Thermo King SR-2 SmartReefer2 Manuals

Thermo King SR-2 SmartReefer2 Manuals

Manuals and User Guides for Thermo King SR-2 SmartReefer2. We have 1 Thermo King SR-2 SmartReefer2 manual available for free PDF download: Diagnostic Manual

Thermo King SR-2 SmartReefer2 Diagnostic Manual

Thermo King SR-2 SmartReefer2 Diagnostic Manual (431 pages)

Microprocessor Control System

Brand: Thermo King | Category: Control Systems | Size: 16 MB

Table of Contents

Section 1 - Sr-2 Safety Information

9
- Table of Contents
  9
- General Practices
  11
- Auto Start/Stop
  11
- Refrigerant
  11
  - Refrigerant First Aid
    12
- Refrigeration Oil
  12
  - Refrigeration Oil First Aid
    12
- Electrical Considerations
  12
  - Microprocessor Service
    12
  - Welding
    12
- Electrical Hazards
  13
  - High Voltage
    13
  - High Voltage First Aid
    13
  - Low Voltage
    13
Section 2 - Sr-2 Hardware Description

17
- Block Diagram
  19
- Control Components
  20
- Control System
  20
- General Description
  20
- Microprocessor On/Off Switch
  20
  - SB Series Units
    21
  - Series Units
    21
- SB Series Controls
  20
- Overcurrent Protection
  21
- HMI Control Panel
  22
  - Real Time Clock
    22
    
    Clock Power
    22
  - Programmable Features
    23
  - Fuse F10
    23
  - Display Heater
    23
  - SR2 HMI Control Panel Connector Maps
    24
    
    HMI Control Panel Connector - Arranged by Use
    24
- Microprocessor
  25
- Interface Board
  27
- Complete SR2 Control System
  36
- Air Temperature Sensors
  37
- Unit Sensors
  37
- Cargowatch Sensors
  39
- Refrigeration Control Components
  40
  - Discharge Pressure Transducer (DPT)
    40
  - Suction Pressure Transducer (SPT)
    40
  - High Pressure Cutout Switch (HPCO)
    40
  - Pilot Solenoid (PS)
    40
  - Electronic Throttling Valve (ETV)
    40
  - Hot Gas Solenoid (HG)
    41
  - Damper Solenoid (DS)
    41
  - Damper Motor
    41
- Engine Control Components
  42
  - Coolant Temperature Sensor
    42
  - Coolant Level Sensor (CLS)
    42
    
    Optical Switch
    42
    
    Magnetic Reed Switch
    42
  - Oil Pressure Switch (LOPS)
    42
  - Oil Level Switch (OLS)
    42
  - Flywheel Sensor (FW)
    42
  - Intake Air Heater
    43
  - Starter Motor (SM)
    43
  - Fuel Solenoid (FSH, FSP)
    43
  - High Speed Solenoid (HS)
    43
  - Alternator Frequency
    43
- Communication Ports
  44
  - Cargowatch Port
    44
  - Servicewatch Port
    44
  - Printer Port
    44
- Optional Electric Standby
  45
  - Model 50 Features
    45
  - High Voltage Components
    46
  - Diesel/Electric Relay K5
    46
  - Heater Contactor HC
    46
  - Phase Detect Module
    46
Guarded Access Menu Features

