RAC 60 BRI

Heating, ventilation and air conditioning (HVAC) unit

Project Bari

MAINTENANCE MANUAL

TK 61454-5-MM Revision 1 (Print Date: November 10, 2016)

Copyright © 2016 Ingersoll Rand Corporation, Thermo King

Electronically Printed in Czech Republic
 The maintenance information in this manual covers unit model:
System Number: 903557
Project: BRI

For further information, refer to:

Parts Manual TK 61447-5-PM
Stocking Guide TK 61445-5-SG

See also general documents listed in Appendix.

This manual is published for informational purposes only and the information so provided
should not be considered as all-inclusive or covering all contingencies. If further information
is required, Thermo King Company (Ingersoll Rand Corporation) should be consulted.

Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms
and conditions are available upon request. Thermo King (Ingersoll Rand) warranty will not
apply to any equipment which has been so repaired or altered outside the manufacturer’s
plants as, in the manufacturer’s judgment, to effect it is stability.

No warranties express or implied, including warranties of fitness for a particular purpose

or merchantability, or warranties arising from course of dealing or usage of trade, are made
regarding the information, recommendations, and descriptions contained herein. Manufacturer
is not responsible and will not be held liable in contract or in tort (including negligence)
for any special, indirect or consequential damages, including injury or damage caused
to vehicles, contents or persons, by reason of the installation of any Thermo King product
or its mechanical failure.

2
 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.
In addition, service personnel must be aware of Federal regulations concerning
the use of refrigerants and the certification of technicians. For additional
information on regulations and technician certification programs, contact
your local THERMO KING dealer.

R-407C
WARNING: Use only Polyol Ester-based (POE) refrigeration compressor oil in
the R-407C system. See Thermo King Parts Manual or Stocking Guide for exact
spare part number.

Do not mix Polyol Ester and standard synthetic compressor oils. Keep Polyol Ester
compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated
with moisture or standard oils, dispose of properly – DO NOT USE!
When servicing Thermo King R-407C systems, use only those service tools certified
for and dedicated to R-407C refrigerant and POE compressor oils. Residual non-
HFC refrigerants or oils will contaminate R-407C system.

3
HISTORY

Rev. Description Author Date

0 Rev. 0 released Michal Kout 5. 10. 2016

1 Proofreading of the whole manual Michal Kout 10. 11. 2016

4
1. About This Manual
Purpose
The purpose of this manual is to provide general maintenance information necessary to operate
and maintain the climate control unit (HVAC unit) at peak operating standards and best lifetime.
This includes safety information, unit information such as technical specification, general unit
description, maintenance procedures and some diagnostic and troubleshooting information.

Before you call Thermo King Service

Before you call Thermo King Service, have the following information on hand (for exact data see serial
plate on your unit):
 Unit type (commonly typed on serial plate after code DESC).
 System or Model number (commonly coded on serial plate after code ITEM).
 System number has usually six digits format (example 901902).
 Model number is the same as System number with M letter at the end (example 901902M).
 Serial number.
Who to call: your Thermo King Dealer Representative or Thermo King Service Centre.

Blank Pages
This manual may contain blank pages at the end of chapters. This is normal. There is no information
missing from the manual.

5
2. Table of Contents

1. About This Manual ................................................................................................................................ 5

2. Table of Contents .................................................................................................................................. 6

3. List of Figures ....................................................................................................................................... 8

4. List of Abbreviations ........................................................................................................................... 10

5. Safety Precautions .............................................................................................................................. 11

5.1. General Practices ......................................................................................................................... 11
5.2. Electrical Hazards......................................................................................................................... 12
5.3. Refrigerant Hazards...................................................................................................................... 13
5.4. Compressor Oil Hazards............................................................................................................... 14
5.5. First Aid ........................................................................................................................................ 15

6. Specifications ...................................................................................................................................... 16
6.1. HVAC System .............................................................................................................................. 16
6.2. Electrical System .......................................................................................................................... 16
6.3. Weights and Dimensions .............................................................................................................. 18
6.4. Photos and Illustrations................................................................................................................. 19

7. Description .......................................................................................................................................... 22
7.1. System Description....................................................................................................................... 22
7.2. General Description of HVAC Unit ................................................................................................ 22
7.3. Main Parts of HVAC Unit .............................................................................................................. 23

8. HVAC Unit Control and Operation ...................................................................................................... 28

8.1. Introduction .................................................................................................................................. 28
8.2. Basic HVAC System – Theory of Operation .................................................................................. 28
8.3. Control System ............................................................................................................................. 30
8.4. ClimaAIRE ID Controller ............................................................................................................... 31
8.4.1. Operating Elements ...................................................................................................................... 31
8.4.2. Operating Concept of ClimaAIRE ID System ................................................................................. 32
8.4.3. Normal Operating Mode................................................................................................................ 32
8.4.4. Setup/Calibration/Test Mode......................................................................................................... 35
8.4.5. ClimaAIRE ID Diagnostic System.................................................................................................. 44
8.4.6. ClimaAIRE ID Inputs and Outputs ................................................................................................. 45
8.5. Application Interface ..................................................................................................................... 47
8.6. Basic Application Description ........................................................................................................ 47
8.7. Start Up ........................................................................................................................................ 51
8.8. Operation ..................................................................................................................................... 51
8.9. Shut Down .................................................................................................................................... 51

9. Light Repair ......................................................................................................................................... 52

9.1. Inspection Recommendations ....................................................................................................... 52
9.2. Maintenance Inspection Schedule................................................................................................. 54
9.2.1. Intervals........................................................................................................................................ 54
9.3. Cleaning ....................................................................................................................................... 57
9.4. Special Tools, Equipments and Supplies ...................................................................................... 58

6
 9.5. Tightening Torque Requirements .................................................................................................. 60
9.6. Long-term Storage ........................................................................................................................ 62
9.7. Electrobox Component Replacement ............................................................................................ 63
9.7.1. Circuit Breaker and Contactor Replacement.................................................................................. 64
9.7.2. Relay Replacement ...................................................................................................................... 66
9.8. Air Filters Replacement ................................................................................................................. 67
9.9. Temperature Sensor Replacement................................................................................................ 68
9.10. Solenoid Coil Replacement ........................................................................................................... 69

10. Troubleshooting .................................................................................................................................. 71

10.1. Analysis Overview ........................................................................................................................ 71

11. Refrigeration Repairs .......................................................................................................................... 74

11.1. Introduction................................................................................................................................... 74
11.2. Refrigeration System Fundamentals ............................................................................................. 75
11.2.1. Introduction................................................................................................................................... 75
11.2.2. Refrigeration Service Tools ........................................................................................................... 76
11.2.3. Contamination .............................................................................................................................. 77
11.2.4. Compressor Oil Color Code .......................................................................................................... 78
11.2.5. Refrigerant Recovery .................................................................................................................... 78
11.2.6. Using Pressurized Nitrogen........................................................................................................... 79
11.2.7. Refrigerant Leak Test Procedure .................................................................................................. 79
11.2.8. Evacuation.................................................................................................................................... 80
11.2.9. System Charging from an Evacuated Condition ............................................................................ 85
11.3. Filter-Drier Replacement ............................................................................................................... 88
11.4. Receiver Tank Replacement ......................................................................................................... 89
11.5. Thermostatic Expansion Valve Replacement ................................................................................ 91
11.6. Compressor Replacement ............................................................................................................ 95
11.7. Low Pressure or High Pressure Switch Replacement .................................................................... 98
11.8. Safety Relief Valve Replacement ................................................................................................ 100
11.9. Solenoid Valve Replacement ...................................................................................................... 101
11.10. Condenser Coil Replacement ..................................................................................................... 103
11.11. Evaporator Coil Replacement ..................................................................................................... 105

12. Electrical Repairs .............................................................................................................................. 108

12.1. Introduction................................................................................................................................. 108
12.2. Evaporator Blower Replacement ................................................................................................. 109
12.3. Condenser Fan Replacement ..................................................................................................... 111
12.4. Heater Assembly Replacement ................................................................................................... 112
12.5. Heater Temperature Switch Replacement ................................................................................... 114

13. Temperature-Pressure Chart ............................................................................................................ 116

14. Index .................................................................................................................................................. 118

15. Appendix............................................................................................................................................ 120

15.1. Schemes, Diagrams and Drawings Index .................................................................................... 120
15.2. Recommended Publications........................................................................................................ 120

7
3. List of Figures
Unit Dimensions ........................................................................................................................... 18
RAC Unit – Outside View ............................................................................................................. 19
RAC Unit – Inside View ................................................................................................................ 20
Electrobox.................................................................................................................................... 21
RAC Unit (Illustrative Picture) ....................................................................................................... 22
Air Filters Installation .................................................................................................................... 26
Refrigeration System.................................................................................................................... 29
Application Diagram ..................................................................................................................... 30
CAID Driver Panel ........................................................................................................................ 31
CAID Keys in Setup/Calibration/Test mode .................................................................................. 35
CAID Function Menu Structure ..................................................................................................... 35
CAID List of Functions.................................................................................................................. 36
CAID Test Mode 1 – Mode Control ............................................................................................... 36
CAID Test Mode 1 – Blower Control ............................................................................................. 36
CAID Scheme of Relay Test Procedure........................................................................................ 37
CAID List of Calibrations .............................................................................................................. 38
CAID Calibration Function Structure ............................................................................................. 39
CAID Setup Function Structure .................................................................................................... 40
CAID Controller Parameters ......................................................................................................... 41
CAID Scheme of Hourmeter ......................................................................................................... 43
CAID List of Alarm Codes ............................................................................................................ 45
CAID Driver Panel Connectors ..................................................................................................... 45
CAID List of Inputs ....................................................................................................................... 46
AID List of Outputs ....................................................................................................................... 46
Controller – Application Interface.................................................................................................. 47
HVAC Operating Stages .............................................................................................................. 48
Control Diagram – Auto Mode ...................................................................................................... 49
Control Diagram – Cool Mode ...................................................................................................... 50
Control Diagram – Heat Mode ...................................................................................................... 50
Special Tools ............................................................................................................................... 59
Fastener Groups .......................................................................................................................... 60
Nominal Tightening Torque .......................................................................................................... 61
Switchboard ................................................................................................................................. 63
Auxiliary Contact Installation (Example)........................................................................................ 64
Circuit Breaker Removal (Example).............................................................................................. 64
Circuit Breaker Adjusting Knob Position ....................................................................................... 65
Relay Installation.......................................................................................................................... 66
Air Filters Installation (Example) ................................................................................................... 67
Temperature Sensor Installation (Example) .................................................................................. 68
Solenoid Coil Installation .............................................................................................................. 69
Testing for Refrigeration Leaks..................................................................................................... 79
Evacuation Station and Unit Hookup ............................................................................................ 83
Constant Pressure Rise After Evacuation ..................................................................................... 84
Pressure Rise that Levels Off After Evacuation ............................................................................ 84
Typical Pressurized Gas Bottle with Pressure Regulator and Gauges ........................................... 87
Filter-drier Installation................................................................................................................... 88
8
Receiver Tank Installation ............................................................................................................ 89
Expansion Solder Type Valve and Sensor Bulb Position ............................................................... 91
Thermostatic Expansion Valve Installation .................................................................................... 94
Compressor Installation ................................................................................................................ 95
Fixing Screw Marking (Example) .................................................................................................. 96
Pressure Switch Installation (Example 1) ...................................................................................... 98
Pressure Switch Installation (Example 2) ...................................................................................... 99
Relief Valve Installation (Example) ............................................................................................. 100
Solenoid Valve Installation ......................................................................................................... 101
Condenser Coil Installation......................................................................................................... 103
Evaporator Coil Installation – A................................................................................................... 105
Evaporator Coil Installation – B................................................................................................... 106
Evaporator Blower Installation (Example) ................................................................................... 109
Evaporator Blower Assembly...................................................................................................... 110
Condenser Fan Installation (Example) ........................................................................................ 111
Heater Assembly Installation ...................................................................................................... 113
Heater Temperature Switch ........................................................................................................ 114

9
4. List of Abbreviations

A/C Air Conditioning PWR Power supply

ATS Ambient temperature (sensor) RTS Return air temperature (sensor)
BLH High pressure cutout switch RPM Routines per minute
BLP Low pressure cutout switch SG Sight glass
CAII ClimaAIRE II panel SPc Set point of control system
CFM Condenser fan motor SRV Safety relief valve
COM Compressor SVE Suction vibration eliminator
DC Direct current SW Software
FAFM Fresh air fan motor TK Thermo King
CH Chassis, power supply ground TR Tank receiver
CR Compressor YLL Solenoid valve, liquid line
CTS Evaporator coil temperature (sensor) XPOW High voltage terminal / connector
DVE Discharge vibration eliminator XLV11 Low voltage
EFM Evaporator blower (motor)
EXP Expansion valve
FAT Fresh air temperature
FD Filter drier
GND Power supply ground
HPCO High pressure cutout switch
Heating, Ventilation and Air
HVAC
Conditioning
HW Hardware
HTR Heater
IND Indicator, liquid
KCOM Contactor, compressor
KHTR Contactor, heater
K2 Ventilation fan relay
LPCO Low pressure cutout switch
LV Low voltage (see "Specifications")
NC Normally closed
NO Normally open
PWM Pulse width modulation

10
5. Safety Precautions
Thermo King recommends that all services be performed by a Thermo King dealer. However, you
should be aware of several general safety practices:

The exclamation symbol appears next to a point that is particularly important.

DANGER: Denotes the possibility of serious injury or death.

WARNING: Denotes the possibility of serious equipment damage or serious personal

injury.

CAUTION: Denotes the possibility of minor to severe equipment damage or personal

injury.

5.1. General Practices

DANGER: Do not operate the compressor with the discharge valve closed.
This condition increases internal pressure, which can cause an explosion.

DANGER: Never apply heat to a sealed refrigeration system or container. The heat
increases internal pressure, which will cause an explosion.

DANGER: Refrigerant in the presence of an open flame, spark or electrical short

produces toxic gases that are severe respiratory irritants.

DANGER: Keep your hands, clothing and tools clear of any rotating parts when
working on a unit that is running. Loose clothing might entangle moving fans, pulleys,
or belts, causing serious injury or possible death.

DANGER: Do not inhale refrigerant. Use caution when working with refrigerant
or a refrigeration system in any confined area with a limited air supply.
The refrigerant displaces air and can cause oxygen depletion, resulting in suffocation
and possible death.

WARNING: Make sure your gauge manifold hoses are in good condition before
using them. Never let them come in contact with moving belts, motors, pulleys or hot
surfaces. Defective gauge equipment can damage components or cause serious injury.

WARNING: Wear goggles or safety glasses when working around air conditioning
systems or batteries. Refrigerant liquid, oil and battery acid can permanently damage
your eyes.

WARNING: Use extreme caution when drilling. Holes might weaken structural
components. Holes drilled into electrical wiring can cause a fire or explosion.

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

11
 WARNING: Be careful when using ladders or scaffolding to install or service air
conditioning systems. Follow the manufacturer's instructions, safety labels and warnings.

CAUTION: Make sure all mounting bolts are tight and are the correct length
for their applications. Improper torque and incorrect bolt lengths can damage
equipment.

CAUTION: If soldering is required, use dry nitrogen to purge the system during
any solder operations. Refer to chapter "Using Pressurized Nitrogen".

5.2. Electrical Hazards

When servicing or repairing an air conditioning unit, the possibility of serious or even fatal injury from
electrical shock exists. Extreme care must be used when working with an air conditioning unit that is
connected to a source of operating power, even if the unit is not running. Lethal voltage potentials can
exist at the unit power cord, inside the electric switchboard box, at the motors, at any junction box
and within the wiring harnesses.

Precautions

 Always turn the HVAC unit OFF. Then disconnect the unit from the primary power source
(power supply) before attempting repair or replacement of major components.

 Use tools with insulated handles. Use tools that are in good condition. Never hold metal tools in
your hand if exposed, energized conductors are within reach.

 Do not make any rapid moves when working with high voltage circuits. Do not grab a falling
tool or other object. People do not contact high voltage wires on purpose. It occurs from
an unplanned movement.

