Ingersoll-Rand THERMO KING NAD Truck Edition V-200 Series User manual

Installation Manual
Providing equipment and services to manage controlled-temperature environments for
food and other temperature-sensitive products, our Climate Control Technologies sector
encompasses both transport and stationary refrigeration solutions. Our product brands include
Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a
manufacturer of refrigeration and food merchandising equipment.
www.thermoking.com www.hussmann.com www.ingersollrand.com
©2008 Ingersoll-Rand Company
Printed in U.S.A. on Recycled Paper
NAD Truck Edition
V-200 and V-300 Series
TK 51856-1-IM (Rev. 7, 02/12)

Installation Manual
NAD Truck Edition
V-200 and V-300 Series
TK 51856-1-IM (Rev. 7, 02/12)
Copyright©2003 Thermo King Corp., Minneapolis, MN, U.S.A.

V-200 and V-300 Installation Manual
Release History
Released 04/03
Rev. 0 05/03
Rev. 1 06/03 Page 38: changed electrical hose to electrical harness.
Rev. 2 10/03 Pages 76-83: replaced text and art, changed heater option information at rear of manual.
Rev. 3 11/03
Rev. 4 01/04
Rev. 5 05/11
Rev. 6 05/04
Rev. 7 02/12 Pages 48-49; added new remote receptacle, removed MTC from manual

3
Introduction
This installation manual was written to help assist with the installation of Thermo King V-200 and V-300 Series refrigeration units with remote evaporators
onto either a truck or a van designed and built for refrigerated applications. Due to its complexity, do not attempt this installation unless you:
• Are an experienced mechanic.
• Can safely lift 34 kg (75 lb).
• Are certified or approved in the repair and maintenance of transport
refrigeration systems.
• Have a basic understanding of electricity and electrical wiring.
• Have the necessary tools and equipment to complete the installation.
• Have a truck body designed and built to meet the requirements of this
installation.
This manual is published for informational purposes only. Thermo King makes no representations or warranties, express or implied, with respect to the
information, recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies.
If further information is required, Thermo King Corporation Service Department should be contacted.
Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the manufacturer’s judgment, to
affect its integrity”.
Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect, special, or consequential
damages whatsoever, arising out of the use of this manual or any information, recommendations or descriptions contained herein.

4
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Tips for a Successful Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Unpacking and Inspecting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Installation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Installation of the Engine Driven Compressor . . . . . . . . . . . . . . . . . . . . . . .16
Installation of the Roof Mounted Condenser Unit . . . . . . . . . . . . . . . . . . . . .18
Installation of the Nose Mounted Condenser Unit . . . . . . . . . . . . . . . . . . . .20
Installation of the Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fabricating Refrigeration Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Installation of Hoses to the Vehicle’s Compressor . . . . . . . . . . . . . . . . . . . .30
Installation of the Jet Cool System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Installation of Hoses to the Condenser Unit . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation of Hoses to the Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
System Leak Check and Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical Connections to the Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation of the Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation of the In-Cab Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation of the Electric Standby Power Supply (OPTION) . . . . . . . . . . . 48
Electrical Connections to the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installing the Heater (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5
Safety Precautions
Caution
Thermo King V-200 and V-300 Condensing units are shipped with a 35-69 kPa (5-10 psi) holding charge of
nitrogen. This holding charge may be safely vented into the atmosphere.
IMPORTANT: Do not release the holding charge until necessary to prevent moisture from entering the
system.
ES Series Remote Evaporators are shipped with a 35-69 kPa (5-10 psi) holding charge of nitrogen. This
holding charge may be safely vented into the atmosphere.
SEVERE COMPRESSOR DAMAGE will result from operating the engine/motor before completing the
system installation which includes: installing the components, releasing the condensing unit holding
charge, releasing the remote unit holding charge, connecting the refrigeration lines, leak testing the
system, evacuation and clean-up, and charging the system.
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.

