Installation Manual. Truck and Trailer Edition CargoLink Installation Manual TK IM (Rev. 4, 1/16)

Installation Manual Truck and Trailer Edition CargoLink Installation Manual TK 55151-11-IM (Rev. 4, 1/16)

Installation Manual Printing History Rev. 0 Rev. 1 Rev. 2 Rev. 3 Rev. 4 (06/12) Released. (07/12) Page 28 - Made minor corrections to Unpairing Door Sensor procedures. (03/14) Added Carrier trailer unit installation instructions and fuel sensor installation instructions. (05/14) Pages 18, 22: Added Safety warnings regarding diesel fuel. (01/16) Removed reference to fuel and temp sensors. 2

Introduction This manual was written to assist with the installation of Thermo King CargoLink Communications System remote wireless door sensors onto Thermo King truck and trailer refrigeration units and Carrier X Series trailer units. The CargoLink door system utilizes remote wireless door sensors that automatically shut off the refrigeration unit or remote evaporator(s) anytime a cargo door is opened and resumes normal operation when the cargo door is closed. The system can operate up to 32 remote wireless sensors between 3 zones in a temperature environment of -40 C to 85 C (-40 F to 185 F). The sensors can also be used to control higher current loads (maximum 150 ma) such as trailer interior lighting when used with relay kit 40-1139. SYSTEM COMPONENTS The system consists of a coordinator module, interconnect harness, antenna, wireless door sensors and magnets. The coordinator module is not intended for outdoor use and must be installed inside the refrigeration unit and connected to the unit s control system. The coordinator module operates with 12 volts from the unit s power supply and is protected by a separate 2 amp fuse. The weatherproof antenna is installed outside the control box and connected to the coordinator module with a coaxial cable. Weatherproof wireless door sensors are individually paired to the coordinator module and then installed in specific zones in the cargo area of the truck or trailer. SYSTEM OPERATION Door sensors - When a cargo door is opened a wireless signal is sent to the coordinator module: the module receives the signal and shuts the host unit or remote evaporator(s) off. When the door is closed a wireless signal is again sent to the coordinator module: the module receives the signal and turns the host unit or remote evaporator(s) back on. Due to its complexity, you should not attempt this installation unless you: Are an experienced mechanic. Are certified or trained in the repair and maintenance of diesel powered refrigeration systems. Have a basic understanding of electricity and electrical wiring. Have the necessary tools and equipment to complete the installation. CargoLink service tool diagnostic manual (TK 55733-11-OD) is also available to address diagnostic issues. Contact your Thermo King dealer for details. 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. Thermo King s warranty shall not apply to any equipment which has been so installed, maintained, repaired or altered as, in the manufacturer s judgment, to affect its integrity. Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect, special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or descriptions contained herein. 3

Table of Contents Introduction................................................ 3 Installation - Required Tools................................... 6 Installation - CargoLink Components............................ 8 Installation - Antenna (TK Trailer Units)........................ 10 Installation - Antenna (TK Truck Units)......................... 12 Installation - Harness Connections (TK Trailer Units).............. 14 Installation - Harness Connections (TK Truck Units)............... 24 Installation - Antenna (Carrier X Series Trailer Units).............. 26 Installation - Harness Connections (Carrier X Series Trailer Units)... 28 Installation - Pairing Sensors................................. 30 Unpairing Sensors.......................................... 32 Installation - Door Sensors.................................... 34 Configuration Modes....................................... 36 LED Indicator Codes........................................ 40 IMPORTANT NOTICE...................................... 43 Installation - Check List...................................... 44 4

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Installation - Required Tools 1. Safety Glasses 2. Anti-Static Wrist Strap 3. Drill with 5/16 Drive Socket 4. 1/2 and 9/16 Open End Wrench 5. Wire Cutter/crimper 6. Heat Gun 7. #1 or #2 Phillips Screw Driver 8. Rubber or Plastic Mallet 6

Installation - Required Tools 7

Installation - CargoLink Components Item Trailer Unit P/N DOOR SENSOR COMPONENTS AND HARDWARE Truck Unit P/N Description 1. 42-0228 42-0228 Coordinator Module 1 2. 42-0240 42-0240 Interconnect Harness 1 3. 51-0757 51-0757 Band Wrap, 4.00 in. long 2 4. 55-2330 55-2330 Band Wrap, 16.00 in. long 4 5. 41-0125 41-0125 Connector, butt splice, 14-16 ga. 5 6. 44-2791 44-2791 Connector, ring terminal, 14-16 ga. 2 7. 42-0238 SB and Carrier) 42-0239 Antenna 1 42-0239 (Precedent) 8. 92-9333 (SB and Carrier) 92-9334 Bracket, antenna mounting 1 93-0860 (Precedent) 9. 55-4829 not required Screw, self-drilling, 1.00 in. long 4 10. 42-0475 42-0475 Connector, terminal splice 6 11. 42-0229 42-0229 Sensor door, wireless * 12. 401143A 401143A Magnet, slim line * 13. 51-1321 51-1321 Screw, TRHSM #10, SS 0.75 in. long * 14. 55-8421 55-8421 Screw, TRHSM #10, SS 1.00 in. long * 15. 55-2001 55-2001 Washer, flat, #10 SS * 16. 51-0176 51-1076 Install clamp 1 * Door sensor and hardware quantity varies per your installation Qty 8

