Thermo King SR-3 Manuals

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 ©2020 Trane Technologies TK 56487-2-OD-EN Introduction This manual is published for informational purposes only. Thermo King® makes no representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted. TThheerrm moo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippm meenntt wwhhiicchh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, m maaiinnttaaiinneedd,, rreeppaaiirreedd oorr aalltteerreedd aass,, iinn tthhee m maannuuffaaccttuurreerr’’ss jjuuddggm meenntt,, ttoo aaffffeecctt iittss iinntteeggrriittyy..”” M Maannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaam maaggee oorr aannyy ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaam maaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss m maannuuaall oorr aannyy iinnffoorrm maattiioonn,, rreeccoom mm meennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iim mpplleem meenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy m maayy ccaauussee ddaam maaggee ttoo tthhee TThheerrm moo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy.. Software License The product includes software that is licensed under a non-exclusive, non-sublicensable, terminable and limited license to use the software as installed on the product for its intended purpose. Any removal, reproduction, reverse engineering, or other unauthorized use of the software is strictly prohibited. Hacking the product or installing unapproved software may void the warranty. The owner or operator shall not reverse engineer, decompile, or disassemble the software, except and only to the extent that such activity is expressly permitted by applicable law notwithstanding this limitation. The product may include third party software separately licensed as specified in any documentation accompanying the product or in an about screen on a mobile application or website that interfaces with the product. Recover Refrigerant NNoottee:: In the USA, EPA Section 609 Certification is required to work on motor vehicle air conditioning systems (MVAC). At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere. When working on transport temperature control systems, a recovery process that prevents or minimizes refrigerant loss to the atmosphere is required by law. In addition, service personnel must be aware of the appropriate European Union, National, Federal, State, and/or Local regulations governing the use of refrigerants and certification of technicians. For additional information on regulations and technician programs, contact your local THERMO KING dealer. SSeerrvviiccee TToooollss - Use the proper service tools. Gauge manifold sets should include appropriate shutoff valves or disconnects near the end of each service line. RReeccoovveerryy EEqquuiippm meenntt - Recovery equipment must be used. Proper recovering, storing and recycling of refrigerants is an important part of all service work. SSeerrvviiccee PPrroocceedduurreess - Recommended procedures must be used to minimize refrigerant loss. CCoom mppoonneennttss m maayy bbee iissoollaatteedd by closing service valves and performing system pump-downs. CCoom mppoonneennttss uunnaabbllee ttoo bbee iissoollaatteedd for service must be repaired only after refrigerant is properly recovered. TK 56487-2-OD-EN 3 Revision History Revision A (Aug 2017) New manual due to software split. Add SLXi-DRC information. Revision B (Mar 2018) Update software revision (DA12/7B12) information throughout manual, general updates throughout manual. Section 3: added Limited Clutch Slip Alarm Clear to Programmable Features, delete REB Type Configured. Section 6: add Service Procedure E01A. Revision C (Jan 2019) Update software revision (DA20/7x20) information throughout manual, general updates throughout manual. Section 4: add Recover HMI from Failed Flashload information. Section 5: update Alarm Code 30, 31, 33, 36, 48, 204. Revision D (Jul 2020) Update software revision (DA25/7x25) information throughout manual, general updates throughout manual, remove Specifications from manual (Specifications are located in applicable maintenance manual), add SLXi Local information. Section 3: add Pharma Defrost. Section 5: update Alarm Code 29. How To Use This Manual Because not everyone is familiar with microprocessor based control systems, please take a few minutes to read this page. It explains the content and structure of this manual. This will make it easier for you to find the information you need. SSeeccttiioonn 11 -- SSaaffeettyy IInnffoorrm