trailer edition sb-110, sb-200tg, sb-210 and sb-310 … · installation manual ... ©2004...

Installation Manual

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

©2004 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

Trailer Edition SB-110, SB-200TG, SB-210 and SB-310

Single Temperature Systems TK 52768-2-IM (Rev. 6, 02/13)

Installation Manual

Trailer EditionSB-110, -210 and SB-310 Single T ystemsTK 52768-2-IM (Re

t© 2004 Ther A. U.S.A.

CopyrighPrinted in

SB-200TG, SBemperature S

v. 6, 02/13)

mo King Corp., Minneapolis, MN, U.S.

2

rmation and additional battery specifications.

arding installing fuel tank under trailer.

forged connecting links and forged locking hooks

Release HistoryReleased (10/04)

Rev. 1 (11/04) Updated to new style bottom pan released by engineering.

Rev. 2 (04/05) Added optional remote controller and harness, new door switch info

Rev. 3 (02/06) 8 - Added DOT/Federal Highway Regulations information reg

Rev. 4 (01/07) Added SB-200TG to the manual.

Rev. 5 (01/10) Pages 60-61 - Added new heavy duty battery hold down bracket.

Rev. 6 (02/13) Pages 31, 33 and 35 - Changed art to show forged clevis and pins, used for lifting the unit.

3

ual for 10 Systems

Trailer Edition Installation ManSB-110, SB-200TG, SB-210 and SB-3

4

TG, SB-210 and SB-310 Single Temperature

ons warranties express or implied, with respect to ould not be regarded as all-inclusive or covering ent should be consulted.

, maintained, repaired or altered as, in the

erty damage or any other direct, indirect, any information, recommendations or

Introduction

Installation Manual-A was written to assist with the installation of the Thermo King SB-110, SB-200refrigeration systems onto trailers 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.)

• Are certified or trained in the repair and maintenance of diesel powered refrigeration systems

• Have a basic understanding of electricity and electrical wiring

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

This manual is published for informational purposes only. Thermo King makes no representatithe information recommendations and descriptions contained herein. Information provided shall contingencies. If further information is required, Thermo King Corporation Service Departm

Thermo King’s warranty shall not apply to any equipment which has been “so installedmanufacturer’s judgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, propspecial, or consequential damages whatsoever, arising out of the use of this manual ordescriptions contained herein.

5

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Trailer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Evaporator Opening Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Mounting Bolt Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Bulkhead Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Status Light Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Rear Remote Controller Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . 26

Door Switch Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Lifting Bar Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Installing the Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Installing the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Installing the Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Installing the Status Light Kit (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Installing the Rear Remote Controller (Option) . . . . . . . . . . . . . . . . . . . . . . 44

Installing the Door Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

CargoWatch Sensor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Connecting the CargoWatch Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Connecting the DAS Sensors - SB-200TG ONLY . . . . . . . . . . . . . . . . . . . . . 56

Installing the Bulkhead Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Installing the Bottom Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

SYSTEM CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6

rtant:

red,

red,

red,

our hands away from fans and belts unning. This should also be considered closing the compressor service valves.

sure gauge manifold hoses are in good et them come in contact with a belt, fan ny hot surface.

sure all mounting bolts are tight and are or their particular application

drill holes in the unit unless absolutely drilled into the unit may weaken ents. Holes drilled into electrical wiring

explosion.

using ladders to install or service ms, always observe the ladder fety labels and warnings. A work ommended method for installations.

ed coil fins are very sharp and can cause s.

Safety Precautions

The symbol appears next to a point that is particularly impo

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

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

CAUTION: Addresses a circumstance that, if encountemay 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 ywhen the unit is rwhen opening and

WARNING: Make condition. Never lmotor pulley, or a

WARNING: Make of correct length f

WARNING: Nevernecessary. Holes structural componcan cause fire or

WARNING: When refrigeration systemanufacturer’s saplatform is the rec

WARNING: Expospainful laceration

7

ed)

il

contact, immediately flush with plenty of water . CALL A PHYSICIAN. Wash skin with soap and

id refrigeration oil contact with the eyes. d or repeated contact of refrigeration oil thing. Wash thoroughly after handling l to prevent irritation.

Safety Precautions (continu

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 O

First Aid

NOTE: In case of eye for at least 15 minuteswater.

