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Summary of Contents for Trane Technologies THERMO KING E-200 Series
- Page 1 Installation Manual Vehicle Powered Truck Edition E-200 Series Single and Multi Temperature Systems Revision B T T K K 6 6 1 1 6 6 9 9 4 4 - - 1 1 8 8 - - I I M M - - E E N N November 2020...
- Page 2 Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a web browser. Scan the Quick Response (QR) code or click or type the web address https://tranetechnologies.iad1.qualtrics.com/jfe/ form/SV_2octfSHoUJxsk6x?Q_CHL=qr&Q_JFE=qdg to complete the survey. ©2020 Trane Technologies TK 61694-18-IM-EN...
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Page 3: Table Of Contents
Table of Contents S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s ................................5 5 Danger, Warning, Caution, and Notice . -
Page 4: S S T T A A N N D D B B Y Y R R E E C C E E P P T T A A C C L L E E B B O O X X I I N N S S T T A A L L L L A A T T I I O O N N ( ( M M O O D D E E L L S S 2 2 0 0 A A N N D D 5 5 0 0 O O N N L L Y
T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Installation Guidelines ............... . . 47 I I n n c c r r e e a a s s e e d d I I d d l l e e S S p p e e e e d d S S e e t t u u p p . -
Page 5: Danger, Warning, Caution, And Notice
Safety Precautions Danger, Warning, Caution, and Notice Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices. Safety advisories appear throughout this manual as required (refer to examples below). Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions. - Page 6 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s S S e e r r v v i i c c e e P P r r o o c c e e d d u u r r e e s s - Recommended procedures must be used to minimize refrigerant loss. C C o o m m p p o o n n e e n n t t s s m m a a y y b b e e i i s s o o l l a a t t e e d d by closing service valves and performing system pump-downs.
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Page 7: O O P P T T I I O O N N A A L L D D I I N N A A D D A A P P T T O O R R ( ( B B Y Y O O R R D D E E R R O O N N L L Y
Required Tools N N o o t t e e : : Equipment such as scales, gauges, refrigerant leak detectors, and torque wrenches should be in good working condition and routinely calibrated to assure accurate readings. Figure 1. BED760 Electric drill Protective gloves Electrical terminal press File... -
Page 8: R R E E Q Q U U I I R R E E D D T T O O O O L L S
R R e e q q u u i i r r e e d d T T o o o o l l s s Adhesive tape Electric connectors Leak detector Measuring tape Electrical wire Nitrogen cylinder Drilling template Voltmeter Refrigerant cylinders Pencil... -
Page 9: D D I I S S C C H H A A R R G G E E P P R R E E S S S S U U R R E E R R E E G G U U L L A A T T O O R R ( ( D D P P R R ) ) A A D D J J U U S S T T M M E E N N T T P P R R O O C C E E D D U U R R E E S S - - M M A A X
Required Support Materials Please have the following support materials to hand prior to starting your installation - as they are listed as reference throughout this manual: 1. Vehicle Powered Truck Installation Standards and Procedures Guide EMEA - located in Infocentral: Technical Publications 2. - Page 10 Auto Start Hard Stop / Disable Connector D D A A N N G G E E R R H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e ! ! T T a a k k e e c c a a r r e e t t h h a a t t t t h h i i s s c c o o n n n n e e c c t t o o r r d d o o e e s s n n o o t t d d i i s s c c o o n n n n e e c c t t t t h h e e A A C C v v o o l l t t a a g g e e i i n n p p u u t t .
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Page 11: Cover And Fan Housing Removal (All Models)
Preparing Condenser for Installation Cover and Fan Housing Removal (All Models) To access the unit mounting holes: 1. Remove plastic condenser cover. 2. Remove the fan housing assembly. (Remove the fan connector). 3. Remove “Power Off Device” Connector and Electric Box Cover. 4. -
Page 12: Fan Housing Modifications (Nosemount Installations Only)
P P r r e e p p a a r r i i n n g g C C o o n n d d e e n n s s e e r r f f o o r r I I n n s s t t a a l l l l a a t t i i o o n n Fan Housing Modifications (Nosemount Installations Only) Turn fan housing over and use a hand saw to trim the area shown for refrigeration hose clearance. - Page 13 Condenser Installation I I m m p p o o r r t t a a n n t t : : See Section 4 - Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide. THESE PROCEDURES MUST BE FOLLOWED! N N o o t t e e : : Nose mount and roof top condenser mounting and access hole dimensions can be found at the back of this manual.
