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Trane Technologies THERMO KING V-520 RT Series Installation Manual

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

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Summary of Contents for Trane Technologies THERMO KING V-520 RT Series

  • Page 1 Installation Manual Truck Edition V-520 RT Series Models 10, 20, 30 and 50 Single Temperature Systems Revision 9 TK-54987-18-IM March 2018...
  • Page 2 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.
  • Page 3 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.
  • Page 4 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: •...

  • Page 5: Table Of Contents

    Table of Contents Safety Precautions ..........6 Fabricating Refrigeration Hoses .
  • Page 6 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.

  • Page 7: Safety Precautions

    Safety Precautions 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.
  • Page 8 Safety Precautions (continued) Battery Installation and Cable Routing Refrigerant WARNING: Improperly installed battery cables could result in WARNING: Although fluorocarbon refrigerants are classified fire or explosion! Battery cables must be installed, routed and as safe refrigerants, certain precautions must be observed secured properly to prevent them from rubbing, chaffing or when handling them or servicing a unit in which they are making contact with hot, sharp or rotating components.

  • Page 9: Tips For A Successful Installation

    Tips for a Successful Installation IMPORTANT INSTALLATION INFORMATION • The V-520 RT must be installed with the refrigeration module facing towards the front of the vehicle. • Read this Installation Manual to understand how all components are to be located and properly installed. •...
  • Page 10 Tips for a Successful Installation (continued) REFRIGERATION HOSES • A separate ground wire must be installed from engine driven compressor to chassis ground. The location used on vehicle chassis • Always keep refrigeration system fittings capped and sealed until the should be clean and free of paint to make a proper ground path.

  • Page 11: Required Tools

    Required Tools 1. Protective Eye Wear 12. Voltmeter 2. Drill 13. Neutral/Alcohol Cure Silicone Sealant (203-436) or equivalent 3. Drill Bits 14. Manifold Gauge Set 4. Tape Measure 15. Evacuation Station 5. Hand Saw 16. Reclaiming Station 6. File 17. Electronic Leak Detector 7.
  • Page 12 Required Tools...

  • Page 13: Dimensions And Weights - Models 10 And 30

    Dimensions and Weights - Models 10 and 30 Approximate Weights: Dimensions Model 10 and MAX 10 Refrigeration and Condenser Modules = 46 kg (100 lbs.) 1137 mm (44.75in.) Model 30 and MAX 30 Refrigeration and Condenser Modules = 52 kg (115 lbs.) 1800 mm (70.85 in.) 172 mm (6.76 in.)

  • Page 14: Dimensions And Weights - Models 20 And 50

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

  • Page 15: Dimensions And Weights - Es500 Evaporators

    Dimensions and Weights - ES500 Evaporators Dimensions 562 mm (22.0 in.) 236 mm (9.29 in.) Approximate Weights: 1304 mm (51.0 in.) 202 mm (8.0 in.) ES500 Model 10 and MAX 10 = 23 kg (51 lbs.) 450 mm (17.7 in.) 150 mm (6.0 in.) ES500 Model 30 and MAX 30 = 33 kg (72 lbs.) 1190 mm (46.85 in.)

  • Page 16: Dimensions - Es500 Evaporator Mounting Holes

    Dimensions - ES500 Evaporator Mounting Holes...

  • Page 17: Dimensions - Refrigeration Module Mounting Holes

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

  • Page 18: Dimensions - Power Pack Module Mounting Holes

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

  • Page 19: Dimensions - Condenser Module Mounting Holes

    Dimensions - Condenser Module Mounting Holes...

  • Page 20: Dimensions - Hmi

    Dimensions - HMI 140 mm (5.50 in.) 46 mm (1.80 in.) 12 mm (.50 in.)

  • Page 21: Installation - Vehicle Powered Compressor

    Installation - Vehicle Powered Compressor Installation Compressor Ground Wire NOTE: Always confirm compressor installation kit is correct for your Install the chassis ground wire to the compressor frame using the supplied vehicle before preceding with the installation. hardware. Ensure the mounting location on the chassis is free of any paint and use anti-corrosion gel (203-377) or equivalent on ground wire Add only 4 oz.
  • Page 22 Installation - Vehicle Powered Compressor Compressor Ground Wire IMPORTANT: Failure to install the compressor ground wire to the chassis may result in intermittent clutch operation and premature clutch failure!

