Trane Thermo King V-520 RT SPECTRUM 50 Installation Manual
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Trane Thermo King V-520 RT SPECTRUM 50 Installation Manual

Trane Thermo King V-520 RT SPECTRUM 50 Installation Manual

Multi-temperature systems truck edition
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Installation Manual
Truck Edition
V-520 RT SPECTRUM
Model 50
Multi-Temperature Systems
Revision 7
TK-55455-18-IM
January 2016

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Summary of Contents for Trane Thermo King V-520 RT SPECTRUM 50

  • Page 1 Installation Manual Truck Edition V-520 RT SPECTRUM Model 50 Multi-Temperature Systems Revision 7 TK-55455-18-IM January 2016...
  • Page 2 Installation Manual Truck Edition V-520 RT SPECTRUM Model 50 Multi-Temperature Systems TK 55455-18-IM (Rev. 7, 01/16) 2020 Trane Technologies © Copyright...
  • Page 3 V-520 RT Installation Manual Release History Released (07/12) Rev. 1 (06/12) Pages 8, 10, 20 and 56: added silicone sealant update, page 39; increased compressor oil quantity. Rev. 2 (09/13) Page 5: changed compressor oil from 203-513 to 203-515. Rev. 3 (12/13) Pages 8, 13 and 14: changed text and art to clarify the minimum distance required from the cargo wall to the rear of the evaporator with or without heat option.
  • Page 4 Introduction This manual was written to assist with the installation of a Thermo King V-520 RT SPECTRUM unit with two ES300 remote evaporators onto trucks designed and built for refrigerated applications. Due to its complexity, you should not attempt this installation unless you: •...

  • Page 5: Table Of Contents

    Table of Contents Safety Precautions ..........6 Important - Suction Line Routing and P-Trap Formation .
  • Page 6 Recover Refrigerant 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. In addition, service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians.

  • Page 7: Safety Precautions

    Safety Precautions symbol appears next to a point that is particularly important: DANGER: Addresses a circumstance that, if encountered, will lead to death or serious injury. WARNING: Addresses a circumstance that, if encountered, might lead to death or serious injury. CAUTION: Addresses a circumstance that, if encountered, may cause damage to equipment or minor injury.
  • Page 8 Safety Precautions (continued) Battery Installation and Cable Routing Refrigerant WARNING: Improperly installed battery cables could result in WARNING: Although fluorocarbon refrigerants are classified fire or explosion! Battery cables must be installed, routed and as safe refrigerants, certain precautions must be observed secured properly to prevent them from rubbing, chaffing or when handling them or servicing a unit in which they are making contact with hot, sharp or rotating components.

  • Page 9: Tips For A Successful Installation

    Tips for a Successful Installation IMPORTANT INSTALLATION INFORMATION • Verify tools and special equipment required for the installation are available and in good operating condition before beginning the • Read this Installation Manual to understand how all components are to installation.
  • Page 10 Tips for a Successful Installation (continued) • Always lubricate hose fittings with refrigerant oil when assembling to • The In-Cab controller must only be mounted inside the vehicle. refrigeration hoses. It should be accessible and visible from the drivers position while not interfering with the driver’s mobility, visibility or access to the vehicle •...

  • Page 11: Required Tools

    Required Tools 1. Protective Eye Wear 12. Voltmeter 2. Drill 13. Neutral/Alcohol Cure Silicone Sealant (203-436) or equivalent 3. Drill Bits 14. Manifold Gauge Set 4. Tape Measure 15. Evacuation Station 5. Hand Saw 16. Reclaiming Station 6. File 17. Electronic Leak Detector 7.
  • Page 12 Required Tools...

  • Page 13: Dimensions And Weight - Model 50 Spectrum

    Dimensions and Weight - Model 50 SPECTRUM Approximate Weight: Complete Model 50 SPECTRUM - (Refrigeration, Power Pack and Condenser Modules) = 86 kg (190 lbs.) Dimensions 1137 mm (44.75in.) 2159 mm (85.00 in) 229 mm (9.00 in.)

  • Page 14: Dimensions And Weight - Es300 Host Evaporator

    Dimensions and Weight - ES300 Host Evaporator Approximate Weight: ES300 Host Evaporator = 18 kg (40 lbs.) Dimensions 524 mm (20.7 in.) 183 mm (7.2 in.) 976.8 mm (38.5 in.) 152 mm (6.0 in.) 455 mm (18.0 in.) 152 mm (6.0 in.) 892 mm (35.0 in.) 147 mm (5.8 in.)