 Treat all wires and connections as high voltage until ammeter and wiring diagram show
otherwise.

 Never work alone on high voltage circuits on the refrigeration unit. Another person should
always be standing by in the event of an accident to shut OFF the HVAC unit and to aid
a victim.

 Have electrically insulated gloves, cable cutters and safety glasses available in the immediate
vicinity in the event of an accident.

WARNING: Control circuits used by air conditioners are low voltage (24 VDC for
example). Use caution when working with electrical circuits that have capacitors.
Some capacitors hold a significant charge that will cause burns or shocks
if accidentally discharged. Make sure capacitors are discharged before working
on electrical circuits.

WARNING: Do not wear jewellery, watches or rings because they increase the risk
of shorting out electrical circuits and damaging equipment or causing severe burns.

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 CAUTION: When working with electrical circuits that contain microprocessors,
always wear an ESD wrist strap and connect the opposite end to the chassis ground
or CH terminal. This precaution will prevent electrostatic discharge from damaging
circuits.
CAUTION: Certain service procedures on air conditioning equipment require that
the system be de-energized. When this precaution is necessary, ensure the battery’s
master switch or service switch is turned OFF. Confirm that power has been removed
before servicing. Equipment that is connected to power is dangerous to service.

5.3. Refrigerant Hazards

DANGER: Do not use a Halide torch. When a flame comes in contact with
refrigerant, toxic gases are produced that will cause suffocation, even death

DANGER: Store refrigerant in proper containers, out of direct sunlight and away
from intense heat. Heat increases pressure inside storage containers, which will cause
them to burst.

DANGER: Do not use oxygen (O2) or compressed air for leak testing systems.
Oxygen mixed with refrigerant is combustible.

WARNING: Wear protective garments and goggles or safety glasses when working
with refrigerant to prevent frostbite and eye injuries.

WARNING: Wear butyl lined gloves when handling refrigerant to help prevent
frostbite.

CAUTION: All charging using the new refrigerants (Azeotropic blends) must be
done in a liquid state. Failure to do this will decrease the system operating efficiency.
Refer to the charging procedures found in this manual for your unit.

CAUTION: When recovering or transferring refrigerant, use a process that prevents

refrigerant from escaping into the atmosphere. Refrigerant damages the earth’s upper
ozone layer.

CAUTION: Refrigerant in a liquid state evaporates rapidly when exposed to

the atmosphere, freezing anything it contacts. Be careful when handling refrigerant
to protect your skin from frostbite.

13
5.4. Compressor Oil Hazards

WARNING: Protect your eyes from contact with compressor oil. The oil will cause
serious eye injuries. Avoid prolonged or repeated contact with compressor oil.
To prevent irritation, wash your hands and clothing thoroughly after handling the oil.

CAUTION: Do not mix compressor oils because that will cause system damage.

CAUTION: Use dedicated equipment to prevent contaminating the system

with the wrong type of oil or refrigerant.

CAUTION: Thermo King uses a variety of compressor oils. Oil used in the system
must be verified. Check "Specification" section in this manual for correct oil. Using
incorrect oil will invalidate the warranty.

CAUTION: When servicing TK units, do not use equipment that might be

contaminated with PAG oils.

CAUTION: Store compressor oil in an approved sealed container to avoid moisture

contamination.

CAUTION: Do not expose compressor oil to the air any longer than necessary.
The oil will absorb moisture, which results in much longer evacuation times
and possible system contamination.

CAUTION: Wipe up spills immediately. Compressor oil can damage paints

and rubber materials.

14
5.5. First Aid

Electrical Shock
IMMEDIATE action must be initiated after a person has received an electrical shock. CALL for
emergency and medical assistance.
LOOK FIRST. DO NOT TOUCH THE VICTIM! You can receive a shock from current flowing
through the victim's body. The person may still be in contact with the electrical source.
The source of shock must be removed immediately. Turn OFF the source of electricity, if possible.
If not, move the source away from you and the person, using a dry, no conducting object made of card-
board, plastic or wood. The electrical wire should be cut with either an insulated instrument (e.g. wooden
handled axe or cable cutters with heavy insulated handles) or by a rescuer wearing electrically insulated
gloves and safety glasses. Whichever method is used, DO NOT LOOK AT THE WIRE while it is being
cut. The ensuing flash can cause burns and blindness.
After separating the victim from power source, check immediately for presence of a pulse and respiration.
If the victim has no pulse, start CPR (Cardio Pulmonary Resuscitation) until the emergency medical
assistance arrives. If the victim has a pulse, respiration may be restored by using mouth-to-mouth
resuscitation.

Compressor and Refrigerant Oil

Eyes
Immediately flush with water for at least 15 minutes. CALL A PHYSICIAN. Wash skin with soap
and water.
Ingestion
Do not induce vomiting. Immediately contact local poison control centre or physician.

Refrigerant
In the event of frostbite, protect the frozen area from further injury, warm the area rapidly and maintain
respiration.
Eyes
Immediately flush eyes with large amounts of water. CALL A PHYSICIAN.
Skin
Flush area with large amounts of warm water. Do not apply heat. Remove contaminated clothing and
shoes. Wrap burns with dry, sterile, bulky dressing to protect from infection. CALL A PHYSICIAN.
Wash contaminated clothing before reuse.
Inhalation
Move victim to fresh air and use CPR (Cardio pulmonary resuscitation) or mouth-to-mouth
resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrives.

15
6. Specifications
6.1. HVAC System
Cooling Capacity 6 kW
Heating Capacity 5 kW (2x 2.5 kW)
Total Air Flow 800 m3/hr at 90 Pa external static pressure
Fresh Air 60 m3/hr
Temperature Range -30 °C to +45 °C
Refrigerant R-407C
Refrigerant Charge 1.9 kg (4.19 lb)
Compressor Model No. ZR28K3E-TFD-522, Hermetic Scroll
Compressor Oil Type Polyol Ester Based Type (required)
TK No. 203-5162
System Compressor Oil Capacity:
Replacement Compressor Charge (each)1 1.12 litter (38 oz.)
High Pressure Cutout Switch: Open 3261 ± 48 kPa (473 ± 7 psig)
Close 2606 ± 262 kPa (378 ± 38 psig)
Low Pressure Cutout Switch: Open 172 ± 48 kPa (25 ± 7 psig)
Close 310 ± 48 kPa (45 ± 7 psig)
High Pressure Relief Valve: Relief Pressure 3447 + 517/-103 kPa (500 +75/-15 psig)
1
When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured so that the same amount of oil can be maintained in the replacement
compressor.

2
Do not use or add standard synthetic or mineral oils to the refrigeration system. If ester based oil becomes
contaminated with moisture or with standard oils, dispose of properly – DO NOT USE!

6.2. Electrical System

Power Supply 400 V 50 Hz, 3 phase
For purpose of this manual is this value applied for term HIGH VOLTAGE
Control System Voltage 24 VDC
For purpose of this manual is this value applied for term LOW VOLTAGE

Circuit Breakers, Fuses, Contactors

See Principal Schematic Diagram or Mounting Assembly Electro Box Diagram in Appendix.
The set points for circuit breakers or limit value for fuses are in diagram labelled under each part, in last line is
value to adjust.
Controller Circuit QSUP
Compressor Motor QCOM
Evaporator Blower Motor QEFM

16
Condenser Fan Motor QCFM
Heater, Stage 1 & 2 QHTR
Low Voltage F1

Contactors
Compressor KCOM
Condenser Fan Motor KCFM
Evaporator Blower Motor KEFM
Heater, Stage 1 KHTR1
Heater, Stage 2 KHTR2
Compressor Motor
Type 400 V, 50 Hz, 3 phase
Number 1
Kilowatts 2.4 kW
Full Load 5.1 A
Condenser Fan Motor
Type 400 V, 50 Hz, 3 phase
Number 1
Kilowatts 0.185 kW
RPM 1350 min-1
Full Load 0.37 A
Evaporator Blower Motor
Type 24 V DC
Number 1
Kilowatts 0.173 kW
RPM 2645 min-1
Full Load 7.2 A
Heater
Input Voltage 400 V, 50 Hz, 3 phase
Heater 2.5 kW, 2 stages
Thermal Overheat Protection:
1st level 90 °C, NC, automatic reset
2nd level 130 °C, NC, automatic reset

17
6.3. Weights and Dimensions
Base Unit Weight (net) 110 kg
Component weight (for repair and replacement)
Compressor 27 kg
Condenser fan 3.6 kg
Evaporator blower assembly 7 kg
Heater assembly 15 kg

BEC547

Unit Dimensions

18
6.4. Photos and Illustrations

8 7

10

1
BEC548
2 6
3
4

1 Electrical switchboard box (Electrobox) 6 Unit frame – side wall

2 Communication & LV connector (XLV1) 7 Condenser fan grille

3 Grounding point 8 Locking element

4 Isolator 9 Top cover

5 Fresh air intake 10 Power supply HV connector (XPOW)

RAC Unit – Outside View

19
 18
13

19 14
15
16

20 17

10
11

1
12
2 BEC549

3
4
5

6
7

1 Unit frame 11 High pressure cutout switch

2 Air intake 12 Grounding point
3 Evaporator coil 13 Electrical switchboard box (Electrobox)
4 Heater 14 Blower compartment
5 Thermostatic expansion valve 15 Filter-drier
6 Liquid solenoid valve 16 Sight glass
7 Compressor 17 Condenser coil
8 Low pressure cutout switch 18 HV connectors
9 Receiver tank 19 LV connectors
10 Safety relief valve 20 Return air reduction

RAC Unit – Inside View

20
 7 8 9 10 11 12 13

14

15

BEB122

1 2 3 4 5 6

1 Electrical switchboard box ----

2 Terminal block XTB1
3 Contactor KCFM Condenser fan motor
4 Contactor KCOM Compressor motor
5 Contactor KHTR1 Heater, stage #1
6 Contactor KHTR2 Heater stage #2
7 Circuit breaker QCFM Condenser fan motor
8 Circuit breaker QCOM Compressor motor
9 Circuit breaker QHTR Heater
10 Relay – shunt-release QHTSR Heater protection
11 Relay assembly KEFM Evaporator blower motor
12 Circuit breaker QEFM Evaporator blower motor
13 Fuse F1 Low voltage circuit protection
14 Power supply connector XPOW High voltage
15 Signal & communication connector XLV1 Low voltage

Electrobox

21
7. Description
7.1. System Description
The train HVAC system consists of more HVAC units intended to keep comfortable conditions in
passenger compartments and driver cabins. This document describes the rooftop unit (RAC) for driver
cabin only (the cab unit).

7.2. General Description of HVAC Unit

The RAC heating, ventilation and air conditioning (HVAC) unit manufactured by Thermo King is
a roof-mount (rooftop) unit designed for A/C systems of the light rail vehicles. The RAC unit
provides cooling, heating and ventilation of the air to keep the temperature conditions comfortable
for the driver's cab.

BEC548

RAC Unit (Illustrative Picture)

Cooling and/or ventilation is accomplished by drawing of air (the return air) from the cab interior to
the entrance chamber where is mixed with fresh air. This mixed air is filtered and then passes through
the evaporator coil, heater and then enters the blower. The blower pressurizes the conditioned air
(cooled or heated or dehumidified) and this pressure move the air from bottom of the unit into
the vehicle air distribution (duct) system.

22
7.3. Main Parts of HVAC Unit
The RAC unit consists of hermetically sealed refrigerant circuit, air system with filters, electrical
circuit, control system, unit frame and covers and auxiliary elements.
The main RAC unit is designed for mounting on rooftop level. Major components of RAC unit are
arranged for easy access and service through hinged cover. The primary assemblies are:
 Compressor assembly
 Evaporator coil assembly incl. thermostatic expansion valve and solenoid valve
 Evaporator blower assembly
 Condenser coil and fan assembly
 Heater assembly
 Electric switchboard box (Electrobox)
 Control box with controller
 Refrigeration circuit accessories:
o Filter-drier
o Liquid receiver tank
o Vibration eliminators
o Sight glass
 Unit protections devices
 Fresh air intake with water eliminator and filters
 Structural frame and cover

Compressor Assembly
The RAC unit is equipped with scroll compressor and accessories. The compressor is specially designed
for use in cooling systems and provides low consumption, low vibrations and high reliability. The
compressor includes internal electrical motor feeded from switchboard, an electrical junction box, built-
in protection and elastic mounting for elimination of vibrations.

Evaporator Coil Assembly and Solenoid Valve

The evaporator coil is an aluminium, wavy fin, copper tube type. Liquid refrigerant flows from
the receiver tank to the evaporator coil through the thermostatic expansion valve.
The expansion valve restricts and controls the flow of liquid refrigerant to the evaporator. The pressure
and temperature condition inside of the evaporator (refrigerant side) and outside of evaporator (air side)
results in heat transfer from the refrigerated air to the evaporator.
The drain pan underneath the evaporator coil is intended to capture any water condensation from
the coil surface. Drain lines allow the water to flow away from the unit.
The solenoid valve closes the refrigeration circuit in the moment when the system is in stand-by.

Evaporator Blower Assembly

The blower is intended to draw the air from vehicle area and after conditioning (cooling or heating or
dehumidification) discharge conditioned air back into the vehicle air distribution system.
The blower is located in centre of unit (behind the evaporator in air flow direction).

23
Condenser Coil and Fan
The RAC unit contains one piece of aluminium, wavy fin, copper tube condenser coil assembly and one
condenser fan assembly.
Pressurized refrigerant gas is discharged by the compressors into the condenser coil for the condensing
phase of the refrigeration cycle. Air is drawn through the coils by one propeller type fans. Refrigerant
gas condenses in the condenser coil, returning the refrigerant to the liquid state.
The fan is designed for pulling of fresh air from internal area RAC unit and this function effect the air
flow through the condenser coil.
The fan assembly consists of fan including electrical motor, rotor with blades, permanently sealed ball
bearings (all in one-piece part), protective grille and fixing parts.

Heater Assembly
The heater assembly consists of heater frame, heating element and overheating protection switches
(two levels of protection).
The heater is located between evaporator coil and evaporator blower.

Electric Switchboard Box (Electrobox)

The electrobox contains switchboard with all electrical components for feeding, controlling and
protection of electrical circuiting. The switchboard box contains both high voltage and low voltage
components.

Control Panel (Controller)

The unit is controlled by the ClimaAIRE ID controller located on the dashboard of the driver’s cab.
ClimaAIRE ID provides system component control and fault indication to simply system service
and maintenance.

Refrigeration Circuit Accessories

Filter-Drier
The filter-drier (dehydrator) is a cartridge soldered type unit intended for protection the refrigerant
against:
 Moisture – by absorbing and retaining it deep within the desiccant.
 Foreign matter – the filter-drier will filter out scale, solder particles, carbon, sludge, dirt
or any other foreign matter with negligible pressure drop. Fine particles that would go
through an ordinary strainer are removed down to a minimum size in one pass filtration.
 Acid – the hydrochloric, hydrofluoric, and various organic acids are adsorbed and held by
the desiccant in a manner similar to the adsorption of moisture.
 Oil sludge and varnish – all refrigeration oils break down to produce varnish, sludge
and organic acids and here are removed.
The filter-drier is located on the side of compressor/condenser compartment near condenser coil.
Liquid Receiver Tank
A liquid receiver tank holds reserve liquid refrigerant that is needed to support variable system
demands. The receiver tank is located in condenser compartment and is connected between
the condenser coil outlet line and the filter-drier.

24
Vibration Eliminators
The compressor suction line and discharge line contain in-line vibration eliminators (situated directly
before and after compressor).
Constructed of stainless steel reinforced flexible hose, the vibration eliminators remove the vibration
and noise that are normally produced by the major mechanical devices and transmitted along refrigerant
lines to more sensitive components.
Sight Glass
The sight glass is simple system equipment that permits visual inspection of oil and/or refrigerant level
and condition.
In the centre of the sight glass is an indicator which changes colour from green when a system is dry, to
yellow when a system is wet and indicates the need for a new drier or repair.
The sight glass is located in liquid line, accessible from return air/electro box area.

