Thermo King E-200 Installation Manual

E-200 Series Single Temperature Systems Installation Manual

TK 56881-18-IM-EN Introduction This manual was written to assist with the general installation of Thermo King® components onto trucks designed and built for refrigerated applications. The TThheerrm moo KKiinngg IInnssttaallllaattiioonn SSttaannddaarrddss aanndd PPrroocceedduurreess GGuuiiddee (TK 56430) provides more detailed information that must be followed to safely and properly complete the entire installation. Due to its complexity, you should not attempt this installation unless you: • Are an experienced mechanic. • Can safely lift 34 kilos (75 lbs.). • In the U.S., EPA 608 certified and trained 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 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. TThheerrm moo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippm meenntt wwhhiicchh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, m maaiinnttaaiinneedd,, rreeppaaiirreedd oorr aalltteerreedd aass,, iinn tthhee m maannuuffaaccttuurreerr’’ss jjuuddggm meenntt,, ttoo aaffffeecctt iittss iinntteeggrriittyy..”” M Maannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaam maaggee oorr aannyy ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaam maaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss m maannuuaall oorr aannyy iinnffoorrm maattiioonn,, rreeccoom mm meennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iim mpplleem meenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy m maayy ccaauussee ddaam maaggee ttoo tthhee TThheerrm moo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy.. Revision History Revision A (02/21) Released new manual. Revision B (07/21) Page 45 - Corrected 115V/1PH electrical plug number. Customer Satisfaction Survey Let your voice be heard! Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a web browser. Scan the Quick Response (QR) code or click or type the web address https://tranetechnologies.iad1.qualtrics.com/jfe/ form/SV_2octfSHoUJxsk6x?Q_CHL=qr&Q_JFE=qdg to complete the survey.

Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Recover Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 RReeqquuiirreedd TToooollss .................................................................................................................................................................... 66 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Required Support Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 AAlltteerrnnaattoorr AAm mppeerraaggee TTeesstt ............................................................................................................................................ 88 Recommended Best Practice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 UUnnppaacckkiinngg aanndd IInnssppeeccttiinngg tthhee UUnniitt.......................................................................................................................... 99 Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspecting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Auto Start Hard Stop / Disable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PPrreeppaarriinngg CCoonnddeennsseerr ffoorr IInnssttaallllaattiioonn.................................................................................................................... 1111 Cover and Fan Housing Removal (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fan Housing Modifications (Nosemount Installations Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 IInnssttaalllliinngg tthhee CCoonnddeennsseerr.............................................................................................................................................. 1133 Condenser Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Roof Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Front Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 EEvvaappoorraattoorr IInnssttaallllaattiioonn ................................................................................................................................................ 1166 Installing the Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 RReeffrriiggeerraanntt HHoossee CCoonnnneeccttiioonnss.................................................................................................................................. 1177 IInnssttaalllliinngg tthhee FFiilltteerr DDrriieerr aanndd SSiigghhtt GGllaassss .......................................................................................................... 1188 W Wiirriinngg CCoonnnneeccttiioonnss ........................................................................................................................................................ 1199 IInnssttaalllliinngg tthhee IInn--CCaabb CCoonnttrroolllleerr................................................................................................................................ 2200 Optional Internal DIN Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 BBaatttteerryy CCoonnnneeccttiioonnss ...................................................................................................................................................... 2222 CCoonnnneeccttiinngg ttoo TThhiirrdd PPaarrttyy HHoollddoovveerr BBaatttteerryy OOppttiioonn .................................................................................... 2233 Hold-over Option Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Controller Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SSttaarrtt//SSttoopp FFuunnccttiioonnaalliittyy .............................................................................................................................................. 2266 Table of Contents

Parts Required before Starting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 IInnccrreeaasseedd IIddllee SSppeeeedd SSeettuupp........................................................................................................................................ 3300 Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Parts Required before Starting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SSttaannddbbyy RReecceeppttaaccllee BBooxx IInnssttaallllaattiioonn ((M Mooddeellss 2200 aanndd 5500 OOnnllyy)).............................................................. 3344 EEvvaappoorraattoorr DDrraaiinn HHoossee IInnssttaallllaattiioonn........................................................................................................................ 3355 ES-100N/ES150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 CCoom mpplleettiinngg tthhee IInnssttaallllaattiioonn........................................................................................................................................ 3377 SSuuccttiioonn PPrreessssuurree RReegguullaattoorr ((SSPPRR)) AAddjjuussttm meenntt PPrroocceedduurreess -- M MAAXX .................................................... 3388 DDiisscchhaarrggee PPrreessssuurree RReegguullaattoorr ((DDPPRR)) AAddjjuussttm meenntt PPrroocceedduurreess -- M MAAXX................................................ 3399 CCoom mpprreessssoorr OOiill AAm moouunnttss aanndd TTyyppee ...................................................................................................................... 4400 RReeccoom mm meennddeedd RReeffrriiggeerraanntt CChhaarrggee bbyy M Mooddeell.................................................................................................. 4411 CChheecckkiinngg tthhee IInnssttaallllaattiioonn ............................................................................................................................................ 4422 CCoonnddeennsseerr aanndd EEvvaappoorraattoorr DDiim meennssiioonnss ............................................................................................................ 4433 SSttaannddbbyy PPoowweerr PPlluugg W Wiirriinngg ...................................................................................................................................... 4455 TTaabbllee ooff CCoonntteennttss

Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices. Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions. The four types of advisories are defined as follows: DDAANNGGEERR HHaazzaarrdd!! IInnddiiccaatteess aann iim mm miinneennttllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, wwiillll rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. W WAARRNNIINNGG HHaazzaarrdd!! IInnddiiccaatteess aa ppootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. CCAAUUTTIIOONN HHaazzaarrdd!! IInnddiiccaatteess aa ppootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, ccoouulldd rreessuulltt iinn m miinnoorr oorr m mooddeerraattee iinnjjuurryy aanndd uunnssaaffee pprraaccttiicceess.. NNOOTTIICCEE HHaazzaarrdd!! IInnddiiccaatteess aa ssiittuuaattiioonn tthhaatt ccoouulldd rreessuulltt iinn eeqquuiippm meenntt oorr pprrooppeerrttyy--ddaam maaggee oonnllyy aacccciiddeennttss.. Recover Refrigerant NNoottee:: In the USA, EPA Section 608 Certification is required to work on refrigeration systems. In the EU, local F-gas Regulations must be observed when working on refrigeration systems. 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. When working on transport temperature control systems, a recovery process that prevents or minimizes refrigerant loss to the atmosphere is required by law. In addition, service personnel must be aware of the appropriate European Union, National, Federal, State, and/or Local regulations governing the use of refrigerants and certification of technicians. For additional information on regulations and technician programs, contact your local THERMO KING dealer. SSeerrvviiccee TToooollss - Use the proper service tools. Gauge manifold sets should include appropriate shutoff valves or disconnects near the end of each service line. RReeccoovveerryy EEqquuiippm meenntt - Recovery equipment must be used. Proper recovering, storing and recycling of refrigerants is an important part of all service work. SSeerrvviiccee PPrroocceedduurreess - Recommended procedures must be used to minimize refrigerant loss. CCoom mppoonneennttss m maayy bbee iissoollaatteedd by closing service valves and performing system pump-downs. CCoom mppoonneennttss uunnaabbllee ttoo bbee iissoollaatteedd for service must be repaired only after refrigerant is properly recovered.

required when installing Thermo King Vehicle Powered Truck Units. Using these tools will assure the installation is done correctly. Many of these are available from Thermo King. *These are included with the Evacuation Station 204-725.

Required Support Materials Please have the following support material in hand prior to starting your installation as it is listed as reference throughout this manual: 1. Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430) located at www.thermoking.com RReeqquuiirreedd TToooollss

Recommended Best Practice Before install of the E-200 it is recommended to get a baseline of the amp draw being consumed by the vehicle. Using an amp clamp on the alternator output wire measure the amp draw: 1. At idle 2. Radio on 3. AC and fans on high 4. Wipers on high 5. Headlights on For the example above we measure 60 amps. The E-200 requires an additional 115 amps excess amperage from the alternator. For best results, this should be available even at idle, at which point the alternator will have approximately 60-75% the rated amperage. EExxaam mppllee:: • Using the amp draw as defined above the vehicle uses 60 amps. • Power requirement of 60A draw from the vehicle + 115A draw of the E-200 = 175A. • Available power at idle needs to be 60-75% of the alternators rated amperage/150-187 amps available for an alternator rated at 250 amps. • Knowing the E-200 and vehicle needs 175 amps we would want an alternator with at least 250 amps or higher.

Unpacking the Unit 1. Open the packaging. 2. Find the unit documentation. 3. Verify that the packaging contains all the accessories indicated on the list attached with the documentation. 4. Check that the hose length is correct before starting the installation. Checking can be carried out by consulting the “Packing List” included with the unit documentation. Inspecting the Unit 1. Open the condenser unit cover and ensure the following: • Neither the cover nor the unit should show any shock damage or imperfections. • The condenser unit should be charged with helium gas. • The voltage of all the electrical components is correct (12/24V). 2. Open the evaporator unit cover and make the following checks: • Neither the cover nor the unit should show any shock damage or imperfections. • The evaporator unit should be charged with helium gas. • The voltage of all the electrical components is correct (12/24V).

