Johnson AE Series Operator's Manual

Cold plate refrigeration system with plc

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MODEL YEAR: 2024-2025

REVISION: B

OPERATOR'S MANUAL

COLD PLATE REFRIGERATION SYSTEM WITH PLC

INCLUDING MAINTENANCE

This manual contains important safety information. Before operating the unit, read this

manual thoroughly. Keep the manual with the truck body.

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Page 1 MODEL YEAR: 2024-2025 REVISION: B OPERATOR’S MANUAL COLD PLATE REFRIGERATION SYSTEM WITH PLC INCLUDING MAINTENANCE This manual contains important safety information. Before operating the unit, read this manual thoroughly. Keep the manual with the truck body.
Page 3: Table Of Contents
Table of Contents Introduction ............................ 5 Safety .............................. 7 Basic Operation Instructions ......................11 Advanced Operation Instructions ....................23 Maintenance ..........................27 Troubleshooting ..........................35 Warranty ............................39 Service and Support ........................41 Glossary ............................43...
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Page 5: Introduction
1 Introduction Congratulations on your purchase of a Johnson Truck Body with Cold Plate refrigeration. We believe that you will enjoy years of reliable service from our equipment and enjoy the benefits of accurate and efficient temperature management in your refrigerated truck. Thank you for choosing us for your refrigerated transport needs.
Page 6 Read this manual carefully and become familiar with your Johnson Refrigeration System. Know its applications, its limitations and any hazards involved. Should you have any further questions, contact Johnson Truck Bodies at (800) 922-8360 and press 6 for Customer Service. This manual should always be kept with the truck body and should remain with the body when it is sold.
Page 7: General Precautions
NOTICE indicates a hazard which, if not avoided, could result in equipment or property damage. Johnson Truck Bodies recommends that all servicing be performed by a trained service technician. However, owners and operators should also learn and observe safe operation and service practices.
Page 8: Electrical Precautions
2.1.2 Electrical Precautions WARNING: Disconnect unit from grid power (if equipped) before servicing or inspecting any part of the unit. CAUTION: If doing electric arc welding on any part of the vehicle, ensure that the welding current will not pass through any portion of the refrigeration system or its wiring. It is best to disconnect and isolate the vehicle’s negative battery terminal before welding.
Page 9 2 . 2 F i r s t A i d M ea s u r es Please familiarize yourself with the first aid measures listed below. In the event of a workplace accident, this will allow you to seek, provide, or advise first aid which is most appropriate for the listed hazards.
Page 10 Please read all the information carefully to avoid injury and system damage. Familiarize yourself with the locations of these labels. If labels become damaged or missing, contact Johnson Truck Bodies for replacements. Table 1: Refrigeration System safety labels and locations...
Page 11: Basic Operation Instructions
3 Basic Operation Instructions Before operating the system, please read the Operator’s Manual completely and retain it for future reference. Carefully observe all warnings, precautions, and instructions on the refrigeration system and adhere to them. This section presents the system components and instructions for pre-cooling, proper loading, operation on route, returning from the route, and defrosting.
Page 12 3 . 1 R ef r i g e r a t i o n S y s t em D i a g r a m Figure 1: Refrigeration System Diagram a. User Interface: Located on the driver-side front corner of the body; allows access and display of refrigeration system information A button on the User Interface allows the refrigeration system to be switched on or off;...
Page 13 3 . 2 U s e r I n t er f a c e In 2024 we have introduced a new User Interface. The User Interface is installed on the front left corner of the truck body. It has a digital color display of refrigeration system information and keypad to access information and adjust system settings.
Page 14 3 . 3 P r e - C o o l i n g I n s t r u c t i o n s The refrigerated compartment must be pre-cooled before loading cargo. Follow these steps: Connect AC Retrieve Cord.
Page 15 Turn On System At the HOME screen, the F4 button is the ON-OFF SWITCH. If Switch Status is OFF, press F4 to turn ON the cooling system. When Switch Status is OFF, the blinking yellow indicator is a reminder that the system is not cooling.
Page 16 Prepare for Use Button F4 to turn System Switch OFF. Departure NOTICE: Do not unplug while the system is running. Unplug and stow power cord. If equipped with Cord Box option, the Cord Box cover must be fully closed and latched;...
Page 17 3 . 5 R o u t e I n s t r u c t i o n s Best practices during the route focus on minimizing the heat load entering the refrigerated compartment. Be aware that the Cold Plate system has a limited total refrigeration capacity. If an excessive amount of heat enters the body during the route, the solution in the Cold Plates will thaw completely.
Page 18 3 . 6 R etu r n i n g F r o m R o u t e I n s tr u c ti o n s The refrigerated compartment must be re-cooled to prepare it for the next route. Follow these steps: Consider Clean frost from plates daily with Defrost Defrosting...
Page 19 Upon connection to AC power, the refrigeration system controller starts up. Start-up takes about 10 seconds. Turn On System At the HOME screen, the F4 button is the ON-OFF SWITCH. If Switch Status is OFF, press F4 to turn ON the cooling system. When Switch Status is OFF, the blinking yellow indicator is a reminder that the system is not cooling.
Page 20 Pre-Cooling Once the Cold Plates are frozen, the Completed refrigeration compressor turns off. The blue indicator goes away, because the compressor is not running. *ANTI SHORT-CYCLE DELAY is a temporary message that the compressor will not immediately re-start for a short time (usually 30 seconds) even if conditions call for additional cooling.
