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Operator’s Manual V-520 RT, V-520 RT MAX TK 55032-18-OP (Rev. 1, 12/2011)

Operator's Manual V-520 RT, V-520 RT MAX

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Page 1: Operator's Manual V-520 RT, V-520 RT MAX

Operator’s Manual

Operator’s Manual

Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Hussmann, a manufacturer of refrigeration and food merchandising solutions, Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Hussmann, a manufacturer of refrigeration and food merchandising solutions, Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

©2011 Ingersoll-Rand Company Printed in U.S.A.

©2011 Ingersoll-Rand Company Printed in U.S.A.

V-520 RT, V-520 RT MAX

TK 55032-18-OP (Rev. 1, 12/2011)

V-520 RT, V-520 RT MAX

TK 55032-18-OP (Rev. 1, 12/2011)

Page 2: Operator's Manual V-520 RT, V-520 RT MAX
Page 3: Operator's Manual V-520 RT, V-520 RT MAX
Page 4: Operator's Manual V-520 RT, V-520 RT MAX

There is nothing complicated about operating and maintaining your Thermo King unit, but a few minutes studying this manual will be time well spent.

Performing pre-trip checks and enroute inspections on a regular basis will minimize on-the-road operating problems. A regular maintenance program will also help to keep your unit in top operating condition. If factory recommended procedures are followed, you will find that you have purchased the most efficient and dependable temperature control system available.

All service requirements, major and minor, should be handled by a Thermo King dealer for four very important reasons:

• They are equipped with the factory recommended tools to perform all service functions

• They have factory trained and certified technicians

• They have genuine Thermo King replacement parts

• The warranty on your new unit is valid only when the repair and replacement of component parts is performed by an authorized Thermo King dealer.

IMPORTANT: This manual is published for informational purposes only and the information furnished herein should not be considered as all-inclusive or meant to cover all contingencies. If more information is required, consult your Thermo King Service Directory for the location and telephone number of the local dealer.

There is nothing complicated about operating and maintaining your Thermo King unit, but a few minutes studying this manual will be time well spent.

Performing pre-trip checks and enroute inspections on a regular basis will minimize on-the-road operating problems. A regular maintenance program will also help to keep your unit in top operating condition. If factory recommended procedures are followed, you will find that you have purchased the most efficient and dependable temperature control system available.

All service requirements, major and minor, should be handled by a Thermo King dealer for four very important reasons:

• They are equipped with the factory recommended tools to perform all service functions

• They have factory trained and certified technicians

• They have genuine Thermo King replacement parts

• The warranty on your new unit is valid only when the repair and replacement of component parts is performed by an authorized Thermo King dealer.

IMPORTANT: This manual is published for informational purposes only and the information furnished herein should not be considered as all-inclusive or meant to cover all contingencies. If more information is required, consult your Thermo King Service Directory for the location and telephone number of the local dealer.

Page 5: Operator's Manual V-520 RT, V-520 RT MAX
Page 6: Operator's Manual V-520 RT, V-520 RT MAX

Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . . 9Battery Installation and Cable Routing . . . . . . . . . . . . 10Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 12First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 12

Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 13Model 50 Units (Electric Standby) . . . . . . . . . . . . 14

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Refrigeration Module . . . . . . . . . . . . . . . . . . . . . . . . . . 17Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Standby Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Electronic Control System . . . . . . . . . . . . . . . . . . . . . .18Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . .21Evaporator Drain Tube Heaters . . . . . . . . . . . . . . . . . .21Electric Standby Operation . . . . . . . . . . . . . . . . . . . . .21Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . .22Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Cool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Model 10 and 20 Units . . . . . . . . . . . . . . . . . . . . . . . . .25

Null Mode - All Units . . . . . . . . . . . . . . . . . . . . . . .26Purge Mode - Model 30 and 50 Units Only . . . . . .26Heat Mode - Model 30 and 50 Units Only . . . . . . .27Defrost Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . .28

Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . . 9Battery Installation and Cable Routing . . . . . . . . . . . . 10Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 12First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 12

Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 13Model 50 Units (Electric Standby) . . . . . . . . . . . . 14

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Refrigeration Module . . . . . . . . . . . . . . . . . . . . . . . . . . 17Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Standby Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Electronic Control System . . . . . . . . . . . . . . . . . . . . . .18Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . .21Evaporator Drain Tube Heaters . . . . . . . . . . . . . . . . . .21Electric Standby Operation . . . . . . . . . . . . . . . . . . . . .21Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . .22Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Cool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Model 10 and 20 Units . . . . . . . . . . . . . . . . . . . . . . . . .25

Null Mode - All Units . . . . . . . . . . . . . . . . . . . . . . .26Purge Mode - Model 30 and 50 Units Only . . . . . .26Heat Mode - Model 30 and 50 Units Only . . . . . . .27Defrost Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . .28

Page 7: Operator's Manual V-520 RT, V-520 RT MAX

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 39Electric Standby Operation . . . . . . . . . . . . . . . . . . 39

Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Entering the Setpoint Temperature . . . . . . . . . . . . . . . 41Initiating the Manual Defrost Cycle . . . . . . . . . . . . . . . 41Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Manual Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Auto Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Buzzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Alarm Code Descriptions . . . . . . . . . . . . . . . . . . . . . . . 45Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . 46Viewing Information Screens . . . . . . . . . . . . . . . . . . . . 46

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Hourmeter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 46

After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 47Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 47Weekly Pretrip Inspection . . . . . . . . . . . . . . . . . . . . . . 48

Weekly Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . 48

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 52Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54AC Electric Compressor Motors and Overload Relays 55Electric Standby Power Requirements . . . . . . . . . . . . 55Solder Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 39Electric Standby Operation . . . . . . . . . . . . . . . . . . 39

Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Entering the Setpoint Temperature . . . . . . . . . . . . . . . 41Initiating the Manual Defrost Cycle . . . . . . . . . . . . . . . 41Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Manual Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Auto Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Buzzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Alarm Code Descriptions . . . . . . . . . . . . . . . . . . . . . . . 45Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . 46Viewing Information Screens . . . . . . . . . . . . . . . . . . . . 46

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Hourmeter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 46

After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 47Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 47Weekly Pretrip Inspection . . . . . . . . . . . . . . . . . . . . . . 48

Weekly Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . 48

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 52Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54AC Electric Compressor Motors and Overload Relays 55Electric Standby Power Requirements . . . . . . . . . . . . 55Solder Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Page 8: Operator's Manual V-520 RT, V-520 RT MAX
Page 9: Operator's Manual V-520 RT, V-520 RT MAX
Page 10: Operator's Manual V-520 RT, V-520 RT MAX

Thermo King recommends that all services be performed by a Thermo King dealer. However, there are several general safety practices which you should be aware of:

WARNING: Always wear goggles or safety glasses when working with or around the refrigeration system or battery. Refrigerant or battery acid can cause permanent damage if it comes in contact with your eyes.

WARNING: Keep hands and loose clothing clear of fans and belts at all times when the unit is operating or when opening or closing compressor service valves.

WARNING: Exposed coil fins can cause painful lacerations. Service work on the evaporator or condenser coils is best left to a certified Thermo King technician.

CAUTION: Use extreme caution when drilling holes in the unit. Drilling into electrical wiring or refrigerant lines could cause a fire. Never drill into structural components.

CAUTION: The unit may start automatically and at any time when the unit On/Off switch is in the On position. Units with CYCLE-SENTRYTM start automatically in both CYCLE-SENTRY mode and Continuous mode. Be sure to turn the On/Off switch Off before opening doors or inspecting or working on any part of the unit..

Thermo King recommends that all services be performed by a Thermo King dealer. However, there are several general safety practices which you should be aware of:

WARNING: Always wear goggles or safety glasses when working with or around the refrigeration system or battery. Refrigerant or battery acid can cause permanent damage if it comes in contact with your eyes.

WARNING: Keep hands and loose clothing clear of fans and belts at all times when the unit is operating or when opening or closing compressor service valves.

WARNING: Exposed coil fins can cause painful lacerations. Service work on the evaporator or condenser coils is best left to a certified Thermo King technician.

CAUTION: Use extreme caution when drilling holes in the unit. Drilling into electrical wiring or refrigerant lines could cause a fire. Never drill into structural components.

CAUTION: The unit may start automatically and at any time when the unit On/Off switch is in the On position. Units with CYCLE-SENTRYTM start automatically in both CYCLE-SENTRY mode and Continuous mode. Be sure to turn the On/Off switch Off before opening doors or inspecting or working on any part of the unit..

Page 11: Operator's Manual V-520 RT, V-520 RT MAX

WARNING: Improperly installed battery could result in a fire or explosion! A Thermo King approved battery must be installed and properly secured to the battery tray.

WARNING: Improperly installed battery cables could result in fire or explosion! Battery cables must be installed, routed and secured properly to prevent them from rubbing, chaffing or making contact with hot, sharp or rotating components.

WARNING: Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire!

CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit. This could result in severe damage to equipment and void the warranty!

CAUTION: Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury.

CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries. Battery acid can cause serious burns when exposed to eyes or skin. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.

CAUTION: Always cover battery terminals to prevent them from making contact with metal components during battery installation. Battery terminals grounding against metal could cause the battery to explode.

WARNING: Improperly installed battery could result in a fire or explosion! A Thermo King approved battery must be installed and properly secured to the battery tray.

WARNING: Improperly installed battery cables could result in fire or explosion! Battery cables must be installed, routed and secured properly to prevent them from rubbing, chaffing or making contact with hot, sharp or rotating components.

WARNING: Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire!

CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit. This could result in severe damage to equipment and void the warranty!

CAUTION: Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury.

CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries. Battery acid can cause serious burns when exposed to eyes or skin. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.

CAUTION: Always cover battery terminals to prevent them from making contact with metal components during battery installation. Battery terminals grounding against metal could cause the battery to explode.

Page 12: Operator's Manual V-520 RT, V-520 RT MAX

Although fluorocarbon refrigerants are classified as safe, observe caution when working with refrigerants or around areas where they are being used in the servicing of your unit.

Observe the following precautions when working with or around refrigerant oil:

CAUTION: Be sure to turn off the high voltage power supply, and disconnect the electric cable before working on the unit. Units with electric standby present a potential electrical hazard.

DANGER: Fluorocarbon refrigerants may produce toxic gases. In the presence of an open flame or electrical short, these gases are severe respiratory irritants CAPABLE OF CAUSING DEATH.

DANGER: Fluorocarbon refrigerants tend to displace air and can cause oxygen depletion which could result in DEATH BY SUFFOCATION. Provide adequate ventilation in enclosed or confined areas.

WARNING: Fluorocarbon refrigerants evaporate rapidly, freezing anything they contact if accidentally released into the atmosphere from the liquid state.

WARNING: Always wear goggles or safety glasses to protect eyes from refrigerant oil contact.

WARNING: Protect skin and clothing from prolonged or repeated contact with refrigerant oil. Rubber gloves are recommended.

WARNING: Wash thoroughly immediately after handling refrigerant oil to prevent irritation.

Although fluorocarbon refrigerants are classified as safe, observe caution when working with refrigerants or around areas where they are being used in the servicing of your unit.

Observe the following precautions when working with or around refrigerant oil:

CAUTION: Be sure to turn off the high voltage power supply, and disconnect the electric cable before working on the unit. Units with electric standby present a potential electrical hazard.

DANGER: Fluorocarbon refrigerants may produce toxic gases. In the presence of an open flame or electrical short, these gases are severe respiratory irritants CAPABLE OF CAUSING DEATH.

DANGER: Fluorocarbon refrigerants tend to displace air and can cause oxygen depletion which could result in DEATH BY SUFFOCATION. Provide adequate ventilation in enclosed or confined areas.

WARNING: Fluorocarbon refrigerants evaporate rapidly, freezing anything they contact if accidentally released into the atmosphere from the liquid state.

WARNING: Always wear goggles or safety glasses to protect eyes from refrigerant oil contact.

WARNING: Protect skin and clothing from prolonged or repeated contact with refrigerant oil. Rubber gloves are recommended.

WARNING: Wash thoroughly immediately after handling refrigerant oil to prevent irritation.

Page 13: Operator's Manual V-520 RT, V-520 RT MAX

For contact with liquid, immediately flush eyes with large amounts of water. Get prompt medical attention.