DDAANNGGEERR HHaazzaarrddoouuss VVoollttaaggee!! TTaakkee ccaarree tthhaatt tthhiiss ccoonnnneeccttoorr ddooeess nnoott ddiissccoonnnneecctt tthhee AACC vvoollttaaggee iinnppuutt.. IIff sseerrvviiccee ooff tthhee eelleeccttrriiccaall bbooxx iiss rreeqquuiirreedd,, yyoouu M MUUSSTT uunnpplluugg tthhee AACC SShhoorree PPoowweerr bbeeffoorree pprroocceeeeddiinngg.. This connector has the following two main functionalities: 1. HHaarrdd SSttoopp - this connector is wired directly to the power relays. When you disconnect (unplug this connector), the relays and the circuit opens immediately stopping the unit. 2. DDiissaabbllee AAuuttoossttaarrtt - during unit commissioning or while any maintenance is being carried out on the unit, and a power off Is needed, is recommended to unplug this connector. In this case, the power relays remain open and the machine cannot start. UUnnppaacckkiinngg aanndd IInnssppeeccttiinngg tthhee UUnniitt

Cover and Fan Housing Removal (All Models) To access the unit mounting holes: 1. Remove plastic condenser cover. 2. Remove the fan housing assembly. (Remove the fan connector). 3. Remove “Power Off Device” Connector and Electric Box Cover. 4. Mounting holes are now accessible.

Turn fan housing over and use a hand saw to trim the area shown for refrigeration hose clearance. NNoottee:: The fan housing assembly will be reinstalled later. 1. Access for Hoses and Harnesses PPrreeppaarriinngg CCoonnddeennsseerr ffoorr IInnssttaallllaattiioonn

Condenser Installation IIm mppoorrttaanntt:: See Section 4 - Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! NNoottee:: Nose mount and roof top condenser mounting and access hole dimensions can be found at the back of this manual. W WAARRNNIINNGG EEqquuiippm meenntt DDaam maaggee!! SSeeaall aallll tthhee hhoolleess iinnssiiddee tthhee eelleeccttrriicc bbooxx wwhhiicchh aarree nnoott uusseedd ffoorr iinnssttaallllaattiioonn ((ddeeppeennddiinngg nnoossee m moouunntt//rrooooff ttoopp)).. OOtthheerrwwiissee wwaatteerr wwiillll ggeett iinnttoo tthhee eelleeccttrriicc bbooxx aanndd ddaam maaggee tthhee ccoom mppoonneennttss.. Figure 1. Condenser Mounting Bolts 1. Mounting holes when unit is mounted on the Front of the Truck (6) 2. Mounting holes when unit is mounted on the Roof of the Truck (6)

Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! 1. Position condenser onto roof and install mounting hardware as shown. a. Rotate rubber compensation washers until condenser is level. b. Tighten hardware to 7 ft-lbs (10 N•m). 2. Reinstall electric box cover and reattach “Power Off Device” connector. 3. Route electrical harnesses through access hole in condenser frame and into cargo area. Figure 2. Roof Mounted Condenser Shown 1 2 3 4 5 6 7 8 9 RCS1678 1. Bolt, M10 2. Washer, large metal M10 3. Washer, flat rubber 4. Vehicle roof 5. Washer, large rubber (with incline) 6. Washer, small rubber (compensation) 7. E-100 Condenser frame 8. Washer, split lock M10 9. Nut, M10 IInnssttaalllliinngg tthhee CCoonnddeennsseerr

Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! 1. Attach supplied foam insulation to rear of condenser as shown. 2. Position condenser onto front of cargo box and install mounting hardware as shown. a. Tighten hardware to 26.5 ft-lb. (36 N•m). 3. Reinstall electric box cover and reattach “Power Off Device” connector. 4. Route electrical harnesses through access hole in condenser frame and into cargo area. Figure 3. Front Mounted Condenser Shown RCS1679 IInnssttaalllliinngg tthhee CCoonnddeennsseerr

IIm mppoorrttaanntt:: See Section 4 - Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! 1. Remove screws securing evaporator cover to evaporator frame and remove cover. NNoottee:: Follow instruction on template to install evaporator on vehicle’s ceiling and to drill access hole for refrigerant hoses and electrical wiring. Check for interference with vehicle electrical wires, etc. before drilling holes. 2. Drill access hole for refrigerant hoses and electrical wiring. 3. Mark mounting locations and drill pilot holes in ceiling. a. Loosely install supplied lag bolts and washers into ceiling pilot holes. b. Tighten bolts until approximately 0.50 in. (6 mm) protrudes from ceiling. 4. Position the evaporator’s keyhole mounting holes onto the lag bolts in the ceiling. a. Slide evaporator so bolts fit into keyhole slots and tighten screws securely. Figure 4. Typical ceiling mounted evaporator shown X4 X4 RCS1618

IIm mppoorrttaanntt:: See Section 6 - Refrigerant Hose and Fittings Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! Figure 5. Hose Connections Shown 1. O-Ring (#4, o-ring seal) 8. Fitting, straight (female o-ring seal, #6 fitting to #8 hose) 2. Fitting, straight (female o-ring seal, #4 fitting to #4 hose) 9. O-Ring (#10, o-ring seal) 3. O-Ring (#6, o-ring seal) 10. Fitting, 90 degree (female o-ring seal, #10 fitting to #10 hose) 4. Fitting, 90 degree (female o-ring seal, #6 fitting to #6 hose) 11. Hose, liquid line (#4, 50 ft) 5. O-Ring (#8, o-ring seal) 12. Hose, defrost line (#6, 50 ft) 6. Fitting, 90 degree (female o-ring seal, #8 fitting to #10 hose) 13. Hose, suction line (#10, 50 ft) 7. Fitting, 90 degree (straight, #6 fitting to #4 hose)

