reimbursement, replaced parts and received
invoices must be presented at a place of business of a Thermo
During the term of this warranty, Thermo King will provide,
King authorized service dealer or other establishment
through a Thermo King authorized service dealer or other
authorized by Thermo King.
establishment authorized by Thermo King, repair or
replacement of any warranted part at no charge to the non-road This warranty covers the following emission-related parts and
engine owner. components:
• Fuel Injection System
22
Emission Control
23
Emission Control
24
Unit Description
General Description Units are offered as Model 30 or Model 50:
This manual covers the following Thermo King models: Model 30: Cooling and hot gas heating on engine operation.
• T-680R, T-880R and T-1080R with reciprocating Model 50: Cooling and hot gas heating on engine operation
compressor. and electric standby operation. Electric evaporator heaters are
optional.
• T-680S, T-880S and T-1080S with scroll compressor.
Engine power for the unit is provided by a diesel engine.
All units are microprocessor based transport temperature
Optional SmartPower electric standby power is provided by an
control systems that use the Premium SR-3 Truck HMI
electric motor. A clutch on the diesel engine isolates the engine
microcontroller to manage system functions.
during electric standby operation.
All units are one-piece, front-mounted, diesel powered cooling The continuous monitoring function of the SR-3
and heating systems designed for straight trucks. The unit microprocessor optimizes the unit’s performance, reducing fuel
mounts on the front of a truck with the evaporator portion consumption and unit down time. The unit has a self check
protruding into the box. They are designed for use with feature that can be run before the daily distribution route to
chlorine free refrigerants. identify possible malfunctions.
The built-in CYCLE-SENTRY, an exclusive Thermo King
feature, automatically starts and stops the unit according to
temperature demands.
25
Unit Description
• Microprocessor Controller, SR-3 Truck • Coolant Expansion Tank with Overflow Bottle
• Engine and Electric (Model 50) Hour Display • Oil Filter, Full Flow
• Symbolic Controller Interface • Robotic Welded Steel Frame with Automotive Grade 2
Coat Paint Finish
• Unit Self Check-pretrip
• X214 Compressor (T-680R and T-880R)
• Aerodynamic Thermo Plastic Recyclable Injection
Molded Skins with In-mold Color • X426 Compressor (T-1080R)
26
Unit Description
• Stainless Steel Condenser and Evaporator Hardware • Quick Oil Drain Kit
• TK374F Tier 4 Diesel Engine (T-680R, T-680S, T-880R • Rear Remote Control (flushmount)
and T-880S)
• Remote Indicator Light
• TK380F Tier 4 Diesel Engine (T-1080R and T-1080S) • Snow Cover
• Telematics
Unit Options • Whisper™ Plus Sound Kit
• Body Mount HMI Enclosure Systems
• Top Cover System
• DAS (Data Acquisition System)
• Door Switch
• CargoLink™ Wireless Sensors
• Easy-Read Thermometer
• Electric Evaporator Heater
• SmartPower™ Electric Standby Operation (Model 50)
• Engine Block Heater
• Fuel Tank
• Hand-held SR-3 Electronic Diagnostic Tool
• Hose Management System
27
Unit Description
Engine
Engine power for the T-680R, T-680S,T-880R and T-880S is
provided by the TK374F, a three-cylinder, EPA Tier 4, special
clean and quiet diesel engine rated at 11.7 continuous
horsepower (8.7 kW) at 2200 RPM. A belt drive system
transfers energy to the compressor, unit fans, and alternator.
Engine power for the T-1080R and T-1080S is provided by the
TK380F, a three cylinder, EPA Tier 4, special clean and quiet
diesel engine rated at 16.2 continuous horsepower (12.1 kW) at
2200 RPM. A belt drive system transfers energy to the
compressor, unit fans and alternator.
28
Unit Description
29
Unit Description
The system monitors and maintains the compartment There are two methods of defrost initiation:
temperature, the engine block temperature, and battery charge SR-3 Microprocessor Controller: The Microprocessor
levels at a point where quick, easy starts are possible. Controller is programmed to automatically initiate timed and
forced defrost cycles. The SR-3 uses temperature sensors to
determine if forced defrost is required.
Manual Defrost: Manual Defrost allows the operator to
initiate a defrost cycle by pressing the DEFROST key. See
“Initiating a Manual Defrost Cycle.”
30
Unit Description
DAS - Data Acquisition System TK 55151 the Truck and Trailer Edition CargoLink Installation
Manual for information about installing the CargoLink system
(Optional) and sensors, and troubleshooting problems with the system.
The DAS (Data Acquisition System) monitors and records the
temperatures of (up to) six additional sensors. The sensors are
independent from the microprocessor controller and are
Electric Standby (Model 50 Units
normally located in the truck box to monitor load temperatures. Only)
DAS data can be downloaded through a serial port to an IBM® The Electric Standby option allows the unit to be operated on
PC compatible computer. WinTrac™ 4.0 (or higher) software either the diesel engine or external electric power.
is used to view and analyze the data. Brief reports can be
printed on a microprinter connected to the serial port. DANGER: High voltage AC power is present
whenever the unit is operating in the Electric mode
and whenever the unit is connected to external
CargoLink™ (Optional) standby power. Voltages of this magnitude can be
CargoLink is a wireless sensor system. The main components lethal. Exercise extreme caution when working on the
are the coordinator module, interconnect harness, antenna, and unit.
wireless sensors. The coordinator module receives information
from the wireless sensors through the antenna, and
communicates with the controller through the interconnect
harness. Currently, only wireless door switches are available.