Flush areas with large amounts of warm water. Do not apply heat. Wrap burns with dry, sterile, bulky dressing to protect from infection or injury. Get prompt medical attention.

Move victim to fresh air and restore breathing if necessary. Stay with victim until arrival of emergency medical personnel.

Immediately flush eyes with large amounts of water for at least 15 minutes while holding the eyelids open. Get prompt medical attention.

Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.

Move victim to fresh air and restore breathing if necessary. Stay with victim until arrival of emergency personnel.

Do not induce vomiting. Immediately contact local poison control center or physician.

For contact with liquid, immediately flush eyes with large amounts of water. Get prompt medical attention.

Flush areas with large amounts of warm water. Do not apply heat. Wrap burns with dry, sterile, bulky dressing to protect from infection or injury. Get prompt medical attention.

Move victim to fresh air and restore breathing if necessary. Stay with victim until arrival of emergency medical personnel.

Immediately flush eyes with large amounts of water for at least 15 minutes while holding the eyelids open. Get prompt medical attention.

Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.

Move victim to fresh air and restore breathing if necessary. Stay with victim until arrival of emergency personnel.

Do not induce vomiting. Immediately contact local poison control center or physician.

Page 14: Operator's Manual V-520 RT, V-520 RT MAX

CAUTION FAN

ATTENZIONE VENTILATORE

ATTENTION VENTILATEUR

ACHTUNG VENTILATOR

CUIDADO VENTILADOR

91-4815

CAUTION FAN

ATTENZIONE VENTILATORE

ATTENTION VENTILATEUR

ACHTUNG VENTILATOR

CUIDADO VENTILADOR

91-4815

Page 15: Operator's Manual V-520 RT, V-520 RT MAX
Page 16: Operator's Manual V-520 RT, V-520 RT MAX

The Thermo King V-520 RT and V-520 RT MAX truck refrigeration systems are designed for vans carrying fresh produce and frozen and deep frozen goods.

There are four basic models:

• Model 10: Cool and defrost on vehicle engine driven compressor operation.

• Model 20: Cool and defrost on both vehicle engine driven compressor operation and electric standby compressor operation.

• Model 30: Cool, heat, and defrost on truck engine driven compressor operation.

• Model 50: Cool, heat, and defrost on both vehicle engine driven compressor operation and electric standby compressor operation.

The refrigeration module and condenser are mounted on the roof of the van (or container). The evaporator is mounted on the cargo compartment ceiling. The main compressor is powered by the vehicle engine via a belt. The refrigeration module, condenser, and compressor are connected by refrigeration hoses.

Model 20 and 50 units also have an standby module mounted between the refrigeration module and condenser. The standby module contains electric motor, standby compressor, and AC components. The electric motor uses a belt to drive the standby compressor.

Control circuits operate on 12 Vdc supplied by the vehicle batteries for over-the-road operation. The refrigeration system is protected by a high pressure transducer and a low pressure cutout switch.

In Model 20 and 50 units the operating mode is selected automatically: When the unit is connected to an electric power source, engine driven operation is automatically blocked. If the vehicle engine is started up while the power cable is still

The Thermo King V-520 RT and V-520 RT MAX truck refrigeration systems are designed for vans carrying fresh produce and frozen and deep frozen goods.

There are four basic models:

• Model 10: Cool and defrost on vehicle engine driven compressor operation.

• Model 20: Cool and defrost on both vehicle engine driven compressor operation and electric standby compressor operation.

• Model 30: Cool, heat, and defrost on truck engine driven compressor operation.

• Model 50: Cool, heat, and defrost on both vehicle engine driven compressor operation and electric standby compressor operation.

The refrigeration module and condenser are mounted on the roof of the van (or container). The evaporator is mounted on the cargo compartment ceiling. The main compressor is powered by the vehicle engine via a belt. The refrigeration module, condenser, and compressor are connected by refrigeration hoses.

Model 20 and 50 units also have an standby module mounted between the refrigeration module and condenser. The standby module contains electric motor, standby compressor, and AC components. The electric motor uses a belt to drive the standby compressor.

Control circuits operate on 12 Vdc supplied by the vehicle batteries for over-the-road operation. The refrigeration system is protected by a high pressure transducer and a low pressure cutout switch.

In Model 20 and 50 units the operating mode is selected automatically: When the unit is connected to an electric power source, engine driven operation is automatically blocked. If the vehicle engine is started up while the power cable is still

Page 17: Operator's Manual V-520 RT, V-520 RT MAX

connected to the electric power source, the unit will continue to operate in electric standby mode. It is not possible to start the engine driven compressor until the power cable is disconnected from the unit.

1. Refrigeration Module

2. Condenser

1. Refrigeration Module

2. Standby Mofule

3. Condenser

connected to the electric power source, the unit will continue to operate in electric standby mode. It is not possible to start the engine driven compressor until the power cable is disconnected from the unit.

1. Refrigeration Module

2. Condenser

1. Refrigeration Module

2. Standby Mofule

3. Condenser

Page 18: Operator's Manual V-520 RT, V-520 RT MAX

• In-Cab Controls with Digital LCD Thermometer

• Hot Gas Defrost

• Defrost Termination Switch

• Oil Separator

• Liquid Injection

• Main Compressor TM 16 XD

• Evaporator Drain Heaters (MAX Units Only)

• Hot Gas Heat (Model 30 and 50 Units Only)

• Electric Standby Compressor, Model 20 and 50 Units

• Door Switch

The refrigeration module is designed to be mounted on the roof in front of the condenser. It contains various refrigeration components and the control box, which contains the electronic control module (ECM).

The condenser is designed to be to be mounted on the roof. It contains the condenser coils and fans.

An evaporator is mounted on the ceiling inside the cargo compartment.

The main compressor is mounted on and driven by the vehicle engine. Refrigeration hoses or lines are used to connect the refrigeration module, condenser, evaporator, compressor and any other components.

• In-Cab Controls with Digital LCD Thermometer

• Hot Gas Defrost

• Defrost Termination Switch

• Oil Separator

• Liquid Injection

• Main Compressor TM 16 XD

• Evaporator Drain Heaters (MAX Units Only)

• Hot Gas Heat (Model 30 and 50 Units Only)

• Electric Standby Compressor, Model 20 and 50 Units

• Door Switch

The refrigeration module is designed to be mounted on the roof in front of the condenser. It contains various refrigeration components and the control box, which contains the electronic control module (ECM).

The condenser is designed to be to be mounted on the roof. It contains the condenser coils and fans.

An evaporator is mounted on the ceiling inside the cargo compartment.

The main compressor is mounted on and driven by the vehicle engine. Refrigeration hoses or lines are used to connect the refrigeration module, condenser, evaporator, compressor and any other components.

Page 19: Operator's Manual V-520 RT, V-520 RT MAX

Model 20 and 50 units have another compressor and an electric motor mounted in the standby module for electric standby operation. The electric standby compressor is connected in parallel with the engine driven compressor. The standby compressor is driven by a belt from the electric motor. Both compressors use the same refrigeration system circuit. Check valves isolate one compressor from the other during operation.

Compressor operation is controlled by the electronic control system, which energizes the compressor clutch during engine operation. The refrigeration system is protected by a high pressure transducer and a low pressure cutout switch.

When the unit is connected to an electric power source, engine driven operation is automatically blocked. If the vehicle engine is started up while the power cable is still connected to the electric power source, the unit will continue to operate in electric standby mode. It is not possible to start the engine driven compressor until the power cable is disconnected from the unit.

The standby module is used only with Model 20 and 50 units. It is designed to be mounted on the roof between the refrigeration module and the condenser. It contains the electric motor, standby compressor, and AC components.

The control circuits operate on 12V supplied by the vehicle batteries for engine operation. On standby operation, the power is rectified from an AC transformer.

The Electronic Control System is composed of an Electronic Control Module (located control box inside the refrigeration module) and the In-Cab Control Box. This In-Cab Control Box allows the truck driver to operate the Thermo King refrigeration unit.

Model 20 and 50 units have another compressor and an electric motor mounted in the standby module for electric standby operation. The electric standby compressor is connected in parallel with the engine driven compressor. The standby compressor is driven by a belt from the electric motor. Both compressors use the same refrigeration system circuit. Check valves isolate one compressor from the other during operation.

Compressor operation is controlled by the electronic control system, which energizes the compressor clutch during engine operation. The refrigeration system is protected by a high pressure transducer and a low pressure cutout switch.

When the unit is connected to an electric power source, engine driven operation is automatically blocked. If the vehicle engine is started up while the power cable is still connected to the electric power source, the unit will continue to operate in electric standby mode. It is not possible to start the engine driven compressor until the power cable is disconnected from the unit.

The standby module is used only with Model 20 and 50 units. It is designed to be mounted on the roof between the refrigeration module and the condenser. It contains the electric motor, standby compressor, and AC components.

The control circuits operate on 12V supplied by the vehicle batteries for engine operation. On standby operation, the power is rectified from an AC transformer.

The Electronic Control System is composed of an Electronic Control Module (located control box inside the refrigeration module) and the In-Cab Control Box. This In-Cab Control Box allows the truck driver to operate the Thermo King refrigeration unit.

Page 20: Operator's Manual V-520 RT, V-520 RT MAX

Refer to the Direct Smart Reefer Microprocessor Control System Diagnostic Manual TK 52573 for complete service information about the Electronic Control System and the related components.

The Electronic Control System has the following characteristics:

• Auto Start

• Soft Start

• Active Display

• Lit Keypad

• Total Hourmeter

• Vehicle Compressor Hourmeter

• Electric Standby Compressor Hourmeter

• Low Battery Voltage Alarm

• Buzzer

• Unit Control without In-Cab Control Box

• Manual or Automatic Defrost

• Maintenance Warning

• Return Air Temperature Sensor

• Setpoint Temperature Reading

• Electric Power Warning

Should the unit stop due to a failure in the power supply, whether during on-the-road or electric standby operation, it will start up again as soon as the power supply is re-established.

All operation modes remain inactive for 15 seconds after an Auto Start.

Refer to the Direct Smart Reefer Microprocessor Control System Diagnostic Manual TK 52573 for complete service information about the Electronic Control System and the related components.

The Electronic Control System has the following characteristics:

• Auto Start

• Soft Start

• Active Display

• Lit Keypad

• Total Hourmeter

• Vehicle Compressor Hourmeter

• Electric Standby Compressor Hourmeter

• Low Battery Voltage Alarm

• Buzzer

• Unit Control without In-Cab Control Box

• Manual or Automatic Defrost

• Maintenance Warning

• Return Air Temperature Sensor

• Setpoint Temperature Reading

• Electric Power Warning

Should the unit stop due to a failure in the power supply, whether during on-the-road or electric standby operation, it will start up again as soon as the power supply is re-established.

All operation modes remain inactive for 15 seconds after an Auto Start.

Page 21: Operator's Manual V-520 RT, V-520 RT MAX

The In-Cab Control Box display is always active and backlit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the In-Cab Control Box (when there is no active alarm).

The In-Cab Control Box keys are always lit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the In-Cab Control Box (when there is no active alarm). The On/Off key is always lit except when the unit is disconnected (no power), and thus indicates the presence of power in the unit.

Total number of hours the unit is in operation.

Number of hours the unit has been operating on-the-road.

Number of hours the unit has been operating in electric standby.

Disconnects the unit when the battery voltage falls below 10.5 Vdc in 12 Vdc systems or below 21 Vdc in 24 Vdc systems.

It is energized when the vehicle battery and the electric power supply are connected at the same time. It is also energized if the doors are opened while the refrigeration unit is running.

The unit can also be operated by the Electronic Control System without the In-Cab Control Box, under conditions selected by the In-Cab Control Box before it is disconnected.

It is possible to choose between manual or automatic defrost.

On-screen warning of the need to carry out maintenance on the unit.

On-screen reading of the temperature in the load compartment.

On-screen setpoint temperature reading.

On-screen warning that the unit is connected to an electric power supply.

The In-Cab Control Box display is always active and backlit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the In-Cab Control Box (when there is no active alarm).

The In-Cab Control Box keys are always lit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the In-Cab Control Box (when there is no active alarm). The On/Off key is always lit except when the unit is disconnected (no power), and thus indicates the presence of power in the unit.

Total number of hours the unit is in operation.

Number of hours the unit has been operating on-the-road.

Number of hours the unit has been operating in electric standby.

