V-500 10/20, V-500 MAX 10/20

TK 51878-1-OP (Rev. 0, 11/04)

Copyright 1999 Thermo King Corp., Minneapolis, MN, USA Printed in USA

Disclaimer
This manual is published for informational purposes only. Thermo King Corporation makes no representations or warranties, express or implied, with respect to the information, recommendations and descriptions contained in this manual and such information, recommendations and descriptions should not be regarded as all-inclusive or covering all contingencies. If you have questions or require further information, please contact your local Thermo King dealer. The procedures described herein should be undertaken only by qualified personnel. Failure to implement these procedures correctly may cause damage to the Thermo King unit or other property or personal injury. Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or any other direct, indirect, special or consequential damage or liability whatsoever, arising out of or resulting from any actions by any person that are contrary to this manual or any of the information, recommendations or descriptions contained herein or the failure of any person to implement the procedures described herein correctly or to follow caution and safety decals located on the Thermo King unit.

Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 First AidRefrigerant . . . . . . . . . . . . . . . . . . . . . . 11 First AidRefrigerant Oil . . . . . . . . . . . . . . . . . . . 11 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 15 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 The evaporator is mounted on the ceiling inside the truck box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 In-Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . .17 Evaporator Drain Tube Heaters . . . . . . . . . . . . . . . . . .17 Electric Standby Operation . . . . . . . . . . . . . . . . . . . . .17 Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . .19 In-Cab Control Box Description . . . . . . . . . . . . . . . .25 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Display Descriptions . . . . . . . . . . . . . . . . . . . . . . .27 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . .31 Cab Control Box Operating Instructions . . . . . . . . . . .32 Displaying Return Air Temperature . . . . . . . . . . . .32 Display Setpoint Temperature . . . . . . . . . . . . . . . .32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Enter Setpoint Temperature. . . . . . . . . . . . . . . . . .33 Defrost Mode Operation . . . . . . . . . . . . . . . . . . . .33 Weekly Pretrip Inspection . . . . . . . . . . . . . . . . . . .34 Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Thermostat Operation . . . . . . . . . . . . . . . . . . . . . . . . .37

Table of Contents

Loading and Enroute Inspections . . . . . . . . . . . . . . 39 Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . . 39 Inspecting the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Maintenance Inspection Schedule . . . . . . . . . . . . . . 49 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 63 Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . . 65 Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 66

List of Figures
Figure 1:Fan Warning . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 2:Caution: High Voltage . . . . . . . . . . . . . . . . . . 12 Figure 3:Belt Warning . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 4:V-500 Condenser Unit . . . . . . . . . . . . . . . . . 14 Figure 5:Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Figure 6:In-Cab Control Box . . . . . . . . . . . . . . . . . . . . 16 Figure 7:Unit Components (Model 20) . . . . . . . . . . . . 21 Figure 8:Condenser Electric and Capacitor Boxes (Model 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Figure 9:Standard Evaporator . . . . . . . . . . . . . . . . . . . 23 Figure 10:Evaporator with Hot Water and Electric Heat Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Figure 11:M-13 In-Cab Control Box . . . . . . . . . . . . . . 25 Figure 12:Display Screen . . . . . . . . . . . . . . . . . . . . . . 26 Figure 13:On/Off Key & LED . . . . . . . . . . . . . . . . . . . .27 Figure 14:Celsius/Fahrenheit LED . . . . . . . . . . . . . . . .28 Figure 15:Setpoint Key & Dial . . . . . . . . . . . . . . . . . . .28 Figure 16:Misc. LEDs . . . . . . . . . . . . . . . . . . . . . . . . .29 Figure 17:Defrost Key & LED . . . . . . . . . . . . . . . . . . . .29 Figure 18:M-13 In-Cab Control Box . . . . . . . . . . . . . . .31 Figure 19:Setpoint Key . . . . . . . . . . . . . . . . . . . . . . . .32 Figure 20:Entering Setpoint . . . . . . . . . . . . . . . . . . . . .33 Figure 21:On/Off Key and Defrost Key . . . . . . . . . . . .34 Figure 22:Electric Power Receptacle . . . . . . . . . . . . . .36 Figure 23:Thermostat Algorithm . . . . . . . . . . . . . . . . .38 Figure 24:Loading Considerations . . . . . . . . . . . . . . . .40 Figure 25:Condenser and Standby Compressor Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

List of Figures

Introduction
There is nothing complicated about operating and maintaining your Thermo King unit, but a few minutes studying this manual will be time well spent. Performing pre-trip checks and enroute inspections on a regular basis will minimize on-the-road operating problems. A regular maintenance program will also help to keep your unit in top operating condition. If factory recommended procedures are followed, you will find that you have purchased the most efficient and dependable temperature control system available. All service requirements, major and minor, should be handled by a Thermo King dealer for four very important reasons: They are equipped with the factory recommended tools to perform all service functions They have factory trained and certified technicians They have genuine Thermo King replacement parts The warranty on your new unit is valid only when the repair and replacement of component parts is performed by an authorized Thermo King dealer. IMPORTANT: This manual is published for informational purposes only and the information furnished herein should not be considered as all-inclusive or meant to cover all contingencies. If more information is required, consult your Thermo King Service Directory for the location and telephone number of the local dealer.

001

Introduction

Safety Precautions
Thermo King recommends all services be performed by a Thermo King dealer. However, there are several general safety practices you should be aware of: DANGER: Never operate the unit with the discharge valve closed because it could cause the compressor to explode, causing death or serious injury. WARNING: Always wear goggles or safety glasses when working with or around the refrigeration system or battery. Refrigerant or battery acid can cause permanent damage if it comes in contact with your eyes. WARNING: Keep hands and loose clothing clear of fans and belts at all times when the unit is operating or when opening or closing compressor service valves. WARNING: Exposed coil fins can cause painful lacerations. Service work on the evaporator or condenser coils is best left to a certified Thermo King technician. CAUTION: Use extreme caution when drilling holes in the unit. Drilling into electrical wiring or refrigerant lines could cause a fire. Never drill into structural components. WARNING: Turn all unit On/Off switches to the Off position before opening doors or inspecting any part of the unit.