52
- Accessing the Guarded Access Menu
  62
  - Bypassing the Security Code
    62
- Guarded Access Menu Features
  62
- Leaving the Guarded Access Menu
  62
- Security Code Protection
  62
- Programmable Features Menu
  63
  - Temperature Units
    63
  - Pressure Units
    63
  - Restart Unit after Shutdown
    63
  - Setpoint High Limit
    64
  - Setpoint Low Limit
    64
  - Fuel Saver II
    64
  - High Speed Pulldown
    65
  - Fresh Frozen Range
    65
  - Door Open Forces
    65
  - Door Open Timeout
    65
  - Sleep Mode after Pretrip
    66
  - Rail Option
    66
  - Rail Alternate
    66
  - Blocked Air Chute Detect
    66
  - Temperature Differential
    66
  - Time to Alarm
    67
  - Door Open Over-Ride
    67
  - Discharge Pressure Setpoint
    67
  - Water Temperature Setpoint
    67
  - Limited Alarm Resets
    67
  - Remote Device
    68
- Alarm Display Menu
  69
- Hourmeter Setup Menu
  69
  - Programmable Hourmeter Sub-Menu
    69
  - Viewable Hourmeter Setup Sub-Menu
    69
- Cycle Sentry Setup Menu
  70
  - Cycle Sentry Amps Level
    70
  - Battery Sentry Voltage Level
    70
- Sensor Calibration Menu
  70
  - Sensor and Alarm Code
    70
- Defrost Setup Menu
  71
- Access Code Setup Menu
  72
  - Enter Access Code
    72
- Language Setup Menu
  72
  - Software Revision Language Support
    72
  - Default Language
    72
  - Enable Language
    72
- Optiset Levels of Operation
  73
  - Standard Unit Operation
    73
  - Economy Mode Unit Operation
    73
  - Optiset Unit Operation
    73
- Optiset Menu
  73
- Programming Optiset Features
  73
- Optiset Feature Flowchart
  74
  - Temperature Units
    74
  - Setpoint Low Limit
    74
  - Setpoint High Limit
    74
  - Fresh Frozen Range
    74
- Optiset Range Limits and Range Selection
  77
  - Range Limits
    77
  - Optiset Range
    77
- Range Mode Settings
  78
  - Economy Mode
    78
  - Cycle Sentry Mode
    79
  - Continuous Mode
    79
- Economy Mode Optiset Features - both Frozen and Fresh Ranges
  80
- Cycle Sentry Mode Optiset Features - both Frozen and Fresh Ranges
  81
- Continuous Mode Optiset Features - Frozen Ranges and Fresh Ranges Without ETV or with Modulation off
  83
- Continuous Mode Optiset Features - Fresh Ranges with ETV and Modulation on
  86
  - Freshset
    86
  - Modulation Control
    86
  - Controlling Sensor
    87
  - Freshset Modulation Pull down Option
    87
  - Freshset Floor Limit
    88
  - Freshset Freeze Protection
    88
  - Freshset High Speed Modulation
    89
  - Freshset High Speed Modulation Ceiling
    89
  - Continuous Door Open Forces
    90
  - Door Open Timeout
    90
- Sensor Configuration Menu - Cargowatch Datalogger
  91
  - Sensor Programming
    91
  - Logging Interval
    91
  - Out of Range Checking (for Current Sensor)
    92
  - Low
    92
  - High
    92
  - Italian Option
    92
  - Sensor Averaging
    93
  - Digital Input Programming
    93
  - Digital in for Cargowatch Digital Input 1, 2, 3 or 4
    93
  - Door Open Logging
    93
  - Digital Input Name for Cargowatch Digital Input 1, 2, 3 or 4
    93
- Unit Configuration Setup Menu
  94
  - Engine Type Is
    94
  - Compressor Type Is
    94
  - ETV Configured
    94
  - Electric Standby Equipped
    94
  - Electric Motor Type Is
    94
  - Diesel to Electric Auto Switch Enabled
    94
  - Electric to Diesel Auto Switch Enabled
    95
  - Unit
    95
  - High Capacity Unit
    95
  - High Capacity Fresh Is
    95
  - Defrost Motor Equipped
    95
  - Fuel Sensor Type
    95
Section 4

99
- HMI Control Panel Features
  101
  - Display
    102
  - Keys
    102
    
    Hard Keys
    102
    
    Soft Keys
    103
  - Display Heater
    103
- Turning the Unit on and off
  104
- The Standard Display
  106
- The Temperaturewatch Display
  106
- Changing the Setpoint
  107
- Starting the Diesel Engine
  110
- Initiating a Manual Defrost Cycle
  111
- Selecting Cycle Sentry or Continuous Mode
  113
- Using the Gauges Key
  115
  - Gauges Available
    116
- Using the Sensors Key
  117
  - Sensors Available
    118
- Using the Main Menu
  120
- Main Menu Choices
  121
  - Languages
    123
  - Alarms
    125
    
