Thermo King B-100-10 User manual

Installation Manual
B-100
Model 10 and 20 with Direct Smart Reefer
TK-54436 -18-IM (Rev. 1,11/09)
Copyright
©
2009 Thermo King Corp., Minneapolis, MN, U.S.A.

2
Release History
Original (7/09) Released
Rev. 1 (11/09) Page 40, changed text from “start-up wire fuse” to “fused ignition circuit”

3
Introduction
This installation manual was written to help assist with the installation of Thermo King refrigeration units powered by vehicle batteries onto either a truck or
a van. The manual comprises sections on condenser, evaporator and other modules that are mounted on the truck or van body, as well as sections on
components and wiring that are to be connected to the vehicle engine from which the unit derives power. 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.

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Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unpacking and Inspecting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the Condenser Unit (roof-mounted) . . . . . . . . . . . . . . . . . . . . . . . 12
Installing the Condenser Unit (front-mounted) . . . . . . . . . . . . . . . . . . . . . . . 16
Installing the ES100 Evaporator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preparing Refrigeration Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Connecting Hoses to the Condenser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connecting Hoses to the ES100 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical Connections in the ES100 Evaporator . . . . . . . . . . . . . . . . . . . . . 28
Drain Circuit in the ES100 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Circuit Seal Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
In Case of Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installing the In-Cab Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Optional Internal DIN Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fitting the Power Supply Units with Electric Standby . . . . . . . . . . . . . . . . 44
Door Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installing the Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installing the Hose Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
In-Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking The Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Charging The Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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Safety Precautions
The symbol appears next to a point that is particularly important.
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.
CAUTION: Addresses a circumstance that, if encountered, may
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.
DANGER: When removing a battery from the Battery Pack,
ALWAYS disconnect the negative battery terminal first. Then
remove the positive terminal. When reconnecting the battery
terminals, connect the positive terminal (+) first, and connect the
negative (-) terminal last.
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: 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.

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Safety Precautions (continued)
Refrigerant
First Aid
• FROST BITE: 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: 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.
WARNING: Control circuits used in the refrigeration unit are low
voltage. This voltage potential is not considered dangerous, but the
large amount of current available can cause severe burns if shorted
to ground.
WARNING: Do not wear jewelry, watches, or rings. These items
can short out electrical circuits and cause severe burns to the wearer.
CAUTION: Use tools with insulated handles that are in good
condition.
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
CAUTION: 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.

7
RECOVERY OF REFRIGERANT
At Thermo King, we recognise 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 national
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.

8
Required Tools
1. Electric drill
2. Set of drill bits
3. Set of glass-shaped cutters
4. Protective goggles
5. Adhesive tape
6. Measuring tape
7. Drilling template
8. Pencil
9. Socket wrenches
10. Fixed wrenches
11. Monkey wrench
12. Silicone
13. Protective gloves
14. File
15. Plastic flanges
16. Riveter
17. Electric connectors
18. Electrical wire
19. Voltmeter
20. Set of screwdrivers
21. Hose cutters
22. Wire strippers
23. Wire cutters
24. Electric and hand saws
25. Electrical terminal press
26. Pincers for hose clips
27. Gauge manifold
28. Vacuum pump
29. Leak detector
30. Nitrogen cylinder
31. Refrigerant cylinders
32. Table-mounted vice
33. Crane or hoist
34. TK refrigerant oil
35. Open Y wrench
36. Torx Tube Wrench

9
Required Tools

10
Operating Method
The operations indicated in this manual should be carried out by a mechanic in the exact sequence in which they are presented in the manual.

11
Unpacking and Inspecting the Unit
Unpacking the Unit
1. Open the packaging.
2. Find the unit documentation.
3. Verify that the packaging contains all the accessories indicated on the
list attached with the documentation.
4. Check that the hose length is correct before starting the installation.
Checking can be carried out by consulting the “Packing List” included
with the unit documentation.
Inspecting the Unit
1. Open the condenser unit cover and ensure the following:
• Neither the cover nor the unit should show any shock damage
or imperfections.
• The condenser battery should be charged with helium gas.
• The voltage of all the electrical components is correct (12/24V).
2. Open the evaporator unit cover and make the following checks:
• Neither the cover nor the unit should show any shock damage
or imperfections.
• The evaporator battery should be charged with helium gas.
• The voltage of all the electrical components is correct (12/24V).

12
Installing the Condenser Unit (roof-mounted)
1. Fit the template according to the instructions given.
2. Mark the position of the drilled holes and openings. Avoid any possible
interference with electrical wires and parts of the vehicle chassis.
3. Drill the holes to hold the condenser unit in place (D 12) and the holes
for routing hoses (D 70).
4. Disassemble the canalizer.
5. Disassemble the electric box support plate on the unit,
by removing the two nuts, 1, securing the plate to the unit chassis.
6. Disassemble the canalizer support bracket plate by removing the two
hold-down bracket screws, 2, from the unit chassis.

13
Installing the Condenser Unit (roof-mounted)
ASA052
T = 10 min.

14
Installing the Condenser Unit (roof-mounted)
1. Fasten two strong straps attached to a crane to the unit. Lift the unit,
making sure that it remains in a horizontal position. If it does not,
change the position of the straps.
2. Place the unit on the roof of the vehicle. Remove the straps and the
crane.
3. Pass the 4 locks crews through the holes in the frame, placing a flat
washer onto each screw. Avoid direct contact between the unit and
the body by using rubber rings.
4. Fit the unit by attaching a nut and a washer onto each screw.
5. Reassemble the electrical box and canalizer support brackets.
6. Pass the hoses through the corresponding hole in the frame.

15
Installing the Condenser Unit (roof-mounted)
T = 12 min.

16
Installing the Condenser Unit (front-mounted)
1. Fit the template according to the instructions given.
2. Mark the position of the drilled holes and openings. Avoid any possible
interference with electrical wires and parts of the vehicle chassis.
3. Drill the holes to hold the condenser unit in place (D 12) and the holes
for routing hoses (D 70).
4. Disassemble the canalizer.
5. Disassemble the electric box support plate on the unit,
by removing the two nuts, 1, securing the plate to the unit chassis.
6. Disassemble the canalizer support bracket plate by removing the two
hold-down bracket screws, 2, from the unit chassis.

17
Installing the Condenser Unit (front-mounted)
T = 10 min.

18
Installing the Condenser Unit (front-mounted)
1. Cut the routing guide Cdown as indicated in the illustration.
2. Fasten the adhesive tape T(supplied by Thermo King) to the rear of the
structure.
3. Fasten two strong straps attached to a crane to the unit. Lift the unit,
making sure that it remains in a horizontal position. If it does not,
change the position of the straps.
4. Pass the 4 locks crews through the holes of the structure and fix them
with a flat washer.
5. Fit the unit by twisting a nut and a Grower washer onto each screw.
Before tightening the screws completely, remove the straps and the
crane.
6. Reassemble the electrical box and canalizer support brackets.
7. Route the hoses through the correct hole in the structure.

19
Installing the Condenser Unit (front-mounted)
C
T = 15 min.

20
Installing the ES100 Evaporator Unit
1. Fit the template according to the instructions given.
2. Mark the position of the drilled holes. Avoid any possible interference
with electrical wires and parts of the vehicle chassis.
3. Drill blind holes to screw the evaporator unit in place. Screw in the
bolts and washers supplied for the ceiling. Do not tighten.
4. Cut the hole to route the moisture drain hose (diameter 22).
5. Install the unit on the ceiling supported by the bolts screwed in
previously.
6. Tighten the bolts.