installation manual - b

Installation Manual - B

Providing equipment and services to manage controlled-temperature environments for food and other temperature-sensitive products, our Climate Control Technologies sector encompasses both transport and stationary refrigeration solutions. Our product brands include Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a manufacturer of refrigeration and food merchandising equipment.

www.thermoking.com www.hussmann.com www.ingersollrand.com

©2008 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

Trailer Edition (NAD) Multi-Temperature

SPECTRUMTM Evaporator Systems (SR-2)TK 53509-2-IM (Rev. 5, 01/12)


Trailer Edition (NAD)Multi-TemperatureSPECTRUM™ Evaporator Systems (SR-2)TK 53509-2-IM (Rev. 5, 01/12)

Copyright© 2006 Thermo King Corp., Minneapolis, MN, U.S.A.

2

Printing History

Released (08/06)

Rev. 1 (01/07) Corrected wiring connections on pages 64-69.

Rev. 2. (04/07) Changed Installation Kit from 800117 to 800118 for configurations E, F and L only on page 9.

Rev. 3 (04/11) Updated art and text by replacing ORS fittings with solder fittings on S-2 and S-3 evaporators.

Rev. 4 (04/11) Pages 80-81 - Revised content of SYSTEM CHECK LIST and renamed it UNIT CHECK LIST.

Rev. 5 (01/12) Changed Installation Kit from 800118 to 800579 for configurations E, F and L only on page 9.

3

Trailer Edition Installation Manual - B

for Multi-Temperature SPECTRUM Evaporator Systems (SR-2)

FOR HOST UNIT INSTALLATION INSTRUCTIONS SEE HOST UNIT INSTALLATION MANUALS

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

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

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

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

judgment, to affect its integrity.”

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

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

descriptions contained herein.

4

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Trailer Multi-Temperature SPECTRUM Selection Guide . . . . . . . . . . . . . . . . 8

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

S-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

S-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

S-2 + S-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

S-3 + S-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Recovering Holding Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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

Installation S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Installation S-2 + S-2 or S-3 + S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Host Tube Connections S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Host Tube Connections (Configuration X Only) . . . . . . . . . . . . . . . . . . . . . . 40

Host Tube Connections (Configuration Y Only) . . . . . . . . . . . . . . . . . . . . . . 42

Host Tube Connections (Configuration Z Only) . . . . . . . . . . . . . . . . . . . . . 44

Evaporator Tube Connections S-2 or S-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Evaporator Tube Connections S-2 + S-2 or S-3 + S-3 . . . . . . . . . . . . . . . . . 50

Evaporator Tube Connections S-3 + S-3 (Configuration X Only) . . . . . . . . 52

Evaporator Tube Connections S-3 (Configuration X Only) . . . . . . . . . . . . . 54

Evaporator Tube Connections S-3 + S-3 (Configuration Y Only) . . . . . . . . 56

Evaporator Tube Connections S-3 + S-3 (Configuration Z Only) . . . . . . . . 60

SB Host & Evaporator Wire Connections - Zone 2 . . . . . . . . . . . . . . . . . . . 64

SB Host & Evaporator Wire Connections - Zone 3 . . . . . . . . . . . . . . . . . . . 66

DE Host & Evaporator Wire Connections - Zone 3 . . . . . . . . . . . . . . . . . . . 68

Drain Hose Resistance Wire Installation Guide . . . . . . . . . . . . . . . . . . . . . . 70

Drain Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Leak Check, Evacuation and Charging Procedures . . . . . . . . . . . . . . . . . . 74

Installing SPECTRUM Evaporator Covers . . . . . . . . . . . . . . . . . . . . . . . . . . 78

UNIT CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5

Safety Precautions

Caution

Thermo King Multi-Temp host units are shipped with a 35 kPa (5 psi) holding charge of R-404A. This

holding charge of approximately 1 kg (2 pounds) of refrigerant must be recovered.

The SPECTRUM remote evaporators are shipped with a 35-69 kPa (5-10 psi) holding charge of nitrogen.

This holding charge may be safely vented into the atmosphere.

SEVERE COMPRESSOR DAMAGE will result from operating the engine before completing the system

installation which includes: installing the components, recovering the host unit holding charge, releasing

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

evacuation and clean-up, and charging the system.

Recover Refrigerant

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

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

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

atmosphere.

6

Safety Precautions

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

DANGER: Addresses a circumstance that, if encountered, will

lead to death or serious injury.

WARNING: Addresses a circumstance that, if encountered, might

lead to death or serious injury.

CAUTION: Addresses a circumstance that, if encountered, may

cause damage to equipment or minor injury.

DANGER: Never operate the unit with the discharge valve closed

because it could cause the compressor to explode, causing death

or serious injury.

DANGER: Never apply heat to a sealed refrigeration system or

container because it could explode, causing death or serious

injury.

DANGER: Fluorocarbon refrigerants, in the presence of an open

flame or electrical short, produce toxic gases that are severe

respiratory irritants capable of causing death.

DANGER: Be careful when working with a refrigerant or

refrigeration system in any enclosed or confined area with a

limited air supply (i.e., a trailer, container or the hold of a ship).

Refrigerant tends to displace air and can cause oxygen depletion

which may result in death by suffocation.

WARNING: Always wear goggles or safety glasses. Refrigerant

liquid, refrigeration oil, and battery acid can permanently damage

the eyes (see First Aid under Refrigeration Oil).

WARNING: Keep your hands away from fans and belts when the

unit is running. This should also be considered when opening and

closing the compressor service valves.

WARNING: Make sure gauge manifold hoses are in good

condition. Never let them come in contact with a belt, fan motor

pulley, or any hot surface.

WARNING: Make sure all fasteners are torqued to specification

and are of correct length for their particular application.

WARNING: When using ladders to install or service refrigeration

systems, always observe the ladder manufacturer’s safety labels

and warnings. A work platform is the recommended method for

installations.

7

Safety Precautions

Refrigerant

First Aid• FROSTBITE: In the event of frost bite, the objectives of First Aid are

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

rapidly and to maintain respiration.

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

amounts of water and get prompt medical attention.

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

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

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

attention. Wash contaminated clothing before reuse.

• INHALATION: Move victim to fresh air and use CPR or

mouth-to-mouth ventilation, if necessary. Stay with victim until arrival

of emergency medical personnel.

Refrigeration Oil

First AidIn 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: Never drill holes in the unit unless absolutely

necessary. Holes drilled into the unit may weaken structural

components. Holes drilled into electrical wiring can cause fire or

explosion.

WARNING: Exposed coil fins are very sharp and can cause

painful lacerations.

WARNING: Regulators used on bottles of nitrogen gas must be

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

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

the refrigeration system to explode if the regulator malfunctions

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

regulated pressure exceeds the relief valve limit.

CAUTION: Recover the refrigerant (R-404A) holding charge

from the host unit prior to making any refrigeration tubing

connections to prevent personal injury!

CAUTION: Remove the nitrogen holding charge from the remote

evaporators prior to making any refrigeration tubing connections

to prevent personal injury!

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.

8

Trailer Multi-Temperature SPECTRUM Selection Guide

9

Trailer Multi-Temperature SPECTRUM Selection Guide

MAXIMUM RECOMMENDED

DIMENSIONSInstallation

Kit(s)Tube Kits

Config.Max.

Dims.

S-3

900280

S-3 + S-3

900280 x 2

B A 17.4 ft. - 800116 818066

E A - 31.2 ft. 800116

800579

818067

* Note 1

F A - 28.0 ft. 800116

800579

818066

I A

B

4.1 ft.

31.2 ft.

-

-

800116 818066

J A - 4.1 ft. 800116

800117

818066

L A - 31.2 ft. 800116

800579

818067

*Note 1

N A 17.4 ft. - 800116

800117

818067

T A

B

31.2 ft.

