Related Manuals for Thermo King V220 Series
Summary of Contents for Thermo King V220 Series
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Page 1: S S E E C C T T I I O O N N 7 7 - - E E L L E E C C T T R R I I C C A A L L S S T T A A N N D D A A R R D D S
User Guide Installation Standards and Procedures Guide V220 and V320 Series Units Revision B T T K K 5 5 6 6 4 4 3 3 0 0 - - 1 1 8 8 - - I I P P - - E E N N June 2022... -
Page 2: S S E E C C T T I I O O N N 1 1 3 3 - - U U N N I I T T P P E E R R F F O O R R M M A A N N C C E E A A D D J J U U S S T T M M E E N N T T S
This guide is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted. -
Page 3: S S E E C C T T I I O O N N 1 1 4 4 - - 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
Please take a few minutes to read this page. It explains the content and structure of this guide. This will make it easier for you to find the information you need. Reading and understanding each section prior to installing a Thermo King Vehicle Powered Truck Refrigeration System will help make for a successful installation. -
Page 4: Table Of Contents
Table of Contents S S e e c c t t i i o o n n 1 1 - - I I n n t t r r o o d d u u c c t t i i o o n n ..............................8 8 Objective. -
Page 5: S S E E C C T T I I O O N N 8 8 - - 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 S S T T A A N N D D A A R R D D S
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 Nosemount and Rooftop Mount Similarities ..........26 Installation Sequence . -
Page 6: S S E E C C T T I I O O N N 3 3 - - 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
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 Tightening Refrigeration Hose Fittings............54 Suction Line Splice Connector . -
Page 7: S S E E C C T T I I O O N N 6 6 - - R R E E F F R R I I G G E E R R A A N N T T H H O O S S E E A A N N D D F F I I T T T T I I N N G G S S S S T T A A N N D D A A R R D D S
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 Hour Meter ................81 Information Menu . -
Page 8: Objective
Following the procedures will help assure the installation is completed in a timely manner. It is also recommended that installers of Thermo King equipment not only become familiar with this manual, but also any other referenced publications listed herein before beginning the installation process. -
Page 9: S S E E C C T T I I O O N N 2 2 - - 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
608 certified. 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 operation of this unit depend upon the strict observance of these precautions. - Page 10 S S e e c c t t i i o o n n 2 2 - - 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 D D A A N N G G E E R R R R i i s s k k o o f f I I n n j j u u r r y y ! ! K K e e e e p p y y o o u u r r h h a a n n d d s s , , c c l l o o t t h h i i n n g g , , a a n n d d t t o o o o l l s s c c l l e e a a r r o o f f m m o o v v i i n n g g p p a a r r t t s s 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 o o r r v v e e h h i i c c l l e e ’...
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Page 11: Auto Start Hazards
S S e e c c t t i i o o n n 2 2 - - 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 Auto Start Hazards C C A A U U T T I I O O N N R R i i s s k k o o f f I I n n j j u u r r y y ! ! -
Page 12: Electrical Hazards
Welding Precautions Take precautions before performing electric welding on any portion of the unit or vehicle to which the unit is attached. Verify welding currents are not allowed to flow through the electronic circuits of the Thermo King unit. TK 56430-18-IP-EN... -
Page 13: Microprocessor Precautions
S S e e c c t t i i o o n n 2 2 - - 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 Microprocessor Precautions The following procedures must be followed when working on microprocessor based control systems: •... -
Page 14: First Aid
S S e e c c t t i i o o n n 2 2 - - 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 15 S S e e c c t t i i o o n n 2 2 - - 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 Figure 1.
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Page 16: Overview
While basic mechanics tools and refrigeration service equipment are a necessity, there are also special tools that are required when installing Thermo King Vehicle Powered Truck Units. Using these tools will assure the installation is done correctly. Many of these are available from Thermo King. - Page 17 S S e e c c t t i i o o n n 3 3 - - 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 RCS481-1 WinTrac Software (latest version must always be used)
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Page 18: Overview
The cargo box size, insulation thickness, door openings per delivery day and temperature requirements must be matched to the Thermo King refrigeration system being installed. The wrong size unit on the wrong size cargo box may not perform as designed. The interactive Unit Selection Guide should be used to verify the correct unit is selected. -
Page 19: Installation Templates
Components are carefully packaged at the factory to prevent damage during shipment. However, if components are found to be damaged, contact the shipping company immediately. Contact Thermo King if components are missing. Before beginning the installation, check the following against the sales order: Confirm all components are accounted for including the kits and any options. -
Page 20: Drilling Holes
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Confirm condenser model and voltages shown on the condenser serial plate matches the sales order. - Page 21 S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s •...