- Page 14 Evaporator Installation I I m m p p o o r r t t a a n n t t : : See Section 4 - Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 61588). THESE PROCEDURES MUST BE FOLLOWED! N N o o t t e e : : Evaporator mounting hole locations can be found at the back of this manual.
- Page 15 Hose Connections I I m m p p o o r r t t a a n n t t : : See Section 6 - Refrigerant Hose and Fittings Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 61588). THESE PROCEDURES MUST BE FOLLOWED! C C A A U U T T I I O O N N S S e e r r v v i i c c e e P P r r o o c c e e d d u u r r e e ! ! T T h h i i s s u u n n i i t t i i s s s s u u p p p p l l i i e e d d w w i i t t h h s s e e r r v v i i c c e e v v a a l l v v e e s s c c l l o o s s e e d d .
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Page 16: H H O O S S E E C C O O N N N N E E C C T T I I O O N N S
H H o o s s e e C C o o n n n n e e c c t t i i o o n n s s Figure 4. Hose Connection Single Temperature Model 20 TK 61694-18-IM-EN... - Page 17 H H o o s s e e C C o o n n n n e e c c t t i i o o n n s s Legend O-RING (#4, o-ring seal) 90 degree Fitting (straight, #6 fitting, #4 hose) Straight Fitting (female o-ring seal, #4 fitting, #4 hose) O-RING (#10, o-ring seal) O-RING (#6, o-ring seal)
- Page 18 H H o o s s e e C C o o n n n n e e c c t t i i o o n n s s Figure 5. Hose Connection Single Temperature Model 50 Legend O-RING (#4, o-ring seal) Straight Fitting (female o-ring seal, #6 fitting, #8 hose) Straight Fitting (female o-ring seal, #4 fitting, #4 hose) O-RING (#10, o-ring seal)
- Page 19 H H o o s s e e C C o o n n n n e e c c t t i i o o n n s s Figure 6. Hose Connection Multi Temperature (2 Zone) Legend O-RING (#4, o-ring seal) O-RING (#10, o-ring seal) Straight Fitting (female o-ring seal, #4 fitting, #4 hose) EE - splicer (#4)
- Page 20 H H o o s s e e C C o o n n n n e e c c t t i i o o n n s s 90 degree Fitting (female o-ring seal, #4 fitting, #4 hose) Hose (Suction Line) (#10, 50 ft) 90 degree Fitting (female o-ring seal, #10 fitting, #10 hose) TK 61694-18-IM-EN...
- Page 21 Installing the Filter Drier and Sight Glass C C A A U U T T I I O O N N S S e e r r v v i i c c e e P P r r o o c c e e d d u u r r e e ! ! T T h h i i s s u u n n i i t t i i s s s s u u p p p p l l i i e e d d w w i i t t h h s s e e r r v v i i c c e e v v a a l l v v e e s s c c l l o o s s e e d d .
- Page 22 Wiring Connections Model 20 & 50 I I m m p p o o r r t t a a n n t t : : See Section 7 - Electrical Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide .THESE PROCEDURES MUST BE FOLLOWED! TK 61694-18-IM-EN...
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Page 23: W W I I R R I I N N G G C C O O N N N N E E C C T T I I O O N N S S M M O O D D E E L
W W i i r r i i n n g g C C o o n n n n e e c c t t i i o o n n s s M M o o d d e e l l 2 2 0 0 & & 5 5 0 0 I I m m p p o o r r t t a a n n t t : : When installing the Power Receptacle. - Page 24 Installing the In-Cab Controller I I m m p p o o r r t t a a n n t t : : See Section 7 - Electrical Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430).
