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Related Manuals for Trane Technologies THERMO KING E-200 Series
Summary of Contents for Trane Technologies THERMO KING E-200 Series
- Page 1 Maintenance Manual Truck Edition E-200 Series Revision C T T K K 6 6 1 1 7 7 1 1 7 7 - - 1 1 8 8 - - M M M M - - E E N N June 2023...
- Page 2 Regulations must be observed when working on refrigeration systems. At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. ©2023 Trane Technologies TK 61717-18-MM-EN...
- Page 3 I I n n t t r r o o d d u u c c t t i i o o n n We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere. When working on transport temperature control systems, a recovery process that prevents or minimizes refrigerant loss to the atmosphere is required by law.
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Page 4: 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 ................................8 8 Danger, Warning, Caution, and Notice . - Page 5 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 Standby Operation................24 Electrical System .
- Page 6 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 Relays ..................47 Relay Testing .
- Page 7 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 Low Pressure Cutout Switch Replacement........... . 63 Removal .
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Page 8: 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 operation of this unit depend upon the strict observance of these precautions. -
Page 9: 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 Battery Installation and Cable Routing 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 ! ! A A n n i i m m p p r r o o p p e e r r l l y y i i n n s s t t a a l l l l e e d d b b a a t t t t e e r r y y c c o o u u l l d d r r e e s s u u l l t t i i n n a a f f i i r r e e , , e e x x p p l l o o s s i i o o n n , , o o r r i i n n j j u u r r y y . -
Page 10: 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 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 ! ! V V a a p p o o r r s s o o r r m m i i s s t t s s f f r r o o m m a a c c o o m m p p r r o o m m i i s s e e d d b b a a t t t t e e r r y y / / c c e e l l l l m m a a y y c c a a u u s s e e r r e e s s p p i i r r a a t t o o r r y y i i r r r r i i t t a a t t i i o o n n . -
Page 11: Refrigerant Oil 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 Refrigerant Oil Hazards W W A A R R N N I I N N G G P P e e r r s s o o n n a a l l P P r r o o t t e e c c t t i i v v e e E E q q u u i i p p m m e e n n t t ( ( P P P P E E ) ) R R e e q q u u i i r r e e d d ! ! P P r r o o t t e e c c t t y y o o u u r r e e y y e e s s f f r r o o m m c c o o n n t t a a c c t t w w i i t t h h r r e e f f r r i i g g e e r r a a n n t t o o i i l l . - 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 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 ! ! D D a a n n g g e e r r o o u u s s t t h h r r e e e e p p h h a a s s e e A A C C e e l l e e c c t t r r i i c c p p o o w w e e r r i i s s p p r r e e s s e e n n t t w w h h e e n n e e v v e e r r 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 i i n n e e i i t t h h e e r r D D i i e e s s e e l l M M o o d d e e , , E E l l e e c c t t r r i i c c M M o o d d e e o o r r H H o o l l d d o o v v e e r r M M o o d d e e a a n n d d w w h h e e n n e e v v e e r r t t h h e e u u n n i i t t i i s s c c o o n n n n e e c c t t e e d d t t o o a a s s o o u u r r c c e e o o f f e e x x t t e e r r n n a a l l s s t t a a n n d d b b y y p p o o w w e e r r .
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Page 13: Low Voltage
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 Low Voltage W W A A R R N N I I N N G G L L i i v v e e E E l l e e c c t t r r i i c c a a l l C C o o m m p p o o n n e e n n t t s s ! ! C C o o n n t t r r o o l l c c i i r r c c u u i i t t s s u u s s e e d d i i n n 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 u u n n i i t t s s a a r r e e l l o o w w v v o o l l t t a a g g e e ( ( 1 1 2 2 t t o o 4 4 8 8 V V d d c c ) ) . - 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 • E E y y e e s s : : For contact with liquid, immediately flush eyes with large amounts of water and get prompt medical attention.
