Read 51331.book text version

Installation Manual - B

Trailer Edition (NAD) Multi-Temperature SPECTRUMTM Evaporator Systems

TK 51331-2-IM (Rev. 9, 06/06)

Copyright© 2001 Thermo King Corp., Minneapolis, MN, U.S.A.

Printing History

Released Rev. 1 Rev. 2 Rev. 3 Rev. 4 Rev. 5 Rev. 6 Rev. 7 Rev. 8 Rev. 9 (08/01) (12/01) Text revisions (02/02) Changes to text pages 52 and 85 (05/02) Changes to art and text (08/02) Changes to art and text (01/03) Deleted extra blank pages at rear of manual (05/04) Combined art and reformatted manual to reduced page count (11/04) Changes to art and text (03/05) Revised SPECTRUM dimensions & ORS locations to agree with engineering drawing. Added print history. (05/06) Added Y configuration page 9, additional tools page 10, removed tool art page 11, aditional notes page 25, revised tubing orientation pages 27, 32, 39, 41, 43, 45, 47, and 49,

2

Trailer Edition Installation Manual - B for Multi-Temperature SPECTRUM Evaporator Systems

FOR HOST UNIT INSTALLATION INSTRUCTIONS SEE HOST UNIT INSTALLATION MANUALS

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.

3

BLANK PAGE

4

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Trailer Multi-Temperature SPECTRUM Selection Guide . . . . . . . . . . . . . . . . 9 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 S-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 S-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 S-2 + S-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 S-3 + S-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Recovering Holding Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Important Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Installation S-2 + S-2 or S-3 + S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Host Tube Connections S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Host Tube Connections S-3 + S-3 (Configuration X Only) . . . . . . . . . . . . . 42 Evaporator Tube Connections S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Evaporator Tube Connections S-2 + S-2 or S-3 + S-3 . . . . . . . . . . . . . . . . . 49 Evaporator Tube Connections S-3 + S-3 (Configuration X Only) . . . . . . . . 50 Evaporator Tube Connections S-3 (Configuration X Only) . . . . . . . . . . . . . 52 Evaporator Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Wire Connections S-3 + S-3 (Configuration X Only) . . . . . . . . . . . . . . . . . . 56 Drain Hose Resistance Wire Installation Guide . . . . . . . . . . . . . . . . . . . . . . 58 Drain Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Leak Check, Evacuation and Charging Procedures . . . . . . . . . . . . . . . . . . 62 Installing SPECTRUM Evaporator Covers . . . . . . . . . . . . . . . . . . . . . . . . . . 66 System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5

Safety Precautions

Caution

Thermo King 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 SPECTRUM remote evaporators are shipped with a 35 kPa (5 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 lines, 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.

6

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.

7

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.

8

Trailer Multi-Temperature SPECTRUM Selection Guide

MAXIMUM RECOMMENDED DIMENSIONS Config. B E F I Max. Dims. A A A A B J L N T A A A A B W (DE) X A B A B Y A B S-3 919171 17.4 ft. 4.1 ft. 31.2 ft. 17.4 ft. 31.2 ft. 4.1 ft. 4.1ft. 31.2 ft. 17.4 ft. 17.4 ft. S-3 + S-3 919171 x 2 31.2 ft. 28.0 ft. 4.1 ft. 31.2 ft. 31.2 ft. 31.2 ft. 880286 N/A 819724 819722 819723 819722 819723 819722 819723 819722 819723 880054 818066 818067 *Note 1 818067 818067 819722 819722 819723 819722 819723 819722 818066 818067 * Note 1 818066 818066 Installation Tube Kits Kit(s)

818066 *Note 1 N/A

NOTE 1: Trailers 48 ft. and longer with configuration E, L or W requires supplemental tube kit 880097. NOTE 2: Transverse mounted evaporators configurations B, F, N and T requires one drain kit 880041 for each evaporator.

9

Required Tools

1. Safety Glasses 2. Tape Measure 3. Screwdrivers - Phillips and Straight Blade 4. Drill 5. Drill Bits 6. Hole Saw 7. Torque Wrench 8. Box and Open End Wrenches - 7/16", 1/2", 9/16", 5/8", 3/4" 9. 12" Adjustable Wrench 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 16. Tubing Cutter 17. Tubing Swages 18. Tubing Brushes 19. Scotch Brite Pads 20. Torch Set 21. 15% Silver Solder(203-364) & Flux (203-365) 22. Heat Shield 23. Manifold Set 24. Evacuation Station (TK-204-725) 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

Required Tools

BLANK PAGE

11

Installation Components

1. Clamps 2. Screws 3. Pre-Bent Tubes 4. Copper Tees 5. Copper Couplings 6. Tube Insulation 7. Refrigerant Tubing (US Only) 8. Drain Hose 9. Copper Elbows 10. Drain Hose Tee 11. Mounting Spacer 12. Terminal Fork 13. Terminal Ring 14. Plastic Band Wraps 15. Jumper Strip 16. Electrical Harnesses

12

Installation Components

13

S-2 Dimensions

NOTE: All mounting locations must be correct to properly install the SPECTRUM 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 1229.4 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 ORS 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 28 and 29.

