Thermo King SR-3 - Diagnostic Manual

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Revision D

July 2020

TTKK 5566448877--22--OODD--EENN

Trailer and Rail Edition

SR-3 Control System

Single Temperature Units

SL-400e, SLX Series, SLXe Series, SLXi Series

Diagnostic Manual

Main Page

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 N5
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 S5
Table of Contents6
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 N7
Danger, Warning, Caution, and Notice20
General Practices20
Auto Start/Stop22
Electrical Hazards22
High Voltage22
Low Voltage23
Other Electrical Considerations23
Controller Service23
Battery23
Welding23
Units Equipped with Telematics23
Remote Control Warning Nameplate24
Refrigerant Hazards24
Refrigerant Oil Hazards25
First Aid26
General Description27
Control System27
Control System Overview28
Control Components29
Microprocessor On/Off Switch30
Over-Current Protection30
HMI Control Panel30
HMI Control Panel Operation31
Real Time Clock31
Cargowatch™ Data Logger32
Programmable Features32
Display Heater32
HMI Control Panel Connector Map33
Base Controller34
Base Controller Hardware Versions34
Base Controller Software Revisions34
Real Time Clock34
Servicewatch Data Logger34
Programmable Features34
Base Controller Operation34
Relay Functions36
Base Controller Fuse Size & Function36
Fuse F1036
Fuse F1537
Smart FET Outputs37
LED Functions37
Board Jumpers38
Connector Locations39
Connector Usage40
Base Controller Connector Maps41
Complete SR-3 Control System with REB Installed46
Unit Sensors46
Air Temperature Sensors46
Graded and Un-Graded Air Temperature Sensors46
Dual Sensors47
Control and Display Return Air Sensors47
Return Air Sensor Clamp47
Control and Display Discharge Air Sensors47
Coil Temperature Sensor47
Ambient Temperature Sensor47
Spare 1 Temperature Sensor47
Cargowatch™ Sensors48
Diagnostic Procedure48
Refrigeration Control Components49
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 Option50
Engine Control Components50
Coolant Temperature Sensor50
Coolant Level Sensor (CLS)50
Oil Pressure Switch (LOPS)50
Oil Level Switch (OLS)50
Flywheel Sensor (FW)50
Intake Air Heater50
Starter Motor (SM)51
Fuel Solenoid (FSH, FSP)51
High Speed Solenoid (HS)51
Alternator Frequency51
Communication Ports51
Cargowatch Port51
USB Port51
Servicewatch Port52
Printer Port52
Optional Electric Standby52
Model 50 Features52
High Voltage Components52
Optional Remote Mount Power Receptacle53
Standby Power Disconnect Switch53
Diesel/Electric Relay K553
Heater Contactor HC53
Phase Detect Module53
SLX Unit Electric Standby Components53
TK Bluebox54
Software Operation55
Software Separation55
HMI Menu Structure55
Standard Display55
Temperaturewatch™ Display56
Main Menu56
Maintenance Menu56
Guarded Access Menu56
Operator Features56
Standard Display56
Temperaturewatch™ Display57
Main Menu58
Main Menu Features59
Flash Drive59
Language59
Alarms59
Gauges59
Sensors59
Data Logger59
Hourmeters60
Mode60
Pretrip60
Electric Standby (Model 50 Units Only)60
Diesel Mode (Model 50 Units Only)60
Adjust Brightness60
Time60
Maintenance Menu61
Maintenance Menu Features62
Accessing the Maintenance Menu62
Hourmeters63
Gauges63
Sensors63
Alarms63
Telematics Status63
Service Test Mode63
Interface Board Test63
Display Self Test63
Evacuation Test63
Software Revision64
Set Time and Date64
