User Manuals: Thermo King SLXi Series Refrigeration

Manuals and User Guides for Thermo King SLXi Series Refrigeration. We have 1 Thermo King SLXi Series Refrigeration manual available for free PDF download: Diagnostic Manual

Thermo King SLXi Series Diagnostic Manual (344 pages)

Single Temperature Units

Brand: Thermo King | Category: Control Systems | Size: 6 MB

S S E E C C T T I I O O N N 3 3 - - S S O O F F T T W W a a R R E E D D E E S S C C R R I I P P T T I I O O N
5
S S E E C C T T I I O O N N 5 5 - - D D I I a a G G N N O O S S T T I I C C S
5
Table of Contents
6
S S E E C C T T I I O O N N 2 2 - - H H a a R R D D W W a a R R E E D D E E S S C C R R I I P P T T I I O O N
7
Danger, Warning, Caution, and Notice
20
General Practices
20
Auto Start/Stop
22
Electrical Hazards
22
High Voltage
22
Low Voltage
23
Other Electrical Considerations
23
Controller Service
23
Battery
23
Welding
23
Units Equipped with Telematics
23
Remote Control Warning Nameplate
24
Refrigerant Hazards
24
Refrigerant Oil Hazards
25
First Aid
26
General Description
27
Control System
27
Control System Overview
28
Control Components
29
Microprocessor On/Off Switch
30
Over-Current Protection
30
HMI Control Panel
30
HMI Control Panel Operation
31
Real Time Clock
31
Cargowatch™ Data Logger
32
Programmable Features
32
Display Heater
32
HMI Control Panel Connector Map
33
Base Controller
34
Base Controller Hardware Versions
34
Base Controller Software Revisions
34
Real Time Clock
34
Servicewatch Data Logger
34
Programmable Features
34
Base Controller Operation
34
Relay Functions
36
Base Controller Fuse Size & Function
36
Fuse F10
36
Fuse F15
37
Smart FET Outputs
37
LED Functions
37
Board Jumpers
38
Connector Locations
39
Connector Usage
40
Base Controller Connector Maps
41
Complete SR-3 Control System with REB Installed
46
Unit Sensors
46
Air Temperature Sensors
46
Graded and Un-Graded Air Temperature Sensors
46
Dual Sensors
47
Control and Display Return Air Sensors
47
Return Air Sensor Clamp
47
Control and Display Discharge Air Sensors
47
Coil Temperature Sensor
47
Ambient Temperature Sensor
47
Spare 1 Temperature Sensor
47
Cargowatch™ Sensors
48
Diagnostic Procedure
48
Refrigeration Control Components
49
Discharge Pressure Transducer (DPT)
49
Suction Pressure Transducer (SPT)
49
High Pressure Cutout Switch (HPCO)
49
Pilot Solenoid (PS)
49
Electronic Throttling Valve (ETV)
49
Hot Gas Bypass Solenoid (HGB)
49
Damper Solenoid (DS)
49
Damper Motor (DM)
50
Fresh Air Exchange Solenoid Option
50
Engine Control Components
50
Coolant Temperature Sensor
50
Coolant Level Sensor (CLS)
50
Oil Pressure Switch (LOPS)
50
Oil Level Switch (OLS)
50
Flywheel Sensor (FW)
50
Intake Air Heater
50
Starter Motor (SM)
51
Fuel Solenoid (FSH, FSP)
51
High Speed Solenoid (HS)
51
Alternator Frequency
51
Communication Ports
51
Cargowatch Port
51
USB Port
51
Servicewatch Port
52
Printer Port
52
Optional Electric Standby
52
Model 50 Features
52
High Voltage Components
52
Optional Remote Mount Power Receptacle
53
Standby Power Disconnect Switch
53
Diesel/Electric Relay K5
53
Heater Contactor HC
53
Phase Detect Module
53
SLX Unit Electric Standby Components
53
TK Bluebox
54
Software Operation
55
Software Separation
55
HMI Menu Structure
55
Standard Display
55
Temperaturewatch™ Display
56
Main Menu
56
Maintenance Menu
56
Guarded Access Menu
56
Operator Features
56
Standard Display
56
Temperaturewatch™ Display
57
Main Menu
58
Main Menu Features
59
Flash Drive
59
Language
59
Alarms
59
Gauges
59
Sensors
59
Data Logger
59
Hourmeters
60
Mode
60
Pretrip
60
Electric Standby (Model 50 Units Only)
