Installation Manual Truck Edition UT-1200X Undermount...

Installation Manual

Truck EditionUT-1200X Undermount Systemswith UTSE or S-3 + S-3 Remote Evaporators

TK-53960-1-IM (Rev. 3, 10/11)

Copyright© 2008 Thermo King Corp., Minneapolis, MN, U.S.A.

Printed in U.S.A.

2

Installation Manual

Release History

Released (06/08)

Rev 1 (06/08) Changed name from UTS-II to UT-1200X

Rev. 2 (02/09) Added installation instructions for the 30 gallon fuel tank and mounting brackets.

Rev. 3 (10/11)Page 10 - Revised Safety Precautions to include new Battery Installation and Cable Routing warnings and cautions.

3

UT-1200X Undermount Systems

4

Introduction

This installation manual was written to assist with the installation of a

Thermo King UT-1200X undermount refrigeration unit and remote

evaporator systems onto trucks specifically designed and built for

refrigerated applications.

Due to its complexity, you should not attempt this installation unless you:

• Are an experienced mechanic.

• Can safely lift 34 kilos (75 lbs).

• Have a basic understanding of electricity and electrical wiring.

• Are certified in the repair and maintenance of refrigeration systems.

• Have the necessary tools and equipment to complete the installation.

This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to

the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering

all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.

Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the

manufacturer’s judgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect,

special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or

descriptions contained herein.

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BLANK PAGE

6

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

UT-1200X Installation Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

S-3 + S-3 Evaporator Installation Kit Components . . . . . . . . . . . . . . . . . . . 16

UT-1200X Condenser Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

UTSE (NAD- A/P) Evaporator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 19

UTSE (EEC) Evaporator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

S-3 + S-3 Evaporator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

In-Cab Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Battery Box Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Important Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Uncrating the UT-1200X Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Installing the UT-1200X Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Installing the Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank . . . . . . . . . 36

Installing the Fuel Pickup Tube Into a Plastic Tank . . . . . . . . . . . . . . . . . . . 38

Installing the Steel Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Installing the Aluminum Fuel Tank (OPTION) . . . . . . . . . . . . . . . . . . . . . . . 42

Installing the Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installing the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Installing UT-1200X Evaporator - EEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Installing UTSE Evaporator - NAD A/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Installing S-3 + S-3 Evaporators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Removing the Holding Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Connecting Refrigeration Tubing–UTSE Evaporator . . . . . . . . . . . . . . . . . 58

Connecting Refrigeration Tubing–S-3 + S-3 Evaporators . . . . . . . . . . . . . . 60

Installing Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Electrical Connections–UTSE Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Electrical Connections–S-3 + S-3 Evaporators . . . . . . . . . . . . . . . . . . . . . . 66

Installing the Door Switch (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

System Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

System Evacuation and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7

Safety Precautions

Caution

Thermo King UT-1200X condensing units are shipped with a 35-69 kPa (5-10 psi) holding charge of

Nitrogen. This holding charge may be safely vented into the atmosphere.

Thermo King S-3 remote evaporators are shipped with a 35-69 kPa (5-10 psi) holding charge of Nitrogen.

This holding charge may be safely vented into the atmosphere.

IMPORTANT: Do not release the holding charge until necessary to prevent moisture from entering the

system.

SEVERE COMPRESSOR DAMAGE will result from operating the engine/motor before completing the

system installation which includes: installing the components, releasing the condensing unit holding

charge, releasing the remote unit holding charge, soldering the refrigeration lines, leak testing the system,

evacuation and clean-up, and charging the system.

Recover Refrigerant

At Thermo King, we recognize the need to preserve the environment and limit the potential harm to the

ozone layer that can result from allowing refrigerant to escape into the atmosphere.

We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the

atmosphere.

8

Safety Precautions

R-404A

DO NOT use Polyol Ester based oil in standard Thermo King units.

DO NOT mix Polyol Ester and standard synthetic compressor oils.

Keep Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated with moisture or standard oils, dispose of properly-DO NOT USE!

CAUTION: Use ONLY Polyol Ester based refrigeration oil (TK P/N 203-413) in R-404A units

CAUTION: When servicing Thermo King R-404A units, use only those service tools certified for and dedicated to R-404A refrigerant and Polyol Ester compressor oils. Residual non-HFC refrigerants and non-HFC refrigerants or oils will contaminate R-404A systems.

9

Safety Precautions

The symbol appears next to a point that is particularly important:

DANGER: Addresses a circumstance that, if encountered, will lead to death or serious injury

WARNING: Addresses a circumstance that, if encountered, might lead to death or serious injury.

CAUTION: Addresses a circumstance that, if encountered, may cause damage to equipment or minor injury.

DANGER: Never operate the unit with the discharge valve closed because it could cause the compressor to explode, causing death or serious injury.

DANGER: Never apply heat to a sealed refrigeration system or container because it could explode, causing death or serious injury

DANGER: Fluorocarbon refrigerants, in the presence of an open flame or electrical short, produce toxic gases that are severe respiratory irritants capable of causing death.

DANGER: Be careful when working with a refrigerant or refrigeration system in any enclosed or confined area with a limited air supply (i.e., a trailer, container or the hold of a ship). Refrigerant tends to displace air and can cause oxygen depletion which may result in death by suffocation.

WARNING: Always wear goggles or safety glasses. Refrigerant liquid, refrigeration oil, and battery acid can permanently damage the eyes (see First Aid under Refrigeration Oil).

WARNING: Keep your hands away from fans and belts when the unit is running. This should also be considered when opening and closing the compressor service valves.

WARNING: Make sure gauge manifold hoses are in good condition. Never let them come in contact with a belt, fan motor pulley, or any hot surface.

WARNING: Make sure all mounting bolts are tight and are of correct length for their particular application

WARNING: Never drill holes in the unit unless absolutely necessary. Holes drilled into the unit may weaken structural components. Holes drilled into electrical wiring can cause fire or explosion.

WARNING: When using ladders to install or service refrigeration systems, always observe the ladder manufacturer’s safety labels and warnings. A work platform is the recommended method for installations.

WARNING: Exposed coil fins are very sharp and can cause painful lacerations.Wear leather work gloves to prevent injury.

10

Safety Precautions (continued)

Battery Installation and Cable Routing Refrigerant

First Aid

FROST BITE: In the event of frost bite, the objectives of First Aid are to

protect the frozen area from further injury, to warm the affected area

rapidly and to maintain respiration.

EYES: For contact with liquid, immediately flush eyes with large amounts

of water and get prompt medical attention.

SKIN: Flush area with large amounts of lukewarm water. Do not apply

heat. Remove contaminated clothing and shoes. Wrap burns with dry,

sterile, bulky dressing to protect from infection/injury. Get medical

attention. Wash contaminated clothing before reuse.

