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Ingersoll-Rand FRIGOBLOCK R Service Training
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Ingersoll-Rand FRIGOBLOCK R Service Training

Ingersoll-Rand FRIGOBLOCK R Service Training

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FRIGOBLOCK R-UNITS
SERVICE-TRAINING
08.01.2018

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Summary of Contents for Ingersoll-Rand FRIGOBLOCK R

  • Page 1 FRIGOBLOCK R-UNITS SERVICE-TRAINING 08.01.2018...
  • Page 2 FRIGOBLOCK R-units 1) Handout 2) Presentation - notes 3) Wiring diagrams 4) Quick reference guide universal remote control 5) Software overview 6) Working instructions  Firmwareupdate ControllerES  Firmwareupdate HMI 7) Service information  si-e-2017_10-CAN-Bus-Plug  si-e-2017_11-CAN-plug-sealing...
  • Page 3 FRIGOBLOCK R units Effective: 29 Sep 2017 Prepared: ML, rs...

  • Page 4: Table Of Contents

    FRIGOBLOCK R units Contents Introduction ................................ 5 CAN bus system ..............................6 Components in the CAN bus system and their functions................7 FRIGOBLOCK CAN-bus cable ........................7 I/O cards ..............................8 ControllerES ............................. 10 HMI ................................11 2.5.1 Places of installation ......................... 11 2.5.2...
  • Page 5 FRIGOBLOCK R units 6.6.1 Electrical design of the RE22-2-R (E heat) ..................48 6.6.2 Electrical design of the RE42-1-R HG ....................51 Unit schematic(s) ............................. 54 FK/HK single compartment / G alternator schematic ................55 FK/HK single compartment / AW alternator schematic ................55 EK / single compartment / G alternator schematic ...................
  • Page 6 FRIGOBLOCK R units 12.2 Software updates ........................... 100 Service ................................101 13.1 Open the component overview ......................101 13.2 Read out the diagnostic log ........................101 13.3 Fault codes ............................. 102 13.4 Check configuration / controller parameters ..................102 13.5 Check the CAN bus error rate ........................

  • Page 7: Introduction

    FRIGOBLOCK R units 1 Introduction FRIGOBLOCK R units are controller governed refrigeration units. Unlike conventional units with relay and contactor control, R units are controlled and monitored by an electronic controller. Temperatures, on and off signals are acquired electronically and - unlike in the past - can be analyzed electronically.

  • Page 8: Can Bus System

    FRIGOBLOCK R units 2 CAN bus system A conventional system needs a separate cable for each information. Hence, the more electronic functions are available, the longer the length and the higher the weight of the cable harness and the number of terminals at the control units.

  • Page 9: Components In The Can Bus System And Their Functions

    2.1 Components in the CAN bus system and their functions Depending on the layout of the refrigeration unit, any number of components can be connected with each other within the CAN bus system. The following components are used in FRIGOBLOCK R units. I/O card...

  • Page 10: I/O Cards

    FRIGOBLOCK R units 2.3 I/O cards The abbreviation I/O card means input / output card. The I/O card is connected to the CAN bus. Temperature data can be acquired and outputs switched via the I/O cards. Connected to the CAN bus, the I/O card receives instructions from the controller, implements them and returns data to the controller.
  • Page 11 FRIGOBLOCK R units For controlling the refrigeration unit, the following signals are received as input signals by the I/O cards:  Compressor motor NM1 winding temperature switch  Winding temperature switches of the condenser fan motors  Outside temperature ...

  • Page 12: Controlleres

    FRIGOBLOCK R units 2.4 ControllerES The ControllerES (ES=Eigenständig or independent, in English) acts as the brain of a refrigeration unit. It is connected to the CAN bus and transmits all instructions for controlling the refrigeration unit. The controller has a blue status LED which shines when voltage is fed to the controller and the controller is ready.

  • Page 13: Hmi

    FRIGOBLOCK R units 2.5 HMI In simple words, the universal remote control, also known as HMI (human machine interface), is the "window to the controller". The universal remote control itself performs no control function, it only accepts instructions and receives signals and displays information.
  • Page 14 FRIGOBLOCK R units MOA box Depending on the version MOA, the universal remote control is installed at the front or the side of the MOA box. Front position Sideways position Rear compartment The universal remote control can also be installed at the rear of the truck or inside the compartment.

  • Page 15: Display Layouts

    FRIGOBLOCK R units 2.5.2 Display layouts The display layout of the universal remote control can be customized. Three different display layouts are available: Standard display EHI display Overview display The display layout can be adapted separately for each installation place.

  • Page 16: Operation

    FRIGOBLOCK R units 2.5.3 Operation Functional description Some buttons are assigned multiple functions. Brief touch: Switches the refrigeration unit on/off LED flashes in alternator mode the moment the unit is switched on LED shines when the refrigeration unit is running...
  • Page 17 FRIGOBLOCK R units Display layout Return air of the displayed compartment Selected compartment, or additional refrigeration unit Selected basic Setpoint values of the displayed compartment  FD1 = chill temperature 1  FD2 = chill temperature 2  TK1 = deepfreeze temperature 1 ...

  • Page 18: Opto-Coupler / Can Gateway

    FRIGOBLOCK R units 2.6 Opto-coupler / CAN gateway In tractor-trailer applications, the length of the cables can cause faults in the CAN bus communication. The solution in such a case is two separate CAN bus systems which are connected by a CAN gateway (a so called opto-coupler). The opto-coupler is installed in the trailer MOA and separates the tractor CAN bus system from the trailer CAN bus system.