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Page 25: I I N N S S T T A A L L L L I I N N G G T T H H E E I I N N - - C C A A B B C C O O N N T T R R O O L L L L E E R
I I n n s s t t a a l l l l i i n n g g t t h h e e I I n n - - C C a a b b C C o o n n t t r r o o l l l l e e r r 4. - Page 26 I I n n s s t t a a l l l l i i n n g g t t h h e e I I n n - - C C a a b b C C o o n n t t r r o o l l l l e e r r 6.
- Page 27 Optional DIN Adaptor (by order only) 1. Place the metal box (J 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 L ) using the 4 screws (K K ). 3.
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Page 28: Tk Lithium Ion Batteries (If Equipped)
TK Lithium Ion HoldOver Battery Installation TK Lithium Ion Batteries (if equipped) When TK Battery option is present, some additional components are installed in the condenser: • Smart Charger Module (SCM): converter for battery charging and discharging. The SCM has the ability to intelligently manage different power sources. - Page 29 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n TK 61694-18-IM-EN...
- Page 30 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n 3.
- Page 31 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n –...
- Page 32 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n 6.
- Page 33 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n 11.
- Page 34 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n 14.
- Page 35 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n 17.
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Page 36: Battery Option
T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n 2 Battery Option I I m m p p o o r r t t a a n n t t : : When working with 2 batteries: •... - Page 37 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n 5.
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Page 38: Bms Installation
T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n 8. - Page 39 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n N N o o t t e e : : The BMS bracket can be installed in various positions to accommodate different orientations of the battery installation.
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Page 40: Tk Lithium Ion Battery Option Configuration And Testing
T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n C C A A U U T T I I O O N N E E q q u u i i p p m m e e n n t t F F a a i i l l u u r r e e ! ! M M a a k k e e s s u u r r e e t t h h a a t t t t h h e e "... - Page 41 T T K K L L i i t t h h i i u u m m I I o o n n H H o o l l d d O O v v e e r r B B a a t t t t e e r r y y I I n n s s t t a a l l l l a a t t i i o o n n operation few minutes until battery charge level is lesser than 80%.
- Page 42 Connecting to Third Party Holdover Battery Option This option uses an auxiliary battery provided by your vehicle manufacturer. It allows the user to maintain the temperature control of the compartment for a certain period when there is no alternator or stand-by power sources available.
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Page 43: C C O O N N N N E E C C T T I I N N G G T T O O T T H H I I R R D D P P A A R R T T Y Y H H O O L L D D O O V V E E R R B B A A T T T T E E R R Y Y O O P P T T I I O O N
C C o o n n n n e e c c t t i i n n g g t t o o T T h h i i r r d d P P a a r r t t y y H H o o l l d d o o v v e e r r B B a a t t t t e e r r y y O O p p t t i i o o n n Hold-over Option Installation Guidelines N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! - Page 44 C C o o n n n n e e c c t t i i n n g g t t o o T T h h i i r r d d P P a a r r t t y y H H o o l l d d o o v v e e r r B B a a t t t t e e r r y y O O p p t t i i o o n n TK 61694-18-IM-EN...
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Page 45: Concept
Start/Stop Functionality I I m m p p o o r r t t a a n n t t : : The presented proposal does not cover all the diversity of vehicle manufacturer implementations. An adaptation to each application will be required. A carefully revision of your vehicle documentation is advised. -
Page 46: Parts Required Before Starting Installation
S S t t a a r r t t / / S S t t o o p p F F u u n n c c t t i i o o n n a a l l i i t t y y Vehicle Battery Fuse (150 A) Ignition Switch... -
Page 47: Installation Guidelines
S S t t a a r r t t / / S S t t o o p p F F u u n n c c t t i i o o n n a a l l i i t t y y Description: TK Service Parts Number: Seal Cable Yellow - Outside Diameter 1.8-2.4mm... - Page 48 S S t t a a r r t t / / S S t t o o p p F F u u n n c c t t i i o o n n a a l l i i t t y y TK 61694-18-IM-EN...
