Thermo King UT-1280 Installation Manual
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Thermo King UT-1280 Installation Manual

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Installation Manual
UT-1280 Single Temperature Systems
Rev. A
T T K K 5 5 6 6 3 3 7 7 4 4 - - 1 1 - - I I M M - - E E N N
May 2022

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Summary of Contents for Thermo King UT-1280

  • Page 1 Installation Manual UT-1280 Single Temperature Systems Rev. A T T K K 5 5 6 6 3 3 7 7 4 4 - - 1 1 - - I I M M - - E E N N May 2022...
  • Page 2 This manual was written to assist with the installation of a T T h h e e r r m m o o K K i i n n g g U U T T - - 1 1 2 2 8 8 0 0 condensing unit and U U T T S S E E o o r r S S - - 3 3 remote evaporators onto truck bodies specifically designed and built for refrigerated applications. Separate installation instructions for Thermo King options (e.g., door switches, status light, fuel tanks, etc.) can be found at www. thermoking.com.

  • Page 3: Table Of Contents

    UT-1280 Condenser ........
  • Page 4 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 Mounting Stud or Bolt Requirements ............33 R R e e m m o o v v i i n n g g H H o o l l d d i i n n g g C C h h a a r r g g e e a a n n d d R R e e f f r r i i g g e e r r a a n n t t T T u u b b i i n n g g B B e e s s t t P P r r a a c c t t i i c c e e s s .

  • 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. Your personal safety and the proper installation of this unit depend upon the strict observance of these precautions.

  • Page 6: Battery Installation And Cable Routing

    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 W W A A R R N N I I N N G G H H a a z z a a r r d d o o f f E E x x p p l l o o s s i i o o n n ! ! N N e e v v e e r r c c l l o o s s e e t t h h e e c c o o m m p p r r e e s s s s o o r r d d i i s s c c h h a a r r g g e e s s e e r r v v i i c c e e v v a a l l v v e e w w h h e e n n t t h h e e u u n n i i t t i i s s o o p p e e r r a a t t i i n n g g .

  • Page 7: Refrigerant Hazards

    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 C C A A U U T T I I O O N N H H a a z z a a r r d d o o u u 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 ! ! S S e e t t a a l l l l u u n n i i t t e e l l e e c c t t r r i i c c a a l l c c o o n n t t r r o o l l s s t t o o t t h h e e O O F F F F p p o o s s i i t t i i o o n n b b e e f f o o r r e e c c o o n n n n e e c c t t i i n n g g b b a a t t t t e e r r y y c c a a b b l l e e s s t t o o t t h h e e b b a a t t t t e e r r y y t t o o p p r r e e v v e e n n t t u u n n i i t t f f r r o o m m s s t t a a r r t t i i n n g g u u n n e e x x p p e e c c t t e e d d l l y y a a n n d d c c a a u u s s i i n n g g p p e e r r s s o o n n a a l l i i n n j j u u r r y y .

  • Page 8: First Aid

    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 First Aid R R E E F F R R I I G G E E R R A A N N T T •...

  • Page 9: Ut-1280 Condenser

    Component Dimensions UT-1280 Condenser TK 56374-1-IM-EN...

  • Page 10: Utse Evaporator (Nad-A/P)

    C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s UTSE Evaporator (NAD-A/P) 61.0 in (1549.4 mm) 59.0 in (1498.6 mm) 1.0 in (25.4 mm)

  • Page 11: S-3 + S-3 Evaporator

    C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s S-3 + S-3 Evaporator 17.7 mm (0.70 in.) 1094.0 mm...

  • Page 12: Hmi Controller

    C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s HMI Controller FRONT VIEW SIDE VIEW 189.0 mm...

  • Page 13: Safety Precautions

    Important Installation Notes Safety Precautions • See “Safety Precautions” beginning on page 5 prior to installing and servicing this product. Evaporator Location N N o o t t e e : : Refer to the illustrations on the following pages. •...
  • Page 14 I I m m p p o o r r t t a a n n t t 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 s s TK 56374-1-IM-EN...