Installation - CargoLink Components DOOR SENSOR COMPONENTS AND HARDWARE 9

Installation - Antenna (TK Trailer Units) Installation Procedures WARNING: Before proceeding with the CargoLink installation, disconnect the positive (+) battery cable at the battery to avoid an electrical shock and to prevent the unit from starting causing personal injury! WARNING: Units equipped with an electric standby must be disconnected from the electrical supply source to avoid an electrical shock and to prevent the unit from starting causing personal injury! IMPORTANT: Always wear an Anti-Static wrist strap when working with the microprocessor or printed circuit boards to prevent static discharge from causing damage to these components. 1. Install the antenna onto the bracket: Remove retaining nut from the antenna and route the cable down through the hole in the bracket. Place the antenna onto the bracket. Slide the retaining nut (with points facing up) back up the antenna cable and attach it securely onto the bottom of the antenna as shown. Tighten to 6.8 Nm. (5 ft-lb) Do not over tighten or damage to the antenna will result! SB Units 2. Open the roadside door: Position the antenna and bracket onto the front wall of the trailer approximately 25.4 mm (1.00 in.) above the control box. IMPORTANT: The antenna must be installed as close to the control box and coordinator module as possible for best wireless signal reception. Secure to the trailer wall with the four self-tapping screws provided. Secure the antenna cable to an existing harness with a tie band approximately 203 mm (8.00 in.) from the base of the antenna. This will provide a strain relief for the cable. 3. Open the control box door: Route the antenna cable into the control box through the main harness access hole. Precedent Units 4. Remove top two bolts on fuel filter. Install bracket on top of fuel filter housing using existing hardware. 5. Route antenna harness to control box as shown. 6. Bandwrap harness away from moving parts. 7. Install clamp as shown to secure harness. 10

Installation - Antenna (TK Trailer Units) SB Trailer Units Precedent Trailer Units 11

Installation - Antenna (TK Truck Units) Installation Procedures WARNING: Before proceeding with the CargoLink installation, disconnect the positive (+) battery cable at the battery to avoid an electrical shock and to prevent the unit from starting causing personal injury! WARNING: Units equipped with an electric standby must be disconnected from the electrical supply source to avoid an electrical shock and to prevent the unit from starting causing personal injury! IMPORTANT: Always wear an Anti-Static wrist strap when working with the microprocessor or printed circuit boards to prevent static discharge from causing damage to these components. 1. Install the antenna onto the bracket: Remove retaining nut from the antenna and route the cable down through the hole in the bracket. Place the antenna onto the bracket. Slide the retaining nut (with points facing up) back up the antenna cable and attach it securely onto the bottom of the antenna as shown. Tighten to 6.8 Nm. (5 ft-lb) Do not over tighten or damage to the antenna will result! 2. Install the antenna bracket onto the two inserts located at the rear of the frame with 1/4-20 (installer supplied) hardware. IMPORTANT: The antenna must be installed as close to the control box and coordinator module as possible for best wireless signal reception. NOTE: On units equipped with a top cover or top screen, place the antenna bracket under the existing standoff bracket and reinstall hardware. Secure the antenna cable to an existing harness with a tie band approximately 203 mm (8.00 in.) from the base of the antenna. This will provide a strain relief for the cable. 3. Open the curbside access door: Route the antenna cable into the control box through the main harness access hole. 12

Installation - Antenna (TK Truck Units) NOTE: On units equipped with a top cover or top screen, place the antenna bracket under the existing standoff bracket and reinstall hardware. 13