maattiioonn This section contains the safety information for the SR-3 control system. Read this material carefully before working on the unit. SSeeccttiioonn 22 -- HHaarrddwwaarree DDeessccrriippttiioonn This section describes the SR-3 control system hardware. It identifies and locates controllers, relays, LEDs, fuses, and other components and provides connector maps for all connectors. SSeeccttiioonn 33 -- SSooffttwwaarree DDeessccrriippttiioonn This section discusses the operation of the SR-3 control system software and programmable features. Each menu and feature is discussed individually to illustrate how they are used. SSeeccttiioonn 44 -- OOppeerraattiioonn This section explains how to operate the SR-3 control system . This information is referenced by material in Section 5 Diagnostics. SSeeccttiioonn 55 -- DDiiaaggnnoossttiiccss This section explains how to diagnose units equipped with the SR-3 control system. It includes both Alarm Code Diagnostics and Other Symptom Diagnostics. This section will reference material in Section 4 Operation and Section 6 Service Procedures. SSeeccttiioonn 66 -- SSeerrvviiccee PPrroocceedduurreess This section includes Service Procedures to assist the technician when servicing units equipped with the SR-3 control system. These procedures are referenced by the diagnostic routines in Section 5 Diagnostics. SSeeccttiioonn 77 -- SSeerrvviiccee IInnffoorrm maattiioonn This section offers service information on the basic component parts of the SR-3 control system. It includes hardware and software history as well as interchangeability information. SSeeccttiioonn 88 -- DDiiaaggrraam mss This section provides a diagram index of the schematic and wiring diagrams associated with this manual and where to locate them. IInnttrroodduuccttiioonn

Optiset Plus The controller can be programmed with OptiSet Plus temperature profiles that allow the user to select named products and/or numeric setpoints. See the appropriate Operator’s Manual for more detailed information about using OptiSet Plus. • Numeric Setpoint - If the controller does not have named products loaded, the far left soft key will display SETPOINT as shown below. This is the factory default setting. Change the numeric setpoint like you normally would on an SR-2 Controller. • Named Products - The controller can be programmed to allow only named products to be selected. In which case the far left soft key will display PRODUCT as shown below. Named products can have a single setpoint, or they can have a setpoint range that allows the user to select a setpoint within that range. NOTE: In OptiSet Plus the terms “numeric setpoint” and “setpoint” mean the same thing and are displayed as numbers. The terms “named product” and “product” mean the same thing and are displayed as words. NOTE: Alarm Code 127, Setpoint Not Entered, may be generated if the + or - soft keys are used to change the numeric setpoint or named product, but the YES or NO soft keys are not used to accept or decline the new setting within 10 seconds. • Named Products or Numeric Setpoint -The controller can be programmed to allow named products or numeric setpoints to be selected. In which case the far left soft key will display PRODUCT/ SETPOINT as shown below. Selecting a Numeric Setpoint To select or change a numeric setpoint complete the following steps. This example shows the Standard Display with the PRODUCT/SETPOINT soft key. Using the Standard Display with the SETPOINT soft key is basically the same but some of the screens differ slightly. 1. Begin at the Standard Display. If the Temperature Watch Display is showing, press the MENU soft key once to return to the Standard Display. 2. Press the PRODUCT/SETPOINT (or SETPOINT) soft key on the Standard Display. 3. The “Named Product / Numeric Setpoint?” Screen briefly appears, then the “Named Product or Numeric Setpoint?” Screen will appear. 4. Press the NUMERIC soft key. 5. The “Setpoint” Screen briefly appears, then the “Current Setpoint Is” Screen will appear. 6. Press the + or - soft keys to change the setpoint. 7. Press the YES soft key to select the new setpoint. • If the NO key is pressed the setpoint change selected with the + or - soft keys will not be accepted, the setpoint will not be changed and the display will return to the Standard Display. • If the YES soft key is pressed, the setpoint change selected with the + or - soft keys will be accepted, and the following screens will appear. 8. The “Programming New Setpoint” Screen will briefly appear. 