  • Page 19: Addressing The Can Bus Components

    FRIGOBLOCK R units 3 Addressing the CAN bus components All components introduced in chapter 2 which can be connected in the CAN bus system need a unique address to enable the communication with the ControllerES. Depending on the place of installation and the function, the components are assigned addresses through the FrigoCENTER.

  • Page 20: Can Address Ranges

    FRIGOBLOCK R units 3.2 CAN address ranges A tractor-trailer unit would have two identical addresses each. To avoid disruption of communication, address ranges are defined. Each component is assigned an address range depending on the system in which it is at home.

  • Page 21: Termination Of The Can Bus System

    FRIGOBLOCK R units 4 Termination of the CAN bus system In order to close the CAN circuit between CAN high and CAN low the ends of the CAN bus must be terminated with a 120 Ohm terminating resistor each. Overtermination with additional or higher resistances should be avoided because that would create communication trouble, even complete components might be destroyed in the CAN bus system.

  • Page 22: Termination Of The Tractor G Alternator

    FRIGOBLOCK R units 4.1 Termination of the tractor G alternator Start: Driver’s cab remote control End: Component with the longest cable route from the MOA (I/0 card in the RE or rear remote control). 120 Ohm terminating resistor location CAN bus cable...

  • Page 23: Termination Of Tractor With Inverter Filter

    FRIGOBLOCK R units 4.2 Termination of tractor with inverter filter Start: Remote control unit in the driver’s cab End: Component with the longest cable route from the MOA (I/0 card in the RE or rear remote control). Additional terminating resistor in the inverter filter...

  • Page 24: Trailer Termination

    FRIGOBLOCK R units 4.3 Trailer termination Start: I/0 card or universal remote control in the MAO. End: Component with the longest cable route from the MOa (I/0 card in the RE or rear remote control unit). 120 Ohm terminating resistor location...

  • Page 25: Shielding Of The Can Bus System

    FRIGOBLOCK R units 5 Shielding of the CAN bus system The CAN bus cable is a shielded cable. In a complete system, the shields of the CAN bus cables must be connected with each other. For that purpose, the shield of each CAN bus cable is separated at the ends, drilled and formed into a separate cable by means of shrinkage tube (see the illustrations below).

  • Page 26: Fk Refrigeration Unit Shield Connection

    FRIGOBLOCK R units 5.1 FK refrigeration unit shield connection The shield connection of the CAN bus in the machine control box of the FK refrigeration unit is made in the manufacturer’s factory. CAN bus connection to ground...

  • Page 27: Hk Refrigeration Unit Siehld Connection

    FRIGOBLOCK R units 5.2 HK refrigeration unit siehld connection The shield connection of the CAN bus in the machine control box of the HK refrigeration unit is made in the manufacturer’s factory. CAN bus connection to ground...

  • Page 28: Ek Refrigeration Unit Shield Connection

    FRIGOBLOCK R units 5.3 EK refrigeration unit shield connection The shield connection in EK refrigeration units must be made in the EK control box by the installation partner. The shields of all CAN bus cables are pulled into the MOA, must be twisted, taken together and connected to ground in the MOA control box of the EK.

  • Page 29: Inverter Filter Shield Connection

    FRIGOBLOCK R units 5.4 Inverter filter shield connection In addition to the shield connection in the refrigeration unit control box, the inverter filter system contains an additional shield connection in the inverter filter. This shield is connected in the manufacturer’s factory.

  • Page 30: Trailer Shield Connection

    FRIGOBLOCK R units 5.5 Trailer shield connection In tractor-trailer units, a shield connection is already made in the tractor. Therefore, the shield of the trailer CAN bus is not connected to ground.

  • Page 31: Drawbar Shield Connection

    FRIGOBLOCK R units 5.6 Drawbar shield connection In a drawbar system, the shield connection must be available both in the tractor and in the trailer system. Therefore, the instructions for each of these units alone also apply here. CAN bus connection to ground...

  • Page 32: Electrical Design Of The Refrigeration Units (System Descriptions)

    FRIGOBLOCK R units 6 Electrical design of the refrigeration units (system descriptions) 6.1 Electrical design of the FK-R Harting B6 03-0342 Aluminum plate 11-0267 (glued in with Sikaflex) ES 27-0028 controller 2 x I/0 cards under the aluminum cover If necessary, a third I/O card can be installed on the...
  • Page 33 FRIGOBLOCK R units Direct-voltage source 400V/24V block B1211137 (01- 0239) Strict separation of power and signal lines (CAN bus)
  • Page 34 FRIGOBLOCK R units Discharged air temperature sensor (27-0006) Intake air temperature sensor (27-0006) Motor cable 4G4 + 2x1mm² (19-0128) Wadi PG16 cable gland NTC sensor, defrost (27-0005) NTC sensor, evaporator output (27-0005)
  • Page 35 FRIGOBLOCK R units 3-phase current feed 400V mains trans- L1 to L3 former feed CAN bus module 1 =+24V 2 = - GND 3 =CAN L Au (Au=gold) 4 =Shiled Au (Au=gold) 5 = CAN H Au (Au=gold) 6 = Steady plus 24V...