14

S-2 Dimensions

WEIGHT = 43 kg (95 lb.)

Reference: 1E02132 Sheet 1

15

S-3 Dimensions

NOTE: All mounting locations must be correct to properly install the SPECTRUM 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 1229.4 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 ORS 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 28 and 29.

16

S-3 Dimensions

WEIGHT = 52 kg (115 lb.)

Reference: 1E02132 Sheet 2

17

S-2 + S-2 Dimensions

NOTE: All mounting locations must be correct to properly install the SPECTRUM 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 1229.4 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 ORS 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 28 and 29.

18

S-2 + S-2 Dimensions

WEIGHT = 43 kg (95 lb.) each

Reference: 1E02132 Sheet 3

19

S-3 + S-3 Dimensions

NOTE: All mounting locations must be correct to properly install the SPECTRUM 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 1229.4 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 ORS 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 28 and 29.

20

S-3 + S-3 Dimensions

WEIGHT = 52 kg (115 lb.) each

Reference: 1E02132 Sheet 4

21

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 62. 1. Set refrigerant recovery device to recover R-404A vapor. 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 lines on host unit. NOTE: Some host units are supplied with two suction lines. Only remove caps from both suction lines if required for your application.

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.

22

Recovering Holding Charge

23

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 1229.4 mm (48.4 in.) or 1 pallet + 4.00 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.

24

Important Installation Notes

25

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 line(s). 3 compartment trailers may have two suction lines in the trough. · A ceiling trough is recommended. If that is not possible, a wall through should be located to allow the lowest suction line to be at least 25 mm (1.00 in.) above the remote evaporator suction line ORS 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. · Clean all threads on ORS fittings prior to installation. · Apply refrigerant oil only to the ORS O-rings. DO NOT APPLY OIL THE ORS FITTINGS THREADS. · When tightening ORS tubing connections, always use a backup wrench to hold the backside of the ORS fitting to prevent the refrigeration tube from twisting. · Torque all ORS connections to the recommended specs. · 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 installation will require two suction tubes: 1-1/8 in. for Zone 2 and 7/8 in. for 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. 2. Midseat the suction and discharge service valves on the host unit. 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. 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. Adjust the nitrogen flow to 5-10 CFH. Proceed with the soldering operations.The nitrogen supply and lantern battery must be maintained for both the remote evaporator and host unit connections.

26

3.

4. 5.

Important Installation Notes

NOTE: SIDE TROUGH ONLY Suction Line(s) must always be located at top of trough.

27

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 the use of an SB-III DE (Dual Evaporator) 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 Spectrum 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 S2+S2 Width Space Left 96 4 88 2 2 86.81 -2.81 59.85 24.15 96 3.5 89 2 2 86.81 -1.81 59.85 25.15 96 3 90 2 2 86.81 -0.81 59.85 26.15 96 2.5 91 2 2 86.81 0.19 not ideal 59.85 27.15 96 2 92 2 2 86.81 1.19 59.85 28.15

28

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 S2+S2 Width Space Left 96 4 88 1 1 86.81 -0.81 59.85 24.15 96 3.5 89 1 1 86.81 -0.19 not ideal 59.85 25.15 96 3 90 1 1 86.81 1.19 59.85 26.15 96 2.5 91 1 1 86.81 2.19 59.85 27.15 96 2 92 1 1 86.81 3.19 59.85 28.15

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 S2+S2 Width Space Left 96 4 88 0.5 0.5 86.81 0.19 not ideal 59.85 27.15 96 3.5 89 0.5 0.5 86.81 1.19 59.85 28.15 96 3 90 0.5 0.5 86.81 2.19 59.85 29.15 96 2.5 91 0.5 0.5 86.81 3.19 59.85 30.15 96 2 92 0.5 0.5 86.81 4.19 59.85 31.15

29

Important Installation Notes

Defrost Drain Tube Connector Installation

IMPORTANT: Follow the instructions below to prevent defrost drain tube water leaks. All Spectrum 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).

30

Important Installation Notes

31

Important Installation Notes

32

Important Installation Notes

33

Installation S-2 or S-3

Ceiling Preparation

IMPORTANT: The trailer ceiling must be structurally strong enough to support the weight of the S-2 evaporator(s) 43 kg (95 lb.) each or S-3 evaporator(s) 52 kg (115 lb.) each. IMPORTANT: The ceiling must be flat and the mounting locations correct for proper SPECTRUM 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 44.45 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 44.45 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.

Evaporator Installation

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 (Detail IV). NOTE: Two additional washers are included in the kit to help assist sloping the evaporator towards the drain.

·

·

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, 120000 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.)

34

Installation S-2 or S-3

35

Installation S-2 + S-2 or S-3 + S-3

Ceiling Preparation

IMPORTANT: The trailer ceiling must be structurally strong enough to support the weight of the S-2 evaporator(s) 43 kg (95 lb.) each or S-3 evaporator(s) 52 kg (115 lb.) each. IMPORTANT: The ceiling must be flat and the mounting locations correct for proper SPECTRUM 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 44.45 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 44.45 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.