6
Safety Precautions
The symbol appears next to a point that is particularly important:
CAUTION: Addresses a circumstance that, if encountered, may
cause damage to equipment or minor injury.
DANGER: Addresses a circumstance that, if encountered, will
lead to death or serious injury.
WARNING: Addresses a circumstance that, if encountered, might
lead to death or serious 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: Always wear goggles or safety glasses. Refrigerant
liquid, refrigeration oil, and battery acid can permanently damage
the eyes (see First Aid under Refrigeration Oil).
WARNING: Keep your hands away from fans and belts when the
unit is running. This should also be considered when opening and
closing the compressor service valves.
WARNING: Make sure gauge manifold hoses are in good
condition. Never let them come in contact with a belt, fan motor
pulley, or any hot surface.
WARNING: Make sure all mounting bolts are tight and are of
correct length for their particular application.
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: When using ladders to install or service refrigeration
systems, always observe the ladder manufacturer’s safety labels
and warnings. A work platform is the recommended method for
installations.
WARNING: Exposed coil fins are very sharp and can cause
painful lacerations.

7
Safety Precautions
Battery Cable Routing Refrigerant
First Aid
• FROSTBITE: In the event of frost bite, the objectives of First Aid are
to protect the frozen area from further injury, to warm the affected area
rapidly and to maintain respiration.
• EYES: For contact with liquid, immediately flush eyes with large
amounts of water and get prompt medical attention.
• SKIN: Flush area with large amounts of lukewarm water. Do not apply
heat. Remove contaminated clothing and shoes. Wrap burns with dry,
sterile, bulky dressing to protect from infection/injury. Get medical
attention. Wash contaminated clothing before reuse.
• INHALATION: Move victim to fresh air and use CPR or
mouth-to-mouth ventilation, if necessary. Stay with victim until arrival
of emergency medical personnel.
Refrigeration Oil
First Aid
In case of eye contact, immediately flush with plenty of water for at least
15 minutes. CALL A PHYSICIAN. Wash skin with soap and water.
WARNING: Improperly installed battery cables could result in
fire or explosion! Battery cables must be installed, routed and
secured properly to prevent them from rubbing, chaffing or
making contact with hot, sharp or rotating components.
WARNING: Do not attach fuel lines or any additional wiring
harnesses to the battery cables as this could cause an
electrical fire!
CAUTION: Do not connect other manufacturer’s equipment or
accessories to the Thermo King unit. This could result in
severe damage to equipment and void the warranty!
CAUTION: Set all unit electrical controls to the OFF position
before connecting battery cables to the battery to prevent unit
from starting unexpectedly and causing personal injury.
CAUTION: Always wear protective clothing, gloves and eye
wear when handling and installing batteries. Battery acid can
cause serious burns when exposed to eyes or skin. If battery
acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with
running cold water for at least twenty minutes and get medical
attention immediately.
WARNING: Although fluorocarbon refrigerants are classified as
safe refrigerants, certain precautions must be observed when
handling them or servicing a unit in which they are used. When
released to the atmosphere in the liquid state, fluorocarbon
refrigerants evaporate rapidly, freezing anything they contact.
WARNING: Avoid refrigeration oil contact with the eyes. Avoid
prolonged or repeated contact of refrigeration oil with skin or
clothing. Wash thoroughly after handling refrigeration oil to
prevent irritation.