Disconnects the unit when the battery voltage falls below 10.5 Vdc in 12 Vdc systems or below 21 Vdc in 24 Vdc systems.

It is energized when the vehicle battery and the electric power supply are connected at the same time. It is also energized if the doors are opened while the refrigeration unit is running.

The unit can also be operated by the Electronic Control System without the In-Cab Control Box, under conditions selected by the In-Cab Control Box before it is disconnected.

It is possible to choose between manual or automatic defrost.

On-screen warning of the need to carry out maintenance on the unit.

On-screen reading of the temperature in the load compartment.

On-screen setpoint temperature reading.

On-screen warning that the unit is connected to an electric power supply.

Page 22: Operator's Manual V-520 RT, V-520 RT MAX

An oil separator is a standard feature. The oil separator separates compressor oil from refrigerant vapor and returns the oil to the compressor through the suction line. The oil separator helps provide positive oil return at high compressor speeds and low operating temperatures. This feature enhances compressor lubrication and extends compressor life.

• V-520 RT 10, V-520 RT 20, V-520 RT 30, and V-520 RT 50 units use R-134a refrigerant.

• V-520 RT MAX 10, V-520 RT MAX 20, V-520 RT MAX 30, and V-520 RT MAX 50 units use R-404A refrigerant.

These units have a liquid injection system to limit discharge temperature of the engine driven compressor.

Evaporator heaters are used in the V-520 RT MAX to avoid drain tube blockage caused by ice accumulation inside the evaporator. Two harnesses are located inside the drain tube. These resistive wires melt the ice while the unit is in Defrost mode.

When the unit is connected to an electric power source, the battery disconnect relay and the standby relay are energized and provide rectified power from the transformer to the electronic control system.

During electric standby operation, the electronic control system controls the operation of the unit by energizing and de-energizing the compressor contactor and standby compressor clutch.

The electronic control system places the unit in cool, heat or defrost by energizing the compressor contactor and standby compressor clutch.

An oil separator is a standard feature. The oil separator separates compressor oil from refrigerant vapor and returns the oil to the compressor through the suction line. The oil separator helps provide positive oil return at high compressor speeds and low operating temperatures. This feature enhances compressor lubrication and extends compressor life.

• V-520 RT 10, V-520 RT 20, V-520 RT 30, and V-520 RT 50 units use R-134a refrigerant.

• V-520 RT MAX 10, V-520 RT MAX 20, V-520 RT MAX 30, and V-520 RT MAX 50 units use R-404A refrigerant.

These units have a liquid injection system to limit discharge temperature of the engine driven compressor.

Evaporator heaters are used in the V-520 RT MAX to avoid drain tube blockage caused by ice accumulation inside the evaporator. Two harnesses are located inside the drain tube. These resistive wires melt the ice while the unit is in Defrost mode.

When the unit is connected to an electric power source, the battery disconnect relay and the standby relay are energized and provide rectified power from the transformer to the electronic control system.

During electric standby operation, the electronic control system controls the operation of the unit by energizing and de-energizing the compressor contactor and standby compressor clutch.

The electronic control system places the unit in cool, heat or defrost by energizing the compressor contactor and standby compressor clutch.

Page 23: Operator's Manual V-520 RT, V-520 RT MAX

The electronic control system places the unit in null by de-energizing the compressor contactor and standby compressor clutch.

• High Pressure Transducer - The high pressure transducer is a pressure sensitive device. It is located in the discharge line near the oil separator outlet.

If the discharge pressure rises above a certain pressure, the ECM opens the circuit to the compressor clutch to stop unit operation.

For units with R-134a, the ECM opens the compressor clutch circuit at 300 psig (2068 kPa) and shuts down the unit. The ECM closes compressor clutch circuit when the pressure drops to 200 psig (1379 kPa).

For units with R-404A, the ECM opens the compressor clutch circuit at 450 psig (3103 kPa) and shuts down the unit. The ECM closes compressor clutch circuit when the pressure drops to 375 psig (2586 kPa).

• Low Pressure Cutout Switch - The Low Pressure Cutout Switch is a pressure sensitive switch located in the suction tube assembly in the refrigeration module. If the suction pressure falls below 5 to 11 in. Hg vacuum (-17 to -34 kPa), the switch opens the LPCO/CH circuit. This signals the ECM to open the circuit to the compressor clutch to stop unit operation.

The Electronic Control Module (ECM) contains the system’s fuses. See Figure 9 on the following pages.

The electronic control system places the unit in null by de-energizing the compressor contactor and standby compressor clutch.

• High Pressure Transducer - The high pressure transducer is a pressure sensitive device. It is located in the discharge line near the oil separator outlet.

If the discharge pressure rises above a certain pressure, the ECM opens the circuit to the compressor clutch to stop unit operation.

For units with R-134a, the ECM opens the compressor clutch circuit at 300 psig (2068 kPa) and shuts down the unit. The ECM closes compressor clutch circuit when the pressure drops to 200 psig (1379 kPa).

For units with R-404A, the ECM opens the compressor clutch circuit at 450 psig (3103 kPa) and shuts down the unit. The ECM closes compressor clutch circuit when the pressure drops to 375 psig (2586 kPa).

• Low Pressure Cutout Switch - The Low Pressure Cutout Switch is a pressure sensitive switch located in the suction tube assembly in the refrigeration module. If the suction pressure falls below 5 to 11 in. Hg vacuum (-17 to -34 kPa), the switch opens the LPCO/CH circuit. This signals the ECM to open the circuit to the compressor clutch to stop unit operation.

The Electronic Control Module (ECM) contains the system’s fuses. See Figure 9 on the following pages.

Page 24: Operator's Manual V-520 RT, V-520 RT MAX
Page 25: Operator's Manual V-520 RT, V-520 RT MAX

F1. Fuse 1 (12Vdc: 5 amps, 24Vdc: 5 amps) Power Supply Circuit to PCB1

F6. Fuse 6 (12Vdc: 10 amps, 24Vdc: 7.5 amps) Condenser Fan Motor (CFM1 and CFM2)

F2. Fuse 2 (12Vdc: 15 amps, 24Vdc: 10 amps) Condenser Fan Motor (CFM1)

F7. Fuse 7 (12Vdc: 15 amps, 24Vdc: 10 amps) Condenser Fan Motor (CFM2)

F3. Fuse 3 (12Vdc: 15 amps, 24Vdc: 10 amps) Evaporator Fan Motor (EFM1)

F8. Fuse 8 Not Used

F4. Fuse 4 (12Vdc: 15 amps, 24Vdc: 10 amps) Evaporator Fan Motor (EFM2)

F9. Fuse 9 (12Vdc: 15 amps, 24Vdc: 10 amps) Evaporator Fan Motor (EFM3)

F5. Fuse 5 (12Vdc: 20 amps, 24Vdc: 10 amps) Compressor Clutch 1 (CCL1), Liquid Injection Switch (LIS), Liquid Injection Valve (LIV), Hot Gas Defrost Solenoid (PS1), Hot Gas Heat Relay (HG), Condenser Blocking Solenoid (PS5), Compressor Contactor (CC), Compressor Clutch 2 (CCL2)

F10. Fuse 10 Not Used

F11. Fuse 11 (12Vdc: 10 amps, 24Vdc: 7.5 amps) Defrost Drain Heaters

F1. Fuse 1 (12Vdc: 5 amps, 24Vdc: 5 amps) Power Supply Circuit to PCB1

F6. Fuse 6 (12Vdc: 10 amps, 24Vdc: 7.5 amps) Condenser Fan Motor (CFM1 and CFM2)

F2. Fuse 2 (12Vdc: 15 amps, 24Vdc: 10 amps) Condenser Fan Motor (CFM1)

F7. Fuse 7 (12Vdc: 15 amps, 24Vdc: 10 amps) Condenser Fan Motor (CFM2)

F3. Fuse 3 (12Vdc: 15 amps, 24Vdc: 10 amps) Evaporator Fan Motor (EFM1)

F8. Fuse 8 Not Used

F4. Fuse 4 (12Vdc: 15 amps, 24Vdc: 10 amps) Evaporator Fan Motor (EFM2)

F9. Fuse 9 (12Vdc: 15 amps, 24Vdc: 10 amps) Evaporator Fan Motor (EFM3)

F5. Fuse 5 (12Vdc: 20 amps, 24Vdc: 10 amps) Compressor Clutch 1 (CCL1), Liquid Injection Switch (LIS), Liquid Injection Valve (LIV), Hot Gas Defrost Solenoid (PS1), Hot Gas Heat Relay (HG), Condenser Blocking Solenoid (PS5), Compressor Contactor (CC), Compressor Clutch 2 (CCL2)

F10. Fuse 10 Not Used

F11. Fuse 11 (12Vdc: 10 amps, 24Vdc: 7.5 amps) Defrost Drain Heaters

Page 26: Operator's Manual V-520 RT, V-520 RT MAX

Model 10 units and 20 operate in Cool or Null, as required, to maintain the load compartment temperature at the setpoint temperature.

Model 30 and 50 units operate in Cool, Null or Heat, as required, to maintain the load compartment temperature at the setpoint temperature.

Defrost cycles occur manually or automatically, as required.

If power is shut off, the unit comes back in Null mode when the unit is restarted. There is a momentary delay at auto start-up for circuit protection.

NOTE: The compressor will “bump start” five times while coming out of Null when the unit is restarted after being turned off. This does not happen if the unit went into Null because it reached setpoint. In a “bump start” the compressor is turned on for about one second and then goes off for about four seconds.

When cooling is required (when there is a requirement to lower the evaporator return air temperature in the load compartment), the controller energizes the compressor clutch (and compressor contactor in model 20 units) and evaporator fans. The controller monitors the discharge pressure through the high

Decrease in Temperature

Temperature Setpoint

Increase in temperature

X C/F above the setpoint

X C/F below the setpoint

COOL

HEAT

NULL MODE

Model 10 units and 20 operate in Cool or Null, as required, to maintain the load compartment temperature at the setpoint temperature.

Model 30 and 50 units operate in Cool, Null or Heat, as required, to maintain the load compartment temperature at the setpoint temperature.

Defrost cycles occur manually or automatically, as required.

If power is shut off, the unit comes back in Null mode when the unit is restarted. There is a momentary delay at auto start-up for circuit protection.

NOTE: The compressor will “bump start” five times while coming out of Null when the unit is restarted after being turned off. This does not happen if the unit went into Null because it reached setpoint. In a “bump start” the compressor is turned on for about one second and then goes off for about four seconds.

When cooling is required (when there is a requirement to lower the evaporator return air temperature in the load compartment), the controller energizes the compressor clutch (and compressor contactor in model 20 units) and evaporator fans. The controller monitors the discharge pressure through the high

Decrease in Temperature

Temperature Setpoint

Increase in temperature

X C/F above the setpoint

X C/F below the setpoint

COOL

HEAT

NULL MODE

Page 27: Operator's Manual V-520 RT, V-520 RT MAX

pressure transducer (THPCO). The condenser fans are energized if necessary and turn on and off as determined by the controller.

The unit operates in Cool mode until the setpoint temperature is reached. The unit then enters Null mode. When the temperature rises to a pre-determined number of degrees, the unit restarts in Cool mode.

V-520 RT units have a triple-cooling capacity (TCC) feature. The controller monitors the discharge pressure through the high pressure transducer (THPCO) and controls the speed of condenser fans by opening and closing relays:

• When discharge pressure is less than 180 psig (1241 kPa), condenser fans receive no voltage and are in Null state.

• When the HP pressure is between 180 psig (1241 kPa) and 300 psig (2068 kPa), condenser fans operate at low speed.

• When the HP pressure is greater than 300 psig (2068 kPa), condenser fans operate at high speed.

The unit operates in Null mode when the setpoint temperature is reached and cooling (or heating) is not required. All outputs are de-energized. If the temperature rises a pre-determined number of degrees, the unit restarts in Cool mode. If the temperature falls a pre-determined number of degrees, and a heat option is present, the unit restarts in Heat mode.

In addition, the evaporator fans might operate during Null mode.

When the temperature falls a pre-determined number of degrees below the setpoint temperature, the controller prepares the unit for the Heat mode by placing the unit in the Null mode for 10 seconds, and then placing the unit in the Purge mode for 45 seconds before shifting to the Heat mode. In the Purge mode the compressor clutch is energized but the evaporator fans are not. This moves the refrigerant from the condenser to the low side to increase the heating capacity.

pressure transducer (THPCO). The condenser fans are energized if necessary and turn on and off as determined by the controller.

