Thermo King V-520 RT Series Installation Manual Download | Manualshive

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TK 56612-18-IM-EN

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Figure 4. MODEL 10, MAX 10, 30 and MAX 30 REFRIGERATION and CONDENSER MODULES

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Summary of Contents for V-520 RT Series

Page 1: ...Revision A July 2018 T TK K 5 56 66 61 12 2 1 18 8 I IM M E EN N Vehicle Powered Truck Edition V 520 RT Series Single and Multi Temperature Systems Installation Manual ...

Page 2: ... 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 nj ju ur ry y p pr ro op...

Page 3: ...Installed Support Plate 16 Alternate Installation Method Lag Bolts 17 P Po ow we er r P Pa ac ck k M Mo od du ul le e I In ns st ta al ll la at ti io on n 1 18 8 Preferred Installation Method Pre Installed Support Plate 19 Alternate Installation Method Lag Bolts 20 C Co on nd de en ns se er r M Mo od du ul le e I In ns st ta al ll la at ti io on n 2 21 1 Preferred Installation Method Pre Installed...

Page 4: ...us st tm me en nt t P Pr ro oc ce ed du ur re es s 3 37 7 SPR Valve Settings 37 CPR Valve Settings Single Temperature Systems 38 CPR Valve Settings SPECTRUM Multi Temperature Systems 39 I In ns st ta al ll la at ti io on n C Ch he ec ck k L Li is st t 4 40 0 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s 4 41 1 C Co om mp po on ne en nt t D Di im me en ns si io on ns s...

Page 5: ...y T Th he er rm mo o K Ki in ng g c co on nd de en ns se er r u un ni it ts s a an nd d r re em mo ot te e e ev va ap po or ra at to or rs s a ar re e s sh hi ip pp pe ed d w wi it th h a a 3 35 5 k kP Pa a 5 5 p ps si i h ho ol ld di in ng g c ch ha ar rg ge e o of f H He el li iu um m B Be e c ca ar re ef fu ul l w wh he en n r re em mo ov vi in ng g c ca ap p T Th hi is s h ho ol ld di in ng g ...

Page 6: ...OLLOWED I Im mp po or rt ta an nt t Failure to add the correct amount and type of oil will damage the compressor Refer to Compressor Oil Requirements p 23 I Im mp po or rt ta an nt t It is critical that a P trap is installed in the suction line b be ef fo or re e the roadside compressor See Section 6 Refrigerant Hose and Fittings Standards in the Thermo King Vehicle Powered Truck Installation Stan...

Page 7: ...TK 56612 18 IM EN 7 Evaporator Installation Preparing Evaporator for Installation Cover Removal All Models 1 Remove plastic cover assembly to access the unit mounting holes ...

Page 8: ...rear of evaporator 1 Remove cap and connect 7 8 tube from accumulator to mating tube inside evaporator I Im mp po or rt ta an nt t Ensure O ring is oiled and properly inserted a Tighten fitting to 28 33 lb ft 2 Secure accumulator to rear of evporator with supplied hardware a Tighten hardware to 5 8 7 8 lb ft E Ev va ap po or ra at to or r I In ns st ta al ll la at ti io on n ...

Page 9: ...p 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 56430 THESE PROCEDURES MUST BE FOLLOWED E Ev va ap po or ra at to or r I In ns st ta al ll la at ti io on n ...

Page 10: ...te Thermo King recommends installing a support plate with mounting studs or threaded inserts installer supplied to the truck s interior roof structure to safely support the weight of the evaporator s The plate should be installed prior to insulating and finishing the cargo area The plate should also position the evaporator the required distance from the front bulkhead wall to allow for refrigerant...

Page 11: ...ide holes into the compartment ceiling and up through the roof b Enlarge guide holes to proper size 4 Outside on the rooftop a Apply silicone sealer around all mounting holes place backing plates over holes and insert mounting bolts down into cargo box 5 Inside the cargo box a Position evaporator onto mounting bolts install washers and locking nuts and hand tighten hardware securely b Trim excess ...

Page 12: ...ng 2 Center evaporator onto ceiling o or r u us se e t te em mp pl la at te e and mark the location of the four mounting holes 3 Drill four 5mm 3 16 in mounting holes into the ceiling 4 Install the supplied 1 4 lag bolts and washers only a few turns into the ceiling 5 Apply neutral alcohol cure silicone sealer installer supplied per the manufacturer s instructions to the top surface of the evapora...

