Trane technologies Thermo king e-200 series User manual

Revision B

November 2020 TTKK 6611669944--1188--IIMM--EENN

Vehicle Powered Truck Edition

E-200 Series

Single and Multi Temperature Sy tem

Installation Manual

Introduction

Thi manual wa written to a i t with the general in tallation of Thermo King®component onto truck de igned and

built for refrigerated application . The TThheerrmmoo KKiinngg IInn ttaallllaattiioonn SSttaannddaarrdd aanndd PPrroocceedduurree GGuuiiddee provide more

detailed information that mu t be followed to afely and properly complete the entire in tallation.

Due to it complexity, you hould not attempt thi in tallation unle you:

• Are an experienced mechanic.

• Can afely lift 34 kilo (75 lb .).

• In the U.S., EPA 608 certified and trained in the repair and maintenance of tran port refrigeration y tem .

• Have a ba ic under tanding of electricity and electrical wiring.

• Have the nece ary tool and equipment to complete the in tallation.

• Have a truck body de igned and built to meet the requirement of thi in tallation.

• Follow all afety precaution outlined in the Thermo King In tallation Standard and Procedure Guide.

Thi manual i publi hed for informational purpo e only. Thermo King make no repre entation warrantie expre

or implied, with re pect to the information recommendation and de cription contained herein. Information provided

hould not be regarded a all-inclu ive or covering all contingencie . If further information i required, Thermo King

Corporation Service Department hould be con ulted.

TThheerrmmoo KKiinngg’’ wwaarrrraannttyy hhaallll nnoott aappppllyy ttoo aannyy eeqquuiippmmeenntt wwhhiicchh hhaa bbeeeenn ““ oo iinn ttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd

oorr aalltteerreedd aa ,, iinn tthhee mmaannuuffaaccttuurreerr’’ jjuuddggmmeenntt,, ttoo aaffffeecctt iitt iinntteeggrriittyy..””

MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy

ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr

aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd

oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee

ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..

Revision History

Revision A (07/19) New manual format.

Revision B (11/20) TK Holdover Battery Installation

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TK 61694-18-IM-EN 3

SSaaffeettyy PPrreeccaauuttiioonn ............................................................................................................................................................ 55

Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

RReeqquuiirreedd TTooooll .................................................................................................................................................................... 77

RReeqquuiirreedd SSuuppppoorrtt MMaatteerriiaall ........................................................................................................................................ 99

AAuuttoo SSttaarrtt HHaarrdd SSttoopp // DDii aabbllee CCoonnnneeccttoorr.. ........ ........ ............ ........ ........ .. .... .......... .......... .......... ........ ............ .... 1100

PPrreeppaarriinngg CCoonnddeenn eerr ffoorr IInn ttaallllaattiioonn.................................................................................................................... 1111

Cover and Fan Hou ing Removal (All Model ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fan Hou ing Modification (No emount In tallation Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CCoonnddeenn eerr IInn ttaallllaattiioonn.................................................................................................................................................. 1133

EEvvaappoorraattoorr IInn ttaallllaattiioonn .. ........ .......... .......... .......... .......... ........ ............ ........ ........ ............ ........ .......... ............ ........ ........ 1144

HHoo ee CCoonnnneeccttiioonn .. ...... .......... ........ .. .... .......... .......... .......... ........ ............ ........ .......... .......... .......... ........ ............ ........ ........ 1155

IInn ttaalllliinngg tthhee FFiilltteerr DDrriieerr aanndd SSiigghhtt GGllaa .......................................................................................................... 2211

WWiirriinngg CCoonnnneeccttiioonn MMooddeell 2200 && 5500.. .......... ........ .......... .......... ........ ............ ........ .......... ............ ........ ........ ............ .. 2222

IInn ttaalllliinngg tthhee IInn--CCaabb CCoonnttrroolllleerr.... .......... .......... .......... ........ ............ ........ ........ .. .... .......... .......... .......... ........ ............ .. 2244

OOppttiioonnaall DDIINN AAddaappttoorr ((bbyy oorrddeerr oonnllyy)) .................................................................................................................. 2277

TTKK LLiitthhiiuumm IIoonn HHoollddOOvveerr BBaatttteerryy IInn ttaallllaattiioonn.. ........ ............ ........ ........ ............ ........ .. .... .......... ........ ............ .... 2288

TK Lithium Ion Batterie (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1 Battery Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 Battery Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

BMS In tallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

TK Lithium Ion Battery Option Configuration and Te ting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