Installation - Harness Connections (TK Trailer Units) Single and Multi-Temperature Units with SR-4 Controllers Installation Procedures - Door Sensors 1. Attach antenna cable to coordinator module and tighten to 135 to 170 N cm (12 to15 in-lb). 2. Attach interconnect harness securely to coordinator module. 3. Attach GND terminal ring to CH ground stud. 4. Attach VIN terminal ring to 2A circuit. 5. Locate DSP-01 wire (Pin 2A) at J3 on controller board: Cut DSP-01 wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of DSP-01 wires and from end of RS wire from interconnect harness. Splice RS and both DSP-01 wires together with a butt splice connector as shown and crimp securely. Use a heat gun to shrink and seal connector. 6. Locate DS-01 wire (Pin 30) at J3 on the controller board: Cut DS-01 wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of DS -01 wire and from DS1 wire from interconnect harness. Splice the single DS-01 wire from the connector to the DS1 wire from interconnect harness with a butt splice and crimp securely. Use a heat gun to shrink and seal connector. Attach terminal splice cap onto the end of the unused DS wire. 7. SINGLE-TEMPERATURE UNITS - Locate wires DS2 and DS3 at interconnect harness: These wires are not used. Attach terminal splice caps onto ends of wires. 8. MULTI-TEMP UNITS - Locate connector wires DS2-INT2-01 and DS3-INT3-01. Cut DS2-01 and DS3-01 wires approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from end of each wire coming from connector. Connect DS2 wire from interconnect harness to DS2-01 wire from connector with a butt splice and crimp securely. Connect DS3 wire from interconnect harness to DS3-01 wire from connector with a butt splice and crimp securely. Attach terminal splice caps onto other ends of DS2 and DS3 wires. ALL UNITS 9. Attach terminal splice caps onto ends of remaining unused interconnect harness wires FI1, FI2, FLR and FLS. Bundle and secure wires inside control box with band wraps. Secure coordinator module with band wraps to main harness inside control box. 10. Reconnect positive (+) battery cable at battery and set unit controls to OFF. 11. Proceed to Installation - Pairing Sensors on page 30. 14

Installation - Harness Connections (TK Trailer Units) Single and Multi-Temperature Units with SR-4 Controllers to CH Not Used to 2A to DSP-01 to DS-01 Not Used NOTE: Connect only if using wireless fuel sensor option Not Used on Single Temp 15

Installation - Harness Connections (TK Trailer Units) Single and Multi-Temperature Units with SR-2 or SR-3 Controllers Installation Procedures 1. Attach antenna cable to coordinator module and tighten to 135 to 170 N cm (12 to15 in-lb). 2. Attach interconnect harness securely to coordinator module. 3. Attach GND terminal ring to CH ground stud J23 on controller board. 4. Attach VIN terminal ring to 2A circuit J25 on controller board. 5. Locate DSP wire (Pin 20) at J7 on controller board: Cut DSP wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of DSP wires and from end of RS wire from interconnect harness. Splice RS and both DSP wires together with a butt splice connector as shown and crimp securely. Use a heat gun to shrink and seal connector. 6. Locate DS wire (Pin 21) at J7 on the controller board: Cut DS wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of DS wire and from DS1 wire from interconnect harness. Splice the single DS wire from the connector to the DS1 wire from interconnect harness with a butt splice and crimp securely. Use a heat gun to shrink and seal connector. Attach terminal splice cap onto the end of the unused DS wire. 7. SINGLE-TEMPERATURE UNITS - Locate wires DS2 and DS3 at interconnect harness: These wires are not used. Attach terminal splice caps onto ends of wires. 8. MULTI-TEMP UNITS - Locate wires DS2 (Pin 33) and DS3 (Pin 35) at J1 on control box door: Cut DS2 and DS3 wires approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from end of each wire coming from connector. Connect DS2 wire from interconnect harness to DS2 wire from connector with a butt splice and crimp securely. Connect DS3 wire from interconnect harness to DS3 wire from connector with a butt splice and crimp securely. Attach terminal splice caps onto other ends of DS2 and DS3 wires. ALL UNITS 9. Attach terminal splice caps onto ends of remaining unused interconnect harness wires FI1, FI2, FLR and FLS. Bundle and secure wires inside control box with band wraps. Secure coordinator module with band wraps to main harness inside control box. 10. Reconnect positive (+) battery cable at battery and set unit controls to OFF. 11. Proceed to Installation - Pairing Sensors on page 30. 16

Installation - Harness Connections (TK Trailer Units) Single and Multi-Temperature Units with SR-2 or SR-3 Controllers to CH Not Used to 2A to DSP to DS Not Used Not Used on Single Temp Units 17

Installation - Harness Connections (TK Trailer Units) Single Temperature Units with MP-V and MP-IV+ Controllers Installation Procedures 1. Attach antenna cable to coordinator module and tighten to 135 to 170 N cm (12 to15 in-lb). 2. Attach interconnect harness securely to coordinator module. 3. Attach GND terminal ring to CH ground stud below relay board. 4. Attach VIN terminal ring to 2A circuit on top of relay board. 5. Locate 8E wire and J9 on controller board: Cut 8E wire approximately 102 mm(4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of the 8E wires and RS wire from interconnect harness. Splice RS and both 8EP wires together with a butt splice connector as shown and crimp securely. Use a heat gun to shrink and seal connector. 6. Locate DS wire (Pin 27) at J3 on controller board: Cut DS wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from both ends of DS wire and from the DS1 wire from interconnect harness. Splice the single DS wire from the connector to the DS1 wire from interconnect harness with a butt splice and crimp securely. Use a heat gun to shrink and seal connector. Attach terminal splice cap onto the end of unused DS wire. 7. Attach terminal splice caps onto ends of remaining unused interconnect harness wires FI1, FI2, FLR, FLS, DS2 and DS3. Bundle and secure wires inside control box with band wraps. Secure coordinator module with band wraps to main harness inside control box. 8. Reconnect positive (+) battery cable at battery and set unit controls to OFF. 9. Proceed to Installation - Pairing Sensors on page 30. 18