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Page 22: Sealing Holes
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Sealing Holes Proper sealing of all holes drilled into the cargo box is very important. -
Page 23: Sealing Refrigerant Lines And Electrical Harnesses
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Sealing Refrigerant Lines and Electrical Harnesses Once the access hole has been cut and all refrigerant hoses and electrical harnesses have been routed and connected, the hole must be sealed properly by following these steps:... -
Page 24: Mounting Hardware
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Mounting Hardware Always use the proper mounting hardware when installing Thermo King equipment. Choosing the wrong hardware can result in equipment failure, vehicle damage, or serious injury. All mounting hardware must be the correct grade, size and length for the application and tightened securely. -
Page 25: Vehicle Powered Truck Units
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s •... -
Page 26: Nosemount And Rooftop Mount Similarities
Completion of the Commissioning Form. Installation Sequence Thermo King has determined the best installation sequence for vehicle powered units to help minimize the installation time. It is recommended the sequence shown below be followed for either nosemount or roof mount units: 1. -
Page 27: Nosemount Condenser Installation
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s 11. - Page 28 S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Figure 10.
- Page 29 S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Figure 12.
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Page 30: Rooftop Mounted Condenser Installation
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Rooftop Mounted Condenser Installation I I m m p p o o r r t t a a n n t t : : Not all Vehicle Powered Truck Units can be installed on the rooftop. -
Page 31: Remote Evaporator Installation
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Figure 14. -
Page 32: Evaporator Installation With Pre-Installed Support Plates
Evaporator Installation with Pre-Installed Support Plates Thermo King recommends installing a support plate with mounting studs or threaded inserts (installer supplied) to the truck’s interior roof structure to safely support the weight of the evaporator(s). The plate should be installed prior to insulating and finishing the cargo area. -
Page 33: Evaporator Installation Without Support Plates
S S e e c c t t i i o o n n 4 4 - - U U n n i i 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 S S t t a a n n d d a a r r d d s s a a n n d d P P r r o o c c e e d d u u r r e e s s Evaporator Installation without Support Plates If no supports or brackets for hanging or mounting the evaporator were added prior to installing the insulation package or liner, thru bolts with backer plates must be used to verify the evaporator is properly secured. -
Page 34: Overview
Section 5 - Compressor Selection and Installation Standards Overview This section defines Thermo King’s requirements for selecting and installing the correct compressor for various vehicle powered units. The installer must follow these requirements to ensure the system operates as designed. Compressor Selection I I m m p p o o r r t t a a n n t t : : The correct compressor MUST be selected for each vehicle powered unit. -
Page 35: Understand Compressor Speeds
To achieve the optimal compressor speeds, the correct compressor pulley must be selected from the table below. Changing the pulley size will change compressor speed. N N o o t t e e : : The 4.69 in. (119 mm) diameter pulley is standard on a Thermo King swash plate compressors. Compressor Pulley Diameters Available 4.69 in. -
Page 36: Calculate The Compressor Speeds
S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s Calculate the Compressor Speeds To calculate the compressor speed, follow the steps below, or obtain a speed calculator from your local dealer. - Page 37 S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s into the drain plug of the compressor.
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Page 38: Torque Specifications
12. Look up the oil charging quantities for the specific model being installed in the unit’s Installation Manual (available on Thermo King Info Central). 13. Pour the correct amount of oil into the suction line where it connects to the vehicle driven compressor. -
Page 39: Ground Strap Installation
S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s Ground Strap Installation Every Vehicle Powered truck unit comes with a compressor ground strap kit. -
Page 40: Belt Alignment
Thermo King compressor,) only the alignment between the compressor and the additional pulley needs to be verified. If the mount kit uses the existing crankshaft pulley and has the Thermo King compressor pulley share the same belt as the OEM vehicle components (such as the alternator, power steering, etc.), the compressor pulley alignment needs to be checked with the components before and after the compressor following the belt path. -
Page 41: Changing Compressor Clutch
S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s Figure 30. - Page 42 S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s Figure 32.
