DoKaSch Opticooler RAP User manual

Operation Manual
Opticooler RAP / RKN
Opticooler
Temperature. That Arrives.
Version: 1.30
Issued: 09. May 2019

Opticooler | Temperature. That Arrives.
Author: M. Thran
Operation Manual Opticooler-TS V1 30_ 2019_05_09.docx09
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Version: 1.30
Issued: 09. May 2019
This operating manual is applicable to:
DoKaSch TEMPERATURE SOLUTIONS GmbH
Container Type
Part Number
RAP Opticooler
BUD 09010-2
RKN Opticooler
BUD 01010
Version
Issue Date
Revision
1.00
16. January 2015
-/-
1.10
22. December 2015
Page 11, 13, 31, 32, 40,
41,Chapter 3.2
1.20
25. February 2016
Chapter 3.2.2.1, 3.2.2.2,
4.3.3
1.30
09. May 2019
All pages

Opticooler | Temperature. That Arrives.
Author: M. Thran
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Mönchhofallee 7 | 65451 Kelsterbach | Germany
Phone: [phone] | Telefax: [phone]
[e-mail] | www.dokasch-ts.com
Index
Copyright............................................................................................................................... 6
Amendments......................................................................................................................... 6
Acronyms.............................................................................................................................. 6
1. Introduction .................................................................................................................... 7
1.1. Safety Advices ........................................................................................................ 7
1.1.1. Warnings.......................................................................................................... 7
1.1.2. Notes ............................................................................................................... 7
1.2. Scope of the Operation Manual............................................................................... 7
1.3. General Safety Rules.............................................................................................. 7
2. The Opticooler................................................................................................................ 8
2.1. Description.............................................................................................................. 8
2.2. Views ...................................................................................................................... 8
2.2.1. RAP Opticooler ................................................................................................ 8
2.2.2. RKN Opticooler................................................................................................ 9
2.3. Design..................................................................................................................... 9
2.3.1. Base Platform .................................................................................................. 9
2.3.2. Cargo Compartment......................................................................................... 9
2.3.3. Doors..............................................................................................................10
2.3.4. Equipment Compartment ................................................................................10
2.3.5. Charging Unit..................................................................................................10
2.3.6. Air Inlets and Outlets.......................................................................................11
2.3.7. Labels.............................................................................................................11
2.3.8. Document Pouch / Place Labels Here.............................................................12
RAP ........................................................................................................12
RKN.........................................................................................................12
2.3.9. Straps .............................................................................................................13
2.3.10. Touch Screen Control Panel........................................................................13
2.4. Touch Screen Displays ..........................................................................................14
2.4.1. Start Screen...................................................................................................14
2.4.2. Basic Screen..................................................................................................14
2.4.3. Confirmation Screen .......................................................................................15
2.4.4. Program Screen..............................................................................................16

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2.5. Alerts......................................................................................................................17
2.5.1. Types of Alerts...............................................................................................17
2.5.2. Sequence of Alerts..........................................................................................17
3. Use and Operation of an Opticooler ..............................................................................18
3.1. General Rules........................................................................................................18
3.1.1. Container ........................................................................................................18
3.1.2. Pre Conditioning..............................................................................................18
3.1.3. Battery Capacity..............................................................................................18
3.1.4. Ambient Temperature Range..........................................................................19
3.2. Charging ................................................................................................................19
3.2.1. Charging Time.................................................................................................19
3.2.2. Charging Cable Bin.........................................................................................19
Position of the Charging Cable Bin...........................................................19
Charging Cable Bin Contents...................................................................20
..................................................................................................................................20
Preparing the Charging Procedure...........................................................21
3.2.3. Charging Procedure........................................................................................22
3.3. Use of Containers ..................................................................................................23
3.3.1. Switch On.......................................................................................................23
3.3.2. Container Programming.................................................................................24
3.3.3. Programming the Container with a Variable Temperature (Program 3) ...........25
3.3.4. Stop a Program..............................................................................................28
3.3.5. Switch Off........................................................................................................29
3.3.6. Acknowledgment of an Alert............................................................................30
Alert 1-3...................................................................................................30
Alert 4 ......................................................................................................30
3.4. Preconditioning ......................................................................................................31
3.4.1. Preconditioning of the Container in a Temperature Controlled Room..............31
3.4.2. Preconditioning of the Container in a Non-Temperature Controlled Room ......31
4. Cargo and Container Handling......................................................................................33
4.1. General Rules........................................................................................................33
4.2. Cargo.....................................................................................................................33
4.3. Loading..................................................................................................................33
4.3.1. Loading Instructions........................................................................................33
4.3.2. Loading Procedure..........................................................................................34
4.3.3. Handling Alerts after Loading..........................................................................34