Refrigerant Type64
Unit Serial Number64
NRMM Speed Calibration64
Guarded Access Menu65
Guarded Access Menu Features66
Security Code Protection67
Accessing the Guarded Access Menu67
Leaving the Guarded Access Menu67
Programmable Features Menu67
Temperature Units67
Pressure Units67
Restart Unit after Shutdown68
Setpoint High Limit68
Setpoint Low Limit68
Fuel Saver II69
High Speed Pulldown69
Fresh Frozen Range69
Door Open Forces69
Door Open Timeout70
Door Timeout Alarm70
Sleep Mode after Pretrip70
Rail Option71
Rail Alternate71
Blocked Air Chute Detect71
Blocked Air Chute Temperature Differential71
Blocked Air Chute Time to Alarm72
Blocked Air Chute Door Open Override72
Discharge Pressure Setpoint72
Water Temperature Setpoint72
Limited Alarm Restart73
Remote Device73
HMI Control Panel COM 1 Default Baud Rate73
HMI Control Panel COM 2 Default Baud Rate73
HMI Control Panel COM 3 Default Baud Rate74
High Temperature Defrost74
Local Authorization of Optiset™ Plus Upload74
Local Authorization of Flashload74
Servicewatch™ Logging Intervals75
Water Temp Sleep Mode Engine Start75
Null Restart Temperature75
High Ambient Discharge Pressure Control75
Decimal Degree Setpoint75
Limited Clutch Slip Alarm Clear76
Pharma Defrost76
Main Menu Configuration Menu76
Add Keypad Lockout to Mode Menu76
Add Sleep to Mode Menu76
Configure Soft Key 2 on Standard Display77
Configure Soft Key 3 on Standard Display77
Add Temperature Units to Mode Menu77
Keypad Lock PIN77
Alarm Display Menu78
Hourmeter Setup Menu78
Program Hourmeter Sub-Menu78
Total Run Time Reminder # 1 Hours78
Total Run Time Reminder # 2 Hours78
Controller Power on Hours79
Pretrip Reminder Hours79
Engine Run Time Reminder # 1 Hours79
Engine Run Time Reminder # 2 Hours79
Electric Run Time Reminder # 1 Hours80
Electric Run Time Reminder # 2 Hours80
Viewable Hourmeter Setup Sub-Menu80
Total Hours80
Total Run Time Hours (if Model 50)81
Total Engine Run Hours81
Electric Run Hours (if Model 50)81
Total Run Time Reminder #1 Hours81
Total Run Time Reminder #2 Hours81
Controller on Hours82
Pretrip Reminder Hours82
Engine Run Time Reminder #1 Hours82
Engine Run Time Reminder #2 Hours82
Electric Run Time Reminder #1 Hours83
Electric Run Time Reminder #2 Hours83
Programmable Service Due Date83
Service Due Date83
Sensor Calibration Menu83
Sensor Wire Identification84
Control Return Air Sensor Grade84
Control Discharge Air Sensor Grade84
Display Return Air Sensor Grade84
Display Discharge Air Sensor Grade85
Spare 1 Sensor Grade85
Cycle Sentry Setup Menu85
Cycle Sentry Amps85
Cycle Sentry Battery Voltage86
Check Battery Condition Alarm86
Low Battery Voltage Timeout in Minutes86
CS Null Duration Timeout in Minutes86
Defrost Setup Menu87
Defrost Interval in Range with Fresh Setpoint87
Defrost Interval Not in Range with Fresh Setpoint87
Defrost Interval in Range with Frozen Setpoint87
Defrost Interval Not in Range with Frozen Setpoint87
Maximum Defrost Duration88
Language Setup Menu88
Enable Language88
Access Code Setup Menu88
Enter Access Code88
Optiset™ Plus Menu88
Optiset Plus Reset89
Temperature Profile Selection89
Optiset Plus Continuous Mode89
High Speed Pulldown89
Fuel Saver II89
Minimum Discharge Air Mode90
Low Speed Cool to Low Speed Cool FS II Switch Point90
Optiset Plus Continuous Modulation Mode90
Controlling Sensor90
Pmax91
Freeze Protection91
High Ambient Temperature Override91