  • Page 15: Dimensions And Weight - Es300 Remote Evaporator

    Dimensions and Weight - ES300 Remote Evaporator Evaporator with SPECTRUM Assembly Approximate Weight: ES300 Remote Evaporator with SPECTRUM Assembly = 33 kg (72 lbs.) Dimensions Evaporator Only 662.9 mm (26.1 in.) 183 mm (7.2 in.) 976.8 mm (38.5 in.) 152 mm (6.0 in.) 455 mm (18.0 in.) 152 mm (6.0 in.) 892 mm (35.0 in.)

  • Page 16: Dimensions - Refrigeration Module Mounting Holes

    Dimensions - Refrigeration Module Mounting Holes Choose one mounting hole per section Dimensions 1107.4 mm (43.60 in.) 466.3 mm (18.36 in.) 393.7 mm (14.50 in.) 235.0 mm (9.25 in.)

  • Page 17: Dimensions - Power Pack Module Mounting Holes

    Dimensions - Power Pack Module Mounting Holes Dimensions 1107.4 mm (43.60 in.) 466.3 mm (18.36 in.) 393.7 mm (14.50 in.) 235.0 mm (9.25 in.)

  • Page 18: Dimensions - Condenser Module Mounting Holes

    Dimensions - Condenser Module Mounting Holes...

  • Page 19: Dimensions - Hmi

    Dimensions - HMI 140 mm (5.50 in.) 46 mm (1.80 in.) 12 mm (.50 in.)
  • Page 20 BLANK PAGE...

  • Page 21: Installation - Vehicle Powered Compressor

    Installation - Vehicle Powered Compressor Installation Compressor Ground Wire NOTE: Always confirm compressor installation kit is correct for your Install the chassis ground wire to the compressor frame using the supplied vehicle before preceding with the installation. hardware. Ensure the mounting location on the chassis is free of any paint. Use anti-corrosion gel (203-377) or equivalent on ground wire connection Add only 4 oz.
  • Page 22 Installation - Vehicle Powered Compressor Compressor Ground Wire IMPORTANT: Failure to install the compressor ground wire to the chassis may result in intermittent clutch operation and premature clutch failure!

  • Page 23: Installation - (2) Es300 Evaporators

    Installation - (2) ES300 Evaporators Support Plates Alternative Installation Method Thermo King recommends securely installing steel support plates with (without pre-installed support plates) mounting studs (installer supplied) directly to the truck’s interior roof 1. Locate and mark the center line (C/L) of the interior compartment structure to safely support the weight of the ES300 evaporators prior to ceiling.
  • Page 24 Installation - (2) ES300 Evaporators Alternative Installation Method Preferred Installation Method...

  • Page 25: Installation - Refrigeration Module

    Installation - Refrigeration Module Support Plates Alternative Installation Method (without pre-installed support plates and pre-cut access hole) Thermo King recommends securely installing steel support plates (installer supplied) to the vehicle’s inner roof support structure prior to insulating 1. Remove plastic cover from refrigeration module and trim foam gasket and finishing the interior ceiling.
  • Page 26 Installation - Refrigeration Module Alternative Installation Method Preferred Installation Method...

  • Page 27: Installation - Power Pack Module

    Installation - Power Pack Module Support Plates Alternative Installation Method Thermo King recommends securely installing steel support plates (installer (without pre-installed support plates and pre-cut access hole) supplied) to the vehicle’s inner roof support structure prior to insulating NOTE: It is recommended the copper tubing be installed onto the and finishing the interior ceiling.
  • Page 28 Installation - Power Pack Module Alternative Installation Method Preferred Installation Method...

  • Page 29: Installation - Condenser Module

    Installation - Condenser Module Support Plates Alternative Installation Method (without pre-installed support plates) Thermo King recommends securely installing steel support plates (installer supplied) to the vehicle’s inner roof support structure prior to insulating 1. Trim the foam gasket away from the two drain holes located in the and finishing the interior ceiling.
  • Page 30 Installation - Condenser Module Alternative Installation Method Preferred Installation Method...