Page 13: ...red distance from the front bulkhead wall to allow for refrigerant and drain hose connections I Im mp po or rt ta an nt t Be sure to install the correct evaporator into each compartment H HO OS ST T Evaporator has drain pan heater wires and installs in F FR RO OZ ZE EN N compartment R RE EM MO OT TE E Evaporator does not have drain pan heater wires and installs in F FR RE ES SH H compartment 1 Sec...

Page 14: ...holes place backing plates over holes and insert mounting bolts down into cargo box 5 Inside the cargo box a Position each evaporator onto mounting bolts install washers and locking nuts and hand tighten hardware securely b Trim excess bolt lengths as needed I Im mp po or rt ta an nt t Apply silicone sealer to exterior bolt heads to prevent water from migrating into the cargo box E Ev va ap po or ...

Page 15: ...ng 2 Center evaporator onto ceiling o or r u us se e t te em mp pl la at te e and mark the location of the four mounting holes 3 Drill four 5mm 3 16 in mounting holes into the ceiling 4 Install the supplied 1 4 lag bolts and washers only a few turns into the ceiling 5 Apply neutral alcohol cure silicone sealer installer supplied per the manufacturer s instructions to the top surface of the evapora...

Page 16: ...e The access hole must be located behind bulkhead and inside the cargo compartment This is necessary so the refrigeration hoses and electrical harness will be located on the inside of the cargo compartment not in the passengers compartment 2 Mark and drill access hole completely through roof and into interior compartment 3 Apply silicone sealant around access hole and install supplied gasket 4 App...

Page 17: ...ctrical harness will be located on the inside of the cargo compartment not in the passengers compartment 2 Mark and drill access hole completely through roof and into interior compartment 3 Apply silicone sealant around access hole and install supplied gasket 4 Use a 2 point lifting device with locking hooks attached to module s two lifting brackets and raise into position on vehicle s roof 5 Mark...

Page 18: ...Im mp po or rt ta an nt t The standby compressor in the power pack module contains oil Tip the module up slightly on a workbench and place rags under the compressor s ORS fittings before removing the protective caps 1 Remove plastic cover assembly from the Power Pack Module 2 Tip module up slightly and place rags under the ORS fittings 3 Remove protective caps from the ORS fittings 4 Lubricate the...

Page 19: ...bolts or inserts on the roof of the vehicle 2 With the cover removed use a 4 point lifting device with locking hooks attached to the module s four lifting holes and raise into position onto vehicle s roof 3 Align the Power Pack s three front mounting studs with the three matching mounting holes on the Refrigeration Module s frame a Install flat washers and locking nuts and tighten hardware securel...

Page 20: ...nd raise into position onto vehicle s roof 2 Align the Power Pack Module s three front mounting studs with the three matching mounting holes on the Refrigeration Module s frame a Attach flat washers locking nuts and tighten hardware securely 3 Use the modules s mounting holes as a template and drill four 5mm 3 16 in holes into the internal structural roof supports 4 Apply silicone sealant around e...

Page 21: ...two drain holes located in the corners of the module 2 Apply silicone sealant around all mounting bolts or inserts on the roof of vehicle 3 Install four 1 4 20 lifting eyebolts installer supplied into the four threaded inserts located on top of the condenser module 4 Use a 4 point lifting device with locking hooks attached to the module s four lifting holes and raise into position onto vehicle s r...

Page 22: ...nt mounting holes of the Condenser Module s cover with the matching four rear mounting brackets with speed nuts on the Refrigeration Module or Power Pack frame a Install four 6mm screws lock washers and flat washers and tighten hardware securely 5 Use the modules s six mounting holes as a template and drill six 5mm 3 16 in mounting holes into the internal structural roof supports 6 Apply silicone ...

Page 23: ...S MUST BE FOLLOWED N No ot te e If utilizing a discharge muffler an additional 3 oz of oil must be added during installation POE 120 Oil Capacity for Units Utilizing Swash Plate Roadside Compressors Oil Supplied in the Unit Oil Added at Installation Model Roadside Compressor System Oil Standby Compressor Add to Roadside Compressor oz Add to Suction Line oz Total Oil added at Installation oz Total ...

