Trailer Edition Precedent S-600M, C-600M and S-600DE with S-2 and S-3 Remote Evaporator Systems TK IM (Rev. 4, 12/15)

Transcription

1 Installation Manual Trailer Edition Precedent S-600M, C-600M and S-600DE with S-2 and S-3 Remote Evaporator Systems TK IM (Rev. 4, 12/15)

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3 Installation Manual - B Trailer Edition Precedent S-600M, C-600M and S-600DE with S-2 and S-3 Remote Evaporator Systems TK IM (Rev. 4, 12/15) Copyright 2013 Thermo King Corp., Minneapolis, MN, U.S.A.

4 Printing History Rev. 0 Rev. 1 Rev. 2 Rev. 3 Rev. 4 (11/13) Released (10/14) Pages 8, 9: Updated Selection Guide (07/15) Added C-600M to manual, pages, 24, 26, 72-74: added evaporator cap plug details, page 75; added important information regarding disabling Eco Pulldown Mode during engine break-in procedures. (10/15) Added DE information. (12/15) Page 71: Changed step 2 to state both the suction and discharge service valves should be back seated, and the receiver tank outlet valve is open. 2

5 Introduction Installation Manual - A (TK IM) was written to assist with the installation of the Thermo King Precedent S-600M C-600M and S-600DE host unit onto trailers specifically designed and built for multi-temperature refrigerated applications. Installation Manual - B (TK IM) was written to assist with the proper installation of the remote evaporators along with Leak Check, Evacuation and Charging Procedures. Center wall partition information is included for DE 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 diesel powered refrigeration systems Have a basic understanding of electricity and electrical wiring Have the necessary tools and equipment to complete the 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. 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. 3

6 Table of Contents Introduction Safety Precautions Precedent S-600M and C-600M Multi-Temperature Selection Guide Required Tools S-3 Dimensions S-3 + S-3 Dimensions Recovering Holding Charge Important Installation Notes Installation S Installation S-3 + S Host Tube Connections S Host Tube Connections (Configuration X Only) Host Tube Connections (Configuration Y Only) Host Tube Connections (Configuration Z Only) Evaporator Tube Connections S Evaporator Tube Connections S-3 + S Evaporator Tube Connections S-3 + S-3 (Configuration X Only) Evaporator Tube Connections S-3 (Configuration X Only) Evaporator Tube Connections S-3 + S-3 (Configuration Y Only) Evaporator Tube Connections S-3 + S-3 (Configuration Z Only) Host & Evaporator Wire Connections - Zone Host & Evaporator Wire Connections - Zone DE Host & Evaporator Wire Connections - Zone Drain Hose Resistance Wire Installation Guide Drain Hose Installation Leak Check, Evacuation and Charging Procedures Installing Remote Evaporator Covers DE Installations UNIT CHECK LIST

7 Safety Precautions Caution Thermo King Precedent S-600M and C-600M Multi-Temp host units are shipped with a 35 kpa (5 psi) holding charge of R-404A. This holding charge of approximately 1 kg (2 pounds) of refrigerant must be recovered. The remote evaporators are shipped with a kpa (5-10 psi) holding charge of nitrogen. This holding charge may be safely vented into the atmosphere. SEVERE COMPRESSOR DAMAGE will result from operating the engine before completing the system installation which includes: installing the components, recovering the host unit holding charge, releasing the remote unit nitrogen holding charge, soldering the refrigeration tubes, leak testing the system, evacuation and clean-up, and charging the system. 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. 5

8 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. 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 fasteners are torqued to specification and are of correct length for their particular application. 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. 6

9 Safety Precautions 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: Exposed coil fins are very sharp and can cause painful lacerations. WARNING: Regulators used on bottles of nitrogen gas must be equipped with relief valves. The pressure in a bottle of nitrogen gas is extremely high. It is high enough to cause components of the refrigeration system to explode if the regulator malfunctions or is set wrong. The relief valve provides a safe outlet in case the regulated pressure exceeds the relief valve limit. CAUTION: Recover the refrigerant (R-404A) holding charge from the host unit prior to making any refrigeration tubing connections to prevent personal injury! CAUTION: Remove the nitrogen holding charge from the remote evaporators prior to making any refrigeration tubing connections to prevent personal injury! Refrigerant 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. First Aid FROSTBITE: 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 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. 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. 7

10 Precedent S-600M and C-600M Multi-Temperature Selection Guide For Optimum Cooling Performance Do Not Exceed The Maximum Recommended Zone Dimensions Shown 2 ZONE (1 EVAP) Qty Qty Qty Qty Qty Qty Qty S-3 Evaporator Zone 2 Evap Install Kit 50/50/50 ft. Tubing Kit Transverse Drain Kit (optional) S-3 Evaporator Zone 2 Evap Install Kit 50/50/50 ft. Tubing Kit Qty S-3 Evaporator Qty Zone 2 Evap Install Kit Qty Evap Harness Kit Qty /50/50 ft. Tubing Kit Qty /15/15 Tubing Extension Kit* 2 ZONE (2 EVAPS) Qty S-3 Evaporator Qty Zone 2 Evap Install Kit Qty Evap Harness Kit Qty /50/50 ft. Tubing Kit Qty Transverse Drain Kit (optional) Qty S-3 Evaporator Qty Zone 2 Evap Install Kit Qty Zone 3 Evap Harness Kit Qty /50/50 ft. Tubing Kit Qty S-3 Evaporator Qty Zone 2 Evap Install Kit Qty Evap Harness Kit Qty /50/50 ft. Tubing Kit Qty /15/15 Tubing Extension Kit* * Required only when evaporators are located at the rear of trailers 48 ft. or longer. 8

11 Precedent S-600M and C-600M Multi-Temperature Selection Guide 3 ZONE DE (1 EVAP) Qty Qty Qty Qty S-3 Evaporator Evap Install Kit 50/50/50 ft. Tubing Kit 30/15/15 Tubing Extension Kit* 3 ZONE (2 EVAPS) Qty S-3 Evaporator Qty Zone 2 Evap Install Kit Qty Zone 3 Evap Install Kit Qty /50/50 ft. Tubing Kit Qty Transverse Drain Kit (optional) Qty S-3 Evaporator Qty Zone 2 Evap Install Kit Qty Zone 3 Evap Install Kit Qty /50/50 ft. Tubing Kit Qty Transverse Drain Kit (optional) Qty Qty S-3 Evaporator Evap Install Kit 3 ZONE (3 EVAPS) Qty Qty S-3 Evaporator Evap Install Kit 3 ZONE (4 EVAPS) Qty Qty S-3 Evaporator Evap Install Kit * Required only when evaporators are located at the rear 9

12 Required Tools 1. Safety Glasses 16. Tubing Cutter 2. Tape Measure 17. Tubing Swages 3. Screwdrivers - Phillips and Straight Blade 18. Tubing Brushes 4. Drill 19. Scotch Brite Pads 5. Drill Bits 20. Torch Set 6. Hole Saw % Silver Solder( ) & Flux ( ) 7. Torque Wrench 22. Heat Shield 8. Box and Open End Wrenches - 7/16, 1/2, 9/16, 5/8, 3/4 23. Manifold Set Adjustable Wrench 24. Evacuation Station (TK ) 10. Crow s Feet - 7/8, 1, 1-3/8 11. Tap and Die Set (Europe only) 12. Wire Stripper 13. Wire Crimper - for insulated terminals 14. Electronic Leak Detector 15. Tube Benders 25. Reclaiming Station 26. Refrigerant Oil 27. Refrigerant and Scale 28. Dry Nitrogen 29. Battery Charger (60 AMP minimum) 30. Mechanical Lift (modified drywall lift) NOTE: Equipment such as scales, gauges, refrigerant leak detectors, and torque wrenches should be in good working condition and routinely calibrated to assure accurate readings. 10

13 Required Tools BLANK PAGE 11

14 S-3 Dimensions NOTE: All mounting locations must be correct to properly install the remote evaporator(s). Mount all evaporators as close to one side wall as possible to minimize drain tube length and reduce exposure to damage. The minimum distance mm (48.4 in.) from the bulkhead to the front of the evaporator must be maintained for proper operation. A, B, C, D, E, and F indicate locations of solder fittings measured vertically from the top of the evaporator and horizontally from the evaporator mounting hole. NOTE: See 96 in. Wide Trailer Installation Matrix on pages 22 and