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: AvoAvoid prolongewith skin or clorefrigeration oi

8

Required Tools

1. Safety Glasses

2. Drill

3. Drill Bits

4. Tape Measure

5. Mechanics Tools

6. Lifting Bar

7. Work Platform (Recommended)

8. Torque Wrench

9. Forged Eyebolts

10. Deutsch Wedge Remover (P/N 204-799)

11. Deutsch Pin Remover (P/N 204-737)

12. Deutsch Terminal Crimper (P/N 204-1038)

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.

9

Required Tools

10

Installation Components

1. Locking Nuts

2. Washers

3. Self Tapping Screws

4. Clamps

5. Cable Ties

6. Fuel Line Hose

1/4 in.

3/8 in.

7. Fuel Line Fittings

1/4 in.

3/8 in.

8. Fuel Line Connector

9. Drain Hose Check Valve

10. Bulkhead (option)

11. Deutsch 6-Pin Connector, Wedge and Terminal Pins

12. Crimp/Solder Butt Connectors and Heat Shrink Tubing

11

Installation Components

12

kg (1635 lbs.)

e refrigeration unit!

ast 1025 mm (40.354 in.) or severe damage to the

520 in.) or severe damage to the equipment will

Trailer Requirements

Approximate WeightSB-110, SB-200TG, SB-210 and SB-310 = 741

DANGER: The front trailer must be structurally strong enough to support the weight of th

CAUTION: The minimum distance from the king pin to the front of the trailer must be at leequipment will result. VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!

CAUTION: The minimum clearance required for the swing radius must be 1664.2 mm (65.result. VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!

13

Trailer Requirements

14

sions
Evaporator Opening Dimen
Evaporator Opening

The location of the unit mounting bolts and evaporator opening in the front wall is critical.VERIFY ALL DIMENSIONS BEFORE INSTALLING UNIT!

NOTE: It may be necessary to relocate the front corner clearance lights to the corner radius of the trailer to prevent damage.

1. The evaporator opening must be square. The diagonal measurements must be ±3.0 mm (0.12 in.)

2. The gasket surface around the opening must be at least 76.2 mm (3.00 in.) wide, be flat ±3.2 mm (0.05 in.) and free of rivets, seams or bolt heads.

DANGER: The front trailer wall must be structurally strong enough to support the weight of the refrigeration unit!

15

ions
Evaporator Opening Dimens

16

ns

lt Specifications

.75 pitch class 8.8 (1/2 in.-13 UNC - 28 Rolled thread rbon steel bolts and locking nuts. All hardware must ichromate finish.

e use of mounting bolts other than those uld result in severe damage to equipment, void or cause personal injury or death!

Mounting Bolt Dimensio

Mounting Bolts

NOTE: The location of the unit mounting bolts in the trailer front wall is critical to proper unit installation.

All mounting bolts must be square with the front wall and securely fastened to the trailer wall in such a manner to allow the mounting nuts be torqued to 82 N•m (60 ft. lbs.) from outside the trailer.

• Mounting bolts are to extend a minimum 57.20 mm (2.25 in.) and a maximum of 63.50 mm (2.50 in.) beyond the front wall.

• Surface of all mounting bolts are to be flat within 2.50 mm (0.10 in.).

Mounting Bo

Use Metric M12 x 1grade 5), medium cabe zinc plated with d

DANGER: Eight mounting bolts must be installed to properly secure the unit to the trailer front wall! Failure to do so could result in severe damage to equipment, void the warranty or cause personal injury or death!

DANGER: Thspecified cothe warranty

17

s
Mounting Bolt Dimension

18

Unit Dimensions

I. Front View

II. Side View

III. Top View

19

Unit Dimensions

20

tion)

ULKHEADo King Dealers.

Shown (Dimensions are approximate)

Bulkhead Dimensions (Op

THERMO KING RECOMMENDS USING A BBulkheads are available from authorized Therm

Return AirflowRestrictions of the return airflow adversely affects the performance of the unit. The area directly behind the evaporator return air inlet must not be restricted.

Bulkhead FunctionA bulkhead is used to keep the return airflow from being restricted if the load shifts. The bulkhead also prevents the load from shifting into the return airflow passageway on the front wall of the trailer.

Typical Bulkhead

I. Front View

II. Side View

21

ion)
Bulkhead Dimensions (Opt

22

ttery Selection and Maintenance.

gned for one 12 volt, Group 31 battery supplied by the

suitable for deep cycling, heavy duty and rated with a /hr.

g table for Thermo King approved batteries. lletin T&T 446 for more information regarding nd Maintenance.