  • Page 15: Defrost Drain Tube Connectors

    I I m m p p o o r r t t a a n n t t 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 s s Defrost Drain Tube Connectors I I m m p p o o r r t t a a n n t t : : Follow the instructions below to prevent defrost drain tube water leaks.

  • Page 16: Evaporator Cap Plugs

    I I m m p p o o r r t t a a n n t t 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 s s Evaporator Cap Plugs Cap plugs are provided to plug the two S-2 evaporator mounting access holes located directly above the drain pan.
  • Page 17 Required Tools Safety Glasses Drill Drill Bits Tape Measure Wire Crimpers Tubing Benders Hole Saw 35% Silver Solder and Flux Tubing Swage Tubing Cuter Refrigerant Oil Torch Set Mechanics Tools Manifold Gauge Set Evacuation Station Reclaiming Station Refrigerant and Scale Dry Nitrogen Tap and Die Set (Europe Only) Battery Charger (60 AMP Minimum)

  • Page 18: 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 Figure 1. Required Tools Shown A M P AFI80 TK 56374-1-IM-EN...
  • Page 19 Condenser Installation Kit Components Unit Mounting Component Special Washer (if required) Fuel Pump Mounting Components Fuel Pump Bracket Fuel Pump 1/2–20 Mounting Bolts, Washers and Locking Nuts Fuel Fittings Fuel Pickup Tube Electrical Installation Components Fuel Holder and 60 Amp Fuse Splice Connector (2 sizes) Battery Cable Lugs (2 sizes) Heat Shrink Sleeving...

  • Page 20: C C O O N N D D E E N N S S E E 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 K K I I T T C C O O M M P P O O N N E E N N T T S

    C C o o n n d d e e n n s s e e 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 K K i i t t C C o o m m p p o o n n e e n n t t s s Figure 2.
  • Page 21 Evaporator Installation Kit Components Evaporator Mounting Components Special Washers (3 sizes) Locking Nuts (1/2-13 and M10 x 1.5) Flat Washers (1/2 '' and 3/8'') Button Plug Screws, Washers and Locking nuts (1/4-20) Washers (1/2''' SAE) Electrical Installation Components Terminal Ring Blue Terminal Fork Blue Terminal Ring (Ampli-Bond Style) Refrigeration Tubing Installation Components...

  • Page 22: E E V V A A P P O O R R A A T T 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 K K I I T T C C O O M M P P O O N N E E N N T T S

    E E v v a a p p o o r r a a t t 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 K K i i t t C C o o m m p p o o n n e e n n t t s s Figure 3.
  • Page 23 10. Remove two rear steel bracket and bottom crate section. 11. Install forged eyebolts into unit’s mounting holes and use an appropriate four point lift to carefully raise unit up from the crate. Figure 4. Uncrating the UT-1280 Condenser Shown TK 56374-1-IM-EN...
  • Page 24 2. Lift unit into position and install onto Z-Channels with four Grade 5 (or better) 5/8 x 11 (16 mm x 2) mounting bolts, washers and locking nuts. a. Tighten hardware securely and torque to 176-230 N•m (130-170 ft-lb). Figure 5. Typical UT-1280 Condenser Installation Shown TK 56374-1-IM-EN...
  • Page 25 Installing the Fuel Pump D D A A N N G G E E R R F F i i r r e e H H a a z z a a r r d d ! ! L L e e a a k k i i n n g g f f u u e e l l l l i i n n e e s s c c o o u u l l d d c c a a u u s s e e a a f f i i r r e e r r e e s s u u l l t t i i n n g g i i n n d d e e a a t t h h o o r r s s e e r r i i o o u u s s i i n n j j u u r r y y . . A A l l l l f f u u e e l l l l i i n n e e f f i i t t t t i i n n g g s s m m u u s s t t b b e e t t i i g g h h t t a a n n d d l l e e a a k k f f r r e e e e .

  • 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 F F U U E E L L P P U U M M P

    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 F F u u e e l l P P u u m m p p Figure 6.