  • Page 36: Electrical Design Of The Hk-R

    FRIGOBLOCK R units 6.2 Electrical design of the HK-R Harting B6 (03-0342) Aluminum panel glued in with Sikaflex (11-0267) Controller ES (27-0028) 2 x I/0 cards under the aluminum cover If necessary, a third I/O card can be installed on the...
  • Page 37 FRIGOBLOCK R units Direct voltage source 400V/24V block B1211137 (01- 0239) Control cabinet HK25SL_R Strict separation of power and signal cables (CAN bus)
  • Page 38 FRIGOBLOCK R units Terminal box with I/0 card Defrost detection temperature sensor (27-0005) Gland Wadi Pg16 (04-0174) Motor cable 4G4 + 2x1mm² (19-0128) Outside temperature sensor (27-0006)
  • Page 39 FRIGOBLOCK R units Intake air temperature sensor (27-0006) 3-phase power supply 400V mains trans- L1 to L3 former feed CAN bus module 1 =+24V 2 = - GND 3 =CAN L Au (Au=gold) 4 =Shield Au (Au=gold) 5 = CAN H Au (Au=gold)

  • Page 40: Electrical Design Of The Ek-R

    FRIGOBLOCK R units 6.3 Electrical design of the EK-R With the exception of 2 different cables, the EK25 / EK25SL (controller ES) is identical with the serial unit. Control cable 7x0.75mm² (19-0126) Control cable 4G4 + 2x1mm² (19-0128) 6.4 Electrical design of the DK-R...
  • Page 41 FRIGOBLOCK R units Separation of power and signal cables (CAN bus) Gland Wadi PG16 (04-0174) Motor cable 4G4 + 2x1mm² (19-0128)
  • Page 42 FRIGOBLOCK R units Condensation temperature sensor (27-0005) Outside temperature sensor (27-0006) MOA switch...

  • Page 43: Electrical Design Of The M0A

    FRIGOBLOCK R units 6.5 Electrical design of the M0A 6.5.1 Electrical design of the M0A FK-R/HK-R 2K HG (22b) RE control (95-ES-1701) MOA (95-ES-1601)
  • Page 44 FRIGOBLOCK R units Mains input 400V/32A CAN bus Alternator input Refrigeration unit Door contact...

  • Page 45: Electrical Design Of The Moa Ek-R E-Heating (17/19)

    FRIGOBLOCK R units 6.5.2 Electrical design of the MOA EK-R E-heating (17/19) Driver’s cab CAN cable RE control EK control EK power cable Door contact RE CAN cable Mains connection RE load cable Alternator input...
  • Page 46 FRIGOBLOCK R units Compressor contactor Evaporator control (fan) Opto-coupler K22 Evaporator control (rod heaters) MOA (95-ES-1601) (only trailer M0A) M0A remote control unit I/0 card ControllerES...

  • Page 47: Electrical Design Of The Moa Ek-R Hg (28)

    FRIGOBLOCK R units 6.5.3 Electrical design of the MOA EK-R HG (28) RE control cables EK power cable DS power cable RE CAN cables Mains connection EK control Alternator input Driver’s cab CAN cable...
  • Page 48 FRIGOBLOCK R units Compressor contactor DS I/0 card Evaporator control (fan) MOA (95-ES-1601_SA01) MOA remote control unit EK I/0 cards ControllerES...

  • Page 49: Electrical Design Of The Moa Ek-R E-Heating/Hg (28)

    FRIGOBLOCK R units 6.5.4 Electrical design of the MOA EK-R E-heating/HG (28)

  • Page 50: Electrical Design Of The Re-R

    FRIGOBLOCK R units 6.6 Electrical design of the RE-R 6.6.1 Electrical design of the RE22-2-R (E heat) Discharge air temperature sensor (27-0006) Defrost temperature sensor (27-0005) fixed by metal clip (Bürklin No.12H4020 / FB 04-0382), including heat transfer compound...
  • Page 51 FRIGOBLOCK R units Intake air temperature sensor (27-0006) I/0 card (27-0002) Fan output Feeding line 7x0.75mm²...
  • Page 52 FRIGOBLOCK R units Fan connection installation Electric heater terminal box Safety klixon Safety klixon...

  • Page 53: Electrical Design Of The Re42-1-R Hg

    FRIGOBLOCK R units 6.6.2 Electrical design of the RE42-1-R HG Discharge air temperature sensor (27-0006) Temperature sensor Defrost temperature sensor Collector pipe (27-0005) (27-0005) fixed by metal clip (Bürklin No.12H4020 / FB 04-0382), including heat transfer compound...
  • Page 54 FRIGOBLOCK R units Intake air temperature sensor (27-0006) I/0 card (27-0002) Fan output Feeder line 12x0.75mm²...
  • Page 55 FRIGOBLOCK R units Fan connection installation Collector pipe temperature sensor (27-0005) Bath heater...

  • Page 56: Unit Schematic(S)

    FRIGOBLOCK R units 7 Unit schematic(s) Many different combinations are possible in connection with R units. Some of these are illustrated by way of example below. Possible combinations Alternator Tractor refrigeration unit Trailer refrigeration unit R unit G alternator R unit...

  • Page 57: Fk/Hk Single Compartment / G Alternator Schematic

    FRIGOBLOCK R units 7.1 FK/HK single compartment / G alternator schematic 7.2 FK/HK single compartment / AW alternator schematic...

  • Page 58: Ek / Single Compartment / G Alternator Schematic

    FRIGOBLOCK R units 7.3 EK / single compartment / G alternator schematic 7.4 EK single compartment / AW alternator schematic...

  • Page 59: Fk/Hk Multiple Compartment / G Alternator Schematic

    FRIGOBLOCK R units 7.5 FK/HK multiple compartment / G alternator schematic 7.6 FK/HK multiple compartment / AW alternator schematic...

  • Page 60: Trailer Ek Multiple Compartment / G Alternator Schematic

    FRIGOBLOCK R units 7.7 Trailer EK multiple compartment / G alternator schematic 7.8 EK multiple compartment / AW alternator schematic...

  • Page 61: Trailer Ek Single Compartment Schematic

    FRIGOBLOCK R units 7.9 Trailer EK single compartment schematic 7.10 Trailer EK multiple compartment schematic...

