Ingersoll-Rand 900829 Maintenance Manual Download Page 104

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102

V-520 20/50 3PH, V-520 MAX 20/50 3PH Schematic Diagram, page 1 of 3

RELEASED 26/Mar/2014

Summary of Contents for 900829

Page 1: ...re TK 5XXXX X PL TK 54343 1 MM 2009 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text in...

Page 2: ......

Page 4: ...een so repaired or altered outside the manufacturer s plants as in the manufacturer s judgment to effect its stability The maintenance information in this manual covers unit models V 520 10 900829 V 5...

Page 5: ...dhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations concerning the use of refrigerant...

Page 6: ..._________________________________________ ________________________________________________________________________ ________________________________________________________________________ ____________...

Page 7: ...fore working on any unit Model Systems Systems Designations Table This table lists the bills of material and kit options that apply to the Thermo King units covered in this manual Use this information...

Page 8: ...y These terms can be confusing because of differences between North America and Europe Please note Curbside The side to the driver s right when the driver is in his seat and facing forward Roadside Th...

Page 9: ...atures 20 Condenser 20 Evaporator 20 Compressor 21 Control Circuits 21 Electronic Control System 21 Oil Separator 22 Refrigerant 22 Liquid Injection System 22 Evaporator Drain Tube Heaters 23 Electric...

Page 10: ...and Installation 40 Evaporator Fan Motors 41 Evaporator Fan Motor Removal and Installation 41 Electric Standby Circuits 41 Refrigeration Maintenance 43 Maintenance Inspection Schedule 43 Evacuating an...

Page 11: ...58 Replacing Refrigerant Hoses Speedy Clip System 59 Compressor Maintenance 60 Refrigerant Handling Instructions 60 Refrigerant Handling Safety 60 Refrigerant Recovery 60 Compressor Function Test 60...

Page 12: ...Table of Contents 10 Electric Standby Mechanical Diagnosis 81 Electric Standby Service Checks 84 Refrigeration Diagnosis Chart 85 Index 86 Wiring Schematic and Refrigeration Diagrams Index 88...

Page 13: ...xample a truck body or garage Refrigerant tends to displace air and can cause oxygen depletion resulting in suffocation and possible death 12 When using ladder or scaffolding use caution and follow ma...

Page 14: ...a door knob can severely damage or destroy solid state integrated circuit components The following procedures must be rigidly adhered to when servicing units to avoid microprocessor damage or destruct...

Page 15: ...h is turned Off before connecting or disconnecting the standby power plug Never attempt to stop the unit by disconnecting the power plug 2 Be certain the unit power plug is clean and dry before connec...

Page 16: ...o King approved battery must be installed and properly secured to the battery tray WARNING Improperly installed battery cables could result in fire or explosion Battery cables must be installed routed...

Page 17: ...901 3PH 2E54902 2E54903 V 520 30 902041 800319 R 134a 2E54898 2E54899 V 520 50 902049 800319 R 134a 1PH 2E54900 2E54901 3PH 2E54902 2E54903 V 520 MAX 10 900831 800319 R 404A 2E54898 2E54899 V 520 MAX...

Page 18: ...t Solenoid Valve PS4 Suction Bypass Solenoid PS6 20 amps 10 amps Fuse 9 Evaporator Fan Motor EFM3 15 amps 10 amps Fuse 10 Evaporator Fan Motor EFM4 15 amps 10 amps Fuse 11 Defrost Drain Heaters DH1 an...

Page 19: ...ERATION SYSTEM V 520 Max Refrigerant Charge V 520 MAX Model 10 8 15 lb 3 70 kg R 404A V 520 MAX Model 20 8 15 lb 3 70 kg R 404A V 520 MAX Model 30 8 25 lb 3 74 kg R 404A V 520 MAX Model 50 8 25 lb 3 7...

