This document is the Operator's Manual for the Thermo King A-Series Single Temperature Unit, a self-contained diesel/electric powered cooling/heating trailer unit designed for transport refrigeration. It features a fully programmable microprocessor controller, DDE (Diesel Direct Electric) architecture, a quiet Thermo King diesel engine, and a Thermo King X430 reciprocating compressor.
Function Description:
The A-Series unit is designed to maintain a required product load temperature during transit. It offers both cooling and heating capabilities. The unit can operate in either Cycle-Sentry™ Stop-Start mode for optimum fuel economy or Continuous Run mode for constant airflow and temperature maintenance. Defrost cycles are initiated automatically based on time or demand, and a manual defrost can also be initiated by the operator under specific conditions. The unit is equipped with telematics as standard, including a TracKing communication device and Bluetooth®, allowing remote monitoring and management via a mobile app. It also supports various communication capabilities for data download and fleet management, such as cable connection with WinTrac™ software, Plug&Play Log Download via USB, Service Log, Compliance Log, Printer Port, and GPRS connection.
Important Technical Specifications:
- Engine: Thermo King TK486VMGS5 (NRMM Stage V compliant) for A-360, A-400, and A-500 models.
- Fuel Type: Diesel fuel conforming to EN590.
- Oil Capacity: 12.3 liters/litres (13 quarts) crankcase and oil filter.
- Oil Type: Petroleum Multi-grade Oil (API Type CI-4, ACEA Class E3) or Synthetic Multi-grade Oil (API Type CI-4, ACEA Class E3 after first oil change).
- Recommended Oil Viscosity (based on ambient temperature):
- -10 C to 50 C (14 F to 122 F): SAE 15W-40 (Synthetic)
- -15 to 40 C (5 to 104 F): SAE 15W-40
- -15 to 40 C (5 to 104 F): SAE 10W-30 (Synthetic or Synthetic Blend)
- -25 to 40 C (-13 to 104 F): SAE 10W-40
- -25 to 30 C (-13 to 86 F): SAE 10W-30
- -30 to 50 C (-22 to 122 F): SAE 5W-40 (Synthetic)
- Below -30 C (-22 F): SAE 0W-30 (Synthetic)
- Nominal Engine RPM:
- A-360: 1200 and 1450 RPM
- A-400: 1050, 1200 and 1450 RPM
- A-500: 1050, 1200, 1450 and 1900 RPM
- Engine Coolant Thermostat: 71°C.
- Engine Coolant Type: Conventional Coolant (green or blue-green, GM 6038M or equivalent, low silicate antifreeze mixture, 50/50 antifreeze/water mixture, not to exceed 60/40) or Extended Life Coolant (ELC) (red, 50/50 concentration of specific equivalents).
- Coolant System Capacity: 5.3 liters/litres (5.6 quarts).
- Radiator Cap Pressure: 0.83 bar (12 psi) (88 kPa).
- Drive: Direct to compressor clutch and belt from electric motor/generator, and belt to water pump.
- Electrical Control System (Low Voltage): 12.8 Vdc to 48 Vdc, 17-36 Vac.
- Battery: Thermo King EnergyONE (880 CCA) AGM battery as standard.
- Battery Charging: Single Temperature as Standard - 12 volt, 37 amp, brush type, Thermo King Alternator. Single Temperature Option - 12 volt, 120 amp, brush type, Thermo King Alternator.
- Electric Motor (9.3 kW Induction): 1450 RPM, 400 Volt, 3 phase, 50 hertz, 19.7 amps Full Load.
- Electric Motor (9.5 kW Induction): 1740 RPM, 460 Volt, 3 phase, 60 hertz, 17.1 amps Full Load.
- Standby Power Requirements:
- Power Supply Circuit Breaker: 400/3/50 (32 ampere), 460/3/60 (32 ampere).
- Power Cord Size: 400/3/50 (Up to 15m, 6mm²; Over 15m, 10mm²), 460/3/60 (Up to 15m, 10mm²; Over 15m, 16mm²).
- TracKing Platform: ARM Cortex-A8, 300MHz, 256MB RAM, 4GB Flash, Linux.
- GSM/GPRS: 3G, Sierra HL8548.
- GPS: u-blox NEO-7M.
- Bluetooth: Version 4.0 Bluetooth Classic / Bluetooth Low Energy (BLE).
- Serial Ports: 2 External Serial Ports for Tracking extensions or Third-Party Connect.
- Input Power: 12V Nominal.
- Backup Battery: Single cell Li-Ion 3.7V Nominal, > 2Ah.
- Environmental Storage Temperature: -40 to +85 C.
Usage Features:
The A-Series Controller HMI (Human Machine Interface) control panel is used to operate the unit and features a display and twelve touch-sensitive keys.
- Power Up and Power Down: Unit can be turned on and off via dedicated hard keys.
- Language Selection: Operators can select their preferred language from the display menu.
- Setpoint Adjustment: Temperature setpoints can be easily changed using navigation keys.
- Defrost Initiation: Manual defrost cycles can be initiated by the operator.
- System Status Display: The HMI provides real-time information on engine, refrigeration, power, and control status.
- Alarm Management: Operators can view and clear alarms.
- Operating Modes: Switch between Cycle-Sentry™ Stop-Start and Continuous Run modes.
- Fuel Gauge: Displays the trailer unit's fuel level in percentage (if equipped with a fuel level sensor).
- Automatic/Manual Switching (Diesel to Electric): The unit can automatically switch to electric mode if the Auto-Switching Enabled feature is set to YES and standby power is detected. Manual switching is also possible.
- Third-Party Device Connectivity: Dedicated connection points are available for external devices, preventing battery discharge during idle periods.
- Trip Report Printing: An optional Thermo King TouchLog datalogger printer allows printing of unit identification numbers, dates, times, setpoints, and data from optional Compliance Log sensors.
Maintenance Features:
- EMI 3000 Package: Standard equipment that extends maintenance intervals for air cleaner, air cleaner element, fuel filter, and dual element oil filter to 3,000 hours or 2 years, whichever comes first.
- Pre-Trip Inspection: Recommended before every trip with refrigerated cargo, including checking fuel supply, engine oil level, engine coolant, battery terminals, belts, electrical connections, structural integrity, and coil cleanliness.
- Enroute Inspections: Recommended every four hours to verify setpoint, check return air temperature, and initiate manual defrost.
- Maintenance Inspection Schedule: Inspection and service intervals are determined by operating hours and unit age, with A, B, and C services at specified intervals (e.g., A Service every 1500 hours or 12 months).
- Safety Decals and Locations: Warning nameplates are located on the HMI, rear remote controller, bulkhead, belt guard, and rear of the evaporator housing.
- Unit Protection Devices: Includes a preheat buzzer, coolant level switch, engine coolant temperature sensor, high pressure cutout switch, high pressure relief valve, low oil level switch, low oil pressure switch, overload relay (for electric standby units), Smart FETs, and fuses.
- Refrigerant Recovery: Thermo King promotes the recovery and limits the loss of refrigerant into the atmosphere, with service personnel aware of federal regulations and certification programs.
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