15 S-3 Dimensions WEIGHT = 52 kg (115 lb.) Reference: 1E02132 Sheet 2 13

16 S-3 + S-3 Dimensions NOTE: All mounting locations must be correct to properly install the remote evaporator(s). Mount all evaporators as close to one side wall as possible to minimize drain tube length and reduce exposure to damage. The minimum distance mm (48.4 in.) from the bulkhead to the front of the evaporator must be maintained for proper operation. A, B, C, D, E, and F indicate locations of solder fittings measured vertically from the top of the evaporator and horizontally from the evaporator mounting hole. NOTE: See 96 in. Wide Trailer Installation Matrix on pages 22 and

17 S-3 + S-3 Dimensions WEIGHT = 52 kg (115 lb.) each Reference: 1E02132 Sheet 4 15

18 Recovering Holding Charge NOTE: The host unit must be placed in the Evacuation Mode to open the normally closed solenoid valves throughout this procedure. See Leak Check, Evacuation and Charging Procedures on page Set refrigerant recovery device to recover R-404A vapor. 2. Recover refrigerant vapor from host unit to 0 kpa (0 psi) from receiver outlet valve and suction service valve. 3. Remove the manifold gauge lines from receiver outlet valve and suction service valve. Leave service valves open to port to act as vents. CAUTION: Make sure holding charge from host unit has been recovered before proceeding to prevent personal injury! NOTE: It is important to minimize the amount of time the tubes are uncapped and open to ambient conditions. Always keep tubes capped until ready to connect and solder. 4. Unsolder tube caps from hot gas, liquid, and suction tubes on host unit. NOTE: Only remove caps from both suction tubes if required for your application. 16

19 Recovering Holding Charge 17

20 Important Installation Notes EVAPORATOR LOCATION The best airflow is achieved when the evaporator is installed an equal distance from each side wall. It is recommended that moving bulkheads not be allowed closer than mm (48.4 in.) or 1 pallet inches from the evaporator outlet (Detail I). The minimum clearance from the bottom to the top of the cargo and all sides of the evaporator except the evaporator outlet should be 101 mm (4.00 in.) (Detail I). NOTE: This minimum clearance does not refer to the trailer LOAD LINE. The evaporator should be located a minimum of 51 mm (2.00 in.) from the trailer wall (Detail IlI). DEFROST DRAINS The drain tube should be offset 35.5 mm (1.4 in.) from the mounting holes (Detail II). The evaporator must be properly mounted to provide a slope towards the drain. This is accomplished by adding one 3/8 in. and one 3/16 in. washers on the drain side and only one 3/8 in. washer on the other side at each mounting surface (Detail III). Defrost drains must exit the evaporator at a 45 angle and have a minimum downward gradient of 267 mm (10.50 in.) from the trailer ceiling to the top of the drain in the trailer wall (Detail III). WALL DRAIN TUBE - (Details II and III) CPVC 1.00 in. ID (Inside Diameter) ELECTRICAL WIRING IMPORTANT: DO NOT CUT THE SENSOR HARNESSES All electrical harness must be secured by clamps at least every 600 mm (24.00 in.). Additional harnesses (options, etc.) can be secured with tie bands to the harnesses that are clamped in place. 18

21 Important Installation Notes 19

22 Important Installation Notes TROUGH LOCATION - (Details IV - VII) The OEM and Dealer should discuss trough locations based on application before the trailer is built. Only one trough is required. The trough should be located in such a way as to allow for proper routing of the suction tube(s). 3 compartment trailers may have two suction tubes in the trough. A ceiling trough is recommended. If that is not possible, a wall through should be located to allow the lowest suction tube to be at least 25 mm (1.00 in.) above the remote evaporator suction tube fitting once secured to the trough. REFRIGERANT TUBING and CONNECTIONS Thermo King Requires the use of bulk rolled refrigeration grade tubing and tube benders to reduce fittings and solder joints where applicable. The use of large radius bends is preferred over copper fitting joints. It is important to minimize the amount of time the tubes are uncapped and open to ambient conditions. Always keep tubes capped until ready to connect and solder. Check tubes and copper fittings for obstructions prior to assembly. Use 15% silver solder for joining all remote refrigerant tubes. Suction and liquid tubes are to be insulated when outside the trough. Hot gas tubes are to be 100% insulated. All refrigeration tubes must be secured by clamps at least every 600 mm (24.00 in.). All dual evaporator installations require two suction tubes (Detail V, VII). Configuration X installations will require two suction tubes: 1-1/8 in. for Zone 2 and 7/8 in. for Zone 3. Configuration Y installations will require two suction tubes: 7/8 in. for Zone 2 and 1-1/8 in. for Zone 3. Configuration Z installations require 1-1/8 in. suction tubes for both Zone 2 and Zone 3. All soldering of tubes should be done according to the best practices soldering document, Section 16, of the Certi-Tech Professional Manual. It is also required that nitrogen or another inert gas be used to purge the tubes while soldering. This prevents oxidation and formation of scale inside tubes. IMPORTANT: The following procedure should be followed to correctly purge the tubes with nitrogen when soldering. 1. Midseat the suction and discharge service valves on the host unit. 2. On one remote evaporator in each remote zone connect a 6 volt lantern battery to the HGS and SOL terminals of the terminal strip. This activates the Hot Gas Solenoid to allow nitrogen to flow. 3. Connect a nitrogen supply hose to the access port on the same remote evaporator that the battery was connected. Make sure the supply hose fitting has a Schrader valve depressor to open the Schrader valve on the access port. 4. Adjust the nitrogen flow to 5-10 CFH. 5. The nitrogen supply and lantern battery must be maintained while soldering the remote and host unit connections. 20

23 Important Installation Notes NOTE: SIDE TROUGH ONLY Suction Tube(s) must always be located at top of trough. 21

24 Important Installation Notes Host Unit Return Air In lane configurations, care must be taken to avoid the inner walls obstructing return air to the host. Not only is host performance impaired, but temperature management will suffer if return air does not flow over the return air sensor. Door Switches Door switches automatically turn off remote evaporators when the corresponding door is opened. This avoids the entry of warm, moist air into the load space. Door switches are recommended for all multi-temp installations. Door Curtains It is always recommended to use good quality insulated curtains on all doors to limit the amount of warm, moist air from entering the load space during door openings. Full Length Lanes Always consider using a S-600M DE (Dual Evaporator) unit where full length lanes are required. This is the most efficient and cost effective solution for these demanding applications, and a product unique to Thermo King. 96 in. Wide Trailer Installation Matrix NOTE: The installation of parallel S3+S3 on a 96 wide trailers may be too tight due to variations of trailer wall thicknesses. Since remote evaporators allow for the drain hose to exit the front, you can install a parallel S3+S3 based on the assumptions shown below. THIS IS AN EXAMPLE, NOT A SPECIFICATION THE TRAILER OEM AND DEALERS ARE EXPECTED TO VALIDATE THESE CALCULATIONS ASSUMING THE DRAIN IS COMING OUT THE SIDE OF THE EVAPORATOR: Trailer Width Wall Thickness Difference Evaporator Clearance from Road Side Wall Evaporator Clearance from Curb Side Wall S3+S3 Width Space Left not ideal 1.19 S2+S2 Width Space Left

25 Important Installation Notes 96 in. Wide Trailer Installation Matrix ASSUMING THE DRAIN IS COMING OUT THE FRONT OF THE EVAPORATOR: Trailer Width Wall Thickness Difference Evaporator Clearance from Road Side Wall Evaporator Clearance from Curb Side Wall S3+S3 Width Space Left not ideal S2+S2 Width Space Left ASSUMING THE DRAIN IS COMING OUT THE FRONT OF THE EVAPORATOR: Trailer Width Wall Thickness Difference Evaporator Clearance from Road Side Wall Evaporator Clearance from Curb Side Wall S3+S3 Width Space Left 0.19 not ideal S2+S2 Width Space Left