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Page 43: Installation
S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s Figure 34. -
Page 44: Setting Air Gap
S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s Figure 36. -
Page 45: Liquid Injection Temperature Sensor Installation Procedures(Max Units Only)
S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s Air Gap Armature Rubber Damper Liquid Injection Temperature Sensor Installation Procedures... - Page 46 S S e e c c t t i i o o n n 5 5 - - C C o o m m p p r r e e s s s s o o r r S S e e l l e e c c t t i i o o n n a a n n d d I I n n s s t t a a l l l l a a t t i i o o n n S S t t a a n n d d a a r r d d s s Figure 40.
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Page 47: Overview
. . This section defines Thermo King’s requirements for fabricating and installing refrigeration hoses and fittings onto vehicle powered truck units. -
Page 48: Allowing For Movement
S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s Allowing for Movement Refrigerant hoses must be installed to allow for changes in length due to component motion, vibration, pressures, and temperatures. -
Page 49: Examples Of Hose Designs
S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s Examples of Hose Designs Before fabricating hoses, always review how each hose will be routed and connected to the component. -
Page 50: Minimum Hose Bend Radius
S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s Minimum Hose Bend Radius •... -
Page 51: Abrasion Protection
Protective Covers and Guards Protective covers and guards are recommended for any exposed refrigeration hoses either inside or outside the cargo box that could become damaged during daily use. These covers and guards are available from Thermo King. TK 56430-18-IP-EN... -
Page 52: Protective Heat Shields
S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s Protective Heat Shields The installation of protective heat shields (installer supplied) is recommended for any exposed refrigeration hoses located near vehicle heat sources such as the exhaust system. -
Page 53: Determining Fitting Type
S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s Determining Fitting Type Figure 47. -
Page 54: O-Rings
Always lubricate the O-Rings with POE refrigerant oil and install correctly into cavity before tightening fittings. Refer (“Tightening Refrigeration Hose Fittings,” p. 54). • The correct replacement O-Rings are available from your Thermo King dealer. Table 7. Replacement Thermo King O-Rings by fitting size. Fitting Size... -
Page 55: Suction Line Splice Connector
S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s Suction Line Splice Connector Certain vehicle powered truck units come equipped with a suction line splice connector with two service ports. -
Page 56: Units With Oil Return Hose
S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s •... - Page 57 S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s Radius,”...
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Page 58: Tk 2000+ System
S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s TK 2000+ System Thermo King uses the TK 2000+ System which is designed for assembly with multi-refrigerant hose only. Assembly Materials Checklist... - Page 59 S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s Figure 54.
- Page 60 S S e e c c t t i i o o n n 6 6 - - R R e e f f r r i i g g e e r r a a n n t t H H o o s s e e a a n n d d F F i i t t t t i i n n g g s s S S t t a a n n d d a a r r d d s s S S n n a a p p o o n n t t h h e e C C a a g g e e 5.
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Page 61: Overview
Section 7 - Electrical Standards Overview The Electrical Standards section of this manual defines how to properly connect the Thermo King electrical harness to the individual components and to the vehicle’s electrical system. This section covers both low voltage (12 Vdc) and high voltage (115 or 230 Vac) connections. -
Page 62: Sealed Connectors
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s Sealed Connectors Sealed connectors are used inside the cargo box, outside the vehicle and in the engine compartment. -
Page 63: Unsealed Connectors
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s Unsealed Connectors Unsealed connectors are designed for use in the interior of the vehicle where protection from moisture and dirt are not required (i.e., In-Cab controller harness).The harness supplied with the unit comes with the in-cab controller connector... -
Page 64: Sealed Splice Connectors
Sealed connectors keep moisture and dirt out of the connector and help prevent corrosion of the connections (i.e., inside the engine compartment). Two types of sealed splice connectors are provided by Thermo King: heat shrink butt splice and a parallel crimp connector with heat shrink tubing. -
Page 65: Heat Shrink Sealed Butt Splice Connectors
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s Heat Shrink Sealed Butt Splice Connectors I I m m p p o o r r t t a a n n t t : : All splice connectors must be sized for the correct gauge wires. -
Page 66: Parallel Crimp Connectors With Heat Shrink Tubing
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s Parallel Crimp Connectors with Heat Shrink Tubing I I m m p p o o r r t t a a n n t t : : All parallel crimp connectors must be sized for the correct gauge wires. -
Page 67: Unit Ground Wire To 12 Vdc Negative Battery Connection
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s Unit Ground Wire to 12 Vdc Negative Battery Connection I I m m p p o o r r t t a a n n t t : : Please seek advice from the vehicle manufacturer for correct connection. -
Page 68: Unit Main Power Connections To 12 Vdc Positive Battery Connection
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s Unit Main Power Connections to 12 Vdc Positive Battery Connection The unit’s main power ( ( 2 2 ) ) wire and the ( ( B B A A T T ) ) wire (with mini-fuse*) must both be connected to the vehicle’s positive battery connection with the supplied large sealed in-line fuse kit. - Page 69 S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s 1.
