Trane Technologies THERMO KING V-520 RT Series User manual

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TK 54987-18-IM Mar 2018
Installation Manual
Truck Edition
V-520 RT Series
Models 10, 20, 30 and 50
Single Temperature Systems
March 2018
Revision 9
TK-54987-18-IM

Installation Manual
Truck Edition
V-520 RT Series
Models 10, 20, 30 and 50
Single Temperature Systems
TK 54987-18-IM (Rev. 9, 03/18)
Copyright©2011 Thermo King Corp., Minneapolis, MN, U.S.A.

2
V-520 RT Installation Manual
Release History
Released (09/11)
Rev. 1 (12/11) Added information on Model 20 and 50 units.
Rev. 2 (03/12) Pages 20, 46 and 47: updated the total amount of oil required by model.
Rev. 3 (06/13) Pages 8, 10, 22 and 66: added silicone sealant update, page 47; increased compressor oil quantity.
Rev. 4 (09/13) Page 5: Changed compressor oil from 203-513 to 203-515.
Rev. 5 (08/14) Page 9, 20, 21, 62 and 63: Added compressor ground wire.
Rev. 6 (01/15) Pages 14, 23, 39 and 45: Changed art to show new horizontal accumulator tank, page 47; updated oil chart.
Rev. 7 (11/15) General update to manual including adding SPR and CPR adjustment procedures, system leak check and
evacuation procedures, updated information on battery connections and how to properly secure maxi fuse holder.
Rev. 8 (01/16) Added new in-line fuse installation procedures.
Rev. 9 (03/18) Page 49, updated amount of oil required for each model, pages 68-69: updated the initial refrigerant charge
amount required for each model.

3
Introduction
This manual was written to assist with the installation of a Thermo King V-520 RT Models 10, 20, 30 and 50 units with a ES500 remote evaporator onto
trucks designed and built for refrigerated 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 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 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 consulted.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tips for a Successful Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dimensions and Weights - Models 10 and 30 . . . . . . . . . . . . . . . . . . . . . . . 12
Dimensions and Weights - Models 20 and 50 . . . . . . . . . . . . . . . . . . . . . . . 13
Dimensions and Weights - ES500 Evaporators . . . . . . . . . . . . . . . . . . . . . . 14
Dimensions - ES500 Evaporator Mounting Holes . . . . . . . . . . . . . . . . . . . . 15
Dimensions - Refrigeration Module Mounting Holes. . . . . . . . . . . . . . . . . 16
Dimensions - Power Pack Module Mounting Holes . . . . . . . . . . . . . . . . . . 17
Dimensions - Condenser Module Mounting Holes . . . . . . . . . . . . . . . . . . . 18
Dimensions - HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation - Vehicle Powered Compressor . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation - ES500 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation - Refrigeration Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation - Power Pack Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation - Condenser Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fabricating Refrigeration Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Important - Suction Line Routing and P-Trap Formation . . . . . . . . . . . . . . 36
Installation - Refrigeration Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
System Leak Check and Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation - Electrical Connections to Condenser. . . . . . . . . . . . . . . . . . . 52
Installation - Electrical Connections to Power Pack . . . . . . . . . . . . . . . . . . 54
Installation - Electrical Connections to Evaporator. . . . . . . . . . . . . . . . . . . 56
Installation - Standby Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation - Evaporator Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installation - In-Cab Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Installation - Electrical Connections to Compressor . . . . . . . . . . . . . . . . . 64
Installation - Electrical Connections to Battery . . . . . . . . . . . . . . . . . . . . . 66
System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SPR and CPR Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5
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.
R-404A / R-134a
WARNING: Use ONLY Polyol Ester based refrigeration compressor oil (TK P/N 203-515) in R-404A and R-134a units.
DO NOT use Polyol Ester based oil in standard Thermo King units.
DO NOT mix Polyol Ester and standard synthetic compressor oils.
Keep Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated with moisture
or standard oils, dispose of properly—DO NOT USE!
WARNING: When servicing Thermo King R-404A and R-134a units, use only those service tools certified for and
dedicated to R-404A or R-134a refrigerant and Polyol Ester compressor oils. Residual non-HFC refrigerants or oils will
contaminate R-404A and R-134a systems.
CAUTION
Thermo King condenser units and remote evaporators are shipped with a 35 kPa (5 psi) holding charge of Nitrogen.
This holding charge may be safely vented into the atmosphere.
CAUTION: SEVERE COMPRESSOR DAMAGE will result from operating the unit before completing the installation
which includes: installing the components, releasing the holding charge, connecting refrigeration lines, leak testing,
evacuation, clean-up and charging of the system with the proper amount and type of refrigerant.