Evaporator Installation

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). 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.

·

·

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, 120000 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.)

36

Installation S-2 + S-2 or S-3 + S-3

37

Host Tube Connections S-2 or S-3

Models: SPECTRUM SB 30-2/30-3 and SPECTRUM DE

1. Suction Line (s) · Single Evaporator Installations - Install 7/8 in. x 7/8 in. coupling onto one suction tube of host unit. Fabricate 7/8 in. suction tube and install onto 7/8 in. coupling.

Item A B C Fittings Required Description 7/8 in. x 7/8 in. Coupling 3/8 in. x 1/2 in. Coupling 5/8 in. x 5/8 in. Coupling Tubing Clamps Required Tube Liquid Hot Gas Suction With Insulation G42 G42 G58 W/O Insulation G14 N/A G35 P/N 553740 552865 556523

NOTE: The second suction tube remains capped. · Multiple Evaporators Installations Only - Install 7/8 in. x 7/8 in. couplings onto each suction tube of host unit. Fabricate 7/8 in. suction tubes and install onto each 7/8 in. coupling.

2. Liquid Line - Install 3/8 in. x 1/2 in. coupling onto liquid tube of host unit. Fabricate 1/2 in. liquid tube and install onto coupling. 3. Hot Gas Line - Install 5/8 in. x 5/8 in. coupling onto hot gas tube of host unit. Fabricate 5/8 in. hot gas tube and install onto coupling. 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. Maximum separation should be 600 mm (24.00 in.) between clamps. NOTE: Ceiling trough shown, wall trough is similar.

38

Host Tube Connections S-2 or S-3

Models: SPECTRUM SB 30-2/30-3 and SPECTRUM DE

Single Evaporator

Multiple Evaporators

DE w/single Evaporator

39

Host Tube Connections S-2 or S-3

Models: SPECTRUM SII 30-2/30-3

1. Suction Line (s) · Single Evaporator Installations - Install 7/8 in. x 7/8 in. coupling onto one suction tube of host unit. Fabricate 7/8 in. suction tube and install onto 7/8 in. coupling.

Item A B C Fittings Required Description 7/8 in. x 7/8 in. Coupling 3/8 in. x 1/2 in. Coupling 5/8 in. x 5/8 in. Coupling Tubing Clamps Required Tube Liquid Hot Gas Suction With Insulation G42 G42 G58 W/O Insulation G14 N/A G35 P/N 553740 552865 556523

NOTE: The second suction tube remains capped. · Multiple Evaporators Installations Only - Install 7/8 in. x 7/8 in. couplings onto each suction tube of host unit. Fabricate 7/8 in. suction tubes and install onto each 7/8 in. coupling.

2. Liquid Line - Install 3/8 in. x 1/2 in. coupling onto liquid tube of host unit. Fabricate 1/2 in. liquid tube and install onto coupling. 3. Hot Gas Line - Install 5/8 in. x 5/8 in. coupling onto hot gas tube of host unit. Fabricate 5/8 in. hot gas tube and install onto coupling. 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. Maximum separation should be 600 mm (24.00 in.) between clamps. NOTE: Ceiling trough shown, wall trough is similar.

40

Host Tube Connections S-2 or S-3

Models: SPECTRUM SII 30-2/30-3

Single Evaporator

Multiple Evaporators

41

Host Tube Connections S-3 + S-3 (Configuration X Only)

Models: SPECTRUM SB 30-3 (Configuration X)

IMPORTANT: This installation requires two different size suction tubes be routed to the remote evaporators for proper operation: · · 1-1/8 in. suction tube from the host unit to the S3 + S3 remote evaporators in Zone 2. 7/8 in. suction tube from the host unit to the rear S3 evaporator.

Fittings Required Item A B C D E Description 7/8 in. x 7/8 in. Coupling 7/8 in. x 1-1/8 in. Coupling 1-1/8 in. x 1-1/8 in. Elbow 3/8 in. x 1/2 in. Coupling 5/8 in. x 5/8 in. Coupling Tubing Clamps Required Tube Liquid Hot Gas Suction (7/8 in.) Suction (1-1/8 in.) With Insulation G42 G42 G58 G66 W/O Insulation G14 N/A G35 G58 P/N 553740 666022 553682 552865 556523

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 Line #1 - Install a 7/8 in. x 7/8 in. coupling onto the first suction tube at the rear of the host unit. Fabricate a 7/8 in. tube, attach onto coupling of suction tube and connect to 7/8 in. suction tube in trough. 2. Suction Line #2 - Install a 7/8 x 1-1/8 in. coupling onto the second suction tube at the rear of the host unit. Fabricate a 1-1/8 in. tube, attach to coupling of suction tube and use 1-1/8 in. elbows to connect to 1-1/8 in. suction tube in trough. 3. Liquid Line - Install a 3/8 in. x 1/2 in. coupling onto liquid tube of the host unit. Fabricate a 1/2 in. liquid tube and install onto the 1/2 in. coupling. 4. Hot Gas - Install a 5/8 in. x 5/8 in. coupling onto the hot gas tube of the host unit. Fabricate a 5/8 in. hot gas tube and install onto the 5/8 in. coupling. 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. Maximum separation should be 600 mm (24.00 in.) between clamps.