4.1 ft.

-

-

800116

800117

818067

W

(DE)

A

B

4.1ft.

31.2 ft.

-

-

800119 818066

*Note 1

X A

B

-

17.4 ft.

31.2 ft.

-

800120 N/A

Y A

B

17.4 ft.

-

-

31.2 ft.

800121 N/A

Z A

B

-

-

-

31.2 ft.

800122 N/A

NOTE 1: Trailers 48 ft. and longer with configuration E, L or W requires supplemental

tube kit 880097.

NOTE 2: Transverse mounted evaporators configurations B, F, N and T requires one

drain kit 880041 for each evaporator.

10

Required Tools

1. Safety Glasses

2. Tape Measure

3. Screwdrivers - Phillips and Straight Blade

4. Drill

5. Drill Bits

6. Hole Saw

7. Torque Wrench

8. Box and Open End Wrenches - 7/16”, 1/2”, 9/16”, 5/8”, 3/4”

9. 12” Adjustable Wrench

10. Crow’s Feet - 7/8”, 1”, 1-3/8”

11. Tap and Die Set (Europe only)

12. Wire Stripper

13. Wire Crimper - for insulated terminals

14. Electronic Leak Detector

15. Tube Benders

16. Tubing Cutter

17. Tubing Swages

18. Tubing Brushes

19. Scotch Brite Pads

20. Torch Set

21. 15% Silver Solder(203-364) & Flux (203-365)

22. Heat Shield

23. Manifold Set

24. Evacuation Station (TK-204-725)

25. Reclaiming Station

26. Refrigerant Oil

27. Refrigerant and Scale

28. Dry Nitrogen

29. Battery Charger (60 AMP minimum)

30. Mechanical Lift (modified drywall lift)

NOTE: Equipment such as scales, gauges, refrigerant leak detectors, and torque wrenches should be in good working condition and routinely calibrated

to assure accurate readings.

11

Required Tools

BLANK PAGE

12

Installation Components

1. Clamps

2. Screws

3. Pre-Bent Tubes

4. Copper Tees

5. Copper Couplings

6. Tube Insulation

7. Refrigerant Tubing (US Only)

8. Drain Hose

9. Copper Elbows

10. Drain Hose Tee

11. Mounting Spacer

12. Terminal Fork

13. Terminal Ring

14. Plastic Band Wraps

15. Jumper Strip

16. Electrical Harnesses

13

Installation Components

14

S-2 Dimensions

NOTE: All mounting locations must be correct to properly install the

SPECTRUM evaporator(s).

Mount all evaporators as close to one side wall as possible to minimize

drain tube length and reduce exposure to damage.

The minimum distance 1229.4 mm (48.4 in.) from the bulkhead to the front

of the evaporator must be maintained for proper operation.

A, B, C, D, E, and F indicate locations of solder fittings measured

vertically from the top of the evaporator and horizontally from the

evaporator mounting hole.

NOTE: See “96 in. Wide Trailer Installation Matrix” on pages 28

and 29.

15

S-2 Dimensions

Reference: 1E02132 Sheet 1

WEIGHT = 43 kg (95 lb.)

16

S-3 Dimensions











and 29.

17

S-3 Dimensions

Reference: 1E02132 Sheet 2WEIGHT = 52 kg (115 lb.)

18

S-2 + S-2 Dimensions











and 29.

19


WEIGHT = 43 kg (95 lb.) eachReference: 1E02132 Sheet 3

20












and 29.

21


WEIGHT = 52 kg (115 lb.) each

Reference: 1E02132 Sheet 4

22

Recovering Holding Charge

NOTE: The host unit must be placed in the Evacuation Mode to open the

normally closed solenoid valves throughout this procedure. See “Leak

Check, Evacuation and Charging Procedures” on page 74.

1. Set refrigerant recovery device to recover R-404A vapor.

2. Recover refrigerant vapor from host unit to 0 kPa (0 psi) from receiver

outlet valve and suction service valve.

3. Remove the manifold gauge lines from receiver outlet valve and

suction service valve. Leave service valves open to port to act as vents.

NOTE: It is important to minimize the amount of time the tubes are

uncapped and open to ambient conditions. Always keep tubes capped

until ready to connect and solder.

4. Unsolder tube caps from hot gas, liquid, and suction lines on host unit.

NOTE: Some host units are supplied with two suction lines. Only remove

caps from both suction lines if required for your application.

CAUTION: Make sure holding charge from host unit has been

recovered before proceeding to prevent personal injury!

23

Recovering Holding Charge

24

Important Installation Notes

EVAPORATOR LOCATION

• The best airflow is achieved when the evaporator is installed an equal

distance from each side wall.

• It is recommended that moving bulkheads not be allowed closer than

1229.4 mm (48.4 in.) or 1 pallet + 4.00 inches from the evaporator

outlet (Detail I).

• The minimum clearance from the bottom to the top of the cargo and all

sides of the evaporator except the evaporator outlet should be 101 mm

(4.00 in.) (Detail I).

NOTE: This minimum clearance does not refer to the trailer LOAD

LINE.

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

the trailer wall (Detail IlI).

DEFROST DRAINS

• The drain tube should be offset 35.5 mm (1.4 in.) from the mounting

holes (Detail II).

• The evaporator must be properly mounted to provide a slope towards

the drain. This is accomplished by adding one 3/8 in. and one 3/16 in.

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

at each mounting surface (Detail III).

• Defrost drains must exit the evaporator at a 45° angle and have a

minimum downward gradient of 267 mm (10.50 in.) from the trailer

ceiling to the top of the drain in the trailer wall (Detail III).

WALL DRAIN TUBE - (Details II and III)

• CPVC

• 1.00 in. ID (Inside Diameter)

ELECTRICAL WIRING

IMPORTANT: DO NOT CUT THE SENSOR HARNESSES

• All electrical harness must be secured by clamps at least every 600 mm

(24.00 in.).

• Additional harnesses (options, etc.) can be secured with tie bands to the

harnesses that are clamped in place.

25


26


TROUGH LOCATION - (Details IV - VII)

• The OEM and Dealer should discuss trough locations based on

application before the trailer is built.

• Only one trough is required.

• The trough should be located in such a way as to allow for proper

routing of the suction line(s). 3 compartment trailers may have two

suction lines in the trough.

• A ceiling trough is recommended. If that is not possible, a wall through

should be located to allow the lowest suction line to be at least 25 mm

(1.00 in.) above the remote evaporator suction line fitting once secured

to the trough.

REFRIGERANT TUBING and CONNECTIONS

• Thermo King Requires the use of bulk rolled refrigeration grade tubing

and tube benders to reduce fittings and solder joints where applicable.

• The use of large radius bends is preferred over copper fitting joints.

• It is important to minimize the amount of time the tubes are uncapped

and open to ambient conditions. Always keep tubes capped until ready

to connect and solder.

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

• Use 15% silver solder for joining all remote refrigerant tubes.

• Suction and liquid tubes are to be insulated when outside the trough.

Hot gas tubes are to be 100% insulated.

• All refrigeration tubes must be secured by clamps at least every 600

mm (24.00 in.).

• All dual evaporator installations require two suction tubes

(Detail V, VII).

• Configuration X installations will require two suction tubes: 1-1/8 in.

for Zone 2 and 7/8 in. for Zone 3.

• Configuration Y installations will require two suction tubes: 7/8 in. for

Zone 2 and 1-1/8 in. for Zone 3.

• Configuration Z installations require 1-1/8 in. suction tubes for both

Zone 2 and Zone 3.

• All soldering of tubes should be done according to the best practices

soldering document, Section 16, of the Certi-Tech Professional

Manual.