CA Dry Cell (AGM)o King EON

03-550 Threaded Stud03-551 SAE Post

Cell (AGM) Technologyter suited for all applicationsh cranking power at lower bient temperaturested for extreme temperaturest for high cycling applications cle-Sentry use) year expected life

perating environment and the atures and frequent discharges uirements.

Battery Dimensions

Refer to Service Bulletin T&T 446 for more information regarding Ba

IMPORTANT: The specified battery, electrical wiring and electronic controls were designed to operate and maintain only the Thermo King refrigeration system and factory authorized Thermo King options.

Trailer units are desiinstaller.

The battery must be minimum of 95 amp

NOTE: See followinRefer to Service BuBattery Selection a

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!

BATTERY APPLICATION TABLE

750 CCA Wet CellThermo King ReliaMax 750SP/N 203-731 Threaded StudP/N 203-730 SAE Post

925 CCA Wet CellThermo King ReliaMax 925NP/N 203-733 Threaded StudP/N 203-732 SAE Post

1150 CThermP/N 2P/N 2

• Wet Cell Technology • Better suited for warmer climates• Less cranking power at low

ambient temperatures• 18-24 month expected life *see

note below• Choose for southern climates

• Wet Cell Technology • Better suited for colder climates• High cranking power at low

ambient temperatures• 18-24 month expected life *see

note below• Choose for northern climates

• Dry• Bet• Hig

am• Sui• Bes

(Cy• 5-7

* NOTE: Wet cell battery life and maintenance requirements are determined by the ocharge/discharge rate (cycles) while the battery is in service. Higher ambient temperwill shorten a wet cell battery’s overall life expectancy and increase maintenance req

23

Battery Dimensions

24

ption)
Status Light Dimensions (O
I. Front View

II. Side View

25

tion)
Status Light Dimensions (Op

26

ns (Option)
Rear Remote Controller Dimensio
I. Front View

II. End View

III. Side View

27

ns (Option)
Rear Remote Controller Dimensio

28

ption)
Door Switch Dimensions (O
I. Front View

II. Side View

29

tion)

II

I

Door Switch Dimensions (Op

II

30

saterial: 76.2 mm (3.00 in.) x 12.7 mm (0.50 in.) mild

links and hooks, clevis and pins with strength equal to of hoist mechanism and meet all safety standards.

maximum strength and safety.

d Pins

ng Links

Hooks

Lifting Bar DimensionI. Recommended m

steel.

II. Use forged chaintotal lift capacity

III. Bolt together for

1. Forged Clevis an

2. Forged Connecti

3. Forged Locking

WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided.

WARNING: All hardware used to assemble the lifting bar must be DIN 931 class 10.9 (SAE grade 8). The use of hardware other than specified may cause personal injury, severe damage to the evaporator and void the warranty.

WARNING: The lifting bar and lifting device combined must be able to support minimum weight of 1360.8 kilos (1 1/2 tons).

31

Lifting Bar Dimensions

32

e Unite plastic stretch wrap from unit.

e the top cardboard cover.

e the outer cardboard wrap.

ion kit boxes, bottom panel, and any other loose rear of unit.

ebolts and 3 point lifting bar to unit.

re holding unit to wooden pallet.

y for installation.

Unpacking the Unit

Units are shipped attached to disposable wooden pallet and wrapped with protective cardboard and plastic stretch wrap.

NOTE: To avoid unnecessary damage to your unit, place the crated unit near the trailer prior to its removal.

IMPORTANT: DO NOT use a sharp knife to remove the stretch wrap or cardboard wrap as damage to the exterior of the unit will result!

Unpacking th• Carefully remov

• Carefully remov

• Carefully remov

• Remove installatcomponents from

• Attach forged ey

• Remove hardwa

• Unit is now read

DANGER: Do not use a forklift to install the unit! This could result in severe damage to the equipment, void the warranty or cause personal injury or death!

WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided (see Lifting Bar Dimensions).

33

Unpacking the Unit

34

on1 forged lifting eyebolts into threaded holes located on it (Detail I).

r to lift unit up to the trailer opening.

t hold the unit to the trailer should be elastic stop provided in the installation kit.

d elastic stop nuts provided in the installation kit. (60 ft. lbs.).