60
Diesel Mode (Model 50 Units Only)
60
Adjust Brightness
60
Time
60
Maintenance Menu
61
Maintenance Menu Features
62
Accessing the Maintenance Menu
62
Hourmeters
63
Gauges
63
Sensors
63
Alarms
63
Telematics Status
63
Service Test Mode
63
Interface Board Test
63
Display Self Test
63
Evacuation Test
63
Software Revision
64
Set Time and Date
64
Refrigerant Type
64
Unit Serial Number
64
NRMM Speed Calibration
64
Guarded Access Menu
65
Guarded Access Menu Features
66
Security Code Protection
67
Accessing the Guarded Access Menu
67
Leaving the Guarded Access Menu
67
Programmable Features Menu
67
Temperature Units
67
Pressure Units
67
Restart Unit after Shutdown
68
Setpoint High Limit
68
Setpoint Low Limit
68
Fuel Saver II
69
High Speed Pulldown
69
Fresh Frozen Range
69
Door Open Forces
69
Door Open Timeout
70
Door Timeout Alarm
70
Sleep Mode after Pretrip
70
Rail Option
71
Rail Alternate
71
Blocked Air Chute Detect
71
Blocked Air Chute Temperature Differential
71
Blocked Air Chute Time to Alarm
72
Blocked Air Chute Door Open Override
72
Discharge Pressure Setpoint
72
Water Temperature Setpoint
72
Limited Alarm Restart
73
Remote Device
73
HMI Control Panel COM 1 Default Baud Rate
73
HMI Control Panel COM 2 Default Baud Rate
73
HMI Control Panel COM 3 Default Baud Rate
74
High Temperature Defrost
74
Local Authorization of Optiset™ Plus Upload
74
Local Authorization of Flashload
74
Servicewatch™ Logging Intervals
75
Water Temp Sleep Mode Engine Start
75
Null Restart Temperature
75
High Ambient Discharge Pressure Control
75
Decimal Degree Setpoint
75
Limited Clutch Slip Alarm Clear
76
Pharma Defrost
76
Main Menu Configuration Menu
76
Add Keypad Lockout to Mode Menu
76
Add Sleep to Mode Menu
76
Configure Soft Key 2 on Standard Display
77
Configure Soft Key 3 on Standard Display
77
Add Temperature Units to Mode Menu
77
Keypad Lock PIN
77
Alarm Display Menu
78
Hourmeter Setup Menu
78
Program Hourmeter Sub-Menu
78
Total Run Time Reminder # 1 Hours
78
Total Run Time Reminder # 2 Hours
78
Controller Power on Hours
79
Pretrip Reminder Hours
79
Engine Run Time Reminder # 1 Hours
79
Engine Run Time Reminder # 2 Hours
79
Electric Run Time Reminder # 1 Hours
80
Electric Run Time Reminder # 2 Hours
80
Viewable Hourmeter Setup Sub-Menu
80
Total Hours
80
Total Run Time Hours (if Model 50)
81
Total Engine Run Hours
81
Electric Run Hours (if Model 50)
81
Total Run Time Reminder #1 Hours
81
Total Run Time Reminder #2 Hours
81
Controller on Hours
82
Pretrip Reminder Hours
82
Engine Run Time Reminder #1 Hours
82
Engine Run Time Reminder #2 Hours
82
Electric Run Time Reminder #1 Hours
83
Electric Run Time Reminder #2 Hours
83
Programmable Service Due Date
83
Service Due Date
83
Sensor Calibration Menu
83
Sensor Wire Identification
84
Control Return Air Sensor Grade
84
Control Discharge Air Sensor Grade
84
Display Return Air Sensor Grade
84
Display Discharge Air Sensor Grade
85
Spare 1 Sensor Grade
85
Cycle Sentry Setup Menu
85
Cycle Sentry Amps
85
Cycle Sentry Battery Voltage
86
Check Battery Condition Alarm
86
Low Battery Voltage Timeout in Minutes
86
CS Null Duration Timeout in Minutes
86
Defrost Setup Menu
87
Defrost Interval in Range with Fresh Setpoint
87
Defrost Interval Not in Range with Fresh Setpoint
87
Defrost Interval in Range with Frozen Setpoint
87
Defrost Interval Not in Range with Frozen Setpoint
87
Maximum Defrost Duration
88
Language Setup Menu
88
Enable Language
88
Access Code Setup Menu
88
Enter Access Code
88
Optiset™ Plus Menu
88
Optiset Plus Reset
89
Temperature Profile Selection
89
Optiset Plus Continuous Mode
89
High Speed Pulldown