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

tubes while soldering. This prevents oxidation and formation of scale

inside tubes.

IMPORTANT: The following procedure should be followed to correctly

purge the tubes with nitrogen when soldering.

1. Midseat the suction and discharge service valves on the host

unit.

2. On one remote evaporator in each remote zone connect a 6 volt

lantern battery to the HGS and SOL terminals of the terminal

strip. This activates the Hot Gas Solenoid to allow nitrogen to

flow.

3. Connect a nitrogen supply hose to the access port on the same

remote evaporator that the battery was connected. Make sure

the supply hose fitting has a Schrader valve depressor to open

the Schrader valve on the access port.

4. Adjust the nitrogen flow to 5-10 CFH.

5. The nitrogen supply and lantern battery must be maintained

while soldering the remote and host unit connections.

27


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

28


Host Unit Return Air

• In lane configurations, care must be taken to avoid the inner walls

obstructing return air to the host. Not only is host performance

impaired, but temperature management will suffer if return air does

not flow over the return air sensor.

Door Switches

• Door switches automatically turn off remote evaporators when the

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

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

multi-temp installations.

Door Curtains

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

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

load space during door openings.

Full Length Lanes

• Always consider the use of an SB-III DE (Dual Evaporator) where

full length lanes are required. This is the most efficient and cost

effective solution for these demanding applications, and a product

unique to Thermo King.

96 in. Wide Trailer Installation MatrixNOTE: The installation of parallel S3+S3 on a 96” wide trailers may be too tight due to variations of trailer wall thicknesses. Since Spectrum evaporators

allow for the drain hose to exit the front, you can install a parallel S3+S3 based on the assumptions shown below.

THIS IS AN EXAMPLE, NOT A SPECIFICATION

THE TRAILER OEM AND DEALERS ARE EXPECTED TO VALIDATE THESE CALCULATIONS

ASSUMING THE DRAIN IS COMING OUT THE SIDE OF THE EVAPORATOR:

Trailer Width 96 96 96 96 96

Wall Thickness 4 3.5 3 2.5 2

Difference 88 89 90 91 92

Evaporator Clearance from Road Side Wall 2 2 2 2 2

Evaporator Clearance from Curb Side Wall 2 2 2 2 2

S3+S3 Width 86.81 86.81 86.81 86.81 86.81

Space Left-2.81 -1.81 -0.81

0.19

not ideal1.19

S2+S2 Width 59.85 59.85 59.85 59.85 59.85

Space Left 24.15 25.15 26.15 27.15 28.15

29


96 in. Wide Trailer Installation Matrix

ASSUMING THE DRAIN IS COMING OUT THE FRONT OF THE EVAPORATOR:




Evaporator Clearance from Road Side Wall 1 1 1 1 1

Evaporator Clearance from Curb Side Wall 1 1 1 1 1

S3+S3 Width 86.81 86.81 86.81 86.81 86.81

Space Left-0.81

-0.19

not ideal1.19 2.19 3.19

S2+S2 Width 59.85 59.85 59.85 59.85 59.85

Space Left 24.15 25.15 26.15 27.15 28.15

ASSUMING THE DRAIN IS COMING OUT THE FRONT OF THE EVAPORATOR:




Evaporator Clearance from Road Side Wall 0.5 0.5 0.5 0.5 0.5

Evaporator Clearance from Curb Side Wall 0.5 0.5 0.5 0.5 0.5

S3+S3 Width 86.81 86.81 86.81 86.81 86.81

Space Left0.19

not ideal1.19 2.19 3.19 4.19

S2+S2 Width 59.85 59.85 59.85 59.85 59.85

Space Left 27.15 28.15 29.15 30.15 31.15

30


Defrost Drain Tube Connector Installation

IMPORTANT: Follow the instructions below to prevent defrost drain

tube water leaks.

All Spectrum remote evaporators are equipped with a quick disconnect

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

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

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

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

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

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

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

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

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

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

(Detail IV).

31


32


33


34

Installation S-2 or S-3

Ceiling Preparation

IMPORTANT: The trailer ceiling must be structurally strong enough to

support the weight of the S-2 evaporator(s) 43 kg (95 lb.) each or S-3

evaporator(s) 52 kg (115 lb.) each.

IMPORTANT: The ceiling must be flat and the mounting locations

correct for proper SPECTRUM evaporator installation. The foam

insulation in the ceiling must be removed from the evaporator mounting

area and aluminium spacers must be installed between the evaporator

mounting plate and trailer ceiling.

NOTE: If the trailer frame is other than aluminum, use mylar film

between aluminum spacer and frame.

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

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

mounting stud using a socket wrench (Detail I).

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

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

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

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

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

threaded hole without damaging the threads. Reinstall mounting studs

or bolts.

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

IMPORTANT: The evaporator must be properly mounted to provide a

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

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

other side at each mounting surface (Detail IV).

1. Remove evaporator cover to access mounting holes.

NOTE: The installation kit provides both metric and imperial nuts

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

Mounting Stud Installations

2. Install the aluminum spacers onto the ceiling mounting studs and raise

the evaporator into position. Secure the evaporator onto the mounting

studs with flat washers and locking nuts (Detail II). Torque to 81.3

N•m (60 ft-lb).

Mounting Bolt Installations

3. Install the mounting bolts, lock washers (installer supplied) and flat

washers onto the evaporator and raise into position. Install the

aluminium spacers and secure the evaporator to the ceiling

(Detail III). Torque to 81.3 N•m (60 ft-lb).

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

tubes to allow for water drainage. Two additional washers are included

in the kit to help assist sloping the evaporator towards the drain

(Detail IV).

35

Installation S-2 or S-3

36

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

Ceiling PreparationIMPORTANT: The trailer ceiling must be structurally strong enough to

support the weight of the S-2 evaporator(s) 43 kg (95 lb.) each or S-3

evaporator(s) 52 kg (115 lb.) each.

IMPORTANT: The ceiling must be flat and the mounting locations

correct for proper SPECTRUM evaporator installation. The foam

insulation in the ceiling must be removed from the evaporator mounting

area and aluminium spacers must be installed between the evaporator

mounting plate and trailer ceiling.

NOTE: If the trailer frame is other than aluminum, use mylar film

between aluminum spacer and frame.

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

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

mounting stud using a socket wrench (Detail I).

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

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

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

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

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

threaded hole without damaging the threads. Reinstall mounting studs

or bolts.

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 aluminum spacers onto the ceiling mounting studs and raise

the evaporator into position. Secure the evaporator onto the mounting

studs with flat washers and locking nuts (Detail II). Torque to 81.3

N•m (60 ft-lb).

Mounting Bolt Installations

3. Install the mounting bolts, lock washers (installer supplied) and flat

washers onto the evaporator and raise into position. Install the

aluminium spacers and secure the evaporator to the ceiling

(Detail III).

4. Install the second evaporator. Torque each evaporator’s mounting

hardware to 81.3 N•m (60 ft-lb).

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

tubes to allow for water drainage (Detail IV).

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

sloping the evaporator towards the drain.

37

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

38

Host Tube Connections S-2 or S-3

1. Suction Line (s)

• SINGLE EVAPORATOR INSTALLATIONS - Install 7/8 in. x

7/8 in. coupling onto one suction tube of host unit. Fabricate 7/8

in. suction tube and install onto 7/8 in. coupling.

NOTE: The second suction tube remains capped.

• MULTIPLE EVAPORATOR INSTALLATIONS ONLY - Install

7/8 in. x 7/8 in. couplings onto each suction tube of host unit.

Fabricate 7/8 in. suction tubes and install onto each 7/8 in.

coupling.

2. Liquid Line - Install 3/8 in. x 1/2 in. coupling onto liquid tube of host

unit. Fabricate 1/2 in. liquid tube and install onto coupling.

