V-220 / V-320 Heater Kits Installation Instructions TK IM (Rev. 0, 06/17)

Installation Manual V-220 / V-320 Heater Kits Installation Instructions TK 56340-18-IM (Rev. 0, 06/17)

Introduction This manual was written to help assist with the installation of the optional coolant heaters / electric heaters for Thermo King V-220, V-320 refrigeration units with remote evaporators. The Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430) provides additional detailed information that must be followed. This guide is available online @thermoking.com. Due to its complexity, do not attempt this installation unless you: Are an experienced mechanic. Can safely lift 34 kg (75 lb). Are certified or approved in the repair and maintenance of transport refrigeration systems. Have a basic understanding of electricity and electrical wiring. Have the necessary tools and equipment to complete the installation. Have a truck body designed and built to meet the requirements of this installation. Follow all safety precautions outlined in the Thermo King Installation Standards and Procedures Guide (TK 56430). This manual is published for informational purposes only. Thermo King makes no representations or 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 contacted. 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. 2

Table of Contents Safety Precautions........................................... 4 Heater Installation........................................... 6 Coolant Pump and Hose Installation............................ 8 Coolant Pump Harness Installation............................. 10 Heater Harness Installation - 1 PH Electric Heat Models Only....... 12 Heater Harness Installation - 3 PH Electric Heat Models Only....... 14 Bleeding and Pressure Testing the Coolant System................ 16 3

Safety Precautions The symbol appears next to a point that is particularly important: CAUTION: Addresses a circumstance that, if encountered, may cause damage to equipment or minor injury. 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. 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, battery acid and antifreeze 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 mounting bolts are tight and are of correct length for their particular application. 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: 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. WARNING: Exposed coil fins are very sharp and can cause painful lacerations. 4

Safety Precautions Refrigerant First Aid 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. 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. Antifreeze and Engine Coolant WARNING: Antifreeze (Ethylene Glycol) is toxic when swallowed. Do not breath mist or vapors. Wash hands thoroughly after handling to prevent irritation. First Aid INGESTION: CALL A PHYSICIAN and get prompt medical attention. INHALATION: Move victim to fresh air and restore and/or support breathing as required. If breathing is difficult, and get prompt medical attention. EYES: In case of eye contact, flush with plenty of water for at least 15 minutes. SKIN: Brief contact with skin is not irritating. Wash skin with soap and water, if irritation persists, seek medical attention. 5

Heater Installation Temperature Sensor Relocation Procedures CAUTION: Before retro-fitting a vehicle powered truck refrigeration unit with a heater system, always disconnect the vehicle s negative (-) battery cable and standby AC electrical power source (if applicable) to prevent the unit from starting and causing personal injury. IMPORTANT: The temperature sensor must be relocated to the heater for the unit to operate properly. 1. Remove evaporator cover and disconnect electrical connectors. 2. Locate the fan with the temperature sensor and remove the four (4) screws securing the fan to the cover. 3. Disconnect and remove the temperature sensor, clamp and mounting hardware. These parts will be reinstalled onto the heater in step #4. Re-route the pink/black wires from the main harness (for the temperature sensor) out of the evaporator so it can be re-connected to the sensor in its new location. Reinstall the fan onto the cover and tighten screws. 4. Reinstall sensor to the OUTSIDE of heater housing, over the oval hole, using clamp and mounting hardware removed earlier. Heater Installation 5. Reinstall the evaporator cover and electrical connectors, replacing the four mounting bolts with the supplied double-sided M5 mounting studs. Tighten hardware to 22 in-lbs (2.5 N m). 6. Position heater assembly onto the mounting studs and secure with the supplied M5 flat washers, lock washers and nuts. Tighten hardware to 22 in-lbs (2.5 N m). Reconnect temperature sensor to mating connector with the pink/black wires from the main harness. Secure harness with tie bands. 7. Locate and drill appropriate size hole in the truck box for the coolant heater hoses to pass through. 6