Low Ambient Temperature Override91
Floor Limit92
High Speed Modulation Ceiling92
High Speed Modulation92
Optiset Plus Cycle Sentry Mode93
MNTL Max Null Timer93
MOTL Min off Timer93
High Speed Pulldown93
Fuel Saver II93
Minimum Ambient94
Maximum Ambient94
Null Restart Temperature94
Minimum Run Time94
Optiset Plus Cycle Sentry Modulation Mode95
MNTL Max Null Timer95
MOTL Min off Timer95
Minimum Run Time95
Null Restart Temperature96
Floor Limit96
Minimum Ambient96
Maximum Ambient96
Sensor Configuration Menu - Cargowatch™ Data Logger96
Cargowatch Sensor Programming97
Logging Interval97
Log Sensor for Cargowatch Sensor 1, 2, 3, 4, 5, or 697
Independent Sensor Name for Cargowatch Sensor 1, 2, 3, 4, 5, or 698
Out of Range Checking (for Current Sensor)98
Low98
High98
Italian Option99
Sensor Averaging99
Digital Input Programming99
Digital in for Cargowatch Digital Input 1, 2, or 399
Door Open Logging99
Digital Input Name for Cargowatch Digital Input 1, 2, or 3100
Countdown Timer100
Conservative Log Count100
SOT on Setpoint101
Automatic SOT at Midnight101
Hardware Configuration Setup Menu101
Unit Type101
Engine Type101
Compressor Type102
ETV Configured102
Electric Standby Equipped102
Electric Heat Option102
Electric Motor Type102
Diesel to Electric Auto Switch Enabled103
Electric to Diesel Auto Switch Enabled103
Unit Model103
High Capacity Unit103
High Capacity Fresh104
Defrost Motor Equipped104
Fuel Sensor Type104
Rear Remote Control Panel104
Rear Remote Control Panel Action105
Pretrip/Sleep Switch Options105
Rd Party Device Control105
Low Fuel Shutdown105
Fresh Air Exchange106
TK Telematics Fuel Level Sensor Type106
TK Telematics Door Switch Enabled106
Cargolink107
Refrigerant Type107
HMI Control Panel108
Control Panel Display108
Display Icons108
Hard Keys109
Soft Keys109
Display Heater109
Turning Unit on109
If a Flash Drive Is Connected110
If a Language Is Enabled111
Turning the Unit off112
The Standard Display113
The Temperaturewatch™ Display113
Changing the Setpoint114
Numerical Setpoints114
Named Products - Optiset Plus114
Both Numerical Setpoints and Named Products115
Changing the Setpoint - Numerical Setpoint115
Changing the Setpoint - Named Product117
Changing the Setpoint - both Numerical Setpoint and Named Product Available118
Starting the Diesel Engine119
Starting the Electric Motor120
Switching from Diesel to Electric120
Switching from Electric to Diesel121
Initiating a Manual Defrost Cycle122
Terminating a Defrost Cycle123
Selecting Cycle Sentry or Continuous Mode123
Using the Gauges Key124
Gauges Available125
Using the Sensors Key125
Sensors Available126
Using the Main Menu126
Main Menu Choices127
USB Flash Drive127
Inserting a USB Flash Drive128
Accessing the Flash Drive Menu128
Downloading the Servicewatch or Cargowatch Data Loggers129
Flash Loading the Base Controller or HMI Control Panel131
Recover HMI from Failed Flashload133
Sending Optiset Plus Files135
Retrieving Optiset Plus Files136
Removing a USB Flash Drive138
Languages138
Alarms140
Log Alarm140
Check Alarm141
Prevent Alarm141
Shutdown Alarm141
Pretrip Alarms142
Low Battery Voltage142
Alarm Codes When Switching between Diesel and Electric142
Clearing Alarm Codes142
Displaying and Clearing Alarm Codes143
Important Alarm Notes144
Data Logger (Cargowatch™)144
Hourmeters147
Mode148
Turn Cycle Sentry on or off149
Select Temperature Units150
Fresh Air Exchange Open or Closed151
