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Trane Technologies THERMO KING V400X Installation Manual

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Installation Manual
V400X, V500X, V600X
Vehicle Powered Truck Edition
Revision A
T T K K 6 6 2 2 0 0 6 6 1 1 - - 1 1 8 8 - - I I M M - - E E N N
March 2023

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Summary of Contents for Trane Technologies THERMO KING V400X

  • Page 1 Installation Manual V400X, V500X, V600X Vehicle Powered Truck Edition Revision A T T K K 6 6 2 2 0 0 6 6 1 1 - - 1 1 8 8 - - I I M M - - E E N N March 2023...
  • Page 2 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. Scan the Quick Response (QR) code or click Technical Publications EMEA Feedback ©2023 Trane Technologies TK 62061-18-IM-EN...

  • 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 Danger, Warning, Caution, and Notice .
  • 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 V V e e h h i i c c l l e e B B a a t t t t e e r r y y C C o o n n n n e e c c t t i i o o n n ............................5 5 0 0 F F i i t t t t i i n n g g 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 - - U U n n i i t t s s w w i i t t h h 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 .

  • 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 operation of this unit depend upon the strict observance of these precautions.
  • Page 6 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 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 - Recommended procedures must be used to minimize refrigerant loss. C C o o m m p p o o n n e e n n t t s s m m a a y y b b e e i i s s o o l l a a t t e e d d by closing service valves and performing system pump-downs.
  • Page 7 Required Tools N N o o t t e e : : Equipment such as scales, gauges, refrigerant leak detectors, and torque wrenches should be in good working condition and routinely calibrated to assure accurate readings. Figure 1. BED760 TK 62061-18-IM-EN...

  • Page 8: 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 Electric drill Protective gloves Electrical terminal press File Set of drill bits Pincers for hose clips Set of glass-shaped cutters Plastic flanges Gauge manifold...
  • Page 9 Required Support Materials Please have the following support materials to hand prior to starting your installation - as they are listed as reference throughout this manual: 1. Vehicle Powered Truck Installation Standards and Procedures Guide EMEA - located in Infocentral: Technical Publications 2.
  • Page 10 Operating Method S S i i n n g g l l e e - - C C o o m m p p a a r r t t m m e e n n t t U U n n i i t t s s The operations indicated in this manual should be carried out by a mechanic in the exact sequence in which they are presented in the manual.

  • Page 11: O O P P E E R R A A T T I I N N G G M M E E T T H H O O D

    O O p p e e r r a a t t i i n n g g M M e e t t h h o o d d TK 62061-18-IM-EN...
  • Page 12 Unpacking and Unit Inspection U U n n p p a a c c k k i i n n g g 1. Open the packaging. 2. Find the unit documentation. 3. Verify that the packaging contains all the accessories indicated on the list attached with the documentation. 4.

  • Page 13: Nose Mount

    Condenser Installation Nose Mount 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 61588) (TK 56430).
  • Page 14 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 2.
  • Page 15 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 This panel should be reinforced at fixing points (A and B) with vertical beams.
  • Page 16 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 Screw Condenser unit Riveted nut...
  • Page 17 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 N N o o t t e e s s : : •...

  • Page 18: Roof Mount

    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 Roof Mount 1.
  • Page 19 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 4.
  • 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 b.
  • Page 21 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 The exit of the refrigerant hoses from the front allows the condenser section to be installed further back on the roof of the vehicle.

  • Page 22: Preparing The Es Evaporator For Installation

    ES Evaporator Preparing the ES Evaporator for Installation 1. Fit the template according to the instructions given. 2. Mark the position of the drilled holes. Avoid any possible interference with electrical wires and parts of the vehicle chassis. 3. Drill blind holes to screw the evaporator unit in place. Screw in the bolts and washers supplied for the ceiling. Do not tighten.

  • Page 23: Evaporator Installation

    E E S S E E v v a a p p o o r r a a t t o o r r Evaporator Installation 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 61588).