Heater Installation 7

Coolant Pump and Hose Installation CAUTION: Engine coolant may be hot. Allow vehicle engine and coolant to cool prior to beginning work on the vehicle. NOTE: The coolant pump should be installed outside the vehicle s insulated box and as close to the engine as possible (see illustration on page 9). Silicon hoses for coolant lines is supplied by the installer. NOTE: The installer must check with the vehicle manufacturer to ensure coolant heater system will not interfere with the vehicle s performance, emissions or void manufacturers warranty. 1. Install the coolant pump securely to the vehicle noting the locations of the INLET and OUTLET hose fittings. 3. Route the OUTLET hose of the coolant pump to the INLET hose fitting of the heater assembly. 4. Install a tee in line with the vehicle s heater coolant return hose. This should be the hose that runs to the vehicle coolant pump inlet. From the tee connect a coolant hose and route it to the OUTLET hose fitting (with air bleeder) on the heater assembly. 5. All coolant hoses should be properly routed and adequately secured every 305 mm (12.00 in.) with clamps. Hoses should be routed and protected from heat sources (i.e., exhaust systems, etc.) Hose protection should be added to prevent rubbing and chaffing against sharp edges. 6. Seal coolant hose access holes with silicone or expanding foam. NOTE: Before starting the vehicle, fill coolant system with the proper coolant and follow Bleeding and Pressure Testing the Coolant System on page 16. IMPORTANT: Mixing of different types of antifreeze may result in cooling system damage. Refer to the vehicles owners manual to identify the proper type of antifreeze. 2. Install a tee in line with the vehicle s coolant pump outlet hose. This should be the hose that runs from the OUTLET of the vehicle s engine coolant pump before the thermostat. Run a hose from this tee to the coolant pump INLET fitting. 8

Coolant Pump and Hose Installation 9

Coolant Pump Harness Installation 1. Remove condenser cover and fan assembly. 2. Attach coolant harness connector (26A-01, CH-01) to mating connector labeled PS 5 (26A, CH5) located in the condenser. 3. Route harness out of the condenser and down to the engine compartment following the heater hoses. Secure harness adequately. 4. Attach connector (26A-02, CH-02) to coolant valve. 5. Attach connector (26A-03, CH-03) to coolant pump. Electric Heat Models Only - Continue with the installation. See warning below. Coolant Heat Models Only - Reinstall condenser fan assembly and cover. See warning below. WARNING: Any unit with the coolant heat / electric heat option will need a new configuration file loaded into the controller by the installer. Failure to properly load the correct configuration file will result in decreased performance and possible damage to the system. See Section 9 in the Vehicle Powered Truck Installation Standards and Procedures Guide TK 56430 for details. 10

Coolant Pump Harness Installation 11

Heater Harness Installation - 1 PH Electric Heat Models Only IMPORTANT: 1 Phase units require modifications to the wiring. This involves simply cutting off four (4) forked terminals, combing the two (2) sets of wires together into one (1) terminal, and installing them onto the motor contactor. These modifications must be done to reduce the amount of connectors on the standby motor contactor from four to two. See Heater Harness Modifications for details. NOTE: Wiring Diagrams and Wiring Schematics can be found in the V-220 / V-320 Diagrams Manual (TK 56545). 1. Attach 10-Pin harness connector securely to the mating connector on the contactor box of the heater assembly. Route the harness from the heater into the condenser. 2. Attach connectors (EF1, EF1-3) and (EF2-HC, EF2-3) to the mating connectors in the condenser. Remove and discard jumpers from the connectors. EF-2 wires are tagged and they must be connected correctly. IMPORTANT: Failure to connect the fan wires correctly may result in unit damage! 3. Attach wire (CH-08) securely to one of the unit s curbside ground studs. 4. Attach wires (CH-04) and (CH-06) securely to one of the unit s ground studs above the condenser coil. 5. Lift up the plastic shield and locate the terminal strip with wire 2RA attached. Attach wire (2A-3) opposite of the 2RA wire location per the illustration on the next page. Secure the fuse holder to the relay plate with one of the screws as shown. Replace plastic shield over terminal strip. Heater Harness Modifications 6. Cut terminal forks off heater harness wires L1-01 and H2-01 and strip 0.25 in. off the ends of both wires. 7. Remove the Black and White wires from the electric standby compressor motor contactor, cut the terminal forks off each wire and strip 0.25 in. off the ends. 8. Join wire L1-01 and the Black wire together and attach a supplied terminal fork using a suitable crimping tool. Reinstall the terminal fork back onto location 3 (L2) on the contactor where the Black wire was originally attached and torque to 7 in-lbs. 9. Join wire H2-01 and the White wire together and attach a supplied terminal fork using a suitable crimping tool. Reinstall the terminal fork back onto location 5 (L3) on the contactor where the White wire was originally attached and torque to 7 in-lbs. 10. Route harness along the top of the condenser frame and secure alongside the main harness with band warps. 11. Neatly bundle and secure all wires with band wraps to prevent chaffing or damage. 12. Reinstall all covers removed during installation. IMPORTANT: Any unit with the coolant heat / electric heat option will need a new configuration file loaded into the controller by the installer. Failure to properly load the correct configuration file will result in decreased performance and possible damage to the system. See Section 9 in the Vehicle Powered Truck Installation Standards and Procedures Guide TK 56430 for details. 12

