Ingersoll-Rand Thermo King V-520 10 Operator's Manual
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Ingersoll-Rand Thermo King V-520 10 Operator's Manual

Ingersoll-Rand Thermo King V-520 10 Operator's Manual

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Operator's Manual
V-520 10/20/30/50,
V-520 MAX
10/20/30/50
TK 54342-1-OP (Rev. 1, 02/12)

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  • Page 1 Operator’s Manual V-520 10/20/30/50, V-520 MAX 10/20/30/50 TK 54342-1-OP (Rev. 1, 02/12)
  • Page 3 V-520 10/20/30/50, V-520 MAX 10/20/30/50 TK 54342-1-OP (Rev. 1, 02/12) Copyright© 2009 Thermo King Corp., Minneapolis, MN, USA Printed in USA...

  • Page 5: Introduction

    Introduction Introduction There is nothing complicated about operating and maintaining IMPORTANT: This manual is published for informational your Thermo King unit, but a few minutes studying this purposes only and the information furnished herein should manual will be time well spent. not be considered as all-inclusive or meant to cover all contingencies.
  • Page 6 Introduction...

  • Page 7: Table Of Contents

    Table of Contents Table of Contents Introduction ....... . . 3 box.
  • Page 8 Table of Contents Entering the Setpoint Temperature ....32 Maintenance Inspection Schedule ... . . 49 In Single-temperature Units: .

  • Page 9: Safety Precautions

    Safety Precautions Safety Precautions Thermo King recommends that all services be performed by a CAUTION: Use extreme caution when drilling holes Thermo King dealer. However, there are several general safety in the unit. Drilling into electrical wiring or practices which you should be aware of: refrigerant lines could cause a fire.

  • Page 10: Electrical Hazard

    Safety Precautions WARNING: Be sure to press the OFF key to turn the DANGER: Fluorocarbon refrigerants tend to controller off before opening doors or inspecting any displace air and can cause oxygen depletion which part of the unit. could result in DEATH BY SUFFOCATION. Provide adequate ventilation in enclosed or confined areas.

  • Page 11: First Aid

    Safety Precautions Skin: Remove contaminated clothing. Wash thoroughly with WARNING: Wash thoroughly immediately after soap and water. Get medical attention if irritation persists. handling refrigerant oil to prevent irritation. Inhalation: Move victim to fresh air and restore breathing if necessary. Stay with victim until arrival of emergency personnel.

  • Page 12: Safety Decals And Locations

    Safety Precautions Safety Decals and Locations AKA99 Figure 2: Automatic Start Caution (Locations vary depending on model. Decals are located near areas AKA98 that contain moving parts which can cause severe Figure 1: Belt Caution (Locations vary depending on injuries if hands or clothing become tangled when the model.

  • Page 13: Model 20/50 Units (Electric Standby)

    Safety Precautions Model 20/50 Units (Electric Standby) CAUTION FAN ATTENTION VENTILATEUR ACHTUNG VENTILATOR ATTENZIONE VENTILATORE CUIDADO VENTILADOR AKB01 ARA183 Figure 4: Electrical Hazard (Locations vary depending on model. Typically located near power receptacle, high voltage tray cover and interface Figure 3: Fan Caution (Locations vary depending on board.) model.
  • Page 14 Safety Precautions...

  • Page 15: Unit Description

    The operating mode is selected automatically: When the unit is connected to an electric power source, engine-driven operation The Thermo King V-520 10/20 and V-520 MAX truck is automatically blocked. If the vehicle engine is started up refrigeration systems are two piece units. The unit is designed...

  • Page 16: Standard Features

    Unit Description Standard Features • In-Cab Controls with Digital LCD Thermometer • Hot Gas Defrost • Defrost Termination Switch • Oil Separator • Liquid Injection • Main Compressor, 6-Cylinder Swash Plate AMA945 Optional Features Figure 6: V-520 Condenser Unit • Electric Compressor, Model 20 and 50 Units •...

  • Page 17: Refrigeration System

    Unit Description Refrigeration System When plugged into standby power, engine operation is automatically locked out. If the truck engine is turned on while Refrigeration hoses or lines are used to connect the condenser, the power cord is still plugged into a power receptacle, the unit the evaporator, the compressor and any other components.