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4.4. Container Handling ................................................................................................35
4.4.1. General Rules.................................................................................................35
4.4.2. Handling..........................................................................................................35
Handling in General: ................................................................................35
Handling of an Empty Container...............................................................35
Handling of a Loaded Container...............................................................35
4.5. Cleaning.................................................................................................................36
4.6. Storage of the Container........................................................................................36
4.6.1. General...........................................................................................................36
4.6.2. Storage of an Empty Container.......................................................................36
4.6.3. Storage of a Loaded Container .......................................................................37
5. Troubleshooting ............................................................................................................38
5.1. No Display..............................................................................................................38
5.2. Batteries do not charge..........................................................................................39
5.3. Alert: Temperature Deviation..................................................................................40
5.4. Alert: Door open.....................................................................................................41
5.5. Alert : Battery Nearly Empty...................................................................................42
6. Technical Specification..................................................................................................43
6.1. RAP Opticooler ......................................................................................................43
6.2. RKN Opticooler......................................................................................................44

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Copyright
Copyright © 2014 DoKaSch GmbH Aluminiumverarbeitung, Air Cargo Equipment + Repair.
This Operational Manual was written and edited by the manufacturer of the Opticoolers “DoKaSch
GmbH Aluminiumverarbeitung, Air Cargo Equipment + Repair”, and published and distributed by
“DoKaSch TEMPERATURE SOLUTIONS GmbH”.
The reproduction and distribution of this publication is permitted for internal use only. This
publication may not be distributed to third parties without the prior written permission of the above
mentioned DoKaSch-Group companies.
Amendments
The content of this manual is for your information and may be changed without notice. Care has
been taken to accuracy during the preparation of this manual. However, the DoKaSch-Group
assumes no liability for incorrect or missing information in this document or for the use of
information contained herein.
DoKaSch GmbH reserves the right to change or revise the product design or the product manual
without reservation. DoKaSch GmbH is not obliged to inform about such amendments or
revisions.
Acronyms
OM Operation Manual
HMI Human Machine Interface, control panel

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1. Introduction
1.1. Safety Advices
The following symbols are used in this manual to identify important information and instructions.
1.1.1. Warnings
This symbol characterizes information and instructions that must be strictly observed. Non-
observance may result in personal injury or death.
This symbol characterizes information and instructions that must be strictly observed. Non-
observance may result in a container damage or failure.
1.1.2. Notes
This symbol characterizes important information and instructions for the use of the RAP / RKN
Opticooler. Such information and instructions have a major impact on the quality of the transport
and the total lifetime of the containers.
1.2. Scope of the Operation Manual
This manual contains information on the intended use, operation, transport and storage of the
DoKaSch RAP Opticooler, part number BUD 09010-2 and the DoKaSch RKN Opticooler, part
number BUD 01010.
Even if the container is used properly and as intended, danger caused by the use of the container
may arise that could potentially cause injuries or damages.
1.3. General Safety Rules
In addition to the safety notes and rules in this manual, all statutory regulations in force in the
respective countries apply for the use of the RAP / RKN Opticooler, e.g.: “IATA Dangerous Goods
Regulations”, import and customs regulations.
Prior to the use of the RAP / RKN Opticooler, the OM must be read. All warnings and safety notes
listed therein must be observed and followed. Furthermore, the information, warning labels and
instructions on the container must be adhered to.
!!!Warning!!!
!Note!
!!Caution!!

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2. The Opticooler
2.1. Description
The RAP / RKN Opticooler is a temperature controlled container specifically developed to transport
temperature sensitive cargo. The container is designed to keep pre-cooled goods at their
temperature. Any cargo compartment temperature in the range of +2°C (35.6°F) to +30°C (86°F)
may be selected for the transport. The container is able to maintain the temperature in the cargo
compartment for several hours with a max. deviation of ± 3°C (± 5,4°F) at an outside temperature
range of -30°C(-22°F) to +50°C (122°F). A data recorder is installed, documenting values such as
cargo compartment temperature, temperature deviations and door openings. The container is
equipped with rechargeable batteries to ensure operation where there is no external power
available, e.g. on aircrafts.
2.2. Views
2.2.1. RAP Opticooler
Fig. 2.1 Door side
Fig. 2.2 Left side
Fig. 2.4 Right side
Fig. 2.3 Rear side

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2.2.2. RKN Opticooler
2.3. Design
2.3.1. Base Platform
The container consists of a base platform, a separate cargo compartment and an equipment
compartment. The base pallet is adapted to fit the container in a suitable locking system in the
aircraft cargo compartment
2.3.2. Cargo Compartment
The cargo compartment of the RAP Opticooler has a capacity of 5 europallets or 4 CP-1 pallets.
The RKN Opticooler has a capacity of 1 europallet or 1 CP-1 pallet. Several attachment points are
available at each sidewall to secure the cargo.
Fig. 2.6 Left side
Fig. 2.5 Door side
Fig. 2.7 Right side
Fig. 2.8 Rear side