Installation - Harness Connections (TK Trailer Units) Single Temperature Units with MP-V and MP-IV+ Controllers to CH Not Used to 2A to 8E at J9 to DS Not Used 19

Installation - Harness Connections (TK Trailer Units) Multi-Temperature Units with MP-IV+ Controller Installation Procedures 1. Attach antenna cable to coordinator module and tighten to 135 to 170 N cm (12 to15 in-lb). 2. Attach interconnect harness securely to coordinator module. 3. Attach GND terminal ring to CH ground stud under relay board. 4. Attach VIN terminal ring to 2A circuit on relay board. 5. Locate 8F wire (Pin 15) on 37 Pin round connector on door: Cut 8F wire approximately 102 mm(4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of both 8F wires and from end of RS wire from interconnect harness. Splice RS and both 8F wires together with a butt splice connector as shown and crimp securely. Use a heat gun to shrink and seal connector. 6. Locate DS wire (Pin 31) on 37 Pin round connector on door: Cut DS wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from both ends of DS wire and from DS1 wire from interconnect harness. Splice the single DS wire from the connector to the DS1 wire from interconnect harness with a butt splice and crimp securely. Use a heat gun to shrink and seal connector. Attach terminal splice cap onto the end of unused DS wire. 7. Locate DS2 wire at J8 and DS3 wire at J10 on relay board: Cut DS2 and DS3 wires approximately 102 mm (4.00 in.) down from each connector. Strip 7mm (0.25 in.) from end of each wire coming from connector. Connect DS2 wire from interconnect harness to DS2 wire from connector with a butt splice and crimp securely. Connect DS3 wire from interconnect harness to DS3 wire from connector with a butt splice and crimp securely. Attach terminal splice caps onto other ends of DS2 and DS3 wires. 8. Attach terminal splice caps onto ends of remaining unused interconnect harness wires FI1, FI2, FLR and FLS. Bundle and secure wires inside control box with band wraps. Secure coordinator module with band wraps to main harness inside control box. 9. Reconnect positive (+) battery cable at battery and set unit controls to OFF. 10. Proceed to Installation - Pairing Sensors on page 30. 20

Installation - Harness Connections (TK Trailer Units) Multi-Temperature Units with MP-IV+ Controller to CH Not Used to 2A to 8F to DS Not Used 21

Installation - Harness Connections (TK Trailer Units) Single Temperature Units with MP-VI Controllers Installation Procedures 1. Attach antenna cable to coordinator module and tighten to 135 to 170 N cm (12 to15 in-lb). 2. Attach interconnect harness securely to coordinator module. 3. Attach GND terminal ring to CH ground stud under controller board. 4. Attach VIN terminal ring to 2 circuit on controller board. 5. Locate 8D wire at J7 on controller board: Cut 8D wire approximately 102 mm(4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of both 8D wires and from end of RS wire from interconnect harness. Splice RS and both 8D wires together with a butt splice connector as shown and crimp securely. Use a heat gun to shrink and seal connector. 6. Locate DS wire (Pin 30) at J15 on control box door: Cut DS wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from both ends of DS wire and from DS1 wire from interconnect harness. Splice the single DS wire from the connector to the DS1 wire from interconnect harness with a butt splice and crimp securely. Use a heat gun to shrink and seal connector. Attach terminal splice cap onto the end of unused DS wire. 7. Attach terminal splice caps onto ends of remaining unused interconnect harness wires FI1, FI2, FLR, FLS, DS1 and DS2. Bundle and secure wires inside control box with band wraps. Secure coordinator module with band wraps to main harness inside control box. 8. Reconnect positive (+) battery cable at battery and set unit controls to OFF. 9. Proceed to Installation - Pairing Sensors on page 30. 22

Installation - Harness Connections (TK Trailer Units) Single Temperature Units with MP-VI Controllers to CH Not Used to 2 to 8D to DS Not Used 23