8
Tips for a Successful Installation
• Read the Installation Manual to understand how and where components
are to be located and installed.
• Verify the vehicle is designed and built for refrigeration applications
including insulated walls, ceilings, floors, with doors that close and seal
tightly.
• Verify the tools and special equipment required for the installation are
available and in good operating condition.
• Verify all measurements before drilling any holes in the vehicle.
• Verify adequate clearance is provided for tilt cab applications before
installing unit.
• Verify there is no interference with any OEM electrical wiring, internal
supports, etc. before drilling any mounting holes.
•VAN APPLICATIONS: Verify the vehicle’s roof and the cargo area
can adequately support the weight of the condenser and evaporator(s).
Add additional supports (installer supplied) if required.
•BOX TRUCK APPLICATIONS: Verify the cargo box front wall and
compartment ceiling can adequately support the weight of the
condenser and evaporator. Add additional supports (installer supplied)
if required.
• Provide protection to the vehicle to prevent damage during the
installation.
• Install all components with correct hardware and tighten securely.
• Seal all mounting holes and access holes with silicone caulk.
• When disassembling components for installation, be sure to reassemble
correctly, use proper hardware and tighten securely.
• Verify the evaporator outlet is facing the correct direction for proper
airflow.
• Verify the rear of the evaporator is installed a minimum distance of
101.1mm (4.00 in.) from the wall to allow for refrigerant hose
connections.
• The refrigeration system fittings of each component should be kept
capped and sealed until the installation of the refrigeration hoses.
• Only cut refrigerant hoses with the correct hose cutting tool (204-677).
NEVER USE A SAW!
• Always use hose fitting tool (204-1045) when assembling
refrigerations hoses.
• Always lubricate hose fittings with refrigerant oil when assembling
refrigeration hoses.
• Always install and lubricate O-rings when connecting refrigeration
hose fittings to component connections.
• Refrigeration hose should be installed onto components in such a way
as to allow for vibration and movement.They should never be stretched
tight.
• All refrigerations connections should be tightened securely using two
wrenches.
•VAN APPLICATIONS: Route electrical and refrigeration hoses from
the vehicle’s compressor up through the floor into the interior of the
van.
•BOX TRUCK APPLICATIONS: Route electrical and refrigeration
hoses from the vehicle’s compressor up the exterior wall of the box
and then route into the box.
• Always use protective sleeving or grommets when routing electrical
harnesses or refrigeration hoses through sheet metal floors or walls.

9
Tips for a Successful Installation
• Always keep electrical harness and refrigeration hoses from rubbing or
chafing against sharp metal objects and near or rotating components.
• Always be sure to reinstall the condenser’s filter drier in the direction
indicated by the arrow.
• Always be sure to install the orifice screen correctly into the expansion
valve of evaporator.
• The use of a electronic leak detector is recommended.
• Superlube or equivalent should be applied to all electrical connections.
• All electrical harnesses should be neatly routed and secured with band
wraps or clamps.
• Evaporator heaters must be installed as far as possible into the drain
hoses. NEVER CUT DRAIN HEATERS.
• Evaporator drain hoses should be installed and routed correctly with no
kinks or sharp bends to provide for proper drainage.
• Flush compressor with oil (203-515).
• The In-Cab controller should be mounted inside the vehicle. It should
be accessible and visible from the drivers position while not interfering
with the driver’s mobility, visibility or access to the vehicle controls
and instruments.
• Electrical power to the In-Cab controller must be connected to a fused
circuit of the vehicle to provide power only when the ignition switch is
in the ON position.
• Verify In-Cab controller is set to the proper voltage (12/24 Vdc) and the
desired temperature scale (C or F).
•ELECTRIC STANDBY MODELS: Be sure the receptacle box is
wired correctly for your application.
• Verify the main power harness is connected properly to the vehicle’s
battery’s positive and negative posts.
• Verify the refrigeration system is charged with the correct type and
amount of refrigerant for your application.
• The condenser fan must be installed and the harness connected before
operating the system or damage to the components will result.
• The remote evaporator fan and cover must be installed and the harness
connected before operating the system or damage to the components
will result.