Installing the Unit

Access to Mounting Holes (Detail II)1. Top side mounting hole through the hinged roadside grille.

2. Center side mounting hole through hinged roadside grille.

3. Lower side mounting hole through hinged roadside panel, and control box hole.

4. Center side mounting hole through hinged lower curbside door.

5. Lower side mounting hole through hinged curbside panel.

6. Center side mounting hole through hinged curbside grille.

7. Top side mounting hole through hinged curbside grille.

8. Top center mounting hole from top of the unit.

Unit Installati9. Install two 5/8-1

the top of the un

10. Use the lifting ba

NOTE: All nuts thanuts (Nylock Type)

11. Attach washer anTorque to 82 N•m

WARNING: Do not use a forklift to install the unit! This could result in severe damage to equipment, void the warranty or cause personal injury or death!

WARNING: Use only locking hooks to safely lift the unit! Failure to use locking hooks could result in severe damage to the equipment, void the warranty or cause personal injury or death! (Detail I).

WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided (see Lifting Bar Dimensions).

35

Installing the Unit

36

es
Installing the Drain Hos
1. Drain Hoses should run straight down the trailer wall from the unit with no kinks or bends.

2. Secure with screws and clamps provided in installation kit.

3. Cut off excess hose and attach drain hose check valves provided in installation kit.

37

s
Installing the Drain Hose

38

k

mendations

el must be used with every tank installation.

wing shows a typical installation with 304.8 mm smember spacing. For other crossmember to TK drawing 5937C22.

rdware to 81 - 88 N•m (60 - 65 ft/lb).

rdware to 48 N•m (35 ft/lb).

ping hardware to 48 N•m (35 ft/lb).

from fuel tank, through conduit and connect to unit. .6 mm (24.0 in.).

ommends the fuel tank be mounted 203.2 mm of the trailer frame. Otherwise, the OEM or installer is sure the fuel tank position meets or exceeds DOT or regulations, when applicable.

228.6 mm (9.00 in.) from center line of trailer.

Installing the Fuel Tan

NOTE: Thermo King supplies the Fuel Tank, Fuel Tank Hangers, Fuel Tank Channels and Fuel Tank Straps. Due to differences in trailer manufacturers, additional support channels may be required to safely support the overall weight of the fuel tank components including the full capacity of diesel fuel. Consult your trailer manufacturer for specific details on proper fuel tank installation and recommendations.

Installation Recom

1. Fuel Tank Chann

NOTE: This dra(12.00 in.) crosspacing, refer

2. Torque 1/2 in. ha

3. Torque 3/8 in. ha

4. Torque band clam

5. Route fuel lines Clamp every 609

6. Thermo King rec(8.00 in.) inside responsible to enFederal Highway

7. Position fuel line

DANGER: An improperly installed fuel tank could lead to serious injury or death! Consult your trailer manufacturer for specific details on proper fuel tank installation and recommendations.

39

Installing the Fuel Tank

40

s

ly line from the unit to the fuel pump to the fuel pickup Install fuel line connector (provided in installation kit), ne at a 45 degree angle and insert into fuel pickup tube m (1.00 in.) from bottom of tank and tighten securely

n line from the unit to the fuel tank return fitting. onnectors and tighten securely.

ap from the fuel vent and point the outlet to the rear of

ient amount of fuel (1/4 tank) to allow the unit to rs during engine break-in and pre-delivery

Installing the Fuel Line

1. Install the fuel line bracket to the pre-drilled hole in the frame. This hole is located in the frame under the compressor (Detail I).

2. Fuel lines should be routed in a protective housing with no kinks or sharp bends (Detail II).

3. Rubber grommets must be used when routing fuel lines through holes in metal (Detail III).

4. Secure all fuel lines with provided clamps (Detail III).

5. Route fuel suppon the fuel tank. cut end of fuel liuntil it is 25.4 m(Detail IV).

6. Route fuel returAttach fuel line c

7. Remove plastic cthe trailer.

NOTE: Add a sufficrun for 8 to 12 houprocedures.

DANGER: Leaking fuel lines could cause a fire resulting in death or serious injury! All fuel line fittings must be tight and leak free!

DANGER: Do not route fuel lines with battery cables or electrical wires, as this could cause a fire!

41

Installing the Fuel Lines

42

(Option)
Installing the Status Light Kit
1. Mount the Status Light in a location so that is visible in the tractor mirror to the driver. Mount securely with the provided screws.