1. Locate the Filter Drier/Sight Glass assembly in your installation kit. 2. Lubricate the o-rings prior to installing them onto each end of the assemblies. 3. Install the assembly with appropriate wrench (hand tighten). 4. Perform vacuum procedure of air from the Filter Drier and Sight Glass via the service valves on either side of this assembly. IIm mppoorrttaanntt:: See Section 10 - System Evacuation Procedures and Section 12 - System Charging Procedures in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! Figure 6. Installing the Filter Drier and Sight Glass

Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! 2 3 7 4 5 6 11 A C D E 8 9 B 1 NBAT 10 + ACC BAT RCS1681 Item Component Description Connections Item Component Description Connections A. Main Harness Connections 4. Temperature Sensor S1/PNK B. To Power Receptacle 5. Evaporator Fan 1 CH_B/EF1 C. To Vehicle Ignition Switch ACC. 6. Drain Line Heater 1 HT1/CH_A D. To Vehicle Battery + BAT+ 7. Defrost Solenoid PS1/CH_Y E. To Vehicle Battery — BAt- 8. Vehicle Battery Fuse (F25) 5A 1. Door Switch DSW1/CHW 9. Ignition Fuse 5A 2. Defrost Temperature Switch DKI/CHB 10. Main Fuse 150A 3. Liquid Solenoid Valve PS3/CHI 11. HMI In-Cab Controller RXD, TXD, 8XP, CH_N

1. Install the mounting bracket for the controller. Its design allows the mounting bracket to be positioned in various places in the cab interior. Find a location which is accessible and visible from the driver’s seat, and which does not restrict the mobility or visibility of either the driver or the vehicle’s instruments and levers. 2. Depending on the location chosen, the base should be mounted following either Option A or Option B. 3. Mount the base of the mounting bracket in the chosen location. Use screws ((CC)), rubber mat ((DD)) and metal plate ((EE)), which are supplied by Thermo King, as indicated in the drawing. 4. When placing the controller on the bracket, rest the controller on the arm ((FF)), and slide it to the right until the arm tab is properly fitted to the controller frame. 5. The tilt of the controller’s front face may be altered by loosening screw ((GG)). 6. Connect the data cable to connector ((HH)). 7. To remove the controller from the bracket, press the tab ((II)) and slide to the left. Figure 7. In-Cab controller shown RCS1622 1 2 3 4 5-6 7

1. Place the DIN adapter metal box ((JJ)) supplied in the housing designed for the radio. Raise the tabs ((M M)) sufficiently to fit the box into the housing. 2. Attach the control to the plastic bracket ((LL)) using the 4 screws ((KK)). 3. Connect the data cable to the control connector ((HH)). 4. Insert the assembly formed by the control box and the plastic bracket into the metal box, until the bracket tabs are properly fitted to the metal box. Figure 8. DIN adaptor shown RCS1623 IInnssttaalllliinngg tthhee IInn--CCaabb CCoonnttrroolllleerr

Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! NNoottee:: If the vehicle is equipped with a battery disconnect switch, always wire the unit after the switch. This allows power to the unit to be turned off by the battery disconnect switch. 1. Route electrical wires BLACK, 01/ BAT, and BROWN to the vehicle battery. 2. Cut wires to the proper lengths. DDoo nnoott ccooiill oorr sspplliiccee tthhee eexxcceessss wwiirree.. a. Strip wires and install the terminals supplied. 3. RREEM MOOVVEE TTHHEE NNEEGGAATTIIVVEE CCAABBLLEE FFRROOM M TTHHEE BBAATTTTEERRYY.. 4. Connect 2 wire to one end of the fuse FP fuse holder (both supplied by Thermo King) and connect the other end of the fuse holder to the battery's positive terminal. a. Install fuse FP (100A/12V or 60A/24V) in the fuse holder. See note above. 5. Connect the 01/BAT wire to one end of the fuse F14 fuse holder (supplied by Thermo King), and connect the other end of the fuse holder to the battery’s positive terminal. a. Install fuse F14 (5A) in the fuse holder. 6. Connect BLACK wire to the battery’s negative terminal. 7. Reconnect the battery’s negative cable. Figure 9. Typical battery connections shown RCS1628 BROWN BLACK

This option uses an auxiliary battery provided by your vehicle manufacturer. It allows the user to maintain the temperature control of the compartment for a certain period when there is no alternator or stand-by power sources available. Some vehicle manufacturers include from factory option to equip a secondary battery of the same technology of the main battery (AGM) with an optional relay (KBAT) and a higher rating alternator to serve auxiliary equipment. Other Vehicle manufacturers may offer it as an option, installed by vehicle dealer. • The holdover time will depend on the thermal losses ad the load conditions. • The energy is taken from a battery supplied with the vehicle. • The KKbbaatt signal is activated by the vehicle ECU that closes the contact when the engine has started. • The KKbbaatt opens when the engine has stopped allowing the E-200 equipment to drain only the secondary battery without compromising the start-up of the engine. 1. Vehicle Secondary Battery 2. Fuse (150 A) 3. Ignition Switch