10
Required Tools
1. Drill
2. Drill Bits (1/8 and 31/64)
3. Hole Saws (3.00 in.)
4. Protective Eye Wear
5. Adhesive Tape
6. Measuring Tape
7. Installation Templates
8. Pencil
9. Sockets and Extensions
10. Open End Wrenches (9/16-13/16-7/8-3/4)
11. Adjustable Wrench (12.00 in.)
12. Silicone Caulk
13. Protective Gloves
14. File
15. Tie Bands
16. Terminal Connectors
17. Electrical Extension Cord
18. Voltmeter
19. Screwdrivers
20. Hose Cutting Tool (204-677)
21. Wire Strippers
22. Wire Cutters
23. Hand Saw
24. Electrical Terminal Crimpers
25. Hose Fitting Tool (204-1045)
26. Manifold Set
27. Evacuation Station
28. Electronic Leak Detector
29. Nitrogen
30. Refrigerant and Scale
31. Table Mounted Vise
32. Overhead Crane or Hoist
33. Refrigerant Oil (203-515)
34. Reclaiming Station
35. Solenoid Valve Magnets (204-1074)
36. Work Platform (Recommended)
37. Torque Wrench
IMPORTANT: Equipment such as scales, gauges, and torque wrenches should be in good working condition and routinely calibrated to assure accurate
readings.

11
Required Tools

12
Unpacking and Inspecting Components
Unpacking the Components
1. Carefully open the packaging and remove the components.
2. Locate the unit documentation.
3. Verify the packaging contains all the accessories indicated on the list
attached with the documentation.
Inspecting the Components
1. Inspect the Condenser and Remote Evaporator for the following:
• Any shipping damage or imperfections.
• Confirm the voltage of all the electrical components is correct
(12/24V)
2. Remove the cover from the Condenser and inspect for the following:
• The condenser is charged with helium gas.
• Defrost is set to 4 hours.
3. Remove the cover from the Remote Evaporator and inspect for the
following:
• The evaporator is charged with helium gas.
• Locate the capsule that contains the expansion valve orifice screen.
IMPORTANT: After unpacking and inspecting all components, please
fill out the Green Tag and return to Thermo King Corporation.

13
Unpacking and Inspecting Components

14
Installation Sequence
Single Compartment Units
The operations indicated in this manual should be carried out by a
mechanic in the exact sequence in which they are presented in the manual.
In order to speed up the installation, two mechanics can work together. In
this case, the installation can be completed in less than eight hours (one
working day). In order to achieve this objective, each mechanic should
have his/her own separate tool kit.
The diagram on the following page shows the way in which the
different tasks should be divided between the two mechanics.
Each mechanic should work on different parts of the vehicle at all times,
and on unrelated tasks, which will avoid interference between them.

15
Installation Sequence

16
Installation of the Engine Driven Compressor
IMPORTANT: DO NOT remove the caps on the Suction and Discharge
fittings on the compressor. These refrigeration hose connections will be
made in a later step.
IMPORTANT: Always confirm installation kit is correct for your vehicle
before preceding.
Flush compressor with oil (203-515).
Install the engine driven compressor onto your vehicle per the instructions
included in your particular compressor installation kit.
CAUTION: Always disconnect the vehicle’s negative (-) battery
cable to prevent damage to equipment or personal injury during
the installation of this product.

17
Installation of the Engine Driven Compressor

18
Installation of the Roof Mounted Condenser Unit
IMPORTANT: Verify the roof of the vehicle can support the weight of the
condenser unit. Additional supports (installer supplied) may be required.
IMPORTANT: Before drilling any mounting holes, verify there is no
interference with any of the vehicle’s OEM electrical wiring, etc.
1. Remove the plastic cover and fan assembly from the condenser unit.
2. Locate and mark the centerline (C/L) of the vehicle’s roof.
3. Position the condenser template (roof mount version) onto the roof
and mark the mounting holes and access holes.
4. Drill 12 mm (.472 in.) mounting holes and a 70 mm (2.75 in.)
refrigerant hose access hole.
5. Apply caulking around all mounting holes.
6. Position the large rubber mounts over each mounting hole and place the
condenser onto the roof.
IMPORTANT: The large rubber mounts must be installed to avoid direct
contact between the condenser and the vehicle’s roof.
7. Install condenser mounting hardware and tighten securely.
8. Reinstall fan assembly only.

19
Installation of the Roof Mounted Condenser Unit