Installation - Harness Connections (TK Truck Units) Single and Multi-Temperature Units with SR-2 Controllers Installation Procedures 1. Attach antenna cable to coordinator module and tighten to 135 to 170 N cm (12 to15 in-lb). 2. Attach interconnect harness securely to coordinator module. 3. Attach GND terminal ring to CH ground stud J23 on controller board. 4. Attach VIN terminal ring to 2A circuit J25 on controller board. 5. Locate DSP wire at J7 (Pin 20) on controller board: Cut DSP wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of DSP wires and from end of RS wire from interconnect harness. Splice RS and both DSP wires together with a butt splice connector as shown and crimp securely. Use a heat gun to shrink and seal connector. 6. Locate DS wire on connector J7 (Pin 21) on the controller board: Cut DS wire approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from ends of DS wire and from DS1 wire from interconnect harness. Splice the single DS wire from the connector to the DS1 wire from interconnect harness with a butt splice and crimp securely. Use a heat gun to shrink and seal connector. Attach terminal splice cap onto the end of the unused DS wire. 7. SINGLE-TEMPERATURE UNITS - Locate wires DS2 and DS3 on interconnect harness: These wires are not used. Attach terminal splice caps onto ends of wires. 8. MULTI-TEMP UNITS - Locate wires DS2 (Pin 33) and DS3 (Pin 35) at J1 on control box door: Cut DS2 and DS3 wires approximately 102 mm (4.00 in.) down from connector. Strip 7mm (0.25 in.) from end of each wire coming from connector. Connect DS2 wire from interconnect harness to DS2 wire from connector with a butt splice and crimp securely. Connect DS3 wire from interconnect harness to DS3 wire from connector with a butt splice and crimp securely. Attach terminal splice caps onto other ends of DS2 and DS3 wires. ALL UNITS 9. Attach terminal splice caps onto ends of remaining unused interconnect harness wires FI1, FI2, FLR and FLS. Bundle and secure wires inside control box with band wraps. Secure coordinator module with band wraps to main harness inside control box. 10. Reconnect positive (+) battery cable at battery and set unit controls to OFF. 11. Proceed to Installation - Pairing Sensors on page 30. 24

Installation - Harness Connections (TK Truck Units) Single and Multi-Temperature Units with SR-2 Controllers to CH Not Used to 2A to DSP to DS Not Used Not Used on Single Temp Units 25

Installation - Antenna (Carrier X Series Trailer Units) Installation Procedures WARNING: Before proceeding with the CargoLink installation, disconnect the positive (+) battery cable at the battery to avoid an electrical shock and to prevent the unit from starting causing personal injury! WARNING: Units equipped with an electric standby must be disconnected from the electrical supply source to avoid an electrical shock and to prevent the unit from starting causing personal injury! IMPORTANT: Always wear an Anti-Static wrist strap when working with the microprocessor or printed circuit boards to prevent static discharge from causing damage to these components. 1. Install the antenna onto the bracket: Remove retaining nut from the antenna and route the cable down through the hole in the bracket. Place the antenna onto the bracket. Slide the retaining nut (with points facing up) back up the antenna cable and attach it securely onto the bottom of the antenna as shown. Tighten to 6.8 Nm. (5 ft-lb) Do not over tighten or damage to the antenna will result! 2. Open the roadside door: Position the antenna and bracket onto the front frame cross member above the control box as shown IMPORTANT: The antenna must be installed as close to the control box and coordinator module as possible for best wireless signal reception. Secure bracket to the frame with rivets (installer supplied). Secure the antenna cable to an existing harness with a tie band approximately 203 mm (8.00 in.) from the base of the antenna. This will provide a strain relief for the cable. 3. Open the control box door: Route the antenna cable into the control box through the main harness access hole. 26

Installation - Antenna (Carrier X Series Trailer Units) NOTE: Truck antenna bracket used on Carrier trailer unit. NOTE: On units equipped with a top cover or 2 27

Installation - Harness Connections (Carrier X Series Trailer Units) Installation Procedures 1. Attach antenna cable to coordinator module and tighten to 135 to 170 N cm (12 to15 in-lb). 2. Attach interconnect harness securely to coordinator module. 3. Attach GND terminal ring to ground stud under control box. 4. Attach VIN terminal ring to HC connector (HC-3 Pin 3). 5. Locate DSA wire: Splice DSA and RS wires together with a butt splice connector. Use a heat gun to shrink and seal connector. 6. Locate DSB wire: Splice the DSB and DS1wires together with a butt splice connector. Use a heat gun to shrink and seal connector. 7. SINGLE-TEMPERATURE UNITS - Locate wires DS2 and DS3 at interconnect harness: These wires are not used. Attach terminal splice caps onto ends of wires. 8. MULTI-TEMP UNITS -Locate REMS1 wire at 2MP3 and REMS2 wire at 2MP13 on the OEM harness. Cut REMS1 and REM S2 wires approximately 102mm (4.00 in.) down from each wired door switch connector. Strip 7mm (0.25 in.)from each wire coming from the connector. Connect DS2 wire from interconnect harness to REMS1 wire from connector with a butt splice and crimp securely. Connect DS3 wire from interconnect harness to REMS2 wire from connector with a butt splice and crimp securely. Attach terminal splice caps onto other ends of REMS1 and REMS2 wires. NOTE: Default setting for Carrier door sensors is Open = Low. Confirm this setting prior to WPAN configuration. Change WPAN as needed based on Door Configuration on page 33. ALL UNITS 9. Attach terminal splice caps onto ends of remaining unused interconnect harness wires FI1, FI2, FLR and FLS. Bundle and secure wires with band wraps. Secure coordinator module with band wraps to main harness as shown. 10. Reconnect positive (+) battery cable at battery and set unit controls to OFF. 11. Proceed to Installation - Pairing Sensors on page 30. 28