NNOOTTIICCEE EEqquuiippm meenntt DDaam maaggee!! DDoo nnoott uussee hhoolldd--oovveerr ffuunnccttiioonnaalliittyy iinn aa vveehhiiccllee wwiitthhoouutt eexxtteennddeedd bbaatttteerryy ooppttiioonn ootthheerrwwiissee tthhee m maaiinn bbaatttteerryy wwiillll bbee ddeepplleetteedd ccoom mpprroom miissiinngg tthhee aabbiilliittyy ttoo ssttaarrtt tthhee eennggiinnee.. W WAARRNNIINNGG HHaazzaarrdd ooff EExxpplloossiioonn!! IIm mpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccaabblleess ccoouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. BBaatttteerryy ccaabblleess m muusstt bbee iinnssttaalllleedd,, rroouutteedd,, aanndd sseeccuurreedd pprrooppeerrllyy ttoo pprreevveenntt tthheem m ffrroom m rruubbbbiinngg,, cchhaaffffiinngg,, oorr m maakkiinngg ccoonnttaacctt wwiitthh hhoott,, sshhaarrpp,, oorr rroottaattiinngg ccoom mppoonneennttss.. Controller Set-up 1. Gateway Controller software version - GC 4.7 or higher 2. In order to enable the hold over the dealer have to change the setting of the parameter H1A to HOSTA =1 (The factory setting is HOSTA = 0). To do so follow the process described in Service Bulletin SB 1228 or save the appropriate WINTRAC file. 3. The following parameters are also required to function correctly: • [H1d] [HOCFR]=45Hz (Compressor frequency in Holdover state) that allows the maintenance personnel to adjust the operating frequency in holdover state. • [H1b] HOTYP=2 (Default setting from factory) that indicates the holdover functionality is performed using the extended battery option. Installation Guidelines 1. Locate the secondary battery and relay contactor into the vehicle. 2. From the main harness, locate the battery wires for BAT, NBAT and ACC1. These wires need to be spliced, and also a fuse holder added to the BAT wire. IIm mppoorrttaanntt:: Please ensure to connect the NBAT wire to ground. The unit will still operate if you fail to do so, however, it will not operate correctly and may be hard to troubleshoot at a later stage. See diagram below. 3. Connect the positive (50 mm2 red wire) with the 150A fuse to the positive of the secondary battery. 4. Connect the negative (50 mm2 black wire) to a ground post as close as possible to the negative terminal of the secondary battery. 5. Connect the BAT wire to the positive terminal of the secondary battery. This wire will power the Gateway in holdover state and will allow to precisely measure the battery condition. 6. Connect the NBAT wire to the negative terminal of the secondary battery . This reference signal allows the gateway to accurately measure the battery voltage without voltage drop. 7. Connect the ACC1 to the ignition switch. (Typically known as K15 output). CCoonnnneeccttiinngg ttoo TThhiirrdd PPaarrttyy HHoollddoovveerr BBaatttteerryy OOppttiioonn

adaptation to each application will be required. A carefully revision of your vehicle documentation is advised. The START/STOP signal has been implemented as a low-side transistor - this means that, when the signal is active, the associated pin XG3-H1 is internally grounded (conducting condition). Otherwise, the pin is in high-impedance condition (blocking condition). Concept • This function is beneficial to improve the refrigeration performance during long periods of engine stops due to vehicle START/STOP activation (eg. Traffic jam, urban distribution with high density of traffic lights etc.) • The Gateway Control Module (GCM) has a digital output (START/STOP signal) that indicates that the refrigeration unit demands electric power from the alternator. • The START/STOP signal can be used to inhibit the start/stop function of the vehicle allowing to: – Maintain the engine running despite the vehicle engine stop conditions are met (Typically the vehicle is stopped, gear not engaged etc.) and/or – Activate the engine start. All the safety precautions have to be considered by the OEM vehicle manufacturer (seat belt fastened, door closed, battery charged etc.). • Check the vehicle documentation if the vehicle is equipped with such a feature and how to integrate into it’s circuitry. • The START/STOP signal is linked to the activation of the Compressor Drive Module (CDM) which is the main consuming load. When the CDM is active the start stop is active. • A delay (3s) between the activation of the START/STOP signal and the activation of the Compressor Drive Module (CDM). NNoottee:: This is to prevent simultaneously starting the vehicle engine with a load due to high current demand from the CDM. • In order to prevent nuisance transients the START/STOP signal is elapsed during a time (3s) when the CDM is disabled by the Gateway controller. • Parameters SSRED and SSFED will need to be adjusted to the customer’s application.