INHALATION: Move victim to fresh air and use CPR or mouth-to-mouth

ventilation, if necessary. Stay with victim until arrival of emergency

medical personnel.

Refrigeration Oil

First Aid

In case of eye contact, immediately flush with plenty of water for at

least 15 minutes. CALL A PHYSICIAN. Wash skin with soap and

water.

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: Although fluorocarbon refrigerants are classified as safe refrigerants, certain precautions must be observed when handling them or servicing a unit in which they are used. When released to the atmosphere in the liquid state, fluorocarbon refrigerants evaporate rapidly, freezing anything they contact.

WARNING: Avoid refrigeration oil contact with the eyes. Avoid prolonged or repeated contact of refrigeration oil with skin or clothing. Wash thoroughly after handling refrigeration oil to prevent irritation.

11

BLANK PAGE

12

Required Tools

1. Safety Glasses

2. Drill

3. Drill Bits

4. Tape Measure

5. Wire Crimpers

6. Tubing Benders

7. Hole Saw

8. 35% Silver Solder & Flux

9. Tubing Swage

10. Tubing Cuter

11. Refrigerant Oil

12. Torch Set

13. Mechanics Tools

14. Manifold Set

15. Evacuation Station

16. Reclaiming Station

17. Refrigerant & Scale

18. Dry Nitrogen

19. Tap & Die Set (Europe Only)

20. Battery Charger (60 AMP Minimum)

21. Electronic Leak Detector

22. Tubing Brushes

23. Scotch Brite Pads

24. Torque Wrench

25. Mechanical Lift (modified drywall lift shown)

26. Digital Contact Thermometer

27. Forklift

NOTE: Torque wrenches should be in good working condition and routinely calibrated to assure accurate readings.

13

Required Tools

14

UT-1200X Installation Kit Components

1. Fuel Pump

2. Fuel Pump Harness

3. Fuel Pump Bracket

4. 1/4'' Fuel Pump Mounting Hardware

5. Fuel Pickup Tube

6. Fuel Line Fittings

7. 3/8'' Fuel Hose

8. Remote Controller with Installation Kit

9. Fuse Holder & Fuse

10. Steel Hold Down Clamps

11. Insulated Support Clamps (5 sizes)

12. Cable Ties (3 sizes)

13. Self-Tapping Screws

14. Battery Cable Terminal Lugs

15. Terminal Ring Connectors

16. Terminal Fork Connectors

17. Terminal Splice Connectors (2 sizes)

18. Heat Shrink Sleeving

19. Filter Drier

20. Sealer

21. Sealing Strip

22. ORS Tube

23. Evap Drain Hose

24. 2-Pin Plug and Wedge

25. 3-Pin Plug and Wedge

26. Sealing Pins

27. Socket

28. Flange 1.375 OD

29. Elbow 1-3/8

30. Elbow 45 1-3/8

31. Nut 13/16-16

15

UT-1200X Installation Kit Components

16

S-3 + S-3 Evaporator Installation Kit Components

1. Suction, Liquid and Hot Gas ORS Tube Assemblies

2. Coupling 1/2 x 3/8

3. Suction Line Tee Assembly 1-3/8 x 7/8 x 7/8

4. Hot Gas Line Tee Assembly 1/2 x 1/2 x 1/2

5. Liquid Line Tee Assembly 1/2 x 3/8 x 3/8

6. Refrigeration Oil

7. Drain Elbow

8. Drain Tube

9. Drain Hose

10. Hose Clamp

11. Terminal Fork

12. Blue Terminal Ring

13. Red Terminal Ring

14. Screw 1/4-20

15. Flat Washer 1/4

16. Lock Nut 1/4 -20

17. Flat Washer 1/2'' SAE

18. Flat Washer 3/8''

19. Self-tapping Screw

20. Insulated Clamps

21. Cable Ties

22. Special Washers

23. Lock Nut 1/2-13

24. Lock Nut M10

25. Button Plug

17

S-3 + S-3 Evaporator Installation Kit Components

18

UT-1200X Condenser Dimensions

19

UTSE (NAD- A/P) Evaporator Dimensions

20

UTSE (EEC) Evaporator Dimensions

21

S-3 + S-3 Evaporator Dimensions

WEIGHT = 52 kg (115 lb.) each

Reference: 1E02132 Sheet 4

22

In-Cab Controller Dimensions

23

Battery Box Dimensions

24

Important Installation Notes

Safety Precautions

See “Safety Precautions” on pages 7 - 10 prior to installing and servicing

this product.

Evaporator Location• The best airflow is achieved when the evaporator is installed an

equal distance from each side wall.

• It is recommended that moving bulkheads not be allowed closer

than 1219 mm (48.00 in.) or 1 pallet from the evaporator outlet

(Detail I).

• The minimum clearance from the bottom of the evaporator to the

top of the cargo should be 101 mm (4.00 in.) (Detail I).

NOTE: This minimum clearance is required under the fan intake

area only and does not refer to the LOAD LINE.

• The evaporator should be located a minimum of 51 mm (2.00 in.)

from the truck wall (Detail II).

Defrost Drains• The evaporator must be properly mounted to provide a slope

towards the drain. This is accomplished by adding one 3/8 in. and

one 3/16 in. washers on the drain side and only one 3/8 in. washer

on the other side at each mounting surface.

• Defrost drains must exit the evaporator at a 45° angle. Drains

should be 267 mm (10.50 in.) from the evaporator to the truck wall

(Detail III).

Door Curtains• It is always recommended to use good quality insulated curtains on

all doors to limit the amount of warm, moist air from entering the

load space during door openings.

Refrigerant Tubing and Electrical Wiring• It is important to minimize the amount of time the tubes are

uncapped and open to ambient conditions. Always keep tubes

capped until ready to connect and solder.

• Check tubes and copper fittings for obstructions prior to assembly.

• It is also required that nitrogen or another inert gas be used to purge

the tubes while soldering. This prevents oxidation and formation of

scale inside tubes.

• Use 35% silver solder for joining all remote refrigerant tubes.

• Insulate suction and hot gas lines.

• All refrigeration tubes should be secured by clamps every 600 mm

(24.00 in.).

• All electrical harness should be secured by clamps or tie bands

every 600 mm (24.00 in.).

• Only one trough (W = Wall and C = Ceiling) is required

(Detail IV & V).

Door Switches• Door switches automatically turn off remote evaporators when the

corresponding door is opened. This avoids the entry of warm, moist

air into the load space. Door switches are recommended for all

multi-temp installations.