Unit Protection Devices

High Pressure Cutout Switch (HPCO)
The high pressure switch is located on the output (high pressure, discharge) line from the compressor.
The relay-type contact of this switch is a part of low voltage (control) circuit, under normal operation is
the contact closed.
If the discharge pressure rises above limit value (see specification in chapter 6), the switch/contact will
open and the compressor will stop immediately. At the same time the control system will receive
the information about this situation.
Low Pressure Cutout Switch (LPCO)
The low pressure switch is located on input line (low pressure, suction line) before the compressor.
The relay-type contact of this switch is a part of low voltage (control) circuit, under normal operation is
the contact closed.
If the suction pressure drops below limit value (see specification in chapter 6), the switch/contact will
open and the compressor will stop immediately. At the same time the control system will receive
the information about this situation.
Safety Relief Valve (SRV)
A safety (high pressure) relief valve is installed on the compressor output line to avoid excessive
pressure build-up within the refrigeration system from extraordinary and unforeseen circumstances.
The valve is a spring-loaded piston type that opens when refrigerant pressure exceeds limit value.
Compressor Overload Protection
Compressor overload protection is a built-in part of compressor.

25
Heat Limiters
The heater is protected by the heat limiters against overheating in two levels:
1. When the temperature on the top of the heater assembly is higher than first limit (1st level – for
exact value see specification in chapter 6) the switch stops the heater. When a new request for
heating appears, the heater can continue in operation.
2. When the temperature is higher than second limit (2nd level – for exact value see specification
in chapter 6), the switch stops heater power supply – the shunt relay switches down an appropriate
circuit breaker. The circuit breaker reset needs to be done manually. Before reset is necessary to
check the reason of protective action.
The switch – heat limiter – is automatically reset if the temperature decreases to approximately 50 °C.

Air Filters
The RAC unit is equipped with fresh air and mixed air filter.
This filters removes impurities from the fresh/return air entering the RAC unit, filters are is located in
front of evaporator coil and on the side wall.
These filters are disposable only, for frequency of changing see the maintenance chapter in this manual.
The filter element is enclosed in filter box (retainer) and can be accessible through unit top cover.

1 5

BEB119
3

1 Condenser coil 4 Fresh air filter

2 Evaporator coil 5 Mixed air filter
3 Electrical switchboard box (Electrobox)

Air Filters Installation

26
Structural Frame and Cover
The RAC structural frame including the covers is manufactured from aluminium.
The top cover provides access into the unit, to all components. The cover is hinged and in open position
can be fixed with support/beam.
Electrobox is closed with separate cover.
Both covers in closed position are secured with locks – the locking elements. For opening/closing use
appropriate tool only!
Unit Decals
Serial number, refrigerant type and warning decals/nameplates are situated on different places on
the unit. These decals provide information that may be necessary for service or repair of the unit.
Service technicians should especially read and follow the instructions on all warning decals.
Serial Number Locations
 Electric motors – nameplate attached to the motor housing.
 Compressor – nameplate attached to the compressor housing.
 HVAC unit – nameplate on the side of the unit.

27
8. HVAC Unit Control and Operation
8.1. Introduction
The refrigeration components of the HVAC unit are all connected in a closed, hermetically sealed
common system to form a refrigerant circuit. The refrigerant system circulates refrigerant between
the evaporator and the condenser coil to provide the requested exchange of heat energy.
The evaporator coil is the heat exchanger for energy transfer from air (the return air, air for car interior)
to the refrigerant. The condenser coil is the heat exchanger for energy transfer from the refrigerant
to the ambient air.
If the working conditions require heating of air (air for car interior) the air is heated in the heater
assembly, the cooling circuit is OFF (except mode Reheat, see below, if enabled). If the working
conditions require just ventilation, the blowers are running to move the air, the fresh air can be added
to return air, the cooling circuit and heater are switched OFF.

8.2. Basic HVAC System – Theory of Operation

The evaporator blowers drive the air with higher temperature (return air) across the evaporator coil.
 If required the cooling function the liquid line valve is open and the heat energy is absorbed
by the refrigerant (a low pressure, low temperature liquid) that in the coil evaporates,
the heater is out of operation.
 If required the heating function the liquid line valve is closed, the evaporator coil is out of
operation, the air is heated in the heater. The cooled or heated air is discharged into the vehicle
air distribution system.
The heat energy is absorbed by the refrigerant (a low pressure, low temperature liquid) that in the coil
evaporates. The cooled air is discharged into vehicle air distribution system.
As the refrigerant evaporates, a low pressure, low temperature, heat-laden vapour is formed.
The refrigerant needs to release the heat energy.
The compressor's suction continuously draws the heat-laden vapours from the evaporator coil. As
the vapours are compressed, it increases its pressure, changing it to high pressure, high temperature
vapours. This increases the vapour temperature and pressure to facilitate heat transfer to the ambient air
and establish a condensing temperature.
As the high-temperature vapours travels through the condenser coil, the heat is dispersed into the
cooling fins, and ambient air is circulated by the condenser fans. As the heat is removed, the vapour
condenses back into a liquid. Thus, the heat absorbed by the refrigerant from the evaporator, is
transferred to the condenser and given off to ambient air.
The high temperature liquid is maintained under high pressure in the receiver, where it is stored until
needed. The receiver serves as a reservoir for the variable demands of liquid refrigerant from
the system.

28
 BEB140

DVE Discharge vibration eliminator SG Sight glass

SRV Relief valve (safety relief valve) EXP Thermostatic expansion valve
BHP BLP
High pressure cutout switch Low pressure cutout switch
HPCO LPCO
FD Filter-drier SVE Suction vibration eliminator
YLL Liquid line valve (solenoid valve) COM Compressor
TR Tank receiver CFM Condenser fan
EFM Evaporator blower

Refrigeration System

From the receiver tank is flowing liquid refrigerant through the filter-drier (dehydrator), where
impurities, solids and moisture are removed. From the filter-drier, the high temperature, high pressured
liquid flows through the solenoid valve to the expansion valve. The expansion valve restricts and
controls the flow of liquid refrigerant to the evaporator where it again absorbs heat from the car interior
air (the return air).

29
8.3. Control System
The control system handles all system functions to maintain the passenger's area at the proper
temperature. The control system consists of controller (driver panel) and control panel (electrical
switchboard) located inside of the rooftop unit.
The controller communicates with control panel (switchboard) and compressor or other optional
equipment via Thermo King uniquely designed harnesses.

BEB123

Application Diagram

30
8.4. ClimaAIRE ID Controller
7 8 9 10 11 12

BEA133
13 14

1 2 3 4 5 6

1 ON/OFF key 8 Temperature icons

2 Mode select key (ESCAPE) 9 Display

3 Temperature key (blue) (DOWN key) 10 Clutch & Boost pump icons
4 Temperature key (red) (UP key) 11 Blower mode icons

5 Blower speed key (ENTER) 12 Fresh air mode icons

6 Fresh air select key 13 Red alarm

7 A/C mode icons 14 Yellow alarm

CAID Driver Panel

8.4.1. Operating Elements

ON/OFF key Press the key to turn the unit ON
When the unit is in operation this Press the key again to turn the unit OFF
key can be used for restart of
controller
Red alarm indicator

Yellow alarm indicator

Mode select key Reheat/Auto mode

A/C mode

Heat mode

Ventilation mode
Display Return air temperature icon
Setpoint icon
Red – Boost pump icon
Blue – Compressor clutch icon

31
 Temperature key DOWN (blue)
Use UP or DOWN key to increase/decrease
temperature setpoint
Temperature key UP (red)

Blower speed key Automatic blower speed

High blower speed
Medium blower speed
Low blower speed
Fresh Air select key Auto mode
Open (100% fresh air)
Half open (50% fresh air)
Closed (Recirculated air only)

8.4.2. Operating Concept of ClimaAIRE ID System

The controller (driver panel) ClimaAIRE ID (CAID) uses two possible operating modes:
 Normal operating mode
 Setup/Calibration/Test mode

8.4.3. Normal Operating Mode

After start (the power supply is activated) the driver panel is set to normal operating mode. In the
normal operating mode the system is running built-in control and diagnostic system.
Functionality of driver panel can be significantly determined by parameters in set-up menu (see chapter
"Function 5: Set Up of controller (SE)" below).
On display can be shown:
 setpoint value – requested temperature (default setting, labelled with setpoint icon)
 Hi or Lo text – in case of Manual mode – see description in Manual mode chapter below
 temperature of return air – when this feature is set by parameter rt (rt = 01)
If the return air temperature is shown on display (labelled with return air temperature icon) then
in case of setpoint change by pressing of UP or DOWN key the new setpoint will be shown for
3 seconds.
 no information (dark, blind display) – when this feature is set by parameter rt (rt = 02)
If the driver panel is set to dark mode with parameter rt = 02 then no information is shown on
display. Only in case of setpoint change by pressing of UP or DOWN key the new setpoint will
be shown for 3 seconds. All other icons on driver panel are visible.
Temperature on the display is shown in °C (default setting) or in °F.

32
Mode Select
In normal operating mode – Auto mode – the controller selects the right mode (cool or heat or
ventilation) automatically.
 Reheat/Auto mode – unit will operate in cool or heat mode based on operating conditions to
ensure proper air temperature and humidity.
 A/C mode – unit will operate in cool mode (based on operating conditions) or ventilation.
 Heat mode – unit will operate in heat mode, cooling will be disabled.
 Ventilation mode – unit will be in ventilation only, cooling will be disabled.

Blower Speed Select

The evaporator blowers move the conditioned air from HVAC unit into interior. Selection of blower
speed determines air flow (amount of air) from HVAC unit into vehicle. In AUTO position the blower
speeds are controlled automatically.
NOTE: When CA ID controller is used in HVAC system equipped with two speeds blowers the LOW
and HIGH blower speeds are applicable – the MEDIUM speed position is not used and if selected
than blowers run in low speed only.

Fresh air/ Smog (Optimal Features)

Using fresh air key driver can control amount of fresh air flows through HVAC unit or can close air
damper in case of smog. This "smog mode" can be easily set by pressing fresh air button.

Automatic mode – the fresh air damper is controlled automatically

Fresh air damper open (100 % FA)

Half open – fresh air damper at 50% position (50 % FA)

Recirculated air – fresh air damper closed (0 % FA)

If no key was pressed in last 2 seconds and fresh air button is pressed once, the FA symbol and
recirculated air symbol lights up together and the fresh air damper is closed for next 10 minutes. After
this period the controller returns to previous FA state (indicated by FA symbol).
If FA key is pressed once more than the "smog mode" is cancelled and FA damper position can be
selected.

33
Automatic ON Feature
Depending on Ao parameter (see "Figure 19: CAID Controller Parameters") the controller (driver panel)
will be switched ON or stays OFF depending on state when power supply was switched OFF:
 If the driver panel was ON when power supply was switched OFF; on next system start –
power supply ON – the driver panel will also start (internal memory keeps the last operating
status; parameter Ao is set to 00).
 If the driver panel was OFF when power supply was switched OFF; on next system start –
power supply ON – the driver panel will stay OFF (internal memory keeps the last operating
status; parameter Ao is set to 00)
OR the driver panel always will be switched ON when the power supply is switched ON
(parameter Ao is set to 01).

Lock Function
Depending on Lc parameter (see "Figure 19: CAID Controller Parameters") the driver panel buttons
functions are obvious or described further (factory settings) or:
 Blower speed key and fresh air select key are locked, have no response on pressing (Lc =01).
 Mode select key, blower speed key and fresh air select key are locked (Lc=02).
 All buttons except ON/OFF key are locked (Lc=03).

Manual Mode (Optional Feature)

ClimaAIRE ID can control HVAC unit in manual mode to operate system directly. Manual mode has to
be enabled by parameter Lt in driver panel setup.
In automatic mode operator can change the setpoint in range from LS (minimal value of setpoint) to HS
(maximal value of setpoint), default range is from 17 °C to 27 °C. When the control mode is changed to
Manual mode then setpoint value can be set to Lo command instead of LS or to Hi command instead of
HS value:
 Lo command switches ON continual signal for compressor/clutch (relay output CR = 1).
 Hi command switches ON continual signal for boost pump (relay output BPR = 1).
With both commands red or blue icons on the right side of display are switched ON. These icons
indicate heating system (boost pump) or cooling (compressor) operation.
By Lt parameter (Lt=02) Manual mode can be enabled with limited duration for 5 minutes. The function
is the same as in above described Manual mode but after 5 minutes:
o Hi command switches back to HS value and thereafter driver panel operates HVAC system
automatically.
o Lo command switches back to LS value and thereafter driver panel operates HVAC system
automatically.

Economic Cool Mode (Optional feature)

Depending on EC parameter (see "Figure 19: CAID Controller Parameters") the driver panel in
STANDARD COOL mode can operate blower(s) in three speeds (low, medium, high) or in
ECONOMY COOL mode can operate blower(s) in medium or high speed only. This feature affect only
COOL mode when compressor is in operation.

34
8.4.4. Setup/Calibration/Test Mode
For access to Setup/Calibration/Test mode the driver panel needs to be in normal operation. Press
and hold the Temperature DOWN key and the Temperature UP key simultaneously for 3 seconds till
text (Function 1) "t-1" will be displayed.
In Setup/Calibration/Test mode the buttons on the panel uses different function – see following table.

ON/OFF key ARROW – DOWN key (blue)

ENTER key ARROW – UP key (red)

ESCAPE key

CAID Keys in Setup/Calibration/Test mode

ClimaAIRE ID Functions
Press the UP or DOWN key repeatedly to scroll
through the function menu. In the
Test/Setup/Calibration mode the operator can
use functions listed in following table.
In main menu of Setup/Calibration/Test mode
the operator can switch the control system OFF
on every time by pressing of the ON/OFF key.
No changes will be applied.
When any function is selected and any value is
changed by DOWN key or UP key, in the same
moment is the change saved to memory.
The driver panel Setup/Calibration/Test mode
always waits for switching OFF (soft restart) –
the Setup/Calibration/Test mode must be
finished by pressing ON/OFF key. Next start
(soft restart) returns the system to the normal
operating mode immediately.
NOTE: In Setup/Calibration/Test mode the BEA688
HVAC unit is out of operation.

CAID Function Menu Structure

35
 Nr. Symbol Function
1 t1 Test mode 1 – basic test of HVAC unit
2 rt Relay test
3 Pr Set up of program number and reading of firmware version
4 CA Calibration of temperature sensors
5 SE Set Up of controller
6 AL Reading and clearing of alarms
7 Hr Reading of hour meter

CAID List of Functions

CAID – Function 1: Test Mode 1 (t1)

The TEST MODE 1 can be used for testing of basic operations. TEST MODE 1 allows to operate
the unit manually independently of control system/control diagrams – for example for charging of
refrigeration system or testing of HVAC unit.
In Setup/Calibration/Test mode with DOWN or UP key select "t1" and press ENTER key. In "Test
mode 1" are available following tests:

1. Cooling/Heating control

Press "Mode key" to change heating and cooling outputs. The following table is
used to verify of all relay outputs and function of heating and cooling

Function Relay / output ON Relay / output OFF LED

Ventilation
Heating KHTR1, KHTR2 KCOM Red – ON
Cooling KCOM KHTR1, 2 Blue – ON
Auto / Reheat KCOM, KHTR1 KHTR2 Red & Blue – ON

CAID Test Mode 1 – Mode Control

2. Blower speed control

Press "Blower speed key" to change evaporator blower speed. The following table
is used to verify of all relay outputs and functions of evaporator blowers.
Symbol Relay / output ON Relay / output OFF
LOW speed KEFM + low speed PWM -
MEDIUM speed KEFM + medium speed PWM -
HIGH speed KEFM + high speed PWM -
Auto - KEFM

CAID Test Mode 1 – Blower Control

36
CAID – Function 2: Relay Test (rt)
In Setup/Calibration/Test mode select "rt" function and press ENTER key.
On the display will show the relay or output symbol and each press of the UP or DOWN key will scroll
to the next item (see following figure). Press ENTER key and corresponding relay/output is energized.