  • Page 31: Fabricating Refrigeration Hoses

    Fabricating Refrigeration Hoses TK 2000 Assembly System Assembly Materials Checklist • Hose Fitting Tools (204-1045 and 204-1128) The TK 2000 System is designed for assembly with Multi-Refrigeration hose only. • Hose Cutting Tools (204-677) The benefits are virtually endless: • TK 2000 Multi-Refrigerant Hose •...
  • Page 32 Fabricating Refrigeration Hoses Cut the Hose Slip on Two Clamps 1. Cut the hose to proper length with an appropriate cutting tool. 2. Install two proper- size clips onto the cut end of the hose. Orientation of Hand-held hose cutter (204-677) has been specially designed for the clips does not affect the performance of the connection.
  • Page 33 Fabricating Refrigeration Hoses Oil the Nipple 4. Insert the nipple into the hose. To ensure that the nipple is fully inserted, check the gap between the cut end of the hose and the 3. Lubricate the nipple with a generous amount of the refrigeration or A/C shoulder on the nipple.
  • Page 34 Fabricating Refrigeration Hoses Snap on the Cage Slide the Clips 5. Snap the cage into the groove on the nipple. The arms should extend 6. Slide the clips over the cage arms and into the channels on each arm. over the hose length. When the cage has been carefully installed in the cage grove, the cage will be able to rotate in the grove.
  • Page 35 Fabricating Refrigeration Hoses Correct Nose of the pliers should be firmly seated under the assembly bump and lock latch. If the pliers are not kept square during closing the clip, the clasp may have Incorrect an offset. Use the pliers to correct the clasp alignment.
  • Page 36 Fabricating Refrigeration Hoses Minimum Bend Radii CAUTION: TK 2000 Speedy Clip System components should not be reused. Failure to follow these instructions and/or the use of All hoses must be routed as to maintain the TK 2000 Speedy Clip System hose with fittings supplied by other minimum bend radii given in the table below.

  • Page 37: Important - Suction Line Routing And P-Trap Formation

    Important - Suction Line Routing and P-Trap Formation Best Practices That Must Be Followed (Refer to the illustration on following page) 1. All hose bends must maintain at least minimum bend radii with no kinks. See “Minimum Bend Radii” on page 35. 2.
  • Page 38 Important - Suction Line Routing and P-Trap Formation ACCEPTABLE From Unit...

  • Page 39: Installation - Refrigeration Tubes To Compressor

    Installation - Refrigeration Tubes to Compressor Power Pack Module Compressor Connections NOTE: The compressor contains oil. Tip the compressor forward to prevent oil from spilling and place rags under the fittings before removing the protective caps to catch any oil. Replace any oil that is spilled.
  • Page 40 Installation - Refrigeration Tubes to Compressor...

  • Page 41: Installation - Refrigeration Hoses

    Installation - Refrigeration Hoses IMPORTANT: All hose bends must maintain at least minimum bend radii with no kinks. See “Minimum Bend Radii” on page 35. Condenser Module Connections 5. Liquid Line - HOST (Frozen Compartment) 1. Liquid Line • Fabricate #6 hose from liquid injection fitting on the condenser module to liquid fitting on HOST unit.
  • Page 42 Installation - Refrigeration Hoses Manifold Fitting C - Connect to vehicle compressor only Manifold Fitting A - Connect to evaporator only...

  • Page 43: Installation - Refrigeration Hoses To Vehicle's Compressor

    Installation - Refrigeration Hoses to Vehicle’s Compressor IMPORTANT: All hose bends must maintain at least minimum bend radii with no kinks. See “Minimum Bend Radii” on page 35. Connections at Refrigeration Module Connections at compressor 1. Discharge Line The refrigeration hoses must be routed from the cargo box, along the vehicle’s chassis to the engine compartment and compressor while •...
  • Page 44 Installation - Refrigeration Hoses to Vehicle’s Compressor Manifold Fitting C Connect to Vehicle’s Compressor Only TOTAL AMOUNT OF OIL REQUIRED MODEL 50 SPECTRUM = 32 ounces total Add 4 oz. to the road compressor, see pages 20-21. Add 23 oz. into the suction hose, see pages 40-41. NOTE: 5 oz.

  • Page 45: System Leak Check And Evacuation

    System Leak Check and Evacuation Solenoid Valve Positions IMPORTANT: Do not install a valve magnet on the Condenser Block Off Solenoid (if present). The condenser block off Solenoid is a normally IMPORTANT: The Liquid Injection Solenoid Valve, Liquid Solenoid open solenoid - installing a valve magnet will close the solenoid. Valves and the Defrost Solenoid Valve must be in the OPEN position 3.
  • Page 46 System Leak Check and Evacuation...

  • Page 47: Installation - Electrical Connections

    Installation - Electrical Connections Rooftop Connections 1. Route the power harness from the Refrigeration Module to the Power Pack Module. 2. Connect the 12-pin connector to the mating connector on the Power Pack Module. 3. Insert the two electrical barrel connectors (2R-01) and (CH10) into the mating terminal connector block on the Power Pack and tighten securely.
  • Page 48 Installation - Electrical Connections...