  • Page 27: Harness Routing And Service Loops

    Installing HMI Controller W W A A R R N N I I N N G G R R i i s s k k o o f f I I n n j j u u r r y y ! ! ! ! D D O O N N O O T T t t u u r r n n t t h h e e u u n n i i t t s s w w i i t t c c h h “...
  • Page 28 I I n n s s t t a a l l l l i i n n g g H H M M I I C C o o n n t t r r o o l l l l e e r r Figure 7.
  • Page 29 . . N N o o t t e e : : Thermo King units are designed for one 12 volt, group 31 battery. The battery must be suitable for deep cycling, heavy duty and rated with a minimum of 95 amp/hr.

  • Page 30: 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 B B A A T T T T E E R R Y Y B B O O X X ( ( O O P P T T I I O O N

    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 B B a a t t t t e e r r y y B B o o x x ( ( O O p p t t i i o o n n ) ) Figure 8.
  • Page 31 Installing UTSE - NAD A/P N N o o t t e e : : Ceiling must be flat and mounting locations correct for proper evaporator installation and operation. Thermo King recommends installing the evaporator with 8 mm (5/16 in.) bolts or studs. 1.

  • Page 32: I I N N S S T T A A L L L L I I N N G G U U T T S S E E - - N N A A D D A A / / P

    I I n n s s t t a a l l l l i i n n g g U U T T S S E E - - N N A A D D A A / / P P Figure 9.

  • Page 33: Ceiling Preparation

    Installing S-3 + S-3 Evaporators Ceiling Preparation I I m m p p o o r r t t a a n n t t : : Ceiling must be flat and mounting locations correct for proper S-3 evaporator installation. Foam insulation in ceiling must be removed from evaporator mounting area and aluminum spacers must be installed between evaporator mounting plate and truck/trailer ceiling.
  • Page 34 I I n n s s t t a a l l l l i i n n g g S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s Figure 10.
  • Page 35 Practices STOP Thermo King UT-1280 condensing units and remote evaporator(s) and are shipped with a 35-69 kPa (5-10 psi) holding charge of Nitrogen. This holding charge may be safely vented into the atmosphere. IMPORTANT: Do not release the holding charge until necessary to prevent moisture from entering the system.
  • Page 36 Connecting Refrigeration Tubing to UTSE N N o o t t e e : : Thermo King recommends the use of bulk rolled refrigeration tubing and tube benders to reduce fittings and solder joints where applicable (Detail I). It is also required that nitrogen or another inert gas be used to purge the tubes before soldering.
  • Page 37 Evaporators N N o o t t e e : : Thermo King recommends the use of bulk rolled refrigeration tubing and tube benders to reduce fittings and solder joints where applicable (Detail I). It is also required that nitrogen or another inert gas be used to purge the tubes before soldering.
  • Page 38 C C o o n n n n e e c c t t i i n n g g R R e e f f r r i i g g e e r r a a t t i i o o n n T T u u b b i i n n g g t t o o S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s Figure 13.
  • Page 39 N N o o t t e e : : For proper drainage the drain hose must slope down continuously from the remote evaporators to the wall drains with no kinks or droop. Thermo King recommends routing each individual drain hose directly out of the truck box to allow faster water drainage.
  • Page 40 Electrical Connections to UTSE 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 ! ! A A l l l l e e l l e e c c t t r r i i c c a a l l w w i i r r e e s s m m u u s s t t b b e e r r o o u u t t e e d d a a n n d d s s e e c c u u r r e e d d p p r r o o p p e e r r l l y y t t o o p p r r e e v v e e n n t t t t h h e e m m f f r r o o m m r r u u b b b b i i n n g g , , c c h h a a f f f f i i n n g g , , o o r r m m a a k k i i n n g g c c o o n n t t a a c c t t w w i i t t h h h h o o t t , , s s h h a a r r p p , , o o r r r r o o t t a a t t i i n n g g c c o o m m p p o o n n e e n n t t s s .
  • Page 41 Electrical Connections to S-3 + S-3 Evaporators 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 ! ! A A l l l l e e l l e e c c t t r r i i c c a a l l w w i i r r e e s s m m u u s s t t b b e e r r o o u u t t e e d d a a n n d d s s e e c c u u r r e e d d p p r r o o p p e e r r l l y y t t o o p p r r e e v v e e n n t t t t h h e e m m f f r r o o m m r r u u b b b b i i n n g g , , c c h h a a f f f f i i n n g g , , o o r r m m a a k k i i n n g g c c o o n n t t a a c c t t w w i i t t h h h h o o t t , , s s h h a a r r p p , , o o r r r r o o t t a a t t i i n n g g c c o o m m p p o o n n e e n n t t s s .
  • Page 42 E E l l e e c c t t r r i i c c a a l l C C o o n n n n e e c c t t i i o o n n s s t t o o S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s Figure 16.
  • Page 43 Evaporator Drain Hose Resistance Wire Installation Guide The following information is provided as a guide to help ensure the proper routing of the drain hose resistance wires. You should supplement this guide with whatever other documentation is required for your facility. I I m m p p o o r r t t a a n n t t : : Only one resistance wire should be installed in the wall defrost drain tube.

