Thermo King B-100-10 Installation Manual
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Thermo King B-100-10 Installation Manual

Thermo King B-100-10 Installation Manual

With direct smart reefer
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Installation Manual
B-100
Model 10 and 20 with Direct Smart Reefer
TK-54436 -18-IM (Rev. 1,11/09)
©
Copyright
2009 Thermo King Corp., Minneapolis, MN, U.S.A.

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Summary of Contents for Thermo King B-100-10

  • Page 1 Installation Manual B-100 Model 10 and 20 with Direct Smart Reefer TK-54436 -18-IM (Rev. 1,11/09) © Copyright 2009 Thermo King Corp., Minneapolis, MN, U.S.A.
  • Page 2 Release History Original (7/09) Released Rev. 1 (11/09) Page 40, changed text from “start-up wire fuse” to “fused ignition circuit”...

  • Page 3: Introduction

    Introduction This installation manual was written to help assist with the installation of Thermo King refrigeration units powered by vehicle batteries onto either a truck or a van. The manual comprises sections on condenser, evaporator and other modules that are mounted on the truck or van body, as well as sections on components and wiring that are to be connected to the vehicle engine from which the unit derives power.

  • Page 4: Table Of Contents

    Table of Contents Introduction ........... . 3 In Case of Leaks .

  • Page 5: Safety Precautions

    Safety Precautions DANGER: When removing a battery from the Battery Pack, symbol appears next to a point that is particularly important. ALWAYS disconnect the negative battery terminal first. Then remove the positive terminal. When reconnecting the battery DANGER: Addresses a circumstance that, if encountered, will lead terminals, connect the positive terminal (+) first, and connect the to death or serious injury.
  • Page 6 Safety Precautions (continued) Refrigerant WARNING: When using ladders to install or service refrigeration systems, always observe the ladder manufacturer’s safety labels and WARNING: Although fluorocarbon refrigerants are classified as safe warnings. A work platform is the recommended method for refrigerants, certain precautions must be observed when handling them installations.
  • Page 7 RECOVERY OF REFRIGERANT At Thermo King, we recognise 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.

  • Page 8: Required Tools

    Required Tools 1. Electric drill 19. Voltmeter 2. Set of drill bits 20. Set of screwdrivers 3. Set of glass-shaped cutters 21. Hose cutters 4. Protective goggles 22. Wire strippers 5. Adhesive tape 23. Wire cutters 6. Measuring tape 24. Electric and hand saws 7.
  • Page 9 Required Tools...

  • Page 10: Operating Method

    Operating Method The operations indicated in this manual should be carried out by a mechanic in the exact sequence in which they are presented in the manual.

  • Page 11: Unpacking And Inspecting The Unit

    Unpacking and Inspecting the Unit Unpacking the Unit Inspecting the Unit 1. Open the packaging. 1. Open the condenser unit cover and ensure the following: 2. Find the unit documentation. • Neither the cover nor the unit should show any shock damage or imperfections.

  • Page 12: Installing The Condenser Unit (Roof-Mounted)

    Installing the Condenser Unit (roof-mounted) 1. Fit the template according to the instructions given. 2. Mark the position of the drilled holes and openings. Avoid any possible interference with electrical wires and parts of the vehicle chassis. 3. Drill the holes to hold the condenser unit in place (D 12) and the holes for routing hoses (D 70).
  • Page 13 Installing the Condenser Unit (roof-mounted) ASA052 T = 10 min.
  • Page 14 Installing the Condenser Unit (roof-mounted) 1. Fasten two strong straps attached to a crane to the unit. Lift the unit, making sure that it remains in a horizontal position. If it does not, change the position of the straps. 2. Place the unit on the roof of the vehicle. Remove the straps and the crane.
  • Page 15 Installing the Condenser Unit (roof-mounted) T = 12 min.

  • Page 16: Installing The Condenser Unit (Front-Mounted)

    Installing the Condenser Unit (front-mounted) 1. Fit the template according to the instructions given. 2. Mark the position of the drilled holes and openings. Avoid any possible interference with electrical wires and parts of the vehicle chassis. 3. Drill the holes to hold the condenser unit in place (D 12) and the holes for routing hoses (D 70).
  • Page 17 Installing the Condenser Unit (front-mounted) T = 10 min.
  • Page 18 Installing the Condenser Unit (front-mounted) 1. Cut the routing guide C down as indicated in the illustration. 2. Fasten the adhesive tape T (supplied by Thermo King) to the rear of the structure. 3. Fasten two strong straps attached to a crane to the unit. Lift the unit, making sure that it remains in a horizontal position.
  • Page 19 Installing the Condenser Unit (front-mounted) T = 15 min.