  • Page 24: Evaporator Drain Hose Installation

    E E S S E E v v a a p p o o r r a a t t o o r r 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 .
  • Page 25 E E S S E E v v a a p p o o r r a a t t o o r r Figure 4. ES-150 Rear and Bottom views Legend Option 1 Hose Heaters Option 2 Hose Connector Aluminium Foil Tape Drain Tube TK 62061-18-IM-EN...
  • Page 26 E E S S E E v v a a p p o o r r a a t t o o r r ES-300 1. Attach Drain Hoses onto both evaporator drain tubes and combine into a single hose using supplied Y Connector. 2.
  • Page 27 Preparing the Refrigeration Hoses 1. Cut the hose to the required length. Use the recommended hose cutters. Do not use saws, knives or similar tools. 2. Pass two clips of appropriate diameter over the hose. 3. Lubricate the cylinder of the fitting to be inserted in the hose, using Thermo King refrigerant oil. 4.
  • Page 28 Hose Connections 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. THESE PROCEDURES MUST BE FOLLOWED! Figure 5.
  • Page 29 H H o o s s e e C C o o n n n n e e c c t t i i o o n n s s O-RING (#6) Fitting - 90 degree #8 O-RING EPDM -#13 Fitting - 90 degree (female O-ring seal, #6 fitting, #6 hose) O-RING (#12)
  • Page 30 H H o o s s e e C C o o n n n n e e c c t t i i o o n n s s O-RING (#6) Tee splicer gauge 10 Fitting - 90 degree (female O-ring seal, #6 fitting, #6 Hose #6 200 ft hose) O-RING (#12)
  • Page 31 H H o o s s e e C C o o n n n n e e c c t t i i o o n n s s O-RING (#6) Tee splicer gauge 10 Fitting - 90 degree (female O-ring seal, #6 fitting, #6 Hose #6 200 ft hose) O-RING (#12)

  • Page 32: C C O O N N N N E E C C T T I I N N G G T T H H E E H H O O S S E E S S T T O O T T H H E E C C O O N N D D E E N N S S E E R R U U N N I I T

    Connecting the Hoses to the Condenser Unit N N o o t t e e : : Remove plugs from all tubing. Lubricate all refrigeration intakes with Thermo King refrigerant oil. Fit an O-ring to the seating in all refrigeration intakes. Check that the O-ring is properly fitted and connect each hose, using two fixed wrenches.
  • Page 33 C C o o n n n n e e c c t t i i n n g g t t h h e e H H o o s s e e s s t t o o t t h h e e C C o o n n d d e e n n s s e e r r U U n n i i t t 1.
  • Page 34 Installing the Wiring Sleeve in the Evaporators 1. Ensure area A is completely free to guarantee maximum air flow. 2. 1 1 0 0 / / 3 3 0 0 M M o o d d e e l l s s : : Use plastic flanges to secure the wiring sleeve to thesupports, B B fitted to the evaporator. 2 2 0 0 / / 5 5 0 0 M M o o d d e e l l s s : : Insert the plastic clips mounted on the electrical hoseinto holes C C to fasten it to the evaporator.
  • Page 35 Wiring Connections 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 .THESE PROCEDURES MUST BE FOLLOWED! Figure 8.