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Page 15: Electrical System
Specifications Electrical System 12 Vdc Fuses E-200 Fuse 1: Main Fuse 150 amps Fuse 3: Evaporator Fan 15 amps Fuse 4: Evaporator second Fan 15 amps Fuse 5: Distribution fuse 20 amps Fuse 6: Drain Heaters 2 amps Fuse 9: Evaporator Fan second compartment 15 amps Fuse 11: Drain Heaters second compartment 2 amps... -
Page 16: Electric Standby Power Supply Requirements
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 driver module Battery Input 11.5 to 14.5 VDC Isolated, balanced three-phase output: 240 VAC Maximum 30–300 Hz (speed controlled) -
Page 17: Compressors
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 Defrost Termination Switch: Opens 48.0 ± 5.0 F (8.9 ± 2.8 C) Closes 36.0 ±... -
Page 18: Solder Applications
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 Oil Type: Motor Voltage: Variable Frequency 230V/3/80Hz PWS V/ph/Hz Defrost Method Hot Gas Defrost Timer Initiation Interval Adjustable, 1 minute to 8 hours, default is 4 hours... -
Page 19: Unit Description
Unit Description Unit Description Thermo King Vehicle Powered Truck Units are two-piece units comprised of a condenser and evaporator designed for fresh, frozen, and deep frozen applications on small trucks and vans. Operated by a variable speed hermetic compressor. During road operation, energy is provided by the vehicle (if available) or by TK batteries (See “Options,”... -
Page 20: System Components
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 • Electric Standby Plug (230V single phase 50Hz/60Hz or 115V single phase 60Hz options) N N o o t t e e : : Some options are available factory installed or as a retrofit option to suit individual customer needs. -
Page 21: Evaporator Drain Line Heaters
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 Evaporator drain line heaters are used in these units to avoid drain line blockage because of ice accumulation inside the evaporator. -
Page 22: Protection Features
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 Protection Features • Discharge (High) Pressure Transducer - The discharge pressure transducer is a pressure sensitive device. It is located in the condenser section discharge line near the oil separator. -
Page 23: Unit Controls
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 • Vehicle Compressor Hourmeter • Vehicle Compressor frequency depending on power available •... -
Page 24: Standby Operation
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 3. In-cab Control Panel (HMI) Display, Keys, Symbols 1. Display It is always active and backlit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the HMI. - 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 These units may be operated in electric standby mode by connecting the proper voltage power cable to the unit’s power receptacle mounted on the vehicle.
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Page 26: Electrical System
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 Electrical System The unit’s controls and refrigeration components operate on 12 Vdc. These units have a hermetic motor-compressor. -
Page 27: Unit Operation
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 o o o o r r S S w w i i t t c c h h e e s s ( ( D D S S W W 1 1 , , D D S S W W 2 2 ) ) - - used to stop unit operation except in defrost mode, when the load compartment doors are opened. -
Page 28: Operation
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 The vehicle engine must be running and the unit must be turned on. On units with Electric Standby, connect the external power cord and the unit switches to Electric mode operation. - 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 Figure 6. E-200 20 Cool Mode Low Pressure Cutout switch (LPCO) Service Valve Expansion Valve Pressure Transducer...
- 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 M M A A X X O O p p e e r r a a t t i i o o n n ( ( O O n n - - R R o o a a d d o o r r 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 ) ) High pressure refrigerant vapor leaves compressor and flows through the the oil separator where oil is separated and returned to a suction line.
- 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 Figure 7. E-200 50 MAX Cool Mode Low Pressure Cutout switch (LPCO) Defrost Line (Hose #6) Relief Valve Pressure Transducer...
- 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 Figure 8. Cool Mode Spectrum Model 50 Engine Operation Low Pressure Cutout switch (LPCO) Defrost Line (Hose #6) Relief Valve Pressure Transducer...
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Page 33: Null Mode
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 The unit operates in Null mode when the setpoint temperature is reached and cooling (or heating) is not required. All outputs are de-energized. -
Page 34: Serial Number Locations
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 Figure 9. Condenser Serial Number Locations Figure 10. Hermetic Compressor Serial Number Location Figure 11. -
Page 35: Unit Components
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 Unit Components Figure 13. Condenser Figure 14. Evaporator TK 61717-18-MM-EN... - 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 Figure 15. ES100N Evaporator with Covers Removed Evaporator Coil Expansion Valve Defrost Limit Switch Temperature Sensor Hot Gas Solenoid (HGS)
- 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 Figure 16. ES200 Evaporator with Covers Removed Evaporator Coil Hot Gas Solenoid (HGS) Liquid Line Solenoid Valve Temperature Sensor Expansion Valve...
- 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 Figure 17. Condenser with Covers Remove Connection Box (SPCB) Service Valve Hermetic Compressor Low Pressure Cut out switch (LPCO) Condenser Coil...
- Page 39 Maintenance Inspection Schedule N N o o t t e e : : Please refer to your E-Series Operator Manual TK 61652-1-OP for Operator Weekly Checks N N o o t t e e : : Please refer to the latest EDAC labour Standards Guide on EMEA infocentral for Service Inspection Schedules for your unit.
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Page 40: Auto Start Hard Stop / Disable Connector
Electrical Maintenance 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 . -
Page 41: Electronic Control System
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 Electronic Control System Refer to the Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096 and the Direct Smart Reefer IV Microprocessor Control System Diagnostic Manual TK 61714 for complete service information about the... -
Page 42: Liquid Injection System
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 Liquid Injection System MAX units use R-404A or R-452A. -
Page 43: Evaporator Fan Motor Removal And Installation
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 Motor Removal and Installation Removal 1. - Page 44 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 Figure 18.