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Page 49: Concept
Increased Idle Speed Setup I I m m p p o o r r t t a a n n t t : : The presented proposal does not cover all the diversity of vehicle manufacturer implementations. An adaptation to each application will be required. A carefully revision of your vehicle documentation is advised. -
Page 50: Parts Required Before Starting Installation
I I n n c c r r e e a a s s e e d d I I d d l l e e S S p p e e e e d d S S e e t t u u p p Vehicle Battery Fuse (150 A) Ignition Switch... -
Page 51: Installation Guidelines
I I n n c c r r e e a a s s e e d d I I d d l l e e S S p p e e e e d d S S e e t t u u p p Description: TK Service Parts Number: Seal Cable Yellow - Outside Diameter 1.8-2.4mm... - Page 52 I I n n c c r r e e a a s s e e d d I I d d l l e e S S p p e e e e d d S S e e t t u u p p TK 61694-18-IM-EN...
- Page 53 Vehicle Battery Connection 1. Pass electrical wires NBAT (black), 01, BAT and 2 (brown) to the battery. 2. Using the recommended tools, cut the wires to the proper length. D D o o n n o o t t c c o o i i l l o o r r s s p p l l i i c c e e t t h h e e e e x x c c e e s s s s w w i i r r e e . . 3.
- Page 54 Standby Receptacle Box Installation (Models 20 and 50 Only) I I m m p p o o r r t t a a n n t t : : See Section 7 - Electrical Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 61588).
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Page 55: Es-100N/Es150
Evaporator Drain Hose Installation I I m m p p o o r r t t a a n n t t : : See Section 8 - Evaporator Drain Hose Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide . - Page 56 E E v v a a p p o o r r a a t t o o r r D D r r a a i i n n H H o o s s e e I I n n s s t t a a l l l l a a t t i i o o n n Figure 10.
- Page 57 Completing the Installation I I m m p p o o r r t t a a n n t t : : BEFORE COMPLETING THE INSTALLATION, YOU MUST PERFORM THE FOLLOWING PROCEDURES IN ACCORDANCE WITH THE THERMO KING INSTALLATION STANDARDS AND PROCEDURES GUIDE: •...
- Page 58 Suction Pressure Regulator (SPR) Adjustment Procedures - MAX I I m m p p o o r r t t a a n n t t : : Using the absence of bubbles in the sight glass as an indicator of correct refrigerant charge can be misleading, Y Y O O U U M M U U S S T T refrigerate the box to 0-5ºC (32-41ºF) to get a more precise indication from the sight glass.
- Page 59 Discharge Pressure Regulator (DPR) Adjustment Procedures - MAX W W A A R R N N I I N N G G E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! L L o o w w e e r r s s e e t t t t i i n n g g s s c c a a n n b b e e s s e e l l e e c c t t e e d d b b a a s s e e d d o o n n l l o o c c a a l l p p r r e e f f e e r r e e n n c c e e s s t t o o o o p p t t i i m m i i z z e e h h e e a a t t i i n n g g o o p p e e r r a a t t i i o o n n .
- Page 60 Compressor Oil Amounts and Type I I m m p p o o r r t t a a n n t t : : Using the absence of bubbles in the sight glass as an indicator of correct refrigerant charge can be misleading, Y Y O O U U M M U U S S T T refrigerate the box to 0-5ºC (32-41ºF) to get a more precise indication from the sight glass.
- Page 61 Recommended Refrigerant Charge by Model I I m m p p o o r r t t a a n n t t : : Failure to add the proper amount of refrigerant will result in decreased system performance. Refer to the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide for information on proper system charging procedures.
- Page 62 Condenser and Evaporator Dimensions N N o o t t e e : : Paper Templates are available to assist in the installation of the Condenser and Evaporator. These Templates provide the installer with a footprint of the component and provide the correct mounting and access hole locations.
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Page 63: C C O O N N D D E E N N S S E E R R A A N N D D E E V V A A P P O O R R A A T T O O R R D D I I M M E E N N S S I I O O N N S
C C o o n n d d e e n n s s e e r r a a n n d d E E v v a a p p o o r r a a t t o o r r D D i i m m e e n n s s i i o o n n s s Figure 13. - Page 64 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 applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938.
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