Related Manuals for Thermo King V-220 Series
Summary of Contents for Thermo King V-220 Series
- Page 1 Maintenance Manual Truck Edition V-220/V-320 Series Revision B T T K K 5 5 6 6 3 3 4 4 2 2 - - 1 1 8 8 - - M M M M - - E E N N September 2018...
- Page 2 TK 56321 V-220/V-320 Heat Kit Installation Manual TK 56340 Vehicle Powered Truck Installation Standards and Procedures TK 56430 Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK 5984 Tool Catalog TK 5955 Evacuation Station Operation and Field Application TK 40612 The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo King units.
- Page 3 EU, local F-gas Regulations must be observed when working on refrigeration systems. R-134aR-404A At Thermo King®, we recognize the need to preserve N N O O T T I I C C E E the environment and limit the potential harm to the...
- Page 4 Wiring, Schematic and Refrigeration diagrams applicable to the unit. Before you Call Thermo King Service! Roadside/Curbside Terminology Who to call: Your Thermo King Service Representative. Roadside/Curbside terminology: These terms can be confusing because of differences between North Before you call Thermo King Service, have the America and Europe.
- Page 5 I I n n t t r r o o d d u u c c t t i i o o n n Customer Satisfaction Survey com/jfe/form/SV_2octfSHoUJxsk6x?Q_CHL=qr&Q_ JFE=qdg to complete the survey. Let your voice be heard! Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a web browser.
- Page 6 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 ..........1 1 0 0 DSR Control System .
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Page 7: Table Of Contents
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 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e ........4 4 2 2 Electrical Contactors . - Page 8 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 Tools Required ..... . 59 Expansion Valve Assembly .
- Page 9 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 O O v v e e r r - - t t h h e e - - R R o o a a d d M M e e c c h h a a n n i i c c a a l l Electric Standby Compressor Belt .
- Page 10 Thermo King dealer and to be aware of i i n n a a n n y y c c o o n n f f i i n n e e d d a a r r e e a a w w i i t t h h a a l l i i m m i i t t e e d d a a i i r r s s u u p p p p l l y y .
- Page 11 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 W W A A R R N N I I N N G G F F i i r r e e H H a a z z a a r r d d ! ! S S h h a a r r p p E E d d g g e e s s ! !
- Page 12 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 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 ! ! C C o o m m b b u u s s t t i i b b l l e e H H a a z z a a r r d d ! !
- Page 13 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 Service W W A A R R N N I I N N G G Precautions 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 m m a a k k e e r r a a p p i i d d m m o o v v e e s s w w h h e e n n w w o o r r k k i i n n g g o o n n h h i i g g h h...
- Page 14 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 • Use normal welding procedures, but keep the •...
- Page 15 Model Systems (System Designations) V-220 and V-320 Truck Refrigeration Systems System Designation System Number Install Kit Refrigerant Schematic, Wiring Diagrams V-220 10 903495 801131 R-134a 3E34872, 3E34873 V-220 20 903496 801132 R-134a 3E34870, 3E34871 V-220 MAX 10 903491 801096 R-404A 3E34872, 3E34873 V-220 MAX 20 903492...
- Page 16 Specifications Electrical System Fuses Fuse 3: Evaporator Fan Motor (EFM1) 15 amps Fuse 4: Evaporator Fan Motor (EFM2) 15 amps Fuse 5: Roadside (Engine) Compressor Clutch (CLU1), Hot Gas Solenoid (HGS), 20 amps Liquid Injection Switch (LISW), Liquid Injection Solenoid (LIS), Electric Standby Compressor Clutch (CLU2), Compressor Motor Contactor (CMC), CPR Bypass Solenoid (BYPS), Condenser Inlet Solenoid (CIS) Fuse 6: Drain Line Heaters (DH1 and DH2)
- Page 17 S S p p e e c c i i f f i i c c a a t t i i o o n n s s Coolant Heat Pump Motor (CP) - Truck Engine Coolant Heat Option Only Current 1.5 Amps at 12 Vdc Resistance...
- Page 18 S S p p e e c c i i f f i i c c a a t t i i o o n n s s Compressor Pressure Regulator (CPR) Valve Setting - Model 30 and 50 Only 24 ±...
- Page 19 S S p p e e c c i i f f i i c c a a t t i i o o n n s s Coil Current 0.25 amps Coil Resistance 48 ohms Capacitors Capacitor Capacitance Smoothing Capacitor (C1) – all voltages 6800 μF Electric Motor Run Capacitor 1 (RC1) –...
- Page 20 S S p p e e c c i i f f i i c c a a t t i i o o n n s s Electric Standby Power Supply Requirements Power Cord Length Power Cord Size (AWG) Voltage Phase Power Supply Circuit Breaker...
- Page 21 Unit Description Introduction DSR Control System The Thermo King V-220/V-320 and V-220/V-320 MAX The DSR Control System is composed of an Electronic truck refrigeration systems are designed for Control Module (ECM) located in the control box, and applications on vans and small-sized trucks with one the In-Cab Control Box.