89
Fuel Saver II
89
Minimum Discharge Air Mode
90
Low Speed Cool to Low Speed Cool FS II Switch Point
90
Optiset Plus Continuous Modulation Mode
90
Controlling Sensor
90
Pmax
91
Freeze Protection
91
High Ambient Temperature Override
91
Low Ambient Temperature Override
91
Floor Limit
92
High Speed Modulation Ceiling
92
High Speed Modulation
92
Optiset Plus Cycle Sentry Mode
93
MNTL Max Null Timer
93
MOTL Min off Timer
93
High Speed Pulldown
93
Fuel Saver II
93
Minimum Ambient
94
Maximum Ambient
94
Null Restart Temperature
94
Minimum Run Time
94
Optiset Plus Cycle Sentry Modulation Mode
95
MNTL Max Null Timer
95
MOTL Min off Timer
95
Minimum Run Time
95
Null Restart Temperature
96
Floor Limit
96
Minimum Ambient
96
Maximum Ambient
96
Sensor Configuration Menu - Cargowatch™ Data Logger
96
Cargowatch Sensor Programming
97
Logging Interval
97
Log Sensor for Cargowatch Sensor 1, 2, 3, 4, 5, or 6
97
Independent Sensor Name for Cargowatch Sensor 1, 2, 3, 4, 5, or 6
98
Out of Range Checking (for Current Sensor)
98
Low
98
High
98
Italian Option
99
Sensor Averaging
99
Digital Input Programming
99
Digital in for Cargowatch Digital Input 1, 2, or 3
99
Door Open Logging
99
Digital Input Name for Cargowatch Digital Input 1, 2, or 3
100
Countdown Timer
100
Conservative Log Count
100
SOT on Setpoint
101
Automatic SOT at Midnight
101
Hardware Configuration Setup Menu
101
Unit Type
101
Engine Type
101
Compressor Type
102
ETV Configured
102
Electric Standby Equipped
102
Electric Heat Option
102
Electric Motor Type
102
Diesel to Electric Auto Switch Enabled
103
Electric to Diesel Auto Switch Enabled
103
Unit Model
103
High Capacity Unit
103
High Capacity Fresh
104
Defrost Motor Equipped
104
Fuel Sensor Type
104
Rear Remote Control Panel
104
Rear Remote Control Panel Action
105
Pretrip/Sleep Switch Options
105
Rd Party Device Control
105
Low Fuel Shutdown
105
Fresh Air Exchange
106
TK Telematics Fuel Level Sensor Type
106
TK Telematics Door Switch Enabled
106
Cargolink
107
Refrigerant Type
107
HMI Control Panel
108
Control Panel Display
108
Display Icons
108
Hard Keys
109
Soft Keys
109
Display Heater
109
Turning Unit on
109
If a Flash Drive Is Connected
110
If a Language Is Enabled
111
Turning the Unit off
112
The Standard Display
113
The Temperaturewatch™ Display
113
Changing the Setpoint
114
Numerical Setpoints
114
Named Products - Optiset Plus
114
Both Numerical Setpoints and Named Products
115
Changing the Setpoint - Numerical Setpoint
115
Changing the Setpoint - Named Product
117
Changing the Setpoint - both Numerical Setpoint and Named Product Available
118
Starting the Diesel Engine
119
Starting the Electric Motor
120
Switching from Diesel to Electric
120
Switching from Electric to Diesel
121
Initiating a Manual Defrost Cycle
122
Terminating a Defrost Cycle
123
Selecting Cycle Sentry or Continuous Mode
123
Using the Gauges Key
124
Gauges Available
125
Using the Sensors Key
125
Sensors Available
126
Using the Main Menu
126
Main Menu Choices
127
USB Flash Drive
127
Inserting a USB Flash Drive
128
Accessing the Flash Drive Menu
128
Downloading the Servicewatch or Cargowatch Data Loggers
129
Flash Loading the Base Controller or HMI Control Panel
131
Recover HMI from Failed Flashload
133
Sending Optiset Plus Files
135
Retrieving Optiset Plus Files
136
Removing a USB Flash Drive
138
Languages
138
Alarms
140
Log Alarm
140
Check Alarm
141
Prevent Alarm
141
Shutdown Alarm
141
Pretrip Alarms
142
Low Battery Voltage
142
Alarm Codes When Switching between Diesel and Electric
142
Clearing Alarm Codes
142
Displaying and Clearing Alarm Codes
143