Display Description Signal Note

EL Evaporator low speed relay KEFM
En Evaporator medium speed relay Not used
EH Evaporator high speed relay KHTR2
CL Compressor clutch relay KCOM Blue icon is ON
bP Boost pump relay KHTR1 Red icon is ON
C0 Modulating coolant valve PWM PWM signal OFF
C1 Modulating coolant valve PWM PWM signal MAX
d0 Damper output Not used
d1 Damper output Not used

CAID Scheme of Relay Test Procedure

After test press ESCAPE key to continue with another function or press ON/OFF key.

CAID – Function 3: Set up of Program Number (Pr)

In Setup/Calibration/Test mode with DOWN or UP key select "Pr" function and press ENTER.
First the firmware version in two steps will be displayed for and then the program number stays
displayed. To change of this program number press the DOWN key or UP key as required.
NOTE: If you want to select a program number which is not available in current firmware version,
you have to upload a new firmware. For more information refer to ClimaAIRE ID Service Manual
(TK 60020-3-MM).
When the desired program number is shown press ENTER key to save a new program number to
memory. To leave of program setup without any changes press ESCAPE key. Press UP or DOWN key
to continue with another function or press ON/OFF key to save all changes and switch OFF (soft restart)
the system.

CAID – Function 4: Calibration (CA)

The controller is checked at factory but after HVAC unit installation the calibration mode should be
used to verify and adjust temperature sensors functionality in the field.

NOTE: Calibration is not a repair for defect sensors or bad connections.

In Setup/Calibration/Test mode select "CA" function with UP or DOWN key and press ENTER key. On
the display is shown name of parameter to calibration.
 Press ENTER again to see its current value.
 To leave the parameter unchanged press ESCAPE key.
 To change the value press DOWN key or UP key as required.

37
 Each press of UP or DOWN key is representing value change about 0.2 degree (0.2 °C). Example:
for increasing of current value for one degree up (+1 °C) press UP key five times.
Because the two digit display don't allow to shows decimal numbers every press of UP or DOWN
key isn't noticeable. However on the right side of display is small orange dot, if this dot is visible
the current value is higher about half degree or more than displayed value (e.g. if the value was 11
degree and the UP key was pressed three times the dot will appears, the value is now between
11.5 and 12 degree).
If the UP or DOWN key is pressed and hold than the value is changing quickly (repeatedly) until
the key is released.
The calibration range/correction for temperature sensors is from -1 °C to +26 °C.
 Press ESCAPE to save new value and continue to next parameter.
If ON/OFF key is pressed now a new value is also saved and the system will restart (soft restart).
 With UP or DOWN key select next parameter to continue in calibration.
After calibration press ESCAPE key to return to Function menu or press ON/OFF key to switch OFF
(soft restart) the system.

Nr. Display Description / Note

1 rA Return air temperature sensor
2 Ct Evaporator coil air temperature sensor
3 At Ambient temperature sensor
4 CF Clutch feedback – no calibration
5 Ub Battery voltage on PWR – no calibration

CAID List of Calibrations

38
BEA689

CAID Calibration Function Structure

39
Function 5: Set Up of Controller (SE)
This setup mode can be used to configure the controller for a specific application or conditions.
In Setup/Calibration/Test mode with UP or DOWN key select "SE" function and press ENTER key.
The system to check/change of the parameters is similar as for calibration. On the display will show
parameter symbols and each press of the UP key will scroll to the next parameter (see following figure).
If required parameter (symbol) is displayed press ENTER key to see its current value.
 To leave the parameter unchanged press ESCAPE key.
 To change the value press DOWN key or UP key to set new parameter as required.
Press MODE key to save and continue with another parameter or press ON/OFF key to switch OFF
the system. At the end press ON/OFF key to save all changes and switch OFF (soft restart) the system.

BEA690

CAID Setup Function Structure

40
Par. Preset Unit Min. value Name Description
value Max. value
Ab 07 °C 0 °C For compressor protection only. If ambient temp.
Ambient switch
is below this parameter the compressor (clutch)
15 °C point
will not start
Fr -3 °C -5 °C Evaporator Freeze protection of evaporator. If temperature
+5 °C antifreeze switch on evaporator coil (CTS) is lower than this
point parameter the compressor will be switched OFF.
NOTE: It is not recommended to change this
parameter.
rh 01 - - Reheat mode 00 - reheat mode disabled – economy auto mode
01 - reheat mode enabled
02 - DELTA T is enabled, reheat is disabled
03 - DELTA T is enabled, reheat is enabled
dt 07 °C 1 °C Delta T Offset for control of return air temperature.
15 °C Set point SPc = Ambient temperature ATS minus
Delta T value.
If the result is less than 22, then SPc = 22 °C
The lowest possible SPc is the set point selected
Ao 00 - - Automatic On 00 = controller will operate the unit in the same
mode as when power was switched OFF
01 = controller will start the unit every time power
is switched on
LS 17 °C 15 °C Low set point Minimum value of set point.
30 °C
HS 27 °C 15 °C High set point Maximum value of set point.
30 °C
00 = Set point shown on display
Default value on the 01 = Return air temperature shown on display
rt 00 - -
display 02 = Blind display – set point value shown for
3 seconds after any change
Old ClimaAIRE I 00 = CAID as original
0C 00 - -
replacement 01 = CAID as replacement of ClimaAIRE I
°C = Temperature on the display in °C
un °C - - Celsius/Fahrenheit
°F = Temperature on the display in °F
EL 45 % 0% Low speed of Low value/frequency for PWM output *
100 % blower
En 66 % 0% Medium speed of Medium value/frequency for PWM output *
100 % blower
Eh 100 % 0% High speed of High value/frequency for PWM output *
100 % blower
00 - Automatic mode – no possibility to set Lo
Lt 00 - -
Limited temperature and Hi set point on display
set point 01 - Manual mode, Lo/Hi set point available
02 - Manual mode limited for 5 minutes only
EC 00 - - Economic cool 00 = Standard cool mode – default value
mode 01 = Economic cool mode
HO 0 °C 0 °C Set point for HEAT mode will be increased by
Heat offset
5 °C offset compare to COOL and REHEAT mode
Lc 00 - - Lock function 00 - no lock (default value)
01 - blower speed key and fresh air select key are
locked (have no function in operation)
02 - mode select key, blower speed key and fresh
air select key are locked
03 - all buttons except ON/OFF key are locked
* PWM output is used on the systems with blower speed controllers or brushless motors

CAID Controller Parameters

41
CAID – Function 6: Reading and Clearing of Alarms (AL)

In Setup/Calibration/Test mode select "AL" function with UP or DOWN key and press ENTER key.
All alarm codes will be displayed for 2 seconds and at the end will be displayed "dE".
 For list of alarm codes see "Figure 21: CAID List of Alarm Codes".
 If no alarm is stored (e.g. previously alarms were cleared) the "no" label will be displayed for
1 second and no more action will be executed.

NOTE: If necessary to keep the alarm codes in memory readable by this way, press ON/OFF key,
the driver panel will be switched OFF and the alarms remains recorded.

 Press the ENTER key to clear all alarms. On the display appears "00" for a short time and then
the system returns to Function menu, on the display will show "AL".

NOTE: Alarms cleared through driver panel remain in internal memory – in history – and can be
read through connected PC with Service software.

At the end always press ON/OFF key to switch (soft restart) the system OFF.

42
CAID – Function 7: Reading of Hourmeter (Hr)
In Setup/Calibration/Test mode with UP or DOWN key select "Hr" function and press ENTER key.
The symbols and each value will be automatically displayed in following scheme and at the end will be
again displayed "Hr".

NOTE: Detailed hourmeter (with minute resolution) is available via PC connection and Service
software.

The whole procedure can be repeated by pressing ENTER key again. With UP or DOWN key select
next function or press ON/OFF key to switch OFF the system.

Display Description Example

Un UNIT
Hr hours
XX 01
YY number of hours in operation 10
ZZ 23 = total running time 11 023 hours
CL COMPRESSOR (Clutch)
Hr hours
XX 00
number of hours when the
YY compressor (clutch) request 05
signal was set ON
ZZ 22 = total "compressor" time 522 hours
CL COMPRESSOR (Clutch)
CY cycles
NN 00
number of ON/OFF cycles
PP 44
during unit operation
RR 11 = total 4 411 ON/OFF clutch cycles
Fr FREEZE
CY cycles
NN number of evaporator coil 00
freeze protection
PP occurrences 00
(see parameter "Fr" in
RR "Figure 19: CAID Controller 15 = total 15 freeze conditions occurrences
Parameters")

CAID Scheme of Hourmeter

43
8.4.5. ClimaAIRE ID Diagnostic System
After start the driver panel is in normal operating mode. In the normal operating mode is running
the built-in diagnostic system.
The ClimaAIRE I D driver panel uses dual alarm system with two levels of signals:
 WARNING (yellow alarm symbol).
 ALARM (red alarm symbol).

When any red alarm (ALARM) appears the alarm code will be blinking on the display until some button
is pushed. If any yellow alarm (WARNING) appears the alarm code will be blinking on the display
for 5 sec.
The alarm codes are stored in the memory to identify possible fault conditions. Up to 40 alarms codes
can be stored. The records can be displayed on the driver panel with the procedure described above.
The complete history can be read by the PC only.

Alarms Description
The WARNING (yellow alarm) symbol will be ON in the case of:
 Low value of any temperature sensor:
o temperature sensor defect
o short circuit of the harness to sensors
o temperature is lower than -35 °C (-31 °F) – resistance of the sensor or of the total circuit
is lower than 1,25 kOhm
 High value of any temperature sensor:
o temperature sensor defect
o open circuit of the harness to sensors
o temperature is higher than 75 °C (167 °F) – resistance of the sensor or of the total circuit
is higher than 2,9 kOhm
With yellow alarm conditions the unit will continue in operation with the wrong data from the sensor.

The ALARM (red alarm) symbol will be ON or blinking in the case of:
 HPCO or LPCO switch is open longer than 10 minutes (alarm code 6).
 HPCO or LPCO switch is cycling – switched OFF 5 times per 10 minutes (alarm code 5).
 Inverter alarm (alarm code 31 – 37, special program for electric bus units only).
Any red alarm will switch the unit to the VENTILATION mode with automatic blower speed. The
driver can change the blower speed manually. The compressor and condenser fans are stopped.
The alarm symbols can be removed by restart of control system (use the ON/OFF key to switch OFF,
wait for 2 seconds, switch ON). After restart – if the reason for alarm is still in existence – the alarm
symbol can appears again. If the alarm comes up again, don't restart the unit more times. In that case
immediately contact the service department or Thermo King representative.
NOTE: For more information, detail list and description of alarms refer to ClimaAIRE ID Service
Manual (TK 60020-3-MM).

44
 Alarm Code Name Symbol Description
01-04 not used -
Cycling HPCO (BHP) or HPCO or LPCO switch is switched off
05 RED
LPCO (BLP) 5 times per 10 minutes
Long delay of HPCO (BHP) or HPCO or LPCO switch is switched off
06 RED
LPCO (BLP) longer than 10 minutes
07 RTS Low YELLOW RTS: Return Air Temperature
CTS: Evaporator Coil Temperature
08 RTS High YELLOW ATS: Ambient (Fresh) Air Temperature
09 CTS Low YELLOW
Low = short circuit or temperature is
10 CTS High YELLOW lower than -35 °C
(the limit value is -35 °C)
11 ATS Low YELLOW
12 ATS High YELLOW High = open circuit (disconnected
sensor) or temperature is higher than
13 – 30 not used - 75 °C (the limit value is 75 °C)
31 – 37 Inverter Alarms RED for SR10E only

CAID List of Alarm Codes

Freeze Protection
Temperature of evaporator coil is measured by sensor (CTS). If this temperature is lower than value in
parameter Fr for more than 30 seconds – that can be dangerous for freezing – the compressor output
signal (CR) is switched OFF (see "Figure 19: CAID Controller Parameters"). The compressor (and the
condenser fan also) can return to operation if temperature of evaporator coil rises approx. 5 °C above
Fr parameter for more than 1 minute.

Compressor Protection
Compressor output (CR) can be switch ON (compressor can start) only if ambient temperature (ATS) is
higher than value of parameter Ab (see "Figure 19: CAID Controller Parameters").

8.4.6. ClimaAIRE ID Inputs and Outputs

Control system inputs are used to monitor system performance and determine operating conditions.
System outputs are used to control of all system component operations.

BEC605

CAID Driver Panel Connectors

NOTE: For more information and detail specification of CAID inputs/outputs refer to ClimaAIRE
ID Service Manual (TK 60020-3-MM).

45
 Operating range
Input Pin Description Note
(min – max)
Ambient temperature -35 °C +75 °C
ATS P1-09
sensor -31 °F 167 °F
Return air temperature -35 °C +75 °C
RTS P1-10
sensor -31 °F 167 °F
-35 °C +75 °C
CTS P1-11 Coil temperature sensor
-31 °F 167 °F
Pressure sensor/switch
31B P1-12 digital, high side input
(LPCO, HPCO)
Supply
P1-13 Supply ground 0 VDC 5 VDC
ground
Power
P1-14 Power supply 10 VDC 35 VDC max.100 mA
supply

CAID List of Inputs

NOTE: For temperature inputs must be used sensors TK 41-4157, TK 41-4335 or TK 41-8780 only.

Output PIN Description Standard type

HTR2 P1-01 Heater, 2nd level 0/1 relay, low side output
EFRM P1-02 ---
DM (DR) P1-03 ---
Compressor and condenser fan
COM P1-04 0/1 relay, low side output
motor
HTR1 P1-05 Heater, 1st level 0/1 relay, low side output
EFM P1-06 Blower motor 0/1 relay, low side output
P1-07 Sensor ground ---
PWM P1-08 Evaporator blower speed PWM 20 kHz, high side output

AID List of Outputs

The driver panel (controller) is equipped with communication connector and can be connected to
portable PC for testing and monitoring (use ClimaAIRE PC Adapter Kit TK 204-1063).
NOTE: For more information see ClimaAIRE ID Service Manual (TK 60020-3-MM).

Communication Connector
D-sub 9pin connector (RS232 standard) for communication with monitor software in portable PC.

46
8.5. Application Interface
ClimaAIRE ID Application
Signal Pin Type Connector, Signal Type, Description
harness active value
Power supply P1-14 --- XLV1-A6 --- 24 VDC
Power supply
Supply ground P1-13 --- XLV1-A5 --- 0 VDC
31B P1-12 DI XLV1-B3 31B DO, +24 VDC Press. switches feedback
ATS P1-09 AI XLV1-B4 ATS AO Ambient air temperature
RTS P1-10 AI XLV1-B5 RTS AO Return air temperature
CTS P1-11 AI XLV1-B7 CTS AO Cond. coil temperature
HTR2 P1-01 DO XLV1-B8 KHTR2 DO Heater, 2nd level
EFRM P1-02 DO --- --- NOT USED ---
DM (DR) P1-03 DO --- --- NOT USED ---
COM, Compressor and
COM P1-04 DO XLV1-B2 DI, +24 VDC
CFM condenser fan motor
HTR1 P1-05 DO XLV1-B7 KHTR1 DO Heater, 1st level
EFM P1-06 DO XLV1-B1 EFM DI, +24 VDC Evap. blower motor
GND for sensors P1-07 --- XLV1-B6 TSB Common sensor ground
PWM P1-08 DO XLV1-A4 DI, PWM Evap. blower speed

Controller – Application Interface

8.6. Basic Application Description

Once the control voltage is connected to ClimaAIRE ID (PWR signal), the roof top unit is controlled
according to the control diagram.
The control variable for regulation of the HVAC unit is used temperature of return air (RTS) value.
The control system monitors all temperature sensors and the temperatures are evaluated for following
conditions:
 Compressor can start if ambient temperature (ATS) is over 5,0°C.
 Temperature on evaporator coil sensor (CTS) – test for freezing:
o If temperature goes down below -2,5°C (over 1 minute), the compressor output is
switched OFF.
o Return to ON state is possible if temperature increase up to 1,7°C.
The control system monitors high pressure (HPCO) and low pressure (LPCO) switches. If pressure is
out of limits 3x per 10 minutes the compressor output is switched OFF. This event is evaluated like
the fault and the HVAC system is switched to ventilation mode. Driver can restart the HVAC system by
on/off switch back to auto mode.
In case of fault in control circuits (overcurrent of evaporator blower), the fault stage is also evaluated
and unit is switched to OFF mode or ventilation mode. In this case, the responsible person must find
the reason for fault (for example opened circuit breaker) and after the repair the controller can be
restarted back to auto mode by ON/OFF switch.
The fault (alarm) stage is indicated on control panel by red triangle. The error on temperature sensor or
sensor circuit is indicated by yellow triangle.
There is one set point (adjustable by thermostat knob) used for control of rooftop HVAC. There is
47
possibility to control air flow from roof unit manually or automatically and there is possibility to set
manually one of working mode.
After initial unit start-up, the controller regulates the compressor, condenser fan motor, solenoid valve,
evaporator blower based on the set point temperature and the return air sensor temperature.
The controller can operate the rooftop HVAC unit in one of the stages listed in following overview.

