Installation Manual - ThermoKing · Installation Manual ... 16 Condensing Unit ... to fresh air and use CPR or mouth-to-mouth

Installation Manual

Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

©2002 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

Truck Edition SPECTRUMTM TS

Multi-Temperature Systems TK 51580-1-IM (Rev. 11, 05/15)

Installation Manual

Truck EditionSPECTRMulti-Te stems

TK 51580-1-IM (Rev. 1

t© 2002 Ther A.
Copyrigh
UM™ TSmperature Sy

1, 05/15)

mo King Corp., Minneapolis, MN, U.S.

2

al strip wire connections.

ent Adapter must be installed on every unit.

r with forged clevis and pins, forged connecting

d setup procedures.

Release HistoryOriginal (05/02)

Rev. 1 (06/02) Revised art and text on pgs. 36, 70, and 88.

Rev. 2 (03/03) Revised art on pg. 73

Rev. 3 (06/04) Added new art and text for 3 temp systems

Rev. 4 (08/04) Revised selection guide art and text

Rev. 5 (02/05) Changed art to show new skin, added printing history

Rev. 6 (03/05) Revised SPECTRUM dimensions, ORS fittings locations and termin

Rev. 7 (08/05) Added new door switch information.

Rev. 8 (03/06) Revised S-2 dimensions (art on pgs. 29, 31, 33, 35).

Rev. 9 (10/06) Added new fuel pump and bracket and note that the Hose Managem

Rev. 10 (02/13) Pages 11, 24, 25, 39 and 41 - Changed art to show revised lifting balinks and forged locking hooks used for lifting the unit.

Rev. 11 (05/15) Pages 94-98: Updated door switch installation information and adde

3

re Systems
Installation Manual for
SPECTRUM™ TS Multi-Temperatu

4

perature truck condensing units and SPECTRUM™

ons warranties express or implied, with respect to ould not be regarded as all-inclusive or covering ent should be consulted.

ined, repaired or altered as, in the manufacturer’s

erty damage or any other direct, indirect, any information, recommendations or

Introduction

This manual was written to assist with the installation of Thermo King SPECTRUM™ TS Multi-Temremote evaporators onto truck bodies specifically designed and built for these applications.Due to its complexity, you should not attempt this installation unless you:

• Are an experienced mechanic.

• Can safely lift 34 kilos (75 lbs.).

• Are certified or trained in the repair and maintenance of diesel powered refrigeration systems.

• Have a basic understanding of electricity and electrical wiring.

• Have the necessary tools and equipment to complete the installation.

This manual is published for informational purposes only. Thermo King makes no representatithe information recommendations and descriptions contained herein. Information provided shall contingencies. If further information is required, Thermo King Corporation Service Departm

Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintajudgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, propspecial, or consequential damages whatsoever, arising out of the use of this manual ordescriptions contained herein.

5

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SPECTRUM TS Multi-Temperature System Selection Guide . . . . . . . . . . . . 9

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Condensing Unit Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Evaporator Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Truck Body Opening Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Condensing Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Service Area Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Receptacle Box Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Battery Box Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

HMI (Human Machine Interface) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 22

Lifting Bar Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Lifting Bar Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

S-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

S-2 + S-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

S-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Important Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Uncrating the Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Installing the Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Installing the Hose Management Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Installing the Fuel Pickup Tube–Steel Tank . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installing the Fuel Pickup Tube–Plastic Tank . . . . . . . . . . . . . . . . . . . . . . . . 46

Installing the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Installing the Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Installing the Power Receptacle Box–International Models . . . . . . . . . . . . 52

Installing the Power Receptacle Box–North American Models . . . . . . . . . 54

Installing the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Installing the Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Installing Covers and Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Removing Holding Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Installation S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Condensing Unit Tube Connections S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . 70

Evaporator Tube Connections S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Wire Connections S-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Wire Connections S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Condensing Unit Tube Connections (2) S-2 + S-2 . . . . . . . . . . . . . . . . . . . . 78

Evaporator Tube Connections (2) S-2 + S-2 . . . . . . . . . . . . . . . . . . . . . . . . . 80

Wiring Connections S-2 + S-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Condensing Unit Tube Connections 3 Temperature Systems . . . . . . . . . . 84

Evaporator Tube Connections 3 Temperature Systems . . . . . . . . . . . . . . . 86

Wiring Connections 3 Temperature Systems . . . . . . . . . . . . . . . . . . . . . . . 88

Drain Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Drain Hose Resistance Wire Installation Guide . . . . . . . . . . . . . . . . . . . . . . 92

Installing the Door Switch (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Door Switch Setup Procedures (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Sensor Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

System Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

System Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Installing Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

6

ith a 35-69 kPa (5-10 psi) holding osphere.

moisture from entering the

a (5-10 psi) holding charge of

otor before completing the he condensing unit holding on lines, leak testing the system,

imit the potential harm to the osphere.

ss of refrigerant into the

Safety Precautions

CautionThermo King Multi-Temp SPECTRUM™ TS condensing units are shipped wcharge of nitrogen. This holding charge may be safely vented into the atm

IMPORTANT: Do not release the holding charge until necessary to preventsystem.

SPECTRUM™ S-2 and S-3 remote evaporators are shipped with a 35-69 kPnitrogen. This holding charge may be safely vented into the atmosphere.

SEVERE COMPRESSOR DAMAGE will result from operating the engine/msystem installation which includes: installing the components, releasing tcharge, releasing the remote unit holding charge, soldering the refrigeratievacuation and clean-up, and charging the system.

Recover RefrigerantAt Thermo King, we recognize the need to preserve the environment and lozone layer that can result from allowing refrigerant to escape into the atm

We strictly adhere to a policy that promotes the recovery and limits the loatmosphere.

7

ortant:

will

might

may

s wear goggles or safety glasses. Refrigerant n oil, and battery acid can permanently damage Aid under Refrigeration Oil).

your hands away from fans and belts when the is should also be considered when opening and ssor service valves.

sure gauge manifold hoses are in good t them come in contact with a belt, fan motor urface.

sure all mounting bolts are tight and are of heir particular application.

using ladders to install or service refrigeration serve the ladder manufacturer’s safety labels ork platform is the recommended method for

Safety Precautions

The symbol appears next to a point that is particularly imp

DANGER: Addresses a circumstance that, if encountered, lead to death or serious injury.

WARNING: Addresses a circumstance that, if encountered,lead to death or serious injury.

CAUTION: Addresses a circumstance that, if encountered,cause damage to equipment or minor injury.

DANGER: Never operate the unit with the discharge valve closed because it could cause the compressor to explode, causing death or serious injury.

DANGER: Never apply heat to a sealed refrigeration system or container because it could explode, causing death or serious injury.

DANGER: Fluorocarbon refrigerants, in the presence of an open flame or electrical short, produce toxic gases 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: Alwayliquid, refrigeratiothe eyes (see First

WARNING: Keep unit is running. Thclosing the compre

WARNING: Makecondition. Never lepulley, or any hot s

WARNING: Makecorrect length for t

WARNING: Whensystems, always oband warnings. A winstallations.

8

t of frost bite, the objectives of First Aid are from further injury, to warm the affected area spiration.

iquid, immediately flush eyes with large prompt medical attention.

rge amounts of lukewarm water. Do not apply ted clothing and shoes. Wrap burns with dry, protect from infection/injury. Get medical ated clothing before reuse.

ctim to fresh air and use CPR or on, if necessary. Stay with victim until arrival rsonnel.

diately flush with plenty of water for at leastCIAN. Wash skin with soap and water.

fluorocarbon refrigerants are classified as ain precautions must be observed when icing a unit in which they are used. When here in the liquid state, fluorocarbon rapidly, freezing anything they contact.

rigeration oil contact with the eyes. Avoid contact of refrigeration oil with skin or ghly after handling refrigeration oil to

Safety Precautions

Refrigerant

First Aid• FROSTBITE: In the even

to protect the frozen arearapidly and to maintain re

• EYES: For contact with lamounts of water and get

• SKIN: Flush area with laheat. Remove contaminasterile, bulky dressing to attention. Wash contamin

• INHALATION: Move vimouth-to-mouth ventilatiof emergency medical pe

Refrigeration Oil

First AidIn case of eye contact, imme15 minutes. CALL A PHYSI

WARNING: Never drill holes in the unit unless absolutely necessary. Holes drilled into the unit may weaken structural components. Holes drilled into electrical wiring can cause fire or explosion.

WARNING: Exposed coil fins are very sharp and can cause painful lacerations.

WARNING: Regulators used on bottles of nitrogen gas must be equipped with relief valves. The pressure in a bottle of nitrogen gas is extremely high. It is high enough to cause components of the refrigeration system to explode if the regulator malfunctions or is set wrong. The relief valve provides a safe outlet in case the regulated pressure exceeds the relief valve limit.

CAUTION: Remove the nitrogen holding charge from the condensing unit and remote evaporators prior to making any refrigeration tubing connections to prevent personal injury!

WARNING: Althoughsafe refrigerants, certhandling them or servreleased to the atmosprefrigerants evaporate

WARNING: Avoid refprolonged or repeatedclothing. Wash thorouprevent irritation.