Safety Precautions

Electrical Hazard
WARNING: Disconnect the high voltage power cable before working on the unit. Units with electric standby present a potential electrical hazard.

Refrigerant
Although fluorocarbon refrigerants are classified as safe, observe caution when working with refrigerants or around areas where they are being used in the servicing of your unit. DANGER: Fluorocarbon refrigerants may produce toxic gases. In the presence of an open flame or electrical short, these gases are severe respiratory irritants CAPABLE OF CAUSING DEATH. DANGER: Fluorocarbon refrigerants tend to displace air and can cause oxygen depletion which could result in DEATH BY SUFFOCATION. Provide adequate ventilation in enclosed or confined areas. WARNING: Fluorocarbon refrigerants evaporate rapidly, freezing anything they contact if accidentally released into the atmosphere from the liquid state.

Refrigerant Oil
Observe the following precautions when working with or around refrigerant oil: WARNING: Always wear goggles or safety glasses to protect eyes from refrigerant oil contact. WARNING: Protect skin and clothing from prolonged or repeated contact with refrigerant oil. Rubber gloves are recommended. WARNING: Wash thoroughly immediately after handling refrigerant oil to prevent irritation.

10

Safety Precautions

First Aid
First AidRefrigerant
Eyes: For contact with liquid, immediately flush eyes with large amounts of water. Seek prompt medical attention. Skin: Flush areas with large amounts of warm water. Do not apply heat. Wrap burns with dry, sterile, bulky dressing to protect from infection or injury. Seek prompt medical attention. Inhalation: Move victim to fresh air and restore breathing if necessary. Stay with victim until emergency personnel arrive.

First AidRefrigerant Oil

Eyes: Immediately flush eyes with large amounts of water for at least 15 minutes while holding the eyelids open. Get prompt medical attention. Skin: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists. Inhalation: Move victim to fresh air and restore breathing if necessary. Stay with victim until emergency personnel arrive. Ingestion: Do not induce vomiting. Immediately contact local poison control center or physician.

11

Safety Precautions

Safety Decals

AMA145

AMA146

Figure 1: Fan Warning

Figure 3: Belt Warning

AMA147

Figure 2: Caution: High Voltage

12

Unit Description
Introduction
The Thermo King V-500 10/20 and V-500 MAX truck refrigeration systems are two piece units. The unit is designed for medium-sized trucks and vans carrying fresh produce and frozen and deep frozen goods. The condenser is mounted on the front of the truck box or container. The evaporator is mounted on the cargo compartment ceiling. The main compressor is powered by the vehicle engine via a belt. The unit is connected to the compressor by refrigeration hoses. In electric standby operation models, the second compressor is driven by an electric motor. Control circuits operate on 12 VDC supplied by the truck batteries for over-the-road operation. The refrigeration system is protected by a high pressure cutout and a low pressure cutout. The in-cab control includes an on/off switch, manual defrost switch, thermometer, thermostat, thermostat adjustments and indicator lights. The operating mode is selected automatically: When the unit is connected to an electric power source, engine-driven operation is automatically blocked. If the vehicle engine is started up while the power cable is still connected to the electric power source, the unit will continue to operate in electric standby mode. It is not possible to start the engine-driven compressor until the power cable is disconnected from the unit. There are two basic models: Model 10: Cool and defrost on truck engine driven compressor operation. Model 20: Cool and defrost on both truck engine driven compressor operation and electric standby compressor operation.

13

Unit Description

Unit Features

AMA508

M-13 In-Cab Control Box with Digital LED Thermometer (Standard) Digital Thermometer Electronic Thermostat (Standard) Defrost Timer (Standard) Defrost Thermostat Hot Gas Defrost (Standard) Manual Defrost Switch (Standard) Oil Separator (Standard) Liquid Injection Main Compressor TM 16 XD Electric Compressor, Model 20 Evaporator Drain Heaters, Max Units Electric/00Water Heat, Model 20 Water Heat, Model 10

Figure 4: V-500 Condenser Unit

14

Unit Description

Refrigeration System
Refrigeration hoses or lines are used to connect the condenser, the evaporator, the compressor and any other components. Model 20 units have another compressor and an electric motor mounted in the condenser section for electric standby operation. The engine compressor is driven by a belt from the engine. The electric standby compressor is connected in parallel with the engine-driven compressor. The standby compressor is hermetically sealed with its electric motor. Both compressors use the same refrigeration system circuit. Check valves isolate one compressor from the other during operation. Compressor operation is controlled by the thermostat, which energizes the compressor clutch during engine operation or starts the electric motor and energizes the compressor clutch on electric standby operation. The refrigeration system is protected by a high pressure cutout switch and a low pressure cutout switch.

When plugged into standby power, engine operation is automatically locked out. If the truck engine is turned on while the power cord is still plugged into a power receptacle, the unit will remain working in electric mode; the engine driven compressor cannot be started until the power cord is unplugged from the unit as the selection of engine operation or standby operation is automatic.

15

Unit Description

AMA510

AJA1772

Figure 5: Evaporator

Figure 6: In-Cab Control Box

Evaporator
The evaporator is mounted on the ceiling inside the truck box.

In-Cab Control Box

Unit operation is controlled with an in-cab control box, which is mounted in the truck cab. It includes an On-Off switch, manual defrost switch, thermometer, thermostat, thermostat adjustment, and indicator lights. The TC unit has an additional cab control box to operate the second compartment. It is switched on and off from the main cab control box and includes a thermometer, thermostat, thermostat adjustment and indicator lights.