- Page 22 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Evaporator Drain Line Heaters A door switch is typically installed to stop unit operation when the cargo compartment door is opened Evaporator drain line heaters are used in these units to to improve temperature control.
- Page 23 All Printed Circuit Boards within this unit, supplied by valve and cool the compressor. Thermo King can be easily identified by the Part Discharge Pressure Transducer (DPT) Number stamped on them. This transducer supplies the discharge pressure from...
- Page 24 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Operation Figure 1. Thermostat Algorithm The vehicle engine must be running and the unit must be turned on.
- Page 25 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 1 1 0 0 pressure vapor.
- Page 26 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 2 2 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n If the compressor discharge temperature rises enough to close the liquid injection switch, the liquid injection N N o o t t e e : : The following shows the Model 20 MAX unit.
- Page 27 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 2 2 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n heat and condenses into high pressure liquid.
- Page 28 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 3 3 0 0 liquid injection line, liquid injection orifice and splice fitting in the suction line to cool the compressor.
- Page 29 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 5 5 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n fitting in the suction line to cool the compressor.
- Page 30 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n C C o o o o l l M M o o d d e e M M o o d d e e l l 5 5 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n and the compressor pressure regulator because the CPR bypass solenoid is closed.
- Page 31 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Null Mode condenser to the low side to increase the heating capacity.
- Page 32 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n H H e e a a t t M M o o d d e e M M o o d d e e l l 3 3 0 0 •...
- Page 33 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n H H e e a a t t M M o o d d e e M M o o d d e e l l 5 5 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n •...
- Page 34 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n H H e e a a t t M M o o d d e e M M o o d d e e l l 5 5 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n •...
- Page 35 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Defrost Mode D D e e f f r r o o s s t t M M o o d d e e M M o o d d e e l l 1 1 0 0 Defrost can be initiated any time the evaporator coil N N o o t t e e : : The following shows the Model 10 MAX unit.
- Page 36 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n D D e e f f r r o o s s t t M M o o d d e e M M o o d d e e l l 2 2 0 0 E E n n g g i i n n e e O O p p e e r r a a t t i i o o n n is open so the refrigerant flows through the hot gas line and the drain pan heater to the evaporator.
- Page 37 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n D D e e f f r r o o s s t t M M o o d d e e M M o o d d e e l l 2 2 0 0 E E l l e e c c t t r r i i c c S S t t a a n n d d b b y y O O p p e e r r a a t t i i o o n n open so the refrigerant flows through the hot gas line and the drain pan heater to the evaporator.
- Page 38 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Serial Number Locations C C O O N N D D E E N N S S E E R R : : Nameplate located on the front inside edge of condenser frame.
- Page 39 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 16. ES220 Evaporator with Covers Removed Hot Gas Solenoid (HGS) Liquid Injection Solenoid (LIS) (MAX Units Only) Evaporator Coil Suction Pressure Regulator Valve (Model 20 MAX Units Only)
- Page 40 U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 18. Condenser with Covers Removed Electric Standby Compressor (Model 20 and 50 Only) Transformer (Model 20 and 50 Only) Discharge Check Valve (Model 20 and 50 Only) Discharge Pressure Transducer...
- Page 41 Maintenance Inspection Schedule N N o o t t e e : : Thermo King reserves the right to deny warranty N N o o t t e e : : See the appropriate chapter in this maintenance coverage on claims due to lack of maintenance manual for instructions on how to correctly or neglect.
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Page 42: Maintenance Inspection Schedule
Electrical Maintenance Maintenance Inspection Schedule Months Months Inspect/Check/Service These Items Daily Weekly or 2000 or 4000 Hours Hours Check unit for any active alarms. • Check unit for proper defrost operation. • Inspect wiring harnesses and connectors. • Check return air temperature sensor calibration. •... -
Page 43: Replacement
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Defrost Termination Switch 9. -
Page 44: Condenser Fan Motor
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Evaporator Fan Motors 3. -
Page 45: Drain Line Heater Replacement
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 3. - Page 46 E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e C C o o n n t t r r o o l l B B o o x x F F u u s s e e s s : : These fuses are located inside the control box and are not on the controller.
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Page 47: Relays
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e H H a a r r n n e e s s s s F F u u s s e e s s : : These fuses are located in wiring harnesses outside of the control box. -
Page 48: Relay Replacement
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 7. -
Page 49: Units Only
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e AC Components Model 20 and Model 50 Units Only W W A A R R N N I I N N G G... -
Page 50: Electrical Contactors
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Electrical Contactors 3. -
Page 51: Transformer - T1
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 3. -
Page 52: Transformer Replacement
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 9. -
Page 53: Start Relay - Sr
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Start Relay –... -
Page 54: Compressor Motor Replacement
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e 8. -
Page 55: Heat Option - Truck Engine Coolant
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e SWS wire from the battery disconnect relay (BDR). -
Page 56: Heat Option - Truck Engine Coolant And Electric Standby Heater Strip
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Heat Option –... -
Page 57: Maintenance Inspection Schedule
Refrigeration Maintenance Maintenance Inspection Schedule Months Months Inspect/Check/Service These Items Daily Weekly or 2000 or 4000 Hours Hours Inspect moisture indicator and refrigerant level. • Inspect refrigerant hoses. • Inspect refrigerant hose connections for leaks. • Check suction/compressor pressure regulator setting (20, 30, 50 MAX Models Only). •... -
Page 58: Charging
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 a a i i n n t t e e n n a a n n c c e e 2. -
Page 59: Refrigeration System Checks
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 a a i i n n t t e e n n a a n n c c e e Refrigeration System Checks Remove Internal Parts From Expansion Valve 1. - Page 60 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 a a i i n n t t e e n n a a n n c c e e 9.
