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SR-2 SmartReefer2
Thermo King SR-2 SmartReefer2 User Manual
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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
Microprocessor Operation
25
Real Time Clock
25
Programmable Features
25
SR2 Microprocessor Connector Maps
26
J1 - 64 Pin Microprocessor/Interface Board Connector
26
J2 - 64 Pin Microprocessor/Interface Board Connector
26
J3 - Microprocessor Sensor - Arranged by Use
26
Interface Board
27
Interface Board Fuse Size & Function
28
Interface Board Relay Functions
28
Interface Board LED Functions
29
Smart FET Outputs
29
Power Side Logic
30
Interface Board Jumpers
30
J27
30
J101 Cold Start Jumper
30
J102
30
J103
30
Interface Board Connector Maps
32
J1 - 64 Pin Microprocessor/Interface Board Connector
32
J2 - 64 Pin Microprocessor/Interface Board Connector
32
J7 - 36 Pin Interface Board to Main Harness Connector- Arranged by Pin Number
32
J6 - Electric Connector - Arranged by Pin Number
33
J8 - Remote Light Connector - Arranged by Pin Number
33
Mini Mate-N-Lok Harness Connectors - Shown from Pin Side of Harness Connector
33
J4 - Power Switch Connector - Arranged by Pin Number
34
J15 - Engine Connector - Arranged by Pin Number
34
J14 - HMI Connector - Arranged by Pin Number
34
J9 - SERVICE WATCH Download Connector - Arranged by Pin Number
34
J12 - Ibox Connector - Arranged by Pin Number
35
J13 - Remote Controller Connector - Arranged by Pin Number
35
Screw Terminal Power Connections
35
Complete SR2 Control System
36
Air Temperature Sensors
37
Graded and Un-Graded Air Temperature Sensors
37
Dual Sensors
37
Dual Sensor Changes
37
Control and Display Return Air Sensors
38
Control and Display Discharge Air Sensors
38
Coil Temperature Sensor
38
Ambient Temperature Sensor
38
Spare 1 Temperature Sensor
38
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
Defrost Interval in Range with Fresh Setpoint
71
Defrost Interval Not in Range with Fresh Setpoint
71
Defrost Interval in Range with Frozen Setpoint
71
Defrost Interval Not in Range with Frozen Setpoint
71
Maximum Defrost Duration
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 Door Open Forces
80
Cycle Sentry Door Open Timeout
80
Continuous Door Open Forces
80
Continuous Door Open Timeout
80
Cycle Sentry Mode Optiset Features - both Frozen and Fresh Ranges
81
Cycle Sentry High Speed Pulldown
81
Cycle Sentry Fuel Saver II
81
Cycle Sentry Low Speed Switch Point
82
Cycle Sentry Null Restart Temperature
82
Cycle Sentry Door Open Forces
82
Cycle Sentry Door Open Timeout
82
Continuous Mode Optiset Features - Frozen Ranges and Fresh Ranges Without ETV or with Modulation off
83
Continuous High Speed Pulldown
83
Continuous Fuel Saver II
83
Continuous Low Speed Switch Point
84
Continuous Fuel Saver II Switch Point
84
Continuous Heat/Cool Switch Point
84
Continuous Door Open Forces
84
Continuous Door Open Timeout
85
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
Pretrip Alarm Codes
190
Switching Modes from Diesel to Electric and Electric to Diesel
190
Clearing Alarm Codes
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
Obtaining Flash Load Files and Preparing Them for Use
346
Preparing Flash Load Files for Use by Wintrac
346
Connecting the Cables
347
Flash Load Details
347
Flash Load Procedure
348
Flash Load Failure During a Flash Load
351
Flash Loading a Microprocessor Already in Flash Load Mode
352
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
4
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Thermo King SR-2 SmartReefer2 Specifications
General
Brand
Thermo King
Model
SR-2 SmartReefer2
Category
Control Systems
Language
English
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