Other wireless sensors will be available in the future. Refer to
31
Unit Description
32
Unit Description
Engine Oil Dipstick: Use the engine oil dipstick to check Engine Oil Pressure Switch/Sensor: The engine oil
the engine oil level. pressure switch/sensor is located on the filter head above the
Receiver Tank Sight Glass: The receiver tank sight glass bypass oil filter. Engine oil pressure should rise immediately
is used to assist in checking the amount of refrigerant in the on starting. If engine oil pressure drops below 10 ± 2 psig (69 ±
system. 14 kPa), the switch/sensor signals the microprocessor to stop
the engine.
Compressor Oil Sight Glass: The compressor oil sight
glass is used to check the relative level of compressor oil in the Preheat Buzzer: The preheat buzzer sounds when the
compressor sump. CYCLE-SENTRY system energizes the glow plugs. This
should warn anyone near the unit that the CYCLE-SENTRY
Unit Protection Devices system is about to start the diesel engine.
High Pressure Cutout Switch (HPCO): This normally Coolant Temperature Sensor: This sensor provides an
closed switch monitors the discharge pressure at the engine coolant temperature input to the microprocessor. If the
compressor. It opens on high discharge pressure to shut the unit engine coolant temperature is too high, the controller stops the
down to prevent damage. unit and records an alarm.
Suction Pressure Regulator (SPR): This component is a Electric Motor Overload Relay (Model 50): The
mechanical control device used to limit the suction pressure to overload relay protects the electric standby motor. The
the compressor. The valve controls suction pressure based on overload relay opens the circuit from the contactor to the
the actual system pressure. (Scroll compressor units: The SPR electric motor if the motor overloads for any reason and an
is not used if the unit is equipped with an ETV.) alarm will occur. The relay resets when the alarm code is
cleared.
Electronic Throttling Valve (ETV): (Scroll compressor
units only.) This component is an electromechanical control Fuses: Sizes and functions are described in the Specifications
device used to limit the suction pressure to the compressor. The section of this manual.
valve is controlled by the microprocessor controller.
33
Unit Description
Figure 14: T-680S Front View (T-680R, T-880S and T-880R are similar)
34
Unit Description
35
Unit Description
1 2 3
4
36
Unit Operation
Premium HMI Control Panel
The Premium Truck HMI (Human/Machine Interface) Control
Panel is available as an option on SR-3 Truck applications. It is
used to operate the unit, display unit information and access all
SR-3 Maintenance and Guarded Access Menus. The Premium
HMI Control Panel communicates with the base controller via
the CAN (Controller Area Network) bus. It is connected to the
base controller via CAN Connector J14 on the interface board. Figure 17: Premium HMI Control Panel
The Premium HMI Control Panel is typically located in the
vehicle driver's compartment. It may be installed in the truck The HMI control panel consists of a display and 8
instrument panel using a DIN mounting ring or under the touch-sensitive keys.
instrument panel using an under dash mounting kit. The display is capable of showing both text and graphics.
The keys on the left and right sides of the display are dedicated
single function "hard" keys.
The four keys under the display are "soft" keys. The functions
of these soft keys change depending on the operation being
performed. If a soft key is active the current key function is
shown in the display directly above the key.
37
Unit Operation
38
Unit Operation
39
Unit Operation
40
Unit Operation
Turning the Unit On and Off NOTE: With extremely cold ambient temperatures it may
take up to 15 seconds for the display to appear on initial
IMPORTANT: Verify the Base Controller On/Off Switch is startup.
turned on before turning on the HMI Control Panel. The
Base Controller On/Off switch is located on the outside of the
control box side of the unit.
If the Premium Truck HMI Control Panel is turned on and the
Base Controller On/Off Switch is turned off, the HMI display
screen will briefly show LOST CONTROLLER POWER. The
HMI will then power down.
The unit is turned on by pressing the ON key and off by Figure 21: Thermo King Logo
pressing the OFF key. When the ON key is pressed the display
briefly shows the THERMO KING Logo as the display Then the startup screen shown in Figure 22 appears while
initializes. communications are established and the unit prepares for
operation.
IMPORTANT: The ON key must be held down until the
Thermo King Logo appears as shown in Figure 21. If the ON
key is not held down long enough (approximately ½ second),
the display may flicker but the unit will not start up. If this
occurs, hold the ON key down until the Thermo King logo
appears.
41
Unit Operation
42
Unit Operation
43
Unit Operation
Pressing the OFF key stops unit operation. The unit shuts down The Standard Display
immediately and the display briefly shows the power down
message. The Standard Display is the default display that appears if no
other display function is selected. The Standard Display shows
the box temperature and setpoint. The box temperature is that
measured by the controlling sensor, usually the return air
sensor. The box temperature in Figure 32 is 35.8 F with a 35 F
setpoint.
The display briefly shows OFF and then goes blank. To start
the unit again, press the ON key.
44
Unit Operation
Pressing the left soft key allows the user to change the
SETPOINT, and pressing the right soft key accesses the MAIN
MENU. The other two soft keys access the GAUGES menu
and the SENSORS menu.
45
Unit Operation
The YES and NO soft keys confirm the setpoint change. When After the YES soft key has been pressed, the display briefly
the desired setpoint has been selected using the "+" and/or "-" shows PROGRAMMING NEW SETPOINT - PLEASE WAIT.
keys, press the YES soft key to confirm and load the new The display then confirms the new setpoint for several
setpoint. If the setpoint is changed using the "+" or "-" keys, seconds.
the change must be confirmed or rejected by pressing the YES
or NO soft key within 10 seconds of changing the setpoint.
Failure to confirm the new setpoint by pressing YES or NO
within 10 seconds of changing the setpoint will result in no
setpoint change. In addition, Alarm Code 127 Setpoint Not
Entered is set, to indicate that the setpoint change was not
completed.