26 Important Installation Notes Defrost Drain Tube Connector Installation IMPORTANT: Follow the instructions below to prevent defrost drain tube water leaks. All remote evaporators are equipped with a quick disconnect fitting that connects the drain pan to the drain tubes (Detail I). To properly install the tube make sure that the tube is fully inserted past the O-ring and up to the stop inside the coupler (Detail II). NOTE: The fitting will grip the tube before it seals with the o-ring. When the tube is in the correct position the O-ring will seal and the teeth will grip the tube keeping it in place. Check the fit by pulling on the tube(s) to insure that it will not pull out of the fitting (Detail III). To disconnect the tube from the fitting: press the collet into the fitting. Hold the collect in place and pull the tube out. The fitting can be re-used. Clean any burrs off the tube before re-inserting it into the fitting (Detail IV). Evaporator Cap Plugs Cap plugs are provided to plug the two evaporator mounting access holes located directly above the drain pan. These plugs must be installed to prevent water in the drain pan from spilling out of these holes and into the cargo area. See pages 26, 72 and 73 for details. 24

27 Important Installation Notes 25

28 Important Installation Notes IMPORTANT: Supplied cap plugs (2 per evap) must be installed to prevent water in drain pan from spilling out of these holes and into cargo area. 26

29 Important Installation Notes 27

30 Installation S-3 Ceiling Preparation IMPORTANT: The trailer ceiling must be structurally strong enough to support the weight of the S-3 evaporator(s) 52 kg (115 lb.) each. IMPORTANT: The ceiling must be flat and the mounting locations correct for proper remote evaporator installation. The foam insulation in the ceiling must be removed from the evaporator mounting area and aluminium spacers must be installed between the evaporator mounting plate and trailer ceiling. NOTE: If the trailer frame is other than aluminum, use mylar film between aluminum spacer and frame. For ceiling mounting stud applications, weld a nut (same thread as stud) onto a mm (1.75 in.) hole saw and turn the nut onto the mounting stud using a socket wrench (Detail I). For ceiling mounting bolt applications, weld a bolt (same thread as tapped hole) onto a mm (1.75 in.) hole saw and turn into the tapped mounting hole using a socket wrench (Detail I). Alternative method is to remove the mounting studs or bolts and use a hole saw with a standard pilot drill small enough to run up into the threaded hole without damaging the threads. Reinstall mounting studs or bolts. Mounting Stud or Bolt Requirements The mounting studs or bolts used to attach the evaporator(s) to the ceiling must be 10.0 mm, (0.50 in., Grade 5, U.S. applications only), medium carbon steel, PSI tensile strength, cadmium plate and dichromate finish. Studs to extend below ceiling 38.0 mm (1.50 in.) to 50.1 mm (2.00 in.) Evaporator Installation IMPORTANT: The evaporator must be properly mounted to provide a slope towards the drain. This is accomplished by adding one 3/8 in. and one 3/16 in. washers on the drain side and only one 3/8 in. washer on the other side at each mounting surface (Detail IV). 1. Remove evaporator cover to access mounting holes. NOTE: The installation kit provides both metric and imperial nuts and washers. Be sure to use the correct ones for your application. Mounting Stud Installations 2. Install the aluminum spacers onto the ceiling mounting studs and raise the evaporator into position. Secure the evaporator onto the mounting studs with flat washers and locking nuts (Detail II). Torque to 81.3 N m (60 ft-lb). Mounting Bolt Installations 3. Install the mounting bolts, lock washers (installer supplied) and flat washers onto the evaporator and raise into position. Install the aluminium spacers and secure the evaporator to the ceiling (Detail III). Torque to 81.3 N m (60 ft-lb). 4. A properly installed evaporator will slope slightly toward the drain tubes to allow for water drainage. Two additional washers are included in the kit to help assist sloping the evaporator towards the drain (Detail IV). 28

31 Installation S-3 29

32 Installation S-3 + S-3 Ceiling Preparation IMPORTANT: The trailer ceiling must be structurally strong enough to support the weight of the S-3 evaporator(s) 52 kg (115 lb.) each. IMPORTANT: The ceiling must be flat and the mounting locations correct for proper remote evaporator installation. The foam insulation in the ceiling must be removed from the evaporator mounting area and aluminium spacers must be installed between the evaporator mounting plate and trailer ceiling. NOTE: If the trailer frame is other than aluminum, use mylar film between aluminum spacer and frame. For ceiling mounting stud applications, weld a nut (same thread as stud) onto a mm (1.75 in.) hole saw and turn the nut onto the mounting stud using a socket wrench (Detail I). For ceiling mounting bolt applications, weld a bolt (same thread as tapped hole) onto a mm (1.75 in.) hole saw and turn into the tapped mounting hole using a socket wrench (Detail I). Alternative method is to remove the mounting studs or bolts and use a hole saw with a standard pilot drill small enough to run up into the threaded hole without damaging the threads. Reinstall mounting studs or bolts. Mounting Stud or Bolt Requirements The mounting studs or bolts used to attach the evaporator(s) to the ceiling must be 10.0 mm, (0.50 in., Grade 5, U.S. applications only), medium carbon steel, PSI tensile strength, cadmium plate and dichromate finish. Studs to extend below ceiling 38.0 mm (1.50 in.) to 50.1 mm (2.00 in.) Evaporator Installation IMPORTANT: The evaporator must be properly mounted to provide a slope towards the drain. This is accomplished by adding one 3/8 in. and one 3/16 in. washers on the drain side and only one 3/8 in. washer on the other side at each mounting surface (Detail IV). 1. Remove evaporator covers to access mounting holes. NOTE: The installation kit provides both metric and imperial nuts and washers. Be sure to use the correct ones for your application. Mounting Stud Installations 2. Install the aluminum spacers onto the ceiling mounting studs and raise the evaporator into position. Secure the evaporator onto the mounting studs with flat washers and locking nuts (Detail II). Torque to 81.3 N m (60 ft-lb). Mounting Bolt Installations 3. Install the mounting bolts, lock washers (installer supplied) and flat washers onto the evaporator and raise into position. Install the aluminium spacers and secure the evaporator to the ceiling (Detail III). 4. Install the second evaporator. Torque each evaporator s mounting hardware to 81.3 N m (60 ft-lb). 5. A properly installed evaporator will slope slightly toward the drain tubes to allow for water drainage (Detail IV). NOTE: Two additional washers are included in the kit to help assist sloping the evaporator towards the drain. 30

33 Installation S-3 + S-3 31

34 Host Tube Connections S-3 IMPORTANT: Clean all tubes and fittings prior to installation and soldering. 1. Suction Tube (s) Single Evaporator Installations - Install 7/8 in. x 7/8 in. coupling (Item A) onto one suction tube of host unit. Fabricate 7/8 in. suction tube, install onto coupling and connect to 7/8 in. suction tube in trough. NOTE: The second suction tube remains capped. Multiple Evaporator Installations (See Important note below) Install 7/8 in. x 7/8 in. couplings (Item A) onto each suction tube of host unit. Fabricate 7/8 in. suction tubes, install onto each coupling and connect to 7/8 in. suction tubes in trough. IMPORTANT: Configurations X, Y and Z require two different size suction tubes routed to the remote evaporators for proper operation. 2. Liquid Tube - Install 3/8 in. x 1/2 in. coupling (Item B) onto liquid tube of host unit. Fabricate 1/2 in. liquid tube, install onto coupling and connect to 1/2 in. liquid tube in trough. 3. Hot Gas Tube - Install 5/8 in. x 5/8 in. coupling (Item C) onto hot gas tube of host unit. Fabricate 5/8 in. hot gas tube, install onto coupling and connect to 5/8 in. hot gas tube in trough. 4. Insulation should be added to all visible segments of suction and liquid tubes not covered by trailer trough cover. Hot gas tubes should be covered 100%. 5. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. NOTE: Ceiling trough shown, wall trough is similar. Fittings Required Item Description P/N A 7/8 in. x 7/8 in. Coupling B 3/8 in. x 1/2 in. Coupling C 5/8 in. x 5/8 in. Coupling Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction G58 G35 32