Page 21 3 . 7 D ef r o s t I n s t r u c t i o n s Cold Plates work best when there is little to no frost buildup on their surface. Excessive frost thickness acts like insulation wrapped around the Cold Plate. This can cause slow temperature recovery after door openings, or even prevent the system from cooling the refrigerated compartment to the design temperature.
Page 22 Table 3: Defrosting flowchart If plugged in, use Button F4 to turn System Switch OFF. Unplug from AC power. Unload all temperature-sensitive products. Warm the Cold Plates; choose method below based on ambient temperature. Ambient Temperature Above 40°F Ambient Temperature Below 40°F Open all doors to the refrigerated Consider moving the truck to a heated garage to use compartment.
Page 23: Advanced Operation Instructions
4 Advanced Operation Instructions This section includes information about advanced features of the User Interface, and an introduction to the display of system faults. This information should not be necessary for ordinary daily operation. 4 . 1 A d v a n ce d U s er I n t e r fa c e F ea t u r e s This section is intended for the advanced user and service technician.
Page 24 Screen Description FAULTS View any active system faults. COUNTERS – Number of times each fault has occurred. SENSORS – View any active sensor faults and their counters HOURS Hour meter to track refrigeration system operation. PUMP-DOWN Special operation modes, generally used by the service technician. Closes the liquid line solenoid while the compressor is running.
Page 25 4 . 2 F a u l t C o n d i t i on s This section introduces what the user will see if a system fault occurs. Table 4: Instructions for fault conditions Fault Conditions User Interface A flashing red indicator shows that a fault is present.
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Page 27: Maintenance
5 Maintenance It is important that every refrigerated truck body owner and/or operator have an organized preventative maintenance program. Preventative maintenance will help to keep your Johnson Refrigeration System in top operating condition. The maintenance schedule below is suggested to ensure that all items receive the proper frequency of attention.
Page 28 5 . 1 C h ec k L i n e C o r d This maintenance task can be part of the driver’s daily responsibilities. Before every use, check the line cord for any damage to the outer jacket. •...
Page 29 5 . 2 C h ec k C o n d en s e r C o i l The condenser coil is located with the compressor, either nose-mounted or skirt-mounted. The condenser coil is like a radiator, using airflow to cool the hot refrigerant. It is a good idea to routinely check if airflow is restricted by unusual debris like leaves, wrappers, bags, etc.
Page 30 5 . 3 C o l d Pl a t e I n s p e c t i o n It is most effective (and most pleasant) to do the Cold Plate Inspection at the conclusion of a defrost process.
Page 31 Figure 8: Example of refrigerant piping in good condition. Red arrow points to a plate bracket. Blue arrow points to vacuum relief port. 901-10113 - 31 - 9/16/2024...
Page 32 5 . 4 C o n d en s i n g U n i t I n s p ec ti o n These checks keep the condensing unit operating in its best condition. Begin by ensuring that the system is unplugged.
Page 33 After completing these power-off checks, remove any tools or service equipment from the condensing unit, and ensure all personnel are clear of the condensing unit. Re-connect power to the refrigeration system and turn it on (see Section 3.3) For the following steps, keep all body parts outside of the condensing unit frame. The unguarded condenser fan can start at any time and might not be running initially.
Page 34 5 . 6 P r o h i bi t e d A d j u s t m en ts The following tasks should never be conducted unless directed to do so by Johnson Truck Bodies. Failure to obtain authorization and directions for refrigeration adjustments could result in warranty revocation, refrigeration system failure, and possible injury to the operator.
Page 35: Troubleshooting
Customer Service at Johnson Truck Bodies. We are dedicated to helping you enjoy trouble-free service from our products. If experiencing a fault, look for it in the “Problem” column.
Page 36 Problem Possible Causes Correction Refrigerated Excessive frost accumulation on Cold Plates See defrosting information in Section 3.7 compartment Excessive time with doors open. Reduce duration of door openings or number temperature not of door openings. adequately maintained during Door strip curtains damaged or missing Maintain strip curtains in good condition.
Page 37 Problem Possible Causes Correction Noisy Compressor: Noise lasts less than 10 seconds. No issue. Loud, metallic rattle Only happens at initial start-up. It can take several seconds for the compressor Unit was not operated for several days or to get fully oiled. more.
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Page 39: Warranty
The refrigerated truck body owner is responsible for the preventative maintenance specified in this Operator’s Manual. If you believe that a repair is eligible for warranty coverage, you must contact Johnson Truck Bodies prior to any warranty work being done. Please have the body serial number ready. Johnson Truck Bodies must provide prior approval for warranty work before a qualified service technician performs any repairs.
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Page 41: Service And Support
From pre-sale to post-sale, we are here for you from the initial sales inquiry to service support through the life of your Johnson equipment. At Johnson Truck Bodies, we are positioned to provide you with the most efficient and convenient local and field support available through our in-house experts and service repair locations nationwide.
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Page 43: Glossary
9 Glossary This glossary helps to explain terms used in the manual. Terms are defined in the context of truck refrigeration with Cold Plates. Some terms have other meanings when used elsewhere. Air Temperature vs. Product Temperature – The air temperature in the refrigerated compartment may fluctuate greatly due to door openings and/or other factors.
Page 44 FRP (Fiberglass Reinforced Plastic) – A composite material made of a plastic matrix containing and reinforced by fine glass fibers. Refrigerant – The working fluid circulated by the condensing unit. A substance which, depending upon its pressure, can exist as a liquid at the desired ambient temperature and can be vaporized at the desired refrigerated temperature.