Stage Active application outputs

Evaporator blower motor (XLV1-B1), PWM (XLV1-A4) on maximum speed,

Full Cool compressor (XLV1-B2)

Evaporator blower motor (XLV1-B1), PWM (XLV1-A4) on medium speed,

Medium Cool compressor (XLV1-B2)

Evaporator blower motor (XLV1-B1), PWM (XLV1-A4) on low speed, compressor

Low Cool (XLV1-B2)

Ventilation Evaporator blower motor (XLV1-B1), PWM (XLV1-A4) on low speed

Heat I Evaporator blower motor (XLV1-B1), PWM (XLV1-A4), heater (XLV1-B7)

Heat II Evaporator blower motor (XLV1-B1), PWM (XLV1-A4) heater (XLV1-B8)

HVAC Operating Stages

HVAC Working Modes

The HVAC unit can operates in one of following working mode. Driver can select the working mode on
control panel by Mode select key.
During next start of control system (ON/OFF button or START signal) is always the Auto mode
activated.
 Auto Mode – according the control diagram.
 Cool Mode – actual operating stage range from Full Cool stage to Ventilation stage according
the control diagram – preferred in summer time.
 Heat Mode – actual operating stage range from Ventilation stage to Heat stage according
the control diagram – preferred in winter time.
 Ventilation Mode – the ventilation only – actual operating stage range from Cool stage to Heat
stage according the HVAC control diagram (except the Reheat stage), but the compressor and
the heater are permanently switched OFF. Automatic operation of evaporator blower will try
to control the internal temperature.
 Defrost / Demist mode – the key “FRESH AIR” on control panel activate Defrost/Demist
mode. Operating stage of rooftop unit is Full Cool blower speed is set to medium. In this
mode is enabled all temperature protection (freezing and compressor protection). This mode is
signalized on control panel by symbol “Fresh Air”. If this mode is not switched off by
the same button than the function automatically disappears after 10 minutes. Driver can switch
on this mode again.

48
Freeze Protection
ClimaAIRE control system checks evaporator coil (by Coil Temperature Sensor – CTS) conditions for
freezing. If the temperature of the cooling coils is lower or equal to -2.5°C for more than 1 minute,
the compressor clutch signal and condenser fan signal is switched off. Compressor clutch signal and
condenser fan signal can be switched on when coil temperature (CTS) will be higher than freeze
temperature + 2°C for more than 3 minutes.
The freeze protection temperature value is adjustable in Set Up mode.

Compressor Protection
If the ambient temperature is lower than 5 °C the compressor clutch signal will not be switched on. If
the ambient temperature drops down during compressor working period then compressor does not stop
although the temperature is below 5 °C.
The compressor protection temperature value is adjustable in Set Up mode.

BEA705

BEA987

Control Diagram – Auto Mode

49
 BEA988

Control Diagram – Cool Mode

BEA989

Control Diagram – Heat Mode

50
8.7. Start Up

Normal start conditions:

 RAC unit power supply available.
 Control voltage (low voltage) available.

Control system start-up signals:

 XLV1 input – low voltage is ON (active, +24 VDC).
In the moment when the control voltage is connected to ClimaAIRE control system, under valid
conditions listed above the HVAC system will start. From the first moment the RAC rooftop unit is
controlled in AUTO mode according to the control diagram (see chapters above).
On start of control system is the Full Cool stage always activated. For regulation of the RAC unit is
control value the temperature of return air (RTS).

What to check if the unit will not start:

 RAC unit power supply.
 Control voltage (low voltage).
 Control system signals.
 Working conditions.
 Main rooftop unit parts (see chapter 8).
If in a short moment after start appears some alarm symbol on the driver panel see chapter 8.4.5 or
chapter 8.

8.8. Operation
Normal operational conditions:
 RAC unit XPOW and XLV1 power supply.
 Control voltage (low voltage) available.
Control system operational signals:
 RTS and CTS values from sensors are within limit.
 Other signals depend on operating conditions and requested working mode.
The HVAC system in normal operating mode is controlled according to the control diagrams or by
manual commands.
For more information see section ”Control system ClimaAIRE ID”.

8.9. Shut Down

For shut down of HVAC system press ON/OFF key on driver panel.
NOTE: Don’t switch OFF the power supply and low voltage supply before the control system is
turned OFF.

51
9. Light Repair
9.1. Inspection Recommendations
To keep the correct functions of the HVAC unit you must periodically execute the following
maintenance procedures. The schedules should be used during the initial service periods (at least during
warranty period).
IMPORTANT: SAFETY FIRST! When servicing or repairing an air conditioning unit,
the possibility of serious or even fatal injury from electrical shock exists. Extreme care must
be used when working with an air conditioning unit. Always respect safety rules, follow
“Safety Precautions”, respect valid local laws and general Health & Safety prescripts.

WARNING: Before any repair action disconnect Power supply (High voltage) XC1
connector and Signal (Low voltage) connector XC2! The unit has no main ON/OFF
switch! The switch on front cover of the switchboard (electro) box is "soft switch"
for switching between control modes only.

CAUTION: Any action on electricity must be provided by electricians with proper

qualifications.
CAUTION: Always use protective gloves when open the unit covers, the fins of
coils can be very sharp!

Thermo King reserves the right to deny warranty coverage on claims due to lack of maintenance
or neglect. Claims in question must be supported by maintenance records.
If you are not really experienced in following actions please call for help Thermo King Service Centre
otherwise is here risk of damage or complications. If you have any questions, please contact your
supplier, Thermo King Representatives or directly Thermo King manufacturer.
All maintenance intervals are based on normal operating conditions. Unusual or extraordinary
conditions require more frequent service intervals. For example, high air pollution could require more
frequent replacement of air filters.
In case of any question or unclear situation please contact Thermo King Representative.

BEFORE ANY SERVICE ACTIVITY STOP THE HVAC UNIT OPERATION WITH:
1. ON/OFF button on driver panel.
2. Turn all the power supply OFF.
3. Disconnection of all electrical connectors.

WARNING: The electrical disconnection is allowed only if all the power supply
cables are without voltage!

52
WHEN THE LAST SERVICE ACTIVITY IS FINISHED:
1. Check the HVAC unit top cover, check if all locking elements are at a proper position.
2. Connect all electrical connectors, check the proper connection.
3. Turn the power supply ON.
4. Enable the unit operation with ON/OFF button on driver panel.
5. Check the HVAC system functionality.

53
9.2. Maintenance Inspection Schedule
9.2.1. Intervals
The following intervals are just a recommendation. The periods may vary – this depends on ambient
conditions, pollution or local transportation laws. Please use common sense then judging replacement
of filters and cleanliness based on first four months of service.
If you need any help please contact Thermo King Representative or Service.

WARNING: When inspecting or servicing the HVAC system, follow all safety rules
and operating procedures, to avoid any physical harm.

120 Days Interval

Component Task

Control system Download unit operating data from the control system using a portable
computer and service software, check alarm records.
For more details see ClimaAIRE ID Service Manual TK 60020-3-MM.
HVAC system Perform a functional check of the HVAC system using a portable computer
and service software.
A complete functional test includes:
 Testing the connection between hardware and software, use function
Communication mode – see "Setup/Calibration/Test mode" on page 38.
For additional information see Service manual for controller.
 Testing the individual functions of the HVAC system, use function
Relay test (rt) – see chapter "Setup/Calibration/Test mode".
Rooftop unit Visually inspect rooftop unit:
Body & frame  Check for secure mounting to vehicle roof.
 Check condition of all covers and attached hardware. Install new parts
and/or hardware as necessary.
 Clean dirt, debris or foreign particles accumulated on all grilles.
Fresh air intake Visually inspect to make sure the fresh air intake is clean and free of dirt,
debris or foreign particles (such as leaves, paper, etc.)
Condenser coil Inspect coil and coil fin surfaces for cleanliness. Vacuum any dirt or debris
from the coil. If necessary, clean with low pressure compressed air or
detergent/water solution.

CAUTION: Air pressure or water spray pressure must not be too high to
prevent from damage of coil fins.

CAUTION: When using a water spray, isolate the return air plenum to
prevent water spray from entering the passenger compartment.
For more information see chapter 9.3.

54
120 Days Interval (continue)

Component Task

Evaporator coil Inspect coil and coil fin surfaces for cleanliness. Vacuum any dirt or debris
from the coil. If necessary, clean with low pressure compressed air or
detergent/water solution.

CAUTION: When using a water spray do it from the inside of the coil
outward (opposite direction of normal airflow) Remove all air filters
before cleaning!
For more information see chapter 9.3.

Heater Inspect heater for sign of overheating.

Air filters Remove and replace filters. Replace any bent or otherwise damaged support
retainers.

CAUTION: The interval of filter changing depends on external conditions

and it needs to be set up based on real air pollution.
For more information see chapter 9.8.

Major components Visually inspect all major components for loose, damaged or broken parts,
check if the fixing elements are tight.

General hardware Visually inspect all hardware, especially screws and nut inserts, locks, hinges,
isolators. Tighten or replace any loose or missing hardware.

Drainage pipes and Inspect the drainage openings. Make sure they are clean and free of debris.
openings
Disconnect drainage hose from channel part and clean drainage hose.

55
360 Days Interval

Component Task

Electrical, wiring Check main/power supply connector on rooftop unit, tighten if necessary.
Carefully check the grounding connections on all frames and covers, tighten
if necessary.
Check integrity of wiring to main electrical system, inspect all wires and
terminals for damage or corrosion. If corrosion is present, clean terminals with
electrical contact cleaner.
Repair or replace any worn or damaged connections, fix any loosen cable.
Check wiring connectors on all pressure and temperature switches.

Switchboard box Clean with vacuum cleaner any dust or debris from switchboard box interior.
Inspect electrical connections for fraying or burned condition. Replace wiring
connectors as necessary.
Inspect contactors and relays. Make sure they are securely mounted. Replace
any parts that are cracked or show sign of overheating.
Check contactor(s) for voltage drop/imbalance across contacts. Where voltage
drop or imbalance is found (indicating high resistance), replace the contactor.

Refrigerant lines Check all refrigerant lines, soldered joints, pressure switch connections for
refrigerant leaks using an electronic leak detector.

Condenser fan Clean any dirt and/or oil accumulations from fan blades, motor, grille.
Inspect fan blades for bent or broken blades. Replace the fan if any part is
damaged. If any doubt exists please contact Thermo King Service for help.
Rotate fan wheel by hand, check for bearing noise, roughness or looseness.
Replace damaged fan if necessary. If any doubt exists please contact Thermo
King Service for help.

Evaporator blower Vacuum accumulations of dust and/or debris from blower motors and wheels.
Check motor mounting hardware. Tighten or replace hardware as necessary.
Check blower wheel hubs for loose or missing hardware. Tighten or replace
hardware as necessary.
Rotate blower by hand. Determine if blower wheel is rubbing/chafing on
housing. Adjust as necessary.
Rotate blower wheel by hand, check for bearing noise, roughness or looseness.
Replace damaged blower if necessary. If any doubt exists please contact
Thermo King Service for help.

56
9.3. Cleaning

HVAC Unit Box and Cover

Use a mild alkaline cleaner or common cleaning agent to clean the cover. Periodically open the HVAC
unit and clean with vacuum cleaner any dirt, debris, impurities from unit inside area.

Evaporator Coil
Use vacuum cleaner to clean the evaporator coil or use low pressure compressed air for blowing-
through from return air side.

CAUTION: Don’t use water or water spray to clean evaporator coil!

At the end inspect coil and fins for damage, and repair if necessary.

Condenser Coil
Clean the condenser coil by blowing low pressure compressed air or a medium pressure warm water
spray from the inside of the coil outward (opposite direction of normal airflow). Inspect coil and fins for
damage, and repair if necessary.
If a buildup of salt or debris is present on the condenser coil, the coil should be cleaned using a mild
alkaline cleaner with a pH of 9.5 to 10.5. For example Thermo King Climador Coil Cleaner or a 2-3
percent solution of SIMPLE GREEN® would make a suitable cleaning solution.
Apply the solution using a pressure spray/wash type apparatus. Spray the condenser coil thoroughly
from both the inside and outside of the coil. Always thoroughly rinse the coil with a fresh water spray.

CAUTION: Air pressure or water spray pressure must not be too high to prevent
from damage of coil fins.

CAUTION: When using a water spray, isolate the return air plenum to prevent water
spray from entering the air duct.

Condenser Fan and Grille

Use a damp cloth (with mild alkaline cleaner), soft brush, to clean the grille. If necessary, dismantle
the fan assembly and carefully clean the propeller/wings manually.

57
9.4. Special Tools, Equipments and Supplies
For maintenance and repairs use basic hand tools in size and type corresponding to intended task.
On some tasks can be necessary to use a special tools or equipment listed in following figure or in
chapter 11.2.2.
For replacement parts (air filters, filter-drier etc.) please refer to Parts Manual (see the Thermo King
publication number on page 3, ask for most up-to-dated version).
NOTE: Types and suppliers of suitable tools can vary from country to country; usually more
products are available in open market. In any doubt about suitable tool please contact your local
Thermo King dealer or directly Thermo King Representative.

Nr. Item Description

1 Refrigerant gauge manifold set Reads system pressures and allows for correct system
servicing.

2 Quick disconnect access valves Keep pressure in gauge lines when gauge manifold is
removed from compressor.

3 2-Stage vacuum pump See chapter 11.2.2.

4 Portable reclaim unit

5 Electronic micron gauge Must have vacuum level readings from 25,000 to 50
microns.
Use an electronic halogen leak detector or soap solution.
6 Electronic leak detector
WARNING: Do not use a Halide torch to detect leaks.
When a flame comes in contact with refrigerant, toxic gases
are produced that might cause suffocation.

7 Expander tool set 14297

8 Fin comb 14142

9 Digital temperature tester

10 Digital multimeter

11 PC Adapter Kit Thermo King P/N 204-1063

12 Clamp tester

13 Pin extractor tool

14 Heat gun With thermometer, common type.

15 Thermometer with remote reading dial Do not use an infrared touch-less thermometer for air
temperature readings. It will give inaccurate readings.

16 Oxygen acetylene torch, solder, flux.

17 Oil test kit Thermo King P/N 203-457

18 Thread locker Loctite (TM) Type 277, Part no. 27731

19 Sealer Technobond, black Thermo King P/N 203-0770

58
Nr. Item Description

20 Sealer Technobond, white Thermo King P/N 203-0771

21 Sealer tape PERMAGUM Thermo King P/N 203-0391

22 Sealer aktivator Sika® Aktivator-205

23 Sealer butyl cork Thermo King P/N 600152A

24 Anti-seize thread lubricant Loctite (TM) Type 8150, Part no. 15376

25 Climador coil cleaner Thermo King P/N 203-0779 Climador container 10l
Thermo King P/N 203-0778 Climador 6x 1l spray

26 Tamper proofing Loctite (TM) Type 7414

27 Lifting device Thermo King P/N 98-7954

28 Vacuum cleaner/hose

29 Flat nozzle

30 Hand spray

31 Valve stem core remover

Special Tools

59
9.5. Tightening Torque Requirements
From Thermo King manufacturing processes some bolting are marked by blue or yellow colour.
 Blue mark – simple tightening indicator (the torque stripe) – for re-tightening always use
the torque wrench and set the torque by following information, use the paint again (the tamper
proofing tool for example, see chapter 9.3). The hardware is marked by blue in case of rotating
or vibrating parts fixation (compressors, blowers etc.) or in special cases or by customer's
requests.
 Yellow mark – internal marking only, for tightening use common sense and best practice,
use the marker again.
 No colour marking – for tightening use common sense and best practice.