Figure 37: New Setpoint
46
Unit Operation
47
Unit Operation
When the engine is preparing to start the HMI control panel Starting the Electric Motor
will display the engine start screen, as shown in Figure 39. The
preheat buzzer sounds during the engine preheat and crank Units equipped with the Electric Standby option only.
sequence. Electric motor starting is automatic in both Continuous Mode
and CYCLE-SENTRY Mode. The motor will start as required
when the unit is turned on. If any keys are being pressed on the
HMI control panel prior to the motor start, the motor start will
be delayed until 10 seconds after the last key is pressed.
CAUTION: The motor may start automatically any time the
unit is turned on.
When the motor is preparing to start the HMI control panel will
Figure 39: Engine Start Screen
display the motor start screen, as shown in Figure 41. The
After the engine is started the display returns to the Standard preheat buzzer sounds for 20 seconds before the electric motor
Display of temperature and setpoint. starts.
Figure 40: Standard Display of Temperature and Figure 41: Motor Start Screen
Setpoint
48
Unit Operation
Figure 42: Standard Display of Temperature and If YES is selected then the display will briefly show the screen
Setpoint in Figure 44.
49
Unit Operation
Switching from Electric to Diesel Turn the unit off and back on using the OFF and ON Keys.
This will clear Alarm Code 91 Check Electric Ready Input and
Units equipped with the Electric Standby option only. Alarm Code 84 Restart Null.
If the Electric to Diesel Autoswitch Enabled feature in NOTE: The CLEAR Soft Key will not clear these two alarms.
Guarded Access is set YES then the unit will automatically Then the prompt screen shown in Figure 46 will appear.
switch to Diesel Mode operation when standby power is turned
off or is no longer available.
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set NO then the prompt screen in Figure 45
will appear when standby power is turned off or is no longer
available. Alarm Code 91 Check Electric Ready Input and
Alarm Code 84 Restart Null will both be set.
If YES is selected then the display will briefly show the screen
in Figure 47. Then Diesel Mode operation will briefly be
confirmed.
50
Unit Operation
51
Unit Operation
The display then shows the Defrost display. The bar indicator Selecting High Speed Lockout
shows approximately how much time remains to complete the
defrost cycle. The bar indicator in Figure 49 shows that the Mode (If Enabled)
defrost cycle is about 25% complete. High speed operation can be locked out in noise sensitive areas
if required.
NOTE: High Speed Lockout Enable must be set to [Enabled]
in the Guarded Access/Programmable Features Menu or this
feature will not be available.
IMPORTANT: HIGH SPEED LOCKOUT TIMEOUT: If
High Speed Lockout Mode is selected, the High Speed Inhibit
Timeout feature may be set to return the unit to normal
Figure 50: Defrost Display operation after a set time period has expired. This prevents
extended operation with high speed operation locked out. The
Terminating a Defrost Cycle time period may be from 15 minutes to 2 hours. If the time
period is set and is exceeded the unit will return to normal
The defrost cycle terminates automatically when the coil
operation, with high speed operation allowed. If this occurs,
temperature is greater than or equal to 52 F (11 C) or the
the message HIGH SPEED LOCKOUT ACTIVE at the top of
defrost timer expires. Defrost can also be terminated by turning
the display will disappear. If necessary to return to High
the unit off and back on.
Speed Lockout Mode, press the High Speed Lockout Key
again.
52
Unit Operation
53
Unit Operation
The display will then return to the Standard Display. If High Using the Gauges Key
Speed Lockout is turned on, the message HIGH SPEED
LOCKOUT ACTIVE will be shown at the top of the display. The GAUGES key allows the operator to view the unit gauges.
To access the GAUGES menu press the GAUGES key.
Pressing the High Speed Lockout key again will turn the The first gauge display will appear. Press the NEXT and
feature off. BACK keys to scroll thru the gauges as desired. The Battery
Voltage Gauge is shown in Figure 56. Press the LOCK key to
lock the selected gauge on the display.
Selecting CYCLE-SENTRY or
Continuous Mode
With Thermo King Truck unit applications, CYCLE-SENTRY
Mode or Continuous Mode operation is selected from the Main
Menu - Mode Submenu. See the Main Menu - Mode Submenu
material later in this section for complete details.
54
Unit Operation
55
Unit Operation
56
Unit Operation
The sensors available are shown in the following list. Data Logger Sensor 3 Temperature - Display the temperature
To return to the Standard Display press the EXIT key. of Data Logger Sensor 3.
Data Logger Sensor 4 Temperature - Display the temperature
Sensors Available of Data Logger Sensor 4.
Return Air Temperature - Displays the temperature of the Data Logger Sensor 5 Temperature - Display the temperature
control return air sensor. of Data Logger Sensor 5.
Discharge Air Temperature - Displays the temperature of the Data Logger Sensor 6 Temperature - Display the temperature
control discharge air sensor. of Data Logger Sensor 6
Temperature Differential - Displays the calculated difference
between the control return air sensor and the control discharge
air sensor.
Using The Main Menu
The Main Menu contains several additional submenus that
Evaporator Coil Temperature - Displays the temperature of the
allow the operator to view information and modify unit
evaporator coil sensor.
operation. To access the Main Menu press the MENU key.
Ambient Air Temperature - Displays the temperature of the
ambient air sensor.
Data Logger Sensor 1 Temperature - Display the temperature
of Data Logger Sensor 1.
Data Logger Sensor 2 Temperature - Display the temperature
of Data Logger Sensor 2.