Control Circuits
The control circuits operate on 12 VDC supplied by the truck batteries for engine operation. On standby operation, the power is rectified from an AC transformer.

16

Unit Description

Refrigerant
The V-500-10 and V-500-20 units use R-134a refrigerant. The V-500 MAX-10 and V-500 MAX-20 units use R-404A refrigerant.

Evaporator Drain Tube Heaters

Evaporator heaters are used in MAX units to avoid drain tube blockage because of ice accumulation inside the evaporator. One heater is located inside each drain tube. These resistive wire heaters melt the ice while the unit is in DEFROST mode.

Liquid Injection System

All V-500 models have a liquid injection system to limit discharge temperature of the engine driven compressor. If the discharge gas leaving the compressor reaches a temperature of 230 5 F (110 3 C) the liquid injection switch closes, providing voltage to the liquid injection solenoid. The solenoid opens a valve, allowing liquid refrigerant to flow from the liquid line near the drier inlet to the metering orifice attached to the suction line fitting on the engine driven compressor. As the refrigerant passes through the metering orifice it expands and evaporates, cooling the suction gas entering the compressor. This cooling effect is transferred to the discharge gas leaving the compressor from the adjacent cavity in the compressor head. When the discharge gas is cooled to 200 5 F (93 3 C), the liquid injection switch opens, the liquid injection solenoid closes and refrigerant no longer flows through the liquid injection system.

Electric Standby Operation

During electric standby operation, the thermostat controls the operation of the unit by energizing and de-energizing the power relay, the electric relays, and the heat contactor. The thermostat places the unit in cool by energizing the motor contactor and the electric relays. The thermostat places the unit in null by de-energizing all the relays and contactors. The thermostat places the unit in heat by energizing the heat contactor.

17

Unit Description

When the power relay and the electric relays are energized, they close contacts that energize the fan relay, the motor contactor, and the electric standby compressor clutch. When the heat contactor is energized, it energizes the electric evaporator heaters and the fan relay.

Oil Separator
An oil separator is a standard feature. The oil separator separates compressor oil from the refrigerant and returns the oil to the compressor through the suction line. The oil separator helps provide positive oil return at high compressor speeds and low operating temperatures. This feature enhances compressor lubrication and extends compressor life.

18

Unit Description

Protection Features
High Pressure Cutout Switch: The High Pressure Cutout Switch is a pressure sensitive switch. If the discharge pressure rises above the switchs opening pressure, the switch stops the unit. When the discharge pressure falls below the switchs closing pressure, the switch closes to restart the unit. Condenser Fan Pressure Switch: This switch helps the unit to keep the condenser head pressure higher in cool ambients and on-road. This feature allows better control of the head pressure and the thermostatic expansion valve, and at the same time increases the evaporator pressure. Defrost is carried out quicker in cool ambients and on-road. Low Pressure Cutout Switch: This switch is a pressure sensitive switch located in the suction line. If the pressure falls below acceptable limits, the switch stops unit operation.

19

Unit Description

Fuses
Fuse 1: Protects the evaporator fan motor (EFM1) from possible overload. Fuse 2: Protects the evaporator fan motor (EFM2) from possible overload. Fuse 3: Protects: The engine-driven compressor clutch coil. Condenser solenoid valve coil (heating option). Hot gas solenoid valve coil.

(Fuses 1, 2, 3 5, 6 and 7 are located on the printed circuit board.) Electric Standby Operation Fuses: Fuse 4 protects the in-cab control box when the unit is in electric standby mode. Fuse 4 is located on the printed circuit board (inside the cab control). Fuse 8 is located in the electric box and protects the transformer from possible overload.

Fuse 5: Protects the condenser fan motor (CFM1) from possible overload. Fuse 6: Protects the condenser fan motor (CFM2) from possible overload. Fuse 7: Protects the evaporator fan motor (EFM3) from possible overload. Fuse 4/1: Protects the in-cab control box from possible overload. It is located inside the in-cab control box.

20

Unit Description

10

11

12

1 2

8 3

4 7 6 5 9. 10. 11. Transformer Cover Condenser Fans AC Compressor Electric Box Defrost Valve
AMA511

1. 2. 3. 4.

Filter-Drier Liquid Sight Glass Liquid Injection Valve Liquid Tank

5. 6. 7.

Oil Separator Electric Standby Compressor Condenser Coil

8. Rectifier Heat Sink 12. Figure 7: Unit Components (Model 20)

21

Unit Description

1 2 3 4

AMA512

AMA519

1. 2.

PC Board 3. Heat Option Contactor Motor Contactor 4. Capacitor Box, single phase only Figure 8: Condenser Electric and Capacitor Boxes (Model 20)

22

Unit Description

4 1

2
AMA513

AMA514

1. 2.

Evaporator Fans Expansion Valve

3. Air Temperature Sensor 4. Defrost Switch Figure 9: Standard Evaporator

23

Unit Description

AMA525

1. 2.

Hot Water Heat Defrost Coil Electric Heat Element

3.

High Temperature Limit Switch

4. Air Temperature Sensor Figure 10: Evaporator with Hot Water and Electric Heat Options

24

In-Cab Control Box Description

Unit operation is controlled with an in-cab control box, which is mounted in the truck cab. It includes an on-off key, manual defrost key, setpoint key, thermometer, thermostat, thermostat adjustment, and indicator lights.

AJA1772

Figure 11: M-13 In-Cab Control Box

25

In-Cab Control Box Description

Display
The display consists of a display screen, keys and indicator LEDs. The display screen shows the return (box) air temperature. The screen will display the setpoint temperature if the setpoint key is pressed.

1 1. 2.

AJA1772

Keys Display Screen

Figure 12: Display Screen

26

In-Cab Control Box Description

Display Descriptions
This section describes the display screen, keys and LED indicators. 1. ON-OFF KEY It is used to Start/Stop the unit. The internal return air temperature will be automatically displayed. ON LED Indicator When on, it indicates that the unit has been started by pressing the on-off key. 2 1

2.

