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21

Installing the ES100 Evaporator Unit

T = 20 min.

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Содержание B-100-10

Страница 1: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 9: ...9 Required Tools...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 33: ...33 Circuit Seal Test...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 57: ...57 Charging the Circuit...

Страница 58: ...58 Outline Drawings...

Страница 59: ...59 Outline Drawings...

Страница 60: ...60 Outline Drawings...

Страница 61: ...61...

Страница 62: ...62...

Страница 63: ...63...

Страница 64: ...64...

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