25


26


Defrost Drain Tube Connectors

IMPORTANT: Follow the instructions below to prevent defrost drain

tube water leaks.

All S-3 remote evaporators are equipped with a quick disconnect fitting

that connects the drain pan to the drain tubes (Detail I).

To properly install the tube make sure that the tube is fully inserted past the

O-ring and up to the stop inside the coupler (Detail II).

NOTE: The fitting will grip the tube before it seals with the o-ring.

When the tube is in the correct position the O-ring will seal and the teeth

will grip the tube keeping it in place. Check the fit by pulling on the tube(s)

to insure that it will not pull out of the fitting (Detail III).

To disconnect the tube from the fitting: press the collet into the fitting.

Hold the collect in place and pull the tube out. The fitting can be re-used.

Clean any burrs off the tube before re-inserting it into the fitting

(Detail IV).

27


28


29


Optional Drain Kit 88041 Shown

30

Uncrating the UT-1200X Condenser

1. Remove all shrink wrap from the unit/crate.

2. Remove the four upright boards that connect the top and bottom

sections of the crate.

3. Remove the control box side cover by removing the four Torx screws.

4. Remove the top crate sections by removing the four carriage bolts.

5. Remove the “toe board” from the bottom crate section.

6. Loosen the 2X quarter turn bolts and latches on the front panel.

7. Rotate the front door 10 to 15 degrees. Pull on handles to release

latches and remove front door.

8. Remove battery box by removing the four screws.

9. Remove the two screws from the front bottom frame member.

10. Remove the two rear steel bracket and bottom crate section.

11. Install forged eyebolts into the unit’s mounting holes and use an

appropriate four point lift to carefully raise the unit up from the crate.

WARNING: Thermo King requires a proper lifting fixture to

safely lift units.

WARNING: Lifting eyebolts must be forged steel and a minimum

M12 (1/2 in.) diameter.

WARNING: Use only locking hooks to attach to the eyebolts.

31

Uncrating the UT-1200X Condenser

32

Installing the UT-1200X Condenser

1. Fabricate and install Z-Channels to the truck box supports with Grade 5

(or better) mounting bolts, washers and locking nuts.

2. Lift unit into position and install onto Z-Channels with four Grade 5 (or

better) 5/8 x 11 (16 mm x 2) mounting bolts, washers and locking nuts.

Tighten hardware securely and torque to 176-230 N•m (130-170 ft-lb).

DANGER: Mount the UT-1200X only to the truck box support

channels. An improper installation could lead to serious injury!

Thermo King recommends the use of fabricated Z-channels to

distribute the weight evenly across the truck box support channels.

All channels, brackets, and hardware must be able to support the

weight of the unit.

WARNING: The use of a forklift to install the UT-1200X is

recommended to prevent equipment damage or personal injury.

33

Installing the UT-1200X Condenser

34

Installing the Battery Box

Important Battery InformationIMPORTANT: See Safety Precautions - “Battery Installation and Cable

Routing” on page 10 for additional information.

NOTE: Thermo King units are designed for one 12 volt, group 31

battery. The battery must be suitable for deep cycling, heavy duty

and rated with a minimum of 95 amp/hr.

1. Install the battery box to the truck in a safe and secure location. Secure battery in place with hold down bracket and rod.

2. Route the positive and negative battery cables into the battery box being sure the rubber grommets are installed in the cable opening.

• Attach the negative cable securely to the negative terminal of the

battery.

3. Attach the in-line fuse holder onto the positive battery cable securely.

• Remove the fuse from the holder. NOTE: The fuse will be

reinstalled after the unit installation is completed.

• Attach the positive negative cable securely to the positive terminal

of the battery.

4. The protective cover will also be installed after the unit installation is completed.

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.

35

Installing the Battery Box

36

Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank

NOTE: The fuel pickup tube supplied in the installation kit will not be

needed when installing an optional Thermo King aluminum fuel tank.

The aluminum tank is already equipped with fuel inlet, fuel outlet and

vent fittings.

1. Tape the paper template (supplied with pickup tube) to the desired

location on the diesel fuel tank and center punch the three holes.

NOTE: Use a magnet, grease or special hole saws/drills that will

minimize metal or aluminum chips from entering the fuel tank.

Thoroughly clean and flush the tank to remove any chips.

Drill:

• 9.5 mm (0.375 in.) diameter holes first.

• 31.8 mm (1.250 in.) diameter hole next.

• Remove the template from the tank and remove any burrs from the

hole.

2. Cut the end of the pickup tube so approximately 25 mm (1.00 in.) is

above the bottom of the fuel tank.

3. Loosen the nut and slide all the parts to the top of the pickup tube

assembly.

4. Hold the parts in position and slide the assembly into the hole at a slight

angle until the bushing is inside the hole.

5. Tip the backup washer and slide it through the hole and position it onto

the bushing. Thread the nut onto the bushing, position as needed to

facilitate fuel line connections and tighten to 54 Nm. (40 ft-lb.).

DANGER: Diesel fuel vapors are potentially explosive. Use

extreme caution when drilling in or around the diesel fuel tank.

Sparks from an electric drill or drill bit could cause an explosion.

Do not smoke while working near the diesel fuel tank. Drain all

diesel fuel from the tank and use nitrogen or an inert gas to purge

the diesel fuel vapors from the tank prior to drilling. Keep the

diesel tank filled with inert gas while drilling.

37

Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank

38

Installing the Fuel Pickup Tube Into a Plastic Tank

1. Tape the paper template (supplied with pickup tube) to the desired

location on the diesel fuel tank and center punch the three holes.

NOTE: Use grease or special hole saws/drills that will minimize

plastic chips from entering the fuel tank Thoroughly clean and flush

the tank to remove any chips.

2. Drill:

• 9.5 mm (0.375 in.) diameter holes first.

• 31.8 mm (1.250 in.) diameter hole next.

• Remove the template from the tank and remove any burrs from the

hole.

3. Cut the end of the pickup tube so approximately 25 mm (1.00 in.) is

above the bottom of the fuel tank.

4. Loosen the nut and slide all the parts to the top of the pickup tube

assembly.

5. Hold the parts in position and slide the assembly into the hole at a slight

angle until the bushing is inside the hole.

6. Tip the backup washer and slide it through the hole and position it onto

the bushing. Thread the nut onto the bushing, position as needed to

facilitate fuel line connections and tighten to 54 Nm. (40 ft-lb.).

DANGER: Diesel fuel vapors are potentially explosive. Use

extreme caution when drilling in or around the diesel fuel tank.

Sparks from an electric drill or drill bit could cause an explosion.

Do not smoke while working near the diesel fuel tank. Drain all

diesel fuel from the tank and use nitrogen or an inert gas to purge

the diesel fuel vapors from the tank prior to drilling. Keep the

diesel tank filled with inert gas while drilling.