AJA1802

Figure 13: On/Off Key & LED

27

In-Cab Control Box Description

5. 4 6. 3 7.

Fahrenheit LED Indicator. When on, it indicates the temperature being displayed is in Degrees Fahrenheit. Setpoint Adjust Dial It is used to adjust the setpoint temperature. Setpoint Key It is used to display the setpoint temperature. 6

AJA1803

Figure 14: Celsius/Fahrenheit LED 3. Celsius LED Indicator When on, it indicates the temperature being displayed is in Degrees Celsius. Minus Sign Indicates the temperature being displayed is below zero.
AJA1804

7 7 Figure 15: Setpoint Key & Dial

4.

28

In-Cab Control Box Description

8 11 9

12
AJA1805 AJA1806

10 Figure 16: Misc. LEDs 8. Power Cord LED When on, it indicates the unit is plugged to the A.C. voltage power supply. AC Overload LED When on, it indicates the unit has been stopped by the AC Overload Relay. Figure 17: Defrost Key & LED 10. Unit Operation LED When on, it indicates the unit is cooling. When the unit is Stopped by the Thermostat, HPCO or LPCO, the Unit Operation LED must be OFF and the ON LED Indicator must remain ON. 11. Defrost LED Indicator When on, it indicates the unit is working on Defrost Mode. 12. Manual Defrost Key It is used to initiate the Defrost Cycle manually.

9.

29

In-Cab Control Box Description

30

Operating Instructions
Thermo King has applied the newest technological advances to develop compact devices that controls unit functioning and displays operating information quickly and accurately. This new Cab Control Box is designed to be used in both new and existing Thermo King units. There is nothing complicated about learning to operate the Cab Control Boxes manufactured by Thermo King, but you will find that a few minutes studying the contents of this manual will be time well spent. This manual is published for informational purposes only and the information furnished herein should not be considered as all-inclusive or meant to cover all contingencies. In-Cab Control Boxes manufactured by Thermo King can work with 12 VDC units. You can also display at your convenience the thermometer & the set point temperature in both Celsius or Fahrenheit degrees. To set the voltage & the Celsius/Fahrenheit selectors, contact your nearest Thermo King dealer.

AJA1772

Figure 18: M-13 In-Cab Control Box

31

Operating Instructions

Cab Control Box Operating Instructions

Displaying Return Air Temperature
During normal operation (unit is ON and cooling), the ON LED Indicator, the Unit Operation LED and Celsius/Fahrenheit LED Indicator should be ON; the return air temperature should be displayed on the screen. (See Figure 21.) 1.
AJA1809

1 Setpoint Key Figure 19: Setpoint Key

Display Setpoint Temperature

1. During normal operation, press the Setpoint Key to display the Setpoint Temperature. (See Figure 19.)

32

Operating Instructions

Enter Setpoint Temperature.

1. 1 2. 3. 2
AJA1807

Press the Setpoint Key. The Setpoint Temperature will be displayed on the screen. (See Figure 20.) At the same time, turn the Setpoint Adjust Dial until the display shows desired temperature.(See Figure 19.) Release the Setpoint Key. The box temperature will be displayed on the screen. (See Figure 19.) CAUTION: The Setpoint Temperature can be changed by turning Setpoint Adjust Dial when Setpoint Key is not pressed.

1. 2.

Setpoint Adjustable Dial Setpoint Key Figure 20: Entering Setpoint

Defrost Mode Operation

Initiate a Manual Defrost: Pressing the Manual Defrost Key will start the defrost cycle if the evaporator coil temperature is below 2.2 C (36 F). The defrost LED will go ON. The unit will return to the cool mode automatically when the defrost cycle is finished. (See Figure 21.)

33

Operating Instructions

Initiate a Automatic Defrost: The defrost timer will initiate a defrost cycle if the evaporator coil temperature is below 2.2 C (36 F). The defrost LED will go ON. The unit will return to the cool mode automatically when the defrost is finished.(See Figure 21.) Stop the Defrost Cycle: Press and release the On-Off Key twice to stop the defrost cycle.

1. 2.

On/Off Key Manual Defrost Key

Figure 21: On/Off Key and Defrost Key

Weekly Pretrip Inspection

The following Weekly Pretrip Inspection should be completed before loading the truck. While the weekly inspection in not a substitute for regularly scheduled maintenance inspections, it is important part of the preventive maintenance program designed to head off operating problems before they happen. 1. 2. LEAKS. Inspect for refrigerant leaks and worn refrigerant lines. Check for proper refrigerant charge level. BELTS. Inspect for cracks, wear and proper belt tension. MOUNTING BOLTS. Inspect bolts for proper tightening. ELECTRICAL. Electrical connections should be securely fastened. Wires and terminals should be free of corrosion, cracks or moisture.

AJA1808

3. 4.

34

Operating Instructions

5.

DEFROST DRAINS. Check the defrost drain hose and fittings to be sure that they are open so condensate can run out during defrosting. Check the bottom end of drain hose to be sure that is not plugged or crushed. STRUCTURAL. Visually check for physical damage. REFRIGERANT CHARGE. Start the unit. Check the sight glass level with the compressor running.

5.

When the unit has finished pre-cooling the truck interior (evaporator temperature dropped below 36 F (2.2 C), initiate a defrost cycle with the manual defrost switch. The defrost cycle should end automatically.

6. 7.

Engine Operation
1. 2. 3. Start the truck engine. Press the on-off switch on the cab control box, the ON/OFF LED must go ON. Dial the thermostat setting above and below the box temperature to check thermostat operation on the cab control box. Set the thermostat at the desired temperature, allow the unit to run for one-half to one hour (longer if possible) before loading the truck. Pre-cooling will remove residual body heat and moisture from the box interior and provide a good test of the refrigeration system

4.