The unit operates in Cool mode until the setpoint temperature is reached. The unit then enters Null mode. When the temperature rises to a pre-determined number of degrees, the unit restarts in Cool mode.

V-520 RT units have a triple-cooling capacity (TCC) feature. The controller monitors the discharge pressure through the high pressure transducer (THPCO) and controls the speed of condenser fans by opening and closing relays:

• When discharge pressure is less than 180 psig (1241 kPa), condenser fans receive no voltage and are in Null state.

• When the HP pressure is between 180 psig (1241 kPa) and 300 psig (2068 kPa), condenser fans operate at low speed.

• When the HP pressure is greater than 300 psig (2068 kPa), condenser fans operate at high speed.

The unit operates in Null mode when the setpoint temperature is reached and cooling (or heating) is not required. All outputs are de-energized. If the temperature rises a pre-determined number of degrees, the unit restarts in Cool mode. If the temperature falls a pre-determined number of degrees, and a heat option is present, the unit restarts in Heat mode.

In addition, the evaporator fans might operate during Null mode.

When the temperature falls a pre-determined number of degrees below the setpoint temperature, the controller prepares the unit for the Heat mode by placing the unit in the Null mode for 10 seconds, and then placing the unit in the Purge mode for 45 seconds before shifting to the Heat mode. In the Purge mode the compressor clutch is energized but the evaporator fans are not. This moves the refrigerant from the condenser to the low side to increase the heating capacity.

Page 28: Operator's Manual V-520 RT, V-520 RT MAX

NOTE: The unit will not go into the Purge mode when coming out of the Null mode because it reached setpoint. The unit will only go into the Purge mode when first going into the Heat mode because the unit is powering up or when going directly from the Cool mode to the Heat mode.

The unit enters Heat mode when the temperature falls a pre-determined number of degrees below the setpoint temperature. Before going into the Heat mode, the controller places the unit the Null mode for 10 seconds and then the Purge mode for 45 seconds before shifting to the Heat mode.

NOTE: The unit only uses the Purge mode before the Heat mode the first time the unit goes into Heat. After that the Purge mode is not used before the Heat mode unless the unit is powering up or when going directly from the Cool mode to the Heat mode.

The unit operates in Heat mode until the setpoint temperature is reached. The unit then enters Null mode.

• If the temperature falls a pre-determined number of degrees, the unit will go into Purge mode for 45 seconds and then go into Heat mode.

• If the temperature rises a pre-determined number of degrees, the unit will go into Cool mode.

NOTE: The unit will not go into the Purge mode when coming out of the Null mode because it reached setpoint. The unit will only go into the Purge mode when first going into the Heat mode because the unit is powering up or when going directly from the Cool mode to the Heat mode.

The unit enters Heat mode when the temperature falls a pre-determined number of degrees below the setpoint temperature. Before going into the Heat mode, the controller places the unit the Null mode for 10 seconds and then the Purge mode for 45 seconds before shifting to the Heat mode.

NOTE: The unit only uses the Purge mode before the Heat mode the first time the unit goes into Heat. After that the Purge mode is not used before the Heat mode unless the unit is powering up or when going directly from the Cool mode to the Heat mode.

The unit operates in Heat mode until the setpoint temperature is reached. The unit then enters Null mode.

• If the temperature falls a pre-determined number of degrees, the unit will go into Purge mode for 45 seconds and then go into Heat mode.

• If the temperature rises a pre-determined number of degrees, the unit will go into Cool mode.

Page 29: Operator's Manual V-520 RT, V-520 RT MAX

Defrost can be initiated any time the evaporator coil temperature is below 36 F (2.2 C). Defrost is initiated automatically by the defrost timer, or manually using the In-Cab Control Box.

Defrost will continue until the evaporator coil temperature rises 48 F (8.9 C) which will end the defrost cycle. Defrost cycle can be also terminated by pressing the On/Off Key to turn the unit off, and then pressing it again to turn the unit back on.

Nameplate located on the back inside wall of refrigeration module frame.

Nameplate located on compressor body. The engine driven compressor is located in the truck engine compartment.

Defrost can be initiated any time the evaporator coil temperature is below 36 F (2.2 C). Defrost is initiated automatically by the defrost timer, or manually using the In-Cab Control Box.

Defrost will continue until the evaporator coil temperature rises 48 F (8.9 C) which will end the defrost cycle. Defrost cycle can be also terminated by pressing the On/Off Key to turn the unit off, and then pressing it again to turn the unit back on.

Nameplate located on the back inside wall of refrigeration module frame.

Nameplate located on compressor body. The engine driven compressor is located in the truck engine compartment.

Page 30: Operator's Manual V-520 RT, V-520 RT MAX

ARA1881

ARA1881

Page 31: Operator's Manual V-520 RT, V-520 RT MAX

1. Hot Gas Heat Relay (HG) - Model 30 Only 7. Liquid Line Check Valve - Model 30 Only

2. Battery Relay (K1) 8. Suction Service Port

3. Control Box 9. Low Pressure Cutout Switch (LPCO)

4. Condenser Blocking Solenoid - Model 30 Only 10. Liquid Line Sight Glass

5. High Pressure Transducer 11. Drier

6. Liquid Injection Solenoid Valve 12. Oil Separator

1. Hot Gas Heat Relay (HG) - Model 30 Only 7. Liquid Line Check Valve - Model 30 Only

2. Battery Relay (K1) 8. Suction Service Port

3. Control Box 9. Low Pressure Cutout Switch (LPCO)

4. Condenser Blocking Solenoid - Model 30 Only 10. Liquid Line Sight Glass

5. High Pressure Transducer 11. Drier

6. Liquid Injection Solenoid Valve 12. Oil Separator

Page 32: Operator's Manual V-520 RT, V-520 RT MAX

ARA1878

ARA1878

Page 33: Operator's Manual V-520 RT, V-520 RT MAX

1. Hot Gas Heat Relay (HG) - Model 50 Only 9. Liquid Injection Solenoid Valve 2. Battery Power Relay (K4) 10. Liquid Line Check Valve - Model 50 Only 3. Standby Power Relay (K3) 11. Suction Pressure Regulator (SPR) 4. Battery Disconnect Relay (K5) 12. Suction Service Port 5. Control Box 13. Low Pressure Cutout Switch (LPCO)6. Discharge Check Valves 14. Liquid Line Sight Glass7. Condenser Blocking Solenoid - Model 50 Only 15. Drier8. High Pressure Transducer 16 Oil Separator

1. Hot Gas Heat Relay (HG) - Model 50 Only 9. Liquid Injection Solenoid Valve 2. Battery Power Relay (K4) 10. Liquid Line Check Valve - Model 50 Only 3. Standby Power Relay (K3) 11. Suction Pressure Regulator (SPR) 4. Battery Disconnect Relay (K5) 12. Suction Service Port 5. Control Box 13. Low Pressure Cutout Switch (LPCO)6. Discharge Check Valves 14. Liquid Line Sight Glass7. Condenser Blocking Solenoid - Model 50 Only 15. Drier8. High Pressure Transducer 16 Oil Separator

Page 34: Operator's Manual V-520 RT, V-520 RT MAX

ARA1809

1. Refrigeration Line Connections 3. Condenser Coils

2. Condenser Fans

ARA1809

1. Refrigeration Line Connections 3. Condenser Coils

2. Condenser Fans

Page 35: Operator's Manual V-520 RT, V-520 RT MAX

AMA514

1. Evaporator Fans 4. Expansion Valve

2. Defrost Termination Switch 5. Temperature Sensor

3. Defrost Solenoid Valve

AMA514

1. Evaporator Fans 4. Expansion Valve

2. Defrost Termination Switch 5. Temperature Sensor

3. Defrost Solenoid Valve

Page 36: Operator's Manual V-520 RT, V-520 RT MAX

ARA1879

1. Standby Compressor 4. Electric Motor Driven Compressor Belt2. Electric Motor 5. Compressor Belt3. Standby Electrical Control Tray

ARA1879

1. Standby Compressor 4. Electric Motor Driven Compressor Belt2. Electric Motor 5. Compressor Belt3. Standby Electrical Control Tray

Page 37: Operator's Manual V-520 RT, V-520 RT MAX

ARA1880

1. Transformer

2. Capacitor - Power Supply

3. Overload Relay

4. Compressor Contactor

5. Transformer Input Fuse Holder (Fuse 23)

6. Capacitor - Run - Single Phase Only

7. Rectifier Heat Sink (Rectifiers Mounted on Back)

8. Capacitor - Start - Single Phase Only

9. Starter Relay - Single Phase Only

ARA1880

1. Transformer

2. Capacitor - Power Supply

3. Overload Relay

4. Compressor Contactor

5. Transformer Input Fuse Holder (Fuse 23)

6. Capacitor - Run - Single Phase Only

7. Rectifier Heat Sink (Rectifiers Mounted on Back)

8. Capacitor - Start - Single Phase Only

9. Starter Relay - Single Phase Only

Page 38: Operator's Manual V-520 RT, V-520 RT MAX

In truck-driven units, temperature control is based on two values: The setting (Setpoint) of the electronic thermostat and the evaporator return air temperature. The difference between these two temperatures will determine the mode of operation: cool, heat, or null.

When the temperature in the load compartment is higher than the setpoint, the unit runs in cool mode to reduce the evaporator return temperature.

When the temperature in the load compartment is lower than the setpoint, the unit changes to heat mode to raise the evaporator return temperature.

Once the Setpoint Temperature has been reached, and while the temperature remains between X F/C above or below the setpoint, there is no demand for transfer of heat or cold, and the unit runs in null mode.

After a scheduled period of time in cool mode, between 1 and 8 hours, the unit runs in this fourth mode of operation to eliminate ice that has accumulated in the evaporator coil. Defrost can be initiated automatically or manually.

Decrease in Temperature

Temperature Setpoint

Increase in temperature

X C/F above the setpoint

X C/F below the setpoint

COOL

HEAT

NULLMODE

In truck-driven units, temperature control is based on two values: The setting (Setpoint) of the electronic thermostat and the evaporator return air temperature. The difference between these two temperatures will determine the mode of operation: cool, heat, or null.

When the temperature in the load compartment is higher than the setpoint, the unit runs in cool mode to reduce the evaporator return temperature.

When the temperature in the load compartment is lower than the setpoint, the unit changes to heat mode to raise the evaporator return temperature.

Once the Setpoint Temperature has been reached, and while the temperature remains between X F/C above or below the setpoint, there is no demand for transfer of heat or cold, and the unit runs in null mode.

After a scheduled period of time in cool mode, between 1 and 8 hours, the unit runs in this fourth mode of operation to eliminate ice that has accumulated in the evaporator coil. Defrost can be initiated automatically or manually.

Decrease in Temperature

Temperature Setpoint

Increase in temperature

X C/F above the setpoint

X C/F below the setpoint

COOL

HEAT

NULLMODE

Page 39: Operator's Manual V-520 RT, V-520 RT MAX

Factory setting for X is 5 F (3 C). During unit installation, this value can be adjusted between 2 and 9 F (1 and 5 C) in increments of 1 F/C.

Units with R-134a refrigerant: Temperatures can be controlled from -8 F to +71 F (-22 C to +22 C).

Units with R-404A refrigerant: Temperatures can be controlled from -26 F to +71 F (-32 C to +22 C).

WARNING: Never operate the unit unless you completely understand the controls; otherwise serious injury may occur.

1. Display It is always active and backlit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the In-Cab Control Box. It normally displays the return air temperature.

2. On/Off Key

This key is used to start/stop the unit. It is always lit except when the unit is disconnected (no power), and thus acts as an indicator of the presence of power in the unit.

3. Select Key

Selects prompt screens and information screens.

4. Up Key Is used to increase the setpoint temperature.

5. Down Key Is used to reduce the setpoint temperature.

6. Enter Key Is used to enter a new command such as manual defrost, etc.

Factory setting for X is 5 F (3 C). During unit installation, this value can be adjusted between 2 and 9 F (1 and 5 C) in increments of 1 F/C.