9. The “New Setpoint Is 40” Screen briefly appears. 10. The Standard Display appears with the new setpoint. NOTE: Pressing the EXIT soft key at any point will return to the Standard Display. NOTE: If no keys are pressed for 30 seconds while in the Named Product Changer Screens, the HMI will return to the Standard Display. Selecting a Named Product To select or change a named product complete the following steps. This example shows the Standard Display with the PRODUCT/SETPOINT soft key. Using the Standard Display with the PRODUCT soft key is basically the same but some of the screens differ slightly. 1. Begin at the Standard Display. If the Temperature Watch Display is showing, press the MENU soft key once to return to the Standard Display. 2. Press the PRODUCT/SETPOINT (or PRODUCT) soft key on the Standard Display. 3. The “Named Product / Numeric Setpoint?” (or Named Product) Screen briefly appears, then the “Named Product or Numeric Setpoint?” (or Named Product) Screen will appear. 4. Press the NAMED soft key. 5. The “Product” Screen briefly appears, then the “Current Product Is” Screen will appear. 6. Press the + or - soft keys to change the named product. 7. Press the YES soft key to select the new named product. • If the NO key is pressed the named product change selected with the + or - soft keys will not be accepted, the named product will not be changed and the display will return to the Standard Display. (Over) 1 2 4 6 7 1 2 4 6 7 • If the YES soft key is pressed, the named product change selected with the + or - soft keys will be accepted, and the following screens will appear. 8. The “Programming Named Product” Screen will briefly appear. NOTE: If the “Change Setpoint for Potatoes” Screen briefly appears, the named product has been programmed with a setpoint range. See “Selecting the Setpoint for a Named Product” below. 9. The “New Named Product Is Potatoes” Screen briefly appears. 10. The Standard Display appears with the new named product. NOTE: Pressing the EXIT soft key at any point will return to the Standard Display. NOTE: If no keys are pressed for 30 seconds while in the Named Product Changer Screens, the HMI will return to the Standard Display. Selecting the Setpoint for a Named Product If the “Change Setpoint for Potatoes” Screen appears after pressing the YES soft key to select a named product, the named product has been programmed with a setpoint range. Complete the following steps to select a setpoint for the named product. 1. The “Change Setpoint for Potatoes” Screen briefly appears, then the “Current Setpoint of Potatoes & Setpoint Range Is 40 to 50” Screen will appear. 2. Press the + /- or EXIT soft keys accordingly as described below. • Press the + or - soft keys to change the current setpoint for the named product. Go to step 6 under “Changing the Setpoint for a Named Product” to continue. OR • Press the EXIT soft key to accept the current setpoint for the named product. The Standard Display will appear with the named product and setpoint. NOTE: Pressing the EXIT soft key at any point will return to the Standard Display. NOTE: If no keys are pressed for 30 seconds while in the Named Product Changer Screens, the HMI will return to the Standard Display and the setpoint will remain at the displayed setpoint. Changing the Setpoint for a Named Product If the named product has been programmed with a setpoint range, the setpoint for the named product can be changed. This example shows the Standard Display with the PRODUCT/SETPOINT soft key. 1. Begin at the Standard Display. If the Temperature Watch Display is showing, press the MENU soft key once to return to the Standard Display. 2. Press the PRODUCT/SETPOINT soft key on the Standard Display. 3. The “Named Product, Numeric Setpoint or Change Setpoint?” Screen will appear. 4. Press the CHANGE SP soft key. 5. The “Change Setpoint for Potatoes” Screen briefly appears, then the “Current Setpoint for Potatoes & Setpoint Range Is 40 to 50” Screen will appear. 6. Press the + or - soft keys to change the setpoint. 7. Press the YES soft key to accept the new setpoint. • If the NO key is pressed the named product setpoint change made with the + or - soft keys will not be accepted, the named product setpoint will not be changed and the display will return to the Standard Display. • If the YES soft key is pressed, the named product setpoint change made with the + or - soft keys will be accepted, and the following screens will appear. 8. The “Programming New Setpoint for Potatoes” Screen will briefly appear. 9. The “New Setpoint Is 40” Screen briefly appears. 10. The Standard Display appears with the new setpoint. NOTE: Pressing the EXIT soft key at any point will return to the Standard Display. NOTE: If no keys are pressed for 30 seconds while in the Named Product Changer Screens, the HMI will return to the Standard Display. SR-2 Smart Reefer 2 Microprocessor Driver Guide to OptiSet Plus Operation TK 54344-2-PC (Rev. 0, 03/09) ©Thermo King Corporation 2 2 1 2 4 6 7