42

Host Tube Connections S-3 + S-3 (Configuration X Only)

Models: SPECTRUM SB 30-3 (Configuration X)

43

Evaporator Tube Connections S-2 or S-3

Models: SPECTRUM SB 30-2/30-3, SPECTRUM SII 30-2/30-3 and SPECTRUM DE

IMPORTANT: Discard O-rings that come with the evaporator and install the new ones that come in the kit. · · · Clean all threads on ORS fittings prior to installation. Apply refrigerant oil only to the ORS O-rings. DO NOT APPLY OIL TO THE ORS FITTING THREADS. When tightening ORS tubing connections, always use a backup wrench to hold the backside of the ORS fitting to prevent the refrigeration tube from twisting. Torque all ORS connections as shown in the table.

:

Fittings Required for SINGLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow 553326 B 5/8 in. x 1/2 in. Elbow 665733 C 1/2 in. x 3/8 in. Elbow 554142 Specifications for Evaporator ORS Fittings O-ring Tube Size Thread Torque Gaskets Liquid 3/8 in. 11/16-16 30 ft-lb 331222 Hot Gas 1/2 in. 13/16-16 40 ft-lb 331015 Suction 7/8 in. 1-3/16-16 60 ft-lb 330566 Tubing Clamps Required With Insulation W/O Insulation G42 G14 G42 N/A G58 G35

·

ZONE 2 (2 Compartment)

1. Suction Line - Fabricate one 7/8 in. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in. elbow, attach 7/8 in. preformed tube and connect to evaporator 7/8 in. ORS fitting. 2. Hot Gas Line - Fabricate a 5/8 in. hot gas tube from host unit and route in trough, install 5/8 in. x 1/2 in. elbow, attach 1/2 in. preformed tube and connect to evaporator 1/2 in. ORS fitting. 3. Liquid Line - Fabricate a 1/2 in. liquid tube from host unit and route in trough, install 1/2 x 3/8 in. elbow, attach 3/8 in. preformed tube and connect to evaporator 3/8 in. ORS fitting. 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. Maximum separation should be 600 mm (24.00 in.) between clamps.

Tube Liquid Hot Gas Suction

44

Evaporator Tube Connections S-2 or S-3

Models: SPECTRUM SB 30-2/30-3, SPECTRUM SII 30-2/30-3 and SPECTRUM DE

S-2 or S-3 Zone 2 (2 compartment)

45

Evaporator Tube Connections S-2 or S-3

Models: SPECTRUM SB 30-2/30-3, SPECTRUM SII 30-2/30-3 and SPECTRUM DE

IMPORTANT: Discard O-rings that come with the evaporator and install the new ones that come in the kit. · Clean all threads on ORS fittings prior to installation. · Apply refrigerant oil only to the ORS O-rings. DO NOT APPLY OIL TO THE ORS FITTING THREADS. · When tightening ORS tubing connections, always use a backup wrench to hold the backside of the ORS fitting to prevent the refrigeration tube from twisting. · Torque all ORS connections as shown in the table. 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. Maximum separation should be 600 mm (24.00 in.) between clamps.

:

ZONE 2 and 3 (3 Compartment)

1. Suction Lines · Fabricate two 7/8 in. suction tubes from host unit and route in trough, install 7/8 in. x 7/8 in. elbows, attach one 7/8 in. preformed tube to evaporator in Zone One and another to the evaporator in Zone Two. 2. Hot Gas Lines · 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, 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 and connect it to the 1/2 in. preformed tube and to the evaporator in Zone 3. 3. Liquid Line · 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, 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 and connect it to the 3/8 in. preformed tube and to the evaporator in Zone 3.

Fittings Required for SINGLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow 553326 B 5/8 in. x 1/2 in. Elbow 665733 C 1/2 in. x 3/8 in. Elbow 554142 Fittings Required for MULTIPLE Evaporator Installations Item Description P/N A 7/8 in. x 7/8 in. Elbow 553326 B 5/8 in. x 5/8 in. x 1/2 in. Tee 660620 C 5/8 in. x 1/2 in. Elbow 665733 D 1/2 in. x 1/2 in. x 3/8 in. Tee 552181 E 1/2 in. x 3/8 in. Elbow 554142 Specifications for Evaporator ORS Fittings O-ring Tube Size Thread Torque Gaskets Liquid 3/8 in. 11/16-16 30 ft-lb 331222 Hot Gas 1/2 in. 13/16-16 40 ft-lb 331015 Suction 7/8 in. 1-3/16-16 60 ft-lb 330566 Tubing Clamps Required With Insulation W/O Insulation G42 G14 G42 N/A G58 G35