Heater Harness Installation - 1 PH Electric Heat Models Only 13

Heater Harness Installation - 3 PH Electric Heat Models Only NOTE: Wiring Diagrams and Wiring Schematics can be found in the V-220 / V-320 Diagrams Manual (TK 56545). 1. Connect 10-Pin harness connector securely to the mating connector on the contactor box of the heater assembly. Route the harness from the heater into the condenser. 2. Connect 2-pin connectors (EF1, EF1-3) and (EF2-HC, EF2-3) to the mating connectors in the condenser. Remove and discard jumpers from the connectors. EF-2 wires are tagged - they must be connected correctly. IMPORTANT: Failure to connect the fan wires correctly may result in unit damage. 3. Attach wire (CH-08) securely to one of the unit s curbside ground studs. 4. Attach wires (CH-04) and (CH-06) securely to one of the unit s ground studs above the condenser coil. 5. Lift up the white plastic shield and locate the terminal strip with wire 2RA attached. Attach wire (2A-3) opposite of the 2RA wire location per the illustration on the next page. Secure the fuse holder to the relay plate with one of the screws as shown. Make sure plastic shield is replaced over terminal strip. 6. Attach terminal fork wire (H2-01) onto the standby compressor motor contactor along with the Red wire. 7. Attach terminal fork wire (L1-01) onto the standby compressor motor contactor along with the Black wire. 8. Route harness along the top of the condenser frame and secure alongside the main harness with band warps. 9. Neatly bundle and secure all wires with band wraps to prevent chaffing or damage. 10. Reinstall all covers removed during installation. IMPORTANT: Any unit with the coolant heat / electric heat option will need a new configuration file loaded into controller by the installer. Failure to properly load the correct configuration file will result in decreased performance and possible damage to the system. See Section 9 in the Vehicle Powered Truck Installation Standards and Procedures Guide TK 56430 for details. 14

Heater Harness Installation - 3 PH Electric Heat Models Only 15

Bleeding and Pressure Testing the Coolant System Bleeding the Coolant System WARNING: Always wear goggles or safety glasses. Refrigerant liquid, refrigeration oil, battery acid and antifreeze can permanently damage the eyes (see First Aid under Refrigeration Oil). IMPORTANT: Any air in the coolant system must be bled after completing the installation using the bleed fitting (see page 9) located on the outlet tube of the heater coil. IMPORTANT: Mixing of different types of antifreeze may result in cooling system damage. Refer to the vehicles owners manual to identify the proper type of antifreeze. 1. Disconnect coolant lines from the fittings at the Thermo King heater coil and fill both the lines with coolant. Reconnect lines to heater. 2. Fill the vehicle s coolant system and purge per the vehicle manufacturers recommendations. 3. Set unit to heat (raise set-point above box temperature) to ensure coolant pump/solenoid are energized. 4. Connect spill-free funnel to radiator cap and fill with coolant. Ensure funnel has coolant present during entire fill process. (You may need to refill several times). 5. Start vehicle engine and allow to reach operating temperature. 6. Remove cap on bleed port and depress valve until coolant is expelled. 7. Reinstall bleed port cap. 8. Cover all heater hoses with insulation on any portion of hose that runs inside the insulated cargo box. This will help minimize the heat addition when the unit is in the cooling mode. NOTE: It is recommended to test drive the vehicle after completing the cooling system bleeding procedure and top off the cooling system with coolant as required. Pressure Testing the Coolant System Pressure testing the system is an optional procedure used to identify leaks. Follow the vehicle s manufacturers recommendations for pressure testing your vehicle s cooling system. When pressure testing the unit, place solenoid valve magnet (TK 204-1074) onto the coolant pump solenoid. IMPORTANT: Do not pressure test the system above the pressure sitting on the engine radiator cap. Damage to the cooling system may occur. 16

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