2. Route harness as shown allowing a “drip-loop” to prevent water from migrating into the Status Light.

3. Secure harness with clamps.

4. Connect to matching connector located behind the battery box and to the left of the control box.

43

Option)
Installing the Status Light Kit (

44

ller (Option)

outing (Steps 3-10)

tive routing of the electrical harness chase and s from the side of the controller box.

ate size hole in the controller box for the harness chase

ase coupling.

ould not protrude more than 6.4 mm (0.25 in.) r box.

tom of controller box before foaming trailer wall.

o controller box and install securely into trailer wall.

(or equivalent) to interface harness connector and o back of controller. Route interface harness through ntroller to controller box with screws.

interface harness from controller to host unit. Secure

rness and strip wire ends. Crimp onto existing splice nk covering.

(or equivalent) and secure connect remote interface r to evaporator harness connector.

.)

in.)

Installing the Rear Remote Contro

Foamed-In-Place InstallationNOTE: Verify mounting location and all dimensions before installing the remote controller.

Preferred Wire Routing (Steps 1,2, 6-10)

NOTE: The preferred routing of the electrical harness chase and interface harness is from the bottom of the controller box.

1. Connect the harness chase to the bottom of controller while providing a drip loop.

2. Install and route a 1/2 in. CPVC drain hose from the bottom of the controller box out of trailer floor.

Alternative Wire R

NOTE: The alternainterface harness i

3. Drill an appropricoupling.

4. Install harness ch

NOTE: Coupling shinside the controlle

5. Install cap in bot

6. Apply chalking t

7. Apply Superlubeattach securely tchase. Secure co

8. Route chase andwith clamps.

9. Cut off excess haand use heat shri

10. Apply Superlubeharness connecto

A. 69.8 mm (2.75 in

B. 196.8 mm (7.75

DANGER: Do not route electrical harness together with fuel lines as this could cause a fire resulting in death or serious injury!

CAUTION: Do not drill holes into refrigeration, electrical or mechanical components or severe damage to the equipment will result!

45

ler (Option)
Installing the Rear Remote Control

46

er (Option)

ote controller with interface connector harness, ase and forward to unit.

railer through chase in floor or I-beam cross unit.

r, measure and drill an appropriate size hole and nto the trailer towards the unit.

backside of the unit with clamps.

harness required to connect to host unit nnector, cut off excess harness and strip wire ting splice and use heat shrink covering.

remote interface harness to the evaporator harness

5 in.)

Installing the Rear Remote Controll

Retro-Fit InstallationNOTE: Verify mounting location and all dimensions before installing the remote controller.

1. Cut opening in trailer wall per dimensions shown.

2. Install and route a 1/2 in. CPVC drain hose and 0.88 O.D. harness chase from the bottom of the controller box out of the trailer.

3. Apply caulking to controller box and install securely in trailer wall.

NOTE: Make sure the drain hose and harness chase are connected properly.

4. Apply caulking to remroute harness down ch

5. Route harness under tmembers towards the

6. From inside the traileroute the harness up i

7. Secure harness to the

8. Measure the length ofevaporator harness coends. Crimp into exis

9. Securely connect the connector.

A. 203 mm (8.0 in.)

B. 107.9 mm (4.25 in.)

C. 38 x 12.7 mm (1.5 x .

DANGER: Do not route electrical harness together with fuel lines as this could cause a fire resulting in death or serious injury!


CAUTION: Rubber grommets must be used when routing electrical harnesses through metal holes!

47

r (Option)
Installing the Rear Remote Controlle

48

tion) installation. Your installation may be different .

maximum gap of 19 mm (0.75 in.) is maintained itch and the magnet. Shims may be required and tic material (aluminum, wood, plastic, etc.) or the

operate properly.

nted ush with the top edge of the door and secure with

ount the switch to the door sill parallel with the e “cross hairs” are aligned and that the maximum n.) is maintained.

ted ush with the bottom edge of the door and secure re.

ount the switch to the floor parallel with the e “cross hairs” are aligned and that the maximum n.) is maintained.

or Installation

ush with the top edge of the door and secure with

ount the switch to the door sill parallel with the e “cross hairs” are aligned and that the maximum n.) is maintained

Installing the Door Switch (OpNOTE: These instructions are intended as reference guide only to assist with a typical door switchdepending on the trailer, the amount and types of doors and the customers particular requirements

Door Switch ComponentsThe door switch consists of a magnet, a switch, non-magnetic mounting hardware and a interface harness to connect to the host unit.