39

Installing the Fuel Pickup Tube Into a Plastic Tank

40

Installing the Steel Fuel Tank

IMPORTANT: Observe the positioning of existing OEM fasteners on the

vehicle frame. The four fasteners used to install the fuel tank brackets

must be located on the frame no higher and no lower than any existing

OEM fasteners.

1. The fuel tank mounting brackets should be positioned 610 mm (24.00

in.) apart to properly support the combined weight of 118 kg (260 lbs.)

which includes the fuel tank, mounting brackets and 30 gallons of

diesel fuel.

• Measure and mark the location of the four mounting holes on the

frame.

• Use a 17 mm (11/16 in.) drill bit and drill four holes in the frame.

2. Install each fuel tank mounting bracket securely onto the truck’s frame

with two, 1/2 -13, Grade 5 bolts, flat washers and locking nuts.

Substitutions are not acceptable!

• Torque the bolts to 81-88 N•m (60-65 ft-lb.).

3. Install the mounting bands T-bolts onto the mounting brackets with flat

washers and locking nuts.

4. Install the fuel tank into the mounting bands.

• Torque the upper mounting band T-bolts to 47 N•m (35 ft-lb.).

IMPORTANT: Do not over tighten the mounting band bolts or damage to

the bands will result!

DANGER: An improperly installed fuel tank could lead to serious

injury or death! Consult your truck’s chassis manufacturer for

specific details on proper fuel tank installation and

recommendations.

41

Installing the Steel Fuel Tank

1

2

3

4

42

Installing the Aluminum Fuel Tank (OPTION)

IMPORTANT: Observe the positioning of existing OEM fasteners on the

vehicle frame. The four fasteners used to install the fuel tank brackets

must be located on the frame no higher and no lower than any existing

OEM fasteners.

1. The fuel tank mounting brackets should be positioned 610 mm (24.00

in.) apart to properly support the combined weight of 118 kg (260 lbs.)

which includes the fuel tank, mounting brackets and 30 gallons of

diesel fuel.

• Measure and mark the location of the four mounting holes on the

frame.

• Use a 17 mm (11/16 in.) drill bit and drill four holes in the frame.

2. Install each fuel tank mounting bracket securely onto the truck’s frame

with two, 1/2 -13, Grade 5 bolts, flat washers and locking nuts.

Substitutions are not acceptable!

• Torque the bolts to 81-88 N•m (60-65 ft-lb.).

3. Install the mounting bands onto the mounting brackets with flat

washers and locking nuts.

• Tighten only the lower T-bolt to 47 N•m (35 ft-lb.).

• Install the self-adhesive rubber strips onto each mounting bracket

as shown.

4. Install the fuel tank into the mounting bands.

• Confirm the rubber strips on both the mounting bands and the

mounting brackets are positioned correctly to prevent metal to

aluminum contact.

• Torque the upper mounting band T-bolts to 47 N•m (35 ft-lb.).

IMPORTANT: Do not over tighten the mounting band bolts or damage to

the bands will result!

DANGER: An improperly installed fuel tank could lead to serious

injury or death! Consult your truck’s chassis manufacturer for

specific details on proper fuel tank installation and

recommendations.

43

Installing the Aluminum Fuel Tank (OPTION)

1

2

3

4

44

Installing the Fuel Pump

S = Supply R = Return

1. The fuel pump must be installed as close to the fuel tank as possible

and not more than 762 mm (30.0 in.) above the fuel in the tank.

2. Fuel lines should be routed in a protective housing with no kinks or

sharp bends.

NOTE: Do not connect unit fuel lines into the truck’s fuel system.

3. Rubber grommets must be used when routing fuel lines through metal.

4. Secure all fuel lines with provided clamps.

5. Route the fuel supply line from fuel tank to the fuel pump inlet.

6. From the fuel pump outlet, route the fuel supply line to the inlet fitting

located on the end of the UT-1200X.

7. Route the fuel return line from fuel outlet located on the end of the

UT-1200X., to the fuel tank pickup return fitting.

8. Connect fuel pump harness securely to the fuel pump and route the

harness to the condenser.

9. Connect the fuel pump harness to the mating connector inside the

condenser. SEE NOTE BELOW.

NOTE: The fuel pump electrical supply connector is located in the upper

rear left corner of the unit near the battery cables. The fuel pump

harness should also exit the frame through the same hole that the battery

wires use.

DANGER: Leaking fuel lines could cause a fire resulting in death

or serious injury! All fuel lines must be tight and leak free!

DANGER: Do not route fuel lines together with battery cables or

electrical wires as this could cause a fire!

45

Installing the Fuel Pump

46

Installing the Controller

IMPORTANT: Always route and secure the harness to prevent rubbing,

chafing or making contact with sharp, moving or hot components. Allow

excess harness for tilt cab applications. Rubber grommets must be used

when routing harness through sheet metal holes.

Harness Routing and Service Loops

• All of the harnesses, except the battery and fuel pump, are secured to

the right rear of the condenser. It is important that the service loop

between this point and the rear of the control box be maintained. The

cables that form this service loop should not be tie banded together or

to any other component. Lack of a proper service loop will not allow

the control box to be fully extended for service procedures.

• As an aid to unit service or repair, it is advisable that the harness that

goes between the condenser and the evaporators, and the in-cab box

cable, have extra length at the condenser end, in case the unit needs to

be lowered from it’s mounting position.

• If the clearance between the back of the condenser unit and the truck

frame allows, the harness may be secured along the bottom of the rear

frame member using the holes provided for tie bands.

Interior Cab Din MountingChoose an appropriate location for the controller inside the truck cab.

Internal Driver Panel DIN Mounting (Detail I)

1. Install DIN (ISO 7736) mounting sleeve into driver panel DIN opening.

2. Bend tabs to secure in position.

3. Connect harness and install controller into DIN sleeve.

External Driver Panel Mounting (Detail II)

4. To install controller on top or under driver panel, install mounting

brackets accordingly, connect harness and mount to driver panel.

47


48


NOTE: Route and secure harness to prevent rubbing, chafing or making

contact with sharp, moving or hot components. Allow excess harness for

tilt cab applications. Rubber grommets must be used when routing

harness through sheet metal holes.

INTERIOR CAB DIN MOUNTING

Choose an appropriate location for the Controller inside the truck cab.

Internal Driver Panel DIN Mounting (Detail A).

1. Install DIN (ISO 7736) mounting sleeve into driver panel DIN opening.

2. Bend tabs to secure in position.

3. Connect harness and install controller into DIN sleeve.

External Driver Panel Mounting (Detail B).