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2.3.3. Doors
The RAP Opticooler has two doors while the RKN Opticooler has one door. These doors can be
opened to approx. 270° and have to be secured with the provided door holders when completely
opened. The door handles can be sealed.
2.3.4. Equipment Compartment
The equipment compartment contains the aggregates as well as the control system and is not
accessible. It must only be opened by personnel authorized by DoKaSch for maintenance and
repair.
2.3.5. Charging Unit
The container is equipped with two independent charging units. The power is supplied via the
external CEE coupling.
Fig. 2.9 CEE coupling charging unit
Fig. 2.11 Electrical requirements
Fig. 2.10 CEE coupling charging unit

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2.3.6. Air Inlets and Outlets
The container has various air inlets and outlets at the equipment compartment. These are essential
for the correct function of the container and must not be covered or blocked. Covering or blocking
may reduce the performance of the container and cause temperature deviation or a reduction of
battery running time. Warm exhaust air is discharged through the upper ventilation grille. It should
be noted that this exhaust air may significantly increase the surrounding temperature. Ventilation
grilles that must not be covered are marked with a DO NOT COVER label.
The warm exhaust air may heat up the ventilation grilles as well as the surrounding surfaces and
cause burns in the worst case. Respective surfaces are marked with the following symbol:
2.3.7. Labels
Various labels are applied on and in the container. These labels contain instructions and information
that must be strictly followed. They shall avoid potential danger caused by the handling personnel
and faults during a transport. The labels do not replace a training of personnel. Solely observing
the labels is not sufficient to handle a container without danger to oneself, to others or to the goods.
Fig. 2.12 Label DO NOT COVER
!!!Warning!!!
DO NOT COVER
Fig. 2.13 Label Hot
Surface

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2.3.8. Document Pouch / Place Labels Here
The container is equipped with a transparent document pouch for any cargo documents. It is fixed
at the rear side of the RAP and at the left side of the RKN. In addition to the document pouch, areas
at the door and the left sidewall ( only RAP ) are marked with a place labels here label. Any adhesive
labels, barcodes, etc. must be attached to these areas only.
RAP
Fig. 2.14 Rear side with document pouch
Fig. 2.15 Place labels here
RKN
Fig. 2.16 Left hand side with document pouch Fig. 2.17 Place labels here
Pouch for
documents
Place labels here
Place for additional
labels / information
Pouch for
documents

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2.3.9. Straps
Handstraps are attached to all four container corners. They facilitate maneuvering the container on
a roller bed. The container must be moved with the straps by hand only. Make sure one can let go
of the handstrap easily at any time, particularly refraining from inserting the hand through the loop.
Otherwise, a significant risk of injury arises in the event of an uncontrolled container movement.
Generally, ensure a safe standing when moving the container.
2.3.10. Touch Screen Control Panel
The container can be programmed for the transport with a touch screen. The screen also provides
different status messages and information for the operator. There is main switch on the left side of
the touch screen to switch the container on and off.
Different IT-interfaces are located left hand of the display labeled as “service” or “data”. They are
for internal maintenance purpose only and are not relevant for the user. Only personnel authorized
by DoKaSch is allowed to use these interfaces.
A flash lamp is located below the touch screen which flashes in case of an alert during transport.
Fig. 2.18 Control cover with HMI
Flashing light
indicating an alert
Touch screen
Control unit (HMI)
)
Service interface
Data interface
Main switch
Service interface

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2.4. Touch Screen Displays
The displays provide information about the operating condition of the container. There are four
different displays:
2.4.1. Start Screen
Display after switching the container on and while booting.
2.4.2. Basic Screen
Display when the container is switched on, but no temperature is selected and no temperature
program is active.
The symbols located at the bottom of the screen and in the top right-hand corner are for internal
maintenance purposes only and are not relevant for the user
Current date
and time
Charging symbol
(flash), only
displayed while
charging.
Current battery
capacity
Alert
acknowledge
button
Fig. 2.19 Start screen
Fig. 2.20 Basic screen
Temperature control mode
Status bar
ULD-ID
Message
window
Message type icon:
•i = information
•red bell = alert
External
temperature
Buttons to start a
temperature
program

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2.4.3. Confirmation Screen
The confirmation screen is used to confirm or refuse a selection. Confirm with YES to continue or
with NO to return to the previous screen.
Display at a program start:
Display at a program end:
Fig. 2.21 Confirmation Screen: Start
Fig. 2.22 Confirmation Screen: STOP