Tube Liquid Hot Gas Suction

46

Evaporator Tube Connections S-2 or S-3

Models: SPECTRUM SB 30-2/30-3, SPECTRUM SII 30-2/30-3 and SPECTRUM DE

47

Evaporator Tube Connections S-2 + S-2 or S-3 + S-3

Models: SPECTRUM SB 30-2/30-3 and SPECTRUM SII 30-2/30-3

NOTE: Discard O-rings that come with the evaporator and install the new ones that come in the kit. · Clean all threads on ORS fittings prior to installation. · Apply refrigerant oil only to the ORS O-rings. DO NOT APPLY OIL THE ORS FITTINGS THREADS. · When tightening ORS tubing connections, always use a backup wrench to hold the backside of the ORS fitting to prevent the refrigeration tube from twisting. · Torque all ORS connections as shown in the table. IMPORTANT: You must connect one suction line from the host to each evaporator. 1. Suction Line #1- Fabricate a 7/8 in. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in. elbow, attach 7/8 in. preformed tube and connect to the first evaporator 7/8 in. ORS fitting. 2. Suction Line #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, attach 7/8 in. preformed tube and connect to the second evaporator 7/8 in. ORS fitting. 3. Hot Gas Line - Fabricate a 5/8 in. hot gas tube from host unit and route in trough, install 5/8 in. x 5/8 in. elbow, fabricate a 5/8 in. tube, connect to 5/8 in. x 1/2 in x 1/2 in tee and attach 1/2 in. preformed tube and connect to evaporator 1/2 in. ORS fitting. 4. Liquid Line - Fabricate a 1/2 in. liquid tube from host unit and route in trough, install 1/2 in. x 1/2 in. elbow, fabricate a 1/2 in. tube, connect to 1/2 in. a 3/8 in. x 3/8 in. tee, attach 3/8 in. preformed tubes and connect to evaporator 3/8 in. ORS fitting. 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. Maximum separation should be 600 mm (24.00 in.) between clamps.

Fittings Required for MULTIPLE Evaporator Installations Item A B C D E Description 7/8 in. x 7/8 in. Elbow 5/8 in. x 5/8 in. Elbow 5/8 in. x 1/2 in. x 1/2 in. Tee 1/2 in. x 1/2 Elbow 1/2 in. x 3/8 in. x 3/8 in. Tee P/N 553326 552187 611044 551483 611042

Specifications for Evaporator ORS Fittings Tube Liquid Hot Gas Suction Size 3/8 in. 1/2 in. 7/8 in. Thread 11/16-16 13/16-16 1-3/16-16 Torque 30 ft-lb 40 ft-lb 60 ft-lb O-ring Gaskets 331222 331015 330566

Tubing Clamps Required Tube Liquid Hot Gas Suction With Insulation G42 G42 G58 W/O Insulation G14 N/A G35

48

Evaporator Tube Connections S-2 + S-2 or S-3 + S-3

Models: SPECTRUM SB 30-2/30-3 and SPECTRUM SII 30-2/30-3

49

Evaporator Tube Connections S-3 + S-3 (Configuration X Only)

Models: SPECTRUM SB 30-3 (Configuration X) Zone 2

NOTE: Due to the difficultly in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown. NOTE: Discard O-rings that come with the evaporator and install the new ones that come in the kit. · Clean all threads on ORS fittings prior to installation. · Apply refrigerant oil only to the ORS O-rings. DO NOT APPLY OIL THE ORS FITTINGS THREADS. · When tightening ORS tubing connections, always use a backup wrench to hold the backside of the ORS fitting to prevent the refrigeration tube from twisting. · Torque all ORS connections as shown in the table. IMPORTANT: You must connect one suction line from the host to each evaporator. 1. Liquid Line - 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, 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. ORS 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. ORS fitting of the 2nd evaporator in Zone 2. 2. Suction Line 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, attach a 7/8 in. tube and connect to the 7/8 in. ORS 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, attach a 7/8 in. tube and connect to the 7/8 in. ORS fitting of the 1st evaporator in Zone 2. 3. Suction Line ZONE 3 - Fabricate a 7/8 in. suction tube from the host unit and route in the trough to the Zone 3. 4. Hot Gas - 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, 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. ORS 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. ORS fitting of the 2nd evaporator in Zone 2. 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. 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 552296 B 1/2 in. x 3/8 in. x 3/8 in. Tee 611042 C 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968 D 7/8 in. x 90° Street Elbow 553325 E 5/8 in. x 5/8 in. x 5/8 in. Tee 550904 F 5/8 in. x 1/2 in. x 1/2 in. Tee 611044 Specifications for Evaporator ORS Fittings O-ring Tube Size Thread Torque Gaskets Liquid 3/8 in. 11/16-16 30 ft-lb 331222 Hot Gas 1/2 in. 13/16-16 40 ft-lb 331015 Suction 7/8 in. 1-3/16-16 60 ft-lb 330566 Tubing Clamps Required With Insulation W/O Insulation Liquid G42 G14 Hot Gas G42 N/A Suction (7/8 in.) G58 G35 Suction (1-18 in.) G66 G58 Tube

50

·

Evaporator Tube Connections S-3 + S-3 (Configuration X Only)