  • Page 23: Installation - Es500 Evaporator

    Installation - ES500 Evaporator Important Installation Recommendations Alternative Installation Method (without pre-installed support plates) IMPORTANT: The interior ceiling of the cargo area must be able to adequately support the weight of the ES500 evaporator. See “Dimensions 1. Remove the plastic cover from the evaporator. and Weights - ES500 Evaporators”...
  • Page 24 Installation - ES500 Evaporator Alternative Installation Method Preferred Installation Method...

  • Page 25: Installation - Refrigeration Module

    Installation - Refrigeration Module Important Installation Recommendations Alternative Installation Method (without pre-installed support plates and pre-cut access hole) IMPORTANT: The roof of the vehicle must be able to adequately support 1. Remove plastic cover from refrigeration module and trim foam gasket the combined weight of the Refrigeration and Condenser Modules for away from the two drain holes located in the corners.
  • Page 26 Installation - Refrigeration Module Alternative Installation Method Preferred Installation Method...

  • Page 27: Installation - Power Pack Module

    Installation - Power Pack Module Important Installation Recommendations Alternative Installation Method (without pre-installed support plates and pre-cut access hole) IMPORTANT: The roof of the vehicle must be able to adequately support NOTE: It is recommended the copper tubing be installed onto the the combined weight of the Refrigeration, Power Pack and Condenser standby compressor prior to installing the Power Pack Module onto the Modules for Model 20 and 50 units.
  • Page 28 Installation - Power Pack Module Alternative Installation Method Preferred Installation Method...

  • Page 29: Installation - Condenser Module

    Installation - Condenser Module IMPORTANT: The roof of the vehicle must be able to adequately support 5. Secure refrigeration module to the roof using the supplied 1/4” lag the combined weight of the Refrigeration and Condenser Modules for bolts and washers and tighten to 36 in-lbs. DO NOT OVERTIGHTEN Model 10 and 30 units or the Refrigeration, Power Pack and Condenser BOLTS!.
  • Page 30 Installation - Condenser Module Alternative Installation Method Preferred Installation Method Model 30 and 50 Only Condenser attaches to Power Pack Module...

  • Page 31: Fabricating Refrigeration Hoses

    Fabricating Refrigeration Hoses TK 2000 Assembly System Assembly Materials Checklist • Hose Fitting Tools (204-1045 and 204-1128) The TK 2000 System is designed for assembly with Multi-Refrigeration hose only. • Hose Cutting Tools (204-677) The benefits are virtually endless: • TK 2000 Multi-Refrigerant Hose •...
  • Page 32 Fabricating Refrigeration Hoses Cut the Hose Slip on Two Clamps 1. Cut the hose to proper length with an appropriate cutting tool. 2. Install two proper- size clips onto the cut end of the hose. Orientation of Hand-held hose cutter (204-677) has been specially designed for the clips does not affect the performance of the connection.
  • Page 33 Fabricating Refrigeration Hoses Oil the Nipple 4. Insert the nipple into the hose. To ensure that the nipple is fully inserted, check the gap between the cut end of the hose and the 3. Lubricate the nipple with a generous amount of the refrigeration or A/C shoulder on the nipple.
  • Page 34 Fabricating Refrigeration Hoses Snap on the Cage Slide the Clips 5. Snap the cage into the groove on the nipple. The arms should extend 6. Slide the clips over the cage arms and into the channels on each arm. over the hose length. When the cage has been carefully installed in the cage grove, the cage will be able to rotate in the grove.
  • Page 35 Fabricating Refrigeration Hoses Correct Nose of the pliers should be firmly seated under the assembly bump and lock latch. If the pliers are not kept square during closing the clip, the clasp may have Incorrect an offset. Use the pliers to correct the clasp alignment.
  • Page 36 Fabricating Refrigeration Hoses Minimum Bend Radii CAUTION: TK 2000 Speedy Clip System components should not be reused. Failure to follow these instructions and/or the use of All hoses must be routed as to maintain the TK 2000 Speedy Clip System hose with fittings supplied by other minimum bend radii given in the table below.

  • Page 37: Important - Suction Line Routing And P-Trap Formation

    Important - Suction Line Routing and P-Trap Formation Best Practices That Must Be Followed (Refer to the illustration on following page) 1. All hose bends must maintain at least minimum bend radii with no kinks. See “Minimum Bend Radii” on page 35. 2.
  • Page 38 Important - Suction Line Routing and P-Trap Formation ACCEPTABLE From Unit...

