Thermo King V-520 RT Series Installation Manual
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Thermo King V-520 RT Series Installation Manual

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Installation Manual
Vehicle Powered Truck Edition
V-520 RT Series
Single and Multi-Temperature Systems
Revision A
T T K K 5 5 6 6 6 6 1 1 2 2 - - 1 1 8 8 - - I I M M - - E E N N
July 2018

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  • Page 1 Installation Manual Vehicle Powered Truck Edition V-520 RT Series Single and Multi-Temperature Systems Revision A T T K K 5 5 6 6 6 6 1 1 2 2 - - 1 1 8 8 - - I I M M - - E E N N...
  • Page 2 Introduction This manual was written to assist with the general installation of Thermo King® components onto trucks designed and built for refrigerated applications. The T T h h e e r r m m o o K K i i n n g g 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 G G u u i i d d e e (TK 56430) provides more detailed information that must be followed to safely and properly complete the entire installation.

  • 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 E E n n g g i i n n e e D D r r i i v v e e n n C C o o m m p p r r e e s s s s 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 .
  • 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 SPECTRUM Multi-Temperature Systems............33 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 .
  • Page 5 I I m m p p o o r r t t a a n n t t : : Additional Safety Precautions must be followed when installing this unit. See “Section 2 - Safety Precautions” in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430).
  • Page 6 Engine Driven Compressor Installation I I m m p p o o r r t t a a n n t t : : See Section 5 - Compressor Selection and Installation Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430).

  • Page 7: Preparing Evaporator For Installation

    Evaporator Installation Preparing Evaporator for Installation Cover Removal (All Models) 1. Remove plastic cover assembly to access the unit mounting holes. TK 56612-18-IM-EN...

  • Page 8: Installing The Accumulator Assembly (Heat Option Only)

    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 Installing the Accumulator Assembly (Heat Option Only) N N o o t t e e : : ES500 shown, ES300 similar.

  • Page 9: Evaporator To Bulkhead Clearance Requirements

    Evaporator to Bulkhead Clearance Requirements 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 56430).

  • Page 10: Es500 Single Temperature Systems

    ES500 Single Temperature Systems 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 56430).

  • Page 11: Alternate Installation Method - Backer Plates

    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 Alternate Installation Method —...

  • Page 12: Alternate Installation Method - Lag Bolts And Adhesive

    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 Alternate Installation Method —...

  • Page 13: Es300 Multi-Temperature Units

    ES300 Multi-Temperature Units 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 56430). THESE PROCEDURES MUST BE FOLLOWED! N N o o t t e e : : Component dimensions are provided at the back of this manual.
  • Page 14 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 3.

  • Page 15: Alternate Installation Method - Lag Bolts And Adhesive

    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 Alternate Installation Method —...

  • Page 16: Preferred Installation Method - Pre-Installed Support Plate

    Preferred Installation Method — Pre-Installed Support Plate 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 refrigeration module. The plate should be installed prior to insulating and finishing the cargo area.

  • Page 17: Alternate Installation Method - Lag Bolts

    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 M M o o d d u u l l 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 Alternate Installation Method —...
  • Page 18 Power Pack Module Installation M M o o d d e e l l s s 2 2 0 0 a a n n d d M M A A X X 2 2 0 0 , , 5 5 0 0 , , M M A A X X 5 5 0 0 a a n n d d S S P P E E C C T T R R U U M M O O N N L L Y Y . . N N o o t t e e : : It is recommended the suction and discharge copper tubing (supplied) be installed onto the standby compressor prior to raising the Power Pack Module onto the roof of the vehicle.

  • Page 19: P P O O W W E E R R P P A A C C K K M M O O D D U U L L 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 N o o t t e e : : Component dimensions are provided at the back of this manual. 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 Power Pack Module. The plate should be installed prior to insulating and finishing the cargo area.

  • Page 20: Alternate Installation Method - Lag Bolts

    P P o o w w e e r r P P a a c c k k M M o o d d u u l l 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 Alternate Installation Method —...

  • Page 21: Preferred Installation Method - Pre-Installed Support Plate

    Preferred Installation Method - Pre-Installed Support Plate 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 Condenser Module. The plate should be installed prior to insulating and finishing the cargo area.

  • Page 22: Alternate Installation Method - Lag Bolts

    C C o o n n d d e e n n s s e e r r M M o o d d u u l l 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 Alternate Installation Method –...
  • Page 23 Compressor Oil Requirements I I m m p p o o r r t t a a n n t t : : See Section 5 – Compressor Selection and Installation Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! I I m m p p o o r r t t a a n n t t : : Compressor oil must be added to the roadside compressor and the suction line during installation.

  • Page 24: Model 10 And Max 10 - Single Temperature Systems

    Model 10 and MAX 10 — Single Temperature Systems 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 56430).

