Thermo King T-500R Maintenance Manual page 136

Connector Pinout
Pin Wire
1 8
2 CH/CHV
3 ER
4 7EA/7E
5 7EB
6 7EC
7 SP-GND
8 SP
9 Unused
Removal and Replacement
1. Turn unit off.
2. Disconnect the unit battery.
3. Disconnect the standby power.
4. Remove the high voltage cover.
5. Disconnect the three wires from the phase select module at the motor contactor.
6. Unplug the phase select module harness.
7. Remove the old phase select module.
8. Install the new phase select module.
9. (3 Phase Applications) Connect the new phase select module wires to the lower contactor (MCA) as follows:
Connect the Brown wire to L1 on the contactor.
Connect the Gray wire to L2 on the contactor.
Connect the Black wire to L3 on the contactor.
Use crimp-on terminals as required.
10. (Single Phase Applications) Connect the new phase select module wires to the lower contactor (MCA) as follows:
Connect the Brown wire to L1 on the contactor.
Connect the Gray wire to L2 on the contactor.
Use crimp-on terminals as required.
Tape the Black wire back onto itself. It is not used on single-phase installations.
11. Connect the plug on the short harness from the phase select module.
12. Install the high voltage cover.
13. Secure wires and wire harnesses as required using cable ties.
14. Connect the unit battery.
15. Perform a Pretrip Test to verify proper operation.
Diagnostics
1. Plug the standby power cord into a known good power supply and turn the unit on.
2. Using a Fluke Meter, test the L1, L2, and L3 circuits at the input to the terminals where the Brown, Blue and Black wires are
connected. The voltage should be between 200-480 VAC between the circuits. If not, repair as necessary to supply the needed
voltage to the unit.
3. Check the 8 circuit to the phase select module for 12 Vdc. If voltage is not present, check the phase select module connector
and the interface board connector for secure connections.
4. If correct AC power is present in step 2 above, then the ER output should measure 12 Vdc. If no voltage is present, replace
the phase select module.
5. If voltage is present on the ER output, then LED 7 (K5 Diesel/Electric Relay) on the interface board should be on. If not,
check the K5 Diesel/Electric Relay circuit on the interface board.
6. If voltage is measured on the ER output, and LED 7 is on, then the 7EA input should measure 12 Vdc. If voltage is not present,
check the phase select module connector and the interface board connector for secure connections.
7. If voltage is present on the ER output and the 7EA input, and LED 7 is on, then either the 7EB or 7EC output should measure
12 Vdc and one of the phase select contactors should be on. If voltage is not present on either the 7EB or 7EC output, replace
the phase select module.
Description
Power to Module
Chassis ground
AC Power OK, output to microprocessor
Power for 7EB or 7EC output
Output to MCA
Output to MCB
Internal ground to enable a jumper circuit for SP logic
Grounded for single phase mode
Electrical Maintenance 8-16