  • Page 39: Installation - Refrigeration Hoses

    Installation - Refrigeration Hoses Model 10 and MAX 10 - Single Temperature Systems IMPORTANT: All hose bends must maintain at least minimum bend radii with no kinks. See “Minimum Bend Radii” on page 35. Condenser Module Connections 5. Suction Line 1.
  • Page 40 Installation - Refrigeration Hoses Model 10 and MAX 10 - Single Temperature Systems Manifold Fitting C Connect to compressor only Manifold Fitting B Not used Manifold Fitting A Connect to evaporator only...
  • Page 41 Installation - Refrigeration Hoses Model MAX 30 - Single Temperature Systems IMPORTANT: All hose bends must maintain at least minimum bend radii with no kinks. See “Minimum Bend Radii” on page 35. Condenser Module Connections 5. Suction Line • Install #16 female 90° ORS fitting onto a #16 hose. 1.
  • Page 42 Installation - Refrigeration Hoses Model MAX 30 - Single Temperature Systems Manifold Fitting C Connect to compressor only Manifold Fitting B Not used Manifold Fitting A Connect to evaporator only...
  • Page 43 Installation - Refrigeration Hoses Model 20, 20 MAX and 50 MAX - Single Temperature Systems Standby Module Compressor Connections NOTE: The compressor contains oil. Tip the compressor forward to prevent oil from spilling and place rags under the fittings before removing the protective caps to catch any oil.
  • Page 44 Installation - Refrigeration Hoses Model 20, 20 MAX and 50 MAX - Single Temperature Systems...
  • Page 45 Installation - Refrigeration Hoses Model 20 and 20 MAX - Single Temperature Systems IMPORTANT: All hose bends must maintain at least minimum bend radii with no kinks. See “Minimum Bend Radii” on page 35. Condenser Module Connections • Route hose through rear access hole of evaporator, install O-ring and attach ORS fitting onto defrost line fitting and tighten securely.
  • Page 46 Installation - Refrigeration Hoses Model 20 and 20 MAX - Single Temperature Systems Manifold Fitting C Connect to compressor only Manifold Fitting A Connect to evaporator only...
  • Page 47 Installation - Refrigeration Hoses Model 50 MAX - Single Temperature Systems IMPORTANT: All hose bends must maintain at least minimum bend radii with no kinks. See “Minimum Bend Radii” on page 35. Condenser Module Connections • Route hose through rear access hole of evaporator, install O-ring and attach ORS fitting onto defrost line fitting and tighten securely.
  • Page 48 Installation - Refrigeration Hoses Model 50 MAX - Single Temperature Systems Manifold Fitting C Connect to compressor only Manifold Fitting A Connect to evaporator only...
  • Page 49 Installation - Refrigeration Hoses Vehicle Powered Compressor Hose Installation The refrigeration hoses must be routed from the cargo box, along the vehicle’s chassis to the engine compartment and compressor while maintaining the minimum bend radii. See “Minimum Bend Radii” on page 35.
  • Page 50 Installation - Refrigeration Hoses Oil Capacity for Units Utilizing Swash Plate Roadside Compressors Oil Supplied in the Unit Oil Added at Installation Add to Add to Total Oil Total Roadside System Standby Roadside Suction added at System Model Compressor Compressor Compressor Line Installation...

  • Page 51: System Leak Check And Evacuation

    System Leak Check and Evacuation Solenoid Valve Positions IMPORTANT: Do not install a valve magnet on the Condenser Block Off Solenoid (if present). The condenser block off Solenoid is a normally IMPORTANT: The Liquid Injection Solenoid Valve, Liquid Solenoid open solenoid - installing a valve magnet will close the solenoid. Valves and the Defrost Solenoid Valve must be in the OPEN position 3.
  • Page 52 System Leak Check and Evacuation...

  • Page 53: Installation - Electrical Connections To Condenser

    Installation - Electrical Connections to Condenser Condenser Fan Connections Models 10 and 30 Models 20 and 50 (not shown) 1. From the Refrigeration Module to the Condenser Module - connect 1. From the Refrigeration Module to the Power Pack Module - connect the Condenser Fan Motor connectors (CF1-01, CFI) and (CF2, CFK) the Condenser Fan Motor connectors (CF1-01, CFI) and (CF2, CFK) to the mating connectors.
  • Page 54 Installation - Electrical Connections to Condenser Condenser Fan Connections...

  • Page 55: Installation - Electrical Connections To Power Pack

    Installation - Electrical Connections to Power Pack Model 20, 20 MAX, 50 and 50 MAX - Single Temperature Systems Procedures 1. Route the harness from the Refrigeration Module to Power Pack: • Connect the 12-pin connector into the mating connector on the Power Pack Module.
  • Page 56 Installation - Electrical Connections to Power Pack...