9

m Selection Guideare kits 819951

are kits 819951

tor kits.

f the truck.

be supplied.

uire different refrigerant and drain tube

ounted in the back of the zone.

tionsEvap arness

Zone 3Install Kit

Door Switch2 Temp

Door Switch 3 Temp

DAS NAD

DAS EEC

DAS EEC

Zone 3

STD 088089 700533 700534 088781 088782 088082

STD --- 1 --- 1 1 ---

STD --- 1 --- 1 1 ---

STD --- 1 --- 1 1 ---

STD --- 1 --- 1 1 ---

STD --- 1 --- 1 1 ---

STD 1 --- 1 1 1 1

STD 1 --- 1 1 1 1

STD 1 --- 1 1 1 1

SPECTRUM TS Multi-Temperature SysteTruck S-2 evaporators 919975 included mounting hardw

Truck S-3 evaporators 919976 included mounting hardw

NOTES:

1. STD = Parts are being supplied with either the condensing unit or evapora

2. Drain kit 880041 is needed to drain on one side toward the front or back o

3. Tubes kit 720201 will be supplied per customer request only - No kit will

4. Quantities specified are for entire truck.

5. Evaporators can be placed at the back of each zone, however this may reqrouting.

* = Configurations that will need at least 1 Tube Kit if the evaporators are m

Installation Configura

Fig. Zone 1 Zone 2 Zone 3

EvapHardware

Kit

TubesKit

OPTION

DrainKit

OPTION

Electric Hardware

Kit

Jumper Kit

OPTION

H

919975

919976

919975

919976

919975 STD 720201 880041 STD 880040

A S-3 S-3 --- STD 1 2 STD ---

B S-2 S-3 --- STD 1 2 STD ---

C S-2 + S-2 S-2 --- STD 1 2 STD 1

D* S-3 S-2 --- STD --- 2 STD ---

E* S-3 S-3-* --- STD --- 4 STD ---

F* S-2 S-2 S-2 STD --- 2 STD ---

G S-2 S-2 S-2 STD 1 4 STD ---

H S-2 S-2 S-2 STD 1 4 STD ---

10

on

on

ale

Detector

s

ixture with forged clevis and pins, forged connecting locking hooks.

Recommended)

Required Tools

1. Safety Glasses

2. Drill

3. Drill Bits

4. Tape Measure

5. Wire Crimpers

6. Tube Benders

7. Hole Saw

8. 15% Solder & Flux (copper to copper)

9. 35% Solder & Flux (copper to brass)

10. Swage

11. Tubing Cutter

12. Refrigerant Oil

13. Torch Set

14. Mechanics Tools

15. Manifold Set

16. Evacuation Stati

17. Reclaiming Stati

18. Refrigerant & Sc

19. Dry Nitrogen

20. Tap and Die Set

21. Battery Charger

22. Electronic Leak

23. Tubing Brushes

24. Scotch Brite Pad

25. 3 Point Lifting Flinks and forged

26. Work Platform (

27. Torque Wrench

28. Mechanical Lift

11

Required Tools

12

mponents

p Tube

s

ws

g

ps

achine Interface)

7736)

nt Adapter

wn Clamps

Condensing Unit Installation Co

1. T-Bolts(International Models Only)

2. Unit Washer1.250 x 0.188 THK

3. Locking Nuts

4. Clamps

5. Self Tapping Screws

6. Exhaust Tube

7. Terminal Rings

8. Cable Ties

9. Fuel Pump Bracket

10. Screws

11. Washers

12. Locking Nuts

13. Fuel Pump Picku

14. Fuel Line Fitting

15. Fuel Pump Elbo

16. Blind Nut

17. Fuel Pump

18. Battery Cable Lu

19. Hold Down Clam

20. HMI (Human M

21. DIN Mount (ISO

22. Fuse Holder

23. Hose Manageme

24. Adapter Hold Do

13

ponents
Condensing Unit Installation Com

14

onents

r

sses

Evaporator Installation Comp

1. Clamps

2. Screws

3. Pre-Bent Tubes

4. Copper Tees

5. Copper Couplings

6. Tube Insulation

7. Refrigerant Tubing (U. S. Only)

8. Drain Hose

9. Copper Elbows

10. Drain Hose Tee

11. Mounting Space

12. Terminal Fork

13. Terminal Ring

14. Cable Ties

15. Jumper Strip

16. Check Valve

17. Electrical Harne

18. Reducing Tee

15

onents
Evaporator Installation Comp

16

sions

l connections are to be made from the condensing unit ss area.

unting location must allow for adequate tilt ondensing Unit Dimensions).

urface of 64 mm (2.50 in.) wide is required around he surface must be flat within 6.4 mm (0.25 in.) for

aling and free of all rivets or bolt heads.

Truck Body Opening Dimen

SPECTRUM TS 30 = 387 kg (853 lbs.)

SPECTRUM TS 50 = 446 kg (984 lbs.)

1. All unit electricathrough this acce

NOTE: Unit moclearance (see C

2. Gasket sealing sboth openings. Tproper gasket se

CAUTION: The truck wall must be structurally strong enough to support the weight of the refrigeration unit.

17

ions
Truck Body Opening Dimens

18

ions
Condensing Unit Dimens

19

s
Service Area Dimension

20

s
Receptacle Box Dimension

21

Battery Box Dimensions

22

Dimensions
HMI (Human Machine Interface)

23

Lifting Bar Details

WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided.

WARNING: All hardware used to assemble the lifting bar must be DIN 931 class 10.9 (SAE Grade 8). The use of hardware other than specified may cause personal injury, severe damage to the equipment and void the warranty.

WARNING: Use forged clevis and pins, forged chain links and forged locking hooks with strength equal to total lift capacity of hoist mechanism and that meet all safety standards.

24

A

B

C

D

3 2 1

3 2 1

SIZE

DWG NO REV

TITLEDRAWN DATE

THIRD ANGLE PROJECTION

D

REVISIONSCHANGE ORDER REV DESCRIPTION DATE APPROVED

CODE IDENT NO

CHECKED

APPROVED

ENG APPVLFINISH

CAD GENERATED DRAWING,DO NOT MANUALLY UPDATE

UNLESS OTHERWISE SPECIFIED TOLERANCES ON DIMENSIONS PER TKS09109

DIAGRAM-LIFTING BAR ASS'YFOR SELF-POWERED

LARGE TRUCK

- --

6/15/90RL

6/15/90TB

1/20/88JO

2 35

SCALE 0.250 SHEET 1 OF 2

J9127C30

HIS H ARE S AND MAY G

AWING THE NLY BY NOT, N AWING IFIED ACTS, G. ALL

-RAND H THEY R

UNLESS OTHERWISE SPECIFIEDDIMENSIONS ARE IN INCHES.INTERPRET DIM AND TOL PERASME Y14.5M - 1994

M GILMAN18-Jun-08 MOVED LIFTING HOLES ALONG REAR BAR, ADDED BRIDGING BAR FOR SPECTRUM TSLIFTING POINT. ADDED WELD SYMBOLS,RE-LABLED ALL LIFTING POINTS

F529536

M GILMAN25-Mar-09 ADDED LIFTING HOLES FOR NEW UNITS,ADDED BRIDGING BAR FOR MULTI-TEMPS.G532334

E KIRBY20-Jan-10 DIM 17.22 WAS 16.42. DIM 11.12 WAS10.42. ADDED TSERIES SPECTRUM VIEWH539147

M GILMAN14-Jun-10 CHG DRAWING AND VIEWS, MOVED HOLES 1-6, ADDED TABLE FOR ALL TRUCK UNITS.I543699

J.DAVIES27-NOV-12REMOVED CHAINS, BOLTS FROM VIEW SHT 1,DEL NOTE 2.J665985

Thermo King

Lifting Bar Details

A

B

C

D

8 7 6 5 4

8 7 6 5 4

NOTES:2. USE TWO CHAIN LINKS WITH A CHAIN LINK MASTER AS SHOWN.3. USE THREE FORGED CLEVIS AND PINS TO ATTACH LIFTING CHAINS.4. EACH ASSEMBLY MUST HAVE STRENGTH EQUAL TO MINIMUM OF 1.5 TIMES THE WEIGHT OF THE HOIST AND MEET ALL SAFETY STANDARDS.

1 4

ENTIRE UNITCLEVIS LIFTINGHOLES (1-5)

INGERSOLL-RAND IS THE SOLE OWNER OF TDRAWING AND ALL INFORMATION IN IT, WHICPROTECTED BY COPYRIGHT AND OTHER LAWBE SUBJECT TO LAWS REGARDING EXPORTININFORMATION OUTSIDE OF THE U.S. THIS DRMAY BE USED ONLY BY ITS RECIPIENTS FOR PURPOSE FOR WHICH IT IS PROVIDED AND OTHE RECIPIENT, WHO AGREES THAT IT WILL WITHOUT INGERSOLL-RAND'S PRIOR WRITTEPERMISSION: 1) DISCLOSE NOR USE THIS DROR THE INFORMATION IN IT EXCEPT AS SPECABOVE; OR 2) MAKE ANY COPIES OF OR EXTRREVISIONS, OR UPDATES FROM THE DRAWINCOPIES MUST BE RETURNED TO INGERSOLLUPON COMPLETION OF THE WORK FOR WHICHAVE BEEN PROVIDED OR UPON ANY EARLIEREQUEST.

UNIT TYPE

FRONT CHAIN LIFT

HOLE LOCATION

ENTIRE UNITCLEVIS LIFTINGHOLE LOCATION

TS 200/300/500/600 - 30 LEFT HOLE 1

TS 200/300/500/600 - 50 LEFT HOLE 2

SPECTRUM TS LEFT HOLE 4

MD II, MD 200, MD 300 - 30 RIGHT HOLE 1

MD II, MD 200, MD 300 - 50 RIGHT HOLE 2

KD II - 30 RIGHT HOLE 1

KD II - 50 RIGHT HOLE 2

RD II - 30 RIGHT HOLE 1

RD II - 50 RIGHT HOLE 2

T SERIES - 30/50 LEFT HOLE 3

T SERIES SPECTRUM LEFT HOLE 5

RELEASED 14/Jan/2013

25

A

B

C

D

2 1

2 1

SIZE

DWG NO REV

DCODE IDENT NO

4.0

(30.3)

.50 THICK

3.5

4X .534

2X .8

2X 3.4

31.7

9127C30 JSHEET 2 OF 2SCALE 0.250

SCALE 0.150WELDING DETAIL

FRONT MEMBER

CENTER MEMBER

REAR MEMBER

SCALE 0.250CENTER MEMBER

2X

2X

I

I

(1.4)

Lifting Bar Dimensions

A

B

C

D

8 7 6 5 4 3

8 7 6 5 4 3

7.9

54.2

3.53.5

27.1

.50 THICK

3.51.75

2X .75

25.1

50.20

26.60

3X .875

1.75

23.50

28.70

.534

4.01.75

.5344.0

2.4

1.752X .75

7.5

1.75

1.0

8.85

11.45

5.0

4X .534

1.75

1.0

8.85

11.45

5.0

4X .534

R1.25

2X .75

1.75

21.1

21.1

2X 58°

(2X )122°

2X 58°

23.6

11.2

17.2

2X 58°

2.12.1

SCALE 0.250REAR MEMBER

SCALE 0.250FRONT MEMBER

I

II

I

(1.6)

26

in.) is approximate spacing between evaporator and or 2590.8 mm (102.00 in.) wide truck with 376.2 mm A narrow 2438 mm (96.00 in.) wide truck will allow .00 in.) spacing depending upon wall thickness. 101.6 mm (2.00 - 4.00 in.) space between the back of o the truck wall.

ve is only relevant to an application where an S-2 is an S-2 + S-2 is used in the adjacent lane.