3. Ignition Switch 4. Relay 5. ECU Parts Required before Starting Installation Description: TK Service Parts Number: 1. Socket Relay (Mini Plug in) 445537 2. Relay 12V (SPST) 419313TKA 4. Connector 2 PIN 414622 6. Terminal Male 0.5-1.5 mm2 414624 SSttaarrtt//SSttoopp FFuunnccttiioonnaalliittyy

7. Seal Cable Yellow - Outside Diameter 1.8-2.4mm 414625 8. Terminal Faston - F 1-2.5 6.3 414494 Installation Guidelines 1. Locate the vehicle battery and relay contactor into the vehicle. 2. From the main harness, locate the battery wires for BAT, NBAT and ACC1. These wires need to be spliced, and also a fuse holder added to the BAT wire. 3. Connect the positive (50 mm2 red wire) with the 150A fuse to the positive of the battery. 4. Connect the negative (50 mm2 black wire) to a ground post as close as possible to the negative terminal of the battery. 5. Connect the BAT wire to the positive terminal of the battery. This wire is connected to K35, and from there needs to be connected to the Vehicle ECU as follows: • Connect BAT4 wire from K35 to pin 85 of the Relay • Connect wire SPST2 from K35 to pin 86 of Relay • Connect pins 87 and 30 to your vehicle ECU (pin 87a is not used) NNoottee:: The way that these pins are connected to the vehicle ECU depends on whether a high-side or a low-side input to the vehicle ECU is required to manage the start stop inhibition. Please consult your vehicle documentation for this information. 6. Connect the NBAT wire to the negative terminal of the secondary battery . This reference signal allows the gateway to accurately measure the battery voltage without voltage drop. IIm mppoorrttaanntt:: Please ensure to connect the NBAT wire to ground. The unit will still operate if you fail to do so, however, it will not operate correctly and may be hard to troubleshoot at a later stage. See diagram below. 7. Connect the ACC1 to the ignition switch. (Typically known as K15 output). SSttaarrtt//SSttoopp FFuunnccttiioonnaalliittyy

IIm mppoorrttaanntt:: The presented proposal does not cover all the diversity of vehicle manufacturer implementations. An adaptation to each application will be required. A careful review of your vehicle documentation is advised. The IIS signal has been implemented as a low-side transistor - this means that, when the signal is active, the associated pin XG3-H1 is internally grounded (conducting condition). Otherwise, the pin is in high-impedance condition (blocking condition). Please refer to your unit schematic for further details. Concept • This function is beneficial to improve the refrigeration performance during long periods of vehicle running in idle (eg. Traffic jam, urban distribution with high density of traffic lights, etc.) • The alternator maximum capacity is obtained at maximum engine rpm. When running in idle, the maximum power is approximately 60% of the rate power. • Some vehicles incorporate a digital or analog input that can used to increase the idle speed. • The Gateway Controller (GC) has a digital output (IIS signal) that indicates that the refrigeration units demand is higher than the alternator can provide. • The IIIS signal can be then used to “tell” the vehicle ECU to increase the idle speed in order to increase the power delivered. • Check the vehicle documentation if the vehicle is equipped with such a feature and how to integrate into their circuitry. • The IIS signal goes active when the Gateway goes to POWER DERATING mode. This state can be identified by a triangle oriented downwards. • The IIS signal it is cleared when the Compressor Drive Module (CDM) becomes inactive. eg when the unit goes to NULL mode.

3. Ignition Switch 4. Relay 5. ECU Parts Required before Starting Installation Description: TK Service Parts Number: 1. Socket Relay (Mini Plug in) 445537 2. Relay 12V (SPST) 419313TKA 4. Connector 2 PIN 414622 6. Terminal Male 0.5-1.5 mm2 414624 IInnccrreeaasseedd IIddllee SSppeeeedd SSeettuupp

7. Seal Cable Yellow - Outside Diameter 1.8-2.4mm 414625 8. Terminal Faston - F 1-2.5 6.3 414494 Installation Guidelines 1. Locate the vehicle battery and relay contactor into the vehicle. 2. From the main harness, locate the battery wires for BAT, NBAT and ACC1. These wires need to be spliced, and also a fuse holder added to the BAT wire. 3. Connect the positive (50 mm2 red wire) with the 150A fuse to the positive of the battery. 4. Connect the negative (50 mm2 black wire) to a ground post as close as possible to the negative terminal of the battery. 5. Connect the BAT wire to the positive terminal of the battery. This wire is connected to K34, and from there needs to be connected to the Vehicle ECU as follows: • Connect BAT5 wire from K34 to pin 85 of the Relay • Connect wire IIS2 from K34 to pin 86 of Relay • Connect pins 87 and 30 to your vehicle ECU (pin 87a is not used) NNoottee:: The way that these pins are connected to the vehicle ECU depends on whether a high-side or a low-side input to the vehicle ECU is required to manage the start stop inhibition. Please consult your vehicle documentation for this information. 6. Connect the NBAT wire to the negative terminal of the secondary battery . This reference signal allows the gateway to accurately measure the battery voltage without voltage drop. IIm mppoorrttaanntt:: Please ensure to connect the NBAT wire to ground. The unit will still operate if you fail to do so, however, it will not operate correctly and may be hard to troubleshoot at a later stage. See diagram below. 7. Connect the ACC1 to the ignition switch. (Typically known as K15 output). IInnccrreeaasseedd IIddllee SSppeeeedd SSeettuupp