• The magnet is always mounted on the door.

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

• Two short interface harnesses are available depending on your particular kit. One allows a single door switch in a single zone to activate a unit shutdown. The other allows two door switches in the same zone to each activate a unit shutdown.

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 interface harness to the door switch per the table below. The harness should be 18 AWG or better, 3 wires, color coded RED, BLACK and WHITE.

Mounting LocationsThe 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 between the door swmust be a non-magnedoor switch will not

(Detail A) Ceiling Mou1. Mount the magnet fl

supplied hardware.

2. Close the door and mmagnet, being sure thgap of 19 mm (0.75 i

(Detail B) Floor Moun1. Mount the magnet fl

with supplied hardwa


(Detail C) Outside Do

1. Mount the magnet flsupplied hardware.


Interface Harness Wiring Door Switch Wiring

RED = (12 Vdc) POWER RED = (12 Vdc) POWER

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

WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT

49

ption)
Installing the Door Switch (O
Right Angle Mounting

Top x Top Mounting

Side x Side Mounting

50

ption)

ear of the host unit.

itch Activation / Single Zone (Detail B)

ace harness (1E30238) to matching door switch 1, 2 or 3) located at the rear of the host unit.

arness (Installer Supplied) from the interface harness tch in that zone - Maximum Two Doors. Connect er the table below (RED/RED, WHITE/WHITE,

K) to each door switch using splice connectors. Crimp s securely and apply heat with a heat gun.

ould be installed, routed and properly secured to age.

verify door switch operation.

rness Wiring Door Switch Wiring

2 Vdc) POWER RED = (12 Vdc) POWER

H) GROUND BLACK = (CH) GROUND

S) OUTPUT WHITE = (DS) OUTPUT


NOTE: The Door Switch Harness Connectors are located at the r

Single Door Switch Activation / Single Zone (Detail A)

1. Attach the interface harness (1E29281) to matching door switch connector (Zone 1, 2 or 3) located at the rear of the host unit.

2. Route a 3 wire harness (INSTALLER SUPPLIED) from the interface harness to a single door switch. Connect matching wires per the table below (RED/RED, WHITE/WHITE, BLACK/BLACK) to each door switch using splice connectors. Crimp splice connectors securely and apply heat with a heat gun.

3. All harnesses should be installed, routed and properly secured to protect from damage.

Multiple Door Sw

4. Attach the interfconnector (Zone

5. Route a 3 wire hto each door swimatching wires pBLACK/BLACsplice connector

6. All harnesses shprotect from dam

7. Operate unit and





Interface Ha

RED = (1

BLACK = (C

WHITE = (D

51

ption)








52

tions

ns

tions

mer.

CargoWatch Sensor Loca

Sensor Location Recommendatio

European Applications

Each cargo area requires a minimum of two sensors.

1. Sensor #1 located in the evaporator side return opening near unit return air sensor (factory installed).

2. Sensor #2 located in the roof area 66% to 75% of the full length of the cargo area (determined by installer).

Domestic Applica

As required by custo

53

ons
CargoWatch Sensor Locati

54

Sensors

in connector and wire into correct connection until it n (Detail I). The wire side of the connector is shown.

end (3) back onto connector (2), apply a light coating lectrical connections and plug sensor back into mating Sensor Interconnect Harness (1).

sor Interconnect Harness to the sensor using the splice p splice connectors securely and apply heat with a

ith appropriate clamps.

SENSOR PLUGS

1 Black into #12

2 Black into #11

3 Black into #10

4 Black into #9

5 Black into #8

6 Black into #7

Connecting the CargoWatch

CONNECTING SENSORS

1. Locate the Sensor Interconnect Harness behind the evaporator access panel.

2. Unplug the connector from the harness.

3. Removes orange end from connector.

4. Remove only the plugs from the connector holes for the sensors you are connecting. Unused holes must remain plugged.

5. Insert WHITE pin connector and wire into correct connection until it locks into position (Detail I). The wire side of the connector is shown.