35 Host Tube Connections S-3 (Except configurations X, Y and Z) 33

36 Host Tube Connections (Configuration X Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. IMPORTANT: Configuration X installation requires two different size suction tubes routed to the remote evaporators for proper operation: 7/8 in. suction tube from the host unit to the S3 evaporator in Zone /8 in. suction tube from the host unit to the S3 + S3 remote evaporators in Zone 2. NOTE: Due to the difficulty in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. 1. Suction Tube #1 - Install a 7/8 in. x 7/8 in. coupling (Item A) onto the first suction tube at the rear of the host unit. Fabricate a 7/8 in. tube, attach onto coupling and connect to 7/8 in. suction tube in trough. 2. Suction Tube #2 - Install a 7/8 x 1-1/8 in. coupling (Item B) onto the second suction tube at the rear of the host unit. Fabricate a 1-1/8 in. tube, attach to coupling and use 1-1/8 in. elbows (Item C) to connect to 1-1/8 in. suction tube in trough. 3. Liquid Tube - Install a 3/8 in. x 1/2 in. coupling (Item D) onto liquid tube of the host unit. Fabricate a 1/2 in. liquid tube, install onto the 1/2 in. coupling and connect to 1/2 in. liquid tube in trough. 4. Hot Gas Tube - Install a 5/8 in. x 5/8 in. coupling (Item E) onto the hot gas tube of the host unit. Fabricate a 5/8 in. hot gas tube, install onto the 5/8 in. coupling and connect to 5/8 in. hot gas tube in trough. 5. Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 6. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. NOTE: Ceiling trough shown, wall trough is similar. Fittings Required Item Description P/N A 7/8 in. x 7/8 in. Coupling B 7/8 in. x 1-1/8 in. Coupling C 1-1/8 in. x 1-1/8 in. Elbow D 3/8 in. x 1/2 in. Coupling E 5/8 in. x 5/8 in. Coupling Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 Suction (1-1/8 in.) G66 G58 34

37 Host Tube Connections (Configuration X Only) 35

38 Host Tube Connections (Configuration Y Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. IMPORTANT: Configuration Y installation requires two different size suction tubes routed to the remote evaporators for proper operation: 7/8 in. suction tube from the host unit to the S3 remote evaporator in Zone /8 in. suction tube from the host unit to the S3 + S3 evaporators in Zone 3. NOTE: Due to the difficulty in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. 1. Suction Tube #1 - Install a 7/8 x 1-1/8 in. coupling (Item A) onto the first suction tube at the rear of the host unit. Fabricate a 1-1/8 in. tube, attach to coupling and use 1-1/8 in. elbows (Item B) to connect to 1-1/8 in. suction tube in trough. 2. Suction Tube #2 - Install a 7/8 in. x 7/8 in. coupling (Item C) onto the second suction tube at the rear of the host unit. Fabricate a 7/8 in. tube, attach to coupling and connect to 7/8 in. suction tube in trough. 3. Liquid Tube - Install a 3/8 in. x 1/2 in. coupling (Item D) onto the liquid tube of the host unit. Fabricate a 1/2 in. liquid tube, attach to coupling and connect to 1/2 in. liquid tube in trough. 4. Hot Gas Tube - Install a 5/8 in. x 5/8 in. coupling (Item E) onto the hot gas tube of the host unit. Fabricate a 5/8 in. hot gas tube, attach to coupling and connect to 5/8 in. hot gas tube in trough. 5. Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 6. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. NOTE: Ceiling trough shown, wall trough is similar. Fittings Required Item Description P/N A 7/8 in. x 1-1/8 in. Coupling B 1-1/8 in. x 1-1/8 in. Elbow C 7/8 in. x 7/8 in. Coupling D 3/8 in. x 1/2 in. Coupling E 5/8 in. x 5/8 in. Coupling Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 Suction (1-1/8 in.) G66 G58 36

39 Host Tube Connections (Configuration Y Only) 37

40 Host Tube Connections (Configuration Z Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. IMPORTANT: Configuration Z installations require two 1-1/8 in. suction tubes routed to the remote evaporators for proper operation: 1-1/8 in. suction tube from the host unit to the S3 + S3 evaporators in Zone /8 in. suction tube from the host unit to the S3 + S3 evaporators in Zone 3. NOTE: Due to the difficulty in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. 1. Suction Tube #1 - Install a 7/8 x 1-1/8 in. coupling (Item A) onto the first suction tube at the rear of the host unit. Fabricate a 1-1/8 in. tube, attach to coupling and use 1-1/8 in. elbows (Item B) to connect to 1-1/8 in. suction tube in trough. 2. Suction Tube #2 - Install a 7/8 x 1-1/8 in. coupling (Item A) onto the second suction tube at the rear of the host unit. Fabricate a 1-1/8 in. tube, attach to coupling and use 1-1/8 in. elbows (Item B) to connect to 1-1/8 in. suction tube in trough. 3. Liquid Tube - Install a 3/8 in. x 1/2 in. coupling (Item C) onto liquid tube of the host unit. Fabricate a 1/2 in. tube, attach to coupling and connect to 1/2 in. liquid tube in trough. 4. Hot Gas Tube - Install a 5/8 in. x 5/8 in. coupling (Item D) onto the hot gas tube of the host unit. Fabricate a 5/8 in. tube, attach to coupling and connect to 5/8 in. hot gas tube in trough. 5. Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 6. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. 7. Ceiling trough shown, wall trough is similar. Fittings Required Item Description P/N A 7/8 in. x 1-1/8 in. Coupling B 1-1/8 in. x 1-1/8 in. Elbow C 3/8 in. x 1/2 in. Coupling D 5/8 in. x 5/8 in. Coupling Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (1-1/8 in.) G66 G58 38

41 Host Tube Connections (Configuration Z Only) 39

42 Evaporator Tube Connections S-3 IMPORTANT: Clean all tubes and fittings prior to installation and soldering. 1. Suction Tube - Fabricate one 7/8 in. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in. elbow (Item A), attach 7/8 in. preformed tube and connect to evaporator 7/8 in. fitting in Zone 2. Solder all fittings. 2. Hot Gas Tube - Fabricate a 5/8 in. hot gas tube from host unit and route in trough, install 5/8 in. x 1/2 in. elbow (Item B), attach 1/2 in. preformed tube and connect to evaporator 1/2 in. fitting in Zone 2. Solder all fittings. 3. Liquid Tube - Fabricate a 1/2 in. liquid tube from host unit and route in trough, install 1/2 x 3/8 in. elbow (Item C), attach 3/8 in. preformed tube and connect to evaporator 3/8 in. fitting in Zone 2. Solder all fittings 4. Insulation should be added to all visible segments of suction and liquid tubes not covered by trailer trough cover. Hot gas tubes should be covered 100%. 5. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. Zone 2 (Two Compartment Trailers) Fittings Required for SINGLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow B 5/8 in. x 1/2 in. Elbow C 1/2 in. x 3/8 in. Elbow Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction G58 G35 40

43 Evaporator Tube Connections S-3 Zone 2 (Two Compartment Trailers) 41

44 Evaporator Tube Connections S-3 IMPORTANT: Clean all tubes and fittings prior to installation and soldering. 1. Suction Tubes Fabricate two 7/8 in. suction tubes from host unit and route in trough, install 7/8 in. x 7/8 in. elbows (Item A), attach one 7/8 in. preformed tube to evaporator in Zone 2 and another to the evaporator in Zone Hot Gas Tubes Zone 2 - Fabricate a 5/8 in. hot gas tube from host unit and route in trough, install 5/8 in. x 5/8 in. x 1/2 in. tee (Item B), attach a 1/2 in. preformed tube and connect it to the evaporator in Zone 2. Zone 3 - From the tee, fabricate another 5/8 in. hot gas tube, attach a 5/8 in. x 1/2 in. elbow (Item B) and connect it to the 1/2 in. preformed tube and to the evaporator in Zone Liquid Tubes Zone 2- Fabricate a 1/2 in. liquid tube from host unit and route in trough, install 1/2 x 1/2 in. x 3/8 in. tee (Item D), attach 3/8 in. preformed tube and connect it to the evaporator in Zone 2. Zone 3 - From the tee, fabricate another 1/2 in. liquid tube, attach a 1/2 in. x 3/8 in. elbow (Item C) and connect it to the 3/8 in. preformed tube and to the evaporator in Zone Insulation should be added to all visible segments of suction and liquid tubes not covered by trailer trough cover. Hot gas tubes should be covered 100%. 5. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. Zones 2 & 3 (Three Compartment Trailers) Fittings Required for SINGLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow B 5/8 in. x 1/2 in. Elbow C 1/2 in. x 3/8 in. Elbow Fittings Required for MULTIPLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow B 5/8 in. x 5/8 in. x 1/2 in. Tee C 5/8 in. x 1/2 in. Elbow D 1/2 in. x 1/2 in. x 3/8 in. Tee E 1/2 in. x 3/8 in. Elbow Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction G58 G35 42