  • Page 20: Installing The Es100 Evaporator Unit

    Installing the ES100 Evaporator Unit 1. Fit the template according to the instructions given. 2. Mark the position of the drilled holes. Avoid any possible interference with electrical wires and parts of the vehicle chassis. 3. Drill blind holes to screw the evaporator unit in place. Screw in the bolts and washers supplied for the ceiling.
  • Page 21 Installing the ES100 Evaporator Unit T = 20 min.

  • Page 22: Preparing Refrigeration Hoses

    2. Pass two clips of appropriate diameter over the hose. 3. Lubricate the cylinder of the fitting to be inserted in the hose, using Thermo King refrigerant oil. 4. Manually insert the fitting into the hose. The hose should touch the projecting part of the fitting without going into it.
  • Page 23 Preparing Refrigeration Hoses T = 10 min.

  • Page 24: Connecting Hoses To The Condenser Unit

    Connecting Hoses to the Condenser Unit 1. Take the plugs off all the tubes. 2. Lubricate all refrigeration intakes with Thermo King refrigerant oil. 3. Place an O-ring on each refrigeration intake. 4. Check that the O-ring is properly positioned and connect each hose using two fixed wrenches.
  • Page 25 Connecting Hoses to the Condenser Unit T = 10 min.

  • Page 26: Connecting Hoses To The Es100 Evaporator

    Connecting Hoses to the ES100 Evaporator 1. Remove plugs from all tubing. 2. Lubricate all refrigeration intakes with Thermo King refrigerant oil. 3. Place an O-ring on each refrigeration intake. 4. Connect each hose using two fixed wrenches. The O-ring should be properly positioned before the fitting is screwed on.
  • Page 27 Connecting Hoses to the ES100 Evaporator T = 14 min.

  • Page 28: Electrical Connections In The Es100 Evaporator

    Electrical Connections in the ES100 Evaporator 1. Pass the electrical hose and the return temperature sensor through as far as the evaporator. 2. Connect the low pressure cutout, the defrost temperature thermostat, the hot gas solenoid valve, and the temperature sensor. 3.
  • Page 29 Electrical Connections in the ES100 Evaporator T = 10 min.

  • Page 30: Drain Circuit In The Es100 Evaporator

    Drain Circuit in the ES100 Evaporator 1. Cut the drain hose to the required length. 2. Connect the hose to the drain tube. Secure connections with plastic flanges. 3. Route the hose through the drain hole and seal hermetically. 4. Check that the corresponding siphon or moisture trap is installed at the end of each drain hose.
  • Page 31 Drain Circuit in the ES100 Evaporator T = 5 min.

  • Page 32: Circuit Seal Test

    Circuit Seal Test 1. Heat the box up to +20ºC/+70ºF using a ventilated radiator. 2. Connect the gauge manifold to the suction 1 and discharge 2 intakes of the condenser unit. 3. Connect the central line of the gauge manifold to the vacuum pump. Use recommended vacuum equipment.
  • Page 33 Circuit Seal Test...

  • Page 34: In Case Of Leaks

    In Case of Leaks 1. Pressurize the circuit to 17 bar / 250 psig with nitrogen. 2. Identify the defective part (fitting, sleeve, line, hose, O-ring, etc.) and replace it with a new part (if in doubt replace the entire joint). Use the recommended leak detector.
  • Page 35 In Case of Leaks / 250 psig...

  • Page 36: Installing The In-Cab Control

    3. Mount the base of the mounting bracket in the chosen location. Use screws (C), rubber mat (D) and metal plate (E), which are supplied by Thermo King, as indicated in the drawing. 4. When placing the in-cab control box on the bracket, rest the in-cab control box on the arm (F), and slide it to the right until the arm tab is properly fitted to the in-cab control box frame.
  • Page 37 Installing the In-Cab Control T = 10 min.

