TK 53542-2-IM (Rev. 7, 06/12) Trailer Edition SPECTRUMTM DE SR-2 Multi-Temperature Systems Installation Manual-A 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.
Installation Manual—A Trailer Edition SPECTRUM™ DE SR-2 Multi-Temperature Systems TK 53542-2-IM (Rev. 7, 06/12) Copyright© 2006 Thermo King Corp., Minneapolis, MN, U.S.A.
Release History Released 08/06 Rev. 1 (01/07) Updated art to show correct 8 wire remote controller harness, multiple door switch harness with diodes and CargoWatch sensor. Rev. 2 (04/09) Updated the battery information page 20 and added new fuel tank bracket installation instructions pages 34-39. Rev. 3 (01/10) Pages 62-63; Added new heavy duty battery hold down bracket. Rev.
SPECTRUM DE SR-2 Multi-Temperature Systems 3
Introduction Installation Manual-A was written to assist with the installation of the Thermo King SPECTRUM DE SR-2 refrigeration 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.
Table of Contents Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Trailer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installing the Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Evaporator Opening Requirements . . . . .
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.
Safety Precautions (continued) Battery Installation and Cable Routing WARNING: Improperly installed battery could result in a fire or explosion! A Thermo King approved battery must be installed and properly secured to the battery tray. WARNING: Improperly installed battery cables could result in fire or explosion! Battery cables must be installed, routed and secured properly to prevent them from rubbing, chaffing or making contact with hot, sharp or rotating components.
Trailer Requirements DANGER: The front trailer must be structurally strong enough to support the weight of the refrigeration unit! Approximate Weight SPECTRUM DE (1670 lbs.) to 885 kg (1950 lbs.) CAUTION: The minimum distance from the king pin to the front of the trailer must be 1025 mm (40.35 in.) or severe damage to the equipment will result. VERIFY THIS DIMENSION BEFORE INSTALLING UNIT! CAUTION: The minimum clearance required for the swing radius must be 1664.2 mm (65.520 in.
Trailer Requirements 9
Evaporator Opening Requirements Evaporator Opening DANGER: The front trailer wall must be structurally strong enough to support the weight of the refrigeration unit! 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.
Evaporator Opening Requirements 11
Mounting Hardware Requirements Mounting Bolts 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! NOTE: The location of the unit mounting bolts in the trailer front wall is critical to proper unit installation.
Mounting Hardware Requirements 13
Unit Dimensions 14
BLANK PAGE 15
Battery Selection Guide Refer to Service Bulletin T&T 446 for more information regarding Battery Selection and Maintenance. 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! 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.
Group 31 Battery Dimensions 17
Lifting Bar Dimensions WARNING: Do not use a fork lift to install 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. WARNING: All hardware used to assemble the lifting bar must be DIN 931 class 10.9 (SAE grade 8).
Lifting Bar Dimensions 19
Surface Mounted Status Light Dimensions (Option) Contact your Thermo King Dealer for specific part numbers.
Flush Mounted Status Light Opening Dimensions (Option) Contact your Thermo King Dealer for specific part numbers. NOTE: Dimensions shown will accommodate the flush mounted Standard Display, Standard and Fuel Combo Display and Triple Combo Display.
Rear Remote Controller Dimensions (Option) Contact your Thermo King Dealer for specific part numbers.
Door Switch Dimensions (Option) Contact your authorized Thermo King Dealer for specific part numbers.
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 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.
Required Tools 25
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.
Installation Components 27
Unpacking the Unit 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). Units are shipped attached to disposable wooden pallet wrapped with protective cardboard and plastic stretch wrap.
Unpacking the Unit 29
Installing the Unit 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.
Installing the Unit 31
Installing the Drain Hoses Installing the Drain Hoses 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.
Installing the Drain Hoses 33
Installing the UFLS (Option) Important Installation Information The Ultrasonic Fuel Level Sensor (UFLS) should be installed into the fuel tank before the tank is installed onto the trailer. If the fuel tank has already been installed, disconnect negative battery cable from unit, disconnect and cap all fuel lines, drain fuel from tank and remove tank from trailer. • DO NOT connect power to the UFLS until it has been installed into the fuel tank.