Only) IIm mppoorrttaanntt:: See Section 7 - Electrical Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! Figure 10. Typical receptacle installation with correct drip loop shown

IIm mppoorrttaanntt:: See Section 8 - Evaporator Drain Hose Standards in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430). THESE PROCEDURES MUST BE FOLLOWED! 1. DO NOT fit band wrap to hold the wires. 2. DO NOT cut the wires to fit. 3. DO NOT cover the Heaters. 4. DO NOT fit more than 4 wires into the tube. ES-100N/ES150 1. Cut the drain hose to the required length. 2. Connect the hose to the drain tube. Secure connections with plastic flanges. 3. Route the hose through the drain hole and seal hermetically. 4. Check that the corresponding siphon or moisture trap is installed at the end of each drain hose. If not, install it. Figure 11. ES-100 Rear and Bottom views

Legend 1. Option 1 Hose 2. Heaters 3. Option 2 Hose 4. Connector 5. Aluminium Foil Tape 6. Drain Tube 7. Nut EEvvaappoorraattoorr DDrraaiinn HHoossee IInnssttaallllaattiioonn

IIm mppoorrttaanntt:: BEFORE COMPLETING THE INSTALLATION, YOU MUST PERFORM THE FOLLOWING PROCEDURES IN ACCORDANCE WITH THE THERMO KING INSTALLATION STANDARDS AND PROCEDURES GUIDE (TK 56430): • SYSTEM EVACUATION PROCEDURES • SYSTEM LEAK CHECK PROCEDURES • SYSTEM CHARGING PROCEDURES • CONFIGURATION SOFTWARE PROCEDURES • CONTROLLER PARAMETER SETUP

Procedures - MAX IIm mppoorrttaanntt:: Using the absence of bubbles in the sight glass as an indicator of correct refrigerant charge can be misleading, YYOOUU M MUUSSTT refrigerate the box to 0-5ºC (32-41ºF) to get a more precise indication from the sight glass. W WAARRNNIINNGG EEqquuiippm meenntt DDaam maaggee!! LLoowweerr sseettttiinnggss ccaann bbee sseelleecctteedd bbaasseedd oonn llooccaall pprreeffeerreenncceess ttoo ooppttiim miizzee hheeaattiinngg ooppeerraattiioonn.. HHIIGGHHEERR vvaallvvee sseettttiinnggss tthhaann ssppeecciiffiieedd wwiillll lleeaadd ttoo ssyysstteem m m maallffuunnccttiioonn iinncclluuddiinngg ooppeerraattiioonn iinntteerrrruuppttiioonn wwhheenn bbooxx iiss wwaarrm m ((m moottoorr oovveerrccuurrrreenntt ccoonnfflliicctt wwiitthh iinnvveerrtteerr lliim miittss)).. IIm mppoorrttaanntt:: All new unit installations require these adjustment procedures. Failure to do so may not allow the unit to operate at its maximum capacity. NNoottee:: The following procedures are for initial settings. Sometimes conditions such as high or low ambient temperatures may require that the settings be fine-tuned for optimum performance. M MAAXX units are equipped with a SPR valve located in the evaporator (See illustration below). The valve is used to limit the load on the compressor. This also affects the current draw of the electric motor. 1. Install gauge manifold set onto the suction service port at the compressor (See illustration below). 2. Attach an additional compound gauge on suction service port located on copper suction tube in evaporator to monitor suction pressure going to the SPR valve (See illustration below). 3. Connect standby power receptacle to an appropriate electric power source. 4. Place jumper wire between the 12 and CHB wires at the defrost termination switch to verify the unit will run in defrost. 5. Start unit and run in defrost on the electric compressor until the pressure on the additional compound gauge attached to the suction service port stabilizes at a pressure above 45 psig (310 kPa). 6. Check the suction pressure on the gauge attached to the service port at the electric compressor. It should be not higher than 40 +-2psig ( 275kPa +-14kPa). 7. If the pressure is not within range, remove the protective cap and adjust the SPR valve to the correct setting. 8. Remove gauge manifold set, the additional compound gauge, and the jumper wire when finished with the procedure. 1. SPR Valve 2. Service Port E-200 3. Service Port Evaporator