IMPORTANT

The nominal values are valid for simple connection only, e.g. metal sheet to metal sheet
connection. If the technology solution is different, always contacts your Thermo King
specialist for more information.
Every time when you will tighten stainless steel screws or nuts use anti-seize thread lubricant.
The torque values are not valid for the bolts used with the isolators to mounting of the HVAC
unit on the vehicle roof. Refer to the installation drawing for correct tightening value.

Step 1: Locate both groups for bolt and nut in following table:

Strength
Group Fastener Material Finish Marking
Class
A Head bolt, machinery type Steel Zinc plated 5.8 5.8
B Head bolt, machinery type Steel Zinc plated 5.8 8.8
C Head bolt, machinery type Steel Zinc plated 10.9 10.9
D Head bolt, machinery type Steel Black&Wax 12.9 12.9
E Head bolt, machinery type St. Steel Passivated A2-70 A2
B Nut, Regular Steel Zinc plated 8 None
C Nut, Regular Steel Zinc plated 10 None
E Nut, Regular St. Steel Passivated A2 None

Fastener Groups

NOTE: The Thermo King standard fastening hardware belongs to the Group E.

60
Step 2: Select the bolt/nut torque by size & group:

Group A Group B Group C Group D Group E

Size Nominal Torque in [Nm]

M4 1.5 2.4 3 3.8 2.2

M5 3.2 5.1 6.4 7.4 4.2

M6 5.7 8.7 11.3 13.2 7.5

M8 13.7 21.1 27.4 32 18.4

M10 27.2 27.2 54 63 36.6

M12 47 73.5 98 107 63

M14 75 117 147 176 98

M16 117 186 235 275 157

Nominal Tightening Torque

Step 3: Adjust both numbers for special conditions:

 Fine threads +10 %.
 Thin or jam nut -50 % (do not add to Group E – see note #3 below).
 Anti-seize lubricant -20 %.
 Unplated carbon steel +10 %.

Step 4: Set the tighten torque in range.

Minimum torque = 0.9 x nominal torque

Maximum torque = 1.2 x nominal torque

Step 5: Set fastener to required torque.

NOTE 1: The torque values are "First-On" and are not applicable to re-used fasteners. The “Figure
32: Nominal Tightening Torque” covers standard new fasteners. Reuse of old fasteners can follow
this guideline but the strength, grade and condition of reused fasteners is not Thermo King
responsibility.

NOTE 2: The torque values listed are seating torques (not break-away values which may be
substantially different).

NOTE 3: The Group E torque values are based on stainless steel screws used with the anti-seize
lubricant.

61
9.6. Long-term Storage

CAUTION: If the HVAC unit will be operated in the workshop, power supply must
be equipped by residual-current device to protect operator.

The storage for more than 6 months is defined as "long-term storage".

To keep the long-term stored HVAC units well-conditioned follow these recommendations:
 Store the HVAC unit inside in dry, tempered (the temperature should be continuous) and low
dust area off direct sunlight.
 Store the HVAC unit in original wooden crate.
 The connectors must be always closed with original covers recommended by connector's
manufacturer.
 The grilles must be appropriately closed to secure the unit before insect or small animals.

For operation after long-term storage do the following:

6. Uncover the unit.
7. Open all access covers such as evaporator and condenser (if applicable).
8. Ensure there are no debris or rodents.
9. Ensure that coils, pipes and harnesses are not damaged. Ensure there are no oil traces.
10. Close all covers.
11. Ensure all high voltage, low voltage and communication connectors are clear of dust, debris or rust.
12. Lift up the unit of the crate and inspect any under frame damage.
13. Before operating the unit ensure the condenser coils are clean.
14. Connect the unit (if applicable).
15. Operate the unit.
16. Check if alarm signal lamp does not shine.

62
9.7. Electrobox Component Replacement

Preparation
1. Switch the unit/control system OFF, follow the steps in chapter 9.1.
2. Open the switchboard box (electro box) cover. Use appropriate key only!
3. Locate the non-functional/damaged part.

4 5 6 7 8

10

BEB125

1 2 3

1 Terminal block 6 Relay assembly

2 Contactors 7 Circuit breaker (1 phase)
3 Fixing screws 8 Fuse
4 Circuit breakers 9 DIN rail
5 Relay – Shunt-release 10 Clamp

Switchboard

63
9.7.1. Circuit Breaker and Contactor Replacement
1. Remove the auxiliary contact from all the circuit breakers, use screwdriver for releasing. Insert the
screwdriver into the gap between auxiliary contact and the circuit breaker and lightly extract.
2. Release screws and pull out the Busbar.
3. Release and remove push-in lugs (fixed with screw).
4. Disconnect wiring, release the screws on input/output side, and remove the wires from connection.

1 5

6
2 7

4 BEB867 BEB868 BEB869 BEB870

1 Auxiliary contact 5 Busbar

2 Screwdriver 6 Seal
3 Transparent cover 7 Setting knob
4 Circuit breaker

Auxiliary Contact Installation (Example)

BEB126

BEB872

Circuit Breaker Removal (Example)

64
NOTE: Releasing (not removing) of neighbouring parts, wiring and DIN-rail clamps can be helpful.

5. Release the cable ties from wiring where necessary.

6. The circuit breakers are mounted by snapping them onto 35 mm rails. To remove push down on the
circuit breaker at first and then pull out/rotate/tilt the lower part with coupling element and
contactor.
7. Release the screws in circuit breaker and contactor and pull out the circuit breaker and contactor
from connectors of coupling element.
8. Check the electrical parameters of new parts carefully, set the load’s rated current on the scale
according to valid electrical diagram, use the setting knob.

IMPORTANT: There are two possible setting marks on the adjusting knob, see
“Figure 36: Circuit Breaker Adjusting Knob Position.”
 Dash marking: Setting mark for the motor starter protector in stand-alone
design.
 Triangular marking: Setting mark for the motor starter protector in side-by-side
design.
IN OUR CASE YOU HAVE TO USE THE TRIANGULAR MARKING FOR
SETTING!

BEC472

Circuit Breaker Adjusting Knob Position

9. Insert the transparent cover, secure it with the seal.

10. Assembly the coupling element, contactor and circuit breaker, fix with screws. Assure that all
fixing screws are properly tightened.
11. Insert new assembly in upper rail side at first then push the lower part until the fixing teeth click.
12. Fix the pushing-lug with fixing screw. Use common sense and best practice for tightening.
13. Connect the wirings to the terminals, according valid electrical diagram, and fix the wires by all
captive screws. Assure that all fixing screws are properly tightened.

65
14. Set the switch on body of circuit breaker to position "1" (ON).
15. Reinstall the Busbar, auxiliary contact in reverse order.
16. Fix the wiring with cable ties where necessary.
17. Insert the electrobox cover and fix it with bolts.
18. Return the HVAC unit into service, see chapter Chyba! Nenalezen zdroj odkazů. for more
information.

9.7.2. Relay Replacement

19. Pull down the retainer clip and release the relay, remove the relay away from its socket.
20. Check the electrical parameters of new relay carefully according valid electrical diagram.
21. Insert new relay into original position. Push the relay into the socket.
22. Pull up the retainer clip, fix the relay.
23. Insert the electrobox cover and fix it with bolts.
24. Return the HVAC unit into service, see chapter Chyba! Nenalezen zdroj odkazů. for more
information.

BEB875 BEB876

1 Relay socket 3 Relay

2 Retainer clip

Relay Installation

66
9.8. Air Filters Replacement

1 5

BEB128

3 4

1 Evaporator coil 4 Fresh air filter

2 Unit frame 5 Fresh air filter holder
3 Mixed air filter 6 Fresh air intake

Air Filters Installation (Example)

Procedure
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Locate the air filter and carefully pull the whole air filter out.
5. Clean the filter or install new filter medium.

NOTE: Use care when removing dirty filters from the unit. Clean with vacuum cleaner any dirt,
dust or foreign particles from air intake before installing of new filter.

6. Put the filter back on its place.

IMPORTANT: Used air filter medium waste disposal can be subject to local laws. Never mix
the filter medium with household trash.

7. Close and secure the top cover with locks. Use appropriate key only!
8. Connect the XPOW and XLV1 connectors, restore the high voltage and low voltage power supply,
switch ON control system.
9. Return the HVAC unit into service, see chapter 9.1 for more information.

67
9.9. Temperature Sensor Replacement
The RAC unit contains more temperature sensors:
 Ambient Air Temperature Sensor (ATS),
 Return Air Temperature Sensor (RTS),
 Coil Temperature Sensor (CTS).

NOTE: Before replacement/installation check the parameters to be sure that a new sensor has
appropriate features.

2
5

BEA636

1 Temperature sensor 4 Temperature sensor connector

2 Unit frame 5 Bushing
3 Duct opening (return air channel)

Temperature Sensor Installation (Example)

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Locate the sensor:
 ATS: in front of fresh air filter, on side of water eliminator box.
 RTS: return air duct channel, in the corner of opening.
 CTS: under thermostatic expansion valve and solenoid valve.
5. Locate and unplug proper sensor connector.
6. Release the bushing and remove the fixing binder when necessary, loose the cable, remove the
sensor.

68
Installation
1. Install and fix new sensor into original position, connect the sensor connector.
2. Tighten bushing and fix the cable with fixing binders where necessary.
3. Close and secure the top cover with locks. Use appropriate key only!
4. Connect the XPOW and XLV1 connectors.
5. Restore the high voltage and low voltage power supply, switch the control system ON.
6. Return the HVAC unit into service, see chapter 12.1 for more information.

9.10. Solenoid Coil Replacement

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Locate the non-functional solenoid valve.
5. Disconnect solenoid valve connector.
6. Release bolt on top of solenoid valve cover, remove the cover.
7. Release the fixing binders from valve wiring where necessary.
8. Release bolt on top of valve/solenoid, remove the coil.

4
1

2 5

3 6

BEC550

1 Solenoid coil fixing bolt 4 Solenoid valve connector

2 Solenoid coil 5 Solenoid valve
3 Bracket 6 Bracket

Solenoid Coil Installation

69
9. Release bushing and disconnect wires from terminals in valve enclosure, remove the solenoid coil
out of unit.

Installation
1. Reinstall the solenoid valve coil, connect the cable to the coil terminal, tighten the bushing.
2. Fix the solenoid coil with bolt on top of the valve.
3. Connect the solenoid valve connector.
4. Fix the wires with binders where necessary.
5. Install the valve cover.
6. Close and secure the top cover with locks. Use appropriate key only!
7. Return the HVAC unit into service, see chapter 11.1 for more information
8. Troubleshooting

70
10. Troubleshooting
10.1. Analysis Overview
Servicing a system consists of checking system pressures and temperatures. You should be familiar
with the system you are working with.

Condition Possible Cause Remedy

HVAC system doesn't No power supply to unit Locate fault and repair – check the power
operate source, XPOW connector.
(condenser fan,
No output signal from controller Check control circuit and controller circuit
evaporator blower)
breakers. Diagnose and repair or replace
doesn't operate – no
wiring or controller.
amperage draw
Rail car temperature does not demand No action.
cooling or ventilation
Compressor does not No power supply to unit Locate fault and repair – check the
operate – no compressor circuit breaker, contactor,
amperage draw terminals, motor.
Open in low voltage control circuit Check control circuit and controller circuit
breakers. Repair as required.

Rail car temperature does not demand No action.

cooling or ventilation

No condenser fan output signal from Diagnose and repair or replace control
control system system or low voltage wiring.

Defective compressor Replace the compressor.

No output signal from controller Diagnose and repair or replace wiring

or controller.
Compressor does not Rotation scroll stuck Replace the compressor.
operate properly; Seized or frozen compressor bearing
excessive amperage
draw or intermittent Improperly wired Check / correct wiring in comparison with
cycling on overload wiring diagram.
Low line voltage Check line voltage – determine location
of voltage drop.
Open circuit in compressor motor winding Check motor stator connections or stator
winding for continuity. If open, replace
the compressor.
Compressor contactor Low line voltage Increase line voltage at least 90% of
burned out compressor motor rating.

Excessive line voltage Reduce line voltage to at least 110% of

compressor motor rating.

Short cycling Eliminate cause of short cycling.

Compressor short Low refrigerant charge Locate and repair refrigerant leak.
cycles Recharge with the refrigerant.

Restricted solenoid valve or expansion Clean or replace faulty valve.

valve
Noisy compressor Loose fixing bolts/nuts Tighten bolts/nuts.

71
 Condition Possible Cause Remedy
Damaged isolator(s) Check, fix or replace the isolator(s).

Refrigerant flooding back Check the expansion valve adjustment.

Scroll rotating backwards Check phases of power supply and the

compressor wiring.

Faulty compressor Repair or replace the compressor.

Condenser fan Loose line connection Tighten connections.

doesn't operate
No condenser fan output signal from Diagnose and repair or replace control
control system system or low voltage wiring.

Defective fan motor Replace fan assembly.

Evaporator blower Loose line connection Tighten connections.

motor does not
operate No evaporator blower output signal from Diagnose and repair or replace control
control system system or low voltage wiring.

Defective motor Replace the motor.

Rail car temperature Compressor does not operate See section “Compressor does not
too high (unit not operate” on page Chyba! Záložka není
cooling) definována..
Shortage of refrigerant
Repair leak and recharge the refrigerant
circuit.
Air in refrigeration system
Evacuate and recharge the refrigeration
circuit.
Iced or dirty evaporator coil
Defrost or clean the evaporator coil.
Restricted lines on high pressure side
Check for clogged or restricted solenoid
valve. Remove the restriction, clean,
repair the refrigerant line, recharge the
refrigerant circuit.
Plugged filter-drier
Change the filter-drier.
Condenser coil dirty or airflow restricted
Clean condenser coil, remove restriction,
or repair or replace condenser fan
assembly.
Expansion valve open too much
Adjust or replace expansion valve.
Expansion valve sensor bulb (power
element) lost its charge Replace expansion valve sensor bulb
(power element).
Expansion valve sensor bulb (power
element) improperly mounted Correct the sensor bulb (power element)
installation.
Expansion valve sensor bulb (power
element) poorly insulated or making poor Correct the sensor bulb (power element)
contact insulation.

72
Condition Possible Cause Remedy
Rail car temperature Heater does not operate The limits switch open, correct the cause.
too low Check or reset corresponding circuit
breaker.

No power supply to heater Tighten the connections, correct the

wiring (see Diagrams in Appendix).

Check the second step limit switch and

corresponding circuit breaker.

Check the dead-man switch.

No heater output signal from controller Repair/replace the wiring or the controller.
Check dead-man switch.

Defective heater Replace the heater if defective.

Restricted air flow Clean the parts as required.

Frosted liquid line Restricted filter-drier Replace filter-drier.

Frosted or sweating Expansion valve admitting excess Check the feeler bulb, adjust expansion
suction line refrigerant valve if necessary.

Iced or dirty evaporator coil Defrost or clean evaporator coil.

Evaporator blower does not operate See “Evaporator blower motor does not
operate” on page Chyba! Záložka není
definována..

Unit in vacuum. Frost Ice plugging expansion valve orifice Apply hot wet cloth to the expansion
on expansion valve valve. Moisture indicated by increase in
only suction pressure.
Replace the dehydrator.

Compressor loses oil Refrigerant leak Repair leak and recharge the HVAC
system with refrigerant.

Compressor oil Short cycling See “Compressor short cycles” on page

migrates Chyba! Záložka není definována..

73
11. Refrigeration Repairs
11.1. Introduction
CAUTION: Safety first! Always respect safety rules, follow “Safety Precautions”,
respect valid local laws and general Health & Safety prescripts.

WARNING: Make sure that HVAC unit and/or vehicle cannot start while servicing
the system.