Page 20: ...515 Defrost Method Hot gas Defrost Timer Initiation Interval Adjustable 1 hour to 10 hours Termination Interval Termination is not timed Defrost is terminated by Klixon switch CAUTION Failure to use c...

Page 21: ...e TK No 203 365 Hot Water Component For hot water tubing connections copper to copper or copper to brass Joint Clearances 0 003 to 0 005 in 0 076 to 0 127 mm Use Solder Type 95 Tin and 5 antimony TK N...

Page 22: ...e to operate in electric standby mode It is not possible to start the engine driven compressor until the power cable is disconnected from the unit There are four basic models Model 10 Cool and defrost...

Page 23: ...s for engine operation On standby operation the power is rectified from an AC transformer Electronic Control System The Electronic Control System is composed of an Electronic Control Module located in...

Page 24: ...units the setpoint temperature of both compartments can be read on the same screen Electric Power Warning On screen warning that the unit is connected to an electric power supply Oil Separator An oil...

Page 25: ...ECM closes when the pressure drops to 200 psig 1379 kPa For units with R 404A the ECM opens the compressor clutch circuit at 450 psig 3103 kPa and shuts down the unit The ECM closes the compressor clu...

Page 26: ...lve PS2 Host Liquid Solenoid Valve PS3 Remote Hot Gas Defrost Solenoid Valve PS4 Suction Bypass Solenoid PS6 F4 Fuse 4 15 amps Evaporator Fan Motor EFM2 F9 Fuse 9 15 amps Evaporator Fan Motor EFM3 F5...

Page 27: ...s with Electric Standby connect the external power cord and the unit switches to Electric mode operation Unit operation can be tailored as required using programmable settings that are shown later is...

Page 28: ...are de energized If the temperature rises a pre determined number of degrees the unit restarts in Cool mode If the temperature falls a pre determined number of degrees and a heat option is present th...

Page 29: ...aporator fans are not This moves the refrigerant from the condenser to the low side to increase the heating capacity See Figure 6 below NOTE The unit will not go into the Purge mode when coming out of...

Page 30: ...enoid is closed and the defrost solenoid is open so high pressure refrigerant vapor leaves the compressor and flows through the defrost line defrost solenoid and drain pan heater to the evaporator The...

Page 31: ...efrost line defrost solenoid and drain pan heater to the evaporator There the refrigerant heats the evaporator and returns to the compressor through the suction lines Some of the refrigerant flows thr...

Page 32: ...dby Compressor 10 Condenser Fans 3 Liquid Injection Valve 7 Condenser Coil 11 AC Compressor Electric Box 4 Receiver Tank 8 Rectifier Heat Sink 12 Defrost Valve Figure 8 Unit Components Model 20 1 3 2...

Page 33: ...Expansion Valve 4 Defrost Switch Figure 10 Evaporator AMA513 1 2 4 3 AMA51 1 Hot Water Heat Defrost Coil 3 High Temperature Limit Switch 2 Electric Heat Element 4 Air Temperature Sensor Figure 11 Eva...

Page 34: ...an be controlled from 26 F to 71 F 32 C to 22 C Unit Controls WARNING Never operate the unit unless you completely understand the controls otherwise serious injury may occur Figure 13 In Cab Control B...

Page 35: ...splay This is the display that appears when the On Off key is pressed and the unit started It normally displays the return air temperature of both load compartments in multi temperature units and the...

Page 36: ...ture Setting Screen IMPORTANT If the SELECT key is not pressed within 20 seconds to select the new Setpoint Temperature the unit will continue to run at the original Setpoint Temperature 4 Remote Comp...

Page 37: ...re 22 Manual Start Once the alarm condition has been rectified the On Off key must be pressed to start up again Press and release the Select key to display the current alarm code on screen If there is...

Page 38: ...Description Manual Start OL Electric Motor Overload Unit protection system during electric standby operation If the problem persists when the unit is restarted contact your Service Dealer bAt Low Batt...