Procedures - MAX W WAARRNNIINNGG EEqquuiippm meenntt DDaam maaggee!! LLoowweerr sseettttiinnggss ccaann bbee sseelleecctteedd bbaasseedd oonn llooccaall pprreeffeerreenncceess ttoo ooppttiim miizzee hheeaattiinngg ooppeerraattiioonn.. HHIIGGHHEERR vvaallvvee sseettttiinnggss tthhaann ssppeecciiffiieedd wwiillll lleeaadd ttoo ssyysstteem m m maallffuunnccttiioonn iinncclluuddiinngg ooppeerraattiioonn iinntteerrrruuppttiioonn wwhheenn bbooxx iiss wwaarrm m ((m moottoorr oovveerrccuurrrreenntt ccoonnfflliicctt wwiitthh iinnvveerrtteerr lliim miittss)).. The DPR setting is factory set, however, the below procedure can be used to check the setting in the case of any doubt. NNoottee:: The measurement of the High Pressure > 6 bar (87 psig) does not necessarily mean that the DPR is set > 6 bar (87 psig). To get a more precise measurement of the DPR setting follow the procedure below in the exact order that it is listed: 1. Cool down the box to -20º C (-4º F). 2. Change operation to heating mode. 3. Attach a gauge manifold to the suction service port (1) and the discharge service port (2). A low loss fitting must be used on the hose connected to the discharge service port. (See illustration below). 4. Operate the unit in high speed heat until the system pressures stabilize. 5. Check High Pressure with the gauges as follows: a. Check the discharge pressure on the gauge attached to the discharge service port. b. A pressure of >= to 6 bar (87 psig) is required for the DPR to function, however It should be within a range of 6 bar (87 psig) to 10 bar (145 psig) and no higher. c. If the setting is incorrect, remove the protective cap and try to adjust the DPR (3) to the correct setting. 6. Remove the gauges to return the unit to normal operation.

IIm mppoorrttaanntt:: Using the absence of bubbles in the sight glass as an indicator of correct refrigerant charge can be misleading, YYOOUU M MUUSSTT refrigerate the box to 0-5ºC (32-41ºF) to get a more precise indication from the sight glass. NNOOTTIICCEE CCoom mpprreessssoorr DDaam maaggee!! FFaaiilluurree ttoo aadddd tthhee ccoorrrreecctt aam moouunntt aanndd ttyyppee ooff ooiill wwiillll ddaam maaggee tthhee ccoom mpprreessssoorr.. Table 1. Oil Capacity for Units Utilizing Hermetic Compressors Oil Supplied in Unit Oil Added at Installation Model Compressor Type Compressor (oz.) Total Oil Added at Installation (oz.) Total System Capacity (oz.) Oil Type E-200 Rotary hermetic (variable speed) 10 oz. (0.29 liter) 4 oz. (0.12 liter) 14 oz. (0.41 liter) PVE Note: The remaining oil supplied (8oz) to be used for greasing the o-rings at the fittings

IIm mppoorrttaanntt:: Failure to add the proper amount of refrigerant will result in decreased system performance. Refer to the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430) for information on proper system charging procedures. Model Recommended Refrigerant Charge (lb.) E-200 20 E-200 MAX 50 E-200 MAX 50 Spectrum 1.3kg (2.8lb) (including 1.5m (60") hoses supplied as standard) R134a 1.3kg (2.8lb) (including 1.5(60") hoses supplied as standard) R452A/ R404A 1.6kg (3.5lb) (including 6m(237") hoses supplied as standard) R452A/ R404A Important: 1. For each additional meter (39") of hose extension, 80g (0.17lb) of refrigerant MUST be added 2. It is a good idea to utilise the WINTRAC tool to set compressor speed at an intermediate level (for example - 60Hz) during refrigeration charge. If the unit is charged with the compressor at full speed, overcurrent protection may trip.

• All holes should be sealed with silicone or foam. • Check with a sheet of paper that the fans blow in the right direction. • The drain circuit should be slanted on all evaporators and the moisture trap should be installed. • The hole should be located at the expansion valve on all evaporators. • The temperature sensor should be connected on all evaporators. • The in-cab control box should be located in a location that it is accessible and visible from the driver’s position. • The contact draw should be made. • Hoses should not be taut (they should be able to absorb vibrations). • Hoses should not rub against moving parts, sharp parts, or parts that can reach high temperatures. • The unit should be connected to the battery. • The seal test should have been carried out.

NNoottee:: Paper Templates are available to assist in the installation of the Condenser and Evaporator. These Templates provide the installer with a footprint of the component and provide the correct mounting and access hole locations. Contact your Thermo King dealer for details. Figure 13. Condenser Nose Mounting/Access Hole Locations Shown Figure 14. Condenser Roof Top Mounting/Access Hole Locations Shown

CCoonnddeennsseerr aanndd EEvvaappoorraattoorr DDiim meennssiioonnss

RCS1714-1 230V/1PH Green or Green/Yellow Black or Brown White or Blue 20A 250V NEMA L6-20P 115V/1PH Green or Green/Yellow Black or Brown White or Blue 20A 250V NEMA L5-20P X Y G

transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com. Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices. TK 56881-18-IM-EN 16 Jul 2021 Supersedes (New) ©2020 Trane Technologies