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Page 45: Fuses
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 Fuses TK 61717-18-MM-EN... -
Page 46: Fuses: Printed Circuit Boards
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 Fuses: Printed Circuit Boards Figure 19. -
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 Figure 20. -
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 1. -
Page 49: Ac Components Model 20 And Model 50 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 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 ! ! -
Page 50: Power Supply
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 Power Supply Removal 1. -
Page 51: Installation
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 52: Tk Lithium Ion Batteries
(“TK Lithium Ion Battery Safety,” p. 9) for further information. Recycling and protecting the environment is very important to us at Thermo King and Trane Technologies. Please following the following link for recycling information. TK Lithium Ion Batteries Recycling Information from... -
Page 53: Evacuating And Charging The Refrigeration System
Refrigeration Maintenance Evacuating and Charging the Refrigeration System Refer to the Vehicle Powered Truck Installation Standards and Procedures TK 61588 (Section 10 – System Evacuation Procedures) and Section 12 – System Charging Procedures) for service information about evacuating and charging the refrigeration system Checking the Refrigerant Charge If the unit has an insufficient charge of refrigerant, the evaporator will be “starved”... -
Page 54: Suction (Low Side) Bump 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 through the liquid line sight glass. -
Page 55: Tools Required
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 Tools Required •... -
Page 56: Putting The Unit Back Into Operation
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 10. -
Page 57: Condenser Coil
Refrigeration Service Operations N N o o t t e e : : It is generally good practice to replace the filter drier whenever the high side is opened or when the low side is opened for an extended period of time. 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 i i s s c c o o n n n n e e c c t t t t h h e e p p o o w w e e r r s s u u p p p p l l y y b b e e f f o o r r e e s s e e r r v v i i c c i i n n g g t t h h e e u u n n i i t t t t o o p p r r e e v v e e n n t t 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 58: Installation
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 4. -
Page 59: Discharge Pressure Transducer (Dpt)
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 25. -
Page 60: Installation
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 Installation 1. -
Page 61: Checking Superheat
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 Checking Superheat 1. -
Page 62: 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 1 1 0 0 °... -
Page 63: Low Pressure Cutout Switch (Lpco)
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 (LPCO) If the suction pressure drops below 5 to 11 in. -
Page 64: Suction Pressure Regulator 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 Suction Pressure Regulator Valve Replacement Removal 1. -
Page 65: Replacing Refrigerant Hoses (Speedy Clip System)
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 Replacing Refrigerant Hoses (Speedy Clip System) Refer to the Vehicle Powered Truck Installation Standards and Procedures Section 6 –... -
Page 66: Electric Standby Compressor
Compressor Maintenance A hermetic Compressor is sealed and cannot be serviced. If the compressor is found to be faulty, then it must be replaced. Electric Standby Compressor Removal Figure 29. Hermetic Compressor Removal Compressor Mount Electrical Cover Cover Nut Compressor Bracket Compressor Overload Switch Cover Gasket... -
Page 67: Installation
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 Cover for compressor electrical terminals 5. - Page 68 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 Figure 30.
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Page 69: Compressor Drive Module Removal And Installation
Compressor Drive Module The Compressor Drive Module is located in the condenser section. It performs two primary functions. First; it monitors and controls the air conditioning compressor. It will receive commands from the Base Controller to turn the compressor On or Off and the desired compressor speed. It monitors the condition of the compressor system and will generate alarms. - Page 70 C C o o m m p p r r e e s s s s o o r r D D r r i i v v e e M M o o d d u u l l e e 5.
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Page 71: Condenser Coil
Structural Maintenance Condenser Coil Clean the coils during scheduled maintenance inspections. Remove any debris (e.g., leaves or plastic wrap) that reduces the air flow. Clean dirty coils with compressed air or a pressure washer. Be careful not to bend the fins when cleaning a coil. - Page 72 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 Figure 33.
- Page 73 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 Figure 35.
- Page 74 Over-the-Road Mechanical Diagnosis CONDITION POSSIBLE CAUSE REMEDY Unit turned On—In-Cab Control Box Vehicle ignition switch is not on Turn the vehicle ignition switch on display does not come on Vehicle Ignition Switch Fuse F14 blown Check for short circuits and replace fuse Dead or disconnected vehicle battery Service the vehicle battery In-Cab Control Box harness disconnected...
- Page 75 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 76 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.
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Page 77: 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
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 78 Refrigeration Diagnosis Chart POSSIBLE CAUSES Overcharge of refrigerant • • • • Shortage of refrigerant • • • • • • • No refrigerant • • • • • • • • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
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Page 79: 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
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 Restricted line on the high side •... - Page 80 Diagram Index The following table lists the diagrams that are relevant to this unit. The diagrams are available on EMEA Info Central. Drawing No. Drawing Title 3E61909 E-200 Outline Drawing 3E66299 E-200_Series Refrigeration Diagram 3E68661 E-200 DSR_IV Wiring Diagram 3E68660 E-200 DSR_IV Schematic Diagram TK 61717-18-MM-EN...
- Page 81 N N o o t t e e s s TK 61717-18-MM-EN...
- Page 82 N N o o t t e e s s TK 61717-18-MM-EN...
- Page 83 N N o o t t e e s s TK 61717-18-MM-EN...
- Page 84 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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