Trane Thermo King ES300 Installation Manual Download

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V-520 RT Installation Manual

Release History

Released

(07/12)

Rev. 1

(06/12) Pages 8, 10, 20 and 56: added silicone sealant update, page 39; increased compressor oil quantity.

Rev. 2

(09/13) Page 5: changed compressor oil from 203-513 to 203-515.

Rev. 3

(12/13) Pages 8, 13 and 14: changed text and art to clarify the minimum distance required from the cargo wall to the

rear of the evaporator with or without heat option.

Rev. 4

(04/14) Pages 24, 26 and 28: added torque of 60 in-lbs for plastic cover screws.

Rev. 5

(08/14) Pages 9, 20, 21, 54 and 55: Added compressor ground wire.

Rev. 6

(11/15) General update to manual including adding SPR and CPR adjustment procedures, system leak check and

evacuation procedures, updated information on battery connections and how to properly secure maxi fuse holder.

Rev. 7

(01/16) Added new in-line fuse installation procedures.

Summary of Contents for Thermo King ES300

Page 1: ...er in sustainable transport temperature control solutions Thermo King has been providing transport temperature control solutions for a variety of applica tions including trailers truck bodies buses air shipboard containers and railway cars since 1938 For more information visit www thermoking com or www tranetechnologies com 2020 Trane Technologies TK 56455 18 IM Jan 2016 Installation Manual Truck ...

Page 3: ...ce required from the cargo wall to the rear of the evaporator with or without heat option Rev 4 04 14 Pages 24 26 and 28 added torque of 60 in lbs for plastic cover screws Rev 5 08 14 Pages 9 20 21 54 and 55 Added compressor ground wire Rev 6 11 15 General update to manual including adding SPR and CPR adjustment procedures system leak check and evacuation procedures updated information on battery ...

Page 4: ...This manual is published for informational purposes only Thermo King makes no representations warranties express or implied with respect to the information recommendations and descriptions contained herein Information provided should not be regarded as all inclusive or covering all contingencies If further information is required Thermo King Corporation Service Department should be consulted Therm...

Page 5: ...le 24 Installation Power Pack Module 26 Installation Condenser Module 28 Fabricating Refrigeration Hoses 30 Important Suction Line Routing and P Trap Formation 36 Installation Refrigeration Tubes to Compressor 38 Installation Refrigeration Hoses 40 Installation Refrigeration Hoses to Vehicle s Compressor 42 System Leak Check and Evacuation 44 Installation Electrical Connections 46 Electrical Conne...

Page 6: ...ix Polyol Ester and standard synthetic compressor oils Keep Polyol Ester compressor oil in tightly sealed containers If Polyol Ester oil becomes contaminated with moisture or standard oils dispose of properly DO NOT USE WARNING When servicing Thermo King R 404A and R 134a units use only those service tools certified for and dedicated to R 404A or R 134a refrigerant and Polyol Ester compressor oils...

Page 7: ... that are severe respiratory irritants capable of causing death DANGER Be careful when working with a refrigerant or refrigeration system in any enclosed or confined area with a limited air supply i e a trailer container or the hold of a ship Refrigerant tends to displace air and can cause oxygen depletion which may result in death by suffocation WARNING Always wear eye protection such as goggles ...

Page 8: ...s as this could cause an electrical fire CAUTION Do not connect other manufacturer s equipment or accessories to the Thermo King unit This could result in severe damage to equipment and void the warranty CAUTION Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury CAUTION Always w...

Page 9: ...ulator assembly for refrigerant hose and drain hose connections The V 520 RT must be installed with the refrigeration module facing towards the front of the vehicle Verify tools and special equipment required for the installation are available and in good operating condition before beginning the installation Verify all measurements before drilling holes in vehicle Verify there is no interference w...

Page 10: ...he location used on the vehicle chassis should be clean and free of paint to make a proper ground path Battery Installation and Cable Routing on page 7 for details The In Cab controller must only be mounted inside the vehicle It should be accessible and visible from the drivers position while not interfering with the driver s mobility visibility or access to the vehicle controls and instruments EL...

Page 11: ...l Alcohol Cure Silicone Sealant 203 436 or equivalent 14 Manifold Gauge Set 15 Evacuation Station 16 Reclaiming Station 17 Electronic Leak Detector 18 Refrigerant and Scale 19 Overhead Crane or Hoist with locking lifting hooks 20 Work Platform Recommended 21 Solenoid Valve Magnet 204 1074 IMPORTANT Equipment such as scales gauges and torque wrenches should be in good working condition and routinel...

Page 12: ...11 Required Tools ...