3. Hot Gas Line - Install 5/8 in. x 5/8 in. coupling onto hot gas tube of

host unit. Fabricate 5/8 in. hot gas tube and install onto coupling.

4. Insulation should be added to all visible segments of suction and liquid

tubes not covered by trailer trough cover. Hot gas tubes should be

covered 100%.

5. Secure all tubing with provided clamps. Maximum separation should

be 600 mm (24.00 in.) between clamps.

NOTE: Ceiling trough shown, wall trough is similar.

Fittings Required

Item Description P/N

A 7/8 in. x 7/8 in. Coupling 553740

B 3/8 in. x 1/2 in. Coupling 552865

C 5/8 in. x 5/8 in. Coupling 556523

Tubing Clamps Required

Tube With Insulation W/O Insulation

Liquid G42 G14

Hot Gas G42 N/A

Suction G58 G35

39

Host Tube Connections S-2 or S-3

Single Evaporator

DE w/single or Parallel Evaporator(s)

Multiple Evaporators

40

Host Tube Connections (Configuration X Only)

IMPORTANT: Configuration X installation requires two different size

suction tubes routed to the remote evaporators for proper operation:

• 1-1/8 in. suction tube from the host unit to the S3 + S3 remote

evaporators in Zone 2.

• 7/8 in. suction tube from the host unit to the S3 evaporator in

Zone 3.

• Due to the difficulty in bending and forming 1-1/8 in. copper

tubing, elbows and fittings may be used as shown.

1. Suction Line #1 - Install a 7/8 in. x 7/8 in. coupling onto the first

suction tube at the rear of the host unit. Fabricate a 7/8 in. tube, attach

onto coupling of suction tube and connect to 7/8 in. suction tube in

trough.

2. Suction Line #2 - Install a 7/8 x 1-1/8 in. coupling onto the second

suction tube at the rear of the host unit. Fabricate a 1-1/8 in. tube,

attach to coupling of suction tube and use 1-1/8 in. elbows to connect to

1-1/8 in. suction tube in trough.

3. Liquid Line - Install a 3/8 in. x 1/2 in. coupling onto liquid tube of the

host unit. Fabricate a 1/2 in. liquid tube and install onto the 1/2 in.

coupling.

4. Hot Gas - Install a 5/8 in. x 5/8 in. coupling onto the hot gas tube of the

host unit. Fabricate a 5/8 in. hot gas tube and install onto the 5/8 in.

coupling.


tubes not covered by the trailer trough cover. Hot gas tubes should be

covered 100%.



Fittings Required


A 7/8 in. x 7/8 in. Coupling 553740

B 7/8 in. x 1-1/8 in. Coupling 666022

C 1-1/8 in. x 1-1/8 in. Elbow 553682

D 3/8 in. x 1/2 in. Coupling 552865

E 5/8 in. x 5/8 in. Coupling 556523



Liquid G42 G14

Hot Gas G42 N/A

Suction (7/8 in.) G58 G35

Suction (1-1/8 in.) G66 G58

41

Host Tube Connections (Configuration X Only)

42

Host Tube Connections (Configuration Y Only)

IMPORTANT: Configuration Y installation requires two different size


• 7/8 in. suction tube from the host unit to the S3 remote

evaporator in Zone 2.

• 1-1/8 in. suction tube from the host unit to the S3 + S3




1. Suction Line #1 - Install a 7/8 x 1-1/8 in. coupling onto the first


attach to coupling of suction tube and use 1-1/8 in. elbows to connect to

1-1/8 in. suction tube in trough.

2. Suction Line #2 - Install a 7/8 in. x 7/8 in. coupling onto the first

suction tube at the rear of the host unit. Fabricate a 7/8 in. tube, attach

onto coupling of suction tube and connect to 7/8 in. suction tube in

trough.



coupling.

4. Hot Gas - Install a 5/8 in. x 5/8 in. coupling onto the hot gas tube of the

host unit. Fabricate a 5/8 in. hot gas tube and install onto the 5/8 in.

coupling.



covered 100%.



Fittings Required


A 7/8 in. x 1-1/8 in. Coupling 666022

B 1-1/8 in. x 1-1/8 in. Elbow 553682



E 5/8 in. x 5/8 in. Coupling 556523



Liquid G42 G14

Hot Gas G42 N/A



43

Host Tube Connections (Configuration Y Only)

44

Host Tube Connections (Configuration Z Only)

IMPORTANT: Configuration Z installations require two 1-1/8 in.








1. Suction Line #1 - Install a 7/8 x 1-1/8 in. coupling onto the first


attach to coupling of suction tube and use 1-1/8 in. elbows to connect

to 1-1/8 in. suction tube in trough.

2. Suction Line #2 - Install a 7/8 x 1-1/8 in. coupling onto the second


attach to coupling of suction tube and use 1-1/8 in. elbows to connect

to 1-1/8 in. suction tube in trough.



coupling.

4. Hot Gas - Install a 5/8 in. x 5/8 in. coupling onto the hot gas tube of

the host unit. Fabricate a 5/8 in. hot gas tube and install onto the 5/8

in. coupling.



covered 100%.



Fittings Required


A 7/8 in. x 1-1/8 in. Coupling 666022

B 1-1/8 in. x 1-1/8 in. Elbow 553682





Liquid G42 G14

Hot Gas G42 N/A


45

Host Tube Connections (Configuration Z Only)

46

Evaporator Tube Connections S-2 or S-3

Zone 2 (Two Compartment Trailers)

IMPORTANT: Clean all tubes and fittings prior to installation and

soldering.

1. Suction Line - Fabricate one 7/8 in. suction tube from host unit and

route in trough, install 7/8 in. x 7/8 in. elbow, attach 7/8 in. preformed

tube and connect to evaporator 7/8 in. fitting in Zone 2. Solder all

fittings.

2. Hot Gas Line - Fabricate a 5/8 in. hot gas tube from host unit and


tube and connect to evaporator 1/2 in. fitting in Zone 2. Solder all

fittings.

3. Liquid Line - Fabricate a 1/2 in. liquid tube from host unit and route

in trough, install 1/2 x 3/8 in. elbow, attach 3/8 in. preformed tube and

connect to evaporator 3/8 in. fitting in Zone 2. Solder all fittings



covered 100%.



Fittings Required for SINGLE Evaporator Installations


A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 1/2 in. Elbow 665733

C 1/2 in. x 3/8 in. Elbow 554142



Liquid G42 G14

Hot Gas G42 N/A

Suction G58 G35

47



48


Zones 2 & 3 (Three Compartment Trailers)


soldering.

1. Suction Lines

• Fabricate two 7/8 in. suction tubes from host unit and route in

trough, install 7/8 in. x 7/8 in. elbows, attach one 7/8 in. preformed

tube to evaporator in Zone 2 and another to the evaporator in

Zone 3. Solder all fittings.

2. Hot Gas Lines

• Zone 2 - Fabricate a 5/8 in. hot gas tube from host unit and route in

trough, install 5/8 in. x 5/8 in. x 1/2 in. tee, attach a 1/2 in.

preformed tube and connect it to the evaporator in Zone 2.

• Zone 3 - From the tee, fabricate another 5/8 in. hot gas tube, attach

a 5/8 in. x 1/2 in. elbow and connect it to the 1/2 in. preformed tube

and to the evaporator in Zone 3. Solder all fittings.

3. Liquid Line

• Zone 2- Fabricate a 1/2 in. liquid tube from host unit and route in

trough, install 1/2 x 1/2 in. x 3/8 in. tee, attach 3/8 in. preformed

tube and connect it to the evaporator in Zone 2. Solder all fittings.