  • Page 36: W W I I R R I I N N G G C C O O N N N N E E C C T T I I O O N N S

    W W i i r r i i n n g g C C o o n n n n e e c c t t i i o o n n s s Sr. no. Description Connection Sr. no. Description Connection Main harness...
  • Page 37 W W i i r r i i n n g g C C o o n n n n e e c c t t i i o o n n s s Figure 9. Wiring Connections (multi temperature V400X, 50 Spectrum, ES200+ES200) TK 62061-18-IM-EN...
  • Page 38 W W i i r r i i n n g g C C o o n n n n e e c c t t i i o o n n s s Sr. no. Description Connection Sr. no. Description Connection Main harness...
  • Page 39 Connecting Hoses to the over-the-road Compressor 1. Prepare the suction and discharge refrigeration hoses. See section: “Preparing Refrigeration Hoses”. 2. Lubricate the compressor refrigeration intakes using Thermo King refrigerant oil. 3. Place an O-ring on each compressor intake. 4. Connect the suction hose to compressor intake S and the discharge hose to intake D. T T h h e e s s u u c c t t i i o o n n i i n n t t a a k k e e c c a a n n n n o o t t b b e e b b e e l l o o w w 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 s s h h a a f f t t .
  • Page 40 Torque to Apply to Compressor Manifold and Fittings 1. The purpose of this section is to indicate the correct torque to apply to Thermo King compressor manifolds (straight and standard models) and fittings to ensure good performance, reliability and longevity of all direct drive units. N N o o t t e e : : 50 Nm = 36.87 ft.lb 40 Nm = 29.50 ft.lb 35 Nm = 25.81 ft.lb...
  • Page 41 Circuit Seal Test (I) N N o o t t e e : : Refer to the VPtruck Installation Standards and Procedures Guide (Section 11 - System Leak Check Procedures) to perform the circuit seal test (I). TK 62061-18-IM-EN...
  • Page 42 Circuit Seal Test (II) N N o o t t e e : : Refer to the VPtruck Installation Standards and Procedures Guide (Section 11 - System Leak Check Procedures) to perform the circuit seal test (II). TK 62061-18-IM-EN...
  • Page 43 In Case of Leaks 1. Pressurize the circuit to 1 1 7 7 b b a a r r with nitrogen. 2. Identify the defective part (fitting, sleeve, line, hose, O-ring, etc.) and replace it with a new part (if in doubt replace the entire joint).
  • Page 44 Leak Check and Evacuation with MAX Spectrum Units N N o o t t e e : : When checking for leaks and during evacuation of MAX SPECTRUM units, all the solenoid valves must be open. The evaporators used in these units have two valves that are normally closed. These are the PS1/PS3 in the main evaporator and the PS4/PS2 in the remote evaporator.
  • Page 45 Leak Chart and Evacuation Procedure for MAX Spectrum Units 1. Ensure that the unit is switched off. 2. Remove all the coils from the PS1/PS3 and PS4/PS2 solenoid valves in the evaporators. 3. Place a magnet with code 204-1074 in each of the solenoid stems specified below: 4.
  • Page 46 Installing the In-Cab Controller 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).

  • Page 47: 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 I I N N - - C C A A B B C C O O N N T T R R O O L L L L E E R

    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 I I n n - - C C a a b b C C o o n n t t r r o o l l l l e e r r 4.
  • Page 48 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 I I n n - - C C a a b b C C o o n n t t r r o o l l l l e e r r 6.
  • Page 49 Optional DIN Adaptor (by order only) 1. Place the metal box (J J ) supplied in the housing designed for the radio. Raise the tabs (M) sufficiently to fit the box into the housing. 2. Attach the control to the plastic bracket (L L ) using the 4 screws (K K ). 3.
  • Page 50 Vehicle Battery Connection 1. Using the recommended tools, cut the wires to the proper length. D D o o n n o o t t c c o o i i l l o o r r s s p p l l i i c c e e t t h h e e e e x x c c e e s s s s w w i i r r e e . . 2.
  • Page 51 Fitting the Power Supply - Units with Electric Standby 1. Install the power supply housing in a protected and accessible location. 2. Route the wire from the unit to the power supply, using the clamps provided. 3. Cut off the excess electrical wire. In order to avoid the coil effect, d d o o n n o o t t r r o o l l l l u u p p t t h h e e e e x x c c e e s s s s 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 . . D D o o n n o o t t c c r r e e a a t t e e s s p p l l i i c c e e s s i i n n t t h h e e 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 .
  • Page 52 Installing the Discharge Adjustable Muffler (Optional) 1. MOUNTING VERTICALLY: Connect the “IN” end (the end with the adjustable stem) to the discharge line leaving the compressor. Always mount the “IN” end up so that the gas flows down through the muffler. 2.
  • Page 53 In-Cab Control Box 1. D D i i s s p p l l a a y y . . 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 In-cab Control Box. It normally displays the return air temperature (of both load compartments in bi-temperature units).