HoldOver Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

HoldOver Te t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Charging Te t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

CCoonnnneeccttiinngg ttoo TThhiirrdd PPaarrttyy HHoollddoovveerr BBaatttteerryy OOppttiioonn .................................................................................... 4422

Hold-over Option In tallation Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Controller Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

In tallation Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

........................................................................................... 44

SSttaarrtt//SSttoopp FFuunnccttiioonnaalliittyy .. ...... .......... .......... .......... .......... ........ ............ ........ ........ .. .... .......... .......... .......... ........ ............ .. 4455

Concept....................................................................................... 45

Part Required before Starting In tallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Table of Contents

4TK 61694-18-IM-EN

In tallation Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

IInnccrreeaa eedd IIddllee SSppeeeedd SSeettuupp.. ........ ........ ............ ........ .......... .......... .......... ........ ............ ........ .......... .......... .......... .......... 4499

Concept....................................................................................... 49

Part Required before Starting In tallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

In tallation Guideline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

VVeehhiiccllee BBaatttteerryy CCoonnnneeccttiioonn ........ .......... .......... .......... ........ ............ ........ .......... .......... .......... .......... .......... ........ ............ 5533

SSttaannddbbyy RReecceeppttaaccllee BBooxx IInn ttaallllaattiioonn ((MMooddeell 2200 aanndd 5500 OOnnllyy)).............................................................. 5544

EEvvaappoorraattoorr DDrraaiinn HHoo ee IInn ttaallllaattiioonn.. .......... ........ .......... .......... ........ ............ ........ .......... ............ ........ ........ ............ .. 5555

ES-100N/ES150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

CCoommpplleettiinngg tthhee IInn ttaallllaattiioonn.......... ........ ............ .......... ........ ............ ........ ........ ............ ........ .......... .......... .......... .......... 5577

SSuuccttiioonn PPrree uurree RReegguullaattoorr ((SSPPRR)) AAddjjuu ttmmeenntt PPrroocceedduurree -- MMAAXX ...... ............ ........ .......... .......... ...... 5588

DDii cchhaarrggee PPrree uurree RReegguullaattoorr ((DDPPRR)) AAddjjuu ttmmeenntt PPrroocceedduurree -- MMAAXX................................................ 5599

CCoommpprree oorr OOiill AAmmoouunntt aanndd TTyyppee .. .......... .......... ........ ............ ........ ........ ............ ........ .. .... .......... ........ ............ .... 6600

RReeccoommmmeennddeedd RReeffrriiggeerraanntt CChhaarrggee bbyy MMooddeell.................................................................................................. 6611

CCoonnddeenn eerr aanndd EEvvaappoorraattoorr DDiimmeenn iioonn ............................................................................................................ 6622

TTaabbllee ooff CCoonntteenntt

TK 61694-18-IM-EN 5

Safety Precautions

Danger, Warning, Caution, and Notice

Thermo King®recommend that all ervice be performed by a Thermo King dealer and to be aware of everal general

afety practice .

Safety advi orie appear throughout thi manual a required (refer to example below). Your per onal afety and the

proper operation of thi unit depend upon the trict ob ervance of the e precaution .

DDAANNGGEERR

EExxaammppllee!!

IInnddiiccaattee aann iimmmmiinneennttllyy hhaazzaarrddoouu iittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, wwiillll rree uulltt iinn ddeeaatthh oorr eerriioouu iinnjjuurryy..

WWAARRNNIINNGG

EExxaammppllee!!

IInnddiiccaattee aa ppootteennttiiaallllyy hhaazzaarrddoouu iittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, ccoouulldd rree uulltt iinn ddeeaatthh oorr eerriioouu iinnjjuurryy..

CCAAUUTTIIOONN

EExxaammppllee!!

IInnddiiccaattee aa ppootteennttiiaallllyy hhaazzaarrddoouu iittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, ccoouulldd rree uulltt iinn mmiinnoorr oorr mmooddeerraattee iinnjjuurryy aanndd

uunn aaffee pprraaccttiiccee ..

NN TTIICCEE

EExxaammppllee!!

IInnddiiccaattee aa iittuuaattiioonn tthhaatt ccoouulldd rree uulltt iinn eeqquuiippmmeenntt oorr pprrooppeerrttyy--ddaammaaggee oonnllyy aacccciiddeenntt ..

Safety Precautions

IImmppoorrttaanntt:: Additional Safety Precautions must be followed when installing this unit. See “Section 2 - Safety

Precautions” in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK

56430).