Installation - Harness Connections (Carrier X Series Trailer Units) to ground stud under control box Not Used to HC round connector HC-3 (Pin 3) to DSA IGN Run to DSB Not Used Secure coordinator module with band wraps to main harness as shown. Not Used on Single Temp Units NOTE: Remote sensor connections REMS1 and REMS2 are configurable on the Carrier Control. Verify the functionality of these connections prior to installing the WPAN.These connections may not be used on all Multi-Temp installations. 29

Pairing Pairing is the process of identifying a specific sensor with a particular zone and must be done before a sensor can be recognized by the CargoLink network. IMPORTANT: Keep all sensors away from the magnets for at least 60 seconds before beginning the pairing process. 1. Bring all sensors and magnets to be paired directly to the coordinator module. See important note above. 2. Verify the red PWR (Power) LED is illuminated on the module. 3. Press and release the switch on the module until the appropriate zone (Z1, Z2 or Z3) LED is illuminated. NOTE: Repeated presses of the switch will cycle through all selections before starting over at the top. 4. Once a zone is selected, press and hold the switch again until the green PAR (Pairing) LED illuminates. Three LED s will now be illuminated on the module indicating that it is in the pairing mode. NOTE: If no action is taken within 30 seconds, the green PAR LED on the module will begin flashing rapidly for 8 seconds and then go out. Repeat step 4 to restart the pairing procedures. 5. With the three LED s illuminated on the module, bring a magnet and sensor together quickly two times within one second and then remove the magnet. NOTE: The correct orientation of the sensor to the magnet must be followed or the pairing process will not work. See page 36 for the correct orientation of the door sensor. The LED on the sensor will quickly flash yellow four times, then a short pause, followed by a continuous flashing green. This indicates the sensor is now ready for the pairing process to begin. 6. While the green LED on the sensor is flashing continuously, bring the magnet and sensor together and apart three times in a row within 10 seconds. When the magnet is recognized by the sensor, the green LED on the sensor will turn off. Installation - Pairing Sensors A installation video is available on TSA Info Central After a few seconds, the PAR and sensor LED s will flash slowly indicating the sensor has been paired to the zone. If unsuccessful, the PAR green LED will flash rapidly and you will need to repeat the sequence starting at step #3. If successful, the sensor LED will flash green when the magnet is brought to or removed from the door sensor. 7. The zone LED on the module remains illuminated for next door sensor association and the pairing timer restarts. 8. To add another door sensor to the same zone - repeat procedure starting at step #4. 9. To add a door sensor to another zone - repeat procedure starting at step #3. IMPORTANT: Be sure to mark the zone programmed (1, 2 or 3) on the label provided on the door sensor so it will be installed in the correct zone. See pairing confirmation below. Pairing Confirmation To confirm which door sensors are paired to what zones, press and release the switch on the coordinator module until the red DR (Door) LED is illuminated. Remove the magnet from a door sensor and the zone LED (Z1, Z2 or Z3) will illuminate indicating what zone that particular door sensor has been paired to. Bringing the magnet back to the door sensor will turn the zone LED (Z1, Z2 or Z3) off. The DR mode will exit after approximately 5 minutes. NOTE: To remove one or more door sensors from a particular zone, see Unpairing Sensors on page 32. 30

Installation - Pairing Sensors Coordinator Module Correct Orientation of Fuel Sensor To Magnet Fuel Sensor Magnet Coordinator Module Switch Correct Orientation of Door Sensor To Magnet Door Sensor Thermo King logo must face magnet Magnet Coordinator Selections PWR = Power / Diagnostic FUEL - Fuel PAR = Pairing TEMP = Temperature Z1 = Zone 1 GUI = Graphical User Interface Z2 = Zone 2 01 = Option 1 Z3 = Zone 3 UN = Unpair DR = Door DI = Diagnostic 31

Unpairing Sensors Procedure NOTE: Unpairing applies to an entire zone. It is not possible to unpair a individual door sensor. 1. Verify the red PWR (Power) LED is illuminated on the coordinator module. 2. Press and release the sensor on the module until the red UN (Unpair) LED is illuminated. 3. Press and hold the sensor again for two seconds. The red UN LED will go out and the green PAR LED will begin flashing rapidly. 4. Press and release the sensor again until the yellow LED for the appropriate Zone to be unpaired is illuminated. Press and hold the sensor again for two seconds. Both PAR and Zone selected LED s will flash rapidly. 5. Open or close the selected door. The PAR LED will continue to flash rapidly. The yellow Zone LED will flash slowly and then continue to flash rapidly. The door sensor LED will flash slowly indicating the unpairing procedure was successful. 6. Repeat procedures for each zone as needed. The unpair mode will time-out in 60 seconds. To exit immediately, press and hold the sensor on the coordinator module until the PWR LED and UN LED are illuminated, then press the sensor to scroll through the modes until only the PWR led is illuminated. 7. Verify that the sensor has successfully been unpaired. The LED on door sensor should no longer flash when the magnet is either introduced to or taken away from the sensor unless the Pairing process is repeated as per the Pairing instructions. 32