  • Page 49: Electrical Connections - Evaporator(S)

    Electrical Connections - Evaporator(s) Installation Remote Evaporator Route the Evaporator Harness from the V-520 condenser into the cargo 8. Defrost Termination Switch (12A, CHB2) to mating connector. box and make the following connections: 9. Hot Gas Defrost Solenoid (28, CHS) to mating connector. 10.
  • Page 50 Electrical Connections - Evaporator(s)

  • Page 51: Installation - Standby Power Receptacle

    Installation - Standby Power Receptacle Procedures NOTE: Thermo King recommends a 20 amp fused power source for electric standby operation. • Verify the receptacle box is wired for the correct voltage for your application. • The standby receptacle box should be installed securely to the exterior of the vehicle.
  • Page 52 Installation - Standby Power Receptacle...

  • Page 53: Installation - Evaporator Drain Hoses

    Installation - Evaporator Drain Hoses REMOTE Evaporator HOST Evaporator 1. Cut the drain hose into two sections of suitable length and attach each 1. Cut the drain hose into two sections of suitable length and attach onto drain hose onto the evaporator drain tubes. the drain tubes.
  • Page 54 Installation - Drain Hoses REMOTE Evaporator HOST Evaporator Defrost Heater Wires...

  • Page 55: Installation - Hmi

    Installation - HMI Procedures 1. From the cargo area, route the multi-conductor Controller Harness with wire colors Blue (CH0), Black (TXD), White (RXD), Brown (9V), and Drain Wire (SHIELD) and the Vehicle Ignition Switch wires (ACC, BAT) to the interior of the cab. •...
  • Page 56 Installation - HMI...

  • Page 57: Installation - Electrical Connections To Compressor

    Installation - Electrical Connections to Compressor Compressor Harness Compressor Ground Wire 1. Route compressor harness with connectors (LIS, CLU) and (CLU1) to 4. Install chassis ground wire from the engine driven compressor to engine compartment. chassis ground using supplied hardware. Use anti-corrosion gel 2.
  • Page 58 Installation - Electrical Connections to Compressor Ensure there is no paint between ground terminal and ground mounting point. Compressor Ground Wire IMPORTANT: Failure to install the compressor ground wire to the chassis may result in intermittent clutch operation and premature clutch failure!

  • Page 59: Installation - Electrical Connections To Battery

    Installation - Electrical Connections to Battery In-Line Fuse Installation Ground Wire IMPORTANT: The in-line fuse must be located in an accessible location 11. Securely crimp and solder the correct size ring terminal onto the CH as close to the battery as possible while keeping it from directly touching wire.
  • Page 60 Installation - Electrical Connections to Battery Positive (+) See Important note below. Negative (-) Heat Shrink Tubing Butt Splice See Important note below. Unit Power Wire IMPORTANT: The ring terminals used must be sized to match the battery power stud or lug bolt. Oversized ring terminals can contribute to high resistance resulting in the fuse overheating and failure.

  • Page 61: System Charging

    System Charging Procedures 9. Run the unit until it reaches a temperature close to that indicated, and a high circuit pressure of 19 bar (275 psig for R-404A). Partially block NOTE: Ensure proper leak check and evacuation procedure was off the air intake to the condenser if necessary. performed.
  • Page 62 System Charging AMOUNT OF REFRIGERANT PER MODEL Model 50 5.00 lbs.

  • Page 63: Spr And Cpr Adjustment Procedures

    SPR and CPR Adjustment Procedures IMPORTANT: The following applicable procedures must be performed on all new unit installations. Failure to do so may not allow the unit to operate at its maximum capacity. NOTE: The following procedures are for initial settings. Sometimes 6.
  • Page 64 SPR and CPR Adjustment Procedures (continued) Suction Bypass CPR Valve (SPECTRUM Units Only) The suction bypass CPR valve is located in the advanced control system module, which is mounted on the back of the evaporator. The advanced control system balances the suction pressure between the fresh and frozen evaporators to allow both evaporators to have equal capacity to control the two zones.

  • Page 65: Installation Check List

    Installation Check List Components are installed with recommended hardware and Compressor was filled with the proper amount and type of oil. tightened securely. All electrical connectors are properly locked in place. All mounting holes and access holes are sealed with Standby Power Receptacle mounted securely to vehicle.
  • Page 66 Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applica- tions, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com...

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Thermo king es300

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