Thermo King B Series Operator's Manual
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Thermo King B Series Operator's Manual

Thermo King B Series Operator's Manual

Units with direct smart reefer
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Operator's Manual
B-Series Units with
Direct Smart Reefer
B-100, B-100 ECO and B-100 MAX (North America)
(Rev. A)
T T K K 5 5 6 6 8 8 6 6 9 9 - - 1 1 8 8 - - O O P P - - E E N N
July 2020

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  • Page 1 Operator’s Manual B-Series Units with Direct Smart Reefer B-100, B-100 ECO and B-100 MAX (North America) (Rev. A) T T K K 5 5 6 6 8 8 6 6 9 9 - - 1 1 8 8 - - O O P P - - E E N N July 2020...
  • Page 2 If more information is required, consult your Thermo King Service Directory for the location and telephone number of the local dealer. T T h h e e r r m m o o K K i i n n g g ’ ’ s s w w a a r r r r a a n n t t y y s s h h a a l l l l n n o o t t a a p p p p l l y y t t o o a a n n y y e e q q u u i i p p m m e e n n t t w w h h i i c c h h h h a a s s b b e e e e n n “...
  • Page 3 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. Copies of the approved Thermo King documentation can be found on the Thermo King iService Portal: http://iservice.thermoking.com/esa TK 56869-18-OP-EN...

  • Page 4: Software License

    You are obliged to complete the declaration for “THERMO KING EQUIPMENT SOFTWARE LICENSE AGREEMENT” before you put your unit in operation.
  • Page 5 I I n n t t r r o o d d u u c c t t i i o o n n Scan the Quick Response (QR) code or click Technical Publications EMEA Feedback TK 56869-18-OP-EN...

  • Page 6: Table Of Contents

    Table of Contents S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s ..................9 9 Danger, Warning, Caution, and Notice .
  • Page 7 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s ................4 4 1 1 Introduction .
  • Page 8 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s M M a a i i n n t t e e n n a a n n c c e e I I n n s s p p e e c c t t i i o o n n S S c c h h e e d d u u l l e e ..........7 7 0 0 W W a a r r r r a a n n t t y y .

  • Page 9: Safety Precautions

    Safety Precautions Danger, Warning, Caution, and Notice Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices. Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions.
  • Page 10 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s D D A A N N G G E E R R H H a a z z a a r r d d o o u u s s G G a a s s e e s s - - P P e e r r s s o o n n a a l l P P r r o o t t e e c c t t i i v v e e E E q q u u i i p p m m e e n n t t ( ( P P P P E E ) ) R R e e q q u u i i r r e e d d ! ! Refrigerant in the presence of an open flame, spark, or electrical short...
  • Page 11 E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e a a n n d d R R i i s s k k o o f f I I n n j j u u r r y y ! ! Never drill holes into the unit unless instructed by Thermo King. Holes drilled into high voltage cables could cause an electrical fire, severe personal injury, or even death.

  • Page 12: Auto Start/Stopauto Start Hazards

    S S h h a a r r p p E E d d g g e e s s ! ! Exposed coil fins can cause lacerations. Service work on the evaporator or condenser coils should only be accomplished by a certified Thermo King technician.
  • Page 13 R R i i s s k k o o f f I I n n j j u u r r y y ! ! Thermo King units can start and run automatically any time the unit’s HMI controller is on. Before removing covers, or working on any part of the unit, always turn off the HMI Main Power On/Off switch.

  • Page 14: Battery Installation And Cable Routing

    H H a a z z a a r r d d o o f f E E x x p p l l o o s s i i o o n n ! ! An improperly installed battery could result in a fire, explosion, or injury. A Thermo King approved battery must be installed and properly secured to the battery tray.
  • Page 15 Always wear goggles or safety glasses and personal protective equipment when working with a battery. Do not replace the battery with any type other than the one approved by Thermo King for this unit. TK 56869-18-OP-EN...