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Page 70: 12 Vdc Positive Ignition Connection
N N o o t t e e : : A standby power cable with mating connector plug will be required by the customer to attach to the truck’s receptacle box. Thermo King recommends that only a correctly sized and fused power source be used for electric standby operation. -
Page 71: Standby Power Cable Wiring Connections
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s INCORRECT - No Drip Loop CORRECT - With Drip Loop Standby Power Cable Wiring Connections... -
Page 72: Electrical Harness Protection
Electrical Harness Protection All Thermo King low voltage (12 Vdc) electrical harnesses and all high voltage power cables (115 and 220 Vac) must be installed and routed correctly to prevent damage. Taking your time to properly route and secure the harnesses will go a long way in providing a trouble free unit. -
Page 73: Routing Harnesses Through Metal Holes
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s Electrical harnesses should be secured to existing frame mounts or Electrical harnesses should be secured to vehicle’s frame with insulated to vehicle’s harnesses with band wraps as shown. -
Page 74: Protective Heat Shields
S S e e c c t t i i o o n n 7 7 - - E E l l e e c c t t r r i i c c a a l l S S t t a a n n d d a a r r d d s s Figure 69. -
Page 75: Overview
Section 8 - Evaporator Drain Hose Standards Overview During normal operation, condensate moisture accumulates on the evaporator coil fins and drips into the drain pan. Drain tubes in the pan allow the water to drain out of the evaporator, down the drain hoses and out of the cargo box onto the ground. - Page 76 S S e e c c t t i i o o n n 8 8 - - 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 S S t t a a n n d d a a r r d d s s Drain hoses must be routed without kinks or sharp bends and Access holes must be sealed both inside and outside with neutral/ adequately secured to wall with clamps.
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Page 77: Drain Heater Standards
S S e e c c t t i i o o n n 8 8 - - 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 S S t t a a n n d d a a r r d d s s Drain hoses must be routed out of the cargo area and exit under the vehicle. - Page 78 S S e e c c t t i i o o n n 8 8 - - 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 S S t t a a n n d d a a r r d d s s Heater wires must extend into the drain pan and inserted into each ES320 MAX 30 / 50, V520 RT and nosemounted SPECTRUM units ONLY: drain hose as far as they will go.
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Page 79: Controller Overview
Section 9 - Configuring Software and Controller Procedures Controller Overview This chapter is a high level overview of the controller. The installer should refer to the DSR III Diagnostic Manual (TK 61096) for more detailed instructions on diagnostics, repair, and operation. Two different controllers are used on VP truck units: the DSR II and DSR III. -
Page 80: Hmi Overview
S S e e c c t t i i o o n n 9 9 - - C C o o n n f f i i g g u u r r i i n n g g S S o o f f t t w w a a r r e e a a n n d d C C o o n n t t r r o o l l l l e e r r P P r r o o c c e e d d u u r r e e s s HMI Overview The HMI is very simple to operate with five buttons and a LCD display screen. -
Page 81: Controller Menu
S S e e c c t t i i o o n n 9 9 - - C C o o n n f f i i g g u u r r i i n n g g S S o o f f t t w w a a r r e e a a n n d d C C o o n n t t r r o o l l l l e e r r P P r r o o c c e e d d u u r r e e s s Condenser Defrost Icon: Appears when the condenser coil is defrosting and at the same time as the defrost icon (the unit is in Condenser Defrost mode) Alarm Icon: Appears when an alarm condition has been detected by the microprocessor. - Page 82 S S e e c c t t i i o o n n 9 9 - - C C o o n n f f i i g g u u r r i i n n g g S S o o f f t t w w a a r r e e a a n n d d C C o o n n t t r r o o l l l l e e r r P P r r o o c c e e d d u u r r e e s s Figure 72.
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Page 83: Configuration Files
. . Every Thermo King Vehicle powered system requires a unit specific configuration file to be loaded onto the DSR controller either at the factory or at the installing dealer depending on which options are being added. - Page 84 S S e e c c t t i i o o n n 9 9 - - C C o o n n f f i i g g u u r r i i n n g g S S o o f f t t w w a a r r e e a a n n d d C C o o n n t t r r o o l l l l e e r r P P r r o o c c e e d d u u r r e e s s Figure 74.