Keypad Lockout151
Start Sleep Mode151
Pretrip152
Pretrip Test Conditions152
Conditions Where Pretrip Tests Are Not Allowed152
Pretrip Test Considerations152
Pretrip Test Sequence152
Performing a Pretrip Test153
Diesel/Electric Menu155
Switching from Diesel to Electric155
Switching from Electric to Diesel156
Adjust Brightness156
Time157
Using the Maintenance Menu158
Entering the Maintenance Menu158
Maintenance Menu Choices159
Hourmeters159
Gauges159
Sensors159
Alarms159
Telematics Status159
Service Test Mode160
Service Test Modes160
Interface Board Test161
Interface Board Test Modes and Current Draw162
Display Self Test162
Evacuation Test163
Software Revision163
Set Time and Date164
Refrigerant Type164
Unit Serial Number165
Using the Guarded Access Menu165
Entering the Guarded Access Menu165
Rear Remote Control Panel (Optional)167
Rear Remote Control Panel Functionality167
Rear Remote Control Action Set to Run167
Rear Remote Control Action Set to Stand by168
Keypad168
Display169
Reading a Typical Remote Standard Display170
Remote Control Panel Lockout170
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 Setpoint171
Selecting Cycle Sentry or Continuous Mode171
Displaying the Discharge Air Temperature172
Viewing and Clearing Alarm Codes172
Starting a Manual Defrost Cycle173
Sending a Start of Trip Marker173
Running a Pretrip Test174
Diagnostics175
Electrostatic Discharge175
Physical Protection176
Corrective Actions as a Result of Alarm Codes176
General 0-200 Series Alarm Codes177
Alarms Exist177
Evaporator Coil Sensor177
Return Control Air Sensor179
Discharge Air Control Sensor182
Ambient Temperature Sensor184
Engine Coolant Temperature Sensor186
Engine Rpm Sensor187
High Evaporator Temperature188
High Discharge Pressure189
Unit or Zone Controlling on Alternate Sensor190
Sensor Shutdown191
Sensor Calibration Check192
Check Intake Air Heater193
Engine Failed to Crank194
High Engine Coolant Temperature195
Low Engine Oil Pressure196
Engine Failed to Start197
Cooling Cycle Check198
Heating Cycle Check199
Cooling Cycle Fault200
Heating Cycle Fault201
Alternator Check202
Check Refrigeration Capacity203
Pretrip or Self Check Abort203
Defrost Damper Circuit Check204
Defrost Damper Stuck205
Check Oil Pressure Switch206
Refrigeration Capacity Low207
Check Engine Rpm208
Check Run Relay Circuit209
Electric Motor Failed to Run210
Check Engine Coolant Level211
Electric Phase Reversed212
Check Water Valve Circuit213
Check High Speed Circuit214
Check Engine Coolant Temperature215
Unit Forced to Low Speed216
Unit Forced to Low Speed Modulation216
Check Fuel System217
Check Hot Gas Bypass Circuit218
Check Air Flow219
Check Belts or Clutch220
Reset Clock220
Check Heat Circuit221
Test Mode Timeout222
Low Battery Voltage223
Ammeter out of Calibration224
Engine Stopped225
Pretrip Reminder226
Abnormal Temperature Differential227
Low Engine Oil Level228
Check Liquid Line Solenoid229
Internal Controller Fault230
Hourmeter Failure230
Controller Reset to Defaults231
Internal Data Logger Overflow231
Restart Null232
Forced Unit Operation233
Check Discharge Pressure Sensor234
Check Suction Pressure Sensor235
Check Electronic Throttling Valve Circuit236
Electric Overload237
Check Electric Ready Input238
Sensor Grades Not Set239
Check Loader #1 Circuit240
Check Loader #2 Circuit241
Low Fuel Level241
Check Fuel Level Sensor242
Door Open Timeout243