CCAAUUTTIIOONN

RRii kk ooff IInnjjuurryy!!

TThheerrmmoo KKiinngg ccoonnddeenn eerr uunniitt aanndd rreemmoottee eevvaappoorraattoorr aarree hhiippppeedd wwiitthh aa 3355 kkPPaa ((55 pp ii)) hhoollddiinngg cchhaarrggee ooff

HHeelliiuumm.. BBee ccaarreeffuull wwhheenn rreemmoovviinngg ccaapp.. TThhii hhoollddiinngg cchhaarrggee mmaayy bbee aaffeellyy vveenntteedd iinnttoo tthhee aattmmoo pphheerree..

Recover Refrigerant

At Thermo King®, we recognize the need to pre erve the environment and limit the potential harm to the ozone layer

that can re ult from allowing refrigerant to e cape into the atmo phere.

We trictly adhere to a policy that promote the recovery and limit the lo of refrigerant into the atmo phere.

When working on tran port temperature control y tem , a recovery proce that prevent or minimize refrigerant

lo to the atmo phere i required by law. In addition, ervice per onnel mu t be aware of the appropriate European

Union, National, Federal, State, and/or Local regulation governing the u e of refrigerant and certification of

technician . For additional information on regulation and technician program , contact your local THERMO KING

dealer.

SSeerrvviiccee TTooooll - U e the proper ervice tool . Gauge manifold et hould include appropriate hutoff valve or

di connect near the end of each ervice line.

RReeccoovveerryy EEqquuiippmmeenntt - Recovery equipment mu t be u ed. Proper recovering, toring and recycling of refrigerant i

an important part of all ervice work.

6TK 61694-18-IM-EN

SSeerrvviiccee PPrroocceedduurree - Recommended procedure mu t be u ed to minimize refrigerant lo .

CCoommppoonneenntt mmaayy bbee ii oollaatteedd by clo ing ervice valve and performing y tem pump-down .

CCoommppoonneenntt uunnaabbllee ttoo bbee ii oollaatteedd for ervice mu t be repaired only after refrigerant i properly recovered.

SSaaffeettyy PPrreeccaauuttiioonn

TK 61694-18-IM-EN 7

Required Tools

NNoottee:: Equipment such as scales, gauges, refrigerant leak detectors, and torque wrenches should be in good working

condition and routinely calibrated to assure accurate readings.

Figure 1.

BED760

1. Electric drill 13. Protective gloves 25. Electrical terminal press

2. Set of drill bits 14. File 26. Pincers for hose clips

3. Set of glass-shaped cutters 15. Plastic flanges 27. Gauge manifold

4. Protective goggles 16. Riveter 28. Vacuum pump

8TK 61694-18-IM-EN

5. Adhesive tape 17. Electric connectors 29. Leak detector

6. Measuring tape 18. Electrical wire 30. Nitrogen cylinder

7 Drilling template 19. Voltmeter 31. Refrigerant cylinders

8. Pencil 20. Set of screwdrivers 32. Table-mounted vice

9. Socket wrenches 21. Hose cutters 33. Crane or hoist

10. Fixed wrenches 22. Wire strippers 34. TK refrigerant oil

11. Monkey wrench 23. Wire cutters 35. Open Y wrench

12. Silicone 24. Electric and hand saws 36. Torx Tube Wrench

37. Torque Wrench

RReeqquuiirreedd TTooooll

TK 61694-18-IM-EN 9

Required Support Materials

Plea e have the following upport material to hand prior to tarting your in tallation - a they are li ted a reference

throughout thi manual:

1. Vehicle Powered Truck In tallation Standard and Procedure Guide EMEA - located in Infocentral: Technical

Publication

2. Commercial Brochure for your unit - include weight pecification and applicable unit option : Commercial

Brochure

3. FFoorr MMuullttii--TTeemmppeerraattuurree UUnniitt oonnllyy -Multi-Temperature Configuration Guide

10 TK 61694-18-IM-EN

Auto Start Hard Stop / Disable Connector

DDAANNGGEERR

HHaazzaarrddoouu VVoollttaaggee!!

TTaakkee ccaarree tthhaatt tthhii ccoonnnneeccttoorr ddooee nnoott ddii ccoonnnneecctt tthhee AACC vvoollttaaggee iinnppuutt.. IIff eerrvviiccee ooff tthhee eelleeccttrriiccaall bbooxx ii