57
Unit Operation
58
Unit Operation
HOURMETERS - Allows the operator to view the unit ELECTRIC STANDBY - If the Electric Standby option is
hourmeters that have the view feature enabled in the Guarded present and the Diesel to Electric Auto-switch feature is set
Access menu. If the view feature for a particular hourmeter is NO, this feature allows the operator to manually select electric
not enabled then that hourmeter will continue to accumulate mode operation. This feature does not appear if the unit does
time but cannot be viewed from the Main Menu. However, all not feature optional Electric Standby or if the Diesel to Electric
hourmeters can be viewed from the Maintenance Menu, even if Auto-switch feature is set YES.
they are not enabled. DIESEL MODE - If a unit equipped with electric standby is
MODE - Allows the operator to change the unit operating running in electric mode and the Electric to Diesel Auto-switch
modes if allowed. Not all modes may appear depending on the feature is set NO, this feature allows the operator to manually
settings selected from the Guarded Access menu and the HMI select diesel mode operation. This feature does not appear if
Control Panel software version. the unit does not feature optional Electric Standby or if the
Electric to Diesel Auto-switch feature is set YES.
• "Turn Off CYCLE-SENTRY Mode/Turn On
CYCLE-SENTRY Mode (If CYCLE-SENTRY is Off unit ADJUST BRIGHTNESS - Allows the operator to adjust the
runs in Continuous). HMI Control Panel display backlight intensity as required by
local conditions.
• Allow Keypad Lockout to be selected.
TIME - Allows the operator to view the unit time and date. The
• Start Sleep Mode.
time and date cannot be changed from this menu.
PRETRIP - Allows the operator to start a Pretrip Test. If an
alarm is active, the Pretrip Test is not allowed and the operator
is prompted to clear the alarm(s).
59
Unit Operation
60
Unit Operation
61
Unit Operation
Repeat the process to select a different language. To select a press the YES key to confirm the choice. Note that all
different Main Menu item press the NEXT key. To return to the languages in the installed HMI Control Panel software (65xx,
Standard Display press the EXIT key. 66xx or 67xx) can be selected using this method.
IMPORTANT: If necessary, English and all other languages
in the installed HMI Control Panel software revision may be
accessed from the Standard Display.
Should it be necessary to change to another language at any
time, return to the Standard Display and then press and hold the
first and last soft keys for 5 seconds as shown in Figure 66. The
Standard Display below is shown in Deutsch (German).
Figure 67: Language Menu
Alarms
Alarm Types
Alarms may be one of four types as shown.
Figure 66: Standard Display in New Language
After 5 seconds the Language Menu will appear in the current
language as shown in Figure 67. Press the + or - keys to select
the desired language. When the desired language is shown
62
Unit Operation
Log Alarms
Log Alarms are indicated for 60 seconds each time the unit is
turned on. This level of alarm serves as a notice to take
corrective action before the condition impacts unit
performance. Maintenance items such as maintenance
hourmeter time-outs are log alarms.
When the unit is turned on the display will show the Thermo
King Logo and then the "Configuring System" message. If log Figure 68: Log Alarm Notice
alarm(s) are present the Log Alarm notice will appear on the NOTE: If required, an engine start may occur while the
display for 60 seconds as shown. The amber K symbol of the display in Figure 68 is shown. This is normal operation.
remote indicator alarm light (if installed) will also be on during
this period. The Standard Display will appear and the remote
indicator alarm light will go to the white T symbol after 60
Check Alarms
seconds. Check Alarms are indicated by an Alarm Icon in the display.
NOTE: The Alarm Icon does not appear on startup with log The amber K symbol of the remote indicator alarm light (if
alarms present. installed) will be on. This level of alarm serves as a notice to
take corrective action before a problem becomes severe. The
unit will run with check alarms but some features and functions
may be inhibited.
63
Unit Operation
64
Unit Operation
possible. The unit will run in this manner for a timed Alarm Codes When Switching Between
interval. If the unit is successfully able to return to full Diesel and Electric
performance for the timed interval without the alarm
re-occurring, the alarm is auto cleared and the unit will run If a shutdown alarm occurs that affects only diesel mode
normally. operation and the unit is switched to electric, the diesel mode
shutdown alarm becomes an electric mode log alarm. This
• All Prevent Alarm events and conditions are logged by the allows the unit to run in electric mode without clearing the
ServiceWatch Data Logger. shutdown alarm that is preventing diesel mode operation. If the
• In general, if the alarm condition re-occurs a defined unit is switched back to diesel mode, the alarm again become a
number of times, the alarm is set as a shutdown alarm and diesel mode shutdown alarm and prevents unit operation.
no further restarts are possible. In the same manner, if a shutdown alarm occurs that affects
NOTE: If the Restart After Shutdown feature in the Guarded only electric mode operation and the unit is switched to diesel,
Access Menu is set for CONTINUOUS, then an unlimited the electric mode shutdown alarm becomes a diesel mode log
number of restart attempts are allowed. alarm to allow diesel mode operation. If the unit is switched
back to electric mode, the alarm reverts to an electric mode
Pretrip Alarm Codes shutdown alarm and prevents unit operation. If the unit is
configured for electric to diesel autoswitch, it automatically
If an alarm occurs during a Pretrip Test the alarm code will be starts and runs in diesel mode if an electric shutdown occurs.
displayed as Pretrip Alarm XX, where XX is the alarm code.
Alarm Code Notification
The Alarm Icon used in previous Thermo King controllers has
been incorporated. If a Check alarm condition occurs the
Alarm Icon will appear in the display as shown in Figure 69.
65
Unit Operation
The following control and display sensor alarm codes can only
be cleared from the Maintenance Menu or Guarded Access
Menu:
• Alarm Code 03 Check Control Return Air Sensor
• Alarm Code 04 Check Control Discharge Air Sensor
The following alarm codes clear automatically.
