Ingersoll-Rand Thermo King V-520 10, Operator'S Manual

Page 1: ...homes Ingersoll Rand s Climate Solutions sector delivers energy ef cient HVACR solutions for customers globally Its world class brands include Thermo King the leader in transport temperature control...

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Page 3: ...Minneapolis MN USA Printed in USA V 520 10 20 30 50 V 520 MAX 10 20 30 50 TK 54342 1 OP Rev 1 02 12 Copyright 2009 Thermo King Corp Minneapolis MN USA Printed in USA V 520 10 20 30 50 V 520 MAX 10 20...

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Page 5: ...onsult your Thermo King Service Directory for the location and telephone number of the local dealer Introduction 3 Introduction There is nothing complicated about operating and maintaining your Thermo...

Page 6: ...Introduction 4 Introduction 4...

Page 7: ...ric Standby Operation 30 Standard Display 31 Single temperature Units 31 Multi temperature Units 32 Table of Contents 5 Table of Contents Introduction 3 Safety Precautions 9 Automatic Start Stop Opera...

Page 8: ...y 61 Glossary 63 Emergency Cold Line 69 Recover Refrigerant 70 CALIFORNIA Proposition 65 Warning 71 Table of Contents 6 Entering the Setpoint Temperature 32 In Single temperature Units 32 In Multi tem...

Page 9: ...start at any time when the unit is connected to live electric power and the controller is turned on Safety Precautions 9 Safety Precautions Thermo King recommends that all services be performed by a T...

Page 10: ...and clothing from prolonged or repeated contact with refrigerant oil Rubber gloves are recommended Safety Precautions 10 Electrical Hazard Refrigerant Although fluorocarbon refrigerants are classifie...

Page 11: ...physician WARNING Wash thoroughly immediately after handling refrigerant oil to prevent irritation Safety Precautions 11 First Aid First Aid Refrigerant Eyes For contact with liquid immediately flush...

Page 12: ...severe injuries if hands or clothing become tangled when the unit automatically starts AKA98 AKA99 Safety Precautions 12 Safety Decals and Locations Figure 1 Belt Caution Locations vary depending on...

Page 13: ...VENTILATORE ATTENTION VENTILATEUR ACHTUNG VENTILATOR CUIDADO VENTILADOR 91 4815 ARA183 AKB01 AKB02 Safety Precautions 13 Figure 3 Fan Caution Locations vary depending on model Decals are located near...

Page 14: ...Safety Precautions 14 Safety Precautions 14...

Page 15: ...defrost on both truck engine driven compressor operation and electric standby compressor operation 15 Unit Description Introduction The Thermo King V 520 10 20 and V 520 MAX truck refrigeration syste...

Page 16: ...re fourth quarter of 2011 and Model 10 SPECTRUM only Hot Gas Heat Model 30 and 50 Units Only AMA945 Unit Description 16 Figure 6 V 520 Condenser Unit Standard Features In Cab Controls with Digital LCD...

Page 17: ...d is unplugged from the unit as the selection of engine operation or standby operation is automatic Unit Description 17 Refrigeration System Refrigeration hoses or lines are used to connect the conden...

Page 18: ...a control panel In cab Control Box that operates the unit Figure 8 In Cab Control Box AMA510 ASA246 Unit Description 18 Figure 7 Evaporator Evaporator The evaporator is mounted on the ceiling inside t...

Page 19: ...is disconnected no power or when the unit is connected but has been manually switched off from the Unit Description 19 The Electronic Control System is composed of an Electronic Control Module locate...

Page 20: ...een Electric Power Warning On screen warning that the unit is connected to an electric power supply Unit Description 20 In cab Control Box when there is no active alarm The On Off key is always lit ex...

Page 21: ...Is used to increase the setpoint temperature 5 Down Key Is used to reduce the setpoint temperature Unit Description 21 Unit Controls WARNING Never operate the unit unless you completely understand th...

Page 22: ...tes the unit is in Defrost Mode 14 Electrical Symbol Indicates that the unit is in Electric Standby Unit Description 22 Refrigerant V 520 10 V 520 20 V 520 30 and V 520 50 units use R 134a refrigerant...

Page 23: ...low operating temperatures This feature enhances compressor lubrication and extends compressor life Unit Description 23 refrigerant passes through the metering orifice it expands and evaporates coolin...

Page 24: ...aters DH1 and DH2 Fuse 20 Transformer Input L1 Fuse 21 Battery Relay Located in 2 wire near battery Unit Description 24 Protection Features High Pressure Transducer The high pressure transducer is a p...

Page 25: ...Injection Valve 7 Condenser Coil 11 AC Compressor Electric Box 4 Liquid Tank 8 Rectifier Heat Sink Unit Description 25 Figure 10 Unit Components Model 20 1 6 11 AMA1412 2 4 5 7 8 9 10 3 1 Filter Drie...