6
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
as 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 eye protection such as 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 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.

7
Safety Precautions (continued)
Battery Installation and Cable Routing 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
NOTE: 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.
CAUTION: Always cover battery terminals to prevent them
from making contact with metal components during battery
installation. Battery terminals grounding against metal could
cause the battery to explode.
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
IMPORTANT INSTALLATION INFORMATION
• Read this Installation Manual to understand how all components are to
be located and properly installed.
• The vehicle’s cargo area must be designed and built for refrigeration
applications with insulated walls, ceilings and floors. All cargo doors
must close and seal tightly.
• The vehicle’s exterior roof must be able to adequately support the
combined weight of the rooftop mounted components. Additional
supports (installer supplied) may be required. See “Dimensions and
Weights - Models 10 and 30” on page 12 and “Dimensions and Weights
- Models 20 and 50” on page 13.
Model 10 - Refrigeration and Condenser Modules
Approximate weight 50 kg(110 lbs.)
Model 20 - Refrigeration, Power Pack and Condenser Modules
Approximate weight 86 kg (190 lbs.)
Model 30 - Refrigeration and Condenser Modules
Approximate weight 52 kg (115 lbs.)
Model 50 - Refrigeration, Power Pack and Condenser Modules
Approximate weight 86 kg (190 lbs.)
• The vehicle’s interior ceiling must be able to adequately support the
weight of the ES500 evaporator. Additional internal structural supports
(installer supplied) may be required.
Model 10 ES500 Evaporator - approximate weight 23 kg (51 lbs.)
Model 30 ES500 Evaporator - approximate weight 33 kg (72 lbs.)
• Thermo King recommends securely installing steel support plates with
mounting studs or threaded inserts (installer supplied) to the truck’s
interior roof structure to mount the V-520 RT refrigeration module,
condenser module and the ES500 evaporator prior to insulating and
finishing the cargo area.
• The V-520 RT must be installed with the refrigeration module facing
towards the front of the vehicle.
• Verify tools and special equipment required for the installation are
available and in good operating condition before beginning the
installation.
• Verify all measurements before drilling holes in vehicle.
• Verify there is no interference with OEM electrical wiring, internal
supports, etc. before drilling holes in vehicle.
• Provide protection to vehicle's finish to prevent damage during the
installation process.
• Install all components using the correct hardware for your particular
application and tighten securely.
• All access holes through the cargo area must be sealed with neutral/
alcohol cure silicone sealant to prevent moisture from entering and air
from escaping.
• Always use protective grommets when routing electrical harnesses or
refrigeration hoses through sheet metal floors or walls.
• Always keep electrical harness and refrigeration hoses from rubbing or
chafing against sharp metal objects or rotating components.
• The fabrication and installation (by the installer) of protective covers
for any exposed refrigerant hoses, drain hoses and electrical wiring
inside or outside the cargo area is recommended.
• Verify the air outlet of the ES500 evaporator is facing the correct
direction for proper airflow before installing.
• Allow a minimum distance of 6.00 in. (152 mm) from the cargo area
wall to the rear of the ES500 evaporator for refrigerant hose and drain
hose connections.
• ES500 evaporator drain hoses should be installed and routed correctly
with no kinks or sharp bends to provide for proper drainage.