Important Alarm Notes
144
Data Logger (Cargowatch™)
144
Hourmeters
147
Mode
148
Turn Cycle Sentry on or off
149
Select Temperature Units
150
Fresh Air Exchange Open or Closed
151
Keypad Lockout
151
Start Sleep Mode
151
Pretrip
152
Pretrip Test Conditions
152
Conditions Where Pretrip Tests Are Not Allowed
152
Pretrip Test Considerations
152
Pretrip Test Sequence
152
Performing a Pretrip Test
153
Diesel/Electric Menu
155
Switching from Diesel to Electric
155
Switching from Electric to Diesel
156
Adjust Brightness
156
Time
157
Using the Maintenance Menu
158
Entering the Maintenance Menu
158
Maintenance Menu Choices
159
Hourmeters
159
Gauges
159
Sensors
159
Alarms
159
Telematics Status
159
Service Test Mode
160
Service Test Modes
160
Interface Board Test
161
Interface Board Test Modes and Current Draw
162
Display Self Test
162
Evacuation Test
163
Software Revision
163
Set Time and Date
164
Refrigerant Type
164
Unit Serial Number
165
Using the Guarded Access Menu
165
Entering the Guarded Access Menu
165
Rear Remote Control Panel (Optional)
167
Rear Remote Control Panel Functionality
167
Rear Remote Control Action Set to Run
167
Rear Remote Control Action Set to Stand by
168
Keypad
168
Display
169
Reading a Typical Remote Standard Display
170
Remote Control Panel Lockout
170
Turning the Unit on or off (Configured for STAND by Operation)
170
Turning the Unit on and off (Configured for RUN Operation)
170
Changing the Setpoint
171
Selecting Cycle Sentry or Continuous Mode
171
Displaying the Discharge Air Temperature
172
Viewing and Clearing Alarm Codes
172
Starting a Manual Defrost Cycle
173
Sending a Start of Trip Marker
173
Running a Pretrip Test
174
Diagnostics
175
Electrostatic Discharge
175
Physical Protection
176
Corrective Actions as a Result of Alarm Codes
176
General 0-200 Series Alarm Codes
177
Alarms Exist
177
Evaporator Coil Sensor
177
Return Control Air Sensor
179
Discharge Air Control Sensor
182
Ambient Temperature Sensor
184
Engine Coolant Temperature Sensor
186
Engine Rpm Sensor
187
High Evaporator Temperature
188
High Discharge Pressure
189
Unit or Zone Controlling on Alternate Sensor
190
Sensor Shutdown
191
Sensor Calibration Check
192
Check Intake Air Heater
193
Engine Failed to Crank
194
High Engine Coolant Temperature
195
Low Engine Oil Pressure
196
Engine Failed to Start
197
Cooling Cycle Check
198
Heating Cycle Check
199
Cooling Cycle Fault
200
Heating Cycle Fault
201
Alternator Check
202
Check Refrigeration Capacity
203
Pretrip or Self Check Abort
203
Defrost Damper Circuit Check
204
Defrost Damper Stuck
205
Check Oil Pressure Switch
206
Refrigeration Capacity Low
207
Check Engine Rpm
208
Check Run Relay Circuit
209
Electric Motor Failed to Run
210
Check Engine Coolant Level
211
Electric Phase Reversed
212
Check Water Valve Circuit
213
Check High Speed Circuit
214
Check Engine Coolant Temperature
215
Unit Forced to Low Speed
216
Unit Forced to Low Speed Modulation
216
Check Fuel System
217
Check Hot Gas Bypass Circuit
218
Check Air Flow
219
Check Belts or Clutch
220
Reset Clock
220
Check Heat Circuit
221
Test Mode Timeout
222
Low Battery Voltage
223
Ammeter out of Calibration
224
Engine Stopped
225
Pretrip Reminder
226
Abnormal Temperature Differential
227
Low Engine Oil Level
228
Check Liquid Line Solenoid
229
Internal Controller Fault
230
Hourmeter Failure
230
Controller Reset to Defaults
231
Internal Data Logger Overflow
231
Restart Null
232
Forced Unit Operation
233
Check Discharge Pressure Sensor
234
Check Suction Pressure Sensor
235
Check Electronic Throttling Valve Circuit
236
Electric Overload
237