Units with R-134a refrigerant: Temperatures can be controlled from -8 F to +71 F (-22 C to +22 C).

Units with R-404A refrigerant: Temperatures can be controlled from -26 F to +71 F (-32 C to +22 C).

WARNING: Never operate the unit unless you completely understand the controls; otherwise serious injury may occur.

1. Display It is always active and backlit except when the unit is disconnected (no power) or when the unit is connected but has been manually switched off from the In-Cab Control Box. It normally displays the return air temperature.

2. On/Off Key

This key is used to start/stop the unit. It is always lit except when the unit is disconnected (no power), and thus acts as an indicator of the presence of power in the unit.

3. Select Key

Selects prompt screens and information screens.

4. Up Key Is used to increase the setpoint temperature.

5. Down Key Is used to reduce the setpoint temperature.

6. Enter Key Is used to enter a new command such as manual defrost, etc.

Page 40: Operator's Manual V-520 RT, V-520 RT MAX

1. Start the truck engine.

2. Press the On/Off Key located in the In-Cab Control Box. The In-Cab Control Box display will be activated.

3. Check the setpoint, and adjust if necessary.

1. Connect the external power supply to the electric power receptacle. Ensure that the power supply is of the correct voltage and phase for the unit.

7. Buzzer It is energized when the vehicle battery and the electric power supply are connected simultaneously. It is also energized if the doors are opened while the refrigeration unit is running.

8. Cool Symbol

(Thermometer with an arrow pointing downward). The unit is cooling.

9. Heat Symbol

(Thermometer with an arrow pointing upward). The unit is heating.

10. C/ F Symbol

Indicates whether the on-screen temperature reading is in degrees Celsius (C) or degrees Fahrenheit (F).

11. Alarm Symbol

Indicates that there is an alarm in the system.

12.Maintenance Symbol

Warns of the need to carry out maintenance to the unit.

13. Defrost Symbol

Indicates the unit is in Defrost Mode.

14. Electrical Symbol

Indicates that the unit is in Electric Standby.

1. Start the truck engine.

2. Press the On/Off Key located in the In-Cab Control Box. The In-Cab Control Box display will be activated.

3. Check the setpoint, and adjust if necessary.

1. Connect the external power supply to the electric power receptacle. Ensure that the power supply is of the correct voltage and phase for the unit.

7. Buzzer It is energized when the vehicle battery and the electric power supply are connected simultaneously. It is also energized if the doors are opened while the refrigeration unit is running.

8. Cool Symbol

(Thermometer with an arrow pointing downward). The unit is cooling.

9. Heat Symbol

(Thermometer with an arrow pointing upward). The unit is heating.

10. C/ F Symbol

Indicates whether the on-screen temperature reading is in degrees Celsius (C) or degrees Fahrenheit (F).

11. Alarm Symbol

Indicates that there is an alarm in the system.

12.Maintenance Symbol

Warns of the need to carry out maintenance to the unit.

13. Defrost Symbol

Indicates the unit is in Defrost Mode.

14. Electrical Symbol

Indicates that the unit is in Electric Standby.

Page 41: Operator's Manual V-520 RT, V-520 RT MAX

2. Press the On/Off Key located in the In-Cab Control Box. The In-Cab Control Box display will be activated. The electric symbol will appear on the screen.

3. Check the setpoint, and adjust if necessary.

NOTE: The operating mode, whether engine driven or electric standby, is selected automatically. When the unit is connected to an electric power source, engine driven operation is automatically blocked. If the truck engine is started up while the power cable is still connected to the electric power source, the unit will continue to operate in electric standby mode.

This is the display that appears when the On/Off key is pressed and the unit started. It normally displays the return air temperature and the current operating mode with the appropriate symbol.

Should there be an alarm, the Alarm symbol will also appear on screen.

The example in the drawing shows: 10.8 C temperature and cool mode.

2. Press the On/Off Key located in the In-Cab Control Box. The In-Cab Control Box display will be activated. The electric symbol will appear on the screen.

3. Check the setpoint, and adjust if necessary.

NOTE: The operating mode, whether engine driven or electric standby, is selected automatically. When the unit is connected to an electric power source, engine driven operation is automatically blocked. If the truck engine is started up while the power cable is still connected to the electric power source, the unit will continue to operate in electric standby mode.

This is the display that appears when the On/Off key is pressed and the unit started. It normally displays the return air temperature and the current operating mode with the appropriate symbol.

Should there be an alarm, the Alarm symbol will also appear on screen.

The example in the drawing shows: 10.8 C temperature and cool mode.

Page 42: Operator's Manual V-520 RT, V-520 RT MAX

The Setpoint Temperature can be quickly and easily changed.

1. Press and release the Select key twice, and the current Setpoint Temperature and the letters SP will appear on screen.

2. Press the Up or Down arrow keys to select the desired Setpoint Temperature. Each time either of these buttons is pressed and released, the Setpoint Temperature will change 1 degree.

3. Press and release the Select key, and the Standard Display will reappear on screen.

IMPORTANT: If the Select key is not pressed within 20 seconds to select the new Setpoint Temperature, the unit will continue to run at the original Setpoint Temperature.

CAUTION: Before initiating a manual defrost, ensure that the unit is not already in a defrost cycle. When the unit is in a defrost cycle the defrost symbol appears on screen.

1. Press and release the Select key once, and the letters dEF will appear (flashing) on screen along with the present defrost condition OFF.

The Setpoint Temperature can be quickly and easily changed.

1. Press and release the Select key twice, and the current Setpoint Temperature and the letters SP will appear on screen.

2. Press the Up or Down arrow keys to select the desired Setpoint Temperature. Each time either of these buttons is pressed and released, the Setpoint Temperature will change 1 degree.

3. Press and release the Select key, and the Standard Display will reappear on screen.

IMPORTANT: If the Select key is not pressed within 20 seconds to select the new Setpoint Temperature, the unit will continue to run at the original Setpoint Temperature.

CAUTION: Before initiating a manual defrost, ensure that the unit is not already in a defrost cycle. When the unit is in a defrost cycle the defrost symbol appears on screen.

1. Press and release the Select key once, and the letters dEF will appear (flashing) on screen along with the present defrost condition OFF.

Page 43: Operator's Manual V-520 RT, V-520 RT MAX

2. To activate manual defrost, press the Enter key and then the Up or Down key and the defrost condition will change to On.

3. Press the Select key twice to return to the Standard Display where the Defrost symbol will appear when the defrost cycle begins (the defrost termination switch must be closed).

2. To activate manual defrost, press the Enter key and then the Up or Down key and the defrost condition will change to On.

3. Press the Select key twice to return to the Standard Display where the Defrost symbol will appear when the defrost cycle begins (the defrost termination switch must be closed).

Page 44: Operator's Manual V-520 RT, V-520 RT MAX

When the unit is not operating properly, the microprocessor records the alarm code, alerts the operator by displaying the Alarm symbol and, depending on the type of alarm, shuts the unit down.

There are three alarm categories:

The alarm stops the unit, and only the Alarm symbol appears on screen.

Once the alarm condition has been rectified, the ON/OFF key must be pressed to start up again.

Press and release the SELECT key to display the current alarm code on screen. If there is more than one active alarm, all the alarm codes on the unit can be viewed in sequence by pressing and releasing the SELECT key.

The alarm stops the unit, the Alarm symbol appears on screen and the unit starts up automatically once the alarm condition has been rectified.

Should a P1E alarm occur - return air temperature read error alarm code - appear, --- will appear on screen together with the alarm symbol, instead of the return air temperature reading.

When the unit is not operating properly, the microprocessor records the alarm code, alerts the operator by displaying the Alarm symbol and, depending on the type of alarm, shuts the unit down.

There are three alarm categories:

The alarm stops the unit, and only the Alarm symbol appears on screen.

Once the alarm condition has been rectified, the ON/OFF key must be pressed to start up again.

Press and release the SELECT key to display the current alarm code on screen. If there is more than one active alarm, all the alarm codes on the unit can be viewed in sequence by pressing and releasing the SELECT key.

The alarm stops the unit, the Alarm symbol appears on screen and the unit starts up automatically once the alarm condition has been rectified.

Should a P1E alarm occur - return air temperature read error alarm code - appear, --- will appear on screen together with the alarm symbol, instead of the return air temperature reading.

Page 45: Operator's Manual V-520 RT, V-520 RT MAX

Press and release the Select key to display the current alarm code on screen. If there is more than one active alarm, all the alarm codes on the unit can be viewed in sequence by pressing and releasing the Select key.

They are energized when the vehicle battery and the electrical supply are connected simultaneously (the unit continues running in standby mode). They are also energized if the doors open, if this option is selected.

Press and release the Select key to display the current alarm code on screen. If there is more than one active alarm, all the alarm codes on the unit can be viewed in sequence by pressing and releasing the Select key.

They are energized when the vehicle battery and the electrical supply are connected simultaneously (the unit continues running in standby mode). They are also energized if the doors open, if this option is selected.

Page 46: Operator's Manual V-520 RT, V-520 RT MAX

OL Electric Motor Overload. Unit protection system during electric standby operation. If the problem persists when the unit is restarted, contact your Service Dealer.

bAt Low Battery Voltage. Unit and battery protection system.

HP High Pressure Alarm. Indicates that the refrigeration system will shut down in the event of excessively high pressure in the refrigerant circuit. If the problem persists when the unit is restarted, contact your Service Dealer.

LP Low Pressure Alarm. Indicates that the refrigeration system will shut down in the event of excessively low pressure in the refrigerant circuit. If the problem persists when the unit is restarted, contact your Service Dealer.

PSE High Pressure Sensor Failure. The high pressure sensor has become faulty or disconnected. Contact your Service Dealer.

tEP Electric Motor Thermal Protection Alarm. If the problem persists when the unit is restarted, contact your Service Dealer.

dr1, dr2 Doors Open. This option must be activated.

OL Electric Motor Overload. Unit protection system during electric standby operation. If the problem persists when the unit is restarted, contact your Service Dealer.

bAt Low Battery Voltage. Unit and battery protection system.

HP High Pressure Alarm. Indicates that the refrigeration system will shut down in the event of excessively high pressure in the refrigerant circuit. If the problem persists when the unit is restarted, contact your Service Dealer.

LP Low Pressure Alarm. Indicates that the refrigeration system will shut down in the event of excessively low pressure in the refrigerant circuit. If the problem persists when the unit is restarted, contact your Service Dealer.

PSE High Pressure Sensor Failure. The high pressure sensor has become faulty or disconnected. Contact your Service Dealer.

tEP Electric Motor Thermal Protection Alarm. If the problem persists when the unit is restarted, contact your Service Dealer.

dr1, dr2 Doors Open. This option must be activated.

Page 47: Operator's Manual V-520 RT, V-520 RT MAX

The alarm condition in the unit must first be corrected. After clearing the alarm condition, press and release the Select key to remove existing Alarm codes. The standard display will appear once the Alarm codes have been cleared.

From the Standard Display use the Select key to display:

1. Alarms (if any active)

2. Manual Defrost

3. Temperature Setpoint

From the Standard Display press the Select key for 3 seconds to open the Hourmeter Menu, then use the Select key to display:

1. HC: Hours remaining to maintenance notice.

tCO (Hot) Control Module Overheating. If the problem persists when the unit is restarted, contact your Service Dealer.

SOF Software failure. Contact your Service Dealer.

P1E Main or Single Cargo Box Return Air Temperature Reading Error (open circuit or short-circuit). Contact your Service Dealer.

C Communications Failure. Contact your Service Dealer.

The alarm condition in the unit must first be corrected. After clearing the alarm condition, press and release the Select key to remove existing Alarm codes. The standard display will appear once the Alarm codes have been cleared.

From the Standard Display use the Select key to display:

1. Alarms (if any active)

2. Manual Defrost

3. Temperature Setpoint

From the Standard Display press the Select key for 3 seconds to open the Hourmeter Menu, then use the Select key to display:

1. HC: Hours remaining to maintenance notice.

tCO (Hot) Control Module Overheating. If the problem persists when the unit is restarted, contact your Service Dealer.

SOF Software failure. Contact your Service Dealer.

P1E Main or Single Cargo Box Return Air Temperature Reading Error (open circuit or short-circuit). Contact your Service Dealer.

C Communications Failure. Contact your Service Dealer.