Figure 69: Alarm Icon
• Alarm Code 64 Pretrip Reminder - Clears when a Pretrip
If a Shutdown Alarm occurs it will be indicated by all of the Test is performed.
following: • Alarm Code 84 Restart Null - Clears when the unit is no
1. The Alarm Icon will appear. longer in a restart null due to a Prevent Alarm.
2. The display and backlight will flash on and off. • Alarm Code 85 Forced Unit Operation - Clears when the
unit is no longer running in a forced mode due to a Prevent
3. The display will switch from normal video to reverse
Alarm.
video and back to normal video. (Light areas become dark
and dark areas become light.) • Alarm Code 91 Check Electric Ready Input - Clears
automatically when the unit starts running.
Clearing Alarm Codes • Alarm Code 92 Sensor Grades Not Set - Clears when the
sensor grade is changed from 5H.
Most alarm codes can be cleared conventionally from the
Alarm Menu using the CLEAR key.
66
Unit Operation
If the Limited Alarm Restarts feature is enabled the following The Language Menu or Alarms Menu will appear. If the
additional alarm codes may only be cleared from the Guarded Language Menu appears press the NEXT key to show the
Access Menu. If this is the case, the CLEAR soft key will not Alarm Menu. When the Alarms Menu is shown press the
appear if the alarms are displayed from the Main Menu or the SELECT key.
Maintenance Menu.
• Alarm Code 10 High Discharge Pressure
• Alarm Code 23 Cooling Cycle Fault
• Alarm Code 24 Heating Cycle Fault
• Alarm Code 32 Refrigeration Capacity Low
67
Unit Operation
If alarms are present, the quantity of alarms (if more than one)
and the most recent alarm code number will be shown. In the
example in Figure 73, there are two alarms present. The most
recent is Alarm Code 5 (Figure 74). It indicates a problem with
the ambient temperature sensor.
68
Unit Operation
69
Unit Operation
70
Unit Operation
71
Unit Operation
72
Unit Operation
73
Unit Operation
74
Unit Operation
75
Unit Operation
76
Unit Operation
77
Unit Operation
Code Description Operator Help The ServiceWatch Data Logger and DAS Data Logger (if
equipped) are accessed using the Data Logger Menu. From the
Manually monitor load
Standard Display, press the MENU key.
151 Out of Range High temperature. Report
alarm at end of the day.
Manually monitor load
Check Display
203 temperature. Report
Return Air Sensor
alarm at end of the day.
Manually monitor load
Check Display
204 temperature. Report
Discharge Air Sensor
alarm at end of the day.
Figure 76: Menu Key
Datalogger The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to display the Data Logger Menu. When
The unit can be equipped with an optional DAS Data Logger if
the Data Logger Menu is shown press the SELECT key.
desired.
A Start of Trip marker can be sent to the unit ServiceWatch
Data Logger and the optional DAS Data Logger (if equipped).
If equipped with the optional DAS Data Logger, the most
recent DAS trip record can be printed. The most recent trip is
defined as the trip following the last Start of Trip marker sent
to the data logger.
Figure 77: Select Key
78
Unit Operation
The first feature that appears is the Start of Trip. To send a Start
of Trip to the ServiceWatch Data Logger and DAS Data
Logger (if equipped), press the SELECT key to select the
feature, and then press it again to send the Start of Trip. The
display will briefly show START OF TRIP COMPLETE to
confirm that a Start of Trip marker was set in the data
logger(s).
Figure 79: Select Key
Pressing the EXIT key returns the display to the Main Menu.
Hourmeters
Hourmeters are displayed using the Hourmeter Menu. Only
hourmeters enabled in the Guarded Access Menu will be
Figure 78: Start of Trip
shown. From the Standard Display, press the MENU key.
NOTE: The start of trip marker is sent to both the
ServiceWatch Data Logger and DAS Data Logger (if
equipped).
Press the NEXT key to select the PRINT feature. The PRINT
screen will appear. Press the SELECT key to print the most
recent trip record to the optional remote printer.
Figure 80: Menu Key
79
Unit Operation
The Language Menu or Alarm Menu will appear. Press the Hourmeter names and definitions are shown in the table below
NEXT key as required to display the Hourmeter Menu. When in the order they appear. Only hourmeters enabled in the
the Hourmeter Menu is shown press the SELECT key. The Guarded Access Menu will be shown. To return to the Standard
Hourmeter Display will appear. Display, press the EXIT key.
80
Unit Operation
Controller Power On: Total hours the controller and HMI Mode
control panel have been turned on.
Various operating modes can be selected using the Mode
Pretrip Reminder : User Programmable - number of hours menu. Not all modes may be available, depending on settings
before a Pretrip Reminder occurs. of other programmable features. The following modes may be
Engine Reminder 1: User Programmable - The number of available.
hours before an Engine Run Time Maintenance Reminder 1
occurs. Turn CYCLE-SENTRY On or Off
Engine Reminder 2: User Programmable - The number of CYCLE-SENTRY Mode can be turned On or Off. If
hours before an Engine Run Time Maintenance Reminder 2 CYCLE-SENTRY Mode is turned Off then unit will run in
occurs. Continuous mode.
Electric Reminder 1: User Programmable - The number of
hours before an Electric Run Time Maintenance Reminder 1 Keypad Lockout
occurs. If enabled in Guarded Access, the keypad can be locked to
Electric Reminder 2: User Programmable - The number of prevent unauthorized use. If the keypad is locked only the ON
hours before an Electric Run Time Maintenance Reminder 2 and OFF keys function. The keypad will remain locked even if
occurs. the unit is turned Off and back on. If Keypad Lockout is active,
press and hold any soft key for 5 seconds to deactivate the
IMPORTANT: If a programmable hourmeter is not enabled feature.
or the view for that hourmeter is not turned on it will not
appear in the display sequence.
81
Unit Operation
Start Sleep Mode Hour to Wake Up: This feature allows the hour the unit is to
wake up to be specified.
