Thermo King B-100-10 Installation Manual Download

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Installation Manual

B-100
Model 10 and 20 with Direct Smart Reefer

TK-54436 -18-IM (Rev. 1,11/09)

Copyright

2009 Thermo King Corp., Minneapolis, MN, U.S.A.

Summary of Contents for B-100-10

Page 2: ...2 Release History Original 7 09 Released Rev 1 11 09 Page 40 changed text from start up wire fuse to fused ignition circuit...

Page 3: ...the installation Have a truck body designed and built to meet the requirements of this installation This manual is published for informational purposes only Thermo King makes no representations or war...

Page 4: ...it 24 Connecting Hoses to the ES100 Evaporator 26 Electrical Connections in the ES100 Evaporator 28 Drain Circuit in the ES100 Evaporator 30 Circuit Seal Test 32 In Case of Leaks 34 Installing the In...

Page 5: ...h may result in death by suffocation DANGER When removing a battery from the Battery Pack ALWAYS disconnect the negative battery terminal first Then remove the positive terminal When reconnecting the...

Page 6: ...service refrigeration systems always observe the ladder manufacturer s safety labels and warnings A work platform is the recommended method for installations WARNING Exposed coil fins are very sharp...

Page 7: ...into the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of national regulations...

Page 8: ...loves 14 File 15 Plastic flanges 16 Riveter 17 Electric connectors 18 Electrical wire 19 Voltmeter 20 Set of screwdrivers 21 Hose cutters 22 Wire strippers 23 Wire cutters 24 Electric and hand saws 25...

Page 9: ...9 Required Tools...

Page 10: ...10 Operating Method 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: ...ith the unit documentation Inspecting the Unit 1 Open the condenser unit cover and ensure the following Neither the cover nor the unit should show any shock damage or imperfections The condenser batte...

Page 12: ...ires and parts of the vehicle chassis 3 Drill the holes to hold the condenser unit in place D 12 and the holes for routing hoses D 70 4 Disassemble the canalizer 5 Disassemble the electric box support...

Page 13: ...13 Installing the Condenser Unit roof mounted ASA052 T 10 min...

Page 14: ...ace the unit on the roof of the vehicle Remove the straps and the crane 3 Pass the 4 locks crews through the holes in the frame placing a flat washer onto each screw Avoid direct contact between the u...

Page 15: ...15 Installing the Condenser Unit roof mounted T 12 min...

Page 16: ...wires and parts of the vehicle chassis 3 Drill the holes to hold the condenser unit in place D 12 and the holes for routing hoses D 70 4 Disassemble the canalizer 5 Disassemble the electric box suppor...

Page 17: ...17 Installing the Condenser Unit front mounted T 10 min...

Page 18: ...nit making sure that it remains in a horizontal position If it does not change the position of the straps 4 Pass the 4 locks crews through the holes of the structure and fix them with a flat washer 5...

Page 19: ...19 Installing the Condenser Unit front mounted C T 15 min...

Page 20: ...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 4 C...

Page 21: ...21 Installing the ES100 Evaporator Unit T 20 min...

Page 22: ...ed in the hose using Thermo King refrigerant oil 4 Manually insert the fitting into the hose The hose should touch the projecting part of the fitting without going into it Clean off excess oil 5 Place...

Page 23: ...23 Preparing Refrigeration Hoses T 10 min...

Page 24: ...e tubes 2 Lubricate all refrigeration intakes with Thermo King refrigerant oil 3 Place an O ring on each refrigeration intake 4 Check that the O ring is properly positioned and connect each hose using...

Page 25: ...25 Connecting Hoses to the Condenser Unit T 10 min...

Page 26: ...ant oil 3 Place an O ring on each refrigeration intake 4 Connect each hose using two fixed wrenches The O ring should be properly positioned before the fitting is screwed on 5 Wrap the hoses with ther...

Page 27: ...27 Connecting Hoses to the ES100 Evaporator T 14 min...

Page 28: ...e and the return temperature sensor through as far as the evaporator 2 Connect the low pressure cutout the defrost temperature thermostat the hot gas solenoid valve and the temperature sensor 3 Connec...