Page 39: ...hich it is loaded Transport refrigeration units are not designed to reduce the load temperature Procedure after loading 1 Ensure that all doors are closed and locked 2 Adjust the thermostat to the des...

Page 40: ...thermostat and thermometer calibration in 32 F 0 C ice water bath Inspect wire harness for damaged wires or connections Refrigeration Heating Weekly Monthly Semi Annual Annually Check condition of or...

Page 41: ...s performed on all evaporators at the same time Defrost initiation and termination settings are accessed through the Guarded Access Menu Refer to the Direct Smart Reefer Microprocessor Control System...

Page 42: ...he suction pressure should return to the stabilized pressure in step 4 8 If the suction pressure does not change check the CLU wire for voltage the LIS wire for continuity the liquid injection solenoi...

Page 43: ...ing down proceed as follows 1 Check the AC line voltage and the transformer input fuse If the AC line voltage is acceptable and the transformer input fuse is intact go to step 2 2 Measure the transfor...

Page 44: ...10 in Connector 2 on PCB1 in the ECM If voltage is not present check the continuity of the PC circuit to junction connector 1 jumper JC1 and the 2B2 2B circuit to the standby power relay If the voltag...

Page 45: ...ly on the solenoid valve and hand tighten the coil retaining nut Evacuation and Charging Procedure The liquid line sight glass helps the operator to determine the amount of charge under established op...

Page 46: ...and the head pressure is at least 180 psig 1241 kPa for R 134a systems or 275 psig 1896 kPa for R 404A systems If necessary raise the head pressure by covering the condenser grille 14 With these cond...

Page 47: ...m for information about adding refrigerant Testing the Refrigerant Charge with a Loaded Box 1 Install a gauge manifold 2 Run the unit in cool on engine driven compressor operation 3 Cover the condense...

Page 48: ...and to check the refrigerant flow See the individual test for a component if you suspect it is not functioning properly Cleanup Procedure for Small Truck Units NOTE If a Van Steenburgh reclaimer is av...

Page 49: ...from the flushing compressor will drain out of the suction line filter Add compressor oil as required Refrigerant oil in the flushing compressor will absorb acids from the system 16 Test the recovere...

Page 50: ...LPCO 8 Receiver Tank 2 Suction Pressure Regulator Model 20 and 50 Only 9 High Pressure Relief Valve 3 Electric Compressor Model 20 and 50 Only 10 Condenser 4 Liquid Injection Solenoid Valve 11 Condens...

Page 51: ...frigerant charge from the system 2 Remove the condenser grille 3 Disconnect the compressor wiring 4 Disconnect the discharge and suction lines 5 Keep the compressor ports and the suction and discharge...

Page 52: ...res to the liquid injection switch at the engine driven compressor 3 On Model 30 and 50 units disconnect the 2 pin connector with the 26 and CHM wires in main wire harness from the wires to the conden...

Page 53: ...probably leaking 9 Remove the gauge manifold set when finished with the test Liquid Solenoid Test SPECTRUM Only 1 Install a gauge manifold set on the engine driven compressor 2 Set the thermostat for...

Page 54: ...ressurize the system and test for leaks 6 Reinstall the condenser grille if removed 7 Evacuate and recharge the system Oil Separator Removal 1 Recover the refrigerant charge 2 Remove the condenser gri...

Page 55: ...valve tube assembly 2 Place the liquid line check valve tube assembly in position and tighten the ORS nut Hold the tubes with a backup wrench on the hex behind the ORS fitting 3 Solder the connection...

Page 56: ...ck valve Installation NOTE A heat sink must be used on the in line check valve when it is being soldered in place to prevent damage to the neoprene seal 1 Clean the tubes for soldering 2 Place the che...

Page 57: ...ion 1 Place the evaporator coil in position and install and tighten the mounting bolts 2 Install the defrost termination switch 3 Install the temperature sensor 4 Install the evaporator fans 5 Clean t...