Page 48: Operator's Manual V-520 RT, V-520 RT MAX

2. tH: The total amount of time the unit has been switched on protecting the load.

3. CC: Engine-driven compressor operating hours.

4. EC: Electric standby compressor operating hours.

5. Return to Main Menu.

Adjust the thermostat setting to above and below the compartment temperature to check thermostat operation (see Figure 17 on page 37).

With the thermostat set at the desired temperature, run the unit for half-an-hour to one hour (or longer if possible) before loading the truck. Pre-cooling eliminates residual heat and acts as a good test of the refrigeration system.

When the unit has finished pre-cooling the truck interior - the evaporator temperature should have dropped below 36 F (2.2 C) - initiate a defrost cycle with the In-Cab Control Box. The defrost cycle should stop automatically.

1. To minimize frost accumulation in the evaporator coil and a heat increase inside the load compartment, ensure that the unit is OFF before opening the doors. (The unit may continue to run when the truck is being loaded in a warehouse with the doors closed.)

2. Carefully check and record the load temperature when loading the truck. Note whether any products are out of temperature range.

3. Load the product in such a way that there is sufficient space for the air to circulate throughout the load. DO NOT block the evaporator inlet or outlet.

4. Product should be pre-cooled before loading. Thermo King units are designed to maintain the load at the temperature at which it is loaded. Transport refrigeration units are not designed to reduce the load temperature.

1. Ensure that all doors are closed and locked.

2. Adjust the thermostat to the desired temperature setpoint.

2. tH: The total amount of time the unit has been switched on protecting the load.

3. CC: Engine-driven compressor operating hours.

4. EC: Electric standby compressor operating hours.

5. Return to Main Menu.

Adjust the thermostat setting to above and below the compartment temperature to check thermostat operation (see Figure 17 on page 37).

With the thermostat set at the desired temperature, run the unit for half-an-hour to one hour (or longer if possible) before loading the truck. Pre-cooling eliminates residual heat and acts as a good test of the refrigeration system.

When the unit has finished pre-cooling the truck interior - the evaporator temperature should have dropped below 36 F (2.2 C) - initiate a defrost cycle with the In-Cab Control Box. The defrost cycle should stop automatically.

1. To minimize frost accumulation in the evaporator coil and a heat increase inside the load compartment, ensure that the unit is OFF before opening the doors. (The unit may continue to run when the truck is being loaded in a warehouse with the doors closed.)

2. Carefully check and record the load temperature when loading the truck. Note whether any products are out of temperature range.

3. Load the product in such a way that there is sufficient space for the air to circulate throughout the load. DO NOT block the evaporator inlet or outlet.

4. Product should be pre-cooled before loading. Thermo King units are designed to maintain the load at the temperature at which it is loaded. Transport refrigeration units are not designed to reduce the load temperature.

1. Ensure that all doors are closed and locked.

2. Adjust the thermostat to the desired temperature setpoint.

Page 49: Operator's Manual V-520 RT, V-520 RT MAX

3. Start the unit.

4. Half an hour after loading the truck, defrost the unit for a moment by pressing the Manual Defrost switch. If the coil temperature drops to below 36 F (2.2 C), the unit will defrost. The defrost cycle should stop automatically.

The following Weekly Pretrip Inspection should be completed before loading the truck. While the weekly inspection in not a substitute for regularly scheduled maintenance inspections, it is important part of the preventive maintenance program designed to head off operating problems before they happen.

1. LEAKS. Inspect for refrigerant leaks and worn refrigerant lines.

2. BELTS. Inspect for cracks, wear and proper belt tension.

3. MOUNTING BOLTS. Inspect bolts are properly tightened.

4. ELECTRICAL. Electrical connections should be securely fastened. Wires and terminals should be free of corrosion, cracks or moisture.

5. DEFROST DRAINS. Check the defrost drain hose and fittings to be sure that they are open so condensate can run out during defrosting. Check the bottom end of drain hose to be sure that is not plugged or crushed.

6. STRUCTURAL. Visually check for physical damage.

7. REFRIGERANT CHARGE. Check for proper refrigerant charge level.

1. Wash the unit.

2. Check for leaks.

3. Check for loose or missing hardware.

4. Check for physical damage to unit.

3. Start the unit.

4. Half an hour after loading the truck, defrost the unit for a moment by pressing the Manual Defrost switch. If the coil temperature drops to below 36 F (2.2 C), the unit will defrost. The defrost cycle should stop automatically.

The following Weekly Pretrip Inspection should be completed before loading the truck. While the weekly inspection in not a substitute for regularly scheduled maintenance inspections, it is important part of the preventive maintenance program designed to head off operating problems before they happen.

1. LEAKS. Inspect for refrigerant leaks and worn refrigerant lines.

2. BELTS. Inspect for cracks, wear and proper belt tension.

3. MOUNTING BOLTS. Inspect bolts are properly tightened.

4. ELECTRICAL. Electrical connections should be securely fastened. Wires and terminals should be free of corrosion, cracks or moisture.

5. DEFROST DRAINS. Check the defrost drain hose and fittings to be sure that they are open so condensate can run out during defrosting. Check the bottom end of drain hose to be sure that is not plugged or crushed.

6. STRUCTURAL. Visually check for physical damage.

7. REFRIGERANT CHARGE. Check for proper refrigerant charge level.

1. Wash the unit.

2. Check for leaks.

3. Check for loose or missing hardware.

4. Check for physical damage to unit.

Page 50: Operator's Manual V-520 RT, V-520 RT MAX

Fuse 1: Power Supply Circuit to PCB1 5 amps 5 ampsFuse 2: Condenser Fan Motor (CFM1) 15 amps 10 ampsFuse 3: Evaporator Fan Motor (EFM1 15 amps 10 ampsFuse 4: Evaporator Fan Motor (EFM2) 15 amps 10 ampsFuse 5: Compressor Clutch 1 (CCL1), Liquid Injection Switch (LIS), Liquid Injection Valve (LIV), Hot Gas Defrost Solenoid (PS1), Hot Gas Heat Relay (HG), Condenser Blocking Solenoid (PS5), Compressor Contactor (CC), Compressor Clutch 2 (CCL2)

20 amps 10 amps

Fuse 6: Condenser Fan Motor (CFM1 and CFM2) 10 amps 7.5 ampsFuse 7: Condenser Fan Motor (CFM2) 15 amps 10 ampsFuse 8: Not UsedFuse 9: Evaporator Fan Motor (EFM3) 15 amps 10 ampsFuse 10: Not UsedFuse 11: Defrost Drain Heaters 10 amps 7.5 ampsFuse 21: Battery Fuse 40 amps 40 ampsFuse 22: Vehicle Ignition/ACC Fuse 10 amps 10 amps

Fuse 1: Power Supply Circuit to PCB1 5 amps 5 ampsFuse 2: Condenser Fan Motor (CFM1) 15 amps 10 ampsFuse 3: Evaporator Fan Motor (EFM1 15 amps 10 ampsFuse 4: Evaporator Fan Motor (EFM2) 15 amps 10 ampsFuse 5: Compressor Clutch 1 (CCL1), Liquid Injection Switch (LIS), Liquid Injection Valve (LIV), Hot Gas Defrost Solenoid (PS1), Hot Gas Heat Relay (HG), Condenser Blocking Solenoid (PS5), Compressor Contactor (CC), Compressor Clutch 2 (CCL2)

20 amps 10 amps

Fuse 6: Condenser Fan Motor (CFM1 and CFM2) 10 amps 7.5 ampsFuse 7: Condenser Fan Motor (CFM2) 15 amps 10 ampsFuse 8: Not UsedFuse 9: Evaporator Fan Motor (EFM3) 15 amps 10 ampsFuse 10: Not UsedFuse 11: Defrost Drain Heaters 10 amps 7.5 ampsFuse 21: Battery Fuse 40 amps 40 ampsFuse 22: Vehicle Ignition/ACC Fuse 10 amps 10 amps

Page 51: Operator's Manual V-520 RT, V-520 RT MAX

Fuse 23: Transformer Input (L1) 5 amps 5 ampsFuse 24: Transformer Output (X1) 5 amps 5 ampsFuse 25: Transformer Output (X4) 5 amps 5 amps

Voltage 13 Vdc Full Load Current 8.7 Amps

Voltage 13 VdcFull Load Current 6.2 Amps

Voltage 12 VdcCurrent 2.3 ampsResistance 5.2 ohms

Voltage 12 VdcCurrent 0.7 ampsResistance 17.0 ohms

Voltage 12 VdcCurrent 2.3 ampsResistance 5.2 ohms

Fuse 23: Transformer Input (L1) 5 amps 5 ampsFuse 24: Transformer Output (X1) 5 amps 5 ampsFuse 25: Transformer Output (X4) 5 amps 5 amps

Voltage 13 Vdc Full Load Current 8.7 Amps

Voltage 13 VdcFull Load Current 6.2 Amps

Voltage 12 VdcCurrent 2.3 ampsResistance 5.2 ohms

Voltage 12 VdcCurrent 0.7 ampsResistance 17.0 ohms

Voltage 12 VdcCurrent 2.3 ampsResistance 5.2 ohms

Page 52: Operator's Manual V-520 RT, V-520 RT MAX

Voltage 12 VdcCurrent 0.9 ampsResistance 14.0 ohms

Voltage 12 VdcCurrent 0.9 ampsResistance 14.0 ohms

Page 53: Operator's Manual V-520 RT, V-520 RT MAX

Refrigerant Charge: V-520 RT - Model 10 4.00 lb (1.81 kg) R-134aV-520 RT - Model 20 5.00 lb (2.27 kg) R-134aV-520 RT - Model 30 4.25 lb (1.93 kg) R-134aV-520 RT - Model 50 5.31 lb (2.41 kg) R-134a

Defrost Termination Switch: Opens 48.0 ± 5.0 F (8.9 ± 2.8 C) Closes 36.0 ± 5.0 F (2.2 ± 2.8 C)

Liquid Injection Switch (LIS): Opens 200 ± 5 F (93 ± 3 C)Closes 230 ± 5 F (110 ± 3 C)

Low Pressure Cutout Switch (LPCO): Opens 5 to 11 in. Hg vacuum (-17 to -37 kPa)Closes 4 to 7 psig (28 to 48 kPa)

Compressor Pressure Regulator (CPR) Valve Setting - Model 30 and 50Only

50.3 psig (347 kPa)

Suction Pressure Regulator (SPR) Valve Setting - Model 20 and 50 Only 35.3 psig (243 kPa)

Refrigerant Charge: V-520 RT MAX - Model 10 4.00 lb (1.81 kg) R-404AV-520 RT MAX - Model 20 5.00 lb (2.27 kg) R-404A

Refrigerant Charge: V-520 RT - Model 10 4.00 lb (1.81 kg) R-134aV-520 RT - Model 20 5.00 lb (2.27 kg) R-134aV-520 RT - Model 30 4.25 lb (1.93 kg) R-134aV-520 RT - Model 50 5.31 lb (2.41 kg) R-134a

Defrost Termination Switch: Opens 48.0 ± 5.0 F (8.9 ± 2.8 C) Closes 36.0 ± 5.0 F (2.2 ± 2.8 C)

Liquid Injection Switch (LIS): Opens 200 ± 5 F (93 ± 3 C)Closes 230 ± 5 F (110 ± 3 C)

Low Pressure Cutout Switch (LPCO): Opens 5 to 11 in. Hg vacuum (-17 to -37 kPa)Closes 4 to 7 psig (28 to 48 kPa)

Compressor Pressure Regulator (CPR) Valve Setting - Model 30 and 50Only

50.3 psig (347 kPa)

Suction Pressure Regulator (SPR) Valve Setting - Model 20 and 50 Only 35.3 psig (243 kPa)

Refrigerant Charge: V-520 RT MAX - Model 10 4.00 lb (1.81 kg) R-404AV-520 RT MAX - Model 20 5.00 lb (2.27 kg) R-404A

Page 54: Operator's Manual V-520 RT, V-520 RT MAX

V-520 RT MAX - Model 30 4.25 lb (1.93 kg) R-404AV-520 RT MAX - Model 50 5.31 lb (2.41 kg) R-404A

Defrost Termination Switch: Opens 48.0 ± 5.0 F (8.9 ± 2.8 C) Closes 36.0 ± 5.0 F (2.2 ± 2.8 C)