4. To install controller on top or under driver panel, install mounting

brackets accordingly, connect harness and mount to driver panel.

(OPTIONAL) EXTERIOR BODY MOUNTING (Detail C)

Choose an appropriate location for the Controller outside on the truck box.

5. Route harness into body mount base from the rear. Harness must route

between gasket and cord retainer cover as shown to prevent water from

entering the controller.

6. Apply Superlube (TK 203-524 or equivalent) to harness connector and

connect harness to the rear of the controller. Carefully install controller

into body mount base making sure the locating boss is oriented on top

as shown.

7. Install cord retainer with cable groove at bottom, and the gasket with

the rounded edges facing up, to the back of the body mount base with

supplied screws. NOTE: Tighten screws securely, but do not

overtighten!

8. Install the body mount base to the truck body with the locating boss

facing UP, and secure with the four self-tapping screws supplied in the

kit. NOTE: Tighten screws securely, but do not overtighten!

9. With the Thermo King Logo facing UP, install the front cover with the

four supplied screws. NOTE: Tighten screws securely, but do not

overtighten!

10. ALL INSTALLATIONS - Install the operation nameplate in a

convenient location for the operator to see.

WARNING: If an electrical power source is connected to the unit,

DO NOT turn the unit switch “ON” before installing the

controller. Uncontrolled start up of the unit may result and cause

personal injury.

49


50

Installing UT-1200X Evaporator - EEC

NOTE: The ceiling must be flat and the mounting locations correct for

proper evaporator installation and operation.

NOTE: Thermo King recommends installing the evaporator with 8 mm

(5/16 in.) bolts or studs.

1. From inside the truck box, locate the center line (CL) and mark its

location on to the truck box ceiling.

2. Measuring from the center line, locate and identify the eight mounting

locations.

3. At each location, drill appropriate size holes into the ceiling support

structure and use a tap and die to thread each hole with the same pitch

thread as the mounting bolts or mounting studs.

4. The foam insulation must be removed from the mounting area on the

ceiling.

• For ceiling mounting stud applications, weld a nut (same thread as

stud) onto a 1-3/4 in. hole saw and turn the nut onto the mounting

stud using a socket wrench (Detail I).

• For ceiling mounting bolt applications, weld a bolt (same thread as

tapped hole) onto a 1-3/4 in. hole saw and turn into the tapped hole

using a socket wrench (Detail I).

5. Install the evaporator:

• For ceiling mounting stud applications, install mounting studs, flat

washers and locking nuts (Detail II).

• For ceiling mounting bolt applications, install mounting bolts,

locking washers and flat washers (Detail III).

6. Aluminum spacers must be used if ceiling is not flat, or if foam exists

between the mounting plate and truck liner (Detail II and Detail III).

7. Install the supplied foam sealing strips and rubber edging before

installing the evaporator.

Torque all mounting bolts to 81 N•m (60 ft-lb)

51

Installing the UTSE Evaporator - EEC

A. 247.50 mm (9.75 in.)

B. 457.20 mm (18.0 in.)

C. 495.15 mm (19.5 in.)

D. 457.20 mm (18.0 in.)

E. 1409.55 mm (55.5 in.)

F. 247.62 mm (9.75 in.)

52

Installing UTSE Evaporator - NAD A/P

NOTE: The ceiling must be flat and the mounting locations correct for

proper evaporator installation and operation.

NOTE: Thermo King recommends installing the evaporator with 8 mm

(5/16 in.) bolts or studs.

1. From inside the truck box, locate the center line (CL) and mark its

location on to the truck box ceiling.

2. Measuring from the center line, locate and identify the five mounting

locations.

3. At each location, drill appropriate size holes into the ceiling support

structure and use a tap and die to thread each hole with the same pitch

thread as the mounting bolts or mounting studs.

4. The foam insulation must be removed from the mounting area on the

ceiling.


stud) onto a 1-3/4 in. hole saw and turn the nut onto the mounting

stud using a socket wrench (Detail I).


tapped hole) onto a 1-3/4 in. hole saw and turn into the tapped hole

using a socket wrench (Detail I).

5. Install the evaporator:

• For ceiling mounting stud applications, install mounting studs, flat

washers and locking nuts (Detail II).

• For ceiling mounting bolt applications, install mounting bolts,

locking washers and flat washers (Detail III).

6. Aluminum spacers must be used if ceiling is not flat, or if foam exists

between the mounting plate and truck liner (Detail II and Detail III).

7. Install the supplied foam sealing strips and rubber edging before

installing the evaporator.

Torque all mounting bolts to 81 N•m (60 ft-lb).

53

Installing the UTSE Evaporator - NAD A/P

A. 749.3 mm (29.50 in.)

B. 1498.6 mm (59.00 in.)

C. 256.4 mm (10.09 in.)

54

Installing S-3 + S-3 Evaporators

Ceiling Preparation

IMPORTANT: The ceiling must be flat and the mounting locations

correct for proper S-3 evaporator installation. The foam insulation in the

ceiling must be removed from the evaporator mounting area and

aluminium spacers must be installed between the evaporator mounting

plate and truck/trailer ceiling.


stud) onto a 44.45 mm (1.75 in.) hole saw and turn the nut onto the

mounting stud using a socket wrench (Detail I).


tapped hole) onto a 44.45 mm (1.75 in.) hole saw and turn into the

tapped mounting hole using a socket wrench (Detail I).

• Alternative method is to remove the mounting studs or bolts and use a

hole saw with a standard pilot drill small enough to run up into the

threaded hole without damaging the threads. Reinstall mounting studs

or bolts.

Mounting Stud or Bolt Requirements

The mounting studs or bolts used to attach the evaporator(s) to the ceiling

must be 10.0 mm, (0.50 in., Grade 5, U.S. applications only), medium

carbon steel, 120000 PSI tensile strength, cadmium plate and dichromate

finish. Studs to extend below ceiling 38.0 mm (1.50 in.) to 50.1 mm (2.00

in.)

Evaporator Installation

1. Remove evaporator cover to access mounting holes.

NOTE: The installation kit provides both metric and imperial nuts

and washers. Be sure to use the correct ones for your application.

Mounting Stud Installations

2. Install the mounting studs into the ceiling. Install the aluminum spacers

onto the mounting studs and raise the evaporator into position. Loosely

secure the evaporator onto the mounting studs with flat washers and

locking nuts. (Detail II).

Do not tighten the mounting hardware at this time.

Mounting Bolt Installations

3. Raise the evaporator into position. Install aluminium spacers, mounting

bolts, lock washers and flat washers and loosely secure the evaporator

to the ceiling. (Detail III).

Do not tighten the mounting hardware at this time.