  • Page 18: Evaporator

    Unit Description Electronic Control System AMA510 Thermo King direct drive refrigeration units are composed of a condenser unit, an evaporator unit (two evaporators in multi-temperature units), a vehicle compressor (in models with electric standby there is a second compressor that is driven by an electric motor) and a control panel (In-cab Control Box) that operates the unit.

  • Page 19: Electronic Control System Description

    Unit Description • Unit Control without In-cab Control Box The Electronic Control System is composed of an Electronic • Manual or Automatic Defrost Control Module (located inside the condenser unit) and the In-cab Control Box. This In-cab Control Box allows the truck •...
  • Page 20 Unit Description In-cab Control Box (when there is no active alarm). The Manual or Automatic defrost: It is possible to choose On/Off key is always lit except when the unit is disconnected between manual or automatic defrost. (no power), and thus indicates the presence of power in the Maintenance Warning: On-screen warning of the need to unit.

  • Page 21: Unit Controls

    Unit Description Unit Controls 1. Display It is always active and backlit except WARNING: Never operate the unit unless you completely when the unit is disconnected (no understand the controls; otherwise serious injury may occur. power) or when the unit is connected but has been manually switched off from the In-cab Control Box In-cab Control Box.

  • Page 22: Refrigerant

    Unit Description 6. Enter Key. Is used to enter a new command such 13. Defrost Indicates the unit is in Defrost Mode. as manual defrost, etc. Symbol. 7. Buzzer. It is energised when the vehicle battery 14. Electrical Indicates that the unit is in Electric and the electric power supply are Symbol.

  • Page 23: Evaporator Drain Tube Heaters

    Unit Description refrigerant passes through the metering orifice it expands and The thermostat places the unit in null by de-energizing all the evaporates, cooling the suction gas entering the compressor. relays and contactors. The thermostat places the unit in heat by This cooling effect is transferred to the discharge gas leaving energizing the heat contactor.

  • Page 24: Protection Features

    Unit Description Protection Features Fuse 5: Protects the Compressor Clutch 1 (CCL1), Liquid Injection Switch (LIS), Liquid Injection Valve (LIV), Host Hot High Pressure Transducer: The high pressure transducer Gas Defrost Solenoid Valve (PS1), Compressor Motor is a pressure sensitive device. It is located in the discharge line Contactor (CC), 26A Circuit to Heat Option near the oil separator or the discharge check valve.
  • Page 25 Unit Description AMA1412 Filter-Drier Oil Separator (under cover) Transformer Cover Liquid Sight Glass Electric Standby Compressor Condenser Fans Liquid Injection Valve Condenser Coil AC Compressor Electric Box Liquid Tank (?) Rectifier Heat Sink Figure 10: Unit Components (Model 20)
  • Page 26 Unit Description AMA1004 AMA1005 Electronic Control Module Capacitor Box (single temp shown) Motor Contactor Figure 11: Condenser Electric and Capacitor Boxes (Model 20 and 50)
  • Page 27 Unit Description AMA514 AMA513 Evaporator Fans Air Temperature Sensor Expansion Valve Defrost Switch Figure 12: Standard Evaporator...
  • Page 28 Unit Description AMA525 Hot Water Heat Defrost Coil High Temperature Limit Switch Electric Heat Element Air Temperature Sensor Figure 13: Evaporator with Hot Water and Electric Heat Options...

  • Page 29: Unit Operation

    Unit Operation Defrost: After a scheduled period of time in cool mode, In truck-driven units, temperature control is based on two values: The setting (Setpoint) of the electronic thermostat and between 1 and 8 hours, the unit runs in this fourth mode of the evaporator return temperature.

  • Page 30: Starting The Unit

    Unit Operation Starting the Unit Factory setting for X is 5 F (3 C). During unit installation, this value can be adjusted by between 2 and 9 F (1 and 5 C) in increments of 1 F/C. Engine Operation Units with R-134a refrigerant: Temperatures can be Start the truck engine.