  • Page 62: Trailer Ek Multiple Compartment And Ds24Ng Schematic

    FRIGOBLOCK R units 7.11 Trailer EK multiple compartment and DS24NG schematic...

  • Page 63: Tractor-Trailer / G Alternator Schematic

    FRIGOBLOCK R units 7.12 Tractor-trailer / G alternator schematic 7.13 Tractor-trailer / AW alternator schematic...

  • Page 64: Wiring Diagrams

    FRIGOBLOCK R units 8 Wiring diagrams Unlike units with conventional contactor technology, controller governed units with CAN bus technology in most cases comply with the customer’s needs without changes to the cabling of the unit. This reduces the number of wiring diagrams for FRIGOBLOCK refrigeration units with controller.

  • Page 65: Software

    FRIGOBLOCK R units 9 Software The controllerES and the universal remote control installed in FRIGOBLOCK R unit systems require software. The software that suits the type of unit must be installed in the controller. FK25i/FK35i (unified software for full inverter units)
  • Page 66 FRIGOBLOCK R units The most recent software can also be downloaded from the protected area of the FRIGOBLOCK homepage (http://www.frigoblock.com/login/login.html). Path: Technical information > Software > Unit software The “Unit software“ folder can be downloaded from there. The folder contains the latest software for all types of controller in FRIGOBLOCK refrigeration units.

  • Page 67: Checklist In Case Of Problems During A Software Update

    FRIGOBLOCK R units 9.1 Checklist in case of problems during a software update □ USB extension cable Do not use a USB extension cable for connecting the IXXAT adapter to the computer □ Computer operating system The computer operating system should be of the latest version □...

  • Page 68: Parameter Setting

    FRIGOBLOCK R units 10 Parameter setting In addition to software, a controllerES also needs parameters. The parameters the controller needs are defined by the constellation of the unit such as, e.g., the type of unit (FK/HK/EK), the unit size (13, 24, 25, etc.), the refrigeration circuit, the defrost interval, etc.
  • Page 69 FRIGOBLOCK R units Category Parameter Relevant Standard Description Comments to … settings IF = Inverter filter KM = refrigerati on unit Setting is made in „Refrigeration Compartm Third compartment Specified whether a third evaporator space configuration“ available? is installed. Configurat...
  • Page 70 FRIGOBLOCK R units Category Parameter Relevant Standard Description Comments to … settings IF = Inverter filter KM = refrigerati on unit Defrosting Auto defrost Specifies whether the defrost timer should be enabled as standard Auto Defrost Specifies the total time to automatic...
  • Page 71 FRIGOBLOCK R units Category Parameter Relevant Standard Description Comments to … settings IF = Inverter filter KM = refrigerati on unit Specifies whether by “OK“ on the Set “Yes“ if you know that always a Miscellane Activate Universal- Remote Filter universal remote control can be conventional unit is used, e.g., when...
  • Page 72 FRIGOBLOCK R units See the unit’s nameplate Type of Specifies the type of the refrigeration Refrigeration unit unit (FK, HK, EK) Warm up during Specifies whether compressor Generator warm-up shall occur at low speed in operation ? alternator mode. Whisper Mode...
  • Page 73 FRIGOBLOCK R units Category Parameter Relevant Standard Description Comments to … settings IF = Inverter filter KM = refrigerati on unit Temperat Deactivate goods With enabled chill service protection, If the temperature difference protection ? the temperature of the air...

  • Page 74: Commissioning

    FRIGOBLOCK R units 11 Commissioning The following chapter describes the Commissioning procedure of R units. Drawbar units should remain separated from each other until both systems are fully addressed and all parameters have been set (items 3 and 4 in the procedure below).

  • Page 75: Can Bus Check

    FRIGOBLOCK R units 11.1 CAN bus check Before voltage is fed to the system, the CAN bus system must be checked for short circuits. Proceed as follows: 1) Turn off the ignition and take out the FRIGOBLOCK fuses 2) Set the MOA switch (tractor and trailer) to alternator 3) Using a multimeter instrument, make the following resistance measurements.

  • Page 76: Termination Check

    FRIGOBLOCK R units 11.2 Termination check As described in chapter 4, only two terminating resistances (each 120 Ω), three in an inverter filter system, each 120 Ω, must be active. The terminating resistances should be as far apart as possible. This ensures that a resistance is always enabled in the driver’s cab remote control (in a tractor-trailer unit version only in the tractor’s remote control) and at the I/0 card...

  • Page 77: Shield Check

    FRIGOBLOCK R units 11.3 Shield check As already described in chapter 5, the shield of the CAN bus must be connected to ground only at one point, in invert filter systems at two points. The connection must be made in the unit’s control box.

  • Page 78: Addressing The Components

    FRIGOBLOCK R units 11.4 Addressing the components As already described in chapter 3, all components in the CAN bus system must be assigned a unique address with CAN address range and ID number to ensure communication within the system. If several components share the same address, the controller cannot tell them apart and all will be addressed at the same time.

  • Page 79: Can Overview

    FRIGOBLOCK R units 11.4.1 CAN overview The FrigoCENTER tool „Component overview“ provides a system overview and facilitates the addressing of the components. All components active in the CAN bus and their assigned address ranges, ID addresses and software versions are displayed here.
  • Page 80 FRIGOBLOCK R units Following are a few examples Solo tractor G alternator Solo tractor inverter filter Trailer EK (solo)
  • Page 81 FRIGOBLOCK R units Drawbar unit G alternator Drawbar unit AW alternator...
  • Page 82 FRIGOBLOCK R units As not all components are assigned addresses in the factory, the suitable ID addresses must be assigned during installation. The components overview often presents the following picture Example: Rigid FK/HK (Single temp) Example: Rigid FK/HK (Multi temp) Present…...
  • Page 83 FRIGOBLOCK R units Example: Rigid EK unit Example: Trailer EK unit Present… Present… Remote drivers cab Still missing or requiring addresses are the following… Still missing or requiring addresses are the following… universal remote control MOA box universal remote control MOA box...