Page 13: ...ensions and Weight Model 50 SPECTRUM Approximate Weight Complete Model 50 SPECTRUM Refrigeration Power Pack and Condenser Modules 86 kg 190 lbs Dimensions A 1137 mm 44 75in B 2159 mm 85 00 in C 229 mm 9 00 in ...

Page 14: ...ht ES300 Host Evaporator Dimensions A 524 mm 20 7 in E 183 mm 7 2 in B 976 8 mm 38 5 in F 152 mm 6 0 in C 455 mm 18 0 in G 152 mm 6 0 in D 892 mm 35 0 in H 147 mm 5 8 in Approximate Weight ES300 Host Evaporator 18 kg 40 lbs ...

Page 15: ... 662 9 mm 26 1 in E 183 mm 7 2 in B 976 8 mm 38 5 in F 152 mm 6 0 in C 455 mm 18 0 in G 152 mm 6 0 in D 892 mm 35 0 in H 147 mm 5 8 in Approximate Weight ES300 Remote Evaporator with SPECTRUM Assembly 33 kg 72 lbs Evaporator Only Evaporator with SPECTRUM Assembly ...

Page 16: ...15 Dimensions Refrigeration Module Mounting Holes Dimensions A 1107 4 mm 43 60 in B 466 3 mm 18 36 in C 393 7 mm 14 50 in D 235 0 mm 9 25 in Choose one mounting hole per section ...

Page 17: ...16 Dimensions Power Pack Module Mounting Holes Dimensions A 1107 4 mm 43 60 in B 466 3 mm 18 36 in C 393 7 mm 14 50 in D 235 0 mm 9 25 in ...

Page 18: ...17 Dimensions Condenser Module Mounting Holes ...

Page 19: ...18 Dimensions HMI A 140 mm 5 50 in B 46 mm 1 80 in C 12 mm 50 in ...

Page 20: ...19 BLANK PAGE ...

Page 21: ...e added later to the system See TOTAL AMOUNT OF OIL REQUIRED on page 43 Install compressor on the vehicle by following the instructions included in the compressor kit Compressor Ground Wire Install the chassis ground wire to the compressor frame using the supplied hardware Ensure the mounting location on the chassis is free of any paint Use anti corrosion gel 203 377 or equivalent on ground wire c...

Page 22: ...nstallation Vehicle Powered Compressor IMPORTANT Failure to install the compressor ground wire to the chassis may result in intermittent clutch operation and premature clutch failure Compressor Ground Wire ...

Page 23: ...ts and tighten hardware securely NOTE The covers for both evaporators will be installed later Alternative Installation Method without pre installed support plates 1 Locate and mark the center line C L of the interior compartment ceiling 2 HOST evaporator Allow a minimum distance of 152 mm 6 00 in from the cargo area wall to the rear of the evaporator for refrigerant hose and drain hose connections...

Page 24: ...23 Installation 2 ES300 Evaporators Alternative Installation Method Preferred Installation Method ...

Page 25: ...le 1 Remove plastic cover from refrigeration module and trim foam gasket away from the two drain holes located in the corners 2 Locate and mark the center line C L of vehicle s roof 3 Determine location of interior bulkhead in relationship to vehicle s roof Mark location of bulkhead on vehicle s roof 4 Use Dimensions Refrigeration Module Mounting Holes on page 15 to mark location on roof of refrig...

Page 26: ...25 Installation Refrigeration Module Alternative Installation Method Preferred Installation Method ...

Page 27: ...o the roof using the supplied 1 4 lag bolts and washers and hand tighten securely NOTE Multiple mounting holes are provided every two inches along the sides of the module for mounting options Choose four mounting holes ideally one in each corner to secure the module Alternative Installation Method without pre installed support plates and pre cut access hole NOTE It is recommended the copper tubing...

Page 28: ...27 Installation Power Pack Module Alternative Installation Method Preferred Installation Method ...

Page 29: ...unting holes of the condenser module s cover with the matching four rear mounting brackets with speed nuts on the power pack s frame Install four 6 mm screws lock washers and flat washers and tighten securely 5 Secure condenser module to the roof using the supplied 1 4 lag bolts and washers and tighten to 36 in lbs DO NOT OVER TIGHTEN BOLTS Alternative Installation Method without pre installed sup...

Page 30: ...29 Installation Condenser Module Preferred Installation Method Alternative Installation Method ...

Page 31: ...eded As easy to use as a pair of Pliers Easy to use in confined areas Assembly Materials Checklist Hose Fitting Tools 204 1045 and 204 1128 Hose Cutting Tools 204 677 TK 2000 Multi Refrigerant Hose Nipple Assembly Appropriately Sized Clips and Cage NOTE The two black O rings on the nipple assembly are of a specific rubber compound and size They should not be removed or replaced Hose Cage Clips Fit...