  • Page 31: Standard Display

    Unit Operation Single-temperature Units NOTE: The operating mode, whether engine-driven or electric standby, is selected automatically. When the unit is connected to an electric power source, engine-driven operation is automatically blocked. If the truck engine is started up while the power cable is still connected to the electric power source, the unit will continue to operate in electric standby mode.

  • Page 32: Multi-Temperature Units

    Unit Operation Multi-temperature Units In Single-temperature Units: Figure 16: Single-temperature Units Figure 15: Multi-temperature Unit Press and release the SELECT key twice, and the current The example in the drawing shows: -10 C temperature and cool Setpoint Temperature and the letters SP will appear on mode in the main compartment, and 2 C temperature and heat screen.

  • Page 33: In Multi-Temperature Units

    Unit Operation In Multi-temperature Units IMPORTANT: If the SELECT key is not pressed within 20 seconds to select the new Setpoint Temperature, the unit will continue to run at the original Setpoint Temperature. Remote Load Compartment: The present Setpoint Temperature in the remote compartment and the letters SP2 will appear on screen.

  • Page 34: Initiating The Manual Defrost Cycle

    Unit Operation Initiating the Manual Defrost Cycle CAUTION: Before initiating a manual defrost, ensure that the unit is not already in a defrost cycle. When the unit is in a defrost cycle the defrost symbol appears on screen. Press and release the SELECT key once, and the letters dEF will appear (flashing) on screen along with the present defrost condition OFF.

  • Page 35: Alarms

    Unit Operation Alarms Press and release the SELECT key to display the current alarm code on screen. If there is more than one active alarm, all the When the unit is not operating properly, the microprocessor alarm codes on the unit can be viewed in sequence by pressing records the alarm code, alerts the operator by displaying the and releasing the SELECT key.

  • Page 36: Buzzers

    Unit Operation Should a P1E alarm occur - return air temperature read error alarm code - appear, --- will appear on screen together with the alarm symbol, instead of the return air temperature reading. Figure 24: P2E Alarm Press and release the SELECT key to display the current alarm Figure 23: P1E Alarm code on screen.

  • Page 37: Alarm Code Descriptions

    Unit Operation Alarm Code Descriptions Alarm Description Low Pressure Alarm. Indicates that the refrigeration system will shut down in the Alarm Description event of excessively low pressure in the Manual Start refrigerant circuit. If the problem persists when the unit is restarted, contact your Electric Motor Overload.

  • Page 38: Clearing Alarm Codes

    Unit Operation Viewing Information Screens Alarm Description Main or Single Cargo Box Return Air Main Menu Temperature Reading Error (open circuit or short-circuit). Contact your Service Dealer. From the Standard Display use the SELECT key to display: Remote Cargo Box Return Air Temperature Alarms (if any active) Reading Error (open circuit or short-circuit).

  • Page 39: Post-Start Inspection

    Unit Operation Post-Start Inspection Carefully check and record the load temperature when loading the truck. Note whether any products are out of Thermostat: Adjust the thermostat setting to above and temperature range. below the compartment temperature to check thermostat Load the product in such a way that there is sufficient operation (see Operating Modes).
  • Page 40 Unit Operation...

  • Page 41: Specifications

    Specifications Electrical System 12 Volt 24 Volt Fuses Fuse 1: Power Supply Circuit 5 amps 5 amps Fuse 2: Condenser Fan Motor (CFM1) 15 amps 10 amps Fuse 3: Evaporator Fan Motor (EF1) 15 amps 10 amps Fuse 4: Evaporator Fan Motor (EF2) 15 amps 10 amps Fuse 5: Compressor Clutch 1 (CCL1), Liquid Injection Switch (LIS),...
  • Page 42 Specifications Electrical System 12 Volt 24 Volt Fuses Fuse 20: Transformer 4 amps 4 amps Fuse 21: Battery Relay 15 amps 15 amps Condenser Fan Motors Voltage Full Load rpm Full Load Current 13 Vdc 3000 9.2 Amps Evaporator Fan Motors Voltage Full Load rpm Full Load Current...