45 Evaporator Tube Connections S-3 Zone 2 & 3 (Three Compartment Trailers) 43

46 Evaporator Tube Connections S-3 + S-3 Zone 2 (Two Compartment Trailers) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. NOTE: You must connect one suction tube from the host to each evaporator. 1. Suction Tube #1- Fabricate a 7/8 in. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in. elbow (Item A), attach 7/8 in. preformed tube and connect to the first evaporator 7/8 in. fitting in Zone Suction Tube #2 - Fabricate a second 7/8 in. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in. elbow (Item A), attach 7/8 in. preformed tube and connect to the second evaporator 7/8 in. fitting in Zone Hot Gas Tube - Fabricate a 5/8 in. hot gas tube from host unit and route in trough, install 5/8 in. x 5/8 in. elbow (Item B), fabricate a 5/8 in. tube, connect to 5/8 in. x 1/2 in x 1/2 in. tee (Item C) and attach 1/2 in. preformed tube and connect to evaporator 1/2 in. fitting in Zone Liquid Tube - Fabricate a 1/2 in. liquid tube from host unit and route in trough, install 1/2 in. x 1/2 in. elbow (Item D), fabricate a 1/2 in. tube, connect to 1/2 in. a 3/8 in. x 3/8 in. tee (Item E), attach 3/8 in. preformed tubes and connect to evaporator 3/8 in. fitting in Zone Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 6. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. Fittings Required for MULTIPLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow B 5/8 in. x 5/8 in. Elbow C 5/8 in. x 1/2 in. x 1/2 in. Tee D 1/2 in. x 1/2 Elbow E 1/2 in. x 3/8 in. x 3/8 in. Tee Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction G58 G35 44

47 Evaporator Tube Connections S-3 + S-3 Zone 2 (Two Compartment Trailers) 45

48 Evaporator Tube Connections S-3 + S-3 (Configuration X Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. NOTE: Due to the difficultly in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. NOTE: You must connect one suction tube from the host to each evaporator. 1. Liquid Tube - Fabricate 1/2 in. liquid tube from the host unit and route in the trough: install 1/2 in. x 1/2 in. x 1/2 in. tee (Item A), fabricate a 1/2 in. tube and route in the trough to Zone 3. from the 1/2 in. x 1/2 in. x 1/2 in. tee (Item A), fabricate a 1/2 in. tube, attach to a 1/2 in. x 3/8 in. x 3/8 in. tee (Item B) and 3/8 in. tube and connect to the 3/8 in. fitting of the 1st evaporator in Zone 2. from the 1/2 in. x 3/8 in. x 3/8 in. tee (B), fabricate a 3/8 in. tube and connect to the 3/8 in. fitting of the 2nd evaporator in Zone 2. Solder all fittings. 2. Suction Tube ZONE 2 - Fabricate a 1-1/8 in. suction tube from the host unit and route in the trough: install 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item C), attach a 7/8 in. tube and connect to the 7/8 in. fitting of the 2nd evaporator in Zone 2. from the 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item C), install a 7/8 in. 90 degree elbow (Item D), attach a 7/8 in. tube and connect to the 7/8 in. fitting of the 1st evaporator in Zone 2. Solder all fittings. 3. Suction Tube ZONE 3 - Fabricate a 7/8 in. suction tube from the host unit and route in the trough to the Zone 3. ZONE 2 4. Hot Gas Tube - Fabricate a 5/8 in. hot gas tube from the host unit and route in the trough: install 5/8 in. x 5/8 in. x 5/8 in. tee (Item E), fabricate a 5/8 in. tube and route in the trough to Zone 3. from the 5/8 in. x 5/8 in. x 5/8 in. tee (Item E), attach a 5/8 in. x 1/2 in. x 1/2 in. tee (Item F) and 1/2 in. tube and connect it to the 1/2 in. fitting of the 1st evaporator in Zone 2. From the 5/8 in. x 1/2 in. x 1/2 in. tee (Item F), attach a 1/2 in. tube and connect it to the 1/2 in. fitting of the 2nd evaporator in Zone Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 6. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. Fittings Required for MULTIPLE Evaporator Installations Item Description P/N A 1/2 in. x 1/2 in. x 1/2 in. Tee B 1/2 in. x 3/8 in. x 3/8 in. Tee C 1-1/8 in. x 7/8 in. x 7/8 in. Tee D 7/8 in. x 90 Street Elbow E 5/8 in. x 5/8 in. x 5/8 in. Tee F 5/8 in. x 1/2 in. x 1/2 in. Tee Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 Suction (1-1/8 in.) G66 G58 46

49 Evaporator Tube Connections S-3 + S-3 (Configuration X Only) ZONE 2 47

50 Evaporator Tube Connections S-3 (Configuration X Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. 1. Suction Tube - Fabricate a 7/8 in. suction tube from the host unit and route in the trough, install 7/8 in. x 7/8 in. elbow (Item A), attach 7/8 in. preformed tube and connect to the evaporator 7/8 in. fitting in Zone Liquid Tube - Fabricate a 1/2 in. liquid tube from the 1/2 in. tee from (Zone 2) evaporator unit, route in the trough, install 1/2 in. x 3/8 in. elbow (Item B), attach 3/8 in. preformed tubes and connect to the evaporator 3/8 in. fitting in Zone Hot Gas Tube - Fabricate a 5/8 in. hot gas tube from the 5/8 in. tee from (Zone 2) evaporate unit, route in the trough, install 5/8 in. x 1/2 in. elbow (Item C), attach 1/2 in. preformed tube and connect to the evaporator 1/2 in. fitting in Zone Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 5. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. NOTE: Ceiling trough shown, wall trough is similar. ZONE 3 Fittings Required for SINGLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow B 1/2 in. x 3/8 in. Elbow C 5/8 in. x 1/2 in. Elbow Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 48

51 Evaporator Tube Connections S-3 (Configuration X Only) ZONE 3 49

52 Evaporator Tube Connections S-3 + S-3 (Configuration Y Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. NOTE: Due to the difficultly in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. IMPORTANT: You must connect one suction tube from the host to each evaporator 1. Suction Tube - Fabricate a 7/8 in. suction tube from the host unit and route in the trough: install 7/8 in. x 7/8 in. elbow, (Item A) attach a 7/8 in. tube and connect to the 7/8 in. fitting of the evaporator in Zone Hot Gas Tube - Fabricate a 5/8 in. hot gas tube from the host unit and route in the trough: install 5/8 in. x 5/8 in. x 5/8 in. tee (B), fabricate a 5/8 in. tube and route in the trough to Zone 3. from the 5/8 in. x 5/8 in. x 5/8 in. tee, attach a 5/8 in. x 1/2 in. x 1/2 in. tee and 1/2 in. tube and connect it to the 1/2 in. fitting of the evaporator in Zone Liquid Tube - Fabricate 1/2 in. liquid tube from the host unit and route in the trough: install 1/2 in. x 1/2 in. x 1/2 in. tee (Item C), fabricate a 1/2 in. tube and route in the trough to Zone 3. from the 1/2 in. x 1/2 in. x 1/2 in. tee, fabricate a 1/2 in. tube, attach to a 1/2 in. x 3/8 in. x 3/8 in. tee and 3/8 in. tube and connect to the 3/8 in. fitting of the evaporator in Zone Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 5. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. ZONE 2 Fittings Required for MULTIPLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow B 5/8 in. x 5/8 in. x 5/8 in. Tee C 1/2 in. x 1/2 in. x 1/2 in. Tee Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 50

53 Evaporator Tube Connections S-3 + S-3 (Configuration Y Only) ZONE 2 51

54 Evaporator Tube Connections S-3 + S-3 (Configuration Y Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. NOTE: Due to the difficultly in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. IMPORTANT: You must connect one suction tube from the host to each evaporator. 1. Suction Tube - Fabricate a 1-1/8 in. suction tube from the host unit and route in the trough: install 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item A), and use 7/8 in. elbows (Item B) to connect the 7/8 in. tubes to the 7/8 in. fittings of each evaporator in Zone Hot Gas Tube- Fabricate a 5/8 in. hot gas tube from the host unit and route in the trough: install 5/8 in. x 5/8 in. x 5/8 in. tee (Item C), and connect the 5/8 in. tubes to the 5/8 in. fittings of each evaporator in Zone Liquid Tube - Fabricate 1/2 in. liquid tube from the host unit and route in the trough: install 1/2 in. x 1/2 in. x 1/2 in. tee (Item D), and connect the 1/2 in. tubes to 1/2 in. fittings of each evaporator in Zone Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 5. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. ZONE 3 Fittings Required for MULTIPLE Evaporator Installations Item Description P/N A 1-1/8 in. x 7/8 in. x 7/8 in. Tee B 7/8 in. x 7/8 in. Elbow C 5/8 in. x 5/8 in. x 5/8 in. Tee D 1/2 in. x 1/2 in. x 1/2 in. Tee Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 Suction (1-1/8 in.) G66 G58 52