  • Page 84: Fk/Hk Single Compartment Addressing Procedure

    FRIGOBLOCK R units 11.4.2 FK/HK single compartment addressing procedure Start with setting the remote control in the MOA. When the remote control is activated for the first time, the following basic settings must be made, depending on the installation site.
  • Page 85 FRIGOBLOCK R units The ControllerES and the I/0 cards of FK/HK single compartment units should have been addressed in the factory. Check that in the component overview. If the address range of the controller needs adjustment, proceed as follows. 1) Select the current address range of the controller in FrigoCENTER 2) In the “Controller/Remote “...

  • Page 86: Fk/Hk Multiple Compartment Addressing Procedure

    FRIGOBLOCK R units 11.4.3 FK/HK multiple compartment addressing procedure Start with setting the remote control in the MOA. When the remote control is activated for the first time, the following basic settings must be made, depending on the installation site.
  • Page 87 FRIGOBLOCK R units The ControllerES and the I/0 cards ID0, ID7 and ID8 (when available) of FK/HK units should have been addressed in the factory. Check that in the component overview. If the address range of the controller needs adjustment, proceed as follows.

  • Page 88: Ek Single Compartment Procedure

    FRIGOBLOCK R units 11.4.4 EK single compartment procedure Start by setting the remote control in the MAO. When the remote control is activated for the first time, the basic settings for the particular location must be made. Procedure  At first select the address range.
  • Page 89 FRIGOBLOCK R units The ControllerES and the I/0 cards are not addressed in the factory. The controller can be found in Advanced „E“ address range in the default settings. To adapt the address range of the controller, proceed as follows.

  • Page 90: Ek Multiple Compartment Procedure

    FRIGOBLOCK R units 11.4.5 EK multiple compartment procedure Start by setting the remote control in the MOA. When the remote control is activated for the first time, the basic settings for the particular location must be made Procedure  At first select the address range.
  • Page 91 FRIGOBLOCK R units The ControllerES and the I/0 cards are not addressed in the factory. The controller can be found in Advanced „E“ address range in the default settings. To adapt the address range of the controller, proceed as follows:...

  • Page 92: Setting The Controlleres Parameters

    FRIGOBLOCK R units 11.5 Setting the ControllerES parameters After addressing all components, the configuration of the unit must be defined by setting the ControllerES parameters. The ControllerES of FK and HK refrigeration units are predefined in the factory but need adaptation at the customer’s place.

  • Page 93: Refrigeration Circuit Diagram

    FRIGOBLOCK R units 11.5.1 Refrigeration circuit diagram The information about the refrigeration circuit diagram can be found in the unit’s control box or on the packaging of the main components. FK/KH control box EK control box Packaging...

  • Page 94: Unit Identification

    FRIGOBLOCK R units 11.5.2 Unit identification At the time of installation of the unit, the unit identification must be saved in the controller via the controller’s parameter setting surface. The following nomenclature applies. “R“ (controller unit) Unit type Unit size...

  • Page 95: Software Update Of All Components

    FRIGOBLOCK R units 11.6 Software update of all components When all components in the system have been addressed and the controller parameters set, the software versions of the universal remote control and the controllers in the system must be checked. The software versions of the components can be verified in the component overview.

  • Page 96: Installation Reports

    FRIGOBLOCK R units 11.6.1 Installation reports...
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  • Page 101: Maintenance

    FRIGOBLOCK R units 12 Maintenance In addition to the maintenance of conventional units, the following items need attention: Reset service interval Component software update 12.1 Reset service interval When maintenance is complete, the service interval in the ControllerES must be reset. This must be done separately for every controller in the system (tractor refrigeration unit, trailer refrigeration unit, inverter filter).

  • Page 102: Software Updates

    FRIGOBLOCK R units 12.2 Software updates As part of the maintenance check to see whether the software versions of all components (ControllerES, universal remote controls, inverter board) are most recent. If they are not, make a software update of the components.

  • Page 103: Service

    FRIGOBLOCK R units 13 Service If you have a technical problem with an R unit this chapter should be a helpful troubleshooting guide. Refer to the checklist below. □ Open the component overview □ Read out the diagnostic memory □...

  • Page 104: Fault Codes

    FRIGOBLOCK R units 13.3 Fault codes In R units, faults are displayed as running text in the universal remote control. Fault relating to the inverter (in inverter filter systems) are shown as binary code in the remote control. For interpretation of binary faults, please refer to the inverter filter training manual (chapter 6).

  • Page 105: Check The Wiring Diagrams

    FRIGOBLOCK R units 13.7 Check the wiring diagrams Check back with the wiring diagrams. Also check to be sure that the three vehicle signals are detected or have been mixed up. Steady plus Ignition 13.8 Power cycle In case of problems with the refrigeration unit, after a software update or after changing parameters in the controller...

  • Page 106: Unit Tool List

    FRIGOBLOCK R units 14 R unit tool list Preconditions Computer a) Windows 10 (32/64) / Windows 8 (32/64) / Windows 7 (32/64) b) Internet link TeamViewer Software a) Maximum Version 10 b) Download:  TeamViewer Homepage: https://www.teamviewer.com/de/download/previous- versions/ FrigoCENTER Software a) Download ...