  • Page 43: Refrigerant System

    Specifications Refrigerant System R-134A REFRIGERATION SYSTEM (V-520) Refrigerant Charge: V-520 - Model 10 7.93 lb (3.60 kg) R-134a V-520 - Model 20 7.93 lb (3.60 kg) R-134a V-520 - Model 30 8.00 lb (3.63 kg) R-134a V-520 - Model 50 8.00 lb (3.63 kg) R-134a Defrost Termination Switch: Opens...

  • Page 44: Compressors

    Specifications Refrigerant System V-520 MAX - Model 30 8.25 lb (3.74 kg) R-404A V-520 MAX - Model 50 8.25 lb (3.74 kg) R-404A V-520 SPECTRUM - Model 10 9.75 lb (4.42 kg) R-404A V-520 SPECTRUM - Model 20 9.75 lb (4.42 kg) R-404A Defrost Termination Switch: Opens 48.0 ±...
  • Page 45 Specifications Compressors (Continued) System Oil Capacity: Model 10 12 oz (355 cc) Model 20 64 oz (1893 cc) Model 30 18 oz (532 cc) Model 50 70 oz (2070 cc) SPECTRUM Model 10 16 oz (473 cc) SPECTRUM Model 20 30 oz (887 cc) Compressor Oil Type Polyol Ester P/N 203-515 Defrost Method:...

  • Page 46: Ac Semi-Hermetic Compressor

    Specifications Belt Tension (Using Tool P/N 204-427) Field Reset Engine Driven Compressor Belt Check vehicle manufacturer specifications AC Semi-Hermetic Compressor Full Load Locked Rotor Voltage/Phase/Frequency Horsepower Kilowatts (Amps) Amps 230V/3PH/60Hz 1740 14.1 86.9 230V/1PH/60Hz 1740 16.0 83.2 400V/3PH/60Hz 1740 29.9 400V/3PH/50Hz 1450 24.9...

  • Page 47: Solder Applications

    Specifications Solder Applications Refrigeration Component For general refrigeration tubing connections: Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm) copper to copper or copper to brass Use: Solder Type 15% Silver TK No. 203-364 Use: Flux Type TK No. 203-365 For refrigeration tubing connections of dissimilar Joint Clearances: 0.003 to 0.005 in.
  • Page 48 Specifications...

  • Page 49: Maintenance Inspection Schedule

    Maintenance Inspection Schedule A closely followed maintenance program will help to keep After first week of operation: your Thermo King unit in top operating condition. The • Check belt tension. following general schedule is provided to assist in monitoring • Tighten unit mounting bolts.

  • Page 50: Electrical

    Maintenance Inspection Schedule Weekly Monthly Semi- Annual Inspect/Service These Items Annual ELECTRICAL • • Check defrost initiation and termination. • • Check thermostat cycle sequence. • • Check operation of protection shutdown circuits. • Check thermostat and thermometer calibration in 0 C (32 F) ice-water bath.
  • Page 51 Maintenance Inspection Schedule Weekly Monthly Semi- Annual Inspect/Service These Items Annual • • Check all unit mounting bolts, brackets, lines, hoses, etc.
  • Page 52 Maintenance Inspection Schedule...

  • Page 53: Loading And Enroute Inspections

    Loading and Enroute Inspections Thermo King refrigeration units are designed to maintain the Pre-cool the cargo compartment. Adjust the setpoint to the required temperature for the product being carried during its desired cargo temperature and allow the unit to run a time in transit.
  • Page 54 Loading and Enroute Inspections Unit Inspection Good Outside Air Circulation Gaskets Equally Compressed Clear Defrost Drains Tight Doors Good Air Circulation Around Load Interior and Exterior Walls and Insulation in Good Condition Cargo at Proper Temperature Prior to Loading AMA1411 Figure 25: Loading Considerations...

  • Page 55: Inspecting The Load

    Loading and Enroute Inspections Inspecting the Load While inspecting to see that the cargo is loaded properly, make sure the evaporator inlets and outlets are not Never assume that the product has been loaded properly. Watch blocked. for and perform the following tasks. It takes only a few Close or supervise the closing of the cargo compartment minutes and could save you or your employer considerable doors.