S-2 Dimensions

All mounting locations must be correct to properly install evaporators.

IMPORTANT: Mount all evaporators as close to one side wall as possible to minimize drain tube length and reduce exposure to damage.

The minimum distance 600 mm (24.00 in.) from the bulkhead to the front of the evaporator must be maintained for proper operation.

A, B, C, D, E, and F indicate locations of ORS fittings measured from trailer ceiling and from edge of Spectrum evaporator.

NOTE: A). 50 mm (2.00truck side wall f(3.00 in.) walls.only 25.4 mm (1B). Allow 50.8 -the evaporator t

The information aboused in one lane and

27

Reference: 1E02132 Sheet 1

S-2 Dimensions

WEIGHT = 43 kg (95 lb.)

28

2.00 in.) is approximate spacing between evaporator all for 2590.8 mm (102.00 in.) wide truck with 376.2

alls. A narrow 2438 mm (96.00 in.) wide truck will mm (1.00 in.) spacing depending upon wall

101.6 mm (2.00 - 4.00 in.) space between the back of o the truck wall.

ve is only relevant to an application where an S-2 is an S-2 + S-2 is used in the adjacent lane.

S-2 + S-2 Dimensions



The minimum distance 609.6 mm (24.00 in.) from the bulkhead to the front of the evaporator must be maintained for proper operation.


NOTE: A). 50 mm (and truck side wmm (3.00 in.) wallow only 25.4 thickness.B). Allow 50.8 -the evaporator t


29

s


S-2 + S-2 Dimension

30

2.00 in.) is approximate spacing between evaporator all for 2590.8 mm (102.00 in.) wide truck with 376.2

alls. A narrow 2438 mm (96.00 in.) wide truck will mm (1.00 in.) spacing depending upon wall

101.6 mm (2.00 - 4.00 in.) space between the back of o the truck wall.

ve is only relevant to an application where an S-3 is another S-3 is used in the adjacent lane.

S-3 Dimensions



The minimum distance 600 mm (24.00 in.) from the bulkhead to the front of the evaporator must be maintained for proper operation.


NOTE: A). 50 mm (and truck side wmm (3.00 in.) wallow only 25.4 thickness.B). Allow 50.8 -the evaporator t


31


S-3 Dimensions

WEIGHT = 52 kg (115 lb.)

32

tes

ing and Electrical Wiringt to minimize the amount of time the tubes are

d open to ambient conditions. Always keep tubes ready to connect and solder.and copper fittings for obstructions prior to assembly.ired that nitrogen or another inert gas be used to purge

ile soldering. This prevents oxidation and formation of ubes.er solder for joining all remote refrigerant tubes.

ion and hot gas lines.ion tubes should be secured by clamps every 600 mm

harness should be secured by clamps or tie bands m (24.00 in.).ugh (W = Wall and C = Ceiling) is required E).orator installations require two suction tubes.

s automatically turn off remote evaporators when the g door is opened. This avoids the entry of warm, moist ad space. Door switches are recommended for all stallations.

ecommended to use good quality insulated curtains on imit the amount of warm, moist air from entering the ring door openings.

Important Installation No

Safety Precautions• See “Safety Precautions” on pages 6 - 8 prior to installing and

servicing this product.

Evaporator Location• The best airflow is achieved when the evaporator is installed an

equal distance from each side wall.• It is recommended that moving bulkheads not be allowed closer

than 1219 mm (48.00 in.) or 1 pallet from the evaporator outlet (Detail A).

• The minimum clearance from the bottom of the evaporator to the top of the cargo should be 101 mm (4.00 in.) (Detail A).NOTE: This minimum clearance is required under the fan intake area only and does not refer to the LOAD LINE.

• The evaporator should be located a minimum of 51 mm (2.00 in.) from the truck wall (Detail B).

Defrost Drains• The evaporator must be properly mounted to provide a slope

towards the drain. This is accomplished by adding one 3/8 in. and one 3/16 in. washers on the drain side and only one 3/8 in. washer on the other side at each mounting surface.

• Defrost drains must exit the evaporator at a 45° angle. Drains should be 267 mm (10.50 in.) from the evaporator to the truck ceiling (Detail C).

Wall Drain Tube• CPVC• 1.00 in. ID (Internal Diameter)

Refrigerant Tub• It is importan

uncapped ancapped until

• Check tubes • It is also requ

the tubes whscale inside t

• Use 35% silv• Insulate suct• All refrigerat

(24.00 in.).• All electrical

every 600 m• Only one tro

(Detail D & • All dual evap

Door Switches• Door switche

correspondinair into the lomulti-temp in

Door Curtains• It is always r

all doors to lload space du

33

es
Important Installation Not

34

tes

the correct position the O-ring will seal and the teeth ping it in place. Check the fit by pulling on the tube(s)

not pull out of the fitting (Detail III).

be from the fitting: press the collet into the fitting. lace and pull the tube out. The fitting can be re-used. the tube before re-inserting it into the fitting


Defrost Drain Tube ConnectorsIMPORTANT: Follow the instructions below to prevent defrost drain tube water leaks.

All Spectrum remote evaporators are equipped with a quick disconnect fitting that connects the drain pan to the drain tubes (Detail I).

To properly install the tube make sure that the tube is fully inserted past the O-ring and up to the stop inside the coupler (Detail II).

NOTE: The fitting will grip the tube before it seals with the o-ring.

When the tube is in will grip the tube keeto insure that it will

To disconnect the tuHold the collect in pClean any burrs off (Detail IV).

35

es

36

tes

37

es

38

Unit

cover and top screen (if equipped)

eyebolts into the lifting holes at the rear frame rails, tighten securely.

t lifting bar securely to the eyebolts and balance point the unit.

of the crate by removing the eight skid bracket screws

rear members of the crate and lift unit up from base 04.8 mm (12.0 in.) (Detail C).

bottom access panels from the unit.

mounting bolts securing the two upright members to ).

install.

Uncrating the Condensing

1. Remove the top

2. Install two liftinginstall nuts, and

3. Attach the 3 poinand slightly raise

4. Remove the base(Detail C).

5. Remove the twoapproximately 3

6. Remove the two

7. Remove the fourthe unit (Detail C

Unit is now ready to

WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided


WARNING: Eyebolts must be forged steel and minimum M12 (1/2 in.) diameter.

WARNING: Use only locking lifting hooks to attach to the lifting eyebolts (Detail A).

The point shown in Detail B, below, is not a major lifting point. Itis used only to level the unit during installation (Detail B).

39

Unit
Uncrating the Condensing

40

Unit

(0.188 in.) mounting washers provided must be used e of the unit and the locking nut holding the unit to the truck.

hardware to 81.4 N•m (60 ft-lb.)

r completing the installation of the unit, be sure to around the opening where the Suction, Liquid and hrough the truck box wall and into the cargo area. prevent water, heat, or debris from entering into the

ow the unit to function properly.

Installing the Condensing

1. Use a 3 point lifting bar to carefully lift the unit up to the truck opening.

2. Install four M12 (1/2-13 in. Grade 5) mounting bolts through the wall of the truck box.

NOTE: The mounting bolts should protrude 63.5 mm (2.50 in.) full thread from the front wall (Detail B).

IMPORTANT: Do not install any compressible washers or other materials between the unit and the truck!

3. The four 4.8 mmbetween the framfront wall of the

4. Torque mounting

IMPORTANT: Afteadd insulating foamHot Gas tubes run tThis must be done totruck box and to all

WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided (See Lifting Bar Dimensions).


WARNING: Use only locking lifting hooks to attach to the lifting eyebolts (Detail A).

WARNING: The use of a safe working platform for truck unit installations is recommended.

41

nit
Installing the Condensing U

42

t Adapter
Installing the Hose Managemen
IMPORTANT: The Hose Management Adapter must be installed to help prevent moisture from entering the control box.

1. The hose management adapter provides a exit point under the unit for the fuel lines, battery cables and drain hoses while also helping prevent moisture from entering the control box.

• Locate the small square holes (two each side) in the rear frame channel under the unit.

• Slide the hose management adapter onto the rear frame channel.

• The two end tabs should grip the frame channel while the two center tabs lock into the matching square holes of the frame.

2. Secure the hose management adapter to the truck cargo box with the two hold down clamps and screws.

NOTE: If Hose Management Kit (719180 or 719184) is used, follow installation instructions supplied with kit.

43

Adapter
Installing the Hose Management

44

el Tank

p tube so approximately 25 mm (1.00 in.) is fuel tank.

all the parts to the top of the pickup tube

n and slide the assembly into the hole at a slight is inside the hole.

nd slide it through the hole and position it onto nut onto the bushing, position as needed to ctions and tighten to 54 Nm. (40 ft-lb.).