  • Page 38: Optional Internal Din Adaptor

    Optional Internal DIN Adaptor 1. Place the metal box (J) supplied in the housing designed for the radio. Raise the tabs (M) sufficiently to fit the box into the housing. 2. Attach the control to the plastic bracket (L) using the 4 screws (K). 3.
  • Page 39 Optional Internal DIN Adaptor T = 5 min.

  • Page 40: Control Cable Connection

    Control Cable Connection 1. Pass cable 01 of the electrical hose through to the cab. 2. Locate the fuse box. 3. Connect wire 01 to the vehicle’s fused ignition circuit. NOTE: Use a splice capable of supporting a 3A electrical current.
  • Page 41 Control Cable Connection T = 5 min.

  • Page 42: Battery Connection

    5. Connect wire 2 to one end of the fuse FP fuse holder (both supplied by Thermo King) and connect the other end of the fuse holder to the battery's positive pole. Install fuse FP (100A/12V or 60A/24V) in the fuse holder.
  • Page 43 Battery Connection T = 15 min.

  • Page 44: Fitting The Power Supply Units With Electric Standby

    Fitting the Power Supply Units with Electric Standby WARNING: Always confirm the supply voltage matches the voltage specifications of your particular unit prior to making any electrical connections. 1. Install the power supply housing in a protected and accessible location. 2.
  • Page 45 Fitting the Power Supply Units with Electric Standby T = 10 min.

  • Page 46: Door Switch Connection

    Door Switch Connection 1. Pass the electrical cable DSW1/CHW through to the door of the compartment of the truck. 2. Connect the door switch to the two-way connector on cable DSW1/CHW.
  • Page 47 Door Switch Connection DSW1/CHW T = 1 min.

  • Page 48: Installing The Deflector

    4. Fit the deflector onto the cover, and secure it via two front holes using the screws supplied by Thermo King. 5. Fit the cover-deflector assembly onto the condenser. 6. Secure the cover-deflector assembly to the condenser via the two rear holes using the screws supplied by Thermo King.
  • Page 49 Installing the Deflector T = 5 min.

  • Page 50: Installing The Hose Covers

    Installing the Hose Covers 1. Place (but do not fit for the moment) the elbow-shaped curved section, aligning it so that the inside coincides with the rim of the hose outlet hole. 2. Mark the left-hand baseline. 3. Mount and fit the straight section of the cover. To ensure the correct curvature, the total width should be 446 mm.
  • Page 51 Installing the Hose Covers T = 12 min.

  • Page 52: In-Cab Control Box

    In-Cab Control Box DISPLAY, KEYS AND SYMBOLS 10. ºC/ºF Symbol. Indicates whether the on-screen temperature reading is in degrees Celsius (ºC) or degrees Fahrenheit (ºF). 11. Alarm Symbol. Indicates that there is an alarm in the system. 12. Maintenance Symbol. Warns of the need to carry out maintenance to the unit.
  • Page 53 In-Cab Control Box INSTALLATION MENU From the Standard Display press the ENTER plus the DOWN key for 3 seconds to enter the Installation Menu: the first parameter will be displayed, the value in the large digits and its name in the small digits. To modify the parameter value press the ENTER key, the value will flash, press the UP or DOWN key to modify the value and confirm by pressing the ENTER key again.
  • Page 54 In-Cab Control Box NAME DESCRIPTION DEFAULT Doors Switches Presence/polarity 0: normally closed, 1: normally open, 2: not present. Buzzer Enable 0: not enabled, 1: enabled, 2: enabled also when keys are pressed, 3: enabled only when keys are pressed. Thermostat Units C: temperature visualization in ºC, F: temperature visualization in ºF.

  • Page 55: Checking The Installation

    Checking the Installation • All holes should be sealed with silicone or foam. • Check with a sheet of paper that the fans blow in the right direction. • The drain circuit should be slanted on all evaporators and the moisture trap should be installed. •...

  • Page 56: Charging The Circuit

    Charging the Circuit 1. Connect the gauge manifold to the suction and discharge line intakes of the condenser unit. 2. Connect the refrigerant bottle to the gauge manifold and place it on a set of scales. 3. Open the refrigerant bottle valve and drain the gauge fitting line. 4.
  • Page 57 Charging the Circuit...

  • Page 58: Outline Drawings

    Outline Drawings...
  • Page 59 Outline Drawings...
  • Page 60 Outline Drawings...

This manual is also suitable for:

B-100-20Es100

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