    Log Alarms
    125
    
    Check Alarms
    125
    
    Prevent Alarms
    125
    
    Shutdown Alarms
    125
    
    Pretrip Alarm Codes
    126
    
    Alarm Codes When Switching between Diesel and Electric
    126
    
    Clearing Alarm Codes
    126
    
    SR2 Alarm Codes
    127
    
    Viewing and Clearing Alarm Codes
    134
    
    Important Alarm Notes
    136
  - Data Logger (Cargowatch)
    137
  - Hourmeters
    140
    
    Hourmeter Names and Definitions
    141
  - Mode
    142
    
    Turn Cycle Sentry on or off
    142
    
    Keypad Lockout
    142
    
    Start Sleep Mode
    142
  - Pretrip
    144
    
    Pretrip Test Conditions
    144
    
    Conditions Where Pretrip Tests Are Not Allowed
    144
    
    Pretrip Test Sequence
    144
  - Adjust Brightness
    151
  - Time
    153
- Maintenance Menu Overview
  154
- Using the Maintenance Menu
  155
- Maintenance Menu Choices
  157
  - Hourmeters
    157
    
    Hourmeter Definitions
    158
  - Gauges
    159
    
    Gauge List
    160
  - Sensors
    161
    
    Sensor List
    162
  - Alarms
    163
    
    Clearing Alarms
    165
  - Service Test Mode
    166
    
    Service Test Modes
    167
    
    Devices Energized - Reciprocating Compressor - Diesel Mode
    167
    
    Devices Energized - Reciprocating Compressor - Electric Mode
    168
  - Interface Board Test
    169
    
    Interface Board Test Modes and Current Draw
    170
  - Display Self Test
    171
  - Evacuation Test
    171
  - Software Revision
    172
  - Set Time and Date
    172
- Guarded Access Menu Overview
  173
- Using the Guarded Access Menu
  174
- Guarded Access Menu Choices
  177
  - Security Code (if Enabled)
    177
  - Programmable Features (some Features Not Available if Optiset Has Been Programmed)
    177
  - Alarms
    177
  - Hourmeters
    178
  - Sensor Calibration
    179
  - Cycle Sentry Setup
    179
  - Defrost Setup
    179
  - Language Setup
    179
  - Access Code Setup
    180
  - Optiset
    180
  - Sensor Configuration (Cargo Watch)
    180
  - Unit Configuration
    180
- Section 5