• Zone 3 - From the tee, fabricate another 1/2 in. liquid tube, attach

a 1/2 in. x 3/8 in. elbow and connect it to the 3/8 in. preformed tube

and to the evaporator in Zone 3. Solder all fittings.



covered 100%.





A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 1/2 in. Elbow 665733

C 1/2 in. x 3/8 in. Elbow 554142

Fittings Required for MULTIPLE Evaporator Installations


A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 5/8 in. x 1/2 in. Tee 660620

C 5/8 in. x 1/2 in. Elbow 665733

D 1/2 in. x 1/2 in. x 3/8 in. Tee 552181

E 1/2 in. x 3/8 in. Elbow 554142



Liquid G42 G14

Hot Gas G42 N/A

Suction G58 G35

49


Zone 2 & 3 (Three Compartment Trailers)

50

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



soldering.

NOTE: You must connect one suction line from the host to each

evaporator.

1. Suction Line #1- Fabricate a 7/8 in. suction tube from host unit and


tube and connect to the first evaporator 7/8 in. fitting in Zone 2. Solder

all fittings.

2. Suction Line #2 - Fabricate a second 7/8 in. suction tube from host

unit and route in trough, install 7/8 in. x 7/8 in. elbow, attach 7/8 in.

preformed tube and connect to the second evaporator 7/8 in. fitting in


3. Hot Gas Line - Fabricate a 5/8 in. hot gas tube from host unit and

route in trough, install 5/8 in. x 5/8 in. elbow, fabricate a 5/8 in. tube,

connect to 5/8 in. x 1/2 in x 1/2 in tee and attach 1/2 in. preformed tube

and connect to evaporator 1/2 in. fitting in Zone 2. Solder all fittings.

4. Liquid Line - Fabricate a 1/2 in. liquid tube from host unit and route

in trough, install 1/2 in. x 1/2 in. elbow, fabricate a 1/2 in. tube, connect

to 1/2 in. a 3/8 in. x 3/8 in. tee, attach 3/8 in. preformed tubes and

connect to evaporator 3/8 in. fitting in Zone 2. Solder all fittings.



covered 100%.





A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 5/8 in. Elbow 552187

C 5/8 in. x 1/2 in. x 1/2 in. Tee 611044

D 1/2 in. x 1/2 Elbow 551483

E 1/2 in. x 3/8 in. x 3/8 in. Tee 611042



Liquid G42 G14

Hot Gas G42 N/A

Suction G58 G35

51

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


52

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

ZONE 2


soldering.

NOTE: Due to the difficultly in bending and forming 1-1/8 in. copper



evaporator.

1. Liquid Line - Fabricate 1/2 in. liquid tube from the host unit and route

in the trough:

• install 1/2 in. x 1/2 in. x 1/2 in. tee, fabricate a 1/2 in. tube and route

in the trough to Zone 3.

• from the 1/2 in. x 1/2 in. x 1/2 in. tee, fabricate a 1/2 in. tube, attach

to a 1/2 in. x 3/8 in. x 3/8 in. tee and 3/8 in. tube and connect to the

3/8 in. fitting of the 1st evaporator in Zone 2. Solder all fittings.

• from the 1/2 in. x 3/8 in. x 3/8 in. tee, fabricate a 3/8 in. tube and

connect to the 3/8 in. fitting of the 2nd evaporator in Zone 2. Solder

all fittings.

2. Suction Line ZONE 2 - Fabricate a 1-1/8 in. suction tube from the

host unit and route in the trough:

• install 1-1/8 in. x 7/8 in. x 7/8 in. tee, attach a 7/8 in. tube and


all fittings.

• from the 1-1/8 in. x 7/8 in. x 7/8 in. tee, install a 7/8 in. 90 degree

elbow, attach a 7/8 in. tube and connect to the 7/8 in. fitting of the

1st evaporator in Zone 2. Solder all fittings.

3. Suction Line ZONE 3 - Fabricate a 7/8 in. suction tube from the host

unit and route in the trough to the Zone 3.

4. Hot Gas - Fabricate a 5/8 in. hot gas tube from the host unit and route

in the trough:



• from the 5/8 in. x 5/8 in. x 5/8 in. tee, attach a 5/8 in. x 1/2 in. x 1/2

in. tee and 1/2 in. tube and connect it to the 1/2 in. fitting of the 1st

evaporator in Zone 2. Solder all fittings.

• From the 5/8 in. x 1/2 in. x 1/2 in. tee, attach a 1/2 in. tube and

connect it to the 1/2 in. fitting of the 2nd evaporator in




covered 100%.





A 1/2 in. x 1/2 in. x 1/2 in. Tee 552296

B 1/2 in. x 3/8 in. x 3/8 in. Tee 611042

C 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

D 7/8 in. x 90° Street Elbow 553325

E 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

F 5/8 in. x 1/2 in. x 1/2 in. Tee 611044



Liquid G42 G14

Hot Gas G42 N/A



53

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

ZONE 2

54

Evaporator Tube Connections S-3 (Configuration X Only)

ZONE 3


soldering.

1. Suction Line - Fabricate a 7/8 in. suction tube from the host unit and

route in the trough, install 7/8 in. x 7/8 in. elbow, attach 7/8 in.

preformed tube and connect to the evaporator 7/8 in. fitting in Zone 3.

Solder all fittings.

2. Liquid Line - Fabricate a 1/2 in. liquid tube from the 1/2 in. tee from

(Zone 2) evaporator unit, route in the trough, install 1/2 in. x 3/8 in.

elbow, attach 3/8 in. preformed tubes and connect to the evaporator 3/8

in. fitting in Zone 3. Solder all fittings.

3. Hot Gas - Fabricate a 5/8 in. hot gas tube from the 5/8 in. tee from

(Zone 2) evaporate unit, route in the trough, install 5/8 in. x 1/2 in.

elbow, attach 1/2 in. preformed tube and connect to the evaporator 1/2

in. fitting in Zone 3. Solder all fittings.



covered 100%.



NOTE: Ceiling trough shown, wall trough is similar.



A 7/8 in. x 7/8 in. Elbow 553326

B 1/2 in. x 3/8 in. Elbow 554142

C 5/8 in. x 1/2 in. Elbow 665733



Liquid G42 G14

Hot Gas G42 N/A


55

Evaporator Tube Connections S-3 (Configuration X Only)

ZONE 3

56

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

ZONE 2


soldering.



IMPORTANT: You must connect one suction line from the host to each

evaporator

1. Suction Line - Fabricate a 7/8 in. suction tube from the host unit and

route in the trough:

• install 7/8 in. x 7/8 in. elbow, attach a 7/8 in. tube and connect to the

7/8 in. fitting of the evaporator in Zone 2. Solder all fittings.


in the trough:




in. tee and 1/2 in. tube and connect it to the 1/2 in. fitting of the



in the trough:





3/8 in. fitting of the evaporator in Zone 2. Solder all fittings.



covered 100%.





A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

C 1/2 in. x 1/2 in. x 1/2 in. Tee 552296



Liquid G42 G14

Hot Gas G42 N/A


57


ZONE 2

58


ZONE 3


soldering.




evaporator.

1. Suction Line - Fabricate a 1-1/8 in. suction tube from the host unit

and route in the trough:

• install 1-1/8 in. x 7/8 in. x 7/8 in. tee, and use 7/8 in. elbows to

connect the 7/8 in. tubes to the 7/8 in. fittings of each evaporator in



in the trough:

• install 5/8 in. x 5/8 in. x 5/8 in. tee, and connect the 5/8 in. tubes to

the 5/8 in. fittings of each evaporator in Zone 3. Solder all fittings.


in the trough:


1/2 in. fittings of each evaporator in Zone 3. Solder all fittings.



covered 100%.