If enabled in Guarded Access, Sleep Mode is used to keep the
engine warm and the battery charged when the unit is not in Minute to Wake Up: This feature allows the minute the unit
use. When the unit is in Sleep Mode the display will show is to wake up to be specified.
"SLEEP" and the current time. When Sleep Mode is entered
Run Pretrip on Wakeup: This feature allows a Pretrip Test
the unit will start and run to confirm proper battery charge
to be automatically run when the unit wakes up.
level and engine temperature.
Mode changes are made using the Mode Menu. From the
IMPORTANT: While in Sleep Mode the unit will not monitor Standard Display, press the MENU key.
or maintain setpoint and load temperature. Fuel level should
be monitored as the unit may run periodically, particularly in
cold weather.
The following features are available in Sleep Mode.
Program Wakeup Time: This feature allows a wakeup time
to be specified. When the selected time is reached the unit will
start and resume normal operation.
If a Wakeup Time is selected the following features are Figure 83: Menu Key
available:
The Language Menu or Alarm Menu will appear. Press the
Day to Wake Up: This feature allows the day of the week the NEXT key as required to show the Mode Menu. When the
unit is to wake up to be specified. Mode Menu is shown press the SELECT key.
82
Unit Operation
Selecting CYCLE-SENTRY or
Continuous Mode
When CYCLE-SENTRY mode is selected the unit will start
and stop automatically to maintain setpoint, keep the engine
warm and the battery charged. When Continuous Mode is
selected, the unit will start automatically and run continuously
Figure 84: Select Key to maintain setpoint and provide constant airflow. From the
Standard Display, press the MENU key.
The first mode change screen will appear. To choose that .
function, press the SELECT key. To Scroll thru the Mode
Menu press the NEXT key.
83
Unit Operation
The Turn Off/Turn On CYCLE-SENTRY screen will appear. The display will confirm the change as shown below.
In the display shown below, the unit is operating in
CYCLE-SENTRY mode. Turning CYCLE-SENTRY mode off
will result in the unit running in Continuous mode.
84
Unit Operation
85
Unit Operation
86
Unit Operation
The display will show SLEEP and the unit will start and stop as
Figure 99: Yes Key
required to keep the engine warm and/or the battery charged.
Sleep mode does not consider setpoint or maintain cargo The display will prompt the operator for the DAY the unit is to
temperatures. To exit Sleep Mode press the EXIT key or turn restart in normal operation. In Figure 100 Monday has been
the unit off and back on. The unit will resume normal operation chosen. Press the YES key to confirm the DAY.
and control to setpoint.
87
Unit Operation
The display will now prompt the operator for the Hour the unit The display will now prompt for a Pretrip Test on Wake-up.
is to restart in normal operation. In Figure 101 4:00 am has Press the YES key to perform a Pretrip Test on Wake-up. If the
been chosen. Press the YES key to confirm the HOUR. Note No key is pressed the unit will resume normal operation on
that 24 hour "military time" is used. Wake-up.
88
Unit Operation
89
Unit Operation
90
Unit Operation
Performing a Pretrip Test The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to display the Pretrip Menu. When the
If a Pretrip Test is initiated with the engine shut down a Full
Pretrip Menu is shown press the SELECT key.
Pretrip Test will be performed. If a Pretrip Test is initiated with
the engine or motor running a Running Pretrip Test is
performed.
• Before initiating a Pretrip Test, clear all alarm codes.
• To stop a Pretrip Test at any time, turn the unit off. Alarm
Code 28 Pretrip Abort will be set. Other alarms may also
be set, depending upon test in progress when the test was
terminated. Figure 106: Select Key
Pretrip Tests are initiated using the Pretrip Menu. From the If the unit is not running a Full Pretrip Test will be initiated. If
Standard Display, press the MENU key. the unit is running in either diesel or electric mode a Running
.
Pretrip will be performed.
91
Unit Operation
If all alarms were not cleared a prompt appears as shown in • The top line of the display indicates the unit is performing
Figure 108. Exit the Pretrip Test, clear all alarms and restart the the non-running portion of the Pretrip Test.
Pretrip Test. • The second line measures test progress. The number of
tests completed of the total number of tests to be
performed is shown. In Figure 109 the unit is performing
Test 1 of 26, Sensor Check.
• The soft keys may be used during the Pretrip Test to select
the Hourmeter, Gauge or Sensor menus.
• To stop a Pretrip Test at any time turn the unit off. This
Figure 108: No Pretrip Prompt will generate Alarm Code 28 Pretrip Abort. Other alarm
codes may also be generated. This is normal when the
If no alarms are present, the Pretrip Test display appears. Pretrip Test is halted before completion.
When the non-running tests are complete the unit will start
automatically and continue with the Running Pretrip Test. In
the example in Figure 110 the unit is in the Running Pretrip
and is performing Test 21 of 26, Cool Test.
92
Unit Operation
Diesel/Electric Menu
The Diesel Mode/Electric Standby menu allows the operator to
Figure 110: Performing Cool Test manually select diesel or electric mode operation. The unit can
also be programmed to automatically select electric mode
When all tests are complete, the results are reported as PASS, operation when standby power is available and to
CHECK or FAIL. If the results are CHECK or FAIL, the automatically select diesel mode operation if standby power
accompanying alarm codes will direct the technician to the fails or is removed. If the unit is programmed to switch
cause of the problem. automatically from diesel to electric and electric to diesel these
screens do not appear.
93
Unit Operation
If the Diesel to Electric Autoswitch Enabled feature in Switching from Electric to Diesel - Units
Guarded Access is set NO then the prompt screen shown in equipped with the Electric Standby option
Figure 112 will appear when standby power is connected and
only
available.
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set YES then the unit will automatically
switch to Diesel Mode operation when standby power is turned
off or is no longer available.