Page 26: ...A1005 1 3 2 AMA1004 1 Electronic Control Module single temp shown 3 Capacitor Box 2 Motor Contactor Unit Description 26 Figure 11 Condenser Electric and Capacitor Boxes Model 20 and 50 AMA1005 1 3 2 A...

Page 27: ...AMA513 1 2 4 3 AMA514 1 Evaporator Fans 3 Air Temperature Sensor 2 Expansion Valve 4 Defrost Switch Unit Description 27 Figure 12 Standard Evaporator AMA513 1 2 4 3 AMA514 1 Evaporator Fans 3 Air Temp...

Page 28: ...Heat Defrost Coil 3 High Temperature Limit Switch 2 Electric Heat Element 4 Air Temperature Sensor Unit Description 28 Figure 13 Evaporator with Hot Water and Electric Heat Options AMA525 1 2 3 4 1 H...

Page 29: ...point Increase in temperature X C F above the setpoint X C F below the setpoint COOL HEAT NULL MODE 29 Unit Operation In truck driven units temperature control is based on two values The setting Setpo...

Page 30: ...ctivated The electric symbol will appear on the screen 3 Check the setpoint and adjust if necessary Unit Operation 30 Factory setting for X is 5 F 3 C During unit installation this value can be adjust...

Page 31: ...mperature Units The example in the drawing shows 10 8 C temperature cool mode and standby operation Unit Operation 31 NOTE The operating mode whether engine driven or electric standby is selected auto...

Page 32: ...ect the new Setpoint Temperature the unit will continue to run at the original Setpoint Temperature Unit Operation 32 Multi temperature Units Figure 15 Multi temperature Unit The example in the drawin...

Page 33: ...ect the new Setpoint Temperature the unit will continue to run at the original Setpoint Temperature Unit Operation 33 In Multi temperature Units Figure 17 Multi temperature Units 1 Main Load Compartme...

Page 34: ...appear when the defrost cycle begins the klixon must be closed Figure 20 Defrost Symbol in Display Unit Operation 34 Initiating the Manual Defrost Cycle CAUTION Before initiating a manual defrost ens...

Page 35: ...d the unit starts up automatically once the alarm condition has been rectified Figure 22 Auto Start Unit Operation 35 Alarms When the unit is not operating properly the microprocessor records the alar...

Page 36: ...tinues running in standby mode They are also energized if the doors open if this option is selected Unit Operation 36 Should a P1E alarm occur return air temperature read error alarm code appear will...

Page 37: ...rted contact your Service Dealer SOF Software failure Contact your Service Dealer Alarm Description Unit Operation 37 Alarm Code Descriptions Alarm Description Manual Start OL Electric Motor Overload...

Page 38: ...Contact your Service Dealer C Communications Failure Contact your Service Dealer Alarm Description Unit Operation 38 Clearing Alarm Codes The alarm condition in the unit must first be corrected After...

Page 39: ...erature drops to below 2 C 35 6 F the unit will defrost The defrost cycle should stop automatically Unit Operation 39 Post Start Inspection Thermostat Adjust the thermostat setting to above and below...

Page 40: ...Unit Operation 40 Unit Operation 40...

Page 41: ...3 15 amps 10 amps Fuse 10 Evaporator Fan Motor EF4 15 amps 10 amps Fuse 11 Heaters 10 amps 7 5 amps 41 Specifications Electrical System Fuses 12 Volt 24 Volt Fuse 1 Power Supply Circuit 5 amps 5 amps...

Page 42: ...ids and Liquid Line Solenoids Voltage Current Resistance 12 Vdc 2 3 amps 5 2 ohms Electrical System Specifications 42 Fuses 12 Volt 24 Volt Fuse 20 Transformer 4 amps 4 amps Fuse 21 Battery Relay 15 a...

Page 43: ...rigerant Charge V 520 MAX Model 10 8 15 lb 3 70 kg R 404A V 520 MAX Model 20 8 15 lb 3 70 kg R 404A Specifications 43 Refrigerant System R 134A REFRIGERATION SYSTEM V 520 Refrigerant Charge V 520 Mode...

Page 44: ...sh Plate 6 Cylinder Electric Standby Compressor Model 20 and 50 Only D211Y Reciprocating 3 Cylinder Specifications 44 V 520 MAX Model 30 8 25 lb 3 74 kg R 404A V 520 MAX Model 50 8 25 lb 3 74 kg R 404...

Page 45: ...lure to use correct Thermo King recommended oil will invalidate your warranty Compressors Continued Specifications 45 System Oil Capacity Model 10 12 oz 355 cc Model 20 64 oz 1893 cc Model 30 18 oz 53...