Page 32: ...se Be sure the cut is made square to the hose length Slip on Two Clamps 2 Install two proper size clips onto the cut end of the hose Orientation of the clips does not affect the performance of the connection However for ease of assembly both clips should have the same orientation CAUTION Failure to slide the clips over the hose at this time will require the clips to be stretched over the hose or f...

Page 33: ...l This MUST be done to lower the force of nipple insertion 4 Insert the nipple into the hose To ensure that the nipple is fully inserted check the gap between the cut end of the hose and the shoulder on the nipple Care should be taken to avoid kinking or other damage to the hose during nipple insertion NOTE Be sure to wipe excess oil from the nipple and hose ...

Page 34: ...clips will be located over the O ring on the nipple The connection will be compatible with the connection s pressure rating Slide the Clips 6 Slide the clips over the cage arms and into the channels on each arm Close the Clips 7 Use the fitting tool 204 1045 or 204 1128 to close the clips The pliers should be positioned squarely on the clip connection points and should remain square during the clo...

Page 35: ...s Nose of the pliers should be firmly seated under the assembly bump and lock latch If the pliers are not kept square during closing the clip the clasp may have an offset Use the pliers to correct the clasp alignment Correct Incorrect ...

Page 36: ...instructions and or the use of TK 2000 Speedy Clip System hose with fittings supplied by other manufactures could result in sudden or unintended escape of refrigerant gases Personal injury and or violations of EPA regulations may occur as a consequence Improperly Installed Clip Properly Installed Clip All hoses must be routed as to maintain the minimum bend radii given in the table below Hose Size...

Page 37: ...it towards the compressor Horizontal angle is acceptable uphill angle is not 3 Hoses should be secured adequately to prevent rubbing or chafing against hot sharp or moving components 4 P Trap to be formed immediately before vertical run upwards to compressor while maintaining minimum bend radius with no kinks It should be a minimum of 2 below the lowest point of the horizontal run hose as shown 5 ...

Page 38: ...37 Important Suction Line Routing and P Trap Formation NOT ACCEPTABLE From Unit ...

Page 39: ...otective caps from the rear of the standby compressor and from the ORS fittings on the refrigeration module Install O rings onto the ORS fittings on the refrigeration module and attach the copper tubes onto the fittings and tighten securely Install O rings onto the suction and discharge copper tube fittings and attach the tubes to the rear of the compressor Secure the tubes to the compressor with ...

Page 40: ...39 Installation Refrigeration Tubes to Compressor ...

Page 41: ...le of REMOTE evaporator install O ring and attach 90 ORS fitting onto suction line fitting and tighten securely 5 Liquid Line HOST Frozen Compartment Fabricate 6 hose from liquid injection fitting on the condenser module to liquid fitting on HOST unit Install the supplied tee splice ORS fitting and a 90 ORS fitting Route hose through rear access hole of HOST evaporator install O ring and attach 90...

Page 42: ...41 Installation Refrigeration Hoses Manifold Fitting C Connect to vehicle compressor only Manifold Fitting A Connect to evaporator only ...

Page 43: ...page 42 Connections at compressor The refrigeration hoses must be routed from the cargo box along the vehicle s chassis to the engine compartment and compressor while maintaining the minimum bend radii See Minimum Bend Radii on page 35 The hoses a should be secured adequately to prevent rubbing or chafing against hot sharp or moving components 1 Install a 90 ORS fitting onto the 16 suction hose an...

Page 44: ...e s Compressor Only TOTAL AMOUNT OF OIL REQUIRED MODEL 50 SPECTRUM 32 ounces total Add 4 oz to the road compressor see pages 20 21 Add 23 oz into the suction hose see pages 40 41 NOTE 5 oz is already factory installed in system NOTE All oil quantities assume swash plate style road compressors only ...

Page 45: ...ve stem When the magnet is installed a click should be heard as the valve opens IMPORTANT Do not install a valve magnet on the Condenser Block Off Solenoid if present The condenser block off Solenoid is a normally open solenoid installing a valve magnet will close the solenoid 3 Remove the coil from the normally closed Defrost Solenoid located in the Evaporator section When the magnet is installed...

Page 46: ...45 System Leak Check and Evacuation ...

Page 47: ...2 pin connector to the mating connector on the Power Pack Module 3 Insert the two electrical barrel connectors 2R 01 and CH10 into the mating terminal connector block on the Power Pack and tighten securely 4 Connect the Condenser Fan Motor connectors CF1 01 CFI and CF2 CHK to the mating connectors in both the Power Pack Module and at the Condenser Module ...