Page 24: ... po or rt ta an nt t T Th he e s su uc ct ti io on n l li in ne e f fr ro om m t th he e e ev va ap po or ra at to or r a an nd d t th he e s su uc ct ti io on n l li in ne e f fr ro om m t tr ru uc ck k e en ng gi in ne e d dr ri iv ve en n c co om mp pr re es ss so or r m mu us st t b be e a at tt ta ac ch he ed d O ON NL LY Y t to o m ma an ni if fo ol ld d f fi it tt ti in ng gs s s sh ho ow w...

Page 25: ...f fr ro om m t th he e e ev va ap po or ra at to or r a an nd d t th he e s su uc ct ti io on n l li in ne e f fr ro om m t th he e t tr ru uc ck k e en ng gi in ne e c co om mp pr re es ss so or r m mu us st t b be e a at tt ta ac ch he ed d O ON NL LY Y t to o t th he e m ma an ni if fo ol ld d f fi it tt ti in ng gs s s sh ho ow wn n o or r s se ev ve er re e d da am ma ag ge e t to o t th he e...

Page 26: ... e f fr ro om m t th he e e ev va ap po or ra at to or r a an nd d t th he e s su uc ct ti io on n l li in ne e f fr ro om m t th he e t tr ru uc ck k e en ng gi in ne e c co om mp pr re es ss so or r m mu us st t b be e a at tt ta ac ch he ed d O ON NL LY Y t to o t th he e m ma an ni if fo ol ld d f fi it tt ti in ng gs s s sh ho ow wn n o or r s se ev ve er re e d da am ma ag ge e t to o t th h...

Page 27: ...llation Standards and Procedures Guide TK 56430 THESE PROCEDURES MUST BE FOLLOWED I Im mp po or rt ta an nt t The suction line from the evaporator and the suction line from truck engine driven compressor must be attached ONLY to manifold fittings shown or severe damage to compressor will result R Re ef fr ri ig ge er ra at ti io on n H Ho os se e I In ns st ta al ll la at ti io on n ...

Page 28: ...llation Standards and Procedures Guide TK 56430 THESE PROCEDURES MUST BE FOLLOWED I Im mp po or rt ta an nt t The suction line from the evaporator and the suction line from truck engine driven compressor must be attached ONLY to manifold fittings shown or severe damage to compressor will result R Re ef fr ri ig ge er ra at ti io on n H Ho os se e I In ns st ta al ll la at ti io on n ...

Page 29: ...andby compressor discharge line from the Standby Compressor to the Oil Separator 2 Remove the retaining nut and coil from the normally closed Liquid Injection Solenoid located near the drier in the condenser section Install a valve magnet on the valve stem When the magnet is installed a click should be heard as the valve opens 3 Remove the coil from the normally closed Defrost Solenoid located in ...

Page 30: ...30 TK 56612 18 IM EN L Le ea ak k C Ch he ec ck k a an nd d E Ev va ac cu ua at ti io on n P Pr ro oc ce ed du ur re es s ...

Page 31: ...tion 7 Electrical Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide TK 56430 THESE PROCEDURES MUST BE FOLLOWED N No ot te e All electrical harnesses must be properly routed and connected securely to the individual components and to the vehicle s electrical system ...

Page 32: ...32 TK 56612 18 IM EN E El le ec ct tr ri ic ca al l C Co on nn ne ec ct ti io on ns s ...

Page 33: ...o King Vehicle Powered Truck Installation Standards and Procedures Guide TK 56430 THESE PROCEDURES MUST BE FOLLOWED N No ot te e All electrical harnesses must be properly routed and connected securely to the individual components and to the vehicle s electrical system E El le ec ct tr ri ic ca al l C Co on nn ne ec ct ti io on ns s ...

Page 34: ...tor Drain Hose Installation I Im mp po or rt ta an nt t See Section 8 Evaporator Drain Hose Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide TK 56430 THESE PROCEDURES MUST BE FOLLOWED ...

Page 35: ...4 40 04 4A A Partially block off the air intake to the condenser if necessary 10 Open the low side valve of the gauge manifold and the refrigerant bottle valve and add refrigerant s sl lo ow wl ly y until no bubbles can be seen through the liquid sight glass 11 Close the refrigerant bottle and gauge manifold valves 12 Leave the unit running for 15 minutes 13 Check that there are no bubbles in the ...