4. Install the second evaporator.

Torque each evaporator’s mounting hardware to 81 N•m (60 ft-lb).

5. A properly installed evaporator will slope slightly toward the drain

tubes to allow for water drainage (Detail IV).

NOTE: Two additional washers are included in the kit to help assist

sloping the evaporator towards the drain.

55

Installing S-3 + S-3 Evaporators

56

Removing the Holding Charge

HG = Hot Gas S = Suction L = Liquid

UT-1200X HOST UNIT

1. Slowly remove the ORS caps to release the Nitrogen holding charge.

Remote Evaporator(s)

2. Slowly remove the ORS caps to release the Nitrogen holding charge.

CAUTION: Thermo King UT-1200X condenser units are shipped

with a 35-69 kPa (5-10 psi) holding charge of Nitrogen. This

holding charge may be vented into the atmosphere.

CAUTION: Thermo King S-3 remote evaporators are shipped

with a 35-69 kPa (5-10 psi) holding charge of Nitrogen. This

holding charge may be vented to the atmosphere.

57

Removing the Holding Charge

58

Connecting Refrigeration Tubing–UTSE Evaporator

NOTE: Thermo King recommends the use of bulk rolled refrigeration

tubing and tube benders to reduce fittings and solder joints where

applicable (Detail I). It is also required that nitrogen or another inert gas

be used to purge the tubes before soldering. This prevents oxidation and

formation of scale inside tubes.

The refrigeration tubing can be routed either outside (as shown) or

inside the truck box depending on the particular installation and

application.

HG = Hot Gas S = Suction L= Liquid

IMPORTANT: Apply refrigerant oil (supplied in the installation kit) to

all refrigerant tube O-rings prior to assembly.

1. Fabricate a 1-3/8 in. suction tube from the evaporator to the condenser

(Detail II). Use the provided flanges and O-rings (Detail II and III) to

connect the suction tube to the evaporator and the condenser.

2. Fabricate a 1/2 in. hot gas tube from the evaporator to the condenser

(Detail II). Use the provided ORS fittings (Detail II and III) to

connect the hot gas tube to the evaporator and the condenser.

3. Fabricate a 1/2 in. liquid tube from the evaporator to the filter drier

(Details II and III).

4. Secure all tubing with provided clamps (Detail IV).

5. Seal around tubing with caulk to prevent air and water leakage.

6. Protective covers should be fabricated to prevent damage to the

refrigeration tubing and electrical wires and installed at the completion

of the installation.

CAUTION: Remove holding charge from host unit and remote

evaporators before proceeding to prevent personal injury!

WARNING: Regulators used on bottles of nitrogen gas must be

equipped with relief valves. The pressure in a bottle of nitrogen

gas is extremely high. It is high enough to cause components of

refrigeration systems to explode if the regulator malfunctions or is

set wrong. The relief valve provides a safe outlet in case the

regulated pressure exceeds the relief valve limit.

59

Connecting Refrigeration Tubing – UTSE Evaporator

60

Connecting Refrigeration Tubing–S-3 + S-3 Evaporators

NOTE: Thermo King recommends the use of bulk rolled refrigeration

tubing and tube benders to reduce fittings and solder joints where

applicable (Detail I). It is also required that nitrogen or another inert gas

be used to purge the tubes before soldering. This prevents oxidation and

formation of scale inside tubes.

The refrigeration tubing can be routed either outside (as shown) or

inside the truck box depending on the particular installation and

application.

HG = Hot Gas S = Suction L = Liquid

IMPORTANT: Apply refrigerant oil (supplied in installation kit) to all

refrigerant tube O-rings prior to assembly.

1. Install a 1-3/8 in. x 7/8 in. x 7/8 in. tee assembly onto the S-3

evaporator’s suction fitting. Attach a pre-bent 7/8 in. suction tube onto

the other S-3 evaporator’s suction fitting and connect it to the tee

assembly (Detail II).

2. Fabricate a 1-3/8 in. suction tube from the tee assembly down to the

condenser unit. Use the provided flange and O-ring to connect the

suction tube to the condenser unit (Detail III).

3. Install a 1/2 in. x 1/2 in. x 1/2 in. tee assembly onto the S-3

evaporator’s hot gas fitting. Attach a pre-bent 1/2 in. hot gas tube onto

the other S-3 evaporator’s hot gas fitting and connect it to the tee

assembly (Detail II).

4. Fabricate a 1/2 in. hot gas tube from the tee assembly down to the

condenser unit. Use the provided ORS fittings to connect the hot gas

tube to the condenser (Detail III).

5. Install a 1/2 in. x 3/8 in. x 3/8 in. tee assembly onto the S-3

evaporator’s liquid fitting. Attach the pre-bent 3/8 in. liquid tube onto

the other S-3 evaporator’s liquid fitting and connect it to the tee

assembly. (Detail II).

6. Fabricate a 1/2 in. liquid tube from the tee to the filter drier

(Detail III).

7. Secure all tubing with provided clamps (Detail IV).

8. Seal around tubing with caulk to prevent air and water leakage.

9. Protective covers should be fabricated to prevent damage to the

refrigeration tubing and electrical wires and installed at the completion

of the installation.

CAUTION: Remove the holding charge from the host unit and

remote evaporators before proceeding to prevent personal injury.

WARNING: Regulators used on bottles of nitrogen gas must be

equipped with relief valves. The pressure in a bottle of nitrogen

gas is extremely high. It is high enough to cause components of

refrigeration systems to explode if the regulator malfunctions or is

set wrong. The relief valve provides a safe outlet in case the

regulated pressure exceeds the relief valve limit

61

Connecting Refrigeration Tubing–S-3 + S-3 Evaporators

62

Installing Drain Hoses

IMPORTANT: For proper drainage the drain hose must slope down

continuously from the remote evaporators to the wall drains with no

kinks or droop.

Thermo King recommends routing each individual drain hose directly

out of the truck box to allow faster water drainage.

1. Insert the entire length of the resistance wire into the drain hose.

IMPORTANT: DO NOT CUT THE RESISTANCE WIRES!

2. Attach drain hose to evaporator drain outlet and secure with supplied

hose clamps.

3. Secure drain hose to the outside of the truck box wall with supplied

clamps and screws.

4. Seal around drain hoses with caulk to prevent air and water leakage.

DANGER: Never bundle resistance wires together as the amount

of heat produced could result in a fire!

63

Installing Drain Hoses

64

Electrical Connections–UTSE Evaporator

NOTE: Route harness wires from the condenser unit, allowing a service

loop, (in case the unit needs to be lowered from it’s mounting position),

then route harness wires to evaporators.