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2.4.4. Program Screen
The program screen is displayed as long as a temperature program is active.
Alert messages are displayed until the operator rectifies the cause of the alert and acknowledges
each alert individually.
Selected program
Current battery
capacity
Current
humidity in
the cargo
compartment
Current
temperature in
the cargo
compartment
Temperature control mode: running on a
set temperature (active program)
Button to end a
program
Alert
acknowledge
button
Fig. 2.23 Program screen
!Note!
External
temperature
Status bar
Current alert or
message
Selected
temperature
Message type icon:
•i = information
•red bell = alert

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Collective alarm
2.5. Alerts
2.5.1. Types of Alerts
There are three operational alerts:
1. Alert message: Temp. deviation.
The cargo compartment temperature is out of
range. The range is set temperature ± 3°C
2. Alert message: Door open.
The doors are not closed properly.
3. Alert message: Batt. nearly empty.
The battery capacity is below 20%.
Alerts 1 - 3 are indicated by an orange
flashing light and a message on the screen.
There is one technical alert:
4. This alert indicates a malfunction of the
temperature control system.
This alert is shown in the status bar on the top
of the display as a red flashing line and the
message: collective alarm.
The orange flashing light will NOT light up.
If an alert is indicated, the reason for the alert must be rectified immediately. If this is not possible,
the container must be moved as soon as possible into a temperature-controlled facility with the set
transport temperature. Otherwise there is a high risk of temperature deviation with negative impact
on the transported cargo up to a total spoilage of the cargo.
2.5.2. Sequence of Alerts
The alerts are display by priority:
1. “Temp. deviation”
2. “Door open”
3. “Batt. nearly empty”
Alert 4 is displayed independently from all other alerts.
Fig. 2.25 Collective alert
!!Caution!!
Fig. 2.24 Alert 1-3, flash light

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3. Use and Operation of an Opticooler
3.1. General Rules
3.1.1. Container
Prior to the use, the container must be checked for damages. The following documents are the
basis for assessing possible damages and wear:
- CMM (25-50-72: RAP, 25-50-69: RKN)
- Wear and Tear description (Traces of use) Opticooler
Do not lock persons or living beings up in the cargo compartment. Danger of suffocation.
3.1.2. Pre Conditioning
The RAP / RKN Opticooler is designed to maintain the temperature of pre-cooled goods. The
container is not designed to cool down or heat up goods. Therefore, preconditioning of the goods
and the container to the exact set temperature is essential.
Improper conditioning of goods leads to a shorter operating time. The container may even not be
able to cool down (or heat up) the cargo to the required temperature. Risk of goods loss.
3.1.3. Battery Capacity
Prior to each transport, the battery capacity must be checked. The container must have a minimum
capacity of 95 % before a transport can start.
The alert “Batt. nearly empty” appears when the battery capacity is below 20%. Plug the container
in within 15 minutes !
A lower battery capacity may result in malfunctions, if the Opticooler runs on battery only. Risk of
goods loss.
When running on battery only, the Opticooler will stop any operation if the battery capacity falls
below 2% –5% (depending on the battery condition).
It will immediately start operation again with the last set temperature when plugged in again, even
if the battery was totally empty for a while.
!!!Warning!!!
!
!!Caution!!
!!Caution!!

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3.1.4. Ambient Temperature Range
The container is designed to operate within an external temperature range between minus 30°C
(minus 22°F) and plus 50°C (plus 122°F). Within this range, the temperature in the cargo
compartment can be kept at the selected value.
Avoid direct sunlight exposure and strong cold winds in any case.
When running on battery, temperatures below -20°C (-4°F) or above +40°C (+104°F) will reduce
the operating time heavily.
3.2. Charging
3.2.1. Charging Time
The container is equipped with two independent charging units and can be charged with one or both
at the same time.
The container charges the fastest at an external temperature between +15°C (59°F) and +20°C
(68°F) using both chargers. Deviations thereof extend the charging time.
The autonomous operating time (battery operation) varies considerably depending on ambient
conditions and cargo. Any possibility to charge the battery must be used.
3.2.2. Charging Cable Bin
The container is equipped with two 2.5 m long charging cables. The cables have a plug type F.
For other sockets, the container is equipped with two sets of adapters of type B, G, J and I. The
cables and adapters are contained within the cable bin. It is mounted at the rear side of the RAP
and at the left side of the RKN.
Position of the Charging Cable Bin
Fig. 3.2 Charging Cable Bin, left
side (RKN)
!!Caution!!
!Note!
Fig. 3.1 Charging Cable Bin, rear
side (RAP)

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Charging Cable Bin Contents
Type F Type B Type G
Used almost everywhere Mainly used in the USA, Mainly used in the
in Europe & Russia, Canada, Mexico & Japan United Kingdom, Ireland,
except for the UK & Ireland Malta, Malaysia & Singapore
Fig. 3.5 Plug Type F
Fig. 3.6 Plug Type B
Fig. 3.7 Plug Type G
Fig. 3.3 View into the Charging
Cable Bin
Fig. 3.4 Overview of the
different adapter types