Models: SPECTRUM SB 30-3 (Configuration X) Zone 2

51

Evaporator Tube Connections S-3 (Configuration X Only)

Models: SPECTRUM SB 30-3 (Configuration X) Zone 3

NOTE: Discard O-rings that come with the evaporator and install the new ones that come in the kit. · Clean all threads on ORS fittings prior to installation. · Apply refrigerant oil only to the ORS O-rings. DO NOT APPLY OIL TO THE ORS FITTING THREADS. · When tightening ORS tubing connections, always use a backup wrench to hold the backside of the ORS fitting to prevent the refrigeration tube from twisting. · Torque all ORS connections as shown in the table. 1. Suction Line - 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, attach 7/8 in. preformed tube and connect to the evaporator 7/8 in. ORS fitting. 2. Liquid Line - 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, attach 3/8 in. preformed tubes and connect to the evaporator 3/8 in. ORS fitting. 3. Hot Gas - 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, attach 1/2 in. preformed tube and connect to the evaporator 1/2 in. ORS fitting. 4. 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. Maximum separation should be 600 mm (24.00 in.) between clamps. NOTE: Ceiling trough shown, wall trough is similar.

Fittings Required for SINGLE Evaporator Installations Item A B C Description 7/8 in. x 7/8 in. Elbow 1/2 in. x 3/8 in. Elbow 5/8 in. x 1/2 in. Elbow P/N 553326 554142 665733

Specifications for Evaporator ORS Fittings Tube Liquid Hot Gas Suction Size 3/8 in. 1/2 in. 7/8 in. Thread 11/16-16 13/16-16 1-3/16-16 Torque 30 ft-lb 40 ft-lb 60 ft-lb O-ring Gaskets 331222 331015 330566

Tubing Clamps Required Tube Liquid Hot Gas Suction (7/8 in.) With Insulation G42 G42 G58 W/O Insulation G14 N/A G35

52

Evaporator Tube Connections S-3 (Configuration X Only)

Models: SPECTRUM SB 30-3 (Configuration X) Zone 3

53

Evaporator Wire Connections

Models: SPECTRUM SB 30-2/30-3,SPECTRUM SII 30-2/30-3 and DE

ZONE 2 - SINGLE EVAPORATOR

1. Connect Control & Fan 1 Harness (5D47948-wires 8-2, LLS2, HGS2, SLS2, FM2, and CH) to matching connectors at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail III). 2. Connect Fan 2 Harness (2C25318-wires FM22 and CH) to matching connector at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail III). 3. S-3 ONLY - Connect Fan 3 Harness (2C25319-wires FM23 and CH) to matching connector at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail III). 4. Connect Sensor Harness (9238C29-wires RTN2, RTP2, CTP2, and CTN2) to matching connector at the host unit (Detail I). Route harness into the evaporator and connect to matching connectors (Detail V). Loop excess harness back on its self and secure with cable ties (Detail VI). DO NOT CUT THE SENSOR HARNESS!

ZONE 3 - SINGLE EVAPORATOR

5. Connect Control & Fan 1 Harness (5D47947-wires 8-3, LLS3, HGS3, SLS3, FM3, and CH) to matching connectors at the host unit (Detail II) and route into the evaporator, cut harness to length, strip wires, attach terminals, and connect to the terminal block (Detail IV). 6. Connect Fan 2 Harness (2C25320-wires FM32 and CH) to matching connector at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail IV). 7. S-3 ONLY -Connect Fan 3 Harness (2C25321-wires FM33 and CH) to matching connector at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail IV). 8. ZONE 3 ONLY - Connect Sensor Harness (9238C61-wires RTN3, RTP3, CTP3, and CTN3) to matching connector at the host unit (Detail I). Route harness into the evaporator and connect to matching connectors (Detail V). Loop excess harness back on its self and secure with cable ties (Detail VI). DO NOT CUT THE SENSOR HARNESS! 9. Secure all harnesses with adequate clamps or ties.

ZONE 2 - PARALLEL EVAPORATORS

IMPORTANT: For parallel S2 or S3 installations in ZONE 2, follow steps #5-7 only. DO NOT connect Sensor Harness (9238C61-wires RTN3, RTP3, CTP3, and CTN3).

54

Evaporator Wire Connections

Host Connections Remote Evaporator Connections

55

Wire Connections S-3 + S-3 (Configuration X Only)

Models: SPECTRUM SB 30-3 (Configuration X) 3 Compartment Only

IMPORTANT: Install Speed Control Harness (2C37305-wires KLX, SC, and FM2) to appropriate matching connections on both terminal strips (Detail IV).