  • Page 56: Enroute Inspections

    Loading and Enroute Inspections Enroute Inspections The evaporator is plugged with frost. Initiate a manual defrost cycle. The defrost cycle will be automatically NOTE: Enroute inspections are recommended every four terminated. hours for the prevention of damage to the cargo. Improper air circulation within the cargo Note the setpoint to make certain no one has altered the compartment.
  • Page 57 Loading and Enroute Inspections The unit may have a low refrigerant charge. If liquid CAUTION: Stop the unit if the compartment is not showing in the unit receiver tank sight glass, the temperature remains outside the desired temperature refrigerant charge may be low. Adding refrigerant or range from the setpoint on two consecutive 30 minute repairing the refrigeration system requires a inspections.
  • Page 58 Loading and Enroute Inspections...

  • Page 59: Serial Number Locations

    Serial Number Locations Serial Number Locations CONDENSER: Nameplate located on the back inside wall of condenser frame. AMA511 ENGINE DRIVEN COMPRESSOR: Nameplate located on compressor body. The engine driven compressor is located in the truck engine compartment. STANDBY COMPRESSOR: Nameplate located on compressor body.
  • Page 60 Serial Number Locations...

  • Page 61: Warranty

    Warranty Warranty Terms of the Thermo King Warranty are available on request. Please reference document TK 51350 for the Thermo King Self-Powered Truck Unit Warranty.
  • Page 62 Warranty...

  • Page 63: Glossary

    Glossary box temperature: The temperature within a This glossary is published for informational purposes only and the information being furnished herein should not be temperature-controlled compartment. considered as all-inclusive or meant to cover all contingencies. Btu (british thermal unit): The quantity of heat required to NOTE: Additional terms not found in the glossary may be raise the temperature of one pound of water by one degree located in the index section of this manual.
  • Page 64 Glossary CFC: Chlorofluorocarbon. A chlorine-based refrigerant condenser: An arrangement of tubing in which the consisting of chlorine, fluorine and carbon. Example: R12. In vaporized and compressed refrigerant is liquefied as heat is many countries it is illegal to release this type of refrigerant to removed.
  • Page 65 Glossary defrost timer: A solid state module that initiates defrost at evaporator: The part of the refrigeration system that absorbs selected intervals. Also establishes a maximum defrost heat during the cooling cycle. duration if normal circuits malfunction. EW: A wall-mounted Thermo King remote evaporator. See dehydrator: A device used to remove moisture from ECT and TLE.
  • Page 66 Glossary fusible link: An electrical safety device (typically a short hp (horsepower): A unit of power equivalent to 746 watts piece of wire) inserted into an electrical circuit. The wire melts or 550 foot-pounds per second. or breaks when the current is increased beyond a specific HPCO (High Pressure Cut Out Switch): A value.
  • Page 67 Glossary movable bulkhead: A thick, insulated, portable wall-like psi: Pounds per square inch. A unit of pressure. device used to compartmentalize a temperature-controlled 1 psi = 0.069 bar = 6.89 kPa. truck or trailer. See bulkhead. psig: Pounds per Square Inch Gauge. Pressure in pounds per Multi-Temp: A Thermo King truck or trailer unit capable of square inch as displayed by a gauge calibrated to zero when maintaining different set-points in multiple compartments.
  • Page 68 Glossary return air temperature: The temperature of the air Vac (volts alternating current): An electric current that returning to the evaporator. See box temperature. reverses direction at regularly recurring intervals. rpm: Revolutions per minute. Vdc (volts direct current): An electric current that flows in one direction only and is constant in value.

  • Page 69: Emergency Cold Line

    Emergency Cold Line The answering service at the factory will assist you in reaching a dealer to get the help you need. The Cold Line is answered 24 hours a day by personnel who will do their best to get you quick service at an authorized Thermo King Dealer.

  • Page 70: Recover Refrigerant

    Recover Refrigerant 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.

  • Page 71: California Proposition 65 Warning

    CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer.
  • Page 74 Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes. ©2011 Ingersoll-Rand Company Printed in U.S.A.

This manual is also suitable for:

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