9
Tips for a Successful Installation (continued)
REFRIGERATION HOSES
• Always keep refrigeration system fittings 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 the correct hose fitting tool (204-1045 or 204-1128) when
assembling refrigerations hoses.
• Always lubricate hose fittings with refrigerant oil when assembling to
refrigeration hoses.
• Always install and lubricate o-rings with refrigerant oil when
connecting refrigeration hose fittings to component connections.
• All refrigeration connections should be tightened securely using two
wrenches.
• Refrigeration hoses should be installed onto components in such a way
as to allow for vibration and movement.THEY SHOULD NEVER BE
STRETCHED TIGHT!
• Refrigeration hoses should be carefully routed from the vehicle’s
engine compartment, up the interior wall of the cargo area.
ELECTRICAL
• Anti-corrosive gel (203-377) or equivalent should always be applied to
all electrical connections.
• All electrical harnesses should be neatly routed and secured with band
wraps or clamps.
• Evaporator heater resistance wires must be installed as far as possible
into the drain hoses. NEVER CUT HEATER RESISTANCE WIRES!
• 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.
• If the vehicle is equipped with a battery disconnect switch, always wire
the unit after the switch. This allows power to the unit to be turned off
by the battery disconnect switch.
• The unit’s power wire (2) must be spliced into the supplied 50 amp fuse
and connected securely to the vehicle’s positive (+) battery connection.
• The unit’s ground harness must be connected securely to the vehicle’s
negative (-) battery connection.
• A separate ground wire must be installed from engine driven
compressor to chassis ground. The location used on vehicle chassis
should be clean and free of paint to make a proper ground path. See
“Compressor Ground Wire” on page 20 for details.
• In-Cab controller must only be mounted inside 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.
ELECTRIC STANDBY MODELS
NOTE: Thermo King recommends a 20 amp fused power source for
electric standby operation.
• Verify receptacle box is wired for correct voltage for your application.
• Standby receptacle box should be installed securely to exterior of
vehicle. It should be easily accessible while not interfering with the
driver’s visibility or operation of the vehicle.
SYSTEM EVACAUTION AND CHARGING
• The Liquid Injection Solenoid Valve, Liquid Line Solenoid Valve, and
the Defrost Solenoid Valve must be in the OPEN position during
evacuation procedures. The valves are normally in the closed position
and must be held open manually using special magnets (204-1074)
designed for this purpose. DO NOT put a magnet onto the Condenser
Blocking Solenoid Valve as this is a normally open valve and a magnet
will close it.
• Thermo King Evacuation Station P/N 204-725 and Evacuation Station
Operation and Field Application Instructions (TK-40612) is required.
• Never evacuate a system without a micron gauge.
• The oil in the evacuation station vacuum pump should be changed after
each use.
• Verify refrigeration system is charged with correct type and amount of
refrigerant for your application.
• Verify refrigeration system has been checked for leaks by using an
electronic leak detector.
• If equipped, verify the SPR and CPR adjustment procedures were
followed and the unit operates at its maximum capacity.

10
Required Tools
1. Protective Eye Wear
2. Drill
3. Drill Bits
4. Tape Measure
5. Hand Saw
6. File
7. Mechanics Tools
8. Torque Wrench
9. Wire Crimper
10. Hose Cutting Tool (204-677)
11. Hose Fitting Tools (204-1045 and 204-1128)
12. Voltmeter
13. Neutral/Alcohol Cure Silicone Sealant (203-436) or equivalent
14. Manifold Gauge Set
15. Evacuation Station
16. Reclaiming Station
17. Electronic Leak Detector
18. Refrigerant and Scale
19. Overhead Crane or Hoist with locking lifting hooks
20. Work Platform (Recommended)
21. Solenoid Valve Magnet (204-1074)
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
Dimensions and Weights - Models 10 and 30
Approximate Weights:
Model 10 and MAX 10 Refrigeration and Condenser Modules = 46 kg (100 lbs.)
Model 30 and MAX 30 Refrigeration and Condenser Modules = 52 kg (115 lbs.)
Dimensions
A. 1137 mm (44.75in.)
B. 1800 mm (70.85 in.)
C. 172 mm (6.76 in.)

13
Dimensions and Weights - Models 20 and 50
Approximate Weights:
Model 20 and MAX 20 Refrigeration, Power Pack and Condenser Modules = 86 kg (190 lbs.)
Model 50 and MAX 50 Refrigeration, Power Pack and Condenser Modules = 86 kg (190 lbs.)
Dimensions
A. 1137 mm (44.75in.)
B. 2159 mm (85.00 in)
C. 229 mm (9.00 in.)

14
Dimensions and Weights - ES500 Evaporators
Dimensions
A. 562 mm (22.0 in.) E. 236 mm (9.29 in.)
B. 1304 mm (51.0 in.) F 202 mm (8.0 in.)
C. 450 mm (17.7 in.) G. 150 mm (6.0 in.)
D. 1190 mm (46.85 in.) H. 192 mm (7.5 in.)
Approximate Weights:
ES500 Model 10 and MAX 10 = 23 kg (51 lbs.)
ES500 Model 30 and MAX 30 = 33 kg (72 lbs.)

15
Dimensions - ES500 Evaporator Mounting Holes

16
Dimensions - Refrigeration Module Mounting Holes
Choose one mounting hole per section
Dimensions
A. 1107.4 mm (43.60 in.)
B. 466.3 mm (18.36 in.)
C. 393.7 mm (14.50 in.)
D. 235.0 mm (9.25 in.)

17
Dimensions - Power Pack Module Mounting Holes
Dimensions
A. 1107.4 mm (43.60 in.)

18
Dimensions - Condenser Module Mounting Holes

19
Dimensions - HMI
A. 140 mm (5.50 in.)
B. 46 mm (1.80 in.)
C. 12 mm (.50 in.)