CAUTION: Always use protective gloves when open the unit covers, the lamellas
of condenser and evaporator coil can be very sharp!

Thermo King reserves the right to deny warranty coverage on claims due to lack of maintenance
or neglect. Claims in question must be supported by maintenance records.
If you are not really experienced in following actions please call for help Thermo King Service Centre
otherwise is here risk of damage or complications. The main repair procedures can be carried out in
specialized workshop only with trained and highly experienced technicians. In case of any question
or unclear situation please contact your supplier or directly Thermo King Manufacturer.
Before starting the replacement procedure, use most up-to-dated Parts Manual or Stocking Guide
to identify the correct spare part suitable for your unit.

BEFORE ANY SERVICE ACTIVITY STOP THE HVAC UNIT OPERATION WITH:
1. ON/OFF button on driver panel.
2. Turn all the power supply OFF.
3. Disconnection of all electrical connectors.

WARNING: The electrical disconnection is allowed only if all the power supply
cables are without voltage!

WHEN THE LAST SERVICE ACTIVITY IS FINISHED:

1. Check the HVAC unit top cover, check if all locking elements are at a proper position.
2. Connect all electrical connectors, check the proper connection.
3. Turn the power supply ON.
4. Enable the unit operation with ON/OFF button on driver panel.
5. Check the HVAC system functionality.

74
11.2. Refrigeration System Fundamentals
11.2.1. Introduction
Some these service procedures on the refrigeration system (refrigeration circuit) can be regulated by
Federal, State or Local laws. Please check the situation and coordinate all the actions with this
regulations and Health & Safety rules.
All regulated refrigeration service procedures must be performed by an EPA certified technician, using
approved equipment and complying with all Federal, State and Local laws.

IMPORTANT: On R-407C refrigerant:

When charging the system, always charge from liquid side and use the refrigerant in a liquid
state. Do not charge vapour in the system!
As R-407C is a blend of three refrigerant of different density, any major leak will imbalance
the ratio, Thermo King recommends always replace the whole (remaining) refrigerant
and recycle the retrieved portion properly per governing laws. Then use new refrigeration
charge by correct recommended weight in liquid state. In case of leak do not “top off”
the refrigeration system.

Basic steps in case of troubles with refrigeration system:

1. Recovery (disposal) of remaining refrigerant
 Vapour recovery
 Liquid recovery
2. Leak Test – identification, location of point of trouble
3. Repair & Check
4. Evacuation
 System preparation and hookup
 Evacuation
 Pressure rise test
5. Charging
6. Functional test of system

General information
If refrigerant has leaked or been removed from the system, check entire system for possible component
damage and refrigerant oil loss.
If any system leak or damage was found, repair the system, recheck the system after repair and conduct
system evacuation.
If the system has some remaining pressure (some refrigerant is present in the system), and the leak is
NOT found, using a leak detector is recommended. Soap and bubbles is the best tool to check minute
leaks that the electronic leak detectors cannot find.
If the leak is already found and the system is almost flat (empty), we recommend evacuating the system
AFTER the repair is done (for example after tightening a fitting).
After any repair we recommend to execute the Leak Test to be sure that system is tight.

75
As the oil used in R-407C scroll compressor is very viscous, rarely an oil charge would be lost. If this
happens, the compressor would have failed already and it that case we recommend replacing
the compressor (or two compressors in sets of 2, depending on unit design), charging the proper oil
charge for new compressor(s) and do the evacuation and charging procedures described further.
After compressor(s) replacements recheck the system again.
It is generally good practice to replace the filter-drier whenever the system is opened and exposed
to ambient for an extended period of time.
IF THERE IS A SUSPICION OF BIG LEAK, IT IS RECOMMENDED THE WHOLE CHARGE IS
RETRIEVED (REMOVED) AND A NEW CHARGE IS PLACED INTO THE SYSTEM AFTER
PERFORMING THE EVACUATION AND CLEANUP STEPS – SEE IMPORTANT NOTE ABOVE.
In the following text are procedures usually described by using of Thermo King evacuation station.
Always follow the safety instructions, procedures and working instructions in specific equipment
manufacturer’s documentation.

11.2.2. Refrigeration Service Tools

CAUTION: When servicing Thermo King R-407C refrigeration systems, use only
service tools (i.e., vacuum pump, refrigerant recovery equipment, gauge hoses, and
gauge manifold set) certified for and dedicated to R-407C refrigerant and Polyol Ester
based compressor oils. Residual non-HFC refrigerants or non-Ester based oils will
contaminate HFC systems.

Unit Service Fittings

The unit uses a hermetically sealed refrigeration system. If you need to recover the refrigerant charge,
you must use the appropriate fittings to connection on service (access) ports (if no service (access) ports
are present then fittings under low (LPCO) or high (HPCO) pressure switches can be used). Install
the service fittings on the suction line and discharge line process tubes located in the compressor
compartment.

Manifold Gauge Set and Hoses

Use a manifold gauge set and hoses dedicated for use with R-407C only.

Evacuation Station
A key element in maintaining high efficiency and low maintenance cost in a transport refrigeration
system is the ability to keep the system free of moisture and non-condensable materials. Contaminants
and moisture are best removed by a vacuum system.
The Thermo King Evacuation Station TK 204-725 has been designed to efficiently evacuate
the refrigeration system for all Thermo King products.

Vacuum Pump
Use a two-stage (for example TK 204-713 or TK 204-699) or any other or more-stage pump from
respective manufacturer for the evacuation. Because residual refrigerant may be present in used pump,
a new vacuum pump should be used and dedicated strictly as an R-407C refrigerant pump.
Use only recommended vacuum pump oils and change oil after every major evacuation.
Because vacuum pump oils are highly refined to obtain low vacuums, failure to follow these
recommendations may result in acidic conditions that will destroy the pump.

76
System Cleanup Devices
Use cleanup devices such as suction line filters if they are properly cleaned with new filters
and cartridges. Remove all standard petroleum and synthetic compressor oils to prevent contamination
of R-407C systems.

Refrigerant Recovery
Use only refrigerant recovery equipment approved for and dedicated to R-407C recovery.

Compressor Oil Acid Test

Perform an oil acid test (oil test kit TK203-457) whenever a system has a substantial refrigerant loss,
a noisy compressor, or dark/dirty oil – see chapter „Compressor Oil Colour Code“.

11.2.3. Contamination
When contaminants have entered the system, a thorough cleanup is required to prevent damage or loss
of compressor. The purpose of evacuation is to remove moisture and air from the refrigeration system.
Even small quantities of air or moisture in a system can cause severe problems.
The presence of moisture, oxygen, and heat under certain conditions can result in many forms of
drainage. Corrosion, sludge, copper plating, oil breakdown, carbon formation, and eventual compressor
failure can be caused by these contaminants. Things that will contaminate a system are (in order of
importance):
 Air (oxygen as a contaminant). Oxygen in the air reacts with the oil. The oil begins to break
down and can eventually lead to carbonization in the compressor and acid buildup. The longer
this breakdown process goes on, the darker the compressor oil becomes until finally the colour
is black, indicating major system contamination. Contamination occurs on the suction line.
 Moisture. Moisture in a system will cause metal corrosion and metal plating. It can freeze in
the expansion valve and cause intermittent operational problems. It reacts in the oil to begin
acid buildup.
 Dirt, dust, metal particles, other foreign materials. Particles in the system will cause severe
damage to all close tolerance items. Do not leave a system open to the infiltration of dirt.
If you must open a system for any reason, seal off the open areas as soon as possible. Do not
work in a dirty environment.
 Acid. Air and moisture cause a chemical breakdown of the oil and the refrigerant. The acid
will accelerate the deterioration of the softer metals (i.e., copper) and cause metal plating
as the softer material begins to cover the inside of the system. This condition can result in
the total destruction of your equipment.

IF ANY OF THE ABOVE CONDITIONS ARE PRESENT PLEASE RECYCLE THE REFRI-
GERANT AND PERFORM A REFRIGERATION SYSTEM CLEANUP – USE A NEW
REFRIGERANT THAT HAS NOT BEEN CONTAMINATED.

77
11.2.4. Compressor Oil Color Code
When unusual colour of oil is detected or presence of moisture is signalized by moisture indicator then
perform a compressor oil acid test.
 Black oil indicates carbonization caused by air in the system.
 Brown oil indicates copper plating caused by moisture in the system.
 Gray or metallic oil indicates bearing wear or piston scoring.

IF THE COMPRESSOR OIL SHOWS AN ACID CONDITION, CHANGE THE OIL,

THE IN-LINE OIL FILTER, THE FILTER-DRIER, AND PERFORM A REFRIGERATION
SYSTEM CLEANUP.

11.2.5. Refrigerant Recovery

CAUTION: Use only refrigerant recovery equipment approved for and dedicated
to R-407C recovery.

It is recommended the whole charge is retrieved and a new charge is placed into the system after
performing the leak and evacuation steps.
When removing refrigerant from a Thermo King refrigeration system, use a recovery process that
prevents or absolutely minimizes the refrigerant that can escape to the atmosphere. Typical service
procedures that require removal of refrigerant from the system include:
 Reducing the refrigerant pressure to a safe working level when maintenance must be
performed on high-pressure side components.
 Emptying the system of refrigerant when an unknown amount of charge is in the system
and a proper charge is required.
 Emptying the system of contaminated refrigerant when the system has become contaminated.

Procedure
1. Locate the service (access) ports on high-pressure side (compressor output pipe) and low pressure
side (compressor input line).
2. Carefully remove the caps from ports. If no service (access) ports are present then fittings under
pressure switches can be used.
3. Install a gauge manifold low pressure line to the service (access) ports on low pressure side
(suction line – compressor input pipe).
4. Attach the gauge manifold high pressure line to the service (access) ports on high pressure side
(discharge line – compressor output pipe).
5. Attach the service line to the recovery station.
6. Purge the lines.

Vapor Recovery
1. Install a gauge manifold on the system. Attach the service line to the recovery machine and purge
the lines. Set the recovery machine for vapour recovery.
2. Keep the HVAC system OFF.
3. Turn ON the recovery machine and open both gauge manifold and hand valves. Continue to
operate the recovery machine until the system pressure drops to 0 kPa (0 bar, 0 psig) pressure.
Follow the liquid recovery instruction in next section.
78
Liquid Recovery
1. Switch ON and operate the system to build discharge pressures to approx.1380 kPa (200 psig).
2. Stop the refrigeration system. Set the recovery station for liquid recovery and turn the recovery
station on.
3. Open (back seat) the manifold gauge high pressure hand valve.
4. Operate the recovery machine until the system pressures reach approximately 0 kPa (0 bar, 0 psig).
5. Close the manifold gauge valves, stop the recovery station and disconnect the lines.

11.2.6. Using Pressurized Nitrogen

The dehydration, pressure testing, purging and soldering can be accomplished with the use of dry
nitrogen (N2). The proper equipment and application of equipment is of greatest importance. Always
use the correct equipment in the correct way to ensure safety.

WARNING: Nitrogen (N2) in the standard gas bottle is under high pressure (20 MPa
at filling, full cylinder at 15 °C, for example).

WARNING: The improper use of high pressure cylinders can cause a physical
damage to components, or personal injury, or cause stress that would lead to failure
of components.

WARNING: Do not use Oxygen (O2), acetylene, or any other pressurized gas on
refrigeration systems or any component of a system.

11.2.7. Refrigerant Leak Test Procedure

Use a reliable Halogen leak detector to leak test the refrigeration system. Inspect carefully for signs
of compressor oil leakage, which is the first sign of a leak in the refrigeration system.
NOTE: Due to environmental concerns and personal safety, the use of a Halide torch is no longer
recommended.

BEA957

Testing for Refrigeration Leaks

Procedure
1. Locate the service (access) ports on high pressure side (the compressor output pipe) and low

79
 pressure side (the compressor input line). Carefully remove the caps from the ports. If no service
(access) ports are present then fittings under pressure switches can be used.
2. Attach the gauge manifold compound gauge line to the port on low pressure side. Attach the high
pressure gauge line to the port on high pressure side.
3. Attach the refrigerant bottle charging hose to the centre of manifold gauge set. Purge the charging
hose of air.
4. Connect the charging hose to the source of nitrogen, carefully follow the safety precautions!
5. Pressurize the system with nitrogen until 345 kPa (3.45 bar) vapour pressure is achieved.
6. Close both hand valves on the manifold gauge.
7. Close the supply valve on the nitrogen bottle.

CAUTION: Nitrogen is under 15,170 kPa (151.70 bar) pressure in a full cylinder
at 21 °C. Do not use oxygen, acetylene, or any other type of pressurized gas in the system.

8. Disconnect the refrigerant charging hose.

9. Check the refrigeration system with the electronic leak detector to inspect all joints
and connections. Use a soap solution as an alternative test.
10. Release pressure and reclaim nitrogen back from system.

11.2.8. Evacuation
Before performing an evacuation be sure that you have conducted the leak check and the system is
repaired and no leaks are found.

System Preparation and Connecting to Evacuation Station

CAUTION: Do not evacuate a system until you are certain that the system is leak
free. A system with less than a full charge of refrigerant should be thoroughly leak
tested. Leaks found must be repaired.

1. Recover refrigerant from the system and reduce the system pressure to the proper level, follow
the evacuation station manufacturer's instructions.
2. Break vacuum with refrigerant and equalize system pressure to 0 kPa (0 bar, 0 psig).
3. Replace the liquid line filter-drier (dehydrator) in refrigeration system.
4. Confirm that the evacuation station functions properly and determine “Blank Off” Pressure.
The Blank Off pressure of the vacuum pump is the deepest vacuum that the vacuum pump
can attain when isolated from the rest of the system. If a vacuum pump (isolated from a
system) is started and the micron meter responds quickly by going to a deep vacuum, the
operator can be confident that the pump and oil are in good condition. If the vacuum pump
fails to reach a deep vacuum within 5 minutes, the operator should suspect the condition
of the oil or the pump. It is recommended that the pump oil be changed first to see if the rate
of reaching a deep vacuum is improved.

5. Connect the evacuation station and refrigerant tank with manifold gauge set (optional) to the

80
 system as indicated in example on the "Figure 42: Evacuation Station and Unit Hookup". Connect
evacuation hoses to the fittings (service access ports) installed on the suction line and liquid line –
see high pressure side (compressor output pipe) and low pressure side (discharge line – compressor
output pipe). If no service (access) ports are present then fittings under low (LPCO) or high
(HPCO) pressure switches can be used.
6. Open evacuation station valves (V1, V3) and valve(s) on gauge manifold. It is only necessary to
open valve V2 when a reading on the micron meter is desired.
7. Open the vacuum pump „Iso Valve“ isolating the pump from refrigeration system. It is
recommended that the valve be kept open at all times.
8. If connecting a refrigerant tank and gauge manifold to the evacuation station, close the manifold
gauge and refrigerant tank valves to prevent refrigerant from being drawn from the tank.

81
System Evacuation
1. Turn ON the vacuum pump. Open the gas ballast valve located on top of the pump housing
behind the handle (the valve is fully open at two turns counter clockwise). Evacuate the system
to 500 microns to achieve a final equilibrium pressure of 2000 microns or less. The final
equilibrium pressure is determined with the Thermo King Evacuation Station using the following
procedure (called a pressure-rise test):
a. Evacuate the system using the evacuation station until the vacuum level reaches 1000 microns.
Then close the gas ballast valve.
b. Continue evacuation to 500 microns or until vacuum stabilizes at its lowest level. Contamination
may delay reaching the lowest level for a period of several or more hours.
c. Close valve to isolate the vacuum pump from the system.
d. Observe the vacuum level on the micron meter. When the meter has stabilized, the value
indicated on the micron meter is the equilibrium pressure. This reading must be 2000 microns
or less.
NOTE: The presence of refrigerant in the compressor oil may prevent a low vacuum reading from
being achieved. Compressor oil can continue to outages for long periods of time.
2. If the vacuum level appears to stall above 500 microns, back seat the discharge service valve
and observe the micron meter.
3. Close valve V1 when the desired vacuum level has been reached.
4. Wait five minutes and then read the micron meter.
5. If the vacuum level remained below 2000 microns for five minutes, the system is ready to charge.
a. A system that is leak free and dry will remain below 2000 microns for five minutes.
b. A system that rises above 2000 microns but stabilizes below atmospheric pressure is probably
contaminated with moisture or has refrigerant outgassing from the compressor oil. Additional
evacuation is required.
c. A drop in pressure indicates that the compressor oil is out-gassing and further evacuation is
necessary.
d. An increase in pressure indicates that a leak exists or there is moisture in the system. Perform
a “Pressure Rise Test” and evaluate.
A system that continues to rise without stabilizing has a leak and must be repaired.