Unit Not Configured Correctly244
Check Electric Heat Circuit245
Multiple Alarms - Can Not Run245
Auto or Manual Switch from Diesel to Electric246
Auto or Manual Switch from Electric to Diesel246
Check Alternator Excite Circuit247
Check Pwm/Liquid Injection Circuit248
Check Diesel/Electric Circuit249
Setpoint Not Entered250
Engine Run Time Maintenance Reminder #1250
Engine Run Time Maintenance Reminder #2251
Electric Run Time Maintenance Reminder #1251
Electric Run Time Maintenance Reminder #2252
Total Unit Run Time Maintenance Reminder #1252
Total Unit Run Time Maintenance Reminder #2253
Controller Power on Hours253
Check Spare Digital Inputs254
Check Spare Digital Outputs254
Damper Gear Motor Heater255
Auto-Switch Diesel to Electric Disabled255
Loss of Controller "On" Feedback Signal256
Software Version Mismatch256
Auto-Switch Electric to Diesel Disabled257
Alarm Not Identified257
Out of Range Low (Hmi)258
Out of Range High (Hmi)259
Optiset File Mismatch260
Optiset File Mismatch - a Long String of Numbers Is Present in Lieu of Named Products but Alarm Code 157 Is Not Present260
Primary (New) Software Failed to Load262
Check Battery Condition262
Check Display Return Air Sensor264
Check Display Discharge Air Sensor266
Auto Fresh Air Exchange Door (Afaed)268
A01A - Base Controller Functional Test270
A01A-1 - Base Controller Automated Test274
A01B - HMI Control Panel Automated Test276
A01C - HMI Control Panel Self Test278
A02A - Recording Existing Programmable Feature Settings280
Setup Sheet - XXXX Software282
A03A - Base Controller Replacement287
A03B - HMI Control Panel Replacement288
A04A - Programmable Feature Setup289
A07A - Performing a Base Controller Cold Restart291
A07B - Performing an HMI Control Panel Cold Restart291
A15A - Setting Unit Temperature Sensor Grade292
A26A - Welding on Units Equipped with Base Controllers294
A28A - Setting Unit Running Time Hourmeters295
A46A - Flash Loading Base Controller Software297
A46B - Flash Loading HMI Control Panel Software297
A47B - Retrieving and Sending Optiset Plus Configurations297
A48A - Phase Detect Module Operation and Diagnostics298
A49A - Cargowatch Data Logger301
A50A - Servicewatch Data Logger301
D01A - Temperature Sensor Test302
D03A - Pressure Transducer Test304
E01A - Low Voltage Disconnect Switch Operation and Diagnostics306
F01A - Oil Level Switch Check and Replacement309
F05A - Oil Pressure Switch Test310
F07B - Magnetic Coolant Level Sensor Test311
F08A - Coolant Temperature Sensor Test312
F09A - RPM Sensor Test and Adjustment313
G03A - Electronic Throttling Valve (ETV) Test314
G04A - Electronic Throttling Valve (ETV) Mechanical Operation Test317
H04A - Wiring Harness Continuity Test319
Base Controller320
Hardware Versions and Service Part Numbers320
Label Identification320
Software Requirements320
Compatibility320
HMI Control Panel321
Hardware Versions and Service Part Numbers321
Label Identification321
Software Requirements321
Compatibility321
SR-2/SR-3 Diagnostic Tool322
Power On/Off Control323
HMI Control Panel - Unit Not Turned on323
HMI Control Panel - Turning the Unit on324
HMI Control Panel - Turning the Unit on from a Remote Control Panel325
HMI Control Panel - Turning the Unit off from a Remote Control Panel327
HMI Control Panel Messages/Causes329

Thermo King SR-3 - Diagnostic Manual

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