Installing the Fuel Pickup Tube–Ste

1. Tape the paper template (supplied with pickup tube) to the desired location on the diesel fuel tank and center punch the three holes.

NOTE: Use a magnet, grease or special hole saws/drills that will minimize steel chips from entering the fuel tank. Thoroughly clean and flush the tank to remove any chips.

2. Drill:

• 9.5 mm (0.375 in.) diameter holes first.

• 31.8 mm (1.250 in.) diameter hole next.

• Remove the template from the tank and remove any burrs from the hole.

3. Cut the end of the pickuabove the bottom of the

4. Loosen the nut and slideassembly.

5. Hold the parts in positioangle until the bushing

6. Tip the backup washer athe bushing. Thread thefacilitate fuel line conne

DANGER: Diesel fuel vapors are potentially explosive. Use extreme caution when drilling in or around the diesel fuel tank. Sparks from an electric drill or drill bit could cause an explosion. Do not smoke while working near the diesel fuel tank. Drain all diesel fuel from the tank and use nitrogen or an inert gas to purge the diesel fuel vapors from the tank prior to drilling. Keep the diesel tank filled with inert gas while drilling.

45

teel Tank
Installing the Fuel Pickup Tube–S

46

lastic Tank

e pickup tube so approximately 25 mm (1.00 in.) is of the fuel tank.

nd slide all the parts to the top of the pickup tube

position and slide the assembly into the hole at a slight shing is inside the hole.

asher and slide it through the hole and position it onto ead the nut onto the bushing, position as needed to e connections and tighten to 54 Nm. (40 ft-lb.).

Installing the Fuel Pickup Tube–P

1. Tape the paper template (supplied with pickup tube) to the desired location on the diesel fuel tank and center punch the three holes.

NOTE: Use grease or special hole saws/drills that will minimize plastic chips from entering the fuel tank Thoroughly clean and flush the tank to remove any chips.

2. Drill:

• 9.5 mm (0.375 in.) diameter holes first.

• 31.8 mm (1.250 in.) diameter hole next.

• Remove the template from the tank and remove any burrs from the hole.

3. Cut the end of thabove the bottom

4. Loosen the nut aassembly.

5. Hold the parts inangle until the bu

6. Tip the backup wthe bushing. Thrfacilitate fuel lin

DANGER: Diesel fuel vapors are potentially explosive. Use extreme caution when drilling in or around the diesel fuel tank. Sparks from an electric drill or drill bit could cause an explosion. Do not smoke while working near the diesel fuel tank. Drain all diesel fuel from the tank and use nitrogen or an inert gas to purge the diesel fuel vapors from the tank prior to drilling. Keep the diesel tank filled with inert gas while drilling.

47

lastic Tank
Installing the Fuel Pickup Tube–P

48

k
Installing the Fuel Tan
DANGER: An improperly installed fuel tank could lead to serious injury or death! Consult your chassis manufacturer for specific details on proper fuel tank installation and recommendations.

49

Installing the Fuel Tank

50

p
Installing the Fuel Pum
1. The fuel pump must be installed as close to the fuel tank as possible and not more than 762 mm (30.0 in.) above the fuel in the fuel tank.

2. Fuel lines should be routed in a protective housing with no kinks or sharp bends.

NOTE: Do not connect unit fuel lines into truck/trailer fuel lines.

3. Rubber grommets must be used when routing fuel lines through metal.

4. Secure all fuel lines with provided clamps.

5. Route fuel line from fuel pump INLET fitting to fuel tank pickup SUPPLY fitting.

6. Route fuel line from fuel pump OUTLET fitting to diesel engine SUPPLY fitting.

7. Route fuel RETURN line from diesel engine to fuel tank pickup RETURN fitting.

DANGER: Leaking fuel lines could cause a fire resulting in death or serious injury! All fuel line fittings must be tight and leak free!

DANGER: Do not route fuel lines with battery cables or electrical wires, as this could cause a fire!

S=Supply R=Return

51

Installing the Fuel Pump

52

ternational Models
Installing the Power Receptacle Box–In
Choose an appropriate location for the Power Receptacle Box.

Front Mount1. Remove cover.

2. Measure and drill four appropriate size holes into truck body.

3. Insert rubber blind nuts into hole in truck body.

4. Install base and fasten with appropriate hardware. Reinstall cover.

5. Route and secure harness with supplied clamps.

DANGER: To prevent serious injury or death, the electric standby power cord must not be connected to the unit during installation!

53

rnational Models
Installing the Power Receptacle Box–Inte

54

th American Models

Detail B)

e plugs from base. Measure and drill two appropriate uck body.

d nuts into hole in truck body.

asten with appropriate hardware. Install hole plugs nting holes and reinstall cover.

harness with supplied clamps.

Installing the Power Receptacle Box–Nor

Choose an appropriate location for the Power Receptacle Box.

Front Mount (Detail A)1. Remove cover.

2. Measure and drill two appropriate size holes into truck body.

3. Insert rubber blind nuts into hole in truck body.

4. Install base and fasten with appropriate hardware. Reinstall cover.

5. Route and secure harness with supplied clamps.

Side Mount (6. Remove cover.

7. Remove two holsize holes into tr

8. Insert rubber blin

9. Install base and finto unused mou

10. Route and secure

DANGER: To prevent serious injury or death, the electric standby power cord must not be connected to the unit during installation!

55

American Models
Installing the Power Receptacle Box–North

56

DIN Mountingte location for the HMI inside the truck cab.

7736) mounting sleeve into driver panel DIN opening.

ure in position.

and install HMI into DIN sleeve.

Installing the HMI

NOTE: Route and secure harness to prevent rubbing, chafing or making contact with sharp, moving or hot components. Allow excess harness for tilt cab applications. Rubber grommets must be used when routing harness through sheet metal holes.

Driver Panel Choose an appropria

1. Install DIN (ISO

2. Bend tabs to sec

3. Connect harness

57

Installing the HMI

58

ox

place with hold down bracket and rod.

ts must be used where cables exit box.

will be installed at a later step.

Installing the Battery B

1. Secure battery in

2. Rubber gromme

3. Protective cover

CAUTION: Battery boxes must be installed securely with proper hardware to prevent them from falling off.

CAUTION: Battery cables must be properly routed and secure to prevent rubbing, chafing or making contact with sharp, moving or hot components.

59

x
Installing the Battery Bo

60

lee the large black cable marked POS+. Route this cable t to the proper length and add battery cable lug from onnect to POSITIVE terminal of battery (Detail B).

Power Wiree the large 8 AWG (#2) wire. Route this wire to the e proper length and add fuse holder assembly. Use

per to securely crimp 8 AWG (#2) wire and fuse nd heat shrink the connection. Apply a liberal amount he 60 amp fuse and fuse holder and then install fuse. holder terminal to the POSITIVE terminal of battery

arness the Fuel Pump harness to the fuel pump and connect ector at the pump.

lee the large black battery cable marked NEG -. Route battery, cut to the proper length and add battery lug kit. Connect to the NEGATIVE terminal of battery

all harnesses and battery cables with provided

Battery Connections

Although the unit comes pre-wired from the factory, wire connections at the battery are required (Detail A). Unroll the harness bundle from the unit.

Positive Cab1. At the unit, locat

to the battery, cuinstallation kit. C

Unit Control 2. At the unit, locat

battery, cut to thbattery cable crimholder together aof Superlube to tConnect the fuse(Detail B).

Fuel Pump H3. Locate and route

to matching conn

Negative Cab4. At the unit, locat

this cable to the from installation(Detail C).

5. Route and secureclamps.

CAUTION: All battery connections and electrical wires must be properly routed and secured to prevent rubbing, chafing or making contact with sharp, moving or hot components. Do not route battery cables together with fuel lines.

CAUTION: All electrical connections must be clean and tightly secured.

CAUTION: Set all electrical controls to the OFF position to prevent the unit from starting.

61

Battery Connections

62

eens
Installing Covers and Scr
Condensing Unit1. Reinstall top cover and top screen (if equipped).

2. Confirm Hose Management Adapter is installed.

3. Reinstall bottom panels.

4. Install exhaust pipe.

5. Install battery cover.

CAUTION: All covers, guards and screens must be securely in place to prevent personal injury or damage to equipment.

63

ens
Installing Covers and Scre

64

BLANK PAGE

65

r before completing the condensing unit holding eration lines, leak testing the

STOP!

Caution

SEVERE COMPRESSOR DAMAGE will result from operating the engine/motosystem installation which includes: installing the components, releasing the charge, releasing the remote evaporator holding charge, soldering the refrigsystem, evacuation and clean-up, and charging the system.

66

ge

ondensing Unitolding charge, slowly remove ORS caps from hot gas, es.

vaporatorolding charge, slowly remove ORS caps from hot gas, es.

S = Suction L = Liquid

Removing Holding Char

SPECTRUM CTo release nitrogen hliquid and suction lin

SPECTRUM ETo release nitrogen hliquid and suction lin

CAUTION: Thermo King Multi-Temp SPECTRUM TS condensing units are shipped with a 35 kPa (5 psi) holding charge of nitrogen. This holding charge may be vented into the atmosphere.

CAUTION: Thermo King SPECTRUM evaporators are shipped with a 35 kPa (5 psi) holding charge of nitrogen. This holding charge may be vented into the atmosphere.

CAUTION: Holding charges must be removed before opening system to avoid serious injury.

HG = Hot Gas

67

e
Removing Holding Charg

68

stallationtor cover to access mounting holes.

allation kit provides both metric and imperial nuts sure to use the correct ones for your application.

Installationsnum spacers onto the ceiling mounting studs and raise to position. Secure the evaporator onto the mounting ashers and locking nuts. (Detail B). •m (60 ft-lb).

Installationsting bolts, lock washers and flat washers onto the aise into position. Install the aluminium spacers and rator to the ceiling. (Detail C).•m (60 ft-lb).

lled evaporator will slope slightly toward the drain r water drainage (Detail D).

ers are included in the kit to help assist sloping the the drain.