  • Page 107: Work Instructions

    FRIGOBLOCK R units 15 Work instructions The following work instructions are available in the protected area of the FRIGOBLOCK homepage ControllerES firmware update Universal remote control firmware update Inverter board firmware update CAN bus connector wiring Rear remote control...
  • Page 108 08.01.2018 FRIGOBLOCK R-UNITS SERVICE-TRAINING 08.01.2018 FRIGOBLOCK R-units grüne Lösung ist blau 08.01.2018 - 2 - Why we do this? Customer advantages • Temperatures visible on a HMI display in the drivers cab, the MOA box (and in the body) •...
  • Page 109 08.01.2018 CAN Bus Standard grüne Lösung ist blau 08.01.2018 - 4 - Components are linked via CAN-Bus • Communication between controller, remote, I/0-cards (and inverter, DC/DC converter) goes via one CAN-Bus cable • A shielded cable connects all these consumers •...
  • Page 110 08.01.2018 CAN-Bus components Purpose and function of the CAN-Bus components – I/0 Cards ( I = Input / O = Output) Details of the I/0 card Ports: • 4 x input signal IN 1-4 • 4 x output signal OUT 1-4 (switched ground) •...
  • Page 111 08.01.2018 CAN-Bus components Purpose and function of the CAN-Bus components – HMI Mounting places: Drivers cab MOA box Remote inside compartment grüne Lösung ist blau 08.01.2018 - 10 - CAN-Bus components Purpose and function of the CAN-Bus components – HMI Display layouts Standard Overview...
  • Page 112 08.01.2018 CAN-Bus components Purpose and function of the CAN-Bus components – CAN gateway To connect two CAN bus systems on drawbar systems is a CAN gateway needed The CAN gate way separates the two CAN bus systems galvanic The data's where transferred optical via fiber glass grüne Lösung ist blau 08.01.2018...
  • Page 113 08.01.2018 CAN Bus Termination CAN High (brown) CAN low (white) grüne Lösung ist blau 08.01.2018 - 16 - CAN Bus Schematic EK unit with G-alternator grüne Lösung ist blau 08.01.2018 - 17 - CAN Bus Schematic FK + RE unit with G-alternator grüne Lösung ist blau 08.01.2018...
  • Page 114 08.01.2018 CAN Bus Schematic FK + RE unit + HMI rear with G-alternator grüne Lösung ist blau 08.01.2018 - 19 - CAN Bus Schematic EK + RE unit with AW-alternator grüne Lösung ist blau 08.01.2018 - 20 - CAN Bus Schematic FK unit + RE with AW-alternator grüne Lösung ist blau 08.01.2018...
  • Page 115 08.01.2018 CAN Bus Schematic FK + RE unit + HMI with AW-alternator grüne Lösung ist blau 08.01.2018 - 22 - CAN Bus Schematic trailer EK unit + RE grüne Lösung ist blau 08.01.2018 - 23 - CAN Bus shield shield separated and twisted shield shrink tube...
  • Page 116 08.01.2018 CAN Bus shield grounding FK unit Ground connection grüne Lösung ist blau 08.01.2018 - 25 - CAN Bus shield grounding HK unit Ground connection grüne Lösung ist blau 08.01.2018 - 26 - CAN Bus shield grounding EK unit Ground connection grüne Lösung ist blau 08.01.2018...
  • Page 117 08.01.2018 CAN Bus shield grounding Inverter Filter Ground connection grüne Lösung ist blau 08.01.2018 - 28 - CAN Bus shield grounding trailer unit NO Ground connection!!! grüne Lösung ist blau 08.01.2018 - 29 - CAN Bus shield grounding Ground connection drawbar system grüne Lösung ist blau...
  • Page 118 08.01.2018 R-units electrical components FK unit Plug brand Harting Al plate, no switches Controller 27-0028 2 I/O cards behind Al housing 1 additional on top possible grüne Lösung ist blau 08.01.2018 - 31 - R-units electrical components FK unit 2 x I / O card Al housing DC power supply grüne Lösung...
  • Page 119 08.01.2018 R-units electrical components FK unit Temperature feeler air out Temperature feeler return air Cable 4G4 + 2x1mm² Cable gland temperature feeler defrost temperature suction gas grüne Lösung ist blau 08.01.2018 - 34 - 400V control R-units electrical components voltage mains FK unit 3 phase power supply Power supply...
  • Page 120 08.01.2018 R-units electrical components RE see handout grüne Lösung ist blau 08.01.2018 - 37 - R-units electrical components MOA box see handout transformer fuse rectifier capacitor part no. 01-0236 part no. 01-249 part no. 01-0233 part no. 01-0235 100 VA 4700µF transformer 400V...
  • Page 121 08.01.2018 CAN Bus Schematic FK unit with AW-alternator grüne Lösung ist blau 08.01.2018 - 40 - CAN Bus Schematic EK unit with G-alternator grüne Lösung ist blau 08.01.2018 - 41 - CAN Bus Schematic EK unit with AW-alternator grüne Lösung ist blau 08.01.2018 - 42 -...
  • Page 122 08.01.2018 CAN Bus Schematic FK unit MT with G-alternator grüne Lösung ist blau 08.01.2018 - 43 - CAN Bus Schematic FK unit MT with AW-alternator grüne Lösung ist blau 08.01.2018 - 44 - CAN Bus Schematic EK unit MT with G-alternator grüne Lösung ist blau 08.01.2018...