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Installation - Door Sensors IMPORTANT INSTALLATION NOTES Each door sensor must be individually paired before being installed. See Installation - Pairing Sensors on page 30. The door sensor must be installed away from traffic (i.e. forklifts) or protected from it. The door sensor and magnet must be installed parallel to each other, not perpendicular. Long cross hair aligns to long cross hair. It is important that a maximum gap of 12.7 mm (0.50 in.) is maintained between the door sensor and the magnet. Shims may be required and must be a non-magnetic material (aluminum, wood, plastic, etc.) or the door sensor will not operate properly. Door sensors can also be used to control higher current loads such as trailer interior lighting when used with relay kit 40-1139. NOTE: Maximum current for each door sensor output DS1, DS2 and DS3 is 150 ma. Door Sensor Components The door sensor consists of a magnet, a sensor and non-magnetic mounting hardware. NOTE: Non-magnetic mounting hardware is included to install the sensors. If alternate hardware is used it must also be non-magnetic or the door sensor will not operate properly. The magnet is always mounted on the door. The sensor is always mounted to a stationary location. Do not mount door sensor on rivets. Mounting Locations The door sensor can be mounted on the inside or outside of either swing out or roll-up doors and can be mounted in various positions to accommodate particular applications. (Detail A) Ceiling Mounted 1. Mount the magnet flush with the top edge of the door and secure with supplied hardware. 2. Close the door and mount the sensor to the door sill parallel with the magnet, being sure the cross hairs are aligned and that the maximum gap of 12.7 mm (0.50 in.) is maintained. (Detail B) Floor Mounted 1. Mount the magnet flush with the bottom edge of the door and secure with supplied hardware. 2. Close the door and mount the sensor to the floor parallel with the magnet, being sure the cross hairs are aligned and that the maximum gap of 12.7 mm (0.50 in.) is maintained. (Detail C) Outside Door Installation 1. Mount the magnet flush with the top edge of the door and secure with supplied hardware. 2. Close the door and mount the sensor to the door sill parallel with the magnet, being sure the cross hairs are aligned and that the maximum gap of 12.7 mm (0.50 in.) is maintained. 34

Installation - Door Sensors 35

Configuration Modes Entering Feature Configuration Mode 1. Verify the red PWR (Power) LED is illuminated on the coordinator module. 2. Press and hold the switch. The PWR LED will turn off and each configuration selection LED (DR, PAR, UN, PWR) will illuminate sequentially every two seconds. These are the features which can be edited. 3. Release the switch when the feature to configure is selected. If no feature is selected, the sequence will stop at PWR. LABEL DR FUEL PAR UN PWR FEATURE CONFIGURATION Door Polarity Selection Door Time out Enable Fuel Input Source Proximity Pairing Factory Defaults None Door Configuration Indication: The Door LED will indicate the current configuration with some number of LED flashes as shown in the following table: NUMBER OF FLASHES DOOR POLARITY DOOR OPEN TIME OUT 1 Open = High Enable 2 Open = Low Enable 3 Open = High Disable 4 Open = Low Disable Select (press, hold, release) the switch on the coordinator module to change the current configuration. This can be repeated until the required configuration is displayed. A short press of the switch will exit the configuration mode and the last displayed selection will be used as the working configuration. 36

Configuration Modes Proximity Pairing Configuration Hold switch until PAR LED is illuminated. Indication: The Pair LED will indicate the current configuration with some number of LED flashes as shown in the following table: NUMBER OF PAR CONFIGURATION FLASHES 1 Off 2 Low 3 Medium 4 High Proximity pairing sets the required signal level used for pairing. If unintentional pairing occurs to door sensors on different trailers, the Proximity Pairing should be increased. Select (press, hold, release) the switch to change the current configuration. This can be repeated until the required configuration is displayed. A short press of the switch will exit the configuration mode and the last displayed selection will be used as the working configuration. 37