Installation S-2 or S-3

Ceiling PreparationIMPORTANT: The ceiling must be flat and the mounting locations correct for proper SPECTRUM evaporator installation. The foam insulation in the ceiling must be removed from the evaporator mounting area and aluminium spacers must be installed between the evaporator mounting plate and trailer ceiling.

• For ceiling mounting stud applications, weld a nut (same thread as stud) onto a 44.45 mm (1.75 in.) hole saw and turn the nut onto the mounting stud using a socket wrench (Detail A).

• For ceiling mounting bolt applications, weld a bolt (same thread as tapped hole) onto a 44.45 mm (1.75 in.) hole saw and turn into the tapped mounting hole using a socket wrench (Detail A).

• Alternative method is to remove the mounting studs or bolts and use a hole saw with a standard pilot drill small enough to run up into the threaded hole without damaging the threads. Reinstall mounting studs or bolts.

Mounting Stud or Bolt RequirementsThe mounting studs or bolts used to attach the evaporator(s) to the ceiling must be 10.0 mm, (0.50 in., Grade 5, U.S. applications only), Medium Carbon Steel, 120000 PSI Tensile Strength, Zinc Plate and Dichromate finish. Studs to extend below ceiling 38.0 mm (1.50 in.) to 50.1 mm (2.00 in.)

Evaporator In1. Remove evapora

NOTE: The instand washers. Be

Mounting Stud2. Install the alumi

the evaporator instuds with flat wTorque to 81.3 N

Mounting Bolt 3. Install the moun

evaporator and rsecure the evapoTorque to 81.3 N

4. A properly instatubes to allow fo

Two additional washevaporator towards

69

Installation S-2 or S-3

70

ns S-2 or S-3

stall pre-bent 90° 1-1/8 in. tube onto suction fitting of (Detail B).

7/8 in. x 7/8 in. tee onto suction tube (Detail B).

/8 in. elbow onto suction tube tee (Detail B).

ves onto suction tubes as close as possible to (Detail B).

internal components of valves before soldering and older.

tubes and install onto check valves (Detail B).

stall pre-bent 90° 3/8 in. tube onto liquid fitting of (Detail B).

/8 in. x 3/8 in. tee onto liquid tube (Detail B).

/8 in. elbow onto liquid tube tee (Detail B).

tubes and install onto liquid tubes (Detail B).

stall pre-bent 90° 1/2 in. tube onto hot gas fitting of (Detail B).

/2 in. x 1/2 in. tee onto hot gas tube (Detail B).

/2 in. elbow onto hot gas tee (Detail B).

tubes and install onto hot gas tubes (Detail B).

suction and hot gas tubes only (Detail B).

with provided clamps (Detail C).

Condensing Unit Tube Connectio

NOTE: Thermo King requires the use of bulk rolled refrigeration tubing and tube benders to reduce fittings and solder joints where applicable (Detail A). It is also required that the use of nitrogen or another inert gas be used to purge the tubes before soldering. This prevents oxidation and formation of scale inside tubes.

NOTE: Discard O-rings that come with the condensing unit. Oil and install new O-rings supplied in kit.

1. Oil O-ring and incondensing unit

2. Install 1-1/8 in. x

3. Install 7/8 in. x 7

4. Install check valcondensing unit

NOTE: Removeuse 35% silver s

5. Fabricate 7/8 in.









14. Add insulation to

15. Secure all tubing

CAUTION: Remove holding charge from condensing unit before proceeding to avoid personal injury.

HG = Hot Gas S = Suction L = Liquid

Item DescriptionPart

Number

#2 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

#3 7/8 in. x 7/8 in. Elbow 553326

#7 3/8 in. x 3/8 in. x 3/8 in. Tee 553251

#8 3/8 in. x 3/8 in. Elbow 552876

#11 1/2 in. x 1/2 in. x 1/2 in. Tee 552296

#12 1/2 in. x 1/2 in. Elbow 558812

71

S-2 or S-3
Condensing Unit Tube Connections

72

S-2 or S-3

. suction tube from the condensing unit and route in l 7/8 in. x 7/8 in. elbow, attach 7/8 in. preformed tube, nd connect to the evaporator 7/8 in. ORS fitting.

. hot gas tube from the condensing unit and route in l 1/2 in. x 1/2 in. elbow, attach 1/2 in. preformed tube, nnect to the evaporator 1/2 in. ORS fitting.

. liquid tube from the condensing unit and route in l 3/8 in. x 3/8 in. elbow, attach 3/8 in. preformed tube, nd connect to the evaporator 3/8 in. ORS fitting.

be added to all segments of suction and hot gas tubes.

with provided clamps.


Evaporator Tube Connections

NOTE: Thermo King requires the use of bulk rolled refrigeration tubing and tube benders to reduce fittings and solder joints where applicable. It is also required that the use of nitrogen or another inert gas be used to purge the tubes before soldering. This prevents oxidation and formation of scale inside tubes.

IMPORTANT: Discard O-rings that come with the evaporator and install the new ones that come in the kit. • Clean all threads on ORS fittings prior to installation.

• Apply refrigerant oil to the O-rings only. DO NOT APPLY OIL TO THE ORS FITTING THREADS.

• When tightening ORS tubing connections, always use a backup wrench to hold the backside of the ORS fitting to prevent the refrigeration tube from twisting.

• Torque all ORS connections as shown in the table.

1. Fabricate a 7/8 inthe trough, instaloil new O-ring a

2. Fabricate a 1/2 inthe trough, instaloil O-ring and co


4. Insulation should


CAUTION: Remove holding charge from the evaporator(s) before proceeding to avoid personal injury.

Item Description P/NA 7/8 in. x 7/8 in. Elbow 553326B 1/2 in. x 1/2 in. Elbow 551483C 3/8 in. x 3/8 in. Elbow 556359

Specifications for Evaporator ORS Fittings

Tube Size Thread TorqueO-ring

GasketsLiquid 3/8 in. 11/16-16 30 ft-lb 331222Hot Gas 1/2 in. 13/16-16 40 ft-lb 331015Suction 7/8 in. 1-3/16-16 60 ft-lb 330566

HG = Hot Gas

73

-2 or S-3
Evaporator Tube Connections S

74

mperature Sensor (CTN-01, CTP-01), Discharge e Sensor (DTN-01, DTP-01) and Return Air nsor (RTN-01, RTP-01) to matching connectors in il C).

rness (2C42229 - CHE-01, FMA-01, CHE-02, ropriate mating connectors at the back of the (Detail A), route harness to evaporator, cut harness to ct to terminal block (Detail B).

connect DH to LLS on S-2 terminal board (Detail B).

ses with adequate clamps or ties.

Wire Connections S-2

S-2 EvaporatorNOTE: Trim all harnesses to appropriate length before installing terminals.

NOTE: Superlube (203-524 or equivalent) must be applied to all electrical connections.

1. Connect Zone Harness (2C42230 - 24 pin connector) to appropriate mating connector at the back of condensing unit (Detail A), route harness to evaporator, cut harness to length and connect to terminal block (Detail B).

NOTE: If Zone Harness is cut to length, use wire CHE-06 from discarded harness length to connect SOL terminal to the ground stud (Detail B).

2. Connect Coil TeAir TemperaturTemperature Seevaporator (Deta

3. Connect Fan HaFMB-01) to appcondensing unit length and conne

4. Move jumper to

5. Secure all harnes

75


76

ature Sensor (CTN-01, CTP-01), Discharge sor (DTN-01, DTP-01) and Return Air (RTN-01, RTP-01) to matching connectors in

(2C42229 - CHE-01, FMA-01, CHE-02, te mating connectors at the back of the il A), route harness to evaporator, cut harness to terminal block (Detail B).

ct DH to LLS on S-3 terminal board (Detail B).

t FM2 to FM3 on S-3 terminal board (Detail B).

ith adequate clamps or ties.


S-3 EvaporatorNOTE: Trim all harnesses to appropriate length before installing terminals.




2. Connect Coil TemperAir Temperature SenTemperature Sensor evaporator (Detail C).

3. Connect Fan HarnessFMB-01) to appropriacondensing unit (Detalength and connect to

4. Move jumper to conne

5. Add jumper to connec

6. Secure all harnesses w

77


78

s (2) S-2 + S-2

nd install pre-bent 90° 1-1/8 in. tube onto suction ondensing unit (Detail B).

1-1/8 in. x 7/8in. tee into suction tube.


/8 in. elbows onto suction tube tees (Detail B).




nd install pre-bent 90° 3/8 in. tube onto liquid ORS sing unit (Detail B).

/8 in. x 3/8 in. tee onto liquid tube (Detail B).

/8 in. elbow onto liquid tube tee (Detail B).


nd install pre-bent 90° 1/2 in. tube onto hot gas ORS sing unit (Detail B).

/2 in. x 1/2 in. tee onto hot gas tube (Detail B).





Condensing Unit Tube Connection



1. Oil new O-ring aORS fitting of c







7. Oil new O-ring afitting of conden













Number

#2 1-1/8 in. x 1- 1/8 in. x 7/8 in. Tee 559517

#3 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

#4 7/8 in. x 7/8 in. Elbow 553326

#8 3/8 in. x 3/8 in. x 3/8 in. Tee 553251

#9 3/8 in. x 3/8 in. Elbow 552876

#12 1/2 in. x 1/2 in. x 1/2 in. Tee 552296

#13 1/2 in. x 1/2 in. Elbow 558812

79

(2) S-2 + S-2
Condensing Unit Tube Connections

80

S-2 + S-2

t connect one suction line from the condensing

ction tube from the condensing unit and route in in. x 7/8 in. elbow, attach 7/8 in. preformed tube,

onnect to the second evaporator 7/8 in. ORS

/8 in. suction tube from the condensing unit and nstall 7/8 in. x 7/8 in. elbow, attach 7/8 in. ew O-ring and connect to the first evaporator 7/8

t gas tube from the condensing unit and route in in. x 1/2 in. elbow, fabricate a 1/2 in. tube,

. x 1/2 in. x 1/2 in. tee, attach to 1/2 in. preformed and connect to the evaporator 1/2 in. ORS fitting.

uid tube from the condensing unit and route in in. x 3/8 in. elbow, fabricate a 3/8 in. tube,

. x 3/8 in. x 3/8 in. tee, attach 3/8 in. preformed and connect to the evaporator 3/8 in. ORS fitting.

added to all segments of suction and hot gas tubes.

h provided clamps.