35

Operating Instructions

Electric Standby Operation

1. Connect the external power supply to the power receptacle. Make sure that the power supply voltage is correct for the unit. The power cord led should go ON. Press the on-off switch in the cab control box, the ON LED should go ON. Dial the thermostat setting above and below the box temperature to check thermostat operation on the cab control box.

4.

Set the thermostat at the desired temperature, allow the unit to run for one-half to one hour (longer if possible) before loading the truck. Pre-cooling will remove residual body heat and moisture from the box interior and provide a good test of the refrigeration system When the unit has finished pre-cooling the truck interior (evaporator temperature dropped below 36 F (2.2 C), initiate a defrost cycle with the manual defrost switch. The defrost cycle should end automatically.

2. 3.

5.

NOTE: Even though the truck engine is started the unit will work on Electric Standby if the power cord is plugged in.

Figure 22: Electric Power Receptacle

36

Operating Instructions

Unit Operation
Units cycle between Cool and Null to maintain the box temperature at the thermostat setpoint. The operating modes are: Cool, Null, and Defrost. The thermostat controls the operation of the unit by energizing and de-energizing the Power Relay (PR). When PR is energized it energizes the evaporator fans, the condenser fans, and the compressor clutch (or the compressor motor contactor during electric stand-by operation). The condenser fan is also controlled by the condenser fan pressure switch (CFPS) on R-134a units. This normally open switch monitors the compressor discharge pressure. When the discharge pressure rises to 180 psi (1241 kPa) the switch closes and energizes the condenser fan. When the discharge pressure drops below 130 psi (896 kpa) the switch opens and de-energizes the condenser fan.

Thermostat Operation
Cool
The thermostat energizes the (PR) at box temperatures higher than 5.4 F (3.0 C) above setpoint. The thermostat keeps PR energized while the box temperature is higher than setpoint. The fans and the compressor run and the unit cools.

Null
The thermostat de-energizes PR at box temperatures lower than setpoint. The thermostat keeps PR de-energized while the box temperature is lower than 5.4 F (3.0 C) above the setpoint temperature. When PR is de-energized and the unit does not operate. On TC units PR is de-energized only when the condition is required from both thermostats.

37

Operating Instructions

Temperature Drop

COOL

Temperature Rise

Defrost
The defrost cycle can be initiated any time the evaporator coil temperature is below 36 F (2.2 C). Defrost is initiated automatically by the defrost timer, or manually by pressing the manual defrost switch. The defrost relay energizes the defrost solenoid valve (and the condenser solenoid valve on units equipped with the heat option) to route hot refrigerant gas to the evaporator when PR is energized. The defrost relay also interrupts power to the evaporator and condenser fans during defrost. The defrost cycle will continue until the evaporator coil temperature rises 8.9 C (48 F), causing the defrost termination switch to open ending the defrost cycle. Defrost cycle can be also terminated stopping the unit pressing the ON/OFF Switch twice.

3.0 C (5.4 F) Above Setpoint Setpoint

NULL

Figure 23: Thermostat Algorithm

38

Loading and Enroute Inspections

Thermo King refrigeration units are designed to maintain the required temperature for the product being carried during its time in transit. Because of the units unique design, special care is required during loading to prevent cargo spoilage. 4. Pre-cool the cargo compartment. Adjust the setpoint to the desired cargo temperature and allow the unit to run a minimum of 30 to 60 minutes (longer if possible) before loading. Check to be certain the setpoint temperature is correct for the cargo. Pre-cooling before loading will remove residual heat and moisture from the cargo compartment and prepare it to receive the refrigerated load. Pre-cooling also provides a good test of the refrigeration system. 5. Make sure products are pre-cooled to the proper temperature before loading. Any variance should be noted on the manifest. Supervise product loading to make sure that there is sufficient air space around and through the load so air flow is not restricted.

Pre-Loading Inspection
1. 2. 3. Inspect all door seals, including vent doors, for condition and a tight seal with no air leakage. Inspect the cargo compartment inside and out for damaged or loose skin and insulation. Inspect the inside of the cargo compartment for damaged walls, air ducts, floor channels or T flooring, clogged defrost drain tubes, and clogged or damaged floor channels which could block the air return, creating isolated areas in the load that are warmer than the desired temperature.

6.

001

39

Loading and Enroute Inspections

4 5

1. 2. 3. 4. 5. 6 6. 7. 8.

Unit Inspection Good Outside Air Circulation Gaskets Equally Compressed Clear Defrost Drains Tight Doors Good Air Circulation Around Load Interior and Exterior Walls and Insulation in Good Condition Cargo at Proper Temperature Prior to Loading

7 8

AMA526

Figure 24: Loading Considerations

40

Loading and Enroute Inspections

Inspecting the Load

Never assume that the product has been loaded properly. Watch for and perform the following tasks. It takes only a few minutes and could save you or your employer considerable time and money later on. 1. Make sure the unit is off before opening the cargo compartment doors. During operation, the unit blows out refrigerated air, and draws in outside air. NOTE: The unit can be run with the doors open if the truck is backed into a refrigerated warehouse with tight door seals. 2. Perform a final check of the load temperature. If the load is too hot or too cold, make a final notation on the manifest. CAUTION: Make sure cargo is pre-cooled to the proper temperature before loading. The unit is designed to maintain temperature, not cool an above-temperature load.

3.

While inspecting to see that the cargo is loaded properly, make sure the evaporator inlets and outlets are not blocked. Close or supervise the closing of the cargo compartment doors. Make sure they are securely locked. Check to make sure the unit setpoint is set at the desired temperature as listed on the manifest. If the unit was stopped, restart using the appropriate starting procedure outlined in this manual. Repeat the after-start inspection. Defrost the unit 30 minutes after loading by starting a manual defrost cycle.