Liquid Injection Switch (LIS): Opens 200 ± 5 F (93 ± 3 C)Closes 230 ± 5 F (110 ± 3 C)

Low Pressure Cutout: Opens 5 to 11 in. Hg vacuum(-17 to 37 kPa)Closes 4 to 7 psig (28 to 48 kPa)

Compressor Pressure Regulator (CPR) Valve Setting - Model 30 and 50Only

50.3 psig (347 kPa)

Suction Pressure Regulator (SPR) Valve Setting - Model 20 and 50 Only 35.3 psig (243 kPa)

Main Compressor TM-16XD, Engine Driven, Swash Plate, 6 CylinderElectric Standby Compressor - Model 20 and 50 Only TM-16XD, Electric Motor Driven, Swash Plate, 6

CylinderSystem Oil Capacity: Model 10 12 oz (355 cc)

Model 20 16 oz (473 cc)

V-520 RT MAX - Model 30 4.25 lb (1.93 kg) R-404AV-520 RT MAX - Model 50 5.31 lb (2.41 kg) R-404A

Defrost Termination Switch: Opens 48.0 ± 5.0 F (8.9 ± 2.8 C) Closes 36.0 ± 5.0 F (2.2 ± 2.8 C)

Liquid Injection Switch (LIS): Opens 200 ± 5 F (93 ± 3 C)Closes 230 ± 5 F (110 ± 3 C)

Low Pressure Cutout: Opens 5 to 11 in. Hg vacuum(-17 to 37 kPa)Closes 4 to 7 psig (28 to 48 kPa)

Compressor Pressure Regulator (CPR) Valve Setting - Model 30 and 50Only

50.3 psig (347 kPa)

Suction Pressure Regulator (SPR) Valve Setting - Model 20 and 50 Only 35.3 psig (243 kPa)

Main Compressor TM-16XD, Engine Driven, Swash Plate, 6 CylinderElectric Standby Compressor - Model 20 and 50 Only TM-16XD, Electric Motor Driven, Swash Plate, 6

CylinderSystem Oil Capacity: Model 10 12 oz (355 cc)

Model 20 16 oz (473 cc)

Page 55: Operator's Manual V-520 RT, V-520 RT MAX

Model 30 16 oz (473 cc)Model 50 24 oz (710 cc)

Compressor Oil Type Polyol Ester P/N 203-515 Defrost Method Hot gasDefrost Timer Initiation Interval Adjustable, 1 hour to 10 hoursDefrost Termination Interval Termination is not timed.

Defrost is terminated by Klixon switch.CAUTION: Failure to use correct Thermo King recommended oil will invalidate your warranty.

Field ResetEngine Driven Compressor Belt Check vehicle manufacturer specificationsElectric Motor Driven Compressor Belt 67 ± 3 Using TK Gauge P/N 204-427

Model 30 16 oz (473 cc)Model 50 24 oz (710 cc)

Compressor Oil Type Polyol Ester P/N 203-515 Defrost Method Hot gasDefrost Timer Initiation Interval Adjustable, 1 hour to 10 hoursDefrost Termination Interval Termination is not timed.

Defrost is terminated by Klixon switch.CAUTION: Failure to use correct Thermo King recommended oil will invalidate your warranty.

Field ResetEngine Driven Compressor Belt Check vehicle manufacturer specificationsElectric Motor Driven Compressor Belt 67 ± 3 Using TK Gauge P/N 204-427

Page 56: Operator's Manual V-520 RT, V-520 RT MAX

230/1/60 2.0 1.5 1750 9.0 11.8230/3/60 2.4 1.8 1750 6.9 11.8

Supply Circuit Breaker 30 ampExtension Cord Size 25 ft - 10 gauge, up to 75 ft - 8 gauge

230/1/60 2.0 1.5 1750 9.0 11.8230/3/60 2.4 1.8 1750 6.9 11.8

Supply Circuit Breaker 30 ampExtension Cord Size 25 ft - 10 gauge, up to 75 ft - 8 gauge

Page 57: Operator's Manual V-520 RT, V-520 RT MAX

Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)Use: Solder Type 15% Silver TK No. 203-364 Use: Flux Type TK No. 203-365Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)Use: Solder Type 35% Silver TK No. 203-366 Use: Flux Type TK No. 203-365

Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)Use: Solder Type 95% Tin and 5% antimony TK No. 204-167 Use: Flux Type TK No. 204-417Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)Use: Solder Type 35% Silver TK No. 203-366 Use: Flux Type TK No. 203-365

Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)Use: Solder Type 15% Silver TK No. 203-364 Use: Flux Type TK No. 203-365Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)Use: Solder Type 35% Silver TK No. 203-366 Use: Flux Type TK No. 203-365

Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)Use: Solder Type 95% Tin and 5% antimony TK No. 204-167 Use: Flux Type TK No. 204-417Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)Use: Solder Type 35% Silver TK No. 203-366 Use: Flux Type TK No. 203-365

Page 58: Operator's Manual V-520 RT, V-520 RT MAX

A closely followed maintenance program will help to keep your Thermo King unit in top operating condition. The following general schedule is provided to assist in monitoring that maintenance.

For more specific detail, see the maintenance manual for your unit and to the PreTrip Inspection chapter in this manual.

After first week of operation:

• Check belt tension.

• Tighten unit mounting bolts.

• Check refrigerant level.

• • Check defrost initiation and termination.• • Check thermostat cycle sequence.• • Check operation of protection shutdown circuits.

• Check thermostat and thermometer calibration in 32 F (0 C) ice-water bath.

• Inspect wire harness for damaged wires or connections.

A closely followed maintenance program will help to keep your Thermo King unit in top operating condition. The following general schedule is provided to assist in monitoring that maintenance.

For more specific detail, see the maintenance manual for your unit and to the PreTrip Inspection chapter in this manual.

After first week of operation:

• Check belt tension.

• Tighten unit mounting bolts.

• Check refrigerant level.

• • Check defrost initiation and termination.• • Check thermostat cycle sequence.• • Check operation of protection shutdown circuits.

• Check thermostat and thermometer calibration in 32 F (0 C) ice-water bath.

• Inspect wire harness for damaged wires or connections.

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• • Check refrigerant level.• Replace dehydrator.• Check compressor pressure regulator and suction pressure regulator

settings if applicable.

• • • • Visually inspect unit and refrigerant hoses for fluid leaks.• • • • Visually inspect unit for damaged, loose or broken parts.• • • • Clean defrost drains.

• • • Inspect belts for condition and proper tension• • • Clean entire unit including evaporator coil and condenser coil.

• • Check all unit mounting bolts, brackets, lines, hoses, etc.

• • Check refrigerant level.• Replace dehydrator.• Check compressor pressure regulator and suction pressure regulator

settings if applicable.

• • • • Visually inspect unit and refrigerant hoses for fluid leaks.• • • • Visually inspect unit for damaged, loose or broken parts.• • • • Clean defrost drains.

• • • Inspect belts for condition and proper tension• • • Clean entire unit including evaporator coil and condenser coil.

• • Check all unit mounting bolts, brackets, lines, hoses, etc.

Page 60: Operator's Manual V-520 RT, V-520 RT MAX

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

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

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61

This glossary is published for informational purposes only and the information being furnished herein should not be considered as all-inclusive or meant to cover all contingencies.

NOTE: Additional terms not found in the glossary may be located in the index section of this manual.

A device located in the suction line to collect liquid refrigerant and meter it safety back to the compressor as gas.

Temperature of the air surrounding an object.

Abbreviation for ampere. The basic measuring unit of electrical current.

A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.

Part of the CYCLE-SENTRY™ system. The Battery Sentry module monitors alternator charge rate and will keep the unit running until the battery is adequately charged.

The temperature within a temperature-controlled compartment.

The quantity of heat required to raise the temperature of one pound of water by one degree Fahrenheit. 1 Btu = 252 calories.

1) return air bulkhead. A metal or plastic “wall” placed at the front of the box to prevent loading of product tightly against the Thermo King unit. (Loading too close to the unit restricts air flow and system efficiency.) 2) bulkhead divider. A thick, insulated “wall” used to separate compartments of a multi-temperature truck or trailer.

The amount of heat required to raise temperature of one gram of water one degree Celsius. 1 calorie = 0.004 Btu.

The metric unit of temperature measurement. The preferred alternate to the term centigrade. Abbreviated “C.”

See Celsius.

61

This glossary is published for informational purposes only and the information being furnished herein should not be considered as all-inclusive or meant to cover all contingencies.

NOTE: Additional terms not found in the glossary may be located in the index section of this manual.

A device located in the suction line to collect liquid refrigerant and meter it safety back to the compressor as gas.

Temperature of the air surrounding an object.

Abbreviation for ampere. The basic measuring unit of electrical current.

A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.

Part of the CYCLE-SENTRY™ system. The Battery Sentry module monitors alternator charge rate and will keep the unit running until the battery is adequately charged.

The temperature within a temperature-controlled compartment.

The quantity of heat required to raise the temperature of one pound of water by one degree Fahrenheit. 1 Btu = 252 calories.

1) return air bulkhead. A metal or plastic “wall” placed at the front of the box to prevent loading of product tightly against the Thermo King unit. (Loading too close to the unit restricts air flow and system efficiency.) 2) bulkhead divider. A thick, insulated “wall” used to separate compartments of a multi-temperature truck or trailer.

The amount of heat required to raise temperature of one gram of water one degree Celsius. 1 calorie = 0.004 Btu.

The metric unit of temperature measurement. The preferred alternate to the term centigrade. Abbreviated “C.”

See Celsius.

Page 63: Operator's Manual V-520 RT, V-520 RT MAX

Chlorofluorocarbon. A chlorine-based refrigerant consisting of chlorine, fluorine and carbon. Example: R12. In many countries it is illegal to release this type of refrigerant to the atmosphere because chlorine damages the earth’s atmosphere. CFC refrigerants are not used in modern Thermo King units.

A thermal device that automatically interrupts an electrical circuit when the current in the circuit exceeds the predetermined amperage rating of the breaker. See amp.

A cooling or heating element made of pipe or tube, formed into a helical or serpentine shape, that may be equipped with thin metal fins to aid heat transfer.

Flexible vinyl curtains used to reduce air exchange between the refrigerated compartment and the outside during door openings.

A gauge calibrated in psig (or kPa) to measure pressure, and in inches of mercury (Kg/cm2) to measure vacuum.

The refrigeration component that compresses refrigerant vapor and creates refrigerant flow.

An arrangement of tubing in which the vaporized and compressed refrigerant is liquefied as heat is removed.

See Hertz.

A door on the evaporator section that closes during defrost to prevent hot air from entering the refrigerated cargo compartment.

An electronic device that monitors and stores unit operating and temperature data for later review. Examples: DMS, DAS, DRS and AccuTrac.

Dual Evaporator. A multi-temp host unit with two evaporators capable of refrigerating two separate, longitudinal compartments.

The removal of accumulated ice from an evaporatorcoil. Periodic defrost is necessary when the evaporator coil is operating below freezing. Defrost is required more frequently when the air passing through the evaporator has a high moisture content.

A component that terminates defrost operation at a specific temperature.

Chlorofluorocarbon. A chlorine-based refrigerant consisting of chlorine, fluorine and carbon. Example: R12. In many countries it is illegal to release this type of refrigerant to the atmosphere because chlorine damages the earth’s atmosphere. CFC refrigerants are not used in modern Thermo King units.

A thermal device that automatically interrupts an electrical circuit when the current in the circuit exceeds the predetermined amperage rating of the breaker. See amp.

A cooling or heating element made of pipe or tube, formed into a helical or serpentine shape, that may be equipped with thin metal fins to aid heat transfer.

Flexible vinyl curtains used to reduce air exchange between the refrigerated compartment and the outside during door openings.

A gauge calibrated in psig (or kPa) to measure pressure, and in inches of mercury (Kg/cm2) to measure vacuum.

The refrigeration component that compresses refrigerant vapor and creates refrigerant flow.

An arrangement of tubing in which the vaporized and compressed refrigerant is liquefied as heat is removed.

See Hertz.

A door on the evaporator section that closes during defrost to prevent hot air from entering the refrigerated cargo compartment.

An electronic device that monitors and stores unit operating and temperature data for later review. Examples: DMS, DAS, DRS and AccuTrac.