Page 58: ...5 Check the continuity between the low pressure cutout switch wires The low pressure cutout switch should be closed when the suction pressure is above 5 to 11 in Hg of vacuum 17 to 37 kPa If the sucti...

Page 59: ...regulator valve from the accumulator Installation 1 Clean the tubes for soldering 2 Place the valve in position and solder the connection 3 Install the mounting hardware 4 Pressurize the system and te...

Page 60: ...n compressor 2 Shut off the fresh compartment by raising its setpoint to the highest setting 3 Start the unit on the engine driven compressor at 1800 to 2000 RPM 4 Bring the frozen compartment to 5 to...

Page 61: ...erant oil Figure 34 Lubricating Cylinder of Fitting 4 Manually insert the fitting into the hose The hose should touch the projecting part of the fitting without rising over it Clean off the excess oil...

Page 62: ...gns of overheating such as discolored stickers on the compressor body 4 Check to make sure the compressor clutch has 12 volt power when energized DANGER Explosion Hazard Never throw or strike refriger...

Page 63: ...otation test Normal rotation of the compressor shaft should be smooth without catching or binding Binding or hang felt during the shaft rotation test have an internal part failure This compressor shou...

Page 64: ...ohms at room temperature Figure 45 Coil Resistance Check 6 Pressure or Pumping Test Compressors circulate refrigerant through the system by creating a pressure differential high and low pressures If...

Page 65: ...e 280 F Suction Short term 6 psig minimum Long term 14 psig minimum Temperature Non operational above 40 F and below 250 F Operating mode between 32 F and 200 F Recommended Pressure Charts The followi...

Page 66: ...Compressor or component replacement Loss of refrigerant and oil mixture Adding oil to the system is required when refrigerant loss occurs due to leakage at any system component Since oil is held in su...

Page 67: ...should be the amount in the new compressor IMPORTANT If less than 3 ounces of oil is drained from the compressor at least 3 ounces should be in the new compressor Do not start and run a compressor wit...

Page 68: ...s been added the system must be topped off by metering liquid refrigerant slowly through the suction side of the compressor while the unit is running Make sure that the high side valve on the gauge ma...

Page 69: ...r deflection or bending must not exceed 0 016 in 0 4 mm Engine brackets which allow mounting ears to exceed 0 016 in 0 4 mm deflection can cause cracked or broken ears Deflection of the ear can also r...

Page 70: ...es of armature assembly 3 Hold armature assembly stationary while removing retaining nut with 3 4 in 19 mm or 14 mm socket wrench Figure 55 Armature Nut Removal Wobble Compressor 1 Shaft Nut 5 Shaft K...

Page 71: ...ature plate assembly using a puller Thread 3 bolts into the threaded holes in the armature assembly Turn center screw clockwise until armature assembly comes loose Figure 57 Armature Removal Wobble Ty...

Page 72: ...out from under clamp Figure 61 Loosen Lead Wire Clamp Screw 2 Remove field coil snap ring 3 Remove the field coil assembly Figure 62 Remove Snap Ring Clutch Replacement Field Coil Installation 1 Place...

Page 73: ...mature Plate Installation 1 Install clutch shims 2 Shim selection determines clutch air gap When installing a clutch on a used compressor try the original shims first When installing a clutch on a com...

Page 74: ...compressor shaft Figure 69 Place Armature on Top of Shaft Tighten Armature Retaining Nut 1 Replace TK 5H and TK 7H retaining nut and torque to specification 1 2 20 20 25 ft lb 27 34 N m 270 350 kg cm...

Page 75: ...ification below 1 4 20 bolts SD 5 2 4 ft lb 2 5 N m 25 50 Kgf cm M5 bolts SD 7 5 8 ft lb 7 11 N m 70 110 kgf cm Figure 72 Check Air Gap Pressure Release Valve PRV Replacement Some compressors are fitt...

