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Ingersoll-Rand THERMO KING E-200 Series, Installation Manual

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Ingersoll-Rand THERMO KING E-200 Series Installation Manual Download Page 6

6

TK 61694-18-IM-EN

Required Tools

N

No

otte

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

1.

Electric drill

13.

Protective gloves

25.

Electrical terminal press

2.

Set of drill bits

14.

File

26.

Pincers for hose clips

3.

Set of glass-shaped cutters

15.

Plastic flanges

27.

Gauge manifold

4.

Protective goggles

16.

Riveter

28.

Vacuum pump

Summary of Contents for THERMO KING E-200 Series

Page 1: ...Revision A July 2019 T TK K 6 61 16 69 94 4 1 18 8 I IM M E EN N Vehicle Powered Truck Edition E 200 Series Single and Multi Temperature Systems Installation Manual ...

Page 2: ...ed d o or r a al lt te er re ed d a as s i in n t th he e m ma an nu uf fa ac ct tu ur re er r s s j ju ud dg gm me en nt t t to o a af ff fe ec ct t i it ts s i in nt te eg gr ri it ty y M Ma an nu uf fa ac ct tu ur re er r s sh ha al ll l h ha av ve e n no o l li ia ab bi il li it ty y t to o a an ny y p pe er rs so on n o or r e en nt ti it ty y f fo or r a an ny y p pe er rs so on na al l i in...

Page 3: ... ec ct ti io on ns s M Mo od de el l 2 20 0 5 50 0 2 20 0 I In n C Ca ab b C Co on nt tr ro ol ll le er r I In ns st ta al ll la at ti io on n 2 22 2 O Op pt ti io on na al l D DI IN N A Ad da ap pt to or r b by y o or rd de er r o on nl ly y 2 25 5 B Ba at tt te er ry y C Co on nn ne ec ct ti io on n 2 26 6 H Ho ol ld do ov ve er r B Ba at tt te er ry y O Op pt ti io on n 2 27 7 Hold over Option ...

Page 4: ... P Pr re es ss su ur re e R Re eg gu ul la at to or r D DP PR R A Ad dj ju us st tm me en nt t P Pr ro oc ce ed du ur re es s M MA AX X 4 44 4 C Co om mp pr re es ss so or r O Oi il l A Am mo ou un nt ts s a an nd d T Ty yp pe e 4 45 5 R Re ec co om mm me en nd de ed d R Re ef fr ri ig ge er ra an nt t C Ch ha ar rg ge e b by y M Mo od de el l 4 46 6 C Co on nd de en ns se er r a an nd d E Ev va a...

Page 5: ... in nt to o t th he e a at tm mo os sp ph he er re e Recover Refrigerant N No ot te e In the USA EPA Section 608 Certification is required to work on refrigeration systems In the EU local F gas 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 allow...

Page 6: ...d be in good working condition and routinely calibrated to assure accurate readings Figure 1 BED760 1 Electric drill 13 Protective gloves 25 Electrical terminal press 2 Set of drill bits 14 File 26 Pincers for hose clips 3 Set of glass shaped cutters 15 Plastic flanges 27 Gauge manifold 4 Protective goggles 16 Riveter 28 Vacuum pump ...

Page 7: ...tmeter 31 Refrigerant cylinders 8 Pencil 20 Set of screwdrivers 32 Table mounted vice 9 Socket wrenches 21 Hose cutters 33 Crane or hoist 10 Fixed wrenches 22 Wire strippers 34 TK refrigerant oil 11 Monkey wrench 23 Wire cutters 35 Open Y wrench 12 Silicone 24 Electric and hand saws 36 Torx Tube Wrench 37 Torque Wrench R Re eq qu ui ir re ed d T To oo ol ls s ...