ZONE 3

6. Connect Control & Fan 1 Harness (5D47947-wires 8-3, LLS3, HGS3, SLS3, FM3, and CH) to appropriate matching connectors at the host unit (Detail II) and route into the evaporator, cut harness to length, strip wires, attach terminals and connect to the terminal block (Detail V). 7. Connect Fan 2 Harness (2C25320-wires FM32 and CH) to appropriate matching connectors at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail V). 8. Connect Fan 3 Harness (2C25321-wires FM33 and CH) to appropriate matching connector at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail V). 9. Connect Sensor Harness (9238C61-wires RTN3, RTP3, CTP3, and CTN3) to appropriate matching connector at the host unit (Detail I). Route harness into the evaporator and connect to matching connector (Detail VI). Loop excess harness back on its self and secure with cable ties (Detail VI). DO NOT CUT THE SENSOR HARNESS! 10. Secure all harnesses with adequate clamps or ties.

ZONE 2

1. Connect Control & Fan 1 Harness (5D47948 - wires 8-2, LLS2, HGS2, SLS2, FM2, and CH) to appropriate matching connectors at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail III). 2. Connect Fan 2 Harness (2C25318-wires FM22 and CH) to appropriate matching connector at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail III). 3. Connect Fan 3 Harness (2C25319-wires FM23 and CH) to appropriate matching connector at the host unit (Detail II) and route into the evaporator, cut harness to length and connect to the terminal block (Detail III). 4. Connect Sensor Harness (9238C29-wires RTN2, RTP2, CTP2, and CTN2) to appropriate matching connector at the host unit (Detail I). Route harness into the evaporator and connect to matching connector (Detail VI). Loop excess harness back onto its self and secure with cable ties. (Detail VII). DO NOT CUT THE SENSOR HARNESS! 5. Install the Interconnect Harness (2C38889 - wires CH, 8-2, SLS2, HGS2, LLS2, FM23, FM22 and FM2) from one evaporator terminal block to the other terminal block as shown (Detail IV).

56

Wire Connections S-3 + S-3 (Configuration X Only)

Models: SPECTRUM SB 30-3 (Configuration X) 3 Compartment Only Host Connections Remote Evaporator Connections

57

Drain Hose Resistance Wire Installation Guide

All SPECTRUM Evaporators

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 33.00 in. (838 mm) of the resistance wire from the drain pan outlet (Detail I). NOTE: 20.00 in. (508 mm) for S-2 evaporators. 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. 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.

58

Drain Hose Resistance Wire Installation Guide

All SPECTRUM Evaporators

59

Drain Hose Installation

All SPECTRUM Evaporators

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 30- 33 and "Drain Hose Resistance Wire Installation Guide" on pages 58- 59 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.

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).

For S-2 and S-3 Applications

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 (Detail I). 2. Connect the single drain hose to the wall drain tube using a short piece of plastic drain hose and clamp as required (Detail I). 3. Replace drain t-fitting with elbow fitting. (Detail I).

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.

For S-2 + S-2 and S-3 + S-3 Applications

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 (Detail II). 5. Connect each drain hose to each wall drain tube using a short piece of plastic drain hose and clamps as required (Detail II).

60

Drain Hose Installation

All SPECTRUM Evaporators

61

Leak Check, Evacuation and Charging Procedures

Set-Up Unit

Place microprocessor in Evacuation Mode to recover holding charge, leak check, evacuate and charge unit. With microprocessor in Evacuation Mode all solenoid valves in refrigeration system are open. This allows refrigeration system to be properly evacuated. Refer to appropriate MULTI-TEMP µP IV Microprocessor Controller Operation & Diagnosis Manual for complete information about microprocessor. Use following procedure to place microprocessor in Evacuation Mode: 1. Connect unit battery and attach battery charger to battery. Battery charger must have an output of at least 60 amps. This keeps battery voltage high enough to reliably operate unit in Evacuation Mode. 2. Place Zone 1, Zone 2 and Zone 3 On-Off switches in ON position. Do not allow unit to start. 3. Clear any alarm codes using CODE and CLEAR keys. 4. Allow display to return to Standard Display. 5. With Standard Display on display, press the TK key and hold down (3 to 5 seconds) until Pre-Trip appears on display. 6. Press SELECT key as required to display REV. Letters REV should appear in lower display and revision number should appear in upper display. 7. With REV on display, press both TK key and CLEAR key and hold down (3 to 5 seconds) until TEST VAC appears on display. 8. Press the Enter to load the Evacuation Mode. Microprocessor is now in Evacuation Mode. Refrigeration system is set up for recovering holding charge, leak checking, evacuation and charging.