- Page 61 Refrigeration Service Operations N N o o t t e e : : It is generally good practice to replace the filter W W A A R R N N I I N N G G drier whenever the high side is opened or when R R i i s s k k o o f f I I n n j j u u r r y y ! ! the low side is opened for an extended period of time.
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Page 62: 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 S S E E R R V V I I C C E E O O P P E E R R A A T T I I O O N N S
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 32. - Page 63 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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 33.
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Page 64: Engine Driven Compressor
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 34. -
Page 65: Electric Standby Compressor
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s 1. -
Page 66: Liquid Injection Solenoid (Lis) Test
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s depending on your unit) wires in main wire harness (CIS) closes, and the hot gas solenoid (HGS) and from the wires to the condenser inlet solenoid... -
Page 67: Solenoid Valve Replacement
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Removal probably stuck closed. -
Page 68: Only)
Refer to Expansion Valve Check/Adjustment in Diagnosing Thermo King Truck and Trailer 8. Turn the unit off and shut off the truck engine. Refrigeration Systems TK 5984 for information Connect the remote control box to an appropriate checking and adjusting the expansion valve. -
Page 69: Expansion Valve Replacement
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 35. -
Page 70: Test
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Low Pressure Cutout Switch Test to the suction service port on the suction tube assembly in the evaporator to monitor suction... -
Page 71: Compressor Pressure Regulator Valve
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Figure 38. -
Page 72: Removal
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 S S e e r r v v i i c c e e O O p p e e r r a a t t i i o o n n s s Liquid Line Check Valve Replacement rings in the ORS fittings for the ends of the check valve assembly. -
Page 73: Compressor Failures
Compressor Maintenance Compressor Failures N N o o t t e e : : The engine driven compressor must be equipped with a ground strap when installed. Whenever a compressor fails check the compressor Refer to Ground Strap Installation in Section speed to verify it is within our guidelines. -
Page 74: Electric Standby Compressor
C C o o m m p p r r e e s s s s o o r r M M a a i i n n t t e e n n a a n n c c e e Electric Standby Compressor Belt mounting bolts and recheck the belt tension. -
Page 75: Maintenance Inspection Schedule
Structural Maintenance Maintenance Inspection Schedule Months Months Inspect/Check/Service These Items Daily Weekly or 2000 or 4000 Hours Hours Inspect exterior of evaporator and condenser. • Inspect evaporator air inlet and outlet for blockage (dirt, debris, cargo, etc.). • Inspect condenser air inlet and outlet for blockage (dirt, debris, etc.). •... -
Page 76: Unit Mounting Bolts
S S t t r r u u c c t t u u r r a a l l M M a a i i n n t t e e n n a a n n c c e e when possible. - Page 77 Over-the-Road Mechanical Diagnosis TK 56342-18-MM-EN...
- Page 78 Electric Standby Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit turned On—In-Cab Control Box Unit not connected to Standby power or Connect power cord. Verify that the Electric Standby display does not come on Standby power is turned off. power is turned on and is the correct voltage. Transformer AC Power Supply Fuse F20 Check for short circuits and replace fuse blown...
- Page 79 Refrigeration Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit short cycles Shortage of refrigerant (low pressure Repair leak and recharge cutout) Restricted expansion valve Clean expansion valve Refrigerant overcharge (high discharge Remove excess charge pressure) Cycling on high discharge pressure Check condenser air flow and fan Dirty condenser coil Clean coil Defrost timer set too low for application.
- Page 80 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 D D i i a a g g n n o o s s i i s s CONDITION POSSIBLE CAUSE REMEDY...
- Page 81 Refrigeration Diagnosis Chart POSSIBLE CAUSES Overcharge of refrigerant • • • • Shortage of refrigerant • • • • • • • No refrigerant • • • • • • • • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
- Page 82 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 D D i i a a g g n n o o s s i i s s C C h h a a r r t t POSSIBLE CAUSES Evaporator fan motor not operating •...
- Page 83 Diagram Index The following table lists the diagrams that are relevant The diagrams are available on TSA Info Central and in to these units. the V-220/V-320 Series Diagrams Manual TK 56454-18- Drawing No. Drawing Title 3E34872 V-220/V-320/MAX 10 Schematic Diagram 3E34873 V-220/V-320/MAX 10 Wiring Diagram 3E34870...
- Page 84 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.