- Page 85 S S e e c c t t i i o o n n 9 9 - - C C o o n n f f i i g g u u r r i i n n g g S S o o f f t t w w a a r r e e a a n n d d C C o o n n t t r r o o l l l l e e r r P P r r o o c c e e d d u u r r e e s s 12.
- Page 86 S S e e c c t t i i o o n n 9 9 - - C C o o n n f f i i g g u u r r i i n n g g S S o o f f t t w w a a r r e e a a n n d d C C o o n n t t r r o o l l l l e e r r P P r r o o c c e e d d u u r r e e s s a.
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Page 87: Overview
Evacuation Procedures Proper evacuation is required to verify ensure unit performance and reliability. The use of the Thermo King Evacuation Station (204725) is recommended, however proper individual devices can also be used (e.g., gauge manifold(s), vacuum pump, micron gauge, etc). - Page 88 S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s Figure 76. 2-Point Evacuation using Thermo King Evacuation Station TK 56430-18-IP-EN...
- Page 89 S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s Figure 77.
- Page 90 S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s Figure 78. 3-Point Evacuation using Thermo King Evacuation Station TK 56430-18-IP-EN...
- Page 91 S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s Figure 79.
- Page 92 S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s Figure 80. 4-Point Evacuation using Thermo King Evacuation Station TK 56430-18-IP-EN...
- Page 93 S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s Figure 81.
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Page 94: Dsr Lll Equipped Units With 544.Xx Firmware
S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s 1. Connect the Thermo King evacuation station, or individual vacuum pump, gauge manifold(s) and micron gauge to the unit. - Page 95 S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s Table 9.
- Page 96 S S e e c c t t i i o o n n 1 1 0 0 - - 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 P P r r o o c c e e d d u u r r e e s s N N o o t t e e : : To leak check the unit refer to: Section 11 - System Leak Check Procedures.
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Page 97: Overview
Section 11 - System Leak Check Procedures Overview It is critical that the unit is leak free to ensure unit performance and reliability. This section outlines the leak check procedure for all Vehicle Powered Truck units utilizing swash plate or reciprocating compressors. I I m m p p o o r r t t a a n n t t : : Failure to properly eliminate system leaks will result in decreased system performance, reliability, and compressor failures. -
Page 98: Using Pressurized Nitrogen
S S e e c c t t i i o o n n 1 1 1 1 - - S S y y s s t t e e m m L L e e a a k k C C h h e e c c k k P P r r o o c c e e d d u u r r e e s s Figure 82. -
Page 99: Procedures
S S e e c c t t i i o o n n 1 1 1 1 - - S S y y s s t t e e m m L L e e a a k k C C h h e e c c k k P P r r o o c c e e d d u u r r e e s s •... -
Page 100: Overview
Section 12 - System Charging Procedures Overview To help ensure optimal system performance and reliability it is critical that proper refrigerant charging procedures are followed during installation and repair events. This section outlines the updated refrigerant charging procedure for all Vehicle Powered Truck units utilizing swash plate or reciprocating compressors. -
Page 101: Suction (Low Side) Bump Charging
S S e e c c t t i i o o n n 1 1 2 2 - - S S y y s s t t e e m m 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 10. -
Page 102: Overview
Section 13 - Unit Performance Adjustments Overview Various models of vehicle powered truck units are equipped with either a Suction Pressure Regulator (SPR) valve or a Compressor Pressure Regulator (CPR) valve. After unit installation, these valves require adjustments for maximum performance. -
Page 103: Commissioning Form Overview
All vehicle powered truck units come with the Commissioning Form (TK 56482) 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 Standards and Procedures Guide and the unit... - Page 104 S S e e c c t t i i o o n n 1 1 4 4 - - 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 83.
- Page 105 S S e e c c t t i i o o n n 1 1 4 4 - - 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 84.
- Page 106 S S e e c c t t i i o o n n 1 1 4 4 - - 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 85.
- Page 107 S S e e c c t t i i o o n n 1 1 4 4 - - 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 86.
- Page 108 S S e e c c t t i i o o n n 1 1 4 4 - - 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 87.
- Page 109 N N o o t t e e s s TK 56430-18-IP-EN...
- Page 110 N N o o t t e e s s TK 56430-18-IP-EN...
- Page 111 N N o o t t e e s s TK 56430-18-IP-EN...
- Page 112 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.