Dual Evaporator. A multi-temp host unit with two evaporators capable of refrigerating two separate, longitudinal compartments.

The removal of accumulated ice from an evaporatorcoil. Periodic defrost is necessary when the evaporator coil is operating below freezing. Defrost is required more frequently when the air passing through the evaporator has a high moisture content.

A component that terminates defrost operation at a specific temperature.

Page 64: Operator's Manual V-520 RT, V-520 RT MAX

A solid state module that initiates defrost at selected intervals. Also establishes a maximum defrost duration if normal circuits malfunction.

A device used to remove moisture from refrigerant. Also called a drier.

The temperature of air leaving the evaporator.

See dehydrator.

A ceiling-mounted Thermo King remote evaporator. See EW and TLE.

Extended Remote Unit Control. (Door switches) An option on Thermo King multi-temperature units to improve temperature control when doors are opened during delivery. When a compartment door is opened, the refrigeration unit for that compartment may be forced to NULL, defrost, or some other mode. Opening a compartment door may also affect the operating mode of other compartments. ERC systems are connected in a variety of ways to meet customer needs.

A device used with a microprocessor to precisely control the refrigeration system.

The part of the refrigeration system that absorbs heat during the cooling cycle.

A wall-mounted Thermo King remote evaporator. See ECT and TLE.

See Fahrenheit.

A unit of temperature measurement used in the United States. Abbreviated “F.”

1) Failure of a refrigeration system to operate normally due to moisture in the refrigerant and the formation of ice at the expansion valve. The expansion valve may be frozen shut or open, causing improper unit operation in either case. 2) The formation of a solid ice mass over the evaporator coil reducing air flow.

An electrical safety device (typically a cartridge) inserted into an electrical circuit. It contains material that will melt or break when the current is increased beyond a specific value. When this occurs, the circuit is opened and electrical current flow is stopped.

A solid state module that initiates defrost at selected intervals. Also establishes a maximum defrost duration if normal circuits malfunction.

A device used to remove moisture from refrigerant. Also called a drier.

The temperature of air leaving the evaporator.

See dehydrator.

A ceiling-mounted Thermo King remote evaporator. See EW and TLE.

Extended Remote Unit Control. (Door switches) An option on Thermo King multi-temperature units to improve temperature control when doors are opened during delivery. When a compartment door is opened, the refrigeration unit for that compartment may be forced to NULL, defrost, or some other mode. Opening a compartment door may also affect the operating mode of other compartments. ERC systems are connected in a variety of ways to meet customer needs.

A device used with a microprocessor to precisely control the refrigeration system.

The part of the refrigeration system that absorbs heat during the cooling cycle.

A wall-mounted Thermo King remote evaporator. See ECT and TLE.

See Fahrenheit.

A unit of temperature measurement used in the United States. Abbreviated “F.”

1) Failure of a refrigeration system to operate normally due to moisture in the refrigerant and the formation of ice at the expansion valve. The expansion valve may be frozen shut or open, causing improper unit operation in either case. 2) The formation of a solid ice mass over the evaporator coil reducing air flow.

An electrical safety device (typically a cartridge) inserted into an electrical circuit. It contains material that will melt or break when the current is increased beyond a specific value. When this occurs, the circuit is opened and electrical current flow is stopped.

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An electrical safety device (typically a short piece of wire) inserted into an electrical circuit. The wire melts or breaks when the current is increased beyond a specific value. When this occurs, the circuit is opened and electrical current flow is stopped.

Hydrochlorofluorocarbon. A chlorine-based refrigerant containing hydrogen, chlorine, fluorine and carbon. Example: R22. Because chlorine damages the earth’s atmosphere, in many countries, it is illegal to release this type of refrigerant to the atmosphere. HCFC refrigerants are not used in modern Thermo King units.

A unit of frequency equal to one cycle per second. Abbreviated “Hz.”

A refrigerant consisting of hydrogen, fluorine and carbon. Examples: R134a and 404A. HFC refrigerants contain no chlorine and are, therefore, considered “safe” for the environment.

A safety valve on the refrigeration system that allows refrigerant to escape from the system if pressure exceeds a predetermined value.

A unit of power equivalent to 746 watts or 550 foot-pounds per second.

Apressure-operated switch that opens to stop unit operation when discharge pressure reaches a predetermined maximum.

A multi-temperature truck or trailer unit designed to allow the placement of deep-frozen cargo in any compartment. See Multi-Temp.

Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar = 0.145 psi.

1) The product being refrigerated and transported. 2) The amount of heat being removed by the refrigeration system. (For example, a compressor is under a heavy heat load when expected to cool a very warm box.)

Apressure-operated switch that opens to stop unit operation when suction pressure reaches a predetermined minimum.

An optional system that reduces load (product) dehydration and avoids “top freeze.”

An electrical safety device (typically a short piece of wire) inserted into an electrical circuit. The wire melts or breaks when the current is increased beyond a specific value. When this occurs, the circuit is opened and electrical current flow is stopped.

Hydrochlorofluorocarbon. A chlorine-based refrigerant containing hydrogen, chlorine, fluorine and carbon. Example: R22. Because chlorine damages the earth’s atmosphere, in many countries, it is illegal to release this type of refrigerant to the atmosphere. HCFC refrigerants are not used in modern Thermo King units.

A unit of frequency equal to one cycle per second. Abbreviated “Hz.”

A refrigerant consisting of hydrogen, fluorine and carbon. Examples: R134a and 404A. HFC refrigerants contain no chlorine and are, therefore, considered “safe” for the environment.

A safety valve on the refrigeration system that allows refrigerant to escape from the system if pressure exceeds a predetermined value.

A unit of power equivalent to 746 watts or 550 foot-pounds per second.

Apressure-operated switch that opens to stop unit operation when discharge pressure reaches a predetermined maximum.

A multi-temperature truck or trailer unit designed to allow the placement of deep-frozen cargo in any compartment. See Multi-Temp.

Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar = 0.145 psi.

1) The product being refrigerated and transported. 2) The amount of heat being removed by the refrigeration system. (For example, a compressor is under a heavy heat load when expected to cool a very warm box.)

Apressure-operated switch that opens to stop unit operation when suction pressure reaches a predetermined minimum.

An optional system that reduces load (product) dehydration and avoids “top freeze.”

Page 66: Operator's Manual V-520 RT, V-520 RT MAX

A thick, insulated, portable wall-like device used to compartmentalize a temperature-controlled truck or trailer. See bulkhead.

A Thermo King truck or trailer unit capable of maintaining different set-points in multiple compartments.

A grade of diesel fuel formulated to prevent “jelling” in low ambient temperatures.

A grade of diesel fuel formulated for moderate to warm ambient temperatures.

An electrical unit measuring the amount of resistance (opposition to the current flow) in an electrical circuit.

1) To cool down an empty box (temperature-controlled area) to the desired load temperature prior to loading. 2) To cool cargo to a desired temperature before loading.

The heating of diesel engine glow plugs prior to start-up. Some engines use an intake manifold heater rather than glow plugs.

Checking the operation of a refrigeration system before loading.

Pounds per square inch. A unit of pressure. 1 psi = 0.069 bar = 6.89 kPa.

Pounds per Square Inch Gauge. Pressure in pounds per square inch as displayed by a gauge calibrated to zero when open to the atmosphere.

A refrigerant storage device included in nearly all Thermo King units.

The medium of heat transfer in a refrigeration system which absorbs heat by evaporating at a low temperature and releases heat by condensing at a higher temperature.

A special oil used to lubricate compressors in refrigeration systems.

A separate evaporator unit located in a second or third compartment of a multi-temperature truck or trailer unit.

A structure (metal or plastic) mounted in the front of a trailer and designed to prevent restriction of return air flow to the Thermo King unit due to improper loading. See bulkhead.

A thick, insulated, portable wall-like device used to compartmentalize a temperature-controlled truck or trailer. See bulkhead.

A Thermo King truck or trailer unit capable of maintaining different set-points in multiple compartments.

A grade of diesel fuel formulated to prevent “jelling” in low ambient temperatures.

A grade of diesel fuel formulated for moderate to warm ambient temperatures.

An electrical unit measuring the amount of resistance (opposition to the current flow) in an electrical circuit.

1) To cool down an empty box (temperature-controlled area) to the desired load temperature prior to loading. 2) To cool cargo to a desired temperature before loading.

The heating of diesel engine glow plugs prior to start-up. Some engines use an intake manifold heater rather than glow plugs.

Checking the operation of a refrigeration system before loading.

Pounds per square inch. A unit of pressure. 1 psi = 0.069 bar = 6.89 kPa.

Pounds per Square Inch Gauge. Pressure in pounds per square inch as displayed by a gauge calibrated to zero when open to the atmosphere.

A refrigerant storage device included in nearly all Thermo King units.

The medium of heat transfer in a refrigeration system which absorbs heat by evaporating at a low temperature and releases heat by condensing at a higher temperature.

A special oil used to lubricate compressors in refrigeration systems.

A separate evaporator unit located in a second or third compartment of a multi-temperature truck or trailer unit.

A structure (metal or plastic) mounted in the front of a trailer and designed to prevent restriction of return air flow to the Thermo King unit due to improper loading. See bulkhead.

Page 67: Operator's Manual V-520 RT, V-520 RT MAX

The temperature of the air returning to the evaporator. See box temperature.

Revolutions per minute.

The temperature selected on a thermostat or microprocessor controller. This is normally the desired box temperature.

When a refrigeration unit cycles between the heat and cool modes more often than normal.

A system component that permits visual inspection of oil or refrigerant level and condition.

A device that controls unit modes of operation to maintain a selected box temperature.

Thin-line evaporator. A Thermo King remote evaporator designed to be compact (thin) while supplying superior air flow. See ECT and EW.

When the top portion of perishable cargo is damaged by freezing temperatures discharged from the refrigeration unit. This may occur near the front of the box when product is placed too close to the cold, discharge air flow.

An electric current that reverses direction at regularly recurring intervals.

An electric current that flows in one direction only and is constant in value.

The basic measuring unit of electrical potential.

The basic measuring unit of electrical power.

The temperature of the air returning to the evaporator. See box temperature.

Revolutions per minute.

The temperature selected on a thermostat or microprocessor controller. This is normally the desired box temperature.

When a refrigeration unit cycles between the heat and cool modes more often than normal.

A system component that permits visual inspection of oil or refrigerant level and condition.

A device that controls unit modes of operation to maintain a selected box temperature.

Thin-line evaporator. A Thermo King remote evaporator designed to be compact (thin) while supplying superior air flow. See ECT and EW.

When the top portion of perishable cargo is damaged by freezing temperatures discharged from the refrigeration unit. This may occur near the front of the box when product is placed too close to the cold, discharge air flow.

An electric current that reverses direction at regularly recurring intervals.

An electric current that flows in one direction only and is constant in value.

The basic measuring unit of electrical potential.

The basic measuring unit of electrical power.

Page 68: Operator's Manual V-520 RT, V-520 RT MAX

If you can’t get your rig rolling, and you have tried the Thermo King North American Service Directory (available from any Thermo King dealer) to reach a dealer without success, thencall the Toll Free Emergency Cold Line Number (888) 887-2202.

The answering service at the factory will assist you in reaching a dealer to get the help you need. The Cold Line is answered 24 hours a day by personnel who will do their best to get you quick service at an authorized Thermo King Dealer.

If you can’t get your rig rolling, and you have tried the Thermo King North American Service Directory (available from any Thermo King dealer) to reach a dealer without success, thencall the Toll Free Emergency Cold Line Number (888) 887-2202.

The answering service at the factory will assist you in reaching a dealer to get the help you need. The Cold Line is answered 24 hours a day by personnel who will do their best to get you quick service at an authorized Thermo King Dealer.

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Operator’s Manual

Operator’s Manual

Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Hussmann, a manufacturer of refrigeration and food merchandising solutions, Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. Its world class brands include Hussmann, a manufacturer of refrigeration and food merchandising solutions, Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

©2011 Ingersoll-Rand Company Printed in U.S.A.

©2011 Ingersoll-Rand Company Printed in U.S.A.

V-520 RT, V-520 RT MAX

TK 55032-18-OP (Rev. 1, 12/2011)

V-520 RT, V-520 RT MAX

TK 55032-18-OP (Rev. 1, 12/2011)