  • Page 54: I I N N - - C C A A B B C C O O N N T T R R O O L L B B O O X

    I I n n - - C C a a b b C C o o n n t t r r o o l l B B o o x x • Firmware versions 121 15/19/21 and 273 02/03: this menu will automatically advance through the following steps: •...
  • Page 55 I I n n - - C C a a b b C C o o n n t t r r o o l l B B o o x x Compartments Priority modulation, time OFF (min) Modulation timer: (Only Priority compartment ON) Selectable from 1 to 30 minutes.
  • Page 56 Checking the Installation • All holes should be sealed with silicone or foam. • Check with a sheet of paper that the fans blow in the right direction. • The drain circuit should be slanted on all evaporators and the moisture trap should be installed. •...
  • Page 57 Standby Receptacle Box Installation (Models 20 and 50 Only) 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 61588).
  • Page 58 Completing the Installation I I m m p p o o r r t t a a n n t t : : BEFORE COMPLETING THE INSTALLATION, YOU MUST PERFORM THE FOLLOWING PROCEDURES IN ACCORDANCE WITH THE THERMO KING INSTALLATION STANDARDS AND PROCEDURES GUIDE: •...
  • Page 59 Suction Pressure Regulator (SPR) Adjustment Procedures I I m m p p o o r r t t a a n n t t : : All new unit installations require these adjustment procedures. Failure to do so may not allow the unit to operate at its maximum capacity.

  • Page 60: S S U U C C T T I I O O N N P P R R E E S S S S U U R R E E R R E E G G U U L L A A T T O O R R ( ( S S 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 S u u c c t t i i o o n n P P r r e e s s s s u u r r e e R R e e g g u u l l a a t t o o r r ( ( S S 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 8.
  • Page 61 Compressor Oil Amounts and Type N N o o t t e e : : Refer to the Maintenance Manual to find the correct amount and type of oil to use in compressor. I I m m p p o o r r t t a a n n t t : : Using the absence of bubbles in the sight glass as an indicator of correct refrigerant charge can be misleading, Y Y O O U U M M U U S S T T refrigerate the box to 0-5ºC (32-41ºF) to get a more precise indication from the sight glass.
  • Page 62 Electrical System 12 Vdc 24 Vdc Fuses Common Fuses Fuse 3: Evaporator Fan Motor (EFM1) 15 amps 10 amps Fuse 4: Evaporator Fan Motor (EFM2) 15 amps 10 amps 20 amps 10 amps Fuse 5: Roadside (Engine) Compressor Clutch (CCL1), Liquid Injection Switch (LIS), Liquid Injection Valve Roadside compressor (LIV1), Liquid Injection Valve Standby compressor (LIV2), EVAP1 Defrost Hot Gas Solenoid Valve (PS1), Compressor Motor Contactor (CMC), Heat Pilot Solenoid (PS5), Bypass valve...

  • Page 63: E E L L E E C C T T R R I I C C A A L L S S Y Y S S T T E E M

    E E l l e e c c t t r r i i c c a a l l S S y y s s t t e e m m Resistance 5.2 ohms 20 ohms Coil for Liquid Injection Solenoid (LIS) – MAX Only Voltage 12 Vdc Current...

  • Page 64: Electric Standby Power Supply Requirements

    E E l l e e c c t t r r i i c c a a l l S S y y s s t t e e m m Transformer Power 700 VA Frequency 50/60 Hz Primary Inputs 0–230–400 Vac Secondary Nominal Voltage 2 x 11.7 Vac (30.4 amps)
  • Page 65 Single temperature SPR Valves Setting S S P P R R d d e e f f a a u u l l t t f f a a c c t t o o r r y y s s e e t t t t i i n n g g SPRs are set to 2 bar as default from factory, measured in the pressure port close to the valve.
  • Page 66 Spectrum SPR Valves Setting S S P P R R d d e e f f a a u u l l t t f f a a c c t t o o r r y y s s e e t t t t i i n n g g SPRs are set to 2 bar as default from factory, measured in the pressure port close to the valve.
  • Page 67 Condenser and Evaporator Dimensions N N o o t t e e : : Paper Templates are available to assist in the installation of the Condenser and Evaporator. These Templates provide the installer with a footprint of the component and provide the correct mounting and access hole locations.

  • Page 68: C C O O N N D D E E N N S S E E R R A A N N D D E E V V A A P P O O R R A A T T O O R R D D I I M M E E N N S S I I O O N N S

    C C o o n n d d e e n n s s e e r r a a n n d d E E v v a a p p o o r r a a t t o o r r D D i i m m e e n n s s i i o o n n s s TK 62061-18-IM-EN...
  • Page 69 C C o o n n d d e e n n s s e e r r a a n n d d E E v v a a p p o o r r a a t t o o r r D D i i m m e e n n s s i i o o n n s s Figure 10.
  • Page 70 N N o o t t e e s s TK 62061-18-IM-EN...
  • Page 71 N N o o t t e e s s TK 62061-18-IM-EN...
  • Page 72 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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