  • Page 16: Electrical Hazards

    E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! Do not connect other manufacturer’s equipment or accessories to the unit or to the TK Batteries unless approved by Thermo King. Failure to do so can result in severe damage to equipment and void the warranty.

  • Page 17: High Voltage

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s High Voltage D D A A N N G G E E R R H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e ! ! When servicing or repairing a temperature control unit, the possibility of serious or even fatal injury from electrical shock exists.
  • Page 18 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e ! ! Treat all wires and connections as if they were high voltage until a meter and wiring diagram indicate otherwise.

  • Page 19: Low Voltage

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e w w / / C C a a p p a a c c i i t t o o r r s s ! ! Be careful when working with electrical circuits that contain capacitors.

  • Page 20: Refrigerant Hazards

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Refrigerant Hazards Although fluorocarbon refrigerants (R-404A/R-452A and R-134a) are classified as safe, observe caution when working with refrigerants or around areas where they are being used in the servicing of your unit.
  • Page 21 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s D D A A N N G G E E R R H H a a z z a a r r d d o o u u s s P P r r e e s s s s u u r r e e s s ! ! Always store refrigerant in proper containers, out of direct sunlight and away from intense heat.

  • Page 22: Refrigerant Oil Hazards

    E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! Use the correct oil in Thermo King systems to avoid damaging equipment and nullifying its warranty.

  • Page 23: First Aid

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! Use dedicated refrigeration equipment to prevent contaminating refrigeration systems with the wrong type of oil or refrigerant.
  • Page 24 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s • I I n n h h a a l l a a t t i i o o n n : : Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary.

  • Page 25: Safety Decals

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s victim away from the current. DO NOT TOUCH the victim. You will receive a shock from current flowing through the victim’s body.
  • Page 26 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Figure 2. Automatic Start Caution Observe all safety decals placed in various locations on the unit. TK 56869-18-OP-EN...
  • Page 27 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Figure 3. Typical Safety Decals TK 56869-18-OP-EN...

  • Page 28: Only)

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Electric Standby Nameplates (Models 20 and 50 Only) Figure 4.
  • Page 29 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s F Gas decal indicates that this equipment Contains fluorinated greenhouse gases.

  • Page 30: Unit Description

    Unit Description Thermo King B-Series are electric powered two-piece units (condenser and evaporator) designed for fresh, frozen, and deep frozen applications for small trucks and vans. The system is powered by the vehicle’s battery during mobile operation. Optional SmartPower© units operate when the unit is connected to an AC power source during stationary operation.

  • Page 31: Options

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n • C C o o n n t t r r o o l l s s - User friendly Direct Smart Reefer (DSR) In-Cab controller. •...

  • Page 32: System Components

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n • Electric Standby Plug (115 Vac, 230 Vac 1phase NOT in V800/V1000, 230 Vac 3 phase, 400 Vac 3 phase) •...

  • Page 33: Compressor(S)

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 7. AC Motor RCS1591 Compressor(s) With E-Series units, mobile operation and electric standby modes operate with a compressor driven by an DC/AC inverter.

  • Page 34: Condenser

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 9. Swash Plate Compressor Condenser The condenser is located on the roof of the vehicle or on the front of the cargo box.

  • Page 35: Evaporator

    U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Evaporator The evaporator is mounted on the ceiling inside the cargo box. The cover can easily be removed for service.
  • Page 36 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 14. DSR In-Cab Controller TK 56869-18-OP-EN...

  • Page 37: Electrical System

    F F o o r r B B - - S S e e r r i i e e s s a a n n d d V V - - S S e e r r i i e e s s : : This in-line fuse is non-serviceable and must only be replaced by an authorized Thermo King Dealer.
  • Page 38 E E l l e e c c t t r r i i c c a a l l S S y y s s t t e e m m Figure 15. V-200 V–300 Condenser, Fuses Location BEE970 Figure 16.
  • Page 39 E E l l e e c c t t r r i i c c a a l l S S y y s s t t e e m m Figure 18. V-800 V–1000 Condenser, Fuses Location BEE976 N N o o t t e e : : Remove the cover to access the fuses.
  • Page 40 E E l l e e c c t t r r i i c c a a l l S S y y s s t t e e m m Figure 20. Fuse Location (condenser cover removed) TK 56869-18-OP-EN...