62

Leak Check, Evacuation and Charging Procedures

Leak Check System

NOTE: Refer to Diagnosing Thermo King Refrigeration Systems (TK-5984-10) 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. 2. Before connecting refrigerant hoses to unit, close valves V1and V4 on evacuation system and turn micron gauge ON. See diagram on page 65. 3. Back seat suction, discharge and receiver tank service valves. Attach evacuation hoses to these three valves (check condition of hose seals). 4. With service valves fully back seated, turn evacuation pump ON and open valve V1 (V2 and V3 should also be open). Micron gauge should move to a deep vacuum. 5. Open valve V4. Micron reading will rise. If micron gauge returns to reading less than 500 microns, proceed to step 6. If micron reading remains high, a leak exists at hose fittings or packing glands. Locate and correct problem. Packing glands that do not seal can be corrected by installing valve stem covers (see step 6). 6. If step 5 was successful, close valve V2 to isolate thermistor. Open suction, discharge and receiver service valves to port. Install brass and steel valve stem covers (with sealing washers) on service valves and tighten. Let vacuum pump continue to operate. 7. After 5 minutes of evacuation, open valve V2 to access thermistor and micron gauge. Micron reading now shows system pressure. 8. Evacuate system to 500 microns plus one additional hour once 500 microns is reached. 9. When acceptable micron level is achieved (500 microns plus one hour for Multi-Temp units), close valve V1 to isolate pump. Turn pump OFF. 10. Observe reading on micron gauge after 5 minutes have elapsed. If vacuum level exceeds 2000 microns after 5 minutes, leak is present or additional evacuation time is required. 11. If vacuum level is acceptable, start pump and open valve V1 to evacuate pressure rise (5 minutes). 12. Close valve V1 and stop pump. Observe micron gauge to confirm that system remains in a deep vacuum. Close valve V4. Unit is ready to charge.

63

Evacuate System

CAUTION: Do not evacuate unit until it is leak free. Unit with less than full refrigerant charge should be leak checked and all leaks must be repaired. NOTE: Unit must be left in evacuation mode. NOTE: Use of Thermo King Evacuation Station (P/N 204-725) and Evacuation Station Operation and Field Application Instructions (TK-40612-2) is required. 1. Recover any refrigerant to 0 psi. (Regulations may require recovery machine to pull system pressure lower than 0 psi).

Leak Check, Evacuation and Charging Procedures

Charge System

NOTE: Unit must be left in Evacuation Mode. 1. Before charging system, make sure refrigerant lines from gauge manifold to refrigerant supply bottle have been evacuated or purged, suction service valve is back seated, and discharge service valve and receiver outlet valve are still open. 2. Set refrigerant supply bottle for liquid. Open gauge manifold hand valve and add a partial charge of R-404A. Add 6.4 kg (14 lb) to a unit with one remote evaporator. Add 6.8 kg (15 lb) to a unit with two remote evaporators. Do not add more than this. Remainder of charge will be added through suction service valve while unit is running. 3. Close gauge manifold hand valve. 4. Back seat (close) receiver outlet valve and discharge service valve. Open suction service valve. 5. Attach high pressure gauge on the gauge manifold to discharge service valve. Open discharge service valve to monitor discharge pressure. 6. Place Zone 1 On-Off switch in OFF position. This forces the unit to exit the Evacuation Mode. 7. Place Zone 1, Zone 2 and Zone 3 On-Off switches in ON position and allow unit to start. 8. Set all zone set points to lowest possible temperatures to insure all zones run in Cool. 9. 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 approximately 138 kPa (20 psi). Maintain discharge pressure of at least 1896 kPa (275 psi). 10. Add refrigerant until ball in receiver 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. 11. Continue to operate unit with all evaporators in Cool for 10 minutes and check position of ball in receiver sight glass. If liquid level has dropped, add liquid refrigerant until level stabilizes near middle of sight glass. 12. Back seat receiver outlet valve and discharge service valve. 13. Record total unit charge on all serial plates.

Remove Refrigerant Hoses

1. Run unit with all evaporators in Cool and receiver outlet and discharge valves back seated. 2. Front seat suction service valve and allow compressor to pump down, 3 to 5 psi (21 to 35 kPa). Stop unit. Remove hose from suction service valve service port. Immediately install the cap on the service port and tighten. 3. Back seat suction service valve. 4. Remove hoses from receiver outlet and discharge service valves. 5. Replace and tighten service port and valve stem caps.

64

Leak Check, Evacuation and Charging Procedures

A. B. C. D. E. F. G. H. I.

V-4 V-3 V-2 V-1 Thermistor Two Stage Vacuum Pump To AC Power Micron Gauge Correct Refrigerant Level

65

Installing SPECTRUM Evaporator Covers

Installing Covers 1. Install FRONT COVER into support channel of evaporator. Secure with screws. 2. Install BACK COVER into support lip of front cover. Secure with screws.

66

Installing SPECTRUM Evaporator Covers

67

System Check List

1. 2. 3. 4. 5. 6. Refrigeration Tubing Properly Secured. Wiring Harnesses Properly Secured. Electrical Connectors Tight. Drain Tubes Properly Routed. Mounting Bolts Tightened and Torqued to Specs. ORS Fittings Tightened and Torqued to Specs. 7. Electrical Connections Properly Crimped 8. 9. Refrigeration System Properly Charged. Refrigeration System Leak Checked.

10. Guards, Covers and Grilles Installed Securely. 11. Run Pre-Trip Test (Refer to Host Unit Operating Manual). 12. Release to Customer.

68

Information

51331.book

68 pages

Report File (DMCA)

Our content is added by our users. We aim to remove reported files within 1 working day. Please use this link to notify us:

Report this file as copyright or inappropriate

452408


Notice: fwrite(): send of 214 bytes failed with errno=104 Connection reset by peer in /home/readbag.com/web/sphinxapi.php on line 531