Page 8: ...t this manual 1 Vehicle Powered Truck Installation Standards and Procedures Guide EMEA located in Infocentral Technical Publications 2 Commercial Brochure for your unit includes weight specifications and applicable unit options Commercial Brochures 3 F Fo or r M Mu ul lt ti i T Te em mp pe er ra at tu ur re e U Un ni it ts s o on nl ly y Multi Temperature Configuration Guides ...

Page 9: ...M MU US ST T u un np pl lu ug g t th he e A AC C S Sh ho or re e P Po ow we er r b be ef fo or re e p pr ro oc ce ee ed di in ng g This connector has the following two main functionalities 1 H Ha ar rd d S St to op p this connector is wired directly to the power relays When you disconnect unplug this connector the relays and the circuit opens immediately stopping the unit 2 D Di is sa ab bl le e A...

Page 10: ...over and Fan Housing Removal All Models To access the unit mounting holes 1 Remove plastic condenser cover 2 Remove the fan housing assembly Remove the fan connector 3 Remove Power Off Device Connector and Electric Box Cover 4 Mounting holes are now accessible ...

Page 11: ...t th he e h ho ol le es s i in ns si id de e t th he e e el le ec ct tr ri ic c b bo ox x w wh hi ic ch h a ar re e n no ot t u us se ed d f fo or r i in ns st ta al ll la at ti io on n d de ep pe en nd di in ng g n no os se e m mo ou un nt t r ro oo of f t to op p O Ot th he er rw wi is se e w wa at te er r w wi il ll l g ge et t i in nt to o t th he e e el le ec ct tr ri ic c b bo ox x a an nd d...

Page 12: ...rmo King Vehicle Powered Truck Installation Standards and Procedures Guide TK 61588 THESE PROCEDURES MUST BE FOLLOWED N No ot te e Evaporator mounting hole locations can be found at the back of this manual Figure 3 Standard Evaporator 10 and 20 Models Minimum distance from cargo wall to rear of evaporator shown 1 Return Air 2 Discharge Air ...

Page 13: ...t th he e f fi il lt te er r d dr ry ye er r a an nd d s si ig gh ht t g gl la as ss s b be ef fo or re e c ch ha ar rg gi in ng g t th he e u un ni it t w wi it th h r re ef fr ri ig ge er ra an nt t A Af ft te er r r re ef fr ri ig ge er ra an nt t c ch ha ar rg ge e t th he e s se er rv vi ic ce e v va al lv ve es s s sh ha al ll l b be e l le ef ft t o op pe en n a an nd d a a t ta am mp pe er...

Page 14: ...14 TK 61694 18 IM EN Figure 4 Hose Connection Single Temperature Model 20 H Ho os se e C Co on nn ne ec ct ti io on ns s ...

Page 15: ...0 o ring seal 3 O RING 6 o ring seal 9 90 degree Fitting female o ring seal 10 fitting 10 hose 4 90 degree Fitting female o ring seal 6 fitting 6 hose 10 Hose Liquid Line 4 50 ft 5 O RING 8 o ring seal 11 Hose Defrost Line 6 50 ft 6 90 degree Fitting female o ring seal 8 fitting 10 hose 12 Hose Suction Line 10 50 ft H Ho os se e C Co on nn ne ec ct ti io on ns s ...

Page 16: ... RING 10 o ring seal 3 O RING 6 o ring seal 10 90 degree Fitting female o ring seal 10 fitting 10 hose 4 90 degree Fitting female o ring seal 6 fitting 6 hose 11 Hose Liquid Line 4 50 ft 5 O RING 8 o ring seal 12 Hose Defrost Line 6 50 ft 6 90 degree Fitting female o ring seal 8 fitting 10 hose 13 Hose Suction Line 10 50 ft 7 90 degree Fitting straight 6 fitting 4 hose H Ho os se e C Co on nn ne e...