  • Page 41: Introduction

    Operating Instructions Introduction In vehicle powered units, temperature control is based on two values: The setting (Setpoint) of the controller and the evaporator return air temperature. The difference between these two temperatures will determine the mode of operation: cool, heat, or null. C C o o o o l l : : When the temperature in the compartment is 3°F (2°C) h h i i g g h h e e r r than the setpoint, the unit runs in cool mode to reduce the evaporator return temperature to achieve the setpoint.

  • Page 42: Unit Controls

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Unit Controls Figure 21.
  • Page 43 O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s 13.
  • Page 44 O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Enter Key Is used to enter a new command such as manual defrost, etc.

  • Page 45: Operating The Unit

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Select Key Is used to scroll through prompt displays and information displays.

  • Page 46: Standby Operation (Models 20 And 50 Only)

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Figure 22.

  • Page 47: Entering The Setpoint Temperature

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s N N o o t t e e : : When the unit is connected to an electric power source, engine driven operation is automatically blocked.

  • Page 48: Initiating Manual Defrost Cycle

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Figure 25.

  • Page 49: Alarms

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Figure 28.

  • Page 50: Electric Standby Nameplates

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Figure 30.

  • Page 51: Clearing Alarm Codes

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Press and release the Select key to display the current alarm code.

  • Page 52: Buzzers (Optional)

    (the unit continues running in standby mode). It can also sound if the door(s) is open or the return air temperature is out of range. Buzzers are configurable to different parameters to suit individual customer needs. Contact your Thermo King Dealer for assistance. TK 56869-18-OP-EN...

  • Page 53: Alarm Code Descriptions

    Contact your Thermo King Dealer. tEP, tP4 Thermal Protection Alarm - If the problem persists when the unit is restarted, contact your Thermo King Dealer. dr1, dr2 Cargo Doors Are Open (Units with door switch option only) - Check if the Doors are open. if not, then the door switches are faulty, or improper door switch configuration.
  • Page 54 O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Alarm Description Remote Cargo Box Return Air Temperature Reading Error (open circuit or short-circuit) Contact your Thermo King Dealer. Communications Failure Contact your Thermo King Dealer. DSR communication lost - Communication lost to the other Electronic Control Module.
  • Page 55 O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Table 2.
  • Page 56 O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s N N o o t t e e : : Refer to the Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096 for more information about Alarm Codes and diagnosis.
  • Page 57 Contact your Thermo King Dealer. tEP, tP4 Thermal Protection Alarm - If the problem persists when the unit is restarted, contect your Thermo King Dealer dr1, dr2 Cargo Doors Are Open (Units with door switch option only) - Check if the Doors are open. if not, then the door switches are faulty, or improper door switch configuration.
  • Page 58 If the problem persists when the unit is restarted, contact your Thermo King Dealer. eMMC erase error - An error occurred while loading parameters to the DSR-IV Controller. Internal, System reset needed, contact your Thermo King Dealer. TK 56869-18-OP-EN...
  • Page 59 - An error occurred while loading parameters to the DSR-IV Controller or performing the datalogging process. Internal, System reset needed, contact your Thermo King Dealer. eMMC read error - An error during powering-up when reading configuration paramenters.

  • Page 60: Viewing Information Displays

    Contact your Thermo King Dealer. Low Battery warning. - Please connect your unit to shore power to charge the TK Battery. If problem persists Contact your Thermo King Dealer. H60 to H63 Battery internal alarm (internal sensors) - Shutdown alarm Contact your Thermo King Dealer.

  • Page 61: Hourmeter Menu

    O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Hourmeter Menu To open the Hourmeter Menu from the Standard Display, press the Select key for three seconds and release, then press the Select key to display:...