Page 76: ...to ensure correct choice of unit Choose initial compressor from Standard Recommended Compressor column Standard Recommended Compressor circle one TK13 TK15 TK16 Step 2 Consult the Compressor Mounting...

Page 77: ...ompressor Speed does not exceed 3 000 RPM continue to Step 5 If the Compressor Speed does exceed 3 000 RPM choose the compressor from the chart below Sustained Compressor Speed circle one Less than 3...

Page 78: ...13 Tab Mount Displacement 8 0 cid 131 cc A 3 28 in 83 3 mm B 4 41 in 112 mm C 9 06 in 230 2 mm D 4 72 in 120 mm 702827 102 1016 TK 15 Tab Mount Displacement 9 0 cid 146 7 cc A 3 28 in 83 3 mm B 4 41...

Page 79: ...146 7 cc A 3 28 in 83 3 mm B 4 41 in 112 mm C 9 33 in 237 mm D 4 72 in 120 mm 702829 102 1018 TK 16 Tab Mount Displacement 10 0 cid 162 9 cc A 3 28 in 83 3 mm B 4 41 in 112 mm C 9 71 in 246 7 mm D 4...

Page 80: ...Check the pulley alignment by holding a 24 to 35 in 60 to 90 cm long rod 0 5 in 13 mm in diameter firmly into the V groove of the clutch pulley and make sure the rod aligns squarely with the engine dr...

Page 81: ...ns when cleaning a coil If possible blow the air or water through the coil in the direction opposite the normal air flow Repair bent fins and any other noticeable damage Unit Mounting Bolts Periodical...

Page 82: ...ll a new drier Expansion Valve Loses Its Charge If the expansion valve loses its charge the valve will close causing the system to go into vacuum Replace the valve Air In System Air is not condensable...

Page 83: ...open Eliminate cause of excessive pressure ECM faulty Repair or replace Compressor faulty Replace compressor Shortage of refrigerant Recharge Low pressure cutout open Recharge leak test Overload rela...

Page 84: ...too warm Precool hot product Excessive superheat at expansion valve Adjust superheat Door seals worn Repair replace Box temperature too high Refrigerant shortage Repair leak and recharge Thermostat s...

Page 85: ...xpansion valve Frosted or sweating suction line Expansion valve set too low admitting excess refrigerant Adjust expansion valve Hot liquid line Shortage of refrigerant Repair leak and recharge Condens...

Page 86: ...power at motor terminals 2 Power at compressor terminals but motor does not run a Replace compressor 3 Compressor hums but does not run a Check for locked rotor b Check for worn bearings Replace if n...

Page 87: ...compressor belt Compressor discharge valves leaking Too much compressor oil in system Loose engine driven compressor pulley Compressor bearing loose or burned out Broken valve plate in compressor Exp...

Page 88: ...ic Standby Circuits 41 electric standby circuits 41 Electric Standby Operation 23 electronic control system 39 entering the setpoint temperature 33 Evaporator 20 evaporator coil 55 79 Evaporator Drain...

Page 89: ...Safety Refrigeration Oil 12 Safety Welding 13 Selecting CYCLE SENTRY or Continuous Mode 33 Serial Number Locations 29 solenoid valve replacement 52 specifications compressor 18 electrical controls 16...

Page 90: ...am 108 110 1E49440 V 520 MAX 20 SPECTRUM 1PH Schematic Diagram 111 113 1E49443 V 520 MAX 20 SPECTRUM 3PH Wiring Diagram 114 116 1E49442 V 520 MAX 20 SPECTRUM 3PH Schematic Diagram 117 119 1E53769 V 52...

Page 91: ...89 V 520 10 30 V 520 MAX 10 30 Wiring Diagram page 1 of 2 Thermo King RELEASED 26 Mar 2014...

Page 92: ...90 V 520 10 30 V 520 MAX 10 30 Wiring Diagram page 2 of 2 RELEASED 26 Mar 2014...