Page 46: ...ft 8 gauge Voltage Power Rating Watts Current Resistance 208 230 2000 14 7 Amps 16 2 ohms at 230 V Specifications 46 Belt Tension Using Tool P N 204 427 AC Semi Hermetic Compressor Electric Standby P...

Page 47: ...g the CPR valve 95 5 solder or equivalent may be used Use 95 5 TK No 204 167 Use Flux TK No 204 417 Specifications 47 Solder Applications Refrigeration Component For general refrigeration tubing conne...

Page 48: ...Specifications 48 Specifications 48...

Page 49: ...fter first week of operation Check belt tension Tighten unit mounting bolts Check refrigerant level 49 Maintenance Inspection Schedule A closely followed maintenance program will help to keep your The...

Page 50: ...lts for condition and proper tension Clean entire unit including evaporator coil and condenser coil Maintenance Inspection Schedule 50 Weekly Monthly Semi Annual Annual Inspect Service These Items ELE...

Page 51: ...unting bolts brackets lines hoses etc Weekly Monthly Semi Annual Annual Inspect Service These Items Maintenance Inspection Schedule 51 Check all unit mounting bolts brackets lines hoses etc Weekly Mon...

Page 52: ...Maintenance Inspection Schedule 52 Maintenance Inspection Schedule 52...

Page 53: ...e sure that there is sufficient air space around and through the load so air flow is not restricted 53 Loading and Enroute Inspections Thermo King refrigeration units are designed to maintain the requ...

Page 54: ...Insulation in Good Condition 8 Cargo at Proper Temperature Prior to Loading 1 6 AMA1411 2 3 4 5 8 7 Loading and Enroute Inspections 54 Figure 25 Loading Considerations 1 Unit Inspection 2 Good Outside...

Page 55: ...ture before loading The unit is designed to maintain temperature not cool an above temperature load Loading and Enroute Inspections 55 Inspecting the Load Never assume that the product has been loaded...

Page 56: ...rned ON Make sure to turn the unit OFF before opening unit doors or inspecting any part of the unit Loading and Enroute Inspections 56 Enroute Inspections NOTE Enroute inspections are recommended ever...

Page 57: ...company office immediately Take all necessary steps to protect and maintain proper load temperature Loading and Enroute Inspections 57 e The unit may have a low refrigerant charge If liquid is not sho...

Page 58: ...Loading and Enroute Inspections 58 Loading and Enroute Inspections 58...

Page 59: ...erial Number Location Figure 26 Condenser and Standby Compressor Serial Number Locations AMA511 2 1 Serial Number Locations 59 Serial Number Locations CONDENSER Nameplate located on the back inside wa...

Page 60: ...Serial Number Locations 60 Serial Number Locations 60...

Page 61: ...on request Please reference document TK 51350 for the Thermo King Self Powered Truck Unit Warranty Warranty 61 Warranty Terms of the Thermo King Warranty are available on request Please reference doc...

Page 62: ...Warranty 62 Warranty 62...

Page 63: ...ure measurement The preferred alternate to the term centigrade Abbreviated C centigrade See Celsius 63 Glossary This glossary is published for informational purposes only and the information being fur...

Page 64: ...defrost termination switch A component that terminates defrost operation at a specific temperature Glossary 64 CFC Chlorofluorocarbon A chlorine based refrigerant consisting of chlorine fluorine and...

Page 65: ...yond a specific value When this occurs the circuit is opened and electrical current flow is stopped Glossary 65 defrost timer A solid state module that initiates defrost at selected intervals Also est...

Page 66: ...d minimum modulation An optional system that reduces load product dehydration and avoids top freeze Glossary 66 fusible link An electrical safety device typically a short piece of wire inserted into a...

Page 67: ...prevent restriction of return air flow to the Thermo King unit due to improper loading See bulkhead Glossary 67 movable bulkhead A thick insulated portable wall like device used to compartmentalize a...

Page 68: ...The basic measuring unit of electrical potential watt The basic measuring unit of electrical power Glossary 68 return air temperature The temperature of the air returning to the evaporator See box te...

Page 69: ...personnel who will do their best to get you quick service at an authorized Thermo King Dealer AKB12 69 Emergency Cold Line If you can t get your rig rolling and you have tried the Thermo King North Am...

Page 70: ...ormation on regulations and technician certification programs contact your local THERMO KING dealer Recover Refrigerant 70 Recover Refrigerant At Thermo King we recognize the need to preserve the envi...

Page 71: ...roposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer 71 CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California t...

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Page 74: ...homes Ingersoll Rand s Climate Solutions sector delivers energy ef cient HVACR solutions for customers globally Its world class brands include Thermo King the leader in transport temperature control...