55 Evaporator Tube Connections S-3 + S-3 (Configuration Y Only) ZONE 3 53

56 Evaporator Tube Connections S-3 + S-3 (Configuration Z Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. NOTE: Due to the difficultly in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. IMPORTANT: You must connect one suction tube from the host to each evaporator. 1. Liquid Tube - Fabricate 1/2 in. liquid tube from the host unit and route in the trough: install 1/2 in. x 1/2 in. x 1/2 in. tee (Item A), fabricate a 1/2 in. tube and route in the trough to Zone 3. from the 1/2 in. x 1/2 in. x 1/2 in. tee, fabricate a 1/2 in. tube, attach to a 1/2 in. x 3/8 in. x 3/8 in. tee (Item B) and 3/8 in. tube and connect to the 3/8 in. fitting of the 1st evaporator in Zone 2. from the 1/2 in. x 3/8 in. x 3/8 in. tee, fabricate a 3/8 in. tube and connect to the 3/8 in. fitting of the 2nd evaporator in Zone Suction Tube ZONE 2 - Fabricate a 1-1/8 in. suction tube from the host unit and route in the trough: install 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item C), attach a 7/8 in. tube and connect to the 7/8 in. fitting of the 2nd evaporator in Zone 2. from the 1-1/8 in. x 7/8 in. x 7/8 in. tee, install a 7/8 in. 90 degree elbow (Item D), attach a 7/8 in. tube and connect to the 7/8 in. fitting of the 1st evaporator in Zone Suction Tube ZONE 3 - Fabricate a 1-1/8 in. suction tube from the host unit and route in the trough to the Zone 3. ZONE 2 4. Hot Gas Tube - Fabricate a 5/8 in. hot gas tube from the host unit and route in the trough: install 5/8 in. x 5/8 in. x 5/8 in. tee (Item E), fabricate a 5/8 in. tube and route in the trough to Zone 3. from the 5/8 in. x 5/8 in. x 5/8 in. tee, attach a 5/8 in. x 1/2 in. x 1/2 in. tee (Item F) and 1/2 in. tube and connect it to the 1/2 in. fitting of the 1st evaporator in Zone 2. From the 5/8 in. x 1/2 in. x 1/2 in. tee, attach a 1/2 in. tube and connect it to the 1/2 in. fitting of the 2nd evaporator in Zone Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 6. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. Fittings Required for MULTIPLE Evaporator Installations Item Description P/N A 1/2 in. x 1/2 in. x 1/2 in. Tee B 1/2 in. x 3/8 in. x 3/8 in. Tee C 1-1/8 in. x 7/8 in. x 7/8 in. Tee D 7/8 in. x 90 Street Elbow E 5/8 in. x 5/8 in. x 5/8 in. Tee F 5/8 in. x 1/2 in. x 1/2 in. Tee Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 Suction (1-1/8 in.) G66 G58 54

57 Evaporator Tube Connections S-3 + S-3 (Configuration Z Only) ZONE 2 55

58 Evaporator Tube Connections S-3 + S-3 (Configuration Z Only) IMPORTANT: Clean all tubes and fittings prior to installation and soldering. NOTE: Due to the difficultly in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. NOTE: You must connect one suction tube from the host to each evaporator. 1. Suction Tube - Fabricate a 1-1/8 in. suction tube from the host unit and route in the trough: install 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item A), and use 7/8 in. elbows (Item B) to connect the 7/8 in. tubes to the 7/8 in. fittings of each evaporator in Zone Hot Gas Tube - Fabricate a 5/8 in. hot gas tube from the host unit and route in the trough: install 5/8 in. x 5/8 in. x 5/8 in. tee (Item C), and connect the 5/8 in. tubes to the 5/8 in. fittings of each evaporator in Zone Liquid Tube - Fabricate 1/2 in. liquid tube from the host unit and route in the trough: install 1/2 in. x 1/2 in. x 1/2 in. tee (Item D), and connect the 1/2 in. tubes to 1/2 in. fittings of each evaporator in Zone Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer trough cover. Hot gas tubes should be covered 100%. 5. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) between clamps. ZONE 3 Fittings Required for MULTIPLE Evaporator Installations Item Description P/N A 1-1/8 in. x 7/8 in. x 7/8 in. Tee B 7/8 in. x 7/8 in. Elbow C 5/8 in. x 5/8 in. x 5/8 in. Tee D 1/2 in. x 1/2 in. x 1/2 in. Tee Tubing Clamps Required Tube With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 Suction (1-1/8 in.) G66 G58 56

59 Evaporator Tube Connections S-3 + S-3 (Configuration Z Only) ZONE 3 57

60 Host & Evaporator Wire Connections - Zone 2 ZONE 2 - SINGLE EVAPORATORS 1. Connect ZONE 2-Sensor Harness (1E33293) at host unit (Detail I). Route harness into evaporator and connect to mating three connectors (Detail II). DO NOT CUT THE SENSOR HARNESS! Loop excess harness back on its self and secure with cable ties (Detail III). 2. Connect ZONE 2-Control Harness (1E33290) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (DH2, SLS2, LLS2, HGS2 and SC2), attach terminal connectors and connect to terminal block (Detail IV). 3. Connect ZONE 2-Fan 1 Harness (1E33414) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM21 and CH21), attach terminal connectors and connect to terminal block and ground stud (Detail IV). 4. Connect ZONE 2-Fan 2 Harness (2C25318) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM22 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail IV). S-3 EVAPORATORS ONLY 5. Connect ZONE 2 -Fan 3 Harness (2C25319) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM23 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail IV). ZONE 2 - PARALLEL EVAPORATORS 1. Connect ZONE 2-Sensor Harness (1E33293) at host unit (Detail I). Route harness into the first evaporator only and connect to mating three connectors (Detail II). NOTE: Although sensors are present in both evaporators, the harness is connected to one evaporator only. DO NOT CUT THE SENSOR HARNESS! Loop excess harness back on its self and secure with cable ties (Detail III). 2. Connect ZONE 2-Control Harness (1E33290) at host unit (Detail I). Route harness into first evaporator, cut to length, strip ends (DH2, SLS2, LLS2, HGS2 and SC2), attach terminal connectors and connect to terminal block (Detail V). 3. Connect ZONE 2-Fan 1 Harness (1E33414) at host unit (Detail I). Route harness into first evaporator, cut to length, strip ends (FM21 and CH21), attach terminal connectors and connect to terminal block and ground stud (Detail V). 4. Connect ZONE 2-Fan 2 Harness (2C25318) at host unit (Detail I). Route harness into first evaporator, cut to length, strip ends (FM22 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail V). S-3 EVAPORATORS ONLY 5. Connect ZONE 2 -Fan 3 Harness (2C25319) at host unit (Detail I). Route harness into first evaporator, cut to length, strip ends (FM23 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail V). 6. Interconnect Harness (1E39857) is used with S-3 evaporators. Route harness into the first evaporator and connect wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH and CH) to terminal block and ground studs (Detail V). Route harness into the second evaporator and connect wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH and CH) to terminal block and ground studs (Detail V). 7. Secure all harnesses with adequate clamps or ties. 58

