Thermo King Diagnoses Service Manual SB 110 210 310 SLX200

Copyright © 2006, 2007, 2008 Thermo King Corp. - Minneapolis, MN, USA Printed in USA DIAGNOSTIC MANUAL SR-2 Single Temp Microprocessor Control System TK 51727-2-OD Rev 1 (09/08) Part 1 – (Sections 1-5) Part 2 – (Sections 6-8) Base Controller/Interface Board Hardware Versions SR-2/A, SR-2/B and SR-2/C HMI Control Panel Versions HMI-1 and HMI-2 and Base Controller Software Revisions through B007 HMI Control Panel Software Revisions through 6512/6612/6712 Used on: SB-110 SB-210 SB-310 SL-400e SLX-100 SLX-200 SLX-400

Revision History SR-2 Diagnostic Manual Preliminary TK 51727-2-OD (Preliminary, 02/04) Full Release TK 51727-2-OD (02/05) Base Controller B002, HMI 6502/6503 Rev 1 TK 51727-2-OD Rev 1 (09/08) Base Controller/IFB Hardware SR-2/A, SR-2/B and SR-2/C HMI Control Panel HMI-1 and HMI-2 Base Controller Software including B007 HMI Control Panel Software including 6512 This manual is published for informational purposes only and the information so provided should not be considered as all-inclusive or covering all contingencies. If further information is required Thermo King Corporation should be consulted. Sale of product shown in this manual is subject to Thermo King's terms and conditions including, but not limited to, the THERMO KING LIMITED EXPRESS WARRANTY. Such terms and conditions are available upon request. Thermo King's warranty will not apply to any equipment which has been "so repaired or altered outside the manufacturer’s plants as, in the manufacturer’s judgment, to affect its stability". No warranties express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising from course of dealing or usage of trade, are made regarding the information, recommendations and descriptions contained herein. Manufacturer is not responsible and will not be held liable in contract or in tort (including negligence) for any special, indirect or consequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any Thermo King product or its mechanical failure.

SR-2 Hardware and Software Features This manual covers the following SR-2 hardware revisions : Base Controller/Interface Board Versions SR-2/A, SR-2/B and SR-2/C and HMI Control Panel Versions HMI-1 and HMI-2 This manual covers the following SR-2 software revisions : Base Controller Software Revisions through B007 and HMI Control Panel Software Revisions through 6512/6612/6712 Earlier versions of hardware and software are similar, but may not include or support all features shown in this manual. See Section 7 of this manual for additional details.

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. Section 1 - Safety information This section contains the safety information for the SR-2 control system. Read this material carefully before working on the unit. Section 2 - Hardware Description This section describes the SR-2 control system hardware. It identifies and locates controllers, relays, LED’s, fuses and other components and provides connector maps for all connectors. Section 3 - Software Description This section discusses the operation of the SR-2 control system software and programmable features. Each menu and feature is discussed individually to illustrate how they are used. Section 4 - Operation This section explains how to operate the SR-2 control system. This information is referenced by material in Section 5 Diagnostics. Section 5 - Diagnostics This section explains how to diagnose units equipped with the SR-2 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. Section 6 - Service Procedures This section includes Service Procedures to assist the technician when servicing units equipped with the SR- 2 control system. These procedures are referenced by the diagnostic routines in Section 5 Diagnostics. Section 7 - Service Information This section offers Service Information on the basic component parts of the SR-2 control system. It includes hardware and software history as well as interchangeability information. Section 8 – Schematics and Wiring Diagrams This section includes the SR-2 control system electrical schematics and unit wiring diagrams.

Control System Notes The following procedures must be followed when working on units equipped with microprocessor based control systems. • Never use testers consisting of a battery and a light bulb to test circuits on any microprocessor based equipment. • The unit must be turned off before connecting or disconnecting the battery. • Any time a graded sensor is replaced it must be calibrated as shown in Service Procedure A15A Temperature Sensor Grade Calibration. • Any time the Base Controller is replaced, these Service Procedures must be used: A02A Recording Existing Programmable Feature Settings A03A Replacement of the Base Controller or Interface Board A04A Programmable Feature Setup • Any time the Interface Board is replaced, Service Procedure A03A Replacement of the Base Controller or Interface Board must be followed. • Any time welding is to be done on the unit or vehicle Service Procedure A26A Welding on Units Equipped with Microprocessors must be followed.

Section 1 – SR-2 Safety Information 1-1 27 August 2008 TABLE OF CONTENTS - SECTION 1 General Practices .................................................................................................................................................... 3 Auto Start/Stop ........................................................................................................................................................ 3 Refrigerant................................................................................................................................................................ 4 Refrigerant First Aid ............................................................................................................................................. 4 Refrigeration Oil....................................................................................................................................................... 4 Refrigeration Oil First Aid ..................................................................................................................................... 4 Electrical Considerations ....................................................................................................................................... 5 Base Controller Service........................................................................................................................................ 5 Welding................................................................................................................................................................. 5 Electrical Hazards.................................................................................................................................................... 5 High Voltage ......................................................................................................................................................... 5 High Voltage First Aid........................................................................................................................................... 5 Low Voltage .......................................................................................................................................................... 6

Section 1 – SR-2 Safety Information 1-2 27 August 2008

Section 1 – SR-2 Safety Information 1-3 27 August 2008 GENERAL PRACTICES 1. Always wear goggles or safety glasses. Refrigerant and battery acid can permanently damage the eyes. 2. Never close the compressor discharge service valve when the unit is running. Never operate the unit with the discharge service valve closed. 3. Keep hands, clothing and tools clear of fans and belts when the unit is running. 4. Be sure gauge manifold hoses are in good condition. Never let them come in contact with belts, fans, pulleys or hot surfaces. 5. Never apply heat to a sealed refrigeration system or container. 6. Refrigerants in the presence of an open flame produce toxic gases. These gases are severe respiratory irritants capable of causing death. 7. Be sure all mounting bolts are the correct length for the application and are securely tightened. 8. Use extreme caution when drilling holes in the unit. Holes may weaken structural components. Holes drilled into wiring can cause fire or explosion. Holes drilled into the refrigeration system will release refrigerant. 9. Use caution when working around exposed coil fins. These fins can cause painful lacerations. 10. Use caution when working with refrigerant in a closed or confined area with a limited air supply such as a trailer, truck, container or hold of a ship. Refrigerant tends to displace air and can cause oxygen depletion. This may result in unconsciousness or death due to suffocation. AUTO START/STOP CAUTION: The unit can start and run automatically any time the unit is turned on. Units start automatically in both Cycle Sentry mode and Continuous mode. Be sure to turn the unit Microprocessor On/Off switch Off before opening doors, doing inspections or working on any part of the unit. SR-2 units may have options that allow for remote starting from a fully off state. Be sure to turn the unit Microprocessor On/Off Switch Off before opening doors, doing inspections or working on any part of the unit. Some SR-2 electronic components are connected directly to un-switched battery power. All connections and circuits labeled with a “2” prefix are directly connected to battery power. Always disconnect the unit starting battery before servicing the unit.

Thermo King Diagnoses Service Manual SB 110 210 310 SLX200

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