Page 93: ...91 V 520 10 30 V 520 MAX 10 30 Schematic Diagram page 1 of 2 Thermo King RELEASED 26 Mar 2014...

Page 94: ...92 V 520 10 30 V 520 MAX 10 30 Schematic Diagram page 2 of 2 Thermo King RELEASED 26 Mar 2014...

Page 95: ...93 V 520 20 50 1PH V 520 MAX 20 50 1PH Wiring Diagram page 1 of 3 Thermo King RELEASED 26 Mar 2014...

Page 96: ...94 V 520 20 50 1PH V 520 MAX 20 50 1PH Wiring Diagram page 2 of 3 RELEASED 26 Mar 2014...

Page 97: ...95 V 520 20 50 1PH V 520 MAX 20 50 1PH Wiring Diagram page 3 of 3 Thermo King RELEASED 26 Mar 2014...

Page 98: ...96 V 520 20 50 1PH V 520 MAX 20 50 1PH Schematic Diagram page 1 of 3 RELEASED 26 Mar 2014...

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Page 100: ...98 V 520 20 50 1PH V 520 MAX 20 50 1PH Schematic Diagram page 3 of 3 RELEASED 26 Mar 2014...

Page 101: ...99 V 520 20 50 3PH V 520 MAX 20 50 3PH Wiring Diagram page 1 of 3 Thermo King RELEASED 26 Mar 2014...

Page 102: ...100 V 520 20 50 3PH V 520 MAX 20 50 3PH Wiring Diagram page 2 of 3 RELEASED 26 Mar 2014...

Page 103: ...101 V 520 20 50 3PH V 520 MAX 20 50 3PH Wiring Diagram page 3 of 3 Thermo King RELEASED 26 Mar 2014...

Page 104: ...102 V 520 20 50 3PH V 520 MAX 20 50 3PH Schematic Diagram page 1 of 3 RELEASED 26 Mar 2014...

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Page 107: ...105 V 520 MAX 10 SPECTRUM Wiring Diagram...

Page 108: ...106 V 520 MAX 10 SPECTRUM Schematic Diagram page 1 of 2 2A 2A...

Page 109: ...107 V 520 MAX 10 SPECTRUM Schematic Diagram page 2 of 2 2A 2A...

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Page 122: ...120 V 520 MAX 20 SPECTRUM 3PH 50 60 Hz Wiring Diagram page 1 of 2...

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Page 124: ...122 V 520 MAX 50 SPECTRUM 1PH Wiring Diagram page 1 of 2 Thermo King RELEASED 26 Mar 2014...

Page 125: ...123 V 520 MAX 50 SPECTRUM 1PH Wiring Diagram page 2 of 2 Thermo King RELEASED 26 Mar 2014...

Page 126: ...124 V 520 MAX 50 SPECTRUM 1PH Schematic Diagram page 1 of 3 RELEASED 26 Mar 2014...

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Page 129: ...127 V 520 MAX 50 SPECTRUM 3PH Wiring Diagram page 1 of 2 Thermo King RELEASED 26 Mar 2014...

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Page 131: ...129 V 520 MAX 50 SPECTRUM 3PH Schematic Diagram page 1 of 3 RELEASED 26 Mar 2014...

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Page 134: ...132 V 520 10 Refrigeration Diagram...

Page 135: ...133 V 520 20 Refrigeration Diagram...

Page 136: ...134 V 520 30 Refrigeration Diagram...

Page 137: ...135 V 520 50 Refrigeration Diagram...

Page 138: ...136 V 520 10 SPECTRUM Refrigeration Diagram...

Page 139: ...137 V 520 20 SPECTRUM Refrigeration Diagram...

Page 140: ...138 V 520 50 SPECTRUM Refrigeration Diagram Thermo King RELEASED 19 Jul 2012...

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Page 142: ...re TK 5XXXX X PL TK 54343 1 MM 2009 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional text in...

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