4. 5. 6. 7. 8.

41

Loading and Enroute Inspections

Enroute Inspections
NOTE: Enroute inspections are recommended every four hours for the prevention of damage to the cargo. 1. 2. Note the setpoint to make certain no one has altered the setting since picking up the load. Note the return air temperature reading. It should be within the desired temperature range. If the return air temperature reading is not within the desired temperature range, it indicates one of the following: a. The unit has not had sufficient time to pull down the temperature. Refer to log, if possible, for history of load (for example, above temperature load, properly pre-cooled cargo compartment, length of time on road). The unit is in defrost or has just completed defrost.

c.

The evaporator is plugged with frost. Initiate a manual defrost cycle. The defrost cycle will be automatically terminated. Improper air circulation within the cargo compartment. Inspect the cargo compartment (if possible) to determine if the evaporator fans are working and properly circulating the air. Poor air circulation can be due to improper loading of the cargo or shifting of the load. WARNING: The unit may START automatically AT ANY TIME while it is turned ON. Make sure to turn the unit OFF before opening unit doors or inspecting any part of the unit.

d.

b.

NOTE: You can cancel defrost by turning the unit off, then restarting the unit.

42

Loading and Enroute Inspections

e.

The unit may have a low refrigerant charge. If liquid is not showing in the unit receiver tank sight glass, the refrigerant charge may be low. Adding refrigerant or repairing the refrigeration system requires a competent mechanic. Refer such problems to the nearest Thermo King dealer or authorized Service Center, or call the Thermo King Cold Line telephone number shown on the inside back cover of this manual for referral.

CAUTION: Stop the unit if the compartment temperature remains outside the desired temperature range from the setpoint on two consecutive 30 minute inspections. Contact the nearest Thermo King Service Center or your company office immediately. Take all necessary steps to protect and maintain proper load temperature. 3. Initiate a Manual Defrost cycle after each Enroute Inspection.

NOTE: If the temperature in the compartment is not within the desired temperature range, repeat the Enroute Inspection every 30 minutes until the compartment temperature comes within the desired temperature range.

43

Loading and Enroute Inspections

44

Specifications
GENERAL
Main Compressor Electrical Compressor System Oil Capacity Compressor Oil Type Refrigerant Defrost Method: Defrost Timer: Initiation Interval Termination Interval Main: Standby Operation: SELTEC TM-16XD FRASCOLD D211Y 5.1 oz (150 cc) 40.1 oz (1200 cc) Polyol Ester P/N 203-515 8.1 lbs (3.7 kg) R-404A 8.0 lbs (3.6 kg) R-134a Hot gas Adjustable, 1 hour to 10 hours Termination is not timed. Defrost is terminated by Klixon switch.

45

Specifications

ELECTRICAL SYSTEM
Fuses Fuse 1: Evaporator Fan Motor (EF1) Fuse 2: Evaporator Fan Motor (EF2) 15 amps 15 amps

Fuse 3: Engine-driven Compressor Clutch Coil, Condenser Solenoid 15 amps Valve Coil (heating option), Hot Gas Solenoid Valve Coil Fuse 5: Condenser Fan Motor (CFM1) Fuse 6: Condenser Fan Motor (CFM2) Fuse 7: Evaporator Fan Motor (EF3) Fuse 4: Electric Standby Fuse 4/1: Cab Control Box Condenser Fan Motors (2) Voltage 13 Vdc Full Load rpm 3000 Full Load Current 9.2 Amps 15 amps 15 amps 15 amps 3 amps 3 amps

46

Specifications

Evaporator Fan Motors (3) Voltage 13 Vdc Full Load rpm 2700 Full Load Current 6.2 Amps

Coils for Hot Gas Solenoids Voltage 12 Vdc AC Electric Motor Voltage 208/230 208/230 Phase 3 1 Frequency 60 Hz 60 Hz Full Load Current 14.1 Amps 16.0 Amps Check vehicle manufacturer specifications Current 2.3 Amps Resistance 5.2 Ohms

BELT TENSION

47

Specifications

Electric Standby Power Requirements (1 and 3 PH) Supply Circuit Breaker Extension Cord Size NOTE: Electrical wiring must conform to all local and national electrical codes. Electric Heaters Voltage 208/230 Power Rating Watts 2000 Current 14.7 Amps Resistance 16.2 Ohms at 230 V 20 Amps 25 ft - 10 gauge, up to 75 ft - 8 gauge

48

Maintenance Inspection Schedule

A closely followed maintenance program will help to keep your Thermo King unit in top operating condition. The following general schedule is provided to assist in monitoring that maintenance. For more specific detail, see the maintenance manual for your unit and to the PreTrip Inspection chapter in this manual. After first week of operation: Check belt tension. Tighten unit mounting bolts. Check refrigerant level.

49

Maintenance Inspection Schedule

Weekly

Monthly

SemiAnnual

Annual

Inspect/Service These Items

ELECTRICAL
Check defrost initiation and termination. Check thermostat cycle sequence. Check operation of protection shutdown circuits. Check thermostat and thermometer calibration in 0 C (32 F) ice-water bath. Inspect wire harness for damaged wires or connections.

REFRIGERATION
Check refrigerant level. Replace dehydrator.

STRUCTURAL
Visually inspect unit and refrigerant hoses for fluid leaks. Visually inspect unit for damaged, loose or broken parts. Clean defrost drains. Inspect belts for condition and proper tension Clean entire unit including evaporator coil and condenser coil.

50

Maintenance Inspection Schedule

Weekly

Monthly

SemiAnnual

Annual

Inspect/Service These Items Check all unit mounting bolts, brackets, lines, hoses, etc.

51

Maintenance Inspection Schedule

52

Warranty
Terms of the Thermo King Warranty are available on request. Please reference document TK 51350 for the Thermo King Vehicle-Powered Truck Unit Warranty.

