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Thermo King SPECTRUM TS Series User Manual

Thermo King SPECTRUM TS Series
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SPECTRUM
TS
TK 51448-1-MM (Rev. 1, 03/06)
Copyright© 2002 Thermo King Corp., Minneapolis, MN, USA.
Printed in USA.

Table of Contents

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Thermo King SPECTRUM TS Series Specifications

General IconGeneral
BrandThermo King
ModelSPECTRUM TS Series
CategoryIndustrial Equipment
LanguageEnglish

Summary

Safety Precautions

General Practices

Describes general safety rules for unit operation and handling.

Auto Start/Stop

Explains the automatic starting behavior of the unit.

Battery Removal

Details the procedure for safely removing the unit's battery.

Refrigerant Hazards

Highlights the dangers associated with handling refrigerants.

Refrigerant Oil Hazards

Details the hazards and precautions for refrigerant oil.

Electrical Hazards

Covers safety risks associated with electrical components and systems.

Welding Precautions

Safety guidelines to follow when performing welding operations on the unit.

First Aid

Emergency procedures to follow in case of exposure to hazardous materials.

Specifications

Engine

Provides detailed specifications for the unit's engine.

Belt Tension

Specifies the correct belt tension settings for various belts.

Refrigeration System

Lists key specifications for the refrigeration system components.

Engine Clutch - Hilliard

Details the engagement and torque specifications for the Hilliard clutch.

Electrical Control System

Lists specifications for the unit's electrical control system.

Defrost Timer

Specifies the adjustable intervals for the defrost timer.

System Controller

Identifies the type of system controller used in the unit.

Electrical Components

Provides current draw and resistance for various electrical components.

Electric Standby (Model 50 Unit Only)

Lists specifications for electric standby operation on Model 50 units.

Standby Power Requirements

Details the required supply circuit breaker and extension cord size.

Maintenance Inspection Schedule

Microprocessor

Outlines maintenance tasks for the microprocessor.

Engine

Lists pre-trip, hourly, and annual engine maintenance tasks.

Engine Oil Change Intervals

Specifies intervals for changing engine oil and filter.

Electrical

Outlines electrical system maintenance checks.

Refrigeration

Lists maintenance tasks for the refrigeration system.

Structural

Covers structural inspection and cleaning tasks.

Unit Description

Unit Overview

Provides a general overview of the SPECTRUM™ TS unit.

Design Features

Lists the key design features of the unit.

Unit Options

Lists available optional features for the unit.

Engine

Details the specifications and changes for the TK 3.95 and TK376 engines.

Clutch

Describes the function and engagement speed of the centrifugal clutch.

ELC (Extended Life Coolant)

Provides information on Extended Life Coolant and its compatibility.

EMI 2000

Details the components and benefits of the EMI 2000 package.

SPECTRUM™ Remote Evaporator

Describes the remote evaporator's function and placement.

Compressor

Describes the unit's high-performance scroll compressor.

SPECTRUM™ TS HMI Control Panel

Explains the Human Machine Interface control panel's display and keys.

Microprocessor Power Switch

Locates and describes the function of the microprocessor power switch.

CYCLE-SENTRY Start/Stop System

Explains the fuel-saving CYCLE-SENTRY system.

Defrost

Describes how the defrost process works and its initiation methods.

DAS - Data Acquisition System (Optional)

Details the optional Data Acquisition System's monitoring and recording capabilities.

Electric Standby (Model 50 Units Only)

Explains the electric standby option for Model 50 units.

Standard Model 50 Features

Lists standard features for units with electric standby.

High Voltage Tray

Describes the contents and location of the high voltage tray.

Phase Detect Module for Truck Unit Model 50 Applications

Details the phase detect module's function and operation.

Unit Instruments

Describes various unit instruments like coolant tank and oil sight glass.

Unit Sensors

Explains how sensors monitor system parameters and their types.

Refrigeration System Components

Describes components of the refrigeration system and their locations.

Refrigeration Cycles

Describes the different refrigeration cycles the unit can perform.

Technician Features

Lists special functions available to technicians through the control system.

Refrigeration System Diagrams

Illustrates refrigeration system flow through various zone configurations.

Zone 1 Cool and Zone 2 Cool

Explains the refrigerant flow during Zone 1 Cool and Zone 2 Cool operation.

Zone 1 Evaporator

Lists the components specific to the Zone 1 Evaporator.

Zone 2 Evaporator

Lists the components specific to the Zone 2 Evaporator.

Condensing Unit

Lists the components within the condensing unit.

Zone 1 Heat and Zone 2 Heat

Explains the refrigerant flow during Zone 1 Heat and Zone 2 Heat operation.