61 Host & Evaporator Wire Connections - Zone 2 59

62 Host & Evaporator Wire Connections - Zone 3 ZONE 3 - SINGLE EVAPORATORS 1. Connect ZONE 3-Sensor Harness (1E33292) at host unit (Detail I). Route harness into evaporator and connect to mating three connectors (Detail II). DO NOT CUT THE SENSOR HARNESS! Loop excess harness back on its self and secure with cable ties (Detail III). 2. Connect ZONE 3-Control Harness (1E33291) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (DH3, SLS3, LLS3, HGS3 and SC3), attach terminal connectors and connect to terminal block (Detail IV). 3. Connect ZONE 3-Fan 1 Harness (1E33417) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM31 and CH31) attach terminal connectors and connect to terminal block and ground stud (Detail IV). 4. Connect ZONE 3-Fan 2 Harness (2C25320) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM32 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail IV). S-3 EVAPORATORS ONLY 5. Connect ZONE 3 -Fan 3 Harness (2C25321) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM33 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail IV). ZONE 3 - PARALLEL EVAPORATORS 1. Connect ZONE 3-Sensor Harness (1E33292) at host unit (Detail I). Route harness into the first evaporator only and connect to mating three connectors (Detail II). NOTE: Although sensors are present in both evaporators, the harness is connected to one evaporator only. DO NOT CUT THE SENSOR HARNESS! Loop excess harness back on its self and secure with cable ties (Detail III). 2. Connect ZONE 3-Control Harness (1E33291) at host unit (Detail I). Route harness into the first evaporator, cut to length, strip ends (DH3, SLS3, LLS3, HGS3 and SC3), attach terminal connectors and connect to terminal block (Detail V). 3. Connect ZONE 3-Fan 1 Harness (1E33417) at host unit (Detail I). Route harness into first evaporator, cut to length, strip ends (FM31 and CH31) attach terminal connectors and connect to terminal block and ground stud (Detail V). 4. Connect ZONE 3-Fan 2 Harness (2C25320) at host unit (Detail I). Route harness into first evaporator, cut to length, strip ends (FM32 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail V). S-3 EVAPORATORS ONLY 5. Connect ZONE 3 -Fan 3 Harness (2C25321) at host unit (Detail I). Route harness into first evaporator, cut to length, strip ends (FM33 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail V). 6. Interconnect Harness (1E39857) is used with S-3 evaporators. Route wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH, and CH) into first evaporator, cut to length, strip ends, attach terminal connectors and connect to terminal block and ground stud (Detail V). Route wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH, and CH) into second evaporator, cut to length, strip ends, attach terminal connectors and connect to terminal block and ground stud (Detail V). 7. Secure all harnesses with adequate clamps or ties. 60

63 Host & Evaporator Wire Connections - Zone 3 61

64 DE Host & Evaporator Wire Connections - Zone 3 ZONE 3 - SINGLE EVAPORATOR 1. Connect ZONE 3-Sensor Harness (1E37605) at host unit (Detail I). Route harness into evaporator and connect to mating three connectors (Detail II). DO NOT CUT THE SENSOR HARNESS! Loop excess harness back on its self and secure with cable ties (Detail III). 2. Connect ZONE 3-Control Harness (1E33291) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (DH3, SLS3, LLS3, HGS3 and SC3), attach terminal connectors and connect to terminal block (Detail IV). 3. Connect ZONE 3-Fan 1 Harness (1E33417) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM31 and CH31) attach terminal connectors and connect to terminal block and ground stud (Detail IV). 4. Connect ZONE 3-Fan 2 Harness (2C25320) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM32 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail IV). S-3 EVAPORATORS ONLY 5. Connect ZONE 3 -Fan 3 Harness (2C25321) at host unit (Detail I). Route harness into evaporator, cut to length, strip ends (FM33 and CH), attach terminal connectors and connect to terminal block and ground stud (Detail IV). 6. Secure all harnesses with adequate clamps or ties. 62

65 DE Host & Evaporator Wire Connections - Zone 3 63

66 Drain Hose Resistance Wire Installation Guide IMPORTANT: The following information is provided as a guide to help ensure the proper routing of the drain hose resistance wires. You should supplement this guide with whatever other documentation is required for your facility. Drain Hose Resistance Wire Installation Guide 1. Remove the resistance wire from the evaporator drain tube and pull the wire out straight. 2. Locate the evaporator defrost drain furthest from the trailer wall (i.e. in the middle of the trailer), and measure in. (838 mm) of the resistance wire from the drain pan outlet (Detail I). 3. Bend the resistance wire at this point and double it over (Detail II). 4. After doubling the resistance wire over (Step #3) take the excess wire and insert it back into the evaporator drain tube (Detail III). 5. Insert the doubled over end of the resistance wire into the drain Tee or 90 degree connector (Detail IV) and then into the crossover drain tube (Detail V). NOTE: The use of either white or blue drain tubes is acceptable when interconnecting multiple evaporators. All Remote Evaporators 6. Attach the drain Tee or 90 degree connector to the evaporator drain tube and push the connector on firmly to engage the O-ring (Detail VI). 7. Pull the resistance wire through the interconnecting drain tube as far as possible and make sure it is not bunched up (Detail VII). 8. Insert the other resistance wire into the other drain Tee connector and as shown (Detail VIII). IMPORTANT: At no time should resistance wires from one side of the drain pan overlap the resistance wires from the other side. 9. Attach the interconnecting drain tube to the opposite Tee connector by pushing the Tee connector on firmly to engage the O-ring (Detail IX). 10. Attach the Tee connector to the evaporator drain tube by pushing the Tee connector on firmly to engage the O-ring (Detail X). 11. Attach and route the evaporator drain tube over to the trailer wall drain. Insert the resistance wire into the trailer wall drain and pull it as far down the wall drain as possible (Detail XI). IMPORTANT: Only one resistance wire should be installed in the wall defrost drain tube. Only the resistance wire from the drain tube closest to the wall should be installed in the trailer drain tube. 64

67 Drain Hose Resistance Wire Installation Guide All Remote Evaporators 65

68 Drain Hose Installation IMPORTANT: DO NOT CUT RESISTANCE WIRES! NOTE: For proper drainage the drain hose must slope down continuously from the evaporator to the wall drains with no kinks or droop. NOTE: See Important Installation Notes on pages and Drain Hose Resistance Wire Installation Guide on pages for detailed instructions on the proper installation procedures of the drain hose and resistance wires. NOTE: Make sure drain tubes are properly seated on tube fittings before mounting to evaporator. Single S-3 Applications (Detail I) 1. Route resistance wires from the evaporator through the plastic drain hoses and insert the entire length of one resistance wire into each wall drain tube. 2. Connect the single drain hose to the wall drain tube using a short piece of plastic drain hose and clamp as required. 3. Replace one drain t-fitting with elbow fitting. For S-3 + S-3 Applications (Detail II) 4. Route resistance wires from the evaporator through the plastic drain hoses and insert the entire length of one resistance wire into each wall drain tubes. 5. Connect each drain hose to each wall drain tube using a short piece of plastic drain hose and clamps as required. All Remote Evaporators For Wall Mounted Tube Applications (Detail III) Insert the entire length of one resistance wire into each wall drain tube. Connect the plastic drain hose from the evaporator. For Wall Mounted Channel Applications (Detail IV) Insert the entire length of one resistance wire into each plastic drain hose. Feed the plastic drain hose down through the wall channel until it exits the bottom of the trailer. Optional Drain Hose Support (Detail V) The use of the optional drain hose support bracket is recommended when the evaporator is mounted sideways (transverse). Front Drain Hose Applications (Detail VI) Install drain t-fittings to allow drain tube to exit the front of the evaporator. Insert the entire length of one resistance wire into each drain hose, and route hose out the front of the cover to the wall drain. 66

69 Drain Hose Installation 67

70 Leak Check, Evacuation and Charging Procedures The following Leak Check, Evacuation and Charging Procedures are for S-600M and C-600M units. Set-up Unit The SR-4 Multi-Temp microprocessor must be placed in Evacuation Test to evacuate and charge the unit. When the microprocessor is in the Evacuation Test it opens all the normally closed solenoid valves in the refrigeration system. This allows the refrigeration system to be evacuated properly. Refer to the appropriate Diagnostic Manual for complete information about the microprocessor. Use the following procedure to set-up the unit and place the microprocessor in the Evacuation Test mode: 1. Press the ON key to turn the unit on. 2. Before the unit starts, press the MENU key. The first screen in the Main Menu (either the Language or Alarms Display) will appear. 3. Press the EXIT key and the unlabeled soft key at the same time, and hold them down for 5 seconds to enter the Maintenance Menu. The first Maintenance Menu feature will appear. 4. Press the NEXT (or BACK) key to scroll through the Maintenance Menu features until the Evacuation Test appears. 5. Press the SELECT key to enter the Evacuation Test. 6. Connect a battery charger to the unit battery. The battery charge must have an output of at least 15 amperes. This will maintain the charge level of the battery during the time required to evacuate and charge the unit. The Evacuation Test is used to open unit valves as required for evacuation. Failure to connect a battery charger may result in the battery voltage falling too low to reliably operate the microprocessor and valves. 7. The microprocessor is now in the Evacuation Test. The refrigeration system is set-up for leak checking, evacuation and charging. Leak Check System NOTE: Refer to Diagnosing Thermo King Refrigeration Systems (TK ) for leak detection procedures. 1. Connect leak test gas (R-404A) supply to center hose of gauge manifold. 2. Attach gauge manifold hoses to suction and discharge service valves. 3. Open suction and discharge valves and pressurize system to 25 psi with leak test gas. Monitor system pressure for one minute. 4. If pressure drops rapidly, there is a large leak. Do not continue until large leak is identified and corrected. If pressure does not change or drops slowly, add enough leak test gas to raise system up to bottle pressure. 5. Check connections made during installation for leaks using electronic leak detector. 6. Recover test gas to repair leaks. System must be vented while repairing solder joint leaks. Pressurize system and check again after a leak has been repaired. 7. If no leaks are found, recover test gas to 0 psi. 68