A 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

B 7/8 in. x 7/8 in. Elbow 553326

C 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

D 1/2 in. x 1/2 in. x 1/2 in. Tee 552296



Liquid G42 G14

Hot Gas G42 N/A



59


ZONE 3

60

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

ZONE 2


soldering.




evaporator.


in the trough:





3/8 in. fitting of the 1st evaporator in Zone 2. Solder all fittings.

• from the 1/2 in. x 3/8 in. x 3/8 in. tee, fabricate a 3/8 in. tube and

connect to the 3/8 in. fitting of the 2nd evaporator in Zone 2.Solder

all fittings.


host unit and route in the trough:

• install 1-1/8 in. x 7/8 in. x 7/8 in. tee, attach a 7/8 in. tube and


all fittings.

• from the 1-1/8 in. x 7/8 in. x 7/8 in. tee, install a 7/8 in. 90 degree

elbow, attach a 7/8 in. tube and connect to the 7/8 in. fitting of the

1st evaporator in Zone 2. Solder all fittings.


host unit and route in the trough to the Zone 3.


in the trough:




in. tee and 1/2 in. tube and connect it to the 1/2 in. fitting of the 1st


• From the 5/8 in. x 1/2 in. x 1/2 in. tee, attach a 1/2 in. tube and

connect it to the 1/2 in. fitting of the 2nd evaporator in Zone 2.

Solder all fittings.



covered 100%.





A 1/2 in. x 1/2 in. x 1/2 in. Tee 552296

B 1/2 in. x 3/8 in. x 3/8 in. Tee 611042

C 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

D 7/8 in. x 90° Street Elbow 553325

E 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

F 5/8 in. x 1/2 in. x 1/2 in. Tee 611044



Liquid G42 G14

Hot Gas G42 N/A



61


ZONE 2

62


ZONE 3


soldering.




evaporator.

1. Suction Line - Fabricate a 1-1/8 in. suction tube from the host unit

and route in the trough:

• install 1-1/8 in. x 7/8 in. x 7/8 in. tee, and use 7/8 in. elbows to

connect the 7/8 in. tubes to the 7/8 in. fittings of each evaporator in



in the trough:


the 5/8 in. fittings of each evaporator in Zone 3. Solder all fittings.


in the trough:


1/2 in. fittings of each evaporator in Zone 3. Solder all fittings.



covered 100%.





A 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

B 7/8 in. x 7/8 in. Elbow 553326

C 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

D 1/2 in. x 1/2 in. x 1/2 in. Tee 552296



Liquid G42 G14

Hot Gas G42 N/A



63


ZONE 3

64

SB Host & Evaporator Wire Connections - Zone 2

ZONE 2 - SINGLE EVAPORATORS1. Connect ZONE 2-Sensor Harness (1E33293) at host unit (Detail I).

• Route harness into evaporator and connect to mating three

connectors (Detail II).

• DO NOT CUT THE SENSOR HARNESS! Loop excess harness

back on its self and secure with cable ties (Detail III).

2. Connect ZONE 2-Control Harness (1E33290) at host unit (Detail I).

• Route harness into evaporator, cut to length, strip ends (DH2,

SLS2, LLS2, HGS2 and SC2), attach terminal connectors and

connect to terminal block (Detail IV).

3. Connect ZONE 2-Fan 1 Harness (1E33414) at host unit (Detail I).

• Route harness into evaporator, cut to length, strip ends (FM21 and

CH21), attach terminal connectors and connect to terminal block

and ground stud (Detail IV).

4. Connect ZONE 2-Fan 2 Harness (2C25318) at host unit (Detail I).


CH), attach terminal connectors and connect to terminal block and

ground stud (Detail IV).

S-3 EVAPORATORS ONLY5. Connect ZONE 2 -Fan 3 Harness (2C25319) at host unit (Detail I).




ZONE 2 - PARALLEL EVAPORATORS1. Connect ZONE 2-Sensor Harness (1E33293) at host unit (Detail I).

• Route harness into the first evaporator only and connect to mating

three connectors (Detail II).

NOTE: Although sensors are present in both evaporators, the harness is

connected to one evaporator only.




• Route harness into first evaporator, cut to length, strip ends (DH2,


connect to terminal block (Detail V).


• Route harness into first evaporator, cut to length, strip ends (FM21

and CH21), attach terminal connectors and connect to terminal

block and ground stud (Detail V).



and CH), attach terminal connectors and connect to terminal block

and ground stud (Detail V).





6. Interconnect Harness (1E39857) is used with both S-2 and S-3

evaporators.

• Route harness into the first evaporator and connect wires (HGS,

SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH and CH) to terminal

block and ground studs (Detail V).

• Route harness into the second evaporator and connect wires (HGS,

SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH and CH) to terminal

block and ground studs (Detail V).

7. Secure all harnesses with adequate clamps or ties.

65


66


ZONE 3 - SINGLE EVAPORATORS

1. Connect ZONE 3-Sensor Harness (1E33292) at host unit (Detail I).











CH31) attach terminal connectors and connect to terminal block

and ground stud (Detail IV).





S-3 EVAPORATORS ONLY

5. Connect ZONE 3 -Fan 3 Harness (2C25321) at host unit (Detail I).




ZONE 3 - PARALLEL EVAPORATORS1. Connect ZONE 3-Sensor Harness (1E33292) at host unit (Detail I).

• Route harness into the first evaporator only and connect to mating

three connectors (Detail II).

NOTE: Although sensors are present in both evaporators, the harness is

connected to one evaporator only.




• Route harness into the first evaporator, cut to length, strip ends

(DH3, SLS3, LLS3, HGS3 and SC3), attach terminal connectors

and connect to terminal block (Detail V).



and CH31) attach terminal connectors and connect to terminal

block and ground stud (Detail V).









6. Interconnect Harness (1E39857) is used with both S-2 and S-3

evaporators.

• Route wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH,

and CH) into first evaporator, cut to length, strip ends, attach

terminal connectors and connect to terminal block and ground stud

(Detail V).

• Route wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH,

and CH) into second evaporator, cut to length, strip ends, attach

terminal connectors and connect to terminal block and ground stud

(Detail V).


67


68

DE Host & Evaporator Wire Connections - Zone 3

ZONE 3 - SINGLE EVAPORATOR

1. Connect ZONE 3-Sensor Harness (1E37605) at host unit (Detail I).










• Route harness into evaporator, cut to length, strip ends

(FM31 and CH31) attach terminal connectors and connect to

terminal block and ground stud (Detail IV).





S-3 EVAPORATORS ONLY

5. Connect ZONE 3 -Fan 3 Harness (2C25321) at host unit (Detail I).





69

DE Host & Evaporator Wire Connections - Zone 3

70

Drain Hose Resistance Wire Installation Guide

All SPECTRUM Evaporators

IMPORTANT: The following information is provided as a guide to help

ensure the proper routing of the drain hose resistance wires. You should

supplement this guide with whatever other documentation is required for

your facility.


1. Remove the resistance wire from the evaporator drain tube and pull the

wire out straight.

2. Locate the evaporator defrost drain furthest from the trailer wall (i.e. in

the middle of the trailer), and measure 33.00 in. (838 mm) of the

resistance wire from the drain pan outlet (Detail I).

NOTE: 20.00 in. (508 mm) for S-2 evaporators.

3. Bend the resistance wire at this point and double it over (Detail II).

4. After doubling the resistance wire over (Step #3) take the excess wire

and insert it back into the evaporator drain tube (Detail III).

5. Insert the doubled over end of the resistance wire into the drain Tee or

90 degree connector (Detail IV) and then into the crossover drain tube

(Detail V).

NOTE: The use of either white or blue drain tubes is acceptable when

interconnecting multiple evaporators.