  • Page 123 08.01.2018 CAN Bus Schematic EK unit MT with AW-alternator grüne Lösung ist blau 08.01.2018 - 46 - CAN Bus Schematic Trailer EK unit grüne Lösung ist blau 08.01.2018 - 47 - CAN Bus Schematic Trailer EK unit MT grüne Lösung ist blau 08.01.2018 - 48 -...
  • Page 124 08.01.2018 CAN Bus Schematic Trailer EK unit MT and DS grüne Lösung ist blau 08.01.2018 - 49 - CAN Bus Schematic drawbar with G-alternator grüne Lösung ist blau 08.01.2018 - 50 - CAN Bus Schematic drawbar with AW-alternator grüne Lösung ist blau 08.01.2018 - 51 -...
  • Page 125 08.01.2018 Wiring diagrams R-units grüne Lösung ist blau 08.01.2018 - 52 - Wiring diagrams R-units FK/HK (Group 12) • 9X-ES-1201_  FK-HK xx_R (SL) with Universal remote and ControllerES; flowchart 22, 24 • 9X-ES-1202_  FK-HK xx_R (SL) with Universal remote and ControllerES; flowchart 17, 19, 31 •...
  • Page 126 08.01.2018 software R-units 08.01.2018 - 55 - Commissioning of R-units - Software + Parameterization Standard-ID o Inverter firmware o Inverter parameterization o ControllerES FB-Filter/FKi Software o ControllerES FB-Filter/FKi parameterization o I/0-card address(es) Advanced1 (refrigeration unit rigid) o ControllerES refrigeration unit software o ControllerES refrigeration unit parameterization o Universal remote drivers cab Software o Universal remote MOA box Software...
  • Page 127 08.01.2018 Commissioning of R-units (8) Remote in MOA box: • Select CAN address range (Advanced 1 or Advanced 2) • Define position (NOG Box) (9) Check CAN overview (FrigoCENTER > Tools > CAN Overview) • All I/O-cards shown with address? •...
  • Page 128 08.01.2018 Required tools grüne Lösung ist blau 08.01.2018 - 62 - Required tools grüne Lösung ist blau 08.01.2018 - 63 - Required tools To be organized by the Servicepartner grüne Lösung ist blau 08.01.2018 - 64 -...
  • Page 129 08.01.2018 FrigoCENTER - Diagnostic Software grüne Lösung ist blau 08.01.2018 - 65 - FrigoCENTER Templates Frigocenter Version 2.1xx Main FrigoCENTER.exe describtion *.fcd Software UF*.hex Controller RES*.hex Parameterization Controller 27-0028 *.prm Inverter *. fcp FrigoPlotter Chanal liste *.sig Save record *.plot Neue Versionen liegen im FRIGOBLOCK Portal (in Planung) http://www.frigoblock.com/login/login.html...
  • Page 130 08.01.2018 Software des ReglerES aktualisieren • Tool „Firmware Update laden“ starten und richtigen CAN-Kreis wählen. • Hex Datei laden. Die Regeleinheit wird automatisch ausgewählt. • Bootlader starten: Am entsprechendem ReglerES leuchtet die blaue LED nicht • Ausführung starten: Programm wird geladen •...
  • Page 131 08.01.2018 ReglerES parametrieren / Serviceintervall Service-Intervall einstellen Service-Intervall zurücksetzen damit die „alten“ Werte überschrieben werden. grüne Lösung ist blau 08.01.2018 - 71 -...
  • Page 132 Quick reference guide for electrically powered FRIGOBLOCK refrigeration devices Control by universal remote control unit...
  • Page 133 At a glance Positions of the main components FRIGOBLOCK refrigeration device type FK / HK / EK Flat evaporator type RE Alternator Mains – 0 – alternator control box (with universal remote control unit) Universal remote control unit in the driver’s cab Inverter filter (for operation via AW alternator) View of single compartment vehicle (example: FKi) C1 &...
  • Page 134 Controls Mains – 0 – alternator control box Motor protection switch (optional) Universal remote control unit Mains-0-alternator selector switch The 400-volt CEE socket outlet (not shown) is installed at the truck superstructure. Universal remote control unit The universal remote control unit is a control point of the refrigeration device and can be used with single and multi-compartment refrigeration devices.
  • Page 135 Functional description Some switches have multiple functions. Press briefly: Switches the refrigeration device on/off LED flashes in alternator mode at the moment of switching on LED gives constant light when the refrigeration device is switched on Press briefly: change the displayed compartment Press and hold: displayed compartment On / Off Press briefly: temperature setting Press and hold: change the basic setpoint...
  • Page 136 Displays Air return flow to the displayed compartment Selected compartment and other refrigeration devices Selected basic setpoint temperature displayed compartment  CH1 = chill temperature 1  CH2 = chill temperature 2  DF1 = deepfreeze temperature 1  DF2 = deepfreeze temperature 2 ...