Check Electric Ready Input
238
Sensor Grades Not Set
239
Check Loader #1 Circuit
240
Check Loader #2 Circuit
241
Low Fuel Level
241
Check Fuel Level Sensor
242
Door Open Timeout
243
Unit Not Configured Correctly
244
Check Electric Heat Circuit
245
Multiple Alarms - Can Not Run
245
Auto or Manual Switch from Diesel to Electric
246
Auto or Manual Switch from Electric to Diesel
246
Check Alternator Excite Circuit
247
Check Pwm/Liquid Injection Circuit
248
Check Diesel/Electric Circuit
249
Setpoint Not Entered
250
Engine Run Time Maintenance Reminder #1
250
Engine Run Time Maintenance Reminder #2
251
Electric Run Time Maintenance Reminder #1
251
Electric Run Time Maintenance Reminder #2
252
Total Unit Run Time Maintenance Reminder #1
252
Total Unit Run Time Maintenance Reminder #2
253
Controller Power on Hours
253
Check Spare Digital Inputs
254
Check Spare Digital Outputs
254
Damper Gear Motor Heater
255
Auto-Switch Diesel to Electric Disabled
255
Loss of Controller "On" Feedback Signal
256
Software Version Mismatch
256
Auto-Switch Electric to Diesel Disabled
257
Alarm Not Identified
257
Out of Range Low (Hmi)
258
Out of Range High (Hmi)
259
Optiset File Mismatch
260
Optiset File Mismatch - a Long String of Numbers Is Present in Lieu of Named Products but Alarm Code 157 Is Not Present
260
Primary (New) Software Failed to Load
262
Check Battery Condition
262
Check Display Return Air Sensor
264
Check Display Discharge Air Sensor
266
Auto Fresh Air Exchange Door (Afaed)
268
A01A - Base Controller Functional Test
270
A01A-1 - Base Controller Automated Test
274
A01B - HMI Control Panel Automated Test
276
A01C - HMI Control Panel Self Test
278
A02A - Recording Existing Programmable Feature Settings
280
Setup Sheet - XXXX Software
282
A03A - Base Controller Replacement
287
A03B - HMI Control Panel Replacement
288
A04A - Programmable Feature Setup
289
A07A - Performing a Base Controller Cold Restart
291
A07B - Performing an HMI Control Panel Cold Restart
291
A15A - Setting Unit Temperature Sensor Grade
292
A26A - Welding on Units Equipped with Base Controllers
294
A28A - Setting Unit Running Time Hourmeters
295
A46A - Flash Loading Base Controller Software
297
A46B - Flash Loading HMI Control Panel Software
297
A47B - Retrieving and Sending Optiset Plus Configurations
297
A48A - Phase Detect Module Operation and Diagnostics
298
A49A - Cargowatch Data Logger
301
A50A - Servicewatch Data Logger
301
D01A - Temperature Sensor Test
302
D03A - Pressure Transducer Test
304
E01A - Low Voltage Disconnect Switch Operation and Diagnostics
306
F01A - Oil Level Switch Check and Replacement
309
F05A - Oil Pressure Switch Test
310
F07B - Magnetic Coolant Level Sensor Test
311
F08A - Coolant Temperature Sensor Test
312
F09A - RPM Sensor Test and Adjustment
313
G03A - Electronic Throttling Valve (ETV) Test
314
G04A - Electronic Throttling Valve (ETV) Mechanical Operation Test
317
H04A - Wiring Harness Continuity Test
319
Base Controller
320
Hardware Versions and Service Part Numbers
320
Label Identification
320
Software Requirements
320
Compatibility
320
HMI Control Panel
321
Hardware Versions and Service Part Numbers
321
Label Identification
321
Software Requirements
321
Compatibility
321
SR-2/SR-3 Diagnostic Tool
322
Power On/Off Control
323
HMI Control Panel - Unit Not Turned on
323
HMI Control Panel - Turning the Unit on
324
HMI Control Panel - Turning the Unit on from a Remote Control Panel
325
HMI Control Panel - Turning the Unit off from a Remote Control Panel
327
HMI Control Panel Messages/Causes
329

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