  • Page 57: Installation - Electrical Connections To Evaporator

    Installation - Electrical Connections to Evaporator Evaporator Connections Procedures MAX UNITS ONLY 7. See “Installation - Evaporator Drain Hoses” on page 60 regarding the Route the remainder of the condenser harness from the refrigeration drain hoses and the correct placement of the drain heater wires module down through the access hole and into the cargo area.
  • Page 58 Installation - Electrical Connections to Evaporator Evaporator Connections...

  • Page 59: Installation - Standby Power Receptacle

    Installation - Standby Power Receptacle Procedures NOTE: Thermo King recommends a 20 amp fused power source for electric standby operation. • Verify the receptacle box is wired for the correct voltage for your application. • The standby receptacle box should be installed securely to the exterior of the vehicle.
  • Page 60 Installation - Standby Power Receptacle...

  • Page 61: Installation - Evaporator Drain Hoses

    Installation - Evaporator Drain Hoses Standard Systems Max Systems 1. Cut the drain hose into two sections of suitable length and attach each 1. Cut the drain hose into two sections of suitable length and attach onto drain hose onto the evaporator drain tubes. the drain tubes.
  • Page 62 Installation - Drain Hoses Standard Systems Max Systems Defrost Heater Wires Defrost Heater Wires...

  • Page 63: Installation - In-Cab Controller

    Installation - In-Cab Controller Procedures 1. From the cargo area route the multi-conductor Controller Harness with wire colors Blue (CHO) Black (TXD) White (RXD), Brown (9V), and Drain Wire (SHIELD) and the Vehicle Ignition Switch Harness wires (ACC, BAT) to the interior of the cab. •...
  • Page 64 Installation - In-Cab Controller...

  • Page 65: Installation - Electrical Connections To Compressor

    Installation - Electrical Connections to Compressor Compressor Harness Compressor Ground Wire 1. Route compressor harness with connectors (LIS, CLU) and (CLU1) to 4. Install chassis ground wire from the engine driven compressor to engine compartment. chassis ground using supplied hardware. Use anti-corrosion gel 2.
  • Page 66 Installation - Electrical Connections to Compressor Ensure there is no paint between ground terminal and ground mounting point. Compressor Ground Wire IMPORTANT: Failure to install the compressor ground wire to the chassis may result in intermittent clutch operation and premature clutch failure!

  • Page 67: Installation - Electrical Connections To Battery

    Installation - Electrical Connections to Battery In-Line Fuse Installation Ground Wire IMPORTANT: The in-line fuse must be located in an accessible location 11. Securely crimp and solder the correct size ring terminal onto the CH as close to the battery as possible while keeping it from directly touching wire.
  • Page 68 Installation - Electrical Connections to Battery Positive (+) See Important note below. Negative (-) Butt Splice Heat Shrink Tubing See Important note below. Unit Power Wire IMPORTANT: The ring terminals used must be sized to match the battery power stud or lug bolt. Oversized ring terminals can contribute to high resistance resulting in the fuse overheating and failure.

  • Page 69: System Charging

    System Charging Procedures 6. Close the refrigerant bottle valve and the high side valve of the gauge manifold. NOTE: Ensure proper leak check and evacuation procedure was 7. Start the vehicle’s engine, run at approximately 1000 rpm and turn the performed.
  • Page 70 System Charging Initial Refrigerant Charge* Model V-520 RT 10 1.85 V-520 RT 10 MAX 1.68 V-520 RT 20 1.90 V-520 RT 20 MAX 1.73 V-520 RT 30 MAX 1.73 V-520 RT 50 MAX 1.78 * Final refrigerant charge will vary based on each unique installation.

  • Page 71: Spr And Cpr Adjustment Procedures

    SPR and CPR Adjustment Procedures IMPORTANT: The following applicable procedures must be performed on all new unit installations. Failure to do so may not allow the unit to operate at its maximum capacity. NOTE: The following procedures are for initial settings. Sometimes 6.
  • Page 72 SPR and CPR Adjustment Procedures (continued) Compressor Pressure Regulator Valve (Single Temperature Model 30 and 50 Only) The compressor pressure regulator valve (CPR) is located in the optional accumulator module mounted on the back of the evaporator. It is used to limit the suction pressure during heat.

  • Page 73: Installation Check List

    Installation Check List Components are installed with recommended hardware and Compressor was filled with the proper amount and type of oil. tightened securely. All electrical connectors are properly locked in place. All mounting holes and access holes are sealed with Standby Power Receptacle mounted securely to vehicle.
  • Page 74 Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938.

This manual is also suitable for:

Thermo king v-520 rt 10Thermo king v-520 rt 20Thermo king v-520 rt 30Thermo king v-520 rt 50

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