1. Route the Evaporator Harness (FM-04, FM-05, AS-02, 8-01, POS-01

and CH-10) and Sensor Harness (DTN-01, DTP-01, CTN-01,

CTP-01, RTN-01 and RTP-01) to the evaporator.

2. Insert the Evaporator Harness wires with pins into the terminal strip

located on the evaporator and tighten screws securely. Attach wire

CH-10 to the ground stud securely.

3. Secure the harness with tie bands using the provided holes along the

base of the evaporator.

4. Route the Sensor Harness (DTN-01, DTP-01, CTN-01, CTP-01,

RTN-01 and RTP-01) to the opposite side of the evaporator.

5. Route the individual wires to the correct sensor, cut the wires to length

and attach the Deutsch terminal pins supplied in the installation kit.

• Insert the pins into the correct locations on the mating 2-pin and

3-pin connectors, secure with locking wedge and connect to the

appropriate sensor (Detail I).

6. Secure the harness with tie bands using the provided holes along the

base of the evaporator.

CAUTION: All electrical wires must be properly routed and

secured to prevent rubbing, chafing, or making contact with

sharp, moving or hot components

CAUTION: All electrical connections must be clean and tightly

secured to prevent damage to equipment.

65

Electrical Connections–UTSE Evaporator

66

Electrical Connections–S-3 + S-3 Evaporators

NOTE: Route harness wires from the condenser unit, allowing a service

loop, (in case the unit needs to be lowered from it’s mounting position),

then route harness wires to the evaporators.

1. Route the Evaporator Harness (FM-04, FM-05, AS-02, 8-01, POS-01

and CH-10) and Sensor Harness (DTN-01, DTP-01, CTN-01,

CTP-01, RTN-01 and RTP-01) to the S-3 MASTER evaporator.

2. Cut the Evaporator Harness to length and re-terminate the wire ends

with the fork and ring terminals supplied in the installation kit. Connect

the wires to the terminal strip and ground stud (Detail I).

3. From the S-3 MASTER evaporator route the interconnect harness

(wires FM-07, FM-08 and FM-09) to the S-3 SUPPORT evaporator

terminal strip and CH-18 to the ground stud (Detail I and II).

4. At the S-3 MASTER evaporator route the individual sensor wires to

the correct sensor, cut to length and attach the Deutsch terminal pins

supplied in the installation kit (Detail III).

• Insert the pins into the mating 2-pin and 3-pin connectors, secure

with locking wedge and connect to the appropriate sensor.

(Detail III).

IMPORTANT: Do not remove the “Master” and “Support” nameplates

until the installation is complete.

CAUTION: All electrical wires must be properly routed and

secured to prevent rubbing, chafing, or making contact with

sharp, moving or hot components.

CAUTION: All electrical connections must be clean and tightly

secured to prevent damage to equipment.

67

Electrical Connections–S-3 + S-3 Evaporators

68

Installing the Door Switch (OPTION)

NOTE: These instructions are intended as reference guide only to assist with a typical door switch installation. Your installation may be different

depending on the truck body, the amount and types of doors and the customers particular requirements.

Door Switch Components

The door switch consists of a magnet, a switch and non-magnetic mounting

hardware.

• The magnet is always mounted on the door.

• The switch (with harness) is always mounted to a stationary location.

• Non-magnetic mounting hardware is included to install the switches. If

alternate hardware is used it must also be non-magnetic or the door

switch will not operate properly.

Installer is to supply and fabricate the harness connecting the evaporator to

the door switch per the table below. The harness should be 18 AWG or

better, 2 wires, color coded RED and BLACK.

Mounting Locations

The door switch can be mounted on the inside or outside of either swing

out or roll-up doors and can be mounted in various positions to

accommodate particular applications.

IMPORTANT INSTALLATION NOTES:

• The door switch must be installed away from traffic (i.e. forklifts) or

protected from it.

• The door switch and magnet must be installed parallel to each other,

not perpendicular. Long cross hair aligns to long cross hair.

• It is important that a maximum gap of 19 mm (0.75 in.) is maintained

between the door switch and the magnet. Shims may be required and

must be a non-magnetic material (aluminum, wood, plastic, etc.) or the

door switch will not operate properly.

(Detail A) Ceiling Mounted

1. Mount the magnet flush with the top edge of the door and secure with

supplied hardware.

2. Close the door and mount the switch to the door sill parallel with the

magnet, being sure the “cross hairs” are aligned and that the maximum

gap of 19 mm (0.75 in.) is maintained.

(Detail B) Floor Mounted

1. Mount the magnet flush with the bottom edge of the door and secure

with supplied hardware.

2. Close the door and mount the switch to the floor parallel with the


gap of 19 mm (0.75 in.) is maintained.

(Detail C) Outside Door Installation

1. Mount the magnet flush with the top edge of the door and secure with

supplied hardware.

2. Close the door and mount the switch to the door sill parallel with the


gap of 19 mm (0.75 in.) is maintained

Evaporator Terminal Board Door Switch Wiring

POS RED = POS

(CH) = GROUND BLACK = (CH) GROUND

69


Right Angle Mounting

Top x Top Mounting

Side x Side Mounting

70


NOTE: THE DOOR SWITCH TERMINAL BOARD CONNECTIONS ARE LOCATED IN THE EVAPORATOR.

Wiring and Connecting the Door Switch

1. Attach a 2 wire harness (INSTALLER SUPPLIED) onto the door

switch wires. Connect matching wires per the table below

(RED/RED, BLACK/BLACK) to each door switch using splice

connectors. Crimp splice connectors securely and apply heat with a

heat gun.

2. Route the 2 wire harness to the evaporator and attach the RED (POS)

wire to the (POS) terminal on the terminal board and the BLACK (CH)

to the ground stud.

IMPORTANT: Always use a grommet when routing wires through the

metal cover plate of the evaporator.

3. Install the supplied relay to socket K11 on control box board.

4. All harnesses should be installed, routed and properly secured to

protect from damage.

5. Operate unit and verify door switch operation.

Interface Harness Wiring Door Switch Wiring

RED = POS RED = POS

BLACK = (CH) GROUND BLACK = (CH) GROUND

71


Interface Harness Wiring Door Switch Wiring

RED = POS RED = POS

BLACK = (CH) GROUND BLACK = (CH) GROUND

Add Relay

72

System Leak Check

1. Connect leak test gas supply (R404A) to the center hose of the gauge

manifold.

2. Attach gauge manifold hoses to the suction and discharge service

valves.

3. Open the suction and discharge valves and pressurize the system with

leak test gas. If desired system pressure may be boosted using nitrogen

gas.

4. Check all connections made during installation for leaks using an

electronic leak detector.