Zone 1 Cool and Zone 2 Heat

Explains the refrigerant flow during Zone 1 Cool and Zone 2 Heat operation.

Zone 1 Cool and Zone 2 Null

Explains the refrigerant flow during Zone 1 Cool and Zone 2 Null operation.

Zone 1 Heat and Zone 2 Null

Explains the refrigerant flow during Zone 1 Heat and Zone 2 Null operation.

Zone 1 Cool and Zone 2 Defrost

Explains the refrigerant flow during Zone 1 Cool and Zone 2 Defrost operation.

Zone 1 Heat and Zone 2 Defrost

Explains the refrigerant flow during Zone 1 Heat and Zone 2 Defrost operation.

Zone 1 Defrost and Zone 2 Null

Explains the refrigerant flow during Zone 1 Defrost and Zone 2 Null operation.

Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat

Explains refrigerant flow for three-zone operation.

Zone 1 Cool, Zone 2 Heat, and Zone 3 Heat

Explains refrigerant flow for three-zone operation with mixed modes.

Zone 1 Cool, Zone 2 Heat and Zone 3 Defrost

Explains refrigerant flow for three-zone operation with defrost.

Inverted Heat Mode

Describes the operation of the inverted heat mode.

Defrost Mode

Explains the defrost mode and its operation.

Start Up and Sweeping Unit Evaporator Coils

Details the process of starting up and sweeping evaporator coils.

Control Box, Fuses and Relays

Describes the contents of the control box, including fuses and relays.

Power Supply Board

Describes the power supply board and its function.

Multi-Temp Option Board

Describes the multi-temp option board and its control functions.

Serial Number Locations

Indicates the location of serial numbers on the unit and components.

Serial Number and Refrigerant Label Locations

Shows the location of serial number and refrigerant labels.

SPECTRUM™ TS Operation

HMI Controller Overview

Provides an overview of the HMI controller's interface and keys.

Display

Explains the function of the display screen for providing unit information.

Microprocessor Power Switch

Locates and describes the function of the microprocessor power switch.

Turning the Unit On and Off

Outlines the procedure for powering the unit on and off.

The Standard Display

Describes the default display showing temperatures and setpoints.

Selecting a Zone Display

Explains how to select and display information for a specific zone.

Turning a Zone On and Off

Details the procedure to turn individual zones on or off.

Changing the Setpoint

Describes how to change the setpoint for a selected zone.

Starting the Diesel Engine

Explains the automatic preheat and start procedure for the diesel engine.

Initiating a Manual Defrost Cycle

Outlines the steps to manually initiate a defrost cycle.

Selecting High Speed Lockout (if enabled)

Explains how to enable or disable high speed operation.

Using the Operators Menu

Guides on accessing and navigating the Operators Menu.

Selecting a Language

Procedure for selecting an alternate display language.

Selecting Cycle Sentry or Continuous Mode

Procedure for switching between Cycle Sentry and Continuous modes.

Selecting Economy Mode

Procedure for enabling or disabling Economy Mode for fuel efficiency.

Selecting Sleep Mode

Procedure for activating and programming Sleep Mode.

Pretrip Tests

Information on performing and verifying unit operation through pretrip tests.

Performing a Pretrip Test

Detailed steps for executing a pretrip test.

Selecting Diesel or Electric Operation

Procedure for manually selecting diesel or electric mode.

Single Temperature Operation

Instructions for operating the unit at a single temperature across all zones.

Display Brightness

Procedure for adjusting the HMI display brightness.

Viewing Hourmeters

Guide on how to access and view unit hourmeters.

Hourmeter Names And Definitions

Provides definitions for various hourmeter names displayed.

Viewing and Clearing Alarm Codes

Explains how to view, interpret, and clear alarm codes.

After Start Inspection

Lists checks to perform after the unit has started running.

Loading Procedure

Steps to follow during cargo loading to minimize frost and heat gain.

Post Load Procedure

Procedures to follow after the cargo has been loaded.

Post Trip Checks

Routine checks to perform after a trip.

Electrical Maintenance

Alternator (Prestolite) Charging System Diagnostic Procedures

Procedures for diagnosing charging system issues with Prestolite alternators.

Interface Board Fuse F8

Explains the function and installation of Interface Board Fuse F8.

Test Equipment for Checking Voltage and Current

Lists necessary test equipment for checking alternator circuits.

Alternator Load Test

Describes the recommended method for testing alternator load output.

General Diagnostic and Warranty Evaluation Procedure

Outlines diagnostic steps before replacing alternators or regulators.

Excessive Voltage Output

Discusses troubleshooting and solutions for excessive voltage output.