Page 29: ...29 Electrical Connections in the ES100 Evaporator T 10 min...

Page 30: ...equired 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 moist...

Page 31: ...31 Drain Circuit in the ES100 Evaporator T 5 min...

Page 32: ...alves on the circuit 5 Start the vacuum pump and maintain suction until it reaches 500 microns 6 Once it reaches 500 microns leave suction running for one hour 7 Close the vacuum pump valve switch off...

Page 33: ...33 Circuit Seal Test...

Page 34: ...to 17 bar 250 psig 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 Use the recommended leak detecto...

Page 35: ...35 In Case of Leaks 250 psig...

Page 36: ...be mounted following either Option A or Option B 3 Mount the base of the mounting bracket in the chosen location Use screws C rubber mat D and metal plate E which are supplied by Thermo King as indica...

Page 37: ...37 Installing the In Cab Control 1 3 T 10 min...

Page 38: ...M sufficiently to fit the box into the housing 2 Attach the control to the plastic bracket L using the 4 screws K 3 Connect the data cable to the control connector H 4 Insert the assembly formed by t...

Page 39: ...39 Optional Internal DIN Adaptor T 5 min...

Page 40: ...e Connection 1 Pass cable 01 of the electrical hose through to the cab 2 Locate the fuse box 3 Connect wire 01 to the vehicle s fused ignition circuit NOTE Use a splice capable of supporting a 3A elec...

Page 41: ...41 Control Cable Connection T 5 min...

Page 42: ...ire 2 to one end of the fuse FP fuse holder both supplied by Thermo King and connect the other end of the fuse holder to the battery s positive pole Install fuse FP 100A 12V or 60A 24V in the fuse hol...

Page 43: ...43 Battery Connection T 15 min...

Page 44: ...clamps provided 3 Cut off the excess electrical wire In order to avoid the coil effect do not roll up the excess electrical wire Do not create splices in the electrical wire 4 Connect the electrical w...

Page 45: ...45 Fitting the Power Supply Units with Electric Standby T 10 min...

Page 46: ...46 Door Switch Connection 1 Pass the electrical cable DSW1 CHW through to the door of the compartment of the truck 2 Connect the door switch to the two way connector on cable DSW1 CHW...

Page 47: ...47 Door Switch Connection DSW1 CHW T 1 min...

Page 48: ...over 3 Remove the cover from the condenser and drill the two front holes 4 Fit the deflector onto the cover and secure it via two front holes using the screws supplied by Thermo King 5 Fit the cover d...

Page 49: ...49 Installing the Deflector T 5 min...

Page 50: ...To ensure the correct curvature the total width should be 446 mm 4 If necessary fit additional straight sections 5 Cut the last straight section to the required length 6 Secure the hoses using the cl...

Page 51: ...51 Installing the Hose Covers T 12 min...

Page 52: ...heating 10 C F Symbol Indicates whether the on screen temperature reading is in degrees Celsius C or degrees Fahrenheit F 11 Alarm Symbol Indicates that there is an alarm in the system 12 Maintenance...

Page 53: ...efrost Initiation Timer Minutes Increments of 30 minutes On time out the unit will switch from cool to the appropriate defrost mode The timer will count all the time the system is in any cool mode The...

Page 54: ...n 2 not present 1 0 2 bE Buzzer Enable 0 not enabled 1 enabled 2 enabled also when keys are pressed 3 enabled only when keys are pressed 2 0 3 tu Thermostat Units C temperature visualization in C F te...

Page 55: ...evaporators The temperature sensor should be connected on all evaporators The in cab control box should be located in a spot that it is accessible and visible from the driver s position The contact d...

Page 56: ...7 Start the vehicle engine running at around 1000 rpm and switch on the unit 8 Set the unit thermostat at 0 C 32 F see operating manual 9 Run the unit until it reaches a temperature close to that ind...

Page 57: ...57 Charging the Circuit...

Page 58: ...58 Outline Drawings...

Page 59: ...59 Outline Drawings...

Page 60: ...60 Outline Drawings...

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