  • Page 62: Unit Operation (Before Loading Refrigerated Cargo)

    Unit Operation and Loading Procedures This chapter describes unit operation and proper loading procedures. Thermo King refrigeration units are designed to maintain the required product load temperature during transit. Transport refrigeration units are not designed to reduce the load temperature. Follow these recommended procedures to help prevent cargo spoilage.
  • Page 63 U U n n i i t t O O p p e e r r a a t t i i o o n n a a n n d d L L o o a a d d i i n n g g P P r r o o c c e e d d u u r r e e s s I I m m p p o o r r t t a a n n t t : : Product should be pre-cooled before loading. Thermo King units are designed to maintain the load at the temperature at which it is loaded.

  • Page 64: Enroute Inspections

    U U n n i i t t O O p p e e r r a a t t i i o o n n a a n n d d L L o o a a d d i i n n g g P P r r o o c c e e d d u u r r e e s s Figure 34.

  • Page 65: Inspection Troubleshooting

    30 minute inspections, especially if the compartment temperature appears to be moving away from the setpoint. 3. Immediately contact the nearest Thermo King Dealer. 4. Take the necessary steps to protect and maintain proper load temperature.
  • Page 66 Qualified and Certified personnel should attempt to service your Thermo King unit. The unit did not start Contact nearest Thermo King dealer, or call automatically. the Thermo King Cold Line for referral. Air leaks in cargo box. Inspect cargo box for air leaks such as doors that are not fully closed or bad/ missing door seals.

  • Page 67: Specifications

    Specifications Fuses FUSED COMPONENT FUSE FUSE FUSE LOCATION NUMBER SIZE Evaporator Fan 1 Controller (in condenser) Evaporator Fan 2 Controller (in condenser) Controller (in condenser) Road Compressor Clutch Standby Compressor Clutch Liquid Injection Switch Liquid Injection Valve Defrost Hot Gas Solenoid Motor Contactor Pilot Heat Solenoid...

  • Page 68: Electric Standby Power Supply Requirements

    S S p p e e c c i i f f i i c c a a t t i i o o n n s s Fuse 1: Main Fuse 100 amps 60 amps Fuse 3: Evaporator Fan Motor 15 amps 10 amps (EFM1)
  • Page 69 S S p p e e c c i i f f i i c c a a t t i i o o n n s s 208/230 20 amp 208/230 20 amp Power Cord Size (AWG) Power Cord Length Voltage Phase Power...

  • Page 70: Maintenance Inspection Schedule

    Maintenance Inspection Schedule A closely followed maintenance program will help to keep your Thermo King unit in top operating condition. The following general schedule is provided to assist in monitoring that maintenance. N N o o t t e e : : All service requirements, major and minor, should be handled by a Thermo King dealer.
  • Page 71 M M a a i i n n t t e e n n a a n n c c e e I I n n s s p p e e c c t t i i o o n n S S c c h h e e d d u u l l e e Inspect/Check/Service These Items •...

  • Page 72: Warranty

    Warranty Terms of the Thermo King North American Vehicle Powered Truck Unit Limited Warranty are available on request from your Thermo King Dealer. Please reference document TK 51350. Serial Number Locations C C O O N N D D E E N N S S E E R R : : Nameplate located on the front inside edge of condenser frame.

  • Page 73: Recover Refrigerant

    Recover Refrigerant At Thermo King®, and FrigoBlock 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. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.

  • Page 74: Emergency Cold Line

    Thermo King Dealer anywhere in the United States by going to thermoking. com or by using the Thermo King North American Service Directory (available from any Thermo King dealer). If you are unable to reach a dealer, then call the Toll Free Emergency Cold Line Number (888) 887-2202. The answering service will assist you in reaching a dealer to get the help you need.
  • Page 75 N N o o t t e e s s TK 56869-18-OP-EN...
  • Page 76 1938. For more information, visit www. thermoking.com or www.tranetechnologies.com. Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

This manual is also suitable for:

B-100B-100 ecoB-100 max

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