Battery

Provides notes and checks related to the unit's battery.

Unit Wiring

Emphasizes inspecting unit wiring and harnesses for damage.

Electrical Contacts

Recommends inspecting electrical contacts for wear.

Charging System (12 Vdc)

Explains initial voltage readings and checks for the 12 Vdc charging system.

Preheat Buzzer

Describes the function of the preheat buzzer.

RPM Sensor

Details the RPM sensor's function and testing procedures.

Glow Plugs

Explains the function, testing, and current draw of glow plugs.

Condenser Fan Rotation (Electric Standby Operation)

Instructions for checking condenser fan rotation during electric standby.

Phase Detect Module for Truck Unit Model 50 Applications

Details the phase detect module's function and operation.

Power Connections

Details the power connections for the phase detect module.

Connector Pinout

Provides the pinout for the phase detect module connector.

Removal and Replacement

Step-by-step procedure for removing and replacing the phase detect module.

Diagnostics - Truck SPECTRUM™ TS Applications

Diagnostic steps for troubleshooting the phase detect module.

Overload Relay

Explains the function and location of the overload relay.

Overload Relay Replacement

Procedure for replacing and setting up a new overload relay.

Engine Maintenance

Engine Change

Notes changes in engine models (TK 3.95 to TK376) for EPA Tier 2 compliance.

EMI 2000

Details the components and benefits of the EMI 2000 package.

Engine Lubrication System

Details the engine's pressure lubrication system and factors affecting oil pressure.

Engine Oil Pressure Switch

Explains the function of the engine oil pressure switch.

Engine Oil Change

Provides the procedure for changing the engine oil.

Oil Filter Change

Outlines the steps for changing the engine oil filter.

Crankcase Breather

Describes the crankcase breather system and its maintenance.

Engine Air Cleaner (EMI 2000)

Details the EMI 2000 air cleaner and its replacement intervals.

Engine Cooling System

Provides a general description of the engine's cooling system.

ELC (Extended Life Coolant)

Information regarding Extended Life Coolant and its approved types.

Antifreeze Maintenance Procedures

Procedures for maintaining antifreeze, including checking and changing.

Bleeding the Cooling System

Procedure for bleeding air from the cooling system.

Engine Thermostat

Recommends the appropriate thermostat rating for optimal engine operation.

Engine Fuel System

Describes the components and operation of the engine fuel system.

Injection Pump Adjustments

Procedures for adjusting engine speed via the injection pump.

Injection Pump Timing TK 3.95 Engine

Detailed procedure for timing the TK 3.95 engine injection pump.

Timing Individual Cylinder Injection TK 3.95 Engine

Procedure for timing individual cylinders on the TK 3.95 engine.

Injection Pump Timing TK376 Engine

Procedure for timing the TK376 engine injection pump.

Injection Pump Removal and Installation TK376 Engine

Steps for removing and installing the TK376 injection pump.

Fuel Limit Screw

Information regarding the fuel limit screw and CARB regulations.

Adjust Engine Valve Clearance

Procedure for adjusting engine valve clearance for optimal performance.

Engine Mounts

Describes the engine mounting system for TK 3.95 and TK376 engines.

Restraining Mount Adjustment

Procedure for adjusting the chain restraining mount for belt tension and alignment.

Refrigeration Maintenance

Evacuation

Explains the importance and principles of system evacuation.

Set Up and Test of Evacuation Equipment

Guides on setting up and testing evacuation equipment for proper performance.

Leak Check System

Procedures for performing a system leak check using various methods.

Unit Evacuation

Detailed steps for evacuating the refrigeration unit.

Unit Charging

Procedure for charging the unit with refrigerant after evacuation.

Refrigerant Leaks

Methods for detecting refrigerant leaks in the system.

Refrigerant Charge

Procedures for testing the refrigerant charge under different conditions.

Checking Compressor Oil

Procedure for checking the compressor oil level.

High Pressure Cutout Switch (HPCO)

Description and testing of the high pressure cutout switch.

Low Side Pump Down

Procedure for performing a low side pump down.

Discharge Pressure Regulator Valve

Describes the function and pre-set pressure of the discharge pressure regulator valve.

Refrigeration System Checks

General checks for the refrigeration system's pressures and refrigerant flow.

Refrigeration Service Operations

Accumulator

Procedures for removing and installing the accumulator.

Compressor

Procedures for removing and installing the compressor.

Shaft Seal Change Procedure

Steps for changing the compressor shaft seal and related components.

Compressor Oil Filter Replacement

Procedure for replacing the compressor oil filter and oil.