Evaporator Tube Connections (2)


NOTE: Discard O-rings that come with the evaporator and install the new ones that come in the kit.• Clean all threads on ORS fittings prior to installation.

• Apply refrigerant oil only to the ORS O-rings. DO NOT APPLY OIL TO THE ORS FITTING THREADS.



IMPORTANT: You musunit to each evaporator.

1. Fabricate a 7/8 in. suthe trough, install 7/8oil new O-ring and cfitting.

2. Fabricate a second 7route in the trough, ipreformed tube, oil nin. ORS fitting.

3. Fabricate a 1/2 in. hothe trough, install 1/2connect to the 1/2 intube, oil new O-ring

4. Fabricate a 3/8 in. liqthe trough, install 3/8connect to the 3/8 intube, oil new O-ring

5. Insulation should be

6. Secure all tubing wit


Items DescriptionPart

Number

A 7/8 in. x 7/8 in. Elbow 553326

B 1/2 in. x 1/2 in. Elbow 558812

C 1/2 in. x 1/2 in. x 1/2 in. Tee 552296

D 3/8 in. x 3/8 in. Elbow 552876

E 3/8 in. x 3/8 in. x 3/8 in. Tee 553251



Gaskets

Liquid 3/8 in. 11/16-16 30 ft-lb 331222

Hot Gas 1/2 in. 13/16-16 40 ft-lb 331015

Suction 7/8 in. 1-3/16-16 60 ft-lb 330566

HG = Hot Gas

81

S-2 + S-2
Evaporator Tube Connections (2)

82

S-2

rness (2C42229 - CHE-01, FMA-01, CHE-02, ropriate mating connectors at the back of the (Detail A), route harness to evaporator, cut harness to ct to terminal block (Detail B).

connect DH to LLS on each S-2 terminal board

Zone Harness (2C42537 - CHE-04, HGS-02, , FS-02) to the first S-2 terminal block and connect the harness to the second S-2 terminal block (Detail B).

Fan Harness (2C42535 - FMA-02, FMB-02, irst S-2 terminal block and connect the other end of e second S-2 terminal block (Detail B).

tional Ground Wire (9156C97 - CHE-07) to the inal board (Detail B).


Wiring Connections S-2 +

S-2 + S-2 EvaporatorsNOTE: Trim all harnesses to appropriate length before installing terminals.NOTE: Superlube (203-524 or equivalent) must be applied to all electrical connections.



2. Connect Coil Temperature Sensor (CTN-01, CTP-01), Discharge Air Temperature Sensor (DTN-01, DTP-01) and Return Air Temperature Sensor (RTN-01, RTP-01) to matching connectors in evaporator (Detail C).

3. Connect Fan HaFMB-01) to appcondensing unit length and conne

4. Move jumper to (Detail B).

5. Connect JumperLLS-03, SLS-02other end of the

6. Connect JumperCHE-03) to the fthe harness to th

7. Connect an addisecond S-2 term


83

S-2
Wiring Connections S-2 +

84

mperature Systems

nd install pre-bent 90° 1-1/8 in. tube onto suction ondensing unit (Detail B).

1-1/8 in. x 7/8in. tee into suction tube.


/8 in. elbows onto suction tube tees (Detail B).




nd install pre-bent 90° 3/8 in. tube onto liquid ORS sing unit (Detail B).

. x 3/8 in. x 3/8 in. tees onto liquid tube (Detail B).

. x 3/8 in. elbows onto liquid tube tee (Detail B).


nd install pre-bent 90° 1/2 in. tube onto hot gas ORS sing unit (Detail B).

. x 1/2 in. x 1/2 in. tees onto hot gas tube (Detail B).





Condensing Unit Tube Connections 3 Te



1. Oil new O-ring aORS fitting of c








8. Install two 3/8 in












Number

#2 1-1/8 in. x 1- 1/8 in. x 7/8 in. Tee 559517

#3 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

#4 7/8 in. x 7/8 in. Elbow 553326

#8 3/8 in. x 3/8 in. x 3/8 in. Tee 553251

#9 3/8 in. x 3/8 in. Elbow 552876

#12 1/2 in. x 1/2 in. x 1/2 in. Tee 552296

#13 1/2 in. x 1/2 in. Elbow 558812

85

perature Systems
Condensing Unit Tube Connections 3 Tem

86

erature Systems

. suction tube from the condensing unit and route in l 7/8 in. x 7/8 in. elbow, attach 7/8 in. preformed tube, nd connect to the evaporator 7/8 in. ORS fitting.

. hot gas tube from the condensing unit and route in l 1/2 in. x 1/2 in. elbow, attach 1/2 in. preformed tube, nnect to the evaporator 1/2 in. ORS fitting.

. liquid tube from the condensing unit and route in l 3/8 in. x 3/8 in. elbow, attach 3/8 in. preformed tube, nd connect to the evaporator 3/8 in. ORS fitting.

be added to all segments of suction and hot gas tubes.

with provided clamps.


Evaporator Tube Connections 3 Temp


IMPORTANT: Discard O-rings that come with the evaporator and install the new ones that come in the kit. • Clean all threads on ORS fittings prior to installation.

• Apply refrigerant oil to the O-rings only. DO NOT APPLY OIL TO THE ORS FITTING THREADS.




2. Fabricate a 1/2 inthe trough, instaloil O-ring and co


4. Insulation should



Item Description P/NA 7/8 in. x 7/8 in. Elbow 553326B 1/2 in. x 1/2 in. Elbow 551483C 3/8 in. x 3/8 in. Elbow 556359



GasketsLiquid 3/8 in. 11/16-16 30 ft-lb 331222Hot Gas 1/2 in. 13/16-16 40 ft-lb 331015Suction 7/8 in. 1-3/16-16 60 ft-lb 330566

HG = Hot Gas

87

rature Systems
Evaporator Tube Connections 3 Tempe

88

re Systems

ne Coil Temperature Sensor (CTN-01, CTP-01), emperature Sensor (DTN-01, DTP-01) and Return e Sensor (RTN-01, RTP-01) to matching connectors etail C).

ne Fan Harness (2C42229 - CHE-01, FMA-01, 1) to appropriate mating connectors at the back of the (Detail A), route harness to correct zone evaporator, gth and connect to terminal block (Detail B).

orator’s jumper to connect DH to LLS on S-2 terminal .


Wiring Connections 3 Temperatu

NOTE: Trim all harnesses to appropriate length before installing terminals.


1. Connect each Zone Harness (2C42230 - 24 pin connector) to appropriate mating connector at the back of condensing unit (Detail A), route harness to correct zone evaporator, cut harness to length and connect to terminal block (Detail B).


2. Connect each zoDischarge Air TAir Temperaturin evaporator (D

3. Connect each zoCHE-02, FMB-0condensing unit cut harness to len

4. Move each evapboard (Detail B)


89

e Systems
Wiring Connections 3 Temperatur

90

Tube Applications (Detail C) of the resistance wire into the wall drain tube. in hose from the evaporator.

Channel Applications (Detail D) of the resistance wire into the plastic drain hose. ose down through the wall channel until it exits the

Hose Support (Detail E)l drain hose support bracket is recommended when be cannot be directly routed into a wall drain.

se Applications (Detail F)o allow drain tube to exit the front of the evaporator, h of one resistance wire into each drain hose, and t of the cover to the wall drain.

Drain Hose Installation

IMPORTANT: DO NOT CUT RESISTANCE WIRES!

NOTE: For proper drainage the drain hose must slope down continuously from the evaporator to the wall drains with no kinks or droop.

NOTE: Make sure drain tubes are properly seated on tube fittings before mounting to evaporator.

S-2 and S-3 Applications (Detail A)1. Route each resistance wire from the evaporator through the plastic

drain hose and insert the entire length of one resistance wire into each wall drain tube.

2. Connect the single drain hose to the wall drain tube using a short piece of plastic drain hose and clamp as required.

3. Replace drain t-fitting with elbow fitting.

S-2 + S-2 Applications (Detail B)4. Route each resistance wire from the evaporator through the plastic

drain hose and insert the entire length of one resistance wire into each wall drain tube.

5. Connect each drain hose to each wall drain tube using a short piece of plastic drain hose and clamps as required.

Wall Mounted Insert the entire lengthConnect the plastic dra

Wall Mounted Insert the entire lengthFeed the plastic drain hbottom of the truck.

Optional DrainThe use of the optionathe evaporator drain tu

Front Drain HoInstall drain t-fittings tinsert the entire lengtroute hose out the fron

DANGER: Never bundle resistance wires together as the amount of heat produced could result in a fire!

91

Drain Hose Installation

92

llation Guide

Tee or 90 degree connector to the evaporator drain e connector on firmly to engage the O-ring (Detail VI).

e wire through the interconnecting drain tube as far as e sure it is not bunched up (Detail VII).

esistance wire into the other drain Tee connector and as III).

t no time should resistance wires from one side of the p the resistance wires from the other side.

onnecting drain tube to the opposite Tee connector by connector on firmly to engage the O-ring (Detail IX).

onnector to the evaporator drain tube by pushing the firmly to engage the O-ring (Detail X).

the evaporator drain tube over to the wall drain. Insert re into the wall drain and pull it as far down the wall (Detail XI).

nly one resistance wire should be installed in the n tube. Only the resistance wire from the drain tube ll should be installed in the trailer drain tube.