Configuration Modes Factory Defaults Configuration Hold switch until UN LED is illuminated. Indication: The Unpair LED will indicate the current configuration with some number of LED flashes as shown in the following table: NUMBER OF FLASHES UN CONFIGURATION 1 No Change 2 Factory Defaults Select (press, hold, release) the switch to change the current configuration. This can be repeated until the required configuration is displayed. Caution: Restoring Factory Defaults will clear all pairing information from the coordinator module. A short press of the switch will exit the configuration mode and the last displayed selection will be used as the working configuration. Exiting Feature Configuration Mode A short press of the switch will exit the configuration mode. This is like normal menu navigation. Switch selection (press, hold, release) is required to change the configuration. The normal HMI time out also applies to configuration mode. If a time out occurs, any configuration changes made prior to the time out will be lost. Door Status Output Press the switch repeatedly until the Door LED is illuminated. The application status will displayed by the Zone LED for each zone. The main reason for the feature is it will aid in installation to show door opening and closing events. Open will result in the Zone LED being on and Closed will result in the Zone LED being off regardless of door polarity configuration. See Door Configuration on page 36. NOTE: Door Status means that missing sensors will be ignored, stuck open sensors will be ignored, and all remaining sensors must be closed to report closed. 38

LED Indicator Codes DOOR SENSOR - LED Indicator Codes LED Color Flash Rate Event Troubleshooting RED 1 flash every 15 seconds Low Battery Replace Sensor GREEN Flashing Successful Pairing Event - Flash once a second for 4 seconds Normal - indicates pairing was successful GREEN/RED Flashing Successful Unpairing Event - Alternating green and red, 1 flash per second for 4 seconds and than turns off. Check door verification to determine if sensor is still associated to coordinator module. Retry unpairing procedure YELLOW 2 flashes every 15 seconds Door Ajar Error Check proximity of door sensor to magnet mounting. Confirm magnet is within 1/2 inch of the door sensor when the door is closed. Adjust sensor as necessary. YELLOW 1 flash Lost communication with coordinator module. Triggered by a door open event, the yellow LED flashes 1 time after the standard door event indication. YELLOW/RED 1 flash Firmware Update in Progress - Alternating yellow and red LED flashes 1 time every 5 seconds, Check antenna connection at coordinator module. Inspect antenna for damage. Inspect sensor installation to make sure there are no obstructions near the sensor that could impede wireless communication. Normal GREEN 1 flash Door Open - The green LED flashes once. Normal GREEN 1 flash Door Closed - The green LED flashes once. Normal 39

LED Indicator Codes COORDINATOR MODULE - LED Indicator Codes LED Color Flash Rate Event Troubleshooting RED Solid Normal Normal RED Flashing Rapidly Internal Error Power cycle by unplugging main 23 pin connector from coordinator module for 30 seconds and then reconnect. Replace coordinator module. NONE No LED Illuminated No power indicated Check GND and VIN connections on harness. Check/replace 2A fuse on harness. Replace coordinator module. GREEN Flashing Unsuccessful Pairing - The PAR green LED will flash rapidly. Retry pairing process Check proximity pairing setting or move sensor closer to the antenna. 40

Troubleshooting NOTE: Additional troubleshooting utilities for both wired connections and wireless sensor system performance are available as part of the Thermo King CargoLink Service tool software package. Please contact your Thermo King dealer for details. Antenna 1. Unplug antenna cable from coordinator module. 2. Using a digital volt meter (DVM) set to measure resistance. NOTE: Be sure to zero out or calibrate resistance measurement tool, verify by touching probes together, reading should be very close to 0.0 ohms. 3. Measure the resistance across the antenna cable: Hold one probe on the center connector. Hold the other probe on the outside of the connector. The results should be under 2 ohms. 4. Replace antenna and cable assembly if faulty. Coordinator Wiring 12 Volt present on DS1 wire when door is open. 12 Volts constant on VIN and RS wires. VIN draws.2 of an Amp constant..4 total amperage drawn (VIN and RS wires) with door open. Pairing For issues with door sensor pairing or to confirm pairing has been completed successfully, please refer to See Installation - Pairing Sensors on page 30. For more information regarding door sensors, see the CargoLink service tool diagnostic manual (TK 55733-11-OD). Please contact your Thermo King dealer for details. 41

IMPORTANT NOTICE USING WIRELESS DEVICES ON AIRPLANES The Federal Communication Commission (FCC) rules prohibit the use of cellular phones using the 800 MHz frequency and other wireless devices on airborne aircraft. In addition to the FCC s rules, the Federal Aviation Administration (FAA) prohibits in-flight use of wireless devices because of potential interference to the aircraft s navigation and communication systems. CargoLink sensors are a wireless device and are included in these FCC and FAA regulations. 42

Installation - Check List Coordinator Module secured with band wraps inside the control box. Antenna installed securely to bracket and bracket installed securely to unit or trailer wall. Antenna cable installed and routed to avoid contact with hot components such as exhaust pipes, muffler, or rotating components such as belts or pulleys. All electrical splice connections are crimped securely and heat shrunk. All electrical wiring inside the control box was neatly routed and secured with tie bands. Each door sensor was programmed prior to installation. With unit running, door sensor operation was checked and verified they function properly. Release unit to customer. 43

2012 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper Ingersoll Rand s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.