Page 48: ...47 Installation Electrical Connections ...

Page 49: ...witch DSW1 CHH to door switch connector NOTE Make sure all harness are neatly routed and secured to prevent rubbing or chafing against sharp edges inside the evaporator assembly Remote Evaporator 8 Defrost Termination Switch 12A CHB2 to mating connector 9 Hot Gas Defrost Solenoid 28 CHS to mating connector 10 Liquid Solenoid 33 CHY to mating connector 11 Temperature Sensor G B to mating connector ...

Page 50: ...49 Electrical Connections Evaporator s ...

Page 51: ...ndby operation Verify the receptacle box is wired for the correct voltage for your application The standby receptacle box should be installed securely to the exterior of the vehicle It should be easily accessible while not interfering with the driver s visibility or operation of the vehicle Do not disassemble receptacle box ...

Page 52: ...51 Installation Standby Power Receptacle ...

Page 53: ...sufficient slope to ensure that the water drains away from the evaporator 3 Allow approximately 7 00 in 180 mm of defrost wire to extend from each defrost tube into the pan 4 Insert the defrost heater wires through each drain hose and along its entire length Do not use band wraps wire ties to hold the defrost heater wires Do not cover or wrap the defrost heater wires Do not cut the defrost heater ...

Page 54: ...53 Installation Drain Hoses REMOTE Evaporator HOST Evaporator Defrost Heater Wires ...

Page 55: ... the rear of the controller Install the controller to the bracket NOTE Install the in cab controller in a location that is accessible and visible from the driver s position and that does not hinder the driver s mobility visibility or access to the vehicle instruments and levers 2 Splice the ACC and BAT with the supplied 10 amp in line fuse using the crimp connector in the kit and attach the in lin...

Page 56: ...55 Installation HMI ...

Page 57: ...or on clutch Compressor Ground Wire 4 Install chassis ground wire from the engine driven compressor to chassis ground using supplied hardware Use anti corrosion gel 203 377 or equivalent on ground wire connection to compressor and vehicle chassis The location used on the vehicle chassis should be clean and free of paint to make a proper ground path IMPORTANT Failure to install the compressor groun...

Page 58: ...ressor IMPORTANT Failure to install the compressor ground wire to the chassis may result in intermittent clutch operation and premature clutch failure Compressor Ground Wire Ensure there is no paint between ground terminal and ground mounting point ...

Page 59: ...ubing onto one wire and position it away from the connection 7 Using the supplied butt splice connector securely crimp and solder the two wires together 8 Position the heat shrink tubing over the entire connection and then apply heat 9 Attach the ring terminal onto the positive battery lug and tighten securely 10 Route and secure the in line fuse to the vehicle or alongside the positive battery ca...

Page 60: ... Unit Power Wire See Important note below Positive Negative See Important note below IMPORTANT The ring terminals used must be sized to match the battery power stud or lug bolt Oversized ring terminals can contribute to high resistance resulting in the fuse overheating and failure ...

Page 61: ...igh side valve of the gauge manifold 7 Start the vehicle s engine run at approximately 1000 rpm and turn the unit ON 8 Set the unit thermostat at 0C 32F see operating manual 9 Run the unit until it reaches a temperature close to that indicated and a high circuit pressure of 19 bar 275 psig for R 404A Partially block off the air intake to the condenser if necessary 10 Open the low side valve of the...

Page 62: ...61 System Charging AMOUNT OF REFRIGERANT PER MODEL Model 50 5 00 lbs ...

Page 63: ...on service port on the copper tube directly before SPR valve shown in illustration to monitor suction pressure at the inlet to the suction pressure regulator 2 Connect the unit power receptacle to an appropriate electric power source 3 Place a jumper wire between the 12 and CHB wires at the defrost termination switch to ensure the unit will run in Defrost 4 Start the unit and run it in Defrost on ...

Page 64: ...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 running set the...

Page 65: ...g components sharp objects or items that can reach high temperatures Compressor was filled with the proper amount and type of oil All electrical connectors are properly locked in place Standby Power Receptacle mounted securely to vehicle All electrical harnesses and wiring is routed and secured adaquately Correct size and amperages fuse was installed in the main power harness to the battery Maxi F...

Page 66: ...er in sustainable transport temperature control solutions Thermo King has been providing transport temperature control solutions for a variety of applica tions including trailers truck bodies buses air shipboard containers and railway cars since 1938 For more information visit www thermoking com or www tranetechnologies com 2020 Trane Technologies TK 56455 18 IM Jan 2016 Installation Manual Truck ...

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