5. Recover test gas pressure to repair leaks. System must be vented while

repairing solder leak joints. Pressurize system again after a leak has

been repaired.

6. If no leaks are found, recover test gas to 0 psi.

73

System Leak Check

74

System Evacuation and Charging

NOTE: The use of Thermo King Evacuation Station P/N 204-725 is

required. Set up and test evacuative equipment prior to performing this

operation. The UT-1200X does not have a discharge service valve,

therefore it is recommended that low-loss fittings be used on any gauge

sets and on evacuation station line connected to discharge line.

System Evacuation and Charging Procedures

The overall procedure is:

• Evacuate the system using a Thermo King Evacuation Station.

• Place a partial charge in the system using the evacuation station.

• Remove the station and place a gauge set on the UT-1200X.

• Complete the charging of the system by simulating a 0 degree F box

and a 100 degree F ambient and utilizing the built in liquid line

sight glass.

System Evacuation

1. Prepare the unit for evacuation. Recover any refrigerant to 0 psi

(regulations may require a recovery machine to pull system pressure

lower than 0 psi).

2. Before connecting refrigerant hoses to unit, close valves V1, V2, and

V4.

3. Back seat suction and receiver tank service valves.

4. Attach evacuation hoses to SSV and RTDV and to the discharge port of

the compressor (check condition of hose seals).

5. Install a low pressure hose from the spare access port on valve V4

service hose to a refrigerant supply. Bottle valve closed.

6. Mid-seat all service valves.

7. Start the vacuum pump and open valves V1, V2, V3, and V4.

8. Energize the Thermax valve. Refer to Service Bulletin T&T 246.

9. Evacuate the system to 500 microns or lowest achievable level between

500 and 1000 microns. Split systems with multi-evaporators should be

evacuated for an additional hour once 500 microns is reached.

10. When acceptable micron level is achieved (500 to 1000 microns plus

one hour for multi-evaporators), close valve V1 to isolate pump. Turn

pump OFF.

11. Observe reading on micron gauge after 5 minutes have elapsed.

Vacuum rise should not exceed 2000 microns. If vacuum level exceeds

2000 microns after 5 minutes, a leak is present or additional evacuation

time is required.

12. If vacuum level is acceptable, start pump and open valve V1 to

evacuate pressure rise (5 minutes).

13. With vacuum pump running, back seat suction service valve. Observe

micron gauge and continue to operate vacuum pump until an

acceptable micron level is achieved.

14. Close valve V1 and stop the pump. Observe micron gauge to confirm

that system remains in deep vacuum. Close valve V4. Unit is now

ready to charge.

CAUTION: Do not evacuate the unit until it is leak free. Units

with less than full refrigerant charge should be leak checked and

all leaks must be repaired.

A. V-4 E. Two Stage Vacuum Pump

B. V-3 F. To AC Power

C. V-2 G. Micron Gauge

D. V-1 H. Thermistor

75


76


Initial System Charge

The UT-1200X utilizes a liquid line sight glass. This is used in order to

attain an optimum charge given varied installations (suction/liquid line

lengths vary).

DO NOT use the receive tank sight glass as an indicator of the required

refrigerant level in the system.

NOTE: Before charging system, make sure refrigerant lines from the

gauge manifold to refrigerant supply bottle have been evacuated or

purged.

1. Suction service valve is back seated and receiver outlet valve is open.

Refrigerant will be added to the high side of the unit with the unit OFF.

2. Set refrigerant supply bottle for liquid. Open gauge manifold hand

valve and add a partial charge of 4.1 kg (9.0 lb.) of R-404A refrigerant.

NOTE: Do not add more than this. Remainder of charge will be added

through suction service valve while unit is running.

3. After the liquid refrigerant is added, close gauge manifold hand valve.

4. Remove hose from discharge line. A low loss fitting on this hose will

prevent excessive loss of refrigerant.

5. Back seat (close) the receiver outlet valve.

6. Front seat the suction service valve (SSV). Run the unit until a 3 to 5

psig (21 to 35 kPa) reading is obtained on the suction gauge. Stop the

unit. Do not run the unit into a deep vacuum as it may damage the scroll

compressor.

7. Back seat (close) suction service valve.

8. Remove the evacuation station hoses.

9. Cap service valve ports, backseat (close) suction service valve (SSV).

Final System Charge

1. Install a gauge manifold set on the suction service valve and the

discharge port of the scroll compressor.

2. Start the unit and set the thermostat to COOL. Maintain a 0 degree F/

-17.8 degree C box and 100 degree F/37degree C ambient. Suction

pressure should be 12-20 psig and discharge pressure to 290-310 psig

(suction service valve cracked). Cover the condenser coil if needed.

3. Observe suction pressure and slowly open gauge manifold hand valve

to allow liquid refrigerant to flow into suction service valve. Control

liquid flow so suction pressure increases approximately 138 kPa (20

psi).

4. Add refrigerant until no bubbles appear in the liquid line sight glass.

5. Stop the flow of refrigerant into the system by closing the low-side

gauge manifold hand valve.

6. Continue to operate unit in COOL for 10 minutes and check for

bubbles in the liquid line sight glass. If bubbles appear, add liquid

refrigerant. The total charge in the system will be about 14 lbs. / 6.6 Kg

of refrigerant.

Removal of Refrigerant Hoses

1. With a low loss fitting on the discharge gauge line, remove this line

from the unit.

2. Run unit in COOL mode.

3. Front seat the suction service valve. Run unit until a 3 to 5 psig (21 to

35 kPa reading is obtained on the suction gauge. Stop the unit.

DO NOT run the unit into a deep vacuum as this may damage the scroll

compressor.

4. Remove the gauge line from the suction service valve and cap the

service port.

5. Backseat suction service valve and cap the valve stem.

6. Unit is now ready for functional check out.

A. V-4 E. Two Stage Vacuum Pump H. Thermistor

B. V-3 F. To AC Power I. Correct Refrigerant

LevelC. V-2 G. Micron Gauge

D. V-1

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System Check List

All Unit Mounting Hardware Torqued to Specifications.

Drain Hoses Properly Routed and Secured.

Fuel Tank Properly Installed.

Fuel Lines Properly Routed and Fuel Fittings Tightened Securely.

Battery Secured Correctly and All Electrical Connections Clean and

Tight.

Wiring Harnesses Properly Routed and Secured.

Refrigeration Systems Properly Charged.

Refrigeration System Leak Checked.

Refrigeration Tubing Properly Secured.

Guards, Covers and Grilles Installed Securely.

Run Pre-Trip Test (Refer to Host Unit Operating Manual).

Release to Customer.

Installation Manual Truck Edition UT-1200X Undermount...

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