Page 17: ...seal 4 fitting 4 hose 10 EE splicer 4 3 O RING 6 o ring seal 11 TEE splicer 10 4 90 degree Fitting female o ring seal 6 fitting 6 hose 12 Hose Fitting straight 6 hose 8 fitting 5 O RING 8 o ring seal 13 Hose Liquid Line 4 50 ft 6 90 degree Fitting female o ring seal 6 fitting 10 hose 14 Hose Defrost Line 6 50 ft H Ho os se e C Co on nn ne ec ct ti io on ns s ...

Page 18: ... 61694 18 IM EN 7 90 degree Fitting female o ring seal 4 fitting 4 hose 15 Hose Suction Line 10 50 ft 8 90 degree Fitting female o ring seal 10 fitting 10 hose H Ho os se e C Co on nn ne ec ct ti io on ns s ...

Page 19: ... ro oo of f s se ea al l f fi it tt te ed d a as s r re ec co om mm me en nd de ed d b by y E EN N 3 37 78 8 2 2 a av vo oi id d r ri is sk k t th ha at t n no ot t e ed du uc ca at te ed d u us se er r c cl lo os se es s v va al lv ve es s t tr ra ap pp pi in ng g l li iq qu ui id d i in n t th he e d dr ry ye er r 1 Locate the Filter Drier Sight Glass assembly in your installation kit 2 Grease t...

Page 20: ...M EN Wiring Connections Model 20 50 I Im mp po or rt ta an nt t See Section 7 Electrical Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide THESE PROCEDURES MUST BE FOLLOWED ...

Page 21: ...rost Temperature Switch 2 DK2 CHOA D To In Cab Display inCAB 9 Drain Line Heater 2 HT2 CHD E To Vehicle Battery BAT 10 Defrost Solenoid 2 Spectrum PS2 CH_G F To Vehicle Battery BAT 11 Motor Evaporator Fan 2 EF2 CH_C G To Power Receptacle 12 HMI RXD TXD 8XP CH_N 1 Evaporator Fan 1 CH_B EF1 13 Door Switch 1 DSW1 CHW 2 Liquid Solenoid Valve PS3 CHI 14 Door Switch 2 Spectrum DSWA CH_FA 3 Defrost Tempe...

Page 22: ...e e a an nd d v vi is si ib bl le e f fr ro om m t th he e d dr ri iv ve er r s s s se ea at t and which does not restrict the mobility or visibility of either the driver or the vehicle s instruments and levers 2 Depending on the location chosen the base should be mounted following either Option A A or Option B B 3 Mount the base of the mounting bracket in the chosen location Use screws C C rubber...

Page 23: ...m F F and slide it to the right until the arm tab is properly fitted to the in cab control box frame 5 The tilt of the in cab control box s front face may be altered by loosening screw G G Connect the data cable to connector H H I In n C Ca ab b C Co on nt tr ro ol ll le er r I In ns st ta al ll la at ti io on n ...

Page 24: ...24 TK 61694 18 IM EN 6 To remove the in cab control box from the bracket press the tab I I and slide to the left I In n C Ca ab b C Co on nt tr ro ol ll le er r I In ns st ta al ll la at ti io on n ...

Page 25: ...he 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 Connect the data cable to the control connector H H 4 Insert the assembly formed by the control box and the plastic bracket into the metal box until the bracket tabs are properly fitted to the metal box ASA417 ...

Page 26: ...e wires and position the terminals supplied with the recommended tools 6 DISCONNECT THE CLAMP FROM THE BATTERY S NEGATIVE TERMINAL 7 Connect the wire wire between the battery and the vehicle starter key and the BAT wire to one end of the fuse F14 fuse holder both supplied by Thermo King and connect the other end of the fuse holder to the battery s positive pole Install fuse F25 5A in the fuse hold...

Page 27: ...attery supplied with the vehicle Some Vehicle manufacturers MB include the factory option to equip a secondary battery of the same technology of the main battery AGM with an optional relay Kbat and a higher rating alternator to serve auxiliary equipment The K Kb ba at t signal is activated by the vehicle ECU that closes the contact when the engine has started The K Kb ba at t opens when the engine...