Scroll Compressor Oil Change

Procedure for changing the oil in a scroll compressor.

Liquid Injection Fitting Change Procedure

Steps for changing the liquid injection fitting.

Condenser/Radiator Coil

Procedures for removing and installing the condenser/radiator coil.

Liquid Injection Valve

Procedures for removing and installing the liquid injection valve.

Dehydrator (Filter-Drier)

Procedures for removing and installing the dehydrator.

High Pressure Cutout Switch

Procedures for removing and installing the high pressure cutout switch.

High Pressure Relief Valve

Procedures for removing and installing the high pressure relief valve.

Receiver Tank

Procedures for removing and installing the receiver tank.

Compressor Oil

Information on the type of compressor oil to use and its properties.

Equipment Recommendations For Use With R-404A

Recommended equipment for R-404A systems.

Vacuum Pumps

Recommendations for selecting and using vacuum pumps for R-404A systems.

Gauge Manifold Sets

Recommendations for gauge manifold sets and their use with R-404A.

System Clean-up

Procedure for cleaning the refrigeration system.

Refrigerant Recovery

Information on adapting systems for R-404A refrigerant recovery.

Throttling Valve

Procedures for removing, disassembling, reassembling, and installing the throttling valve.

Solenoid Valves

Procedures for removing and installing solenoid valves.

In-Line Check Valves

Description, removal, and installation procedures for in-line check valves.

Condenser Inlet Check Valve Repair

Procedure for repairing the condenser inlet check valve.

Condenser Inlet Check Valve Replacement

Procedure for replacing the condenser inlet check valve.

Hilliard Clutch Maintenance

Large Truck Unit Centrifugal Clutch Change

Procedure for changing the centrifugal clutch on large truck units.

Clutch Maintenance

General maintenance procedures for inspecting and servicing the clutch.

Tools Required

Lists the specific tools needed for clutch maintenance.

Disassembly Procedure

Step-by-step guide for disassembling the clutch.

Assembly Procedure (Using New Bearings and Seal)

Procedure for assembling the clutch with new bearings and seal.

Structural Maintenance

Unit and Engine Mounting Bolts

Instructions for checking and tightening unit and engine mounting bolts.

Unit Inspection

Guidance on inspecting the unit for loose wires, leaks, or damage.

Condenser and Radiator Coils

Procedures for cleaning condenser and radiator coils.

Fan Location

Instructions for correctly positioning the fan assembly during mounting.

Mechanical Diagnosis

Unit switch On—nothing happens

Troubleshooting steps when the unit switch is on but nothing occurs.

Unit switch On—Indicator lights come on but engine does not crank

Troubleshooting steps when lights are on but the engine fails to crank.

Engine cranks but fails to start

Troubleshooting steps when the engine cranks but does not start.

Engine stops after starting

Troubleshooting steps when the engine stops after initial start.

Engine does not reach full power

Troubleshooting steps when the engine fails to reach full power.

Engine is sooting heavily, emits thick black clouds of smoke (excessive fuel to air ratio)

Troubleshooting excessive fuel to air ratio causing black smoke.

Engine knocks

Troubleshooting steps for engine knocking.

Engine runs hot

Troubleshooting steps when the engine is running hot.

Oil pressure too low or drops suddenly

Troubleshooting steps for low or suddenly dropping oil pressure.

High oil consumption

Troubleshooting steps for high oil consumption.

Blue Smoke (oil consumption)

Troubleshooting causes of blue smoke indicating oil consumption.

White Smoke (fuel is not burning)

Troubleshooting causes of white smoke indicating fuel not burning.

Battery is not recharging

Troubleshooting steps when the battery is not recharging.

Electric Standby (Optional) Diagnosis

Unit switch On—Microprocessor display does not come on

Troubleshooting steps when the microprocessor display is blank.

Unit switch On—Microprocessor display comes on but electric motor does not run

Troubleshooting steps when the motor does not run despite the display being on.

Electric motor hums but does not run

Troubleshooting steps when the electric motor hums but fails to run.

Contact chatter

Troubleshooting causes of contact chatter in electrical circuits.

Contact welding or freezing

Troubleshooting causes of contact welding or freezing.

Battery is not recharging

Troubleshooting steps when the battery is not recharging.

Refrigeration Diagnosis

Overcharge of refrigerant

Lists possible causes for refrigerant overcharge.

Shortage of refrigerant

Lists possible causes for refrigerant shortage.

No refrigerant

Lists possible causes for a lack of refrigerant.

Air through condenser too hot (ambient)

Lists possible causes for hot ambient air affecting the condenser.

Air flow through condenser restricted

Lists possible causes for restricted air flow through the condenser.