Simple to Start: 1. Press the ON Key. 2. A series of start-up screens will appear. 3. The Standard Display appears showing setpoint and box temperature when the unit is running. 4. The Standard Display defaults to the “Temperature Watch” screen after 2 1/2 minutes. This screen displays same setpoint and box temperature in larger font. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. Simple to Set: CYCLE-SENTRY or Continuous Run 1. Return to the Standard Display. 2. Press the MODE SELECTION Key. 3. The “Programming Continuous Mode” or “Programming CYCLE- SENTRY Mode” screen briefly appears. 4. The “New System Mode is Continuous” screen or the “New System Mode CYCLE- SENTRY” screen briefly appears. 5. The Standard Display appears and the heading on top of screen reads the new mode. 6. Pressing the MODE SELECTION Key again will change the unit back to the previous mode. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. 3 1 4 1 2 & 6 5 5 Simple to Set: Setpoint Temperature 1. Return to the Standard Display. 2. Press the SETPOINT Key on the Standard Display. 3. Press the + or - Keys to change the setpoint reading. 4. Press the YES or NO key accordingly. 5. The Standard Display appears with setpoint changed to the new setpoint. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. Simple to Check: Gauges 1. Return to the Standard Display. 2. Press the GAUGES Key. 3. Press BACK or NEXT Keys to scroll through following gauges: Coolant Temperature, Coolant Level, Engine Oil, Pressure, Amps, Battery Voltage, Engine RPM, Discharge Pressure, Suction Pressure, ETV Position, I/O. If no keys are pressed within 30 seconds, the screen will return to the Standard Display. 4. Press the LOCK Key to display any gauge screen for an indefinite period. Press the key again to unlock the screen. 5. Press the EXIT Key to return to the Standard Display. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. 2 1 4 3 5 1 2 5 4 3 3 Simple to Defrost: Initiate Manual Defrost 1. Return to the Standard Display. 2. Press the DEFROST Key. 3. Miscellaneous defrost programming screens appear. 4. A modified Standard Display screen appears. The bar indicator will fill in showing the time remaining to complete the Defrost cycle. When the Defrost cycle is complete the display returns to Standard Display screen. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. Simple to Access: Sensors 1. Return to the Standard Display. 2. Press the SENSORS Key. 3. Press the BACK or NEXT Keys to scroll through the following sensor screens: Control Return Air Temperature, Display Return Air Temperature, Control Discharge Air Temperature, Display Discharge Air Temperature, Temperature Differential, Evaporator Coil Temperature, Ambient Air Temperature, Spare 1 Temperature, Datalogger Temperature Sensors 1-6 and the Board Temperature Sensor. If no keys are pressed within 30 seconds, the screen will return to the Standard Display. 4. Press the LOCK Key to display any sensor screen for an indefinite period. Press the key again to unlock the screen. 5. Press the EXIT Key to return to the Standard Display. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. 2 1 3 4 2 1 5 4 3 3 Simple to Check: Pretrip Test 1. Clear all alarm codes. 2. Return to the Standard Display. 3. Press the MENU key. 4. Press the NEXT Key as required to show the Pretrip Menu. 5. Press the SELECT Key to start a Pretrip Test. 6. If the unit is not running, a Full Pretrip will be initiated. If the unit is running in either diesel or electric mode, a Running Pretrip will be performed. 7. When all tests are complete, the results are reported as PASS, CHECK or FAIL. If the results are CHECK or FAIL, the accompanying alarm codes will direct the technician to the cause of the problem. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. Simple to Check: Hourmeters 1. Return to the Standard Display screen. 2. Press the MENU Key. 3. Scroll through Main Menu by repeatedly pressing the NEXT and BACK Keys until the hourmeters Main Menu Screen appears. 4. Press the SELECT Key to enter the Hourmeters Menu. 5. Press the NEXT and BACK Keys to view the Hourmeter Displays. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. 3 2 5 4 7 2 1 4 3 & 5 3 & 5 Simple to View: Cause of Alarm 1. Return to the Standard Display Screen. 2. Press the MENU Key. 3. Press the NEXT Key until the Alarm Menu appears. 4. Press the SELECT Key. The Alarm Display will appear 5. If no alarms are present, Alarm 00 is shown. 6. Press the EXIT Key to return to the Standard Display. 7. If alarms are present, the quantity of alarms and the most recent alarm code number will be shown. 8. If there is more than one alarm, press the NEXT Key to view each alarm. 9. If a serious alarm occurs, the unit will be shut down to prevent damage to the unit or the load. If this occurs, the display will show that the unit is shut down and display the alarm code that caused the shutdown. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. Simple to View: Clearing Alarm Codes 1.Press the CLEAR Key to clear an alarm. 2. The display screen will return to the Standard Display when the alarms are cleared. 3. Press the HELP key for additional information regarding the alarm shown on the display. Also see the complete Alarm Code list in the next column. NOTE: For more detailed information, see the Operation chapter in the appropriate unit operating manual. 2 1 7 4 3 6 5 1 3 2 Simple to Determine: Cause of Alarm 0 No Alarms Exist 2 Evaporator Coil Sensor 3 Control Return Air Sensor 4 Control Discharge Air Sensor 5 Ambient Air Sensor 6 Coolant Temp Sensor 7 Engine RPM Sensor 9 High Evaporator Temperature 10 High Discharge Pressure 11 Unit Controlling on Alternate Sensor 12 Sensor or Digital Input Shutdown 13 Sensor Check 15 Check Glow Plugs/Intake Air Heater 17 Engine Failed to Crank 18 High Engine Coolant Temperature 19 Low Engine Oil Pressure 20 Engine Failed to Start 21 Cooling Cycle Check 22 Heating Cycle Check 23 Cooling Cycle Fault 24 Heating Cycle Fault 25 Alternator Check 26 Refrigeration Capacity 28 Pretrip or Self Check Abort 29 Defrost Damper Circuit 30 Defrost Damper Stuck 31 Oil Pressure Switch 32 Refrigeration Capacity Low 33 Check Engine RPM 35 Run Relay Circuit 36 Electric Motor Failed to Run 37 Engine Coolant Level 38 Electric Phase Reversed 39 Water Valve Circuit 40 High Speed Circuit 41 Check Engine Coolant Temperature 42 Unit Forced to Low Speed 43 Unit Forced to Low Speed Modulation 44 Check Fuel System 45 Hot Gas Bypass or Hot Gas Bypass Circuit 46 Check Air Flow 48 Check Belts/Clutch 50 Reset Clock 52 Heat Circuit 54 Test Mode Time-out 61 Low Battery Voltage 62 Ammeter Out of Calibration 63 Engine Stopped 64 Pretrip Reminder 65 Abnormal Temperature Differential 66 Low Engine Oil Level 67 Liquid Line Solenoid Circuit 68 Internal Controller Fault 70 Hourmeter Failure 74 Controller Reset to Defaults 77 Controller EPROM Checksum Failure 79 Internal Data Logger Overflow 80 Compressor Temp Sensor 81 High Compressor Temp 82 High Compressor Temperature Shutdown 83 Low Engine Coolant Temperature 84 Restart Null 85 Forced Unit Operation 86 Discharge Pressure Sensor 87 Suction Pressure Sensor 89 Check Electronic Throttling Valve Circuit 90 Electric Overload 91 Electric Ready Input 92 Sensor Grades Not Set 93 Low Compressor Suction Pressure 94 Loader #1 Circuit 95 Loader #2 Circuit 96 Low Fuel Level 98 Fuel Level Sensor 99 High Compressor Pressure Ratio 108 Door Open Time-out 111 Unit Not Configured Correctly 113 Electric Heat Circuit 114 Multiple Alarms - Cannot Run 117 Auto switch from Diesel to Electric 118 Auto switch from Electric to Diesel 120 Alternator Exciter Circuit 121 Liquid Injection Circuit 122 Diesel/Electric Relay Circuit 127 Setpoint Not Entered 128 Engine Run Time Maintenance Reminder #1 129 Engine Run Time Maintenance Reminder #2 130 Electric Run Time Maintenance Reminder #1 131 Electric Run Time Maintenance Reminder #2 132 Total Unit Run Time Maintenance Reminder #1 133 Total Unit Run Time Maintenance Reminder #2 134 Controller Power On Hours 135 Check Spare Digital Inputs 136 Check Spare Digital Outputs 137 Check Damper Motor Heater Output 141 Autoswitch Diesel to Electric Disabled 145 Loss of Controller "On" Feedback Signal 146 Software Version Mismatch 148 Autoswitch Electric to Diesel Disabled 149 Alarm Not Identified 150 Out of Range Low 151 Out of Range High 157 OptiSet Plus Mismatch 203 Display Return Air Sensor 204 Display Discharge Air Sensor 252 Check Fresh Air Exchange Circuit SR-3 Smart Reefer 3 Microprocessor Driver Guide to Simple Operation TK 55072-2-PC (Rev. 0, 04/11) ©Thermo King Corporation