Page 28: ...2 In order to enable the hold over the dealer have to change the setting of the parameter H1A to HOSTA 1 The factory setting is HOSTA 0 To do so follow the process described in Service Bulletin SB 1228 or save the appropriate WINTRAC file 3 HOTYP 2 Default setting from factory that indicates the holdover functionality is performed using the extended battery option Installation Guidelines 1 Locate ...

Page 29: ...TK 61694 18 IM EN 29 H Ho ol ld do ov ve er r B Ba at tt te er ry y O Op pt ti io on n ...

Page 30: ... can be used to inhibit the start stop function of the vehicle allowing to Maintain the engine running despite the vehicle engine stop conditions are met Typically the vehicle is stopped gear not engaged etc and or Activate the engine start All the safety precautions have to be considered by the OEM vehicle manufacturer seat belt fastened door closed battery charged etc Check the vehicle documenta...

Page 31: ...y 5 ECU Parts Required before Starting Installation Description TK Service Parts Number 1 Socket Relay Mini Plug in 445537 2 Relay 12V SPST 419313TKA 4 Connector 2 PIN 414622 6 Terminal Male 0 5 1 5 mm2 414624 S St ta ar rt t S St to op p F Fu un nc ct ti io on na al li it ty y ...

Page 32: ...nect BAT4 wire from K35 to pin 85 of the Relay Connect wire SPST2 from K35 to pin 86 of Relay Connect pins 87 and 30 to your vehicle ECU pin 87a is not used N No ot te e The way that these pins are connected to the vehicle ECU depends on whether a high side or a low side input to the vehicle ECU is required to manage the start stop inhibition Please consult your vehicle documentation for this info...

Page 33: ...TK 61694 18 IM EN 33 S St ta ar rt t S St to op p F Fu un nc ct ti io on na al li it ty y ...

Page 34: ...igh density of traffic lights etc The alternator maximum capacity is obtained at maximum engine rpm If the engine is running in idle the maximum power delivered is less than half of the rated maximum power Some vehicles incorporate a digital or analog input that can used to increase the idle speed The Gateway Controller GC has a digital output IIS signal that indicates that the refrigeration units...

Page 35: ...5 ECU Parts Required before Starting Installation Description TK Service Parts Number 1 Socket Relay Mini Plug in 445537 2 Relay 12V SPST 419313TKA 4 Connector 2 PIN 414622 6 Terminal Male 0 5 1 5 mm2 414624 I In nc cr re ea as se ed d I Id dl le e S Sp pe ee ed d S Se et tu up p ...

Page 36: ...ect BAT5 wire from K34 to pin 85 of the Relay Connect wire IIS2 from K34 to pin 86 of Relay Connect pins 87 and 30 to your vehicle ECU pin 87a is not used N No ot te e The way that these pins are connected to the vehicle ECU depends on whether a high side or a low side input to the vehicle ECU is required to manage the start stop inhibition Please consult your vehicle documentation for this inform...

Page 37: ...TK 61694 18 IM EN 37 I In nc cr re ea as se ed d I Id dl le e S Sp pe ee ed d S Se et tu up p ...

Page 38: ...d 50 Only I Im mp po or rt ta an nt t See Section 7 Electrical Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide TK 61588 THESE PROCEDURES MUST BE FOLLOWED Figure 8 Typical receptacle installation with correct drip loop shown ...

Page 39: ...ap to hold the wires 3 DO NOT cut the wires to fit 4 DO NOT cover the Heaters 5 DO NOT fit more than 4 wires into the tube ES 100N ES150 1 Cut the drain hose to the required length 2 Connect the hose to the drain tube Secure connections with plastic flanges 3 Route the hose through the drain hole and seal hermetically 4 Check that the corresponding siphon or moisture trap is installed at the end o...