6. Attach the drain Tee or 90 degree connector to the evaporator drain

tube and push the connector on firmly to engage the O-ring (Detail VI).

7. Pull the resistance wire through the interconnecting drain tube as far as

possible and make sure it is not bunched up (Detail VII).

8. Insert the other resistance wire into the other drain Tee connector and as

shown (Detail VIII).

IMPORTANT: At no time should resistance wires from one side of the

drain pan overlap the resistance wires from the other side.

9. Attach the interconnecting drain tube to the opposite Tee connector by

pushing the Tee connector on firmly to engage the O-ring (Detail IX).

10. Attach the Tee connector to the evaporator drain tube by pushing the

Tee connector on firmly to engage the O-ring (Detail X).

11. Attach and route the evaporator drain tube over to the trailer wall drain.

Insert the resistance wire into the trailer wall drain and pull it as far

down the wall drain as possible (Detail XI).

IMPORTANT: Only one resistance wire should be installed in the

wall defrost drain tube. Only the resistance wire from the drain tube

closest to the wall should be installed in the trailer drain tube.

71



72

Drain Hose Installation


IMPORTANT: DO NOT CUT RESISTANCE WIRES!

NOTE: For proper drainage the drain hose must slope down

continuously from the evaporator to the wall drains with no kinks or

droop.

NOTE: See “Important Installation Notes” on pages 30- 33 and “Drain

Hose Resistance Wire Installation Guide” on pages 70- 71 for detailed

instructions on the proper installation procedures of the drain hose and

resistance wires.

NOTE: Make sure drain tubes are properly seated on tube fittings before

mounting to evaporator.

For S-2 and S-3 Applications

1. Route resistance wires from the evaporator through the plastic drain

hoses and insert the entire length of one resistance wire into each

wall drain tube (Detail I).

2. Connect the single drain hose to the wall drain tube using a short piece

of plastic drain hose and clamp as required (Detail I).

3. Replace drain t-fitting with elbow fitting. (Detail I).

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

4. Route resistance wires from the evaporator through the plastic drain

hoses and insert the entire length of one resistance wire into each

wall drain tubes (Detail II).

5. Connect each drain hose to each wall drain tube using a short piece of

plastic drain hose and clamps as required (Detail II).

For Wall Mounted Tube Applications (Detail III)

Insert the entire length of one resistance wire into each wall drain tube.

Connect the plastic drain hose from the evaporator.

For Wall Mounted Channel Applications (Detail IV)

Insert the entire length of one resistance wire into each plastic drain

hose. Feed the plastic drain hose down through the wall channel until it

exits the bottom of the trailer.

Optional Drain Hose Support (Detail V)

The use of the optional drain hose support bracket is recommended when

the evaporator is mounted sideways (transverse).

Front Drain Hose Applications (Detail VI)

Install drain t-fittings to allow drain tube to exit the front of the evaporator,

insert the entire length of one resistance wire into each drain hose, and

route hose out the front of the cover to the wall drain.

73

Drain Hose Installation


74

Leak Check, Evacuation and Charging Procedures

Set-up Unit

The SR-2 Multi-Temp microprocessor must be placed in the Evacuation

Test mode to evacuate and charge the unit. When the microprocessor is in

the Evacuation Test mode it opens all the normally closed solenoid valves

in the refrigeration system. This allows the refrigeration system to be

evacuated properly. Refer to the appropriate Diagnostic Manual for

complete information about the microprocessor. Use the following

procedure to set-up the unit and place the microprocessor in the Evacuation

Test mode:

1. Press the ON key to turn the unit on.

2. Before the unit starts, press the MENU key. The first screen in the

Main Menu (either the Language or Alarms Display) will appear.

3. Press the EXIT key and the unlabeled soft key at the same time, and

hold them down for 5 seconds to enter the Maintenance Menu. The first

Maintenance Menu feature will appear.

4. Press the NEXT (or BACK) key to scroll through the Maintenance

Menu features until the Evacuation Test mode appears.

5. Press the SELECT key to enter the Evacuation Test mode.

6. Connect a battery charger to the unit battery. The battery charge must

have an output of at least 15 amperes. This will maintain the charge

level of the battery during the time required to evacuate and charge the

unit. The Evacuation Test mode is used to open unit valves as required

for evacuation. Failure to connect a battery charger may result in the

battery voltage falling too low to reliably operate the microprocessor

and valves.

7. The microprocessor is now in the Evacuation Test mode. The

refrigeration system is set-up for leak checking, evacuation and

charging.

75


Leak Check SystemNOTE: Refer to Diagnosing Thermo King Refrigeration Systems

(TK-5984-10) for leak detection procedures.

1. Connect leak test gas (R-404A) supply to center hose of gauge

manifold.

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

3. Open suction and discharge valves and pressurize system to 25 psi with

leak test gas. Monitor system pressure for one minute.

4. If pressure drops rapidly, there is a large leak. Do not continue until

large leak is identified and corrected. If pressure does not change or

drops slowly, add enough leak test gas to raise system up to bottle

pressure.

5. Check connections made during installation for leaks using electronic

leak detector.

6. Recover test gas to repair leaks. System must be vented while repairing

solder joint leaks. Pressurize system and check again after a leak has

been repaired.

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

Evacuating the System

NOTE: The use of the Thermo King Evacuation Station (P/N 204-725 or

204-744) and Evacuation Station Operation and Field Application

Instruction (TK-40612-2) is required.

1. Be sure all refrigerant has been recovered from the unit.

2. Connect a vacuum pump and gauge manifold for three-point

evacuation to the suction service valve, discharge service valve, and

receiver tank outlet valve.

3. Verify proper operation of the Evacuation Station as shown in the

Evacuation Station Operation Manual (TK-40612).

4. Start the vacuum pump and mid-seat the suction service valve,

discharge service valve, and receiver tank outlet valve.

5. Install service valve stem caps with seals and tighten them. The valve

stems should remain capped while evacuating the unit.

6. Evacuate the unit to 500 microns, or the lowest achievable level

between 500 and 1,000 microns.

7. Continue to evacuate the unit for one additional hour after reaching 500

microns, or the lowest achievable level between 500 and 1,000

microns. This insures complete evacuation of the remote evaporators

and lines.

8. Close the Evacuation Station valve nearest the vacuum pump (V1) to

isolate the vacuum pump from the system. Turn the vacuum pump off.

9. Observe the micron gauge. The system pressure should remain below

2000 microns for 5 minutes. If the pressure does not hold, check for

leaks (if a leak is suspected) or continue evacuation (if system is not

dry).

10. Restart the vacuum pump, open the Evacuation Station valve nearest

the vacuum pump (V1) and repeat steps 6, 8, and 9 as required until

system pressure remains below 2000 microns for 5 minutes.

11. When system pressure remains below 2000 microns for 5 minutes,

restart the vacuum pump and open the Evacuation Station valve nearest

the vacuum pump (V1).

12. With the vacuum pump running, back seat the suction service valve.

Replace the valve cap, re-close the Evacuation Station valve nearest the

vacuum pump (V1), and stop the vacuum pump.

13. Close valve V4. The unit is ready to charge.

NOTE: Do not exercise the service valves with the unit in a deep vacuum

unless the vacuum pump is operating.

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

with less than full refrigerant charge should be leak checked and

all leaks must be repaired

76


Charging the SystemNOTE: The unit must be left in the Evacuation Test.

1. Insure that all compartment bulkheads are open. Ceiling mounted

bulkheads should not be stored close to the evaporator outlets as this

will restrict airflow.

2. Before charging system, make sure the refrigerant lines from the gauge

manifold to the refrigerant supply bottle have been evacuated or

purged, the suction service valve is back seated, and the discharge

service valve and receiver tank outlet valve are still open.