Air through condenser too cold (ambient)

Lists possible causes for cold ambient air affecting the condenser.

Air in refrigerant system

Lists possible causes for air contamination in the refrigerant system.

Condenser fan blades bent or broken

Lists possible causes for bent or broken condenser fan blades.

Air short cycling around evaporator coil

Lists possible causes for air short cycling around the evaporator coil.

Air through evaporator restricted

Lists possible causes for restricted air flow through the evaporator.

Evaporator needs defrosting

Lists possible causes for the evaporator needing defrost.

Compressor discharge valves leaking

Lists possible causes for leaking compressor discharge valves.

Scroll compressor seals leaking

Lists possible causes for leaking scroll compressor seals.

Too much compressor oil in system

Lists possible causes for excess compressor oil in the system.

Faulty oil pump in compressor

Lists possible causes for a faulty compressor oil pump.

Loose compressor pulley

Lists possible causes for a loose compressor pulley.

Compressor bearing loose or burned out

Lists possible causes for loose or burned out compressor bearings.

Broken discharge check valve in compressor

Lists possible causes for a broken discharge check valve.

Expansion valve power element lost its charge

Lists possible causes for expansion valve power element failure.

Expansion valve feeler bulb making poor contact

Lists possible causes for poor feeler bulb contact.

Expansion valve open too much

Lists possible causes for the expansion valve being open too much.

Expansion valve closed too much

Lists possible causes for the expansion valve being closed too much.

Expansion valve needle eroded or leaking

Lists possible causes for an eroded or leaking expansion valve needle.

Expansion valve partially closed by ice, dirt or wax

Lists possible causes for partial closure of the expansion valve.

Liquid refrigerant entering compressor

Lists possible causes for liquid refrigerant entering the compressor.

Restricted line on the low side

Lists possible causes for a restricted low side line.

Restricted line on the high side

Lists possible causes for a restricted high side line.

Restricted drier

Lists possible causes for a restricted drier.

Evaporator shutter open

Lists possible causes for the evaporator shutter being open.

Evaporator shutter stuck closed

Lists possible causes for the evaporator shutter being stuck closed.

Suction service valve back seated

Lists possible causes for the suction service valve being back seated.

Faulty CIS

Lists possible causes for a faulty Condenser Inlet Solenoid.

Faulty Hot Gas Solenoid

Lists possible causes for a faulty Hot Gas Solenoid.

Loose or broken electrical connections

Lists possible causes for loose or broken electrical connections.

Thermostat or thermometer out of calibration

Lists possible causes for calibration issues with thermostat or thermometer.

Suction pressure gauge out of calibration

Lists possible causes for suction pressure gauge calibration issues.

Leaky receiver tank outlet valve

Lists possible causes for a leaky receiver tank outlet valve.

DPR Valve Faulty

Lists possible causes for a faulty Discharge Pressure Regulator valve.

Remote Evaporator Specifications

Refrigeration System

Lists specifications for the remote evaporator's refrigeration system.

Electrical

Lists specifications for the remote evaporator's electrical components.

Remote Evaporator Unit Description

Unit Operation

Describes how the remote evaporator operates in different modes.

Defrost

Explains the defrost process for the remote evaporator.

Operating Modes

Lists the available operating modes for the remote evaporator.

Unit Features

Lists the key features of the remote evaporator unit.

Unit Protection Devices

Describes the protection devices used in the remote evaporator unit.

Serial Number Location

Indicates the location of the serial number nameplate on the unit.

Remote Evaporator Electrical Maintenance

SPECTRUM™ Microprocessor Controlled Components

Refers to the appropriate manual for maintenance of microprocessor components.

Unit Wiring

Emphasizes inspecting unit wiring and harnesses for damage.

Remote Evaporator Refrigeration Service Operations

Expansion Valve Assembly

Procedures for removing and installing the expansion valve assembly.

Evaporator Coil

Procedures for removing and installing the evaporator coil.

Solenoid Valves

Procedures for removing and installing solenoid valves.

Check Valve Replacement

Procedure for replacing in-line check valves.

Check Valve Repair

Procedure for repairing check valves.

Remote Evaporator Structural Maintenance

Unit Inspection

Guidelines for inspecting the remote evaporator unit for damage.

Defrost Drains

Instructions for cleaning defrost drains to ensure they remain open.

Evaporator Coil

Procedure for cleaning the evaporator coil and inspecting fins.

Remote Evaporator System Diagnosis

Load temperature too high

Troubleshooting steps for diagnosing high load temperatures.

Evaporator fan motor does not run

Troubleshooting steps for an evaporator fan motor that is not running.

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