53

Warranty

54

Glossary
This glossary is published for informational purposes only and the information being furnished herein should not be considered as all-inclusive or meant to cover all contingencies. NOTE: Additional terms not found in the glossary may be located in the index section of this manual. accumulator: A device located in the suction line to collect liquid refrigerant and meter it safety back to the compressor as gas. ambient air temperature: Temperature of the air surrounding an object. amp: Abbreviation for ampere. The basic measuring unit of electrical current. bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi. Battery Sentry: Part of the CYCLE-SENTRY system. The Battery Sentry module monitors alternator charge rate and will keep the unit running until the battery is adequately charged. box temperature: The temperature within a temperature-controlled compartment. Btu (british thermal unit): The quantity of heat required to raise the temperature of one pound of water by one degree Fahrenheit. 1 Btu = 252 calories. bulkhead: 1) return air bulkhead. A metal or plastic wall placed at the front of the box to prevent loading of product tightly against the Thermo King unit. (Loading too close to the unit restricts air flow and system efficiency.) 2) bulkhead divider. A thick, insulated wall used to separate compartments of a multi-temperature truck or trailer. calorie: The amount of heat required to raise temperature of one gram of water one degree Celsius. 1 calorie = 0.004 Btu. Celsius: The metric unit of temperature measurement. The preferred alternate to the term centigrade. Abbreviated C. centigrade. See Celsius.

001

55

Glossary

CFC: Chlorofluorocarbon. A chlorine-based refrigerant consisting of chlorine, fluorine and carbon. Example: R12. In many countries it is illegal to release this type of refrigerant to the atmosphere because chlorine damages the earths atmosphere. CFC refrigerants are not used in modern Thermo King units. circuit breaker: A thermal device that automatically interrupts an electrical circuit when the current in the circuit exceeds the predetermined amperage rating of the breaker. See amp. coil: A cooling or heating element made of pipe or tube, formed into a helical or serpentine shape, that may be equipped with thin metal fins to aid heat transfer. cold curtains: Flexible vinyl curtains used to reduce air exchange between the refrigerated compartment and the outside during door openings. compound gauge: A gauge calibrated in psig (or kPa) to measure pressure, and in inches of mercury (Kg/cm2) to measure vacuum. compressor: The refrigeration component that compresses refrigerant vapor and creates refrigerant flow.

condenser: An arrangement of tubing in which the vaporized and compressed refrigerant is liquefied as heat is removed. cycles per second: See Hertz. damper door: A door on the evaporator section that closes during defrost to prevent hot air from entering the refrigerated cargo compartment. data logger: An electronic device that monitors and stores unit operating and temperature data for later review. Examples: DMS, DAS, DRS and AccuTrac. DE: Dual Evaporator. A multi-temp host unit with two evaporators capable of refrigerating two separate, longitudinal compartments. defrost: The removal of accumulated ice from an evaporator coil. Periodic defrost is necessary when the evaporator coil is operating below freezing. Defrost is required more frequently when the air passing through the evaporator has a high moisture content. defrost termination switch: A component that terminates defrost operation at a specific temperature.

56

Glossary

defrost timer: A solid state module that initiates defrost at selected intervals. Also establishes a maximum defrost duration if normal circuits malfunction. dehydrator: A device used to remove moisture from refrigerant. Also called a drier. discharge air temperature: The temperature of air leaving the evaporator. drier: See dehydrator. ECT: A ceiling-mounted Thermo King remote evaporator. See EW and TLE. ERC: Extended Remote Unit Control. (Door switches) An option on Thermo King multi-temperature units to improve temperature control when doors are opened during delivery. When a compartment door is opened, the refrigeration unit for that compartment may be forced to NULL, defrost, or some other mode. Opening a compartment door may also affect the operating mode of other compartments. ERC systems are connected in a variety of ways to meet customer needs. ETV (Electronic Throttling Valve) : A device used with a microprocessor to precisely control the refrigeration system.

evaporator: The part of the refrigeration system that absorbs heat during the cooling cycle. EW: A wall-mounted Thermo King remote evaporator. See ECT and TLE. F: See Fahrenheit. Fahrenheit: A unit of temperature measurement used in the United States. Abbreviated F. freeze up: 1) Failure of a refrigeration system to operate normally due to moisture in the refrigerant and the formation of ice at the expansion valve. The expansion valve may be frozen shut or open, causing improper unit operation in either case. 2) The formation of a solid ice mass over the evaporator coil reducing air flow. fuse: An electrical safety device (typically a cartridge) inserted into an electrical circuit. It contains material that will melt or break when the current is increased beyond a specific value. When this occurs, the circuit is opened and electrical current flow is stopped.

57

Glossary

fusible link: An electrical safety device (typically a short piece of wire) inserted into an electrical circuit. The wire melts or breaks when the current is increased beyond a specific value. When this occurs, the circuit is opened and electrical current flow is stopped. HCFC: Hydrochlorofluorocarbon. A chlorine-based refrigerant containing hydrogen, chlorine, fluorine and carbon. Example: R22. Because chlorine damages the earths atmosphere, in many countries, it is illegal to release this type of refrigerant to the atmosphere. HCFC refrigerants are not used in modern Thermo King units. Hertz: A unit of frequency equal to one cycle per second. Abbreviated Hz. HFC: A refrigerant consisting of hydrogen, fluorine and carbon. Examples: R134a and 404A. HFC refrigerants contain no chlorine and are, therefore, considered safe for the environment. high pressure relief valve: A safety valve on the refrigeration system that allows refrigerant to escape from the system if pressure exceeds a predetermined value.

hp (horsepower): A unit of power equivalent to 746 watts or 550 foot-pounds per second. HPCO (High Pressure Cut Out Switch): A pressure-operated switch that opens to stop unit operation when discharge pressure reaches a predetermined maximum. invertible: A multi-temperature truck or trailer unit designed to allow the placement of deep-frozen cargo in any compartment. See Multi-Temp. kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar = 0.145 psi. load: 1) The product being refrigerated and transported. 2) The amount of heat being removed by the refrigeration system. (For example, a compressor is under a heavy heat load when expected to cool a very warm box.) LPCO (Low Pressure Cut Out Switch): A pressure-operated switch that opens to stop unit operation when suction pressure reaches a predetermined minimum. modulation: An optional system that reduces load (product) dehydration and avoids top freeze.