  • Page 44: 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 R R E E S S I I S S T T A A N N C C E E W W I I R R 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 G G U U I I D D E

    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 R R e e s s i i s s t t a a n n c c e e W W i i r r 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 G G u u i i d d e e Figure 17.
  • Page 45 System Leak Check 1. Connect leak test gas supply (R404A) to center hose of gauge manifold. 2. Attach gauge manifold hoses to suction and discharge service valves. 3. Open suction and discharge valves and pressurize system with leak test gas. If desired system pressure may be boosted using nitrogen gas.

  • Page 46: S S Y Y S S T T E E M M E E V V A A C C U U A A T T I I O O N N A A N N D D C C H H A A R R G G I I N N G G P P R R O O C C E E D D U U R R E E S

    N N o o t t e e : : The use of Thermo King Evacuation Station P/N 204-725 is required. Set up and test evacuative equipment prior to performing this operation. The UT-1280 does not have a discharge service valve, therefore it is recommended that low-loss fittings be used on any gauge sets and on evacuation station line connected to discharge line.
  • Page 47 S S y y s s t t e e m m E E v v a a c c u u a a t t i i o o n n a a n n d d C C h h a a r r g g i i n n g g P P r r o o c c e e d d u u r r e e s s Two Stage Vacuum Pump To AC Power Micron Gauge...

  • Page 48: Initial System Charge

    S S y y s s t t e e m m E E v v a a c c u u a a t t i i o o n n a a n n d d C C h h a a r r g g i i n n g g P P r r o o c c e e d d u u r r e e s s Initial System Charge The UT-1280 utilizes a liquid line sight glass. This is used in order to attain an optimum charge given varied installations (suction/liquid line lengths vary).
  • Page 49 S S y y s s t t e e m m E E v v a a c c u u a a t t i i o o n n a a n n d d C C h h a a r r g g i i n n g g P P r r o o c c e e d d u u r r e e s s Micron Gauge Two Stage Vacuum Pump Thermistor...
  • Page 50 Installing the S-3 Evaporator Covers Cap plugs are provided to plug the two evaporator mounting access holes located directly above the drain pan. These plugs must be installed to prevent water in the drain pan from spilling out of these holes and into the cargo area. 1.

  • Page 51: Commissioning Form Overview

    All self-powered truck units come with the Commissioning Form (TK 56640) included in the documents package. This form is also available online at Thermo King ReqDirect. By completing the Commissioning Form, the i i n n s s t t a a l l l l e e r r confirms the installation was done per Thermo King’s Installation Manual and the unit operates as it should.
  • Page 52 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 18.
  • Page 53 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 19.
  • Page 54 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 20.

  • Page 55: Pre-Delivery Inspection (Pdi) Form Overview

    PDI Form (TK 56641) is also included in the documents package of all vehicle powered truck units. This form is also available online at Thermo King ReqDirect. The PDI form is used when the unit installation was performed by someone other then the selling party.
  • Page 56 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 21.
  • Page 57 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 22.
  • Page 58 N N o o t t e e s s TK 56374-1-IM-EN...
  • Page 59 N N o o t t e e s s TK 56374-1-IM-EN...
  • Page 60 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com. Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

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