  • Page 137: System Operation

    System operation Alternator mode (while driving) The purpose of the FRIGOBLOCK refrigeration device is to refrigerate or heat a vehicle superstructure. Energy is supplied electrically Pull the mains plug before you from the drive off Switch: at “Alternator“ position  mains / (external supply 32 A), ...

  • Page 138: Operation

    The setpoint temperature for the selected Operation compartment can be changed by pressing the The different compartments can be switched on, the temperatures and speeds set at the button. A setpoint temperature is universal remote control unit; besides faults can suggested in the display.
  • Page 139 Switching on the compartments Depending on the type of refrigeration device Press to set a lower temperature; press and the number of compartments in the superstructure, the different compartments can be switched on and off. Select the required to set a higher temperature. The changed temperature is displayed in the highlighted part of the display.

  • Page 140: Heating Mode

    Defrosting mode If defrosting is required, confirm the prompt “Start defrosting? Are you sure?“ by pressing When a compartment is in defrosting mode, the LED lights to indicate that mode. button. The display of the compartment in defrosting mode shows the present temperature of the evaporator pack.

  • Page 141: Changing The Speed

    Changing the speed Faults When an inverter filter is used, the refrigeration Refrigeration device in alternator mode without output can be adapted to the unit. Press the function:  Inspect fuses F1 + F2 and F31, F32, F33 resp.. button several times until the required Place: Truck fuse panel.

  • Page 142: General Points

    General points 1. For smooth operation of the FRIGOBLOCK refrigeration device and maintaining the refrigeration output as well as for saving energy, clean the condenser at intervals of four weeks; the refrigeration device must be switched off for that activity. The cleaner should contain a corrosion inhibitor, be insensitive to metallic materials and not exceed a temperature of 60°C.
  • Page 143 Software Übersicht / Software Overview 10 Tasten Display / 10 Key Display Date: 14.06.2017 / OS Maschinen Typ / Regler & Fernbedienung (27-0001) / verfügbare Sprachen / Unit type Controller & Remote Control (27-0001) available languages R24012017FKi-EST-b2111 German FK25i / FK35i EST FK 35 SL EST R12092016FK-SL-EST-b2070 German...
  • Page 144 Firmware Update – ES Controller Preparations  Plug the laptop computer into the diagnostic port of the truck via the IXXAT USB to CAN adapter  Start the FrigoCENTER software of your laptop  Start the ignition of the truck ...
  • Page 145 Firmware Update – ES Controller Firmware update Address range: Standard ID 1) On the remote control unit, go to “FBF firmware update“ in “Settings” and press to confirm. Procedure:  In the start screen, press and hold the button until the menu opens ...
  • Page 146 Firmware Update – ES Controller 4) Press the “Load HEX file …“ button. 5) Select the xxx.hex file you need. current installed firmware version displayed. 6) Then press “Enable boot loader“ and “Start execution“ in this sequence. The firmware update is now made. After that, the current installed firmware version is displayed again.
  • Page 147 Firmware Update – ES Controller Address range: Advanced “1“ 1) Select the “Advanced 1” address range in the FrigoCENTER. 2) Go to “Carry out firmware update“ in the “Controller/remote control“ pull-down menu. A second window opens: "Firmware update“. 3) Press the “Load HEX file …“ button. 4) Select the xxx.hex file you need.
  • Page 148 Firmware Update – ES Controller Address range: Advanced “2“ 1) Select the “Advanced 2” address range in the FrigoCENTER. 2) Go to “Carry out firmware update“ in the “Controller/remote control“ pull-down menu. A second window opens: "Firmware update“. 3) Press the “Load HEX file …“ button. 4) Select the xxx.hex file you need.
  • Page 149 Firmware Update – Universal Remote Control Unit Preparations  Plug the laptop computer into the diagnostic port of the truck via the IXXAT USB to CAN adapter  Start the FrigoCENTER software of your laptop  Start the ignition of the truck ...
  • Page 150 Firmware Update – Universal Remote Control Unit Address range: Advanced “1“ 1) Select the “Advanced 1” address range in the FrigoCENTER. 2) Go to “Carry out firmware update“ in the “Controller/remote control“ pull-down menu. A second window opens: "Firmware update“. 3) Press the “Load HEX file …“...
  • Page 151 Firmware Update – Universal Remote Control Unit 8) Then select the “N0G box RC unit“. 9) Then press “Enable boot loader“ and “Start execution“ in this sequence. The firmware update is now made. After that, the current installed firmware versions are displayed again.
  • Page 152 Firmware Update – Universal Remote Control Unit Address range: Advanced “2“ 1) Select the “Advanced 2” address range in the FrigoCENTER. 2) Go to “Carry out firmware update“ in the “Controller/remote control“ pull-down menu. A second window opens: "Firmware update“. 3) Press the “Load HEX file …“...
  • Page 153 Firmware Update – Universal Remote Control Unit 8) Then select the “N0G box RC unit“. 9) Then press “Enable boot loader“ and “Start execution“ in this sequence. The firmware update is now made. After that, the current installed firmware versions are displayed again.
  • Page 154 Serviceinformation 2017 / 07 Version: 1 Date: 20.07.2017 Category: Electrics Author: D. Zabel Subject: Modified CAN bus plug system Situation: The CAN bus plugs in use so far are standard plugs without special coding. As a result of that, wrong connections, for example, to the camera system are possible.
  • Page 155 CAN bus socket 03-0351 (front view) Pin configuration +24 Volt - ignition/switched (red ) PIN 1.5mm² Ground (blue) PIN 1.5mm² CAN Low (white) PIN 1.0mm² Screen PIN 1.0mm² CAN High (brown) PIN 1.0mm² – Volt contin. voltage (red/black) PIN 1.0mm² Pin not assigned –...
  • Page 156 CAN bus plug 03-0352 (rear view) Configuration +24 Volt - ignition/switched (red) PIN 1.5mm² Ground (blue) PIN 1.5mm² CAN Low (white) PIN 1.0mm² Screen PIN 1.0mm² CAN High (brown) PIN 1.0mm² – Volt contin. voltage (red/black) PIN 1.0mm² Pin not assigned – insert PIN 1,0mm²...

  • Page 157: Installation

    installation The diameter of the CAN bus cable is smaller than the screw connection at the CAN bus plug/socket. To provide reliable sealing and protect the cable from damage due to vibration the following procedure should be followed: Additional material: 1.
  • Page 158 Serviceinformation 2017 / 11 Version: 1 Date: 20.07.2017 Category: Electrics Author: D. Zabel Subject: Use of Harting socket housing with inverter filter units Situation: The EMC characteristics of the new Harting socket housing are distinctly better and the resistance to corrosion is higher.

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Frigoblock fk-rFrigoblock hk-rFrigoblock ek-rFrigoblock dk-rFrigoblock m0a fk-rFrigoblock m0a hk-r ... Show all
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