58

Glossary

movable bulkhead: A thick, insulated, portable wall-like device used to compartmentalize a temperature-controlled truck or trailer. See bulkhead. Multi-Temp: A Thermo King truck or trailer unit capable of maintaining different set-points in multiple compartments. no. 1 diesel fuel: A grade of diesel fuel formulated to prevent jelling in low ambient temperatures. no. 2 diesel fuel: A grade of diesel fuel formulated for moderate to warm ambient temperatures. ohm: An electrical unit measuring the amount of resistance (opposition to the current flow) in an electrical circuit. pre-cooling: 1) To cool down an empty box (temperature-controlled area) to the desired load temperature prior to loading. 2) To cool cargo to a desired temperature before loading. pre-heat: The heating of diesel engine glow plugs prior to start-up. Some engines use an intake manifold heater rather than glow plugs. pre-trip inspection: Checking the operation of a refrigeration system before loading.

psi: Pounds per square inch. A unit of pressure. 1 psi = 0.069 bar = 6.89 kPa. psig: Pounds per Square Inch Gauge. Pressure in pounds per square inch as displayed by a gauge calibrated to zero when open to the atmosphere. receiver tank: A refrigerant storage device included in nearly all Thermo King units. refrigerant: The medium of heat transfer in a refrigeration system which absorbs heat by evaporating at a low temperature and releases heat by condensing at a higher temperature. refrigerant oil: A special oil used to lubricate compressors in refrigeration systems. remote evaporator: A separate evaporator unit located in a second or third compartment of a multi-temperature truck or trailer unit. return air bulkhead: A structure (metal or plastic) mounted in the front of a trailer and designed to prevent restriction of return air flow to the Thermo King unit due to improper loading. See bulkhead.

59

Glossary

return air temperature: The temperature of the air returning to the evaporator. See box temperature. rpm: Revolutions per minute. setpoint: The temperature selected on a thermostat or microprocessor controller. This is normally the desired box temperature. short cycling: When a refrigeration unit cycles between the heat and cool modes more often than normal. sight glass: A system component that permits visual inspection of oil or refrigerant level and condition. thermostat: A device that controls unit modes of operation to maintain a selected box temperature. TLE: Thin-line evaporator. A Thermo King remote evaporator designed to be compact (thin) while supplying superior air flow. See ECT and EW. top freeze: When the top portion of perishable cargo is damaged by freezing temperatures discharged from the refrigeration unit. This may occur near the front of the box when product is placed too close to the cold, discharge air flow.

Vac (volts alternating current): An electric current that reverses direction at regularly recurring intervals. Vdc (volts direct current): An electric current that flows in one direction only and is constant in value. volts: The basic measuring unit of electrical potential. watt: The basic measuring unit of electrical power.

60

Index
A After Start Inspection 37 C Cab Control Box Operating Instructions (M-13, M-16, M-17) 32 Compressor 15 Control Circuits 16 D Defrost Mode Operation (M-13, and M-16 only). 33 Display 26 Display Setpoint Temperature 32 Displaying Return Air Temperature 32 E Electric Standby Operation 17 Electrical Hazard 10 ELECTRICAL SYSTEM 46 Emergency Cold Line 65 enroute inspections 39, 42 Enter Setpoint Temperature. 33 Evaporator 16 Evaporator Drain Tube Heaters 17 F First Aid-Refrigerant 11 First Aid-Refrigerant Oil 11 Fuses 20 G GENERAL 45 General Display Information 26 I In-Cab Control Box 16 In-Cab Control Box Description 25 inspecting load 41 Introduction 13 introduction 7

61

Index

K keypad TK logo 27 L Liquid Injection System 17 loading inspections 39 loading procedures pre-loading inspection 39 M Maintenance 49 Maintenance Inspection Schedule 49 O Oil Separator 18 Operating Instructions 31 P pre-loading inspection 39 Protection Features 19 R Refrigerant 10, 17

Refrigerant Oil 11 S Safety Decals 12 Safety Precautions 9 standard display 27 T TK logo key 27 U Unit Description 13 Unit Features 14 Unit Operation 37 W warranty 53 Weekly Pretrip Inspection 34

62

Serial Number Locations

Serial Number Locations

CONDENSER: Nameplate located on the back inside wall of condenser frame. ENGINE DRIVEN COMPRESSOR: Nameplate located on compressor body. The engine driven compressor is located in the truck engine compartment. STANDBY COMPRESSOR: Nameplate located on compressor body. The Standby compressor is located inside the Condenser assembly. 1 2
AMA511

1. 2.

Condenser Serial Number Location Stand By Compressor Serial Number Location

Figure 25: Condenser and Standby Compressor Serial Number Locations

63

Serial Number Locations

64

Emergency Cold Line

The answering service at the factory will assist you in reaching a dealer to get the help you need. The Cold Line is answered 24 hours a day by personnel who will do their best to get you quick service at an authorized Thermo King Dealer.

AKB12

If you cant get your rig rolling, and you have tried the Thermo King North American Service Directory (available from any Thermo King dealer) to reach a dealer without success, then call the Toll Free Emergency Cold Line Number (888) 887-2202.

65

Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape 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 Federal regulations concerning the use of refrigerants and the certification of technicians. For additional information on regulations and technician certification programs, contact your local THERMO KING dealer.

66

001