3. Set the refrigerant supply bottle for liquid. Open the gauge manifold

hand valve and add a partial charge of R-404A. Add 14 lb (6.4 kg) to a

unit with one remote evaporator. Add 15 lb (6.8 kg) to a unit with two

remote evaporators. Do not add more than this. The remainder of

charge will be added through suction service valve while unit is

running.

4. Close the gauge manifold hand valve.

5. Back seat (close) the receiver tank outlet valve and discharge service

valve.

6. Exit the Evacuation Test by turning the unit Off and then back On.

7. Turn all zones On and set all zone set points for the lowest possible

temperature to insure that all zones run in Cool mode. Allow the unit to

start.

8. Front seat the suction service valve and allow the compressor to pump

down to 1 to 3 psi (7 to 21 kPa). Stop the unit.

9. Remove the evacuation manifold hoses from the receiver tank outlet

valve, the discharge service valve, and the suction service valve.

Replace and tighten the service port and valve stem caps on the

receiver tank outlet valve.

10. Attach the gauge manifold (with the refrigerant supply bottle still

connected) to the compressor. Attach the low side gauge to the suction

service valve. Mid-seat the suction service valve. Attach the high

pressure gauge on to the discharge service valve. Open the discharge

service valve to monitor the discharge pressure.

11. Turn the unit On, turn all zones On (with all zone set points set to the

lowest possible temperature), and allow the unit to start.

12. Observe the suction pressure and slowly open the gauge manifold hand

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

Control the liquid flow so the suction pressure increases 20 to 25 psi

(138 to 172 kPa). Maintain a discharge pressure of 325 to 400 psi (2241

to 2758 kPa).

13. Add refrigerant until the ball in the receiver tank sight glass rises to the

middle of the sight glass, then close the gauge manifold hand valve.

Make sure the liquid level does not rise above the top of the sight glass.

14. Continue to operate the unit and monitor the sight glass until all

compartment temperatures are at or below 0 F (-18 C).

15. Check the position of the ball in the receiver tank sight glass. If the

liquid level has dropped, add liquid refrigerant until the level stabilizes

near the middle of the sight glass. Do not exceed the recommended

refrigerant charge for the unit model.

16. Close the hand valve on the refrigerant supply bottle.

17. Back seat the discharge service valve.

18. Open both hand valves on the gauge manifold.

19. Front seat the suction service valve and allow the compressor to pump

down to 1 to 3 psi (7 to 21 kPa). Stop the unit.

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

service port.

21. Remove the gauge line from the discharge service valve and cap the

service port.

22. Back seat the suction service valve and cap the valve stem.

23. Cap the valve stem on the discharge service valve.

24. Secure all the gauge lines to the gauge line anchors.

25. Record total unit charge on all serial plates.

77


A. V-4

B. V-3

C. V-2

D. V-1

E. Thermistor

F. Two Stage Vacuum Pump

G. To AC Power

H. Micron Gauge

I. Correct Refrigerant Level

78

Installing SPECTRUM Evaporator Covers

Installing Covers

1. Install FRONT COVER into support channel of evaporator.

Secure with screws.

2. Install BACK COVER into support lip of front cover.

Secure with screws.

79

Installing SPECTRUM Evaporator Covers

80

UNIT CHECK LIST

UNIT CHECK LIST

Visually inspect the unit for transit and handling damage. File claim

with delivery carrier.

Install the unit as outlined in the Thermo King Installation Manual.

If the unit has a separate fuel tank add 10 gallons of fuel to the tank.

BEFORE STARTING THE UNIT

Check battery and battery cable installation.

Inspect fuel line routing checking for rubbing, chaffing or laying on

hot surfaces.

Visually inspect the unit for the following: Loose or improperly

fitting bolts, brackets, hardware, hose connections and hose routing.

Inspect all wiring connections and routing.

Check defrost drain hoses and kazoos.

Check unit mounting hardware for tightness.

Check compressor and engine mounts.

Check compressor clutch if equipped.

Install refrigeration gauge manifold. (Multi-Temp units only)

Check engine oil level.

Check condenser and evaporator section for cleanliness and signs of

refrigerant leaks.

Check front bulkhead and air chute if equipped.

Check damper door, bushings and springs.

MULTI-TEMP UNITS (REMOTE EVAPORATORS)

Check evaporator(s) sections for cleanliness.

Leak test interconnecting tubing.

Check for damage, loose or missing bolts and hardware on remote

evaporator(s).

Check for proper installation of drain tubes, drain kazoos and drain

tube heater wires.

Check for properly routed refrigerant lines wiring harnesses for

remote evaporator(s). Check for properly routed harnesses for remote

controller.

Check for proper installation of remote evaporator guards if

equipped.

Check remote harness wiring plugs in the host evaporator.

Check wiring, connections, and terminals in the remote

evaporator(s).

Check compartment bulk head(s) for proper fit if equipped.

START AND RUN UNIT (ON MULTI-TEMP UNITS START ONLY THE HOST UNIT)

Check for proper oil pressure, coolant temperature, oil, fuel, or

coolant leaks.

Check alternator charge.

Cycle the unit and ensure the unit functions in the correct modes and

the mode indicators are working.

Set for continuous run with thermostat set point at 32 F (0 C) and run

the unit to 32 F (0 C).

81

UNIT CHECK LIST (continued)

Observe and record refrigerant operating pressures in relation to

ambient and box temperatures.

Verify the readings above are correct for the conditions.

When box reaches 32 F (0 C) check calibration of thermostat,

thermometer and data logger.

Run unit for 30 minutes at 32 F (0 C). During this period check for

correct cycling.

Reset thermostat to 50 F (10 C).

Check throttling valve while in the heat cycle.

Check operation of Modulation system if equipped.

For Single Temp units perform a controlled check of the refrigerant

level. For Multi-temps check the charge per multi-temp unit

procedures.

MULTI-TEMP UNITS

Install the compartment bulk head(s) if equipped.

Check for correct rotation of remote evaporator fans.

Check for correct cycling and operation of remote evaporator fans.

ALL UNITS

Initiate and check defrost operation and termination. Check operation

and adjustment of damper door and remote fans. Each zone on

multi-temps must be checked for proper operation.

Set the unit for Cycle Sentry Operation.

Check for proper operation of all door switches.

Remove the compartment bulk head(s) if equipped.

Set the unit for continuous run. Continue to run the unit with the back

doors open, alternating between high speed cool and heat until at

least 6 hours (10 hours preferred) are shown on the engine run time

hour meter to ensure complete break in of the engine, time for the

belts and other moving parts to take out the initial tension and

adjustment.

ELECTRIC STANDBY OPERATIONAL CHECKS

Test AC electrical contacts and connections by connecting to AC

power and running.

Check for correct electric motor rotation.

Cycle thermostat and check for correct modes of operation.

Power source not available to test AC.

STOP UNIT

On Multi-temp units leak test interconnecting tubing.

Check and readjust all belt tensions using TK belt gauge 204-427.

Check for oil, fuel, coolant, refrigerant and exhaust leaks.

Check engine oil and coolant level.

Check entire unit for loosened hardware and fittings.

Check and adjust all skin, door and panels for correct alignment and

operation.

Complete the commissioning registration process.

Release unit.


Providing equipment and services to manage controlled-temperature environments for food and other temperature-sensitive products, our Climate Control Technologies sector encompasses both transport and stationary refrigeration solutions. Our product brands include Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a manufacturer of refrigeration and food merchandising equipment.

www.thermoking.com www.hussmann.com www.ingersollrand.com

©2008 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

Trailer Edition (NAD) Multi-Temperature

SPECTRUMTM

Evaporator Systems (SR-2)TK 53509-2-IM (Rev. 5, 01/12)

installation manual - b

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