Page 40: ...10 ES 150 Rear and Bottom views Legend 1 Option 1 Hose 2 Heaters 3 Option 2 Hose 4 Connector 5 Aluminium Foil Tape 6 Drain Tube 7 Nut E Ev va ap po or ra at to or r D Dr ra ai in n H Ho os se e I In ns st ta al ll la at ti io on n ...

Page 41: ...gle hose using supplied Y Connector 2 M MA AX X U Un ni it ts s O On nl ly y Install heaters into each drain hose as far away as they will go Legend A Inside Cargo Box B Ouside Cargo Box 1 Heaters 2 Drain Pan E Ev va ap po or ra at to or r D Dr ra ai in n H Ho os se e I In ns st ta al ll la at ti io on n ...

Page 42: ...LETING THE INSTALLATION YOU MUST PERFORM THE FOLLOWING PROCEDURES IN ACCORDANCE WITH THE THERMO KING INSTALLATION STANDARDS AND PROCEDURES GUIDE SYSTEM EVACUATION PROCEDURES SYSTEM LEAK CHECK PROCEDURES SYSTEM CHARGING PROCEDURES CONFIGURATION SOFTWARE PROCEDURES CONTROLLER PARAMETER SETUP ...

Page 43: ... high or low ambient temperatures may require that the settings be fine tuned for optimum performance M MA AX X units are equipped with a SPR valve located in the evaporator See illustration below The valve is used to limit the load on the compressor This also affects the current draw of the electric motor 1 Install gauge manifold set onto the suction service port at the compressor See illustratio...

Page 44: ...edure can be used to check the setting in the case of any doubt N No ot te e The measurement of the High Pressure 6 bar 87 psig does not necessarily mean that the DPR is set 6 bar 87 psig To get a more precise measurement of the DPR setting follow the procedure below in the exact order that it is listed 1 Cool down the box to 20º C 4º F 2 Change operation to heating mode 3 Attach a gauge manifold ...

Page 45: ... ur re e t to o a ad dd d t th he e c co or rr re ec ct t a am mo ou un nt t a an nd d t ty yp pe e o of f o oi il l w wi il ll l d da am ma ag ge e t th he e c co om mp pr re es ss so or r Table 1 Oil Capacity for Units Utilizing Hermetic Compressors Oil Supplied in Unit Oil Added at Installation Model Compressor Type Compressor oz Total Oil Added at Installation oz Total System Capacity oz Oil T...

Page 46: ...00 20 E 200 MAX 50 E 200 MAX 50 Spectrum 1 3kg 2 8lb including 1 5m 60 hoses supplied as standard R134a 1 3kg 2 8lb including 1 5 60 hoses supplied as standard R452A R404A 1 6kg 3 5lb including 6m 237 hoses supplied as standard R452A R404A Important 1 For each additional meter 39 of hose extension 80g 0 17lb of refrigerant MUST be added 2 It is a good idea to utilise the WINTRAC tool to set compre...

Page 47: ...plates can be downloaded and printed from EMEA Infocentral in the following location Technical Publications Vehicle Powered Truck Drawings and Diagrams Installation Templates I Im mp po or rt ta an nt t See Section 4 Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide TK 61588 THESE PROCEDURES MUST BE FOLLOWED Figure 11 Co...

Page 48: ...48 TK 61694 18 IM EN Figure 13 Centre of Gravity C Co on nd de en ns se er r a an nd d E Ev va ap po or ra at to or r D Di im me en ns si io on ns s ...

Page 49: ...TK 61694 18 IM EN 49 N No ot te es s ...

Page 50: ...50 TK 61694 18 IM EN N No ot te es s ...

Page 51: ...TK 61694 18 IM EN 51 N No ot te es s ...

Page 52: ...ransport and protect food and perishables and increase industrial productivity and efficiency We are a global business committed to a world of sustainable progress and enduring results ingersollrand com Ingersoll Rand 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 c...

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