Drain Hose Resistance Wire Insta

IMPORTANT: The following information is provided as a guide to help ensure the proper routing of the drain hose resistance wires. You should supplement this guide with whatever other documentation is required for your facility.

Drain Hose Resistance Wire Installation Guide

1. Remove the resistance wire from the evaporator drain tube and pull the wire out straight.

2. Locate the evaporator defrost drain furthest from the wall (i.e. in the middle of the cargo box), and measure 33.00 in. (838 mm) of the resistance wire from the drain pan outlet (Detail I).

NOTE: 20.00 in. (508 mm) for S-2 evaporators.

3. Bend the resistance wire at this point and double it over (Detail II).

4. After doubling the resistance wire over (Step #3) take the excess wire and insert it back into the evaporator drain tube (Detail III).

5. Insert the doubled over end of the resistance wire into the drain Tee or 90 degree connector (Detail IV) and then into the crossover drain tube (Detail V).

NOTE: The use of either white or blue drain tubes is acceptable when interconnecting multiple evaporators.

6. Attach the drain tube and push th

7. Pull the resistancpossible and mak

8. Insert the other rshown (Detail V

IMPORTANT: Adrain pan overla

9. Attach the intercpushing the Tee

10. Attach the Tee cTee connector on

11. Attach and routethe resistance widrain as possible

IMPORTANT: Owall defrost draiclosest to the wa

93

ation Guide
Drain Hose Resistance Wire Install

94

ION)

oLink Installation Manual.ch installation. Your installation may be nts. After the door switches are installed they

TION NOTES: installed away from traffic (i.e. forklifts) or

gnet must be installed parallel to each other, cross hair aligns to long cross hair.

ximum gap of 19 mm (0.75 in.) is maintained and the magnet. Shims may be required and material (aluminum, wood, plastic, etc.) or the rate properly.

t Angle Mounting with the top edge of the door and secure with

t the switch to the door sill parallel with the cross hairs” are aligned and that the maximum is maintained.

op Mounting with the bottom edge of the door and secure

t the switch to the floor parallel with the cross hairs” are aligned and that the maximum is maintained.

- Side x Side Mounting with the top edge of the door and secure with

e switch to the door sill parallel with the s hairs” are aligned and that the maximum gap ained

Installing the Door Switch (OPT

When installing CargoLink wireless door switches, see TK 55151 CargNOTE: These instructions are intended as reference guide only to assist with a typical hard wired door switdifferent depending on the cargo box, the amount and types of doors and the customers particular requiremeneed to be activated through the HMI. See “Door Switch Setup Procedures (OPTION)” on page 98.

Door Switch ComponentsThe door switch consists of a magnet, a switch, non-magnetic mounting hardware and a interface harness to connect to the host unit. If alternate hardware is used it must also be non-magnetic or the door switch will not operate properly.

• The magnet is always mounted on the door.

• The switch (with harness) is always mounted to a stationary location.

• Two short interface harnesses are available:41-7281 allows a single door switch in a single zone to activate a unit shutdown. 41-7282 allows two door switches (maximum two doors) in the same zone to each activate a unit shutdown.

Installer is to supply and fabricate the harness connecting the interface harness to the door switch per the illustrations. The harness should be 18 AWG or better, 3 wires, color coded RED, BLACK and WHITE.

Mounting LocationsThe door switch can be mounted on the inside or outside of either swing out or roll-up doors and can be mounted in various positions to accommodate particular applications.

IMPORTANT INSTALLA• The door switch must be

protected from it.

• The door switch and manot perpendicular. Long

• It is important that a mabetween the door switchmust be a non-magnetic door switch will not ope

(Detail A) Ceiling - Righ1. Mount the magnet flush

supplied hardware.

2. Close the door and mounmagnet, being sure the “gap of 19 mm (0.75 in.)

(Detail B) Floor - Top x T1. Mount the magnet flush

with supplied hardware.

2. Close the door and mounmagnet, being sure the “gap of 19 mm (0.75 in.)

(Detail C) Outside Door 1. Mount the magnet flush

supplied hardware.

Close the door and mount thmagnet, being sure the “crosof 19 mm (0.75 in.) is maint

95

TION)
Installing the Door Switch (OP
Right Angle Mounting

Top x Top Mounting

Side x Side Mounting

96

PTION)

itch Activation / Single Zone (Detail B)

ace harness (41-7282) to the door switch connector r of the unit.

arness (installer supplied) from the interface harness tch - Maximum Two Doors. Connect matching wires w (RED/RED, WHITE/WHITE,

K) to each door switch using splice connectors. Crimp s securely and apply heat with a heat gun.

ould be installed, routed and properly secured to age

Installing the Door Switch (O

Single Door Switch Activation / Single Zone (Detail A)

1. Attach the interface harness (41-7281) to the door switch connector located at the rear of the unit.

2. Route a 3 wire harness (installer supplied) from the interface harness to a single door switch. Connect matching wires per the table below (RED/RED, WHITE/WHITE, BLACK/BLACK) to each door switch using splice connectors. Crimp splice connectors securely and apply heat with a heat gun.

3. All harnesses should be installed, routed and properly secured to protect from damage.

Multiple Door Sw

4. Attach the interflocated at the rea

5. Route a 3 wire hto each door swiper the table beloBLACK/BLACsplice connector

6. All harnesses shprotect from dam

97

TION)
Installing the Door Switch (OP
Interface Harness Wiring Door Switch Wiring

(R) RED = (12 Vdc) POWER (R) RED = (12 Vdc) POWER

(B) BLACK = (CH) GROUND (B) BLACK = (CH) GROUND

(W) WHITE = (DS) OUTPUT (W) WHITE = (DS) OUTPUT

98

PTION)

oor switch function to be set to operate in one of

ace the zone in Running Null when the zone door ds and allow the zone to run when zone door is If the unit is operating as a single zone or zone llowed the unit will be forced to Null (unit off).

into Null (zone off) when the zone door is opened w the zone to run 5 seconds after zone door is perating as a single zone or zone Null is not be forced to Null (unit off). Door switch Null is er zones are in Null.

t will shut down for the time interval selected by r this time period elapses the unit will restart even n. is feature only appears if Timed Off operation is Off sets a time limit for door open event. If the t operation resumes even if the door is still open. m 1 to 4 hours in 10 minute increments. The ur.

opening and closing only. No other unit action. elay to log door open and door closed.

unit into Null (unit off) when any door is opened w the unit to run when all doors are closed for 5

nning in Null.

52-1-OD for complete information about the

Door Switch Setup Procedures (O

Accessing the Guarded Access Menu• From the Standard Display press the MENU key. The controller will

display the Operator Menu.

• From the first Operator Menu display (either Alarms or Language) press and hold both the EXIT key and the key with no label above it for 5 seconds.

• After 5 seconds the controller will display the Maintenance Menu. Press the NEXT key until the Time and Date Menu appears.

• From the Time and Date Menu press and hold both the EXIT key and the key with no label above it for 5 seconds.

• After 5 seconds the controller will display a Security Code challenge. If no Security Code has been set the display will show “1”.

• Press the YES key to enter the Guarded Access Menu. If a Security Code has been set the operator is prompted to enter the correct code and press the YES key to enter the Guarded Access Menu. If the correct Security Code is not entered, access to the Guarded Access Menu will be denied.

• Enter Programmable Features Menu, then scroll to DOOR ACTION (or DOOR OPEN FORCES) display.

Door Open is EnabledThis feature allows the Door Open Feature to be enabled or disabled. If Door Open is set ENABLED the door switch will operate as selected with the Door Action feature below. If the Door Open is set DISABLED the door switch has no function. The default setting is DISABLED.

Door ActionThis feature allows the dthe following schemes.

1. Running in Null - Plis opened for 2 seconclosed for 5 seconds.Running Null is not a

2. Null - Force the zonefor 2 seconds and alloclosed. If the unit is oallowed, the unit willnot allowed if all oth

3. Timed Off - The uniSelect Time Off. Afteif the door is still opeSelect Time Off - Thselected. Select Timetime is exceeded, uniThe time range is frodefault setting is 1 ho

4. Log Only - Log doorThere is a 4 second d

5. Unit Off - Force the for 2 seconds and alloseconds.

The default setting is Ru

NOTE: Refer to TK-516microprocessor.

99

BLANK PAGE

100

es

Definition

Ambient or outside air temperature

Temperature of the air returning to the Zone 1 evaporator.

Temperature of the air leaving the Zone 1 evaporator.

(Discharge air temperature) minus (return air temperature) for Zone 1.

Temperature of the Zone 1 evaporator coil.





Temperature measured by the optional Spare Sensor 1 (if installed).





Sensor Calibration Procedur

Temperature Sensor CalibrationIn order to achieve maximum accuracy the return air and discharge air temperature sensors as well as the spare temperature sensor are graded sensors. Sensors are graded by the manufacturer with a sensor grade from 1 to 9. Each sensor is then further graded as low, center or high within each grade range. Sensor grades are physically stamped on each sensor and range from 1L to 9H. A sensor in the center grade range is stamped with the grade number only. These grades eliminate the need for sensors to be calibrated using an ice water bath.

Due to sensor calibration scaling factors Grade 5H sensors do not exist (Grade 5L and 5 do exist). Therefore, grade 5H is the sensor grade factory default as it indicates the sensor grade has not been set.

Sensor grade settings are checked when unit power switch is turned on. If any return, discharge or spare air sensor is indicating a valid temperature and is set to Grade 5H then Alarm Code 111 will be set during a Pretrip Test. This alarm clears automatically when all graded sensors are set to a value other than Grade 5H.

Other unit sensors (coil temperature, ambient temperature, engine coolant temperature and compressor temperature) are ungraded sensors and need not be calibrated.