6. Insert BLACK plocks into positio

Reinstall orangeof Superlube to econnector on the

7. Connect the Senconnectors. Crimheat gun.

8. Secure sensor w

SENSOR PLUGS

1 #1 and #12

2 #2 and #11

3 #3 and #10

4 #4 and #9

5 #5 and #8

6 #6 and #7

SENSOR PLUGS

1 White into #1

2 White into #2

3 White into #3

4 White into #4

5 White into #5

6 White into #6

55

ensors
Connecting the CargoWatch S

56

-200TG ONLY

NEG-) pin connector and wire into correct connection position (Detail I). The wire side of the connector is

end (3) back onto connector (2), apply a light coating lectrical connections and plug sensor back into mating Sensor Interconnect Harness (1).

ting of Superlube to electrical connections and plug correct mating connector.

ppropriate clamps.

ge

5 White into #5

6 White into #6

SENSOR PLUGS

1 Black into #12

2 Black into #11

3 Black into #10

4 Black into #9

5 Black into #8

6 Black into #7

SENSOR PLUGS

Connecting the DAS Sensors - SB

CONNECTING SENSORS

NOTE: All sensor harness wires are coded WHITE (POS+) and BLACK (NEG-). Each sensor must be connected correctly or the DAS will not function correctly.

1. Locate the Sensor Interconnect Harness behind the evaporator access panel.

2. Unplug the connector from the harness.

3. Carefully remove orange end from connector.

4. Remove only the plugs from the connector holes for the sensors you are connecting. Unused holes must remain plugged.

1. Insert WHITE (POS+) pin connector and wire into correct connection until it locks into position (Detail I). The wire side of the connector is shown.

2. Insert BLACK (until it locks intoshown.

Reinstall orangeof Superlube to econnector on the

3. Apply a light coaeach sensor into

Secure sensor with a

A = Terminal Pin

B = Connector Body

C = Sealing Boot

D = Connector Wed

SENSOR PLUGS

1 #1 and #12

2 #2 and #11

3 #3 and #10

4 #4 and #9

5 #5 and #8

6 #6 and #7

SENSOR PLUGS

1 White into #1

2 White into #2

3 White into #3

4 White into #4

57

00TG ONLY
Connecting the DAS Sensors - SB-2

58

ption)

ULKHEADo King dealers.

tiono keep the return airflow from being restricted if the head also prevents the load from shifting into the eway on the front wall of the trailer.

ad Shownnufacturer specific details for proper installation and

Installing the Bulkhead (O

THERMO KING RECOMMENDS USING A BBulkheads are available from authorized Therm

Return AirflowRestrictions of the return airflow adversely affects the performance of the unit. The area directly behind the evaporator return air inlet must not be restricted.

Bulkhead FuncA bulkhead is used tload shifts. The bulkreturn airflow passag

Typical BulkheFollow bulkhead marecommendations.


59

tion)
Installing the Bulkhead (Op

60

vy Duty Battery Hold Down

y into the tray.

hold down bracket and rods. Loosely install hardware

old down rods must fit into the notch located on the battery. You may have to move the electrical access this notch.

the battery hold down bracket over the two existing e support channel.

rior to March 2010 will require the two existing support channel be drilled completely through the 66 dia. (H) drill bit.

ounting bolts and flat washers through the hold down ort channel. Install the flat washers and locking nuts are to 13.5 N•m (120 in-lbs).

battery hold down rods to 2.25 N•m (20 in -lbs.)ghten as this may crack or distort the battery!

battery cable on the positive battery post first to ntal electrical shorting.

battery cable on negative battery post second to ntal electrical shorting.

Installing the Battery

Standard Battery Hold Down Bracket1. Install battery into the tray and secure with hold down bracket and rods.

Tighten the two battery hold down rods to 2.25 N•m (20 in -lbs.) DO NOT over tighten as this may crack or distort the battery!

NOTE: One of the hold down rods must fit into the notch located on the channel under the battery. You may have to move the electrical harness slightly to access this notch.

2. Install positive + battery cable on the positive battery post first to minimize accidental electrical shorting.

3. Install negative - battery cable on negative battery post second to minimize accidental electrical shorting.

Optional HeaBracket1. Install the batter

2. Install the batteryonto the rods.

NOTE: One of the hthe channel under harness slightly to

3. Align the tab of holes in the fram

NOTE: Units built pholes in the frame channel using a 0.2

4. Install the two mbracket and suppand torque hardw

5. Tighten the two DO NOT over ti

6. Install positive +minimize accide

7. Install negative -minimize accide

CAUTION: Set all electrical controls to the OFF position before connecting the battery to prevent the unit from starting!

CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries!

CAUTION: Cover battery terminals to prevent accidental shorting during battery installation!

61

Optional ttery Hold Down Bracket

Installing the BatteryStandard

Battery Hold Down Bracket Heavy Duty Ba

62

an

e stainless steel mounting hardware.

its Only Bolts - Position the bottom pan under the unit by holes in the rear of the bottom pan with the four holes frame.

er the unit, secure the rear of the bottom pan with the 20 x 1.00'' torx head screws, 1/4'' lock washers and meter flat washers supplied in the installation kit.

Bolts - Open the center curbside and roadside doors tom pan front mounting tabs.

er the unit, secure the front of the bottom pan by the four 1/4-20 x 1.00'' torx head screws and 1/4'' flat upplied in the installation kit into the mounting holes.

inside the unit, install the four 1/4'' flat washers, 1/4'' hers and 1/4'' nuts supplied in the installation kit.

mounting bolts to 30 in-lb.

doors.

Installing the Bottom P

NOTE: It is recommended that a anti-seize lubricant be applied to the threads of th

SB-110, SB-210 and SB-310 Units1. Remove the four 1/4-20 x .75 screws, lock washers and flat washers

attached to the front of the bottom pan. These will be re-installed in Step #3.

2. Rear Mounting Bolts - Position the bottom pan under the unit and align the four holes in the rear of the bottom pan with the four holes in the rear of the frame.

• From under the unit, secure the rear of the bottom pan with the four 1/4-20 x 1.00'' torx head screws, 1/4” lock washers and 1.00'' diameter flat washers supplied in the installation kit.

3. Front Mounting Bolts - Open the center curbside and roadside doors to access the bottom pan front mounting tabs.

• From inside the unit, secure the bottom pan with the four1/4-20 x .75'' screws, lock washers and flat washers removed in step #1.

4. Torque all eight mounting bolts to 30 in-lb.

5. Close and secure doors.

SB-200TG Un1. Rear Mounting

aligning the fourin the rear of the

• From undfour 1/4-1.00'' dia

2. Front Mountingto access the bot

• From undinsertingwashers s

• Then fromlock was

3. Torque all eight

4. Close and secure

63

n-200TG Units Only

Installing the Bottom PaSB-110, SB-210 and SB-310 Units SB

64

d correctly and all connections clean and tight.

guards and bottom pan installed securely.

est (refer to Host Unit Operating Manual).

r load for eight hours to properly break-in engine.

tomer.

SYSTEM CHECK LIST

All unit mounting hardware torqued to specifications.

No air gaps between unit and trailer wall.

Drain hoses properly routed and secured.

Fuel tank properly installed.

Fuel lines properly routed and fuel fittings tightened securely.

Bulkhead properly designed and installed.

Battery secure

Doors, covers,

Run Pre-Trip t

Run unit unde

Release to cus

65

lems after installation, check the items listed below

CURE

urn unit switch “ON”lean and tighten connectionsecharge or replace battery

dd fuel to tankheck fuel line routingheck connectionsleed air from fuel lines

leed air from fuel linesheck fuel lines for kinks

ecure doorsecure grillesecure guards and covers

heck for bulkhead blocking air return inletheck for pinched or kinked drain hosesheck installation of sill gasket

Troubleshooting Guide

.

All Thermo King refrigeration units are pre-tested at the factory prior to shipping. If your unit has probfirst. If further assistance is required, consult your Thermo King dealer

SYMPTOM CAUSE

No display on control panel No power to unitBad battery connectionLow voltage

TCR

Diesel engine cranks over but will not start No fuelKinked/pinched fuel linesFuel lines connected wrong at tank or unitAir in fuel lines

ACCB

Diesel engine starts but lacks power Air in fuel linesLow fuel pressure

BC

Rattling noise from unit when running Loose component SSS

Ice buildup on evaporator coil Evaporator coil restriction

Air leakage into trailer

CCC

Installation Manual

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

©2004 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

Trailer Edition SB-110, SB-200TG, SB-210 and SB-310

Single Temperature Systems TK 52768-2-IM (Rev. 6, 02/13)

trailer edition sb-110, sb-200tg, sb-210 and sb-310 … · installation manual ... ©2004...

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