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set NO then the prompt screen shown in
Figure 112: Standby Power connected & available Figure 114 will appear when standby power is turned off or is
no longer available. Alarm Code 91 Check Electric Ready
If YES is selected then the display will briefly show the screen
Input and Alarm Code 84 Restart Null will both be set.
in Figure 113.
94
Unit Operation
Turn the unit off and back on using the OFF and ON Keys.
This will clear Alarm Code 91 Check Electric Ready Input and
Alarm Code 84 Restart Null. NOTE: The CLEAR Soft Key
will not clear these two alarms. Then the prompt screen shown
in Figure 115 will appear.
95
Unit Operation
.
The Display Brightness menu will appear as shown below.
Press the + or - keys to select the desired display brightness.
When the desired brightness is shown press the YES key to
confirm the choice.
96
Unit Operation
Time
The system time and date is viewed using the Main Menu.
Time and Date cannot be changed from the Main Menu. From
the Standard Display, press the MENU key.
.
97
Loading and Enroute Inspections
Thermo King refrigeration units are designed to maintain the 4. Pre-cool the cargo compartment. Adjust the setpoint to the
required temperature for the product being carried during its desired cargo temperature and allow the unit to run a
time in transit. Because of the unit’s unique design, special care minimum of 30 to 60 minutes (longer if possible) before
is required during loading to prevent cargo spoilage. loading. Check to be certain the setpoint temperature is
correct for the cargo.
Pre-Loading Inspection Pre-cooling before loading will remove residual heat and
moisture from the cargo compartment and prepare it to
1. Inspect all door seals, including vent doors, for condition receive the refrigerated load. Pre-cooling also provides a
and a tight seal with no air leakage. good test of the refrigeration system.
2. Inspect the cargo compartment inside and out for damaged 5. Make sure products are pre-cooled to the proper
or loose skin and insulation. temperature before loading. Any variance should be noted
3. Inspect the inside of the cargo compartment for damaged on the manifest.
walls, air ducts, floor channels or “T” flooring, clogged 6. Supervise product loading to make sure that there is
defrost drain tubes, and clogged or damaged floor sufficient air space around and through the load so air flow
channels which could block the air return, creating is not restricted.
isolated areas in the load that are warmer than the desired
temperature.
98
Loading and Enroute Inspections
Inspecting the Load 3. While inspecting to see that the cargo is loaded properly,
make sure the evaporator inlets and outlets are not
Never assume that the product has been loaded properly. Watch blocked.
for and perform the following tasks. It takes only a few
minutes and could save you or your employer considerable 4. Close or supervise the closing of the cargo compartment
time and money later on. doors. Make sure they are securely locked.
1. Make sure the unit is off before opening the cargo 5. Check to make sure the unit setpoint is set at the desired
compartment doors. During operation, the unit blows out temperature as listed on the manifest.
refrigerated air, and draws in outside air. 6. If the unit was stopped, restart using the appropriate
NOTE: The unit can be run with the doors open if the starting procedure outlined in this manual.
truck is backed into a refrigerated warehouse with tight 7. Repeat the after-start inspection.
door seals.
8. Defrost the unit 30 minutes after loading by starting a
2. Perform a final check of the load temperature. If the load manual defrost cycle.
is too hot or too cold, make a final notation on the
manifest.
99
Loading and Enroute Inspections
100
Loading and Enroute Inspections
101
Specifications
Engine
Model: T-680R, T-680S, T-880R & T-880S TK374F (Tier 4)
T-1080R & T-1080S TK380F (Tier 4)
Fuel Type No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Oil Capacity:T-680S and T-880S
Crankcase & Oil Filter 9.0 quarts (8.5 liters)
T-680S and T-880S w/Bypass Oil Filter 10.0 quarts (9.5 liters) Fill to full mark on dipstick
T-1080R & T-1080S Crankcase & Oil Filter 12.0 quarts (11.4 liters)
T-1080R & T-1080S w/Bypass Oil Filter 13.0 quarts (12.3 liters) Fill to full mark on dipstick
Oil Type API Classification CI-4 or better
(ACEA Rating E3 or better for Europe)
Oil Viscosity 14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic)
5 to 104 F (-15 to 40 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic)
Below -22 F (-30 C): SAE 0W-30 (Synthetic)
102
Specifications
Engine (Continued)
Engine rpm: Low Speed Operation 1625 ± 25 rpm
High Speed Operation Reciprocating Compressor: 2200 ± 25 rpm
Scroll Compressor: 2200 ± 25 rpm
Engine Oil Pressure 20 to 50 psig (138 to 345 kPa) in low speed
40 to 60 psig (276 to 414 kPa) in high speed
Intake Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature 70 F (21 C)
Fuel Injection Timing 16 ± 1 degrees BTDC
Injection Nozzle Pressure 1784 to 1929 psig (12,300 to 13,300 kPa)
Low Oil Pressure Switch/Sensor 10 ± 2 psig (69 ± 14 kPa)—shutdown
High Coolant Temperature Sensor 220 ± 5 F (104 ± 3 C)—shutdown
Engine Thermostat 160 F (71 C)
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Specifications
Engine (Continued)
Engine Coolant Type
ELC (Extended Life Coolant), which is “RED”
Use a 50/50 concentration of any of the following equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
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Specifications
Engine (Continued)
Units Built Prior to October 2016 Units with coolant expansion tank only
Coolant System Capacity:
T-680R, T-680S, T-880R, T-880S 6.0 quarts (5.7 liters)
T-1080R, T-1080S 6.5 quarts (6.2 liters)
15 psig (103 kPa)
Coolant Expansion Tank Cap Pressure
7 psig (48 kPa) after November 2015
Units Built After October 2016 Units with coolant expansion tank and overflow bottle
Coolant System Capacity:
T-680R, T-680S, T-880R, T-880S 7.64 quarts (7.23 liters)
T-1080R, T-1080S 8.36 quarts (7.91 liters)
Coolant Expansion Tank Cap Pressure 10 psig (69 kPa)
Belt Tension
Belt Tension No. on TK Gauge Frequency Gauge P/N 204-1903
P/N 204-427 Setting Where Applicable
New Belt Field Reset New Belt Field Reset
Water Pump Belt 40 40
Engine/Electric Motor (Jackshaft) – 81 77 62 Hz 55 Hz
Static Belt Tensioner
Electric Motor (Jackshaft)/Compressor Automatically tensioned by tensioner position. See “Belts” in
105
appropriate Maintenance Manual Chapter.