Installing the UFLS (Option) 35
Installing the Fuel Tank - 50 Gallon, 22'' Diameter, Aluminum OPEN STYLE TANK MOUNTING BRACKET IMPORTANT FUEL TANK INSTALLATION INFORMATION Effective the first quarter of 2011, all 50 gallon, 22'' diameter, aluminum fuel tanks will come equipped with the mounting flange for the Ultrasonic Fuel Level Sensor (USFLS) option. • A.
Installing the Fuel Tank - 50 Gallon, 22'' Diameter, Aluminum OPEN STYLE TANK MOUNTING BRACKET Standard crossmember spacing shown. For other crossmember spacing, refer to TK-54238-2-IM. Non-standard crossmember spacing of 9'', 15'' and 16'' also requires Kit 701658 (90-399) NOTE: Location of mounting holes may change if other trailer options are added. Flange Tank can be mounted on either side of trailer.
Installing the Fuel Tank - 50 Gallon, 22'' Diameter, Aluminum OPEN STYLE TANK MOUNTING BRACKET Fuel Tank Installation NOTE: Location of mounting holes may change if other trailer options are added. 1. Locate the existing sets of 10.3 mm (.406'' dia.) pre-punched holes in the crossmembers. See note above. 2. Align the two holes of each hanger bracket with the holes in the crossmember and secure with two, 3/8-16 screws, washers and locking nuts. Torque the hardware to 42 N•m (31 ft-lb). 3.
Installing the Fuel Tank - 50 Gallon, 22'' Diameter, Aluminum OPEN STYLE TANK MOUNTING BRACKET NOTE: Location of mounting holes may change if other trailer options are added.
Installing the Fuel Lines Fuel Line Installation 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! 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).
Installing the Fuel Lines Verify the factory installed fuel line fittings are tight prior to mounting the bracket onto the frame.
Installing the UFLS Harness (Option) “Solid State” Ultrasonic Fuel Level Sensor (UFLS) Harness Installation and Routing Harness Connections NOTE: The Ultrasonic Fuel Level Sensor (UFLS) is an option for 22” 50 gallon fuel tanks only and requires Interconnect Harness Kit 702414. IMPORTANT: The use of the supplied crimp and solder style connectors with separate heat shrink tubing is required when connecting the sensor harness to the UFLS.
Installing the UFLS Harness (Option) Ultrasonic Fuel Level Sensor (UFLS) Crimp and Solder Style Connectors Heat Shrink Tubing Interconnect Harness 43
Installing the Status Light (Option) Installation NOTE: Surface mounted status light installation shown, flush mounted light installs into recessed opening (see “Flush Mounted Status Light Opening Dimensions (Option)” on page 21) and electrical connections are made the same. 1. Mount the Status Light in a location so that is visible in the tractor mirror to the driver. • Mark and drill the four mounting holes using a 3/16'' drill. • Mount the status light in position with the supplied rivets.
Installing the Status Light (Option) 8-Pin 4-Pin 45
DE Split-Evaporator Installation CAUTION: Do not drill holes into refrigeration, electrical or mechanical components or severe damage to the equipment will result! Return Airflow Restrictions 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 Function A bulkhead is used to keep the return airflow from being restricted if the load shifts.
DE Split-Evaporator Installation I II 47
DE Split-Evaporator Installation Sealing Air Gaps NOTE: The following areas must be properly sealed to prevent air leakage and allow the unit to operate correctly. 1. Area Above the DE Evaporator Section - If the remote tubing is routed across the trailer to the curbside compartment, this area requires foam block be cut to fit around the insulated tubing and harness. 2.
DE Split-Evaporator Installation I II III 49
DE Split-Evaporator Installation Typical DE Split-evaporator Installation Only one of many possible configurations is shown for the Spectrum DE application. 6. The entire triangular are, inside the bulkhead, where the air crosses over to the opposite compartment must be insulated with at least 1.00 in. (25.4 mm) thick foam insulation. NOTE: The Spectrum DE 30-2 does not have the capability for a remote evaporator. 7.
DE Split-Evaporator Installation 7 1 8 11 6 (7 288 31 .0 5 m in. m) 5 4 9 (6 24.0 09 0 mm in.