  • Page 25: Model 30 And Max 30 - Single Temperature Systems

    Model 30 and MAX 30 — Single Temperature Systems 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 56430).

  • Page 26: Model 20, Max 20 And Max 50 - Single Temperature Systems

    Model 20, MAX 20 and MAX 50 — Single Temperature Systems 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 56430).

  • Page 27: Max 50 - Single Temperature Systems

    MAX 50 — Single Temperature Systems 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 56430).

  • Page 28: Spectrum Multi-Temperature Systems

    SPECTRUM Multi-Temperature Systems 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 56430). THESE PROCEDURES MUST BE FOLLOWED!

  • Page 29: Solenoid Valve Positions

    Leak Check and Evacuation Procedures Solenoid Valve Positions I I m m p p o o r r t t a a n n t t : : The Liquid Injection Solenoid Valve, Liquid Solenoid Vales and the Defrost Solenoid Valve must be in the OPEN position during the evacuation procedures.
  • Page 30 L L e e a a k k C C h h e e c c k k a a n n d d 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 TK 56612-18-IM-EN...

  • Page 31: Single Temperature Systems

    Single Temperature Systems 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). THESE PROCEDURES MUST BE FOLLOWED! N N o o t t e e : : All electrical harnesses must be properly routed and connected securely to the individual components and to the vehicle’s electrical system.
  • Page 32 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 TK 56612-18-IM-EN...

  • Page 33: Spectrum Multi-Temperature Systems

    SPECTRUM Multi-Temperature Systems 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). THESE PROCEDURES MUST BE FOLLOWED! N N o o t t e e : : All electrical harnesses must be properly routed and connected securely to the individual components and to the vehicle’s electrical system.
  • Page 34 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 (TK 56430). THESE PROCEDURES MUST BE FOLLOWED!
  • Page 35 System Charging Procedures I I m m p p o o r r t t a a n n t t : : Ensure proper leak check and evacuation procedures were performed before charging the system. 1. If gauge set is still connected from the evacuation process, ensure gauge set is free of non-condensables and connect the refrigerant bottle to the gauge manifold.

  • Page 36: 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 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 TK 56612-18-IM-EN...

  • Page 37: Spr Valve Settings

    SPR and CPR Adjustment Procedures MODEL V-520 RT 10 / 10 MAX V-520 RT 20 / 20 MAX V-520 RT 30 / 30 MAX V-520 RT 50 / 50 MAX V-520 RT SPECTRUM SPR Valve Settings The SPR valve located in the Refrigeration Module is used to limit the load on the standby compressor. This also affects the current draw on the electric motor.

  • Page 38: Cpr Valve Settings - Single Temperature Systems

    S S P P R R a a n n d d C C 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 CPR Valve Settings —...

  • Page 39: Cpr Valve Settings - Spectrum Multi-Temperature Systems

    S S P P R R a a n n d d C C 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 CPR Valve Settings —...
  • Page 40 Installation Check List ☐ All components are installed with recommended hardware and tightened securely. ☐ All mounting holes and access holes are sealed with neutral/alcohol cure silicone sealant. ☐ All covers, guards or screens are installed securely on unit. ☐ Evaporator drain hoses are installed and angled downward for proper drainage. ☐...
  • Page 41 Commissioning and PDI Forms I I m m p p o o r r t t a a n n t t : : See Section 14 – Commissioning and PDI Forms in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430).
  • Page 42 Component Dimensions and Weights Figure 1. ES500 EVAPORATORS TK 56612-18-IM-EN...

  • Page 43: 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 A A N N D D W W E E I I G G H H T T S

    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 a a n n d d W W e e i i g g h h t t s s Figure 2.
  • Page 44 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 a a n n d d W W e e i i g g h h t t s s Figure 3.
  • Page 45 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 a a n n d d W W e e i i g g h h t t s s Figure 4.
  • Page 46 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 a a n n d d W W e e i i g g h h t t s s Figure 5.
  • Page 47 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 a a n n d d W W e e i i g g h h t t s s Figure 6.
  • Page 48 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 a a n n d d W W e e i i g g h h t t s s Figure 7.
  • Page 49 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 a a n n d d W W e e i i g g h h t t s s Figure 8.
  • Page 50 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 a a n n d d W W e e i i g g h h t t s s Figure 9.
  • Page 51 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 a a n n d d W W e e i i g g h h t t s s Figure 10.
  • Page 52 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 a a n n d d W W e e i i g g h h t t s s Figure 11.
  • Page 53 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 a a n n d d W W e e i i g g h h t t s s Figure 12.
  • Page 54 N N o o t t e e s s TK 56612-18-IM-EN...
  • Page 55 N N o o t t e e s s TK 56612-18-IM-EN...
  • Page 56 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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