Any time a graded sensor is replaced the sensor grade of the replacement sensor must be checked and set.

Only configured zones appear in sensor calibration menu unless a valid sensor reading is detected.

The Temperature Sensor Calibration Display allows the technician to view and change the grade of return, discharge and spare sensors.

Sensor Name

Ambient Temp Sensor

Zone 1Return Air Temp

Zone 1 Discharge Air Temp

Zone 1 Temp Differential

Zone 1 Coil Temp

Zone 2 Return Air Temp


Zone 2Temp Differential

Zone 2Coil Temp

Spare Temp 1

Zone 3 Return Air Temp


Zone 3 Temp Differential

Zone 3Coil Temp

101

res

res PREVIOUS key to chose the desired sensor.

ensor is shown press the SELECT key to chose the grade can now be changed using the - and/or + keys.

ensor grade is shown press the YES key to set the

nfirm that the grade is being changed as shown new sensor grade will appear.

timum performance the sensor grades for all discharge air sensors must be properly set. Failure educed performance and/or nuisance alarm codes.

Sensor Calibration Procedu

Accessing the Guarded Access Menu• From the Standard Display press the MENU key. The controller will

display the Operator Menu.

• From the first Operator Menu display (either Alarms or Language) press and hold both the EXIT key and the key with no label above it for 5 seconds.

• After 5 seconds the controller will display the Maintenance Menu. Press the NEXT key until the Time and Date Menu appears.

• From the Time and Date Menu press and hold both the EXIT key and the key with no label above it for 5 seconds.

• After 5 seconds the controller will display a Security Code challenge. If no Security Code has been set the display will show “1”.

• Press the YES key to enter the Guarded Access Menu. If a Security Code has been set the operator is prompted to enter the correct code and press the YES key to enter the Guarded Access Menu. If the correct Security Code is not entered, access to the Guarded Access Menu will be denied.

• From the Guarded Access Menu scroll to SENSOR CALIBRATION.

Setup Procedu• Press the NEXT or

• When the desired ssensor. The sensor

• When the desired sgrade.

• The display will cobelow and then the

IMPORTANT: For opreturn air sensors and to do so may result in r

102

he Systemgnosing Thermo King Refrigeration Systems

ak detection procedures.

t gas (R-404a) supply to center hose of gauge

nifold hoses to the suction service valve and the port.

stem with leak test gas. If desired, system pressure using nitrogen gas.

ns made during installation for leaks using electronic or soap bubbles.

to repair leaks. System must be vented while repairing . Pressurize the system and check again after a leak

d.

und recover test gas to 0 psig.

System Leak Check

Set-up UnitPlace microprocessor in Evacuation Mode to leak check, evacuate and charge unit. With the SPECTRUM microprocessor in the evacuation mode all solenoid valves in the refrigeration system are open. This allows the refrigeration system to be properly evacuated.

NOTE: Refer to appropriate Operation & Diagnosis Manual for complete information about the microprocessor.

Use the following procedure to place the SPECTRUM microprocessor in the Evacuation Mode:

A. Connect unit battery and attach a battery charger to the battery. The battery must be capable of at least 20 amperes output. This will maintain the charge level of the battery during the time required to leak check, evacuate and charge the unit.

B. Turn the unit on. (DO NOT allow the diesel engine or electric motor to start).

C. From the main screen on the HMI, enter the Menu screen by pushing MENU.

D. At the first Operator Menu screen that appears; either the Language Display or the Alarms Display, press and hold the unlabeled soft key and the EXIT key for 5 seconds.

E. The Maintenance Hourmeter Menu will appear. Press the NEXT key as required to show the Evacuation Mode Menu.

F. When the Evacuation Mode Menu is shown press the SELECT key.

G. The unit will stay in Evacuation Mode until the battery voltage falls below a minimum voltage or the EXIT key is pressed.

Leak Check tNOTE: Refer to Dia(TK-5984-10) for le

1. Connect leak tesmanifold.

2. Attach gauge madischarge service

3. Pressurize the symay be boosted

4. Check connectioleak detector and

5. Recover test gassolder joint leakshas been repaire

6. If no leaks are fo

103

System Leak Check

104

of evacuation, open valve V2 to access thermistor and icron reading now shows system pressure.

to 500 microns or lowest achievable level between crons. Multi-Temp units should be evacuated for an nce 500 microns is reached.

micron level is achieved (500 to 1000 microns plus i-Temp units), close valve V1 to isolate pump. Turn

on micron gauge after 5 minutes have elapsed. If ceeds 2000 microns after 5 minutes, leak is present or ation time is required.

is acceptable, start pump and open valve V1 to e rise (5 minutes).

mp running, back seat suction service valve. Observe d continue to operate vacuum pump until an n level is achieved.

nd stop pump.Observe micron gauge to confirm that n a deep vacuum. Close valve V4. harge.

or Evacuation and Charging Diagram below.

E. Two Stage Vacuum Pump

F. To AC Power

G. Micron Gauge

H. Thermistor

System Evacuation

System EvacuationIMPORTANT: Do not evacuate unit until it is leak free. Unit with less than a full refrigerant charge should be leak checked and all leaks must be repaired.

NOTE: Use of Thermo King Evacuation Station (P/N 2040725) and Evacuation Station Operation and Field Application Instructions (TK-40612-2) is required.

1. Recover any refrigerant to 0 psig. (Regulations may require recovery machine to pull system pressure lower than 0 psig).

2. Before connecting refrigerant hoses to unit, close valves V1 and V4 on the evacuation system and turn micron gauge ON.

3. Back seat suction and receiver tank service valves. Attach evacuation hoses to these two valves as well as the discharge service port (check condition of hose seals).

4. With service valves fully back seated, turn evacuation pump ON and open valve V1 (V2 and V3 should also be open). Micron gauge should move to a deep vacuum.

5. Open valve V4. Micron reading will rise. If micron gauge returns to reading less than 500 microns, proceed to step 6. If micron reading remains high, a leak exists at hose fittings or packing glands. Locate and correct problem. Packing glands that do not seal can be corrected by installing valve stem covers (see step 6).

6. If step 5 was successful, close valve V2 to isolate thermistor. Open suction, discharge and receiver service valves to port. Install brass and steel valve stem covers (with sealing washers) on service valves and tighten. Let vacuum pump continue to operate.

7. After 5 minutes micron gauge. M

8. Evacuate system500 and 1000 miadditional hour o

9. When acceptableon hour for Multpump OFF.

10. Observe readingvacuum level exadditional evacu

11. If vacuum level evacuate pressur

12. With vacuum pumicron gauge anacceptable micro

13. Close valve V1 asystem remains iUnit is ready to c

Legend f

A. V-4

B. V-3

C. V-2

D. V-1

105

System Evacuation

106

e gauge manifold valve when the receiver sight glass full.

n air temperature of 0 F (-18 C), a suction pressure of to 124 kPa), and a discharge pressure of 300 psig

er tank sight glass. The refrigerant level should remain 3/4 full over a period of no less than 5 minutes.

ditions the Liquid Injection Valve will cycle on and the refrigerant level in the receiver tank sight glass . Therefore, monitoring the receiver tank sight glass utes to make sure that the average level of

five-minute period is between 1/2 and 3/4 full is

or Evacuation and Charging Diagram below

E. Two Stage Vacuum Pump

F. To AC Power

G. Micron Gauge

H. Thermistor

System Charging

System ChargingIMPORTANT: Unit must be leak checked and fully evacuated before charging.

1. Install a gauge manifold. Attach the low side gauge to the service port on the suction service valve. Attach the high side gauge to the service port on the discharge line near the condenser.

2. Close the valves on the gauge manifold.

3. Mid seat the compressor suction service valve.

4. Connect a refrigerant supply to the gauge manifold service line and purge the line.

5. Set the refrigerant supply bottle to liquid and open the hand valve.

6. Open the high side gauge manifold valve. Add a partial charge of 10 lbs. (4.5 kg) of liquid refrigerant and close the high side gauge manifold valve. The reminder of the charge will be added as a liquid through the low side gauge manifold valve.

7. Set both zones to HIGH SPEED COOL through the HMI Service Test Mode.

8. Observe the suction pressure and slowly open the low side gauge manifold valve to allow liquid refrigerant to flow into the compressor suction service valve.

9. Control the liquid flow so the suction pressure increases approximately 20 psi (138 kPa).

10. Maintain a discharge pressure of at least 300 psig (2068 kPa) while adding refrigerant.

11. Close the low sidshows 1/2 to 3/4

12. Establish a retur13 to 18 psig (90(2068 kPa).

13. Check the receivbetween 1/2 and

NOTE: At these conoff. As this happenswill raise and lowerfor a period of 5 minrefrigerant over thisrequired.

Legend f

A. V-4

B. V-3

C. V-2

D. V-1

107

System Charging

108

Installing Covers

Installing Covers1. Install front cover into support channel of evaporator. Secure with

screws.

2. Install back cover into support lip of front cover. Secure with screws.

3. Attach side covers.

109

Installing Covers

110

ion System Charged and Free of Leaks

ch Operation Checked

, Covers and Grilles Installed

re-Trip Test (Refer to Unit Operating Manual)

Customer

System Check List

Condensing Unit Bolts Tighten and Torqued to Specs.

Evaporator Mounting Bolts Torqued to Specs.

Wiring Harnesses Routed, Connected and Secured

Refrigeration Tubing Connected, Insulated and Secured

Drain Tubes Installed, Routed and Secured

Refrigerat

Door Swit

All Guards

Run Unit P

Release to

Installation Manual

Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

©2002 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

Truck Edition SPECTRUM

TM TS

Multi-Temperature Systems TK 51580-1-IM (Rev. 11, 05/15)

Documents

Installation Manual - ThermoKing · Installation Manual ... 16 Condensing Unit ... to fresh air and use CPR or mouth-to-mouth