Page 36: ...36 TK 56612 18 IM EN S Sy ys st te em m C Ch ha ar rg gi in ng g P Pr ro oc ce ed du ur re es s ...

Page 37: ...uge to the suction service port on the copper tube directly before the SPR valve to monitor suction pressure at the inlet to the suction pressure regulator 2 Connect the unit s power receptacle to an appropriate electric power source 3 Place a jumper wire between the 1 12 2 and C CH HB B wires at the defrost termination switch to ensure the unit will run in Defrost 4 Start the unit and run it in D...

Page 38: ...and run the unit in Heat on the engine driven compressor until the pressure on the additional compound gauge attached to the evaporator suction service port stabilizes at a pressure above 60 psig 414 kPa 4 Check the suction pressure on the gauge attached to the suction service port at the compressor It should be 50 0 5 psig 345 34 kPa If the setting is incorrect remove the protective cap and adjus...

Page 39: ...t 1800 to 2000 RPM 4 Bring the frozen compartment to 5 to 7 F 3 to 4 C above desired setpoint Record the suction pressure and then shut the unit off 5 Remove the suction bypass solenoid coil and install a magnet P N 204 1074 to close valve 6 Raise the frozen compartment setpoint to the highest level on the HMI and lower the fresh compartment setpoint to 35 F 2 C and start the unit 7 With the unit ...

Page 40: ...rb vibrations Refrigerant hoses are not making contact with moving sharp or hot components Suction Line P Trap installed correctly Compressor is filled with the proper amount and type of oil All electrical connectors are locked securely in place Standby Power Receptacle if applicable is mounted securely to vehicle All electrical harnesses and wiring is routed and secured adequately Correct size an...

Page 41: ...e TK 56430 THESE PROCEDURES MUST BE FOLLOWED All vehicle powered truck units come with a Commissioning Form TK 56482 and PDI Form TK 56444 included with the documents package Completing both these forms helps assure Thermo King equipment is installed with the highest degree of quality reliability and durability to meet or exceed the expectations of our customer resulting in total customer satisfac...

Page 42: ...42 TK 56612 18 IM EN Component Dimensions and Weights Figure 1 ES500 EVAPORATORS ...

Page 43: ...TK 56612 18 IM EN 43 Figure 2 ES300 HOST EVAPORATORS C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 44: ...44 TK 56612 18 IM EN Figure 3 ES300 REMOTE EVAPORATOR C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 45: ...TK 56612 18 IM EN 45 Figure 4 MODEL 10 MAX 10 30 and MAX 30 REFRIGERATION and CONDENSER MODULES C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 46: ...46 TK 56612 18 IM EN Figure 5 MODEL 20 MAX 20 50 and MAX 50 REFRIGERATION and CONDENSER MODULES C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 47: ...TK 56612 18 IM EN 47 Figure 6 HMI CONTROLLER C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 48: ...48 TK 56612 18 IM EN Figure 7 REFRIGERATION MODULE MOUNTING HOLE DIMENSIONS C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 49: ...TK 56612 18 IM EN 49 Figure 8 POWER PACK MODULE MOUNTING HOLE DIMENSIONS C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 50: ...50 TK 56612 18 IM EN Figure 9 CONDENSER MODULE MOUNTING HOLE DIMENSIONS C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 51: ...TK 56612 18 IM EN 51 Figure 10 ES500 EVAPORATOR MOUNTING HOLE LOCATIONS and DIMENSIONS C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 52: ...52 TK 56612 18 IM EN Figure 11 ES300 EVAPORATOR MOUNTING HOLE LOCATIONS and DIMENSIONS C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 53: ...TK 56612 18 IM EN 53 Figure 12 ES300 EVAPORATOR MOUNTING HOLE LOCATIONS and DIMENSIONS C Co om mp po on ne en nt t D Di im me en ns si io on ns s a an nd d W We ei ig gh ht ts s ...

Page 54: ...54 TK 56612 18 IM EN N No ot te es s ...

Page 55: ...TK 56612 18 IM EN 55 N No ot te es s ...

Page 56: ... bodies buses air shipboard containers and railway cars since 1938 For more information visit www thermoking com or www tranetechnologies com Thermo King 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 conscious print practices TK 56612 18 IM EN 01 Jul 2018 Supersede...

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