Installing the Rear Remote Controller (Option) Foamed-In-Place Installation NOTE: Verify mounting location and all dimensions before installing the remote controller. A = 69.8 mm (2.75 in.) B = 196.8 mm (7.75 in.) 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! Harness Connections 7.
Installing the Rear Remote Controller (Option) 53
Installing the Rear Remote Controller (Option) Retro-Fit Installation NOTE: Verify mounting location and all dimensions before installing the 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! CAUTION: Rubber grommets must be used when routing electrical harnesses through metal holes! 1.
Installing the Rear Remote Controller (Option) 55
Installing the Door Switch (Option) When installing CargoLink wireless door switches, see TK 55151 CargoLink Installation Manual. NOTE: These instructions (pages 56-59) are intended as reference guide only to assist with a typical hard wired door switch installation. Your installation may be different depending on the trailer, the amount and types of doors and the customers particular requirements.
Installing the Door Switch (Option) Right Angle Mounting Top x Top Mounting Side x Side Mounting 57
Installing the Door Switch (Option) Contact your Thermo King Dealer for specific part numbers. NOTE: The Door Switch Harness Connectors are located at the rear of the unit (See DETAIL C). Single Door Switch Activation / Single Zone (Detail A) Multiple Door Switch Activation / Single Zone (Detail B) 1. Attach the interface harness to the door switch connector located at the rear of the unit. 4. Attach the interface harness to the door switch connector at the rear of the unit. 2.
Installing the Door Switch (Option) Interface Harness Wiring RED = (12 Vdc) POWER Door Switch Wiring RED = (12 Vdc) POWER BLACK = (CH) GROUND BLACK = (CH) GROUND WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT Door Switch Connectors Interface Harness Wiring RED = (12 Vdc) POWER Door Switch Wiring RED = (12 Vdc) POWER BLACK = (CH) GROUND BLACK = (CH) GROUND WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT 59
CargoWatch™ Sensor Locations (Option) Sensor locations for Domestic Applications as required by customer. 1. Sensor #1 is located in the evaporator side return opening near unit return air sensor (factory installed). 2. Sensor #2 as required by customer.
CargoWatch™ Sensor Locations (Option) 61
Connecting the CargoWatch™ Sensors (Option) NOTE: ONLY CargoWatch Sensors Can Be Used CONNECTING SENSORS NOTE: The sensor are not polarity sensitive. 6. Insert BLACK pin connector and wire into correct connection until it locks into position (Detail I). The wire side of the connector is shown. SENSOR PLUGS 1. Locate the CargoWatch Sensor Harness behind the evaporator access panel. 1 Black into #12 2 Black into #11 2. Unplug the connector from the harness. 3 Black into #10 3.
Connecting the CargoWatch™ Sensors (Option) 63
Installing the Battery CAUTION: Set all electrical controls to the OFF position before connecting the battery to prevent the unit from starting! Optional Heavy Duty Battery Hold Down Bracket 1. Install the battery into the tray. 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! 2. Install the battery hold down bracket and rods.
Installing the Battery Standard Battery Hold Down Bracket Optional Heavy Duty Battery Hold Down Bracket 65
Installing the Bottom Pan Installation NOTE: Anti-seize lubricant applied to the threads of the stainless steel mounting hardware is recommended. 1. 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. • 3.
Installing the Bottom Pan MODEL 50 UNITS ONLY The receptacle box needs to be lifted up to access one of the bottom pans front mounting bolts.
STOP! SPECTRUM DE MULTI-TEMPERATURE SYSTEMS ONLY! TO INSTALL THE SPECTRUM REMOTE EVAPORATORS AND COMPLETE THIS INSTALLATION REFER TO: INSTALLATION MANUAL-B TRAILER EDITION SPECTRUM SR-2 MULTI-TEMPERATURE SYSTEMS TK 53509-2-IM 68
STOP 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 lbs.) of refrigerant must be recovered.
TK 53542-2-IM (Rev. 7, 06/12) Trailer Edition SPECTRUMTM DE SR-2 Multi-Temperature Systems Installation Manual-A 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.