71 Leak Check, Evacuation and Charging Procedures The following Leak Check, Evacuation and Charging Procedures are for S-600M and C-600M units. Evacuating the System CAUTION: Do not evacuate the system until it is leak free. A unit with less than full refrigerant charge should be leak checked and all leaks must be repaired NOTE: The use of the Thermo King Evacuation Station (P/N or ) and Evacuation Station Operation and Field Application Instruction (TK ) is required. 1. Be sure all refrigerant has been recovered from the unit. 2. Connect a vacuum pump and gauge manifold for three-point evacuation to the suction service valve, discharge service valve, and receiver tank outlet valve. 3. Verify proper operation of the Evacuation Station as shown in the Evacuation Station Operation Manual (TK-40612). 4. Start the vacuum pump and mid-seat the suction service valve, discharge service valve, and receiver tank outlet valve. 5. Install service valve stem caps with seals and tighten them. The valve stems should remain capped while evacuating the unit. 6. Evacuate the unit to 500 microns, or the lowest achievable level between 500 and 1,000 microns. 7. Continue to evacuate the unit for one additional hour after reaching 500 microns, or the lowest achievable level between 500 and 1,000 microns. This insures complete evacuation of the remote evaporators and tubes. 8. Close the Evacuation Station valve nearest the vacuum pump (V1) to isolate the vacuum pump from the system. Turn the vacuum pump off. 9. Observe the micron gauge. The system pressure should remain below 2000 microns for 5 minutes. If the pressure does not hold, check for leaks (if a leak is suspected) or continue evacuation (if system is not dry). 10. Restart the vacuum pump, open the Evacuation Station valve nearest the vacuum pump (V1) and repeat steps 6, 8, and 9 as required until system pressure remains below 2000 microns for 5 minutes. 11. When system pressure remains below 2000 microns for 5 minutes, restart the vacuum pump and open the Evacuation Station valve nearest the vacuum pump (V1). 12. With the vacuum pump running, back seat the suction and discharge service valves. Replace the valve cap, re-close the Evacuation Station valve nearest the vacuum pump (V1), and stop the vacuum pump. 13. Close valve V4. The unit is ready to charge. NOTE: Do not exercise the service valves with the unit in a deep vacuum unless the vacuum pump is operating. 69

72 Leak Check, Evacuation and Charging Procedures V-4 2. V-3 3. V-2 4. V-1 5. Two-Stage Vacuum Pump 6. To AC Power 7. Vacuum or Micron Gauge 8. Thermistor 9. Correct Refrigerant Level Multi-Temp Evacuation and Charging (Two Zone Unit Shown Other Units Similar) 70

73 Leak Check, Evacuation and Charging Procedures The following Leak Check, Evacuation and Charging Procedures are for S-600M and C-600M units. Charging the System NOTE: The unit must be left in the Evacuation Test. 1. Insure all compartment bulkheads are open. Ceiling mounted bulkheads should not be stored close to the evaporator outlets as this will restrict airflow. 2. Before charging system, make sure refrigerant lines from the gauge manifold to refrigerant supply bottle have been evacuated or purged, the suction and discharge service valves are back seated, and receiver tank outlet valve is still open. 3. Set refrigerant supply bottle for liquid. Open gauge manifold hand valve and add a partial charge of R-404A through the receiver tank outlet valve. Add 14 lb (6.4 kg) to a unit with one remote evaporator. Add 15 lb (6.8 kg) to a unit with two remote evaporators. Do not add more than this. The remainder of charge will be added through suction service valve while unit is running. 4. Close gauge manifold hand valve. 5. Back seat (close) the receiver tank outlet valve. 6. Exit Evacuation Test by turning unit Off and then back On. 7. Turn all zones On and set all zone set points for lowest possible temperature to insure that all zones run in Cool mode. Allow unit to start. 8. Front seat suction service valve and allow compressor to pump down to 1 to 3 psi (7 to 21 kpa). Stop the unit. 9. Remove evacuation manifold hoses from receiver tank outlet valve, discharge service valve, and suction service valve. Replace and tighten service port and valve stem caps on receiver tank outlet valve. 10. Attach gauge manifold (with refrigerant supply bottle still connected) to compressor. Attach low side gauge to suction service valve. Mid-seat suction service valve. Attach high pressure gauge on to discharge service valve. Open discharge service valve to monitor discharge pressure. 11. Turn unit On, turn all zones On (with all zone set points set to the lowest possible temperature), and allow unit to start. 12. Observe suction pressure and slowly open gauge manifold hand valve to allow liquid refrigerant to flow into suction service valve. Control liquid flow so suction pressure increases 20 to 25 psi (138 to 172 kpa). Maintain a discharge pressure of 325 to 400 psi (2241 to 2758 kpa). 13. Add refrigerant until ball in receiver tank sight glass rises to middle of sight glass, then close gauge manifold hand valve. Make sure liquid level does not rise above top of sight glass. 14. Continue to operate unit and monitor sight glass until all compartment temperatures are at or below 0 F (-18 C). 15. Check position of ball in receiver tank sight glass. If liquid level has dropped, add liquid refrigerant until level stabilizes near middle of sight glass. Do not exceed recommended refrigerant charge for unit model. 16. Close hand valve on refrigerant supply bottle. 17. Back seat discharge service valve. 18. Open both hand valves on gauge manifold. 19. Front seat suction service valve and allow compressor to pump down to 1 to 3 psi (7 to 21 kpa). Stop the unit. 20. Remove gauge line from suction service valve and cap service port. 21. Remove gauge line from discharge service valve and cap service port. 22. Back seat suction service valve and cap valve stem. 23. Cap valve stem on discharge service valve. 24. Secure all gauge lines to gauge line anchors. 71

74 Installing Remote Evaporator Covers Installing Cap Plugs Cap plugs are provided to plug the two evaporator mounting access holes located directly above the drain pan. These plugs must be installed to prevent water in the drain pan from spilling out of these holes and into the cargo area. 1. Install the supplied cap plugs - 2 per evaporator. Installing Covers 2. Install FRONT COVER into support channel of evaporator. Secure with screws. 3. Install BACK COVER into support lip of front cover. Secure with screws. 72

75 Installing Remote Evaporator Covers 73

76 DE Installations Critical DE Installation Requirements All center-partition (longitudinally split trailer) installations are unique due to the splitting of the air supply outlets and air supply returns. The following details are critical to this installation: Unit Bulkhead - A special DE specific unit bulkhead must be installed and sealed properly to split the air supply returns for each compartment. Contact your Thermo King Dealer for details. Center Partition - The center partition must be installed and sealed properly to split the air supply outlets for each compartment. Rear Compartment Bulkhead - At least one rear compartment bulkhead must always be installed with a frozen compartment. Air Gaps - All air gaps must be properly sealed with foam insulation or caulking. Bulkheads and Center Partition Installation 1. Install the DE specific bulkhead onto the rear of the unit. Contact your Thermo King Dealer for details. 2. Center Divider Partition must have a tight seal along the floor and ceiling of the trailer and the back of the unit. All air gaps must be sealed completely with foam insulation or caulking. 3. At least one rear compartment bulkhead must always be installed with a frozen compartment. 74

77 DE Installations Alternative Roll Up Door Application Shown With Rear Compartment Bulkheads Installed Swing Door Application Shown With Rear Compartment Bulkheads Installed 75