183
- Diagnostics
  187
- Electrostatic Discharge
  188
- Microprocessor Notes
  188
- Alarm Types
  189
  - Log Alarms
    189
  - Check Alarms
    189
  - Prevent Alarms
    189
  - Shutdown Alarms
    189
- Corrective Actions as a Result of Alarm Codes
  189
- Special Considerations
  190
- Check Evaporator Coil Sensor
  191
- No Alarms Exist
  191
- Check (Control) Return Air Sensor
  193
- Check (Control) Discharge Air Sensor
  195
- Check Ambient Temperature Sensor
  197
- Check Coolant Temperature Sensor
  199
- Check Engine RPM Sensor
  201
- High Evaporator Temperature
  202
- High Discharge Pressure
  203
- Unit Controlling on Alternate Sensor
  204
- Sensor Shutdown
  205
- Sensor Check
  206
- Check Intake Air Heater
  207
- Engine Failed to Crank
  208
- High Engine Coolant Temperature
  209
- Low Engine Oil Pressure
  210
- Engine Failed to Start
  212
- Cooling Cycle Check
  213
- Heating Cycle Check
  214
- Cooling Cycle Fault
  215
- Heating Cycle Fault
  216
- Alternator Check
  217
- Check Refrigeration Capacity
  218
- Pretrip Abort
  219
- Check Defrost Damper Circuit
  220
- Defrost Damper Stuck
  221
- Check Oil Pressure Switch
  222
- Refrigeration Capacity Low
  223
- Check Engine RPM
  224
- Check Run Relay Circuit
  225
- Electric Motor Failed to Run
  226
- Check Engine Coolant Level
  227
- Check Water Valve Circuit
  228
- Electric Phase Reversed
  228
- Check High Speed Circuit
  229
- Check Engine Coolant Temperature
  230
- Unit Forced to Low Speed
  231
- Unit Forced to Low Speed Modulation
  231
- Check Fuel System
  232
- Check Hot Gas or Hot Gas Bypass Circuit
  233
- Check Air Flow
  234
- Check Belts or Clutch
  235
- Reset Clock
  235
- Check Heat Circuit
  236
- Test Mode Timeout
  237
- Low Battery Voltage
  238
- Ammeter out of Calibration
  239
- Engine Stopped
  240
- Pretrip Reminder
  241
- Check Liquid Line Solenoid Circuit
  242
- Low Engine Oil Level
  242
- Hourmeter Failure
  243
- Internal Controller Fault Code
  243
- Controller Reset to Defaults
  244
- Internal Data Logger Overflow
  244
- Check Compressor Temp Sensor
  245
- High Compressor Temp
  245
- High Compressor Temp Shutdown
  245
- Low Engine Coolant Temperature
  245
- Restart Null
  246
- Forced Unit Operation
  247
- Check Discharge Pressure Sensor
  248
- Check Suction Pressure Sensor
  249
- Check Electronic Throttling Valve Circuit
  250
- Electric Overload
  251
- Check Electric Ready Input
  252
- Sensor Grades Not Set
  253
- Check Loader #1 Circuit
  254
- Check Loader #2 Circuit
  254
- Low Compressor Suction Pressure
  254
- Low Fuel Level
  254
- Check Fuel Level Sensor
  255
- High Compressor Pressure Ratio
  255
- Door Open Timeout
  256
- Unit Not Configured Correctly
  256
- Check Electric Heat Circuit
  257
- Check High Pressure Cut in Switch
  257
- Check High Pressure Cut out Switch
  257
- Auto Switch from Diesel to Electric
  258
- Auto Switch from Electric to Diesel
  258
- Check Pwm/Liquid Injection Circuit
  258
- Check Diesel/Electric Circuit
  259
- Setpoint Not Entered
  259
- Check Spare Digital Inputs
  260
- Controller Power on Hours
  260
- Electric Run Time Maintenance Reminder #1
  260
- Electric Run Time Maintenance Reminder #2
  260
- Engine Maintenance Run Time Reminder #2
  260
- Engine Run Time Maintenance Reminder #1
  260
- Total Unit Run Time Maintenance Reminder #1
  260
- Total Unit Run Time Maintenance Reminder #2
  260
- Check Damper Motor Heater Output
  261
- Check Spare Digital Outputs
  261
- Check Display Return Air Sensor
  262
- Check Display Discharge Air Sensor
  264
Section 6 - Sr-2 Service Procedure A46A

345
Section 6 - Sr-2 Service Procedure A46B

353
- Obtaining Flash Load Files and Preparing Them for Use
  354
- Connecting the Cables
  355
- Preparing Flash Load Files for Use by Wintrac
  355
- Flash Load Recovery
  356
- Flash Load Procedure
  357
Section 6 - Sr-2 Service Procedure A50A

371
- Downloads
  372
- Servicewatch Time and Date
  372
- To View the Customer Level Data
  373
  - Customer Level Data
    373
- To View the Technician Level Data
  374
  - Technician Level Data
    375
Section 7 - Sr-2 Information

409
- Software Features and Interchange
  411
  - Microprocessor Software
    411
  - HMI Control Panel Software
    412
  - Diagnostic Tool Software
    412
- Hardware Features and Interchange
  413
  - Microprocessor
    413
  - Interface Board
    413
  - HMI Control Panel
    413
  - Microprocessor/Interface Board/Hmi Control Panel Tester
    414
- Economy Mode Settings
  415
  - Cycle Sentry Mode Normal (Default) Settings Vs Economy Mode Settings
    415
  - Continuous Mode Normal (Default) Settings Vs Economy Mode Settings
    416
- Bulletins
  417
  - NAD Service Bulletins
    417
  - NAD Warranty Bulletins
    417
  - ESA Service Bulletins
    418
  - ESA Warranty Bulletins
    418

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