Specifications
Engine Clutch
Engagement 600 ± 100 RPM
Dynamic Torque 66 ft-lb (89.5 N•m) minimum @ 1600 RPM
Refrigeration System
Reciprocating Compressor
Compressor Model:
Unit Model: T-680R and T-880R Thermo King X214
T-1080R Thermo King X426
Refrigerant Charge: T-680R 8.0 lb (3.6 kg) R-404A
T-880R 8.5 lb (3.9 kg) R-404A
T-1080R 9.0 lb (4.1 kg) R-404A
*Compressor Oil Charge:
X214 in T-680R and T-880R 3.2 quarts (3.0 liters)
X426 in T-1080R 4.3 quarts (4.1 liters)
Compressor Oil Type Ester base P/N 203-513 required
106
Specifications
Refrigeration System
Suction Pressure Regulator Valve Setting:
T-680R 28 to 31 psig (193 to 214 kPa)
T-880R 35 to 37 psig (241 to 255 kPa)
T-1080R 21 to 23 psig (145 to 159 kPa)
High Pressure Cutout Switch: Open 470 ± 7 psig (3241 ± 48 kPa)
Close 375 ± 38 psig (2586 ± 262 kPa)
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured. This is to be sure that the same amount of oil can be added before placing the
replacement compressor in the unit.
Scroll Compressor
Compressor Model:
Unit Model: T-680S and T-880S TK04 Scroll 4 HP
T-1080S TK06 Scroll 6 HP
Refrigerant Charge:
T-680S and T-880S 7.0 lb (3.2 kg) R-404A
T-1080S 7.5 lb (3.4 kg) R-404A
*Compressor Oil Charge 2.0 quarts (1.9 liters)
107
Specifications
Refrigeration System
Compressor Oil Type Ester base P/N 203-516 required for Scroll compressor
Discharge Pressure Regulator Valve Setting 350 ± 5 psig (2413 ± 34 kPa)
High Pressure Cutout Switch: Open 470 ± 7 psig (3241 ± 48 kPa)
Close 375 ± 38 psig (2586 ± 262 kPa)
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured. This is to be sure that the same amount of oil can be added before placing the
replacement compressor in the unit.
108
Specifications
Fuses
Fuse Size Function
F2 15A Power to On/Off Switch
F3 40A Fuel Sol Pull-In/Starter Circuit
None No Fuse - All Bosch and Thermo King Alternators
F4
2A 2A Fuse - All Prestolite Alternators
F5 40A Preheat Circuit
F6 15A Damper and High Speed Circuits
F7 2A 8XP Circuit - Controller On Feedback to HMI
F8 5A 2A Power to CAN Connector J12
F9 5A 2A Power to CAN Connector J14
F10 10A 8X Power (Install fuse in right position)
F12 5A 2A Power to CAN Connector J13
F13 2A 8FC Circuit (Remote Status Light/Optional Power)
F20 2A Alternator Sense
F21 60A Main Fuse (2 Circuit)
109
Specifications
Fuses (Continued)
Fuse Size Function
F25 7.5A HPCO Switch Circuit
F26 5A Power to CAN Connector J98
F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with
Prestolite Alternator.
F10 When fuse F10 is installed in the right position the On/Off keys on the HMI turn the unit on and off. When
fuse F10 is installed in the left position the unit will start and run without the HMI control panel.
Electrical Components
Component Current Draw (Amps) Resistance
at 12.5 Vdc (Ohms)
Glow Plugs (3) Each 4.3 2.3 ± 0.2
Fuel Solenoid: Pull In Coil 35 to 45 0.2 to 0.3
Hold In Coil 0.5 24 to 29
High Speed (Throttle) Solenoid 3.3 3.8
Damper Solenoid 5.7 2.2
110
Specifications
111
Specifications
112
Specifications
113
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep After first week of operation:
your Thermo King unit in top operating condition. The • Check belt tension.
following general schedule is provided to assist in monitoring
that maintenance. • Tighten unit mounting bolts.
For more specific detail, see the maintenance manual for your • Check coolant level.
unit and to the PreTrip Inspection chapter in this manual. • Check refrigerant oil level.
• Check refrigerant level.
l
114
Maintenance Inspection Schedule
115
Maintenance Inspection Schedule
116
Maintenance Inspection Schedule
117
Maintenance Inspection Schedule
118
Maintenance Inspection Schedule
119
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50047 for the Thermo King
Self-Powered Truck Unit Warranty.
120
Serial Number and Refrigerant Label
Locations
Write the unit model and unit serial number in the spaces
provided in the following Emergency Cold Line chapter. This
information is needed to service the unit.
121
Serial Number and Refrigerant Label Locations
AQA183
Figure 126: X214 Reciprocating Compressor Serial Figure 127: X426 Reciprocating Compressor Serial
Number Location Number Location
122
Serial Number and Refrigerant Label Locations
1
2
123
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.
124
Emergency Cold Line
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AMA1585
125
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
126
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.