82
 1

V3
V2

V1

7 2
1
3
6
4

5
BEC551

1 Service connection ports 6 Calibration Standard

2 Gas ballast valve 7 Micron Meter

3 ISO valve 8 Sensor

4 Two stage vacuum pump 9 Manifold gauge

5 To electricity Vx Hand valves

Evacuation Station and Unit Hookup

83
Pressure Rise Test
Evacuate the system and close valve V1. With valves V3 and V2 open, the pump is isolated
and the system is held under a vacuum. If the micron meter rises, one of the following conditions exists.
 Leak: Watch the movement of the micron meter needle indicating pressure level. If the needle
continues to rise (the pressure in system increase) until it reaches atmospheric pressure, it is an
indication that a leak exists somewhere in the system. When a leak is in a system, the vacuum
will eventually stabilize at atmospheric pressure.

1 Constant pressure rise indicates leak

2 Time axis
3 Pressure (vacuum) axis
4 Atmospheric pressure level

BEA311

Constant Pressure Rise After Evacuation

 Moisture: When the pressure rise and then stabilizes at a level below atmospheric pressure,
this indicates that the system is vacuum tight, but is still wet and requires additional
dehydration and evacuation time.

Pressure rise that levels off indicates

1
moisture in refrigeration system
2 Time axis
3 Pressure (vacuum) axis
4 Atmospheric pressure level

BEA312

Pressure Rise that Levels Off After Evacuation

84
Factors Affecting the Speed of System Evacuation
The time required to evacuate a system varies. Factors that influence evacuation time are:
 System size.
 Amount of moisture contained in the system.
 Ambient temperature.
 Internal restrictions within the system.
 External restrictions between the system and the vacuum pump.
 Hose diameter and length. Laboratory tests show that the evacuation time can be significantly
reduced by larger diameter hoses and shorter hoses. To obtain optimum pumping speed, keep
hoses as short as possible and as large in diameter as possible.
Heat Saves Time
Applying heat to a system decreases evacuation time. Increasing the temperature of the compressor oil
and refrigerant speeds up the vaporization of any water presents in the system. Heat lamps, electric
heaters, and fans can be applied to the compressor crankcase and other parts of the system to increase
the temperature of the refrigerant and compressor oil.

WARNING: Do not use a torch or other concentrated heat source to heat the
compressor or other refrigeration system component.

End of Evacuation Process

1. Close the valve(s) on gauge manifold.
2. Open the gas ballast valve (located on top of the pump housing behind the handle).
3. Stop the vacuum pump.

11.2.9. System Charging from an Evacuated Condition

IMPORTANT: On R-407C refrigerant:

When charging the system, always charge from liquid side and use the refrigerant in a liquid
state. Do not charge vapour in the system!
In case of leak do not “top off” the refrigeration system. Always reclaim all remaining charge
(and send it to special recycling stores) and use new refrigeration charge by correct
recommended weight in liquid state.

Procedure
1. Connect the charging hose to the port on high pressure side (on liquid line, near high pressure
cutout switch, HPCO). If no service (access) port is present then fitting under high (HPCO)
pressure switch can be used.
2. Charge the proper amount of liquid R407C into system, for example by using a „push/pull“ reclaim
unit. For amount of the R-407C refrigerant see chapter 6 refer to HVAC system.
3. Close the refrigerant tank valve when the correct amount (by weight) of refrigerant has been added.
4. Remove charging hose and reinstall caps on service (access) ports (or high pressure cutout HPCO
valve if necessary). Check these connecting points with an electronic leak detector.
5. Perform a system functional check out.

85
Safety Precautions
Observe the proper handling of cylinders:
 Keep protective cap on cylinder when not in use.
 Secure cylinder in proper storage area or fastened to cart.
 Do not expose to excessive heat or direct sun light.
 Do not drop, dent, or damage cylinder.
 Use a pressure regulator and a safety pressure relief valve as part of the pressure testing
equipment. The safety pressure relief valve should be the non- adjustable, non-tempering type.
The valve should bypass any time the pressure exceeds its setting.
 Open valve slowly. Use regulators and safety valves that are in good working order.
 The regulator should have two gauges: one to read tank pressure, the other to read line
pressure. Properly maintained equipment will allow leak testing, purging, and dehydration
to be done safely.

WARNING: All here described procedures should utilize the following MAXIMUM
gas pressure:

Leak Testing: 1034 to 1200 kPa

Purging/Dehydration: 69 to 138 kPa
Soldering: 35 kPa

86
 1 2

6
3

BEA959

1 Line pressure 4 Pressure test line to system

2 Tank pressure 5 Safety valve
3 Tank 6 Pressure regulator

Typical Pressurized Gas Bottle with Pressure Regulator and Gauges

Procedure
1. Attach a gauge manifold. Close both hand valves on the gauge manifold.
2. Connect charging hose to nitrogen source. Adjust the pressure regulator to the proper pressure
for the required procedure.
3. Purge system high side to low side.

NOTE: The specification of nitrogen technical gas should follow these parameters:
Cleanness: N2 99,999 % or better
Admixtures: O2 3 ppm or less
H2 O 5 ppm or less
CnHm 5 ppm or less

87
11.3. Filter-Drier Replacement

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Recover the refrigerant from the system. See chapter 11.2 and refer to "Evacuation procedure".
5. Release and remove the fixing clamp.
6. Unsolder the inlet/outlet cartridge pipes, use a guard to protect other parts against damage from
applied heat during this process (wet cloth can be also effective).
7. Remove the old filter-drier cartridge.

BEC552

1 Filter-drier 3 Fixing clamp screw

2 Blower motor power cable 4 Fixing clamp

Filter-drier Installation

Installation
1. Clean connection fittings, remove the protective plugs from the new filter-drier.
2. Align new filter-drier cartridge in original position in liquid line.
3. Clean the surfaces of joints, use brazing flux on joints.

4. Carefully solder inlet and outlet connections to new filter-drier cartridge, use a guard to protect
other parts against damage from applied heat during this process (wet cloth can be also effective).

NOTE: Use dry nitrogen to purge the system during any solder operations; see chapter 11.2.6.
5. Check visually the joints (use a mirror for opposite or hidden sides).
6. Insert the fixing clamp, tighten the screw.

88
7. Reinstall the other parts/accessories.
8. Pressurize the refrigeration system and check for leaks. See chapter 11.2.7.
9. Evacuate the system. See chapter 11.2.8.
10. Recharge the system. See chapter 11.2.9.
11. Close and secure the top cover with locks. Use appropriate key only!
12. Connect high voltage (XPOW) and low voltage (XLV1) connectors, switch ON the control system.
13. Close the switchboard box (electrobox), secure the cover with locks. Use appropriate key only!
14. Turn the power supply ON, check the functionality
15. Return the HVAC unit into service, see chapter 11.1 for more information.

11.4. Receiver Tank Replacement

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Recover the refrigerant from the system. See chapter 11.2 and refer to "Evacuation procedure".
5. Release and remove the fixing clamp.
6. Unsolder the inlet/outlet cartridge pipes, use a guard to protect other parts against damage from
applied heat during this process (wet cloth can be also effective).
7. Remove the old receiver tank.

BEC553 4

1 Receiver tank 3 Fixing clamp

2 Outline pipe 4 Inlet pipe

Receiver Tank Installation

89
Installation
1. Clean connection fittings, remove the protective plugs from the new filter-drier.
2. Align new filter-drier cartridge in original position in liquid line.
3. Clean the surfaces of joints, use brazing flux on joints.

4. Carefully solder inlet and outlet connections to new filter-drier cartridge, use a guard to protect
other parts against damage from applied heat during this process (wet cloth can be also effective).

NOTE: Use dry nitrogen to purge the system during any solder operations; see chapter 11.2.6.
5. Check visually the joints (use a mirror for opposite or hidden sides).
6. Insert the fixing clamp, tighten the screw.
7. Reinstall the other parts/accessories.
8. Pressurize the refrigeration system and check for leaks. See chapter 11.2.7.
9. Evacuate the system. See chapter 11.2.8.
10. Recharge the system. See chapter 11.2.9.
11. Close and secure the top cover with locks. Use appropriate key only!
12. Connect high voltage (XPOW) and low voltage (XLV1) connectors, switch ON the control system.
13. Close the switchboard box (electrobox), secure the cover with locks. Use appropriate key only!
14. Turn the power supply ON, check the functionality
15. Return the HVAC unit into service, see chapter 11.1 for more information.

90
11.5. Thermostatic Expansion Valve Replacement
The thermostatic expansion valve meters liquid refrigerant into the evaporator coil at a predetermined
rate to keep the coil fully refrigerated and ensure complete vaporization of the refrigerant before it
leaves the coil. The expansion valve is controlled by the temperature and the pressure in the suction
line.

3
2

4
A

1 C
BEA427
5

6 B

1 Sensor bulb 5 Fixed orifice A Side view

2 Outlet (Typical) 6 Filter B End view
3 Power head 7 Inlet (Typical) Location of bulb on side of suction
C
4 Adjustment line 4 or 8 o’clock position

Expansion Solder Type Valve and Sensor Bulb Position

Thermo King expansion valves are factory preset and do not require adjustment. When diagnosing
refrigeration problems, eliminate other possible causes before servicing the valve.
The expansion valve must be serviced by an experienced refrigeration mechanic.
Usually two services are performed on the expansion valve:
1. Replacing a damaged power element. A broken power element causes the valve to close
and the unit to operate in a vacuum.
2. Cleaning and securing the power element sensor bulb to the suction line. Poor contact of the sensor
bulb causes the valve to operate by air temperature, indicated by frosting of the suction line and a
slight rise in suction pressure to flooding of the coil. Wrap the bulb and suction line with insulating
tape, TK Part No. 203-428.

CAUTION: Thermo King expansion valves are factory preset and do not require
adjustment. Establishing controlled conditions in the field is difficult. Before adjusting
the expansion valve, check the following causes for an out-of-range reading.

91
Sensor Bulb Contact
1. Remove the insulating tape from the sensor bulb.
2. Loosen two copper bands, remove the sensor bulb from the suction line.
3. Clean the suction line and the sensor bulb with fine abrasive paper or cloth. Do not use acids or
polishes to clean copper.
4. Coat the sensor bulb and suction line with a light film of oil to prevent oxidation.
5. Install the sensor bulb in clamps on the side of the line in the original position. Tighten the clamps
and replace the insulation on the bulb.

Superheat: Measurement and Adjustment

NOTE: Be sure the temperature reading instrument and compound pressure gauge are calibrated.

Measurement
1. Install a pressure gauge in the expansion valve external equalizer line. This will indicate
the pressure.
2. Run the unit. Allow the system to run until the interior of the vehicle has cooled to within 5 degrees
of thermostat set point.
3. Subtract the temperature reading obtained from the suction line near the expansion valve sensor
bulb on the unit suction line to obtain the expansion valve superheat setting.
Using the Pressure-Temperature Chart in this manual, convert the pressure measured at
the equalizer line to the equivalent temperature.
Example:
Sensor Bulb Suction Line Temperature (°C/F)
- Suction Pressure Temperature Conversion (°C/F)
= Superheat (K)
NOTE: To properly check the superheat, you must have a stable condition. To establish a stable
operating condition, run the unit at least 15 minutes so the evaporator air inlet temperature reaches
21 °C to 27 °C (70 °F to 80 °F). Read the pressure and temperature difference simultaneously.
Temperature difference should be 5.5 to 8 K.

4. Check the following:

 Dirty air filters or other cause of reduced air flow.
 Sensor bulb leaking, bulb placed improperly on refrigerant line, or bulb not properly wrapped
with insulating tape.
 Kinked capillary tube.
5. After the above items have been checked, replace the expansion valve with a factory preset part if
necessary adjustment.

Adjustment
1. Remove the cap over the adjusting stem.

92
2. To reduce superheat, turn the adjusting stem counter clockwise.
3. Make no more than one turn of the stem at one time. Observe the change in superheat closely to
prevent overshooting the desired setting. As much as 30 minutes may be required to obtain the new
balance after the adjustment has been made.
4. Remove the pressure gauge and thermometer from the equalizer line.
5. Return the HVAC unit into service, see chapter 11.1 for more information.

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Recover the refrigerant from the system. See chapter 11.2 and refer to "Evacuation procedure ".
5. Disconnect temperature sensor connector, release fixing binders where necessary.
6. Carefully remove the insulation.
7. Remove the sensor bulb from the clamps, taking care not to kink the capillary tube.
8. Unsolder the equalizer and the inlet and outlet line connections, use a guard to protect other parts
against damage from applied heat during this process (wet cloth can be also effective).
9. Remove the expansion valve.

DANGER: Do not solder on a closed system. Pressure can build up and may cause
an explosion. If soldering is required, use dry nitrogen to purge the system during any
solder operations. See chapter 11.2.6.

93
 4

1 5

3
8

BEC554

1 Thermostatic expansion valve 5 Valve inlet pipe

2 Sensor bulb connection pipe 6 Fixing nut
3 Valve outlet – pipe(s) to the evaporator 7 U-bracket holder
4 Valve holder 8 Pressure equalizer line

Thermostatic Expansion Valve Installation

Installation
1. Compare the new valve to the one removed. Adjust the length of the sensor bulb capillary tube.
Secure it to the valve body in the same manner as the original valve. This prevents damage to
the tube by vibration-induced chafing. Once the length is adjusted, feed the bulb through the
required routing.
2. Clean tubing connections before installing the valve, clean the surfaces of joints, use brazing flux
on joints.
3. Position the valve in the unit, carefully solder inlet and outlet connections, use a guard to protect
other parts against damage from applied heat during this process (wet cloth can be also effective).
4. Taking care not to kink the capillary tube, position the remote sensor bulb in the clamp on the side
of the suction line in exactly the same spot from which it was removed.

NOTE: Use dry nitrogen to purge the system during any solder operations; see chapter 11.2.6.

5. Check visually the joints (use a mirror for opposite or hidden sides).
6. Reinstall the temperature sensor, use fixing binders where necessary.
7. Pressurize the refrigeration system and check for leaks. See chapter 11.2.7.
8. Add insulation where necessary.
9. Evacuate the system. See chapter 11.2.8.
10. Recharge the system. See chapter 11.2.9.

94
11. Close and secure the top cover with locks. Use appropriate key only!
12. Return the HVAC unit into service, see chapter 11.1 for more information.

11.6. Compressor Replacement

WARNING: When inspecting or servicing the HVAC system, follow all safety rules
and operating procedures, to avoid any physical harm.

5
2

BEC555

1 Compressor 4 Compressor suction line (inlet pipe)

2 Junction box 5 Lifting lug
Compressor discharge line (outlet pipe)
3 6 Compressor fixing bolts
with vibration eliminator

Compressor Installation

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Open the junction (terminal) box on the compressor.
5. Release connections, release bushing, use appropriate tools for releasing.

95
6. Pull out the wires from the junction (terminal) box.
7. Recover the refrigerant from the system. See chapter 11.2 and refer to "Evacuation procedure".
8. Carefully unsolder the joints on the input/output (suction/discharge) compressor line, use a guard to
protect other parts against damage from applied heat during this process (wet cloth can be also
effective).
9. Check if any part will not obstruct to removing of the whole compressor assembly.
10. Release the fixing bolts from each corner of compressor.
11. Attach appropriate lifting tool/hook to the lifting lug on the top of compressors.
12. Use suitable lifting device to transport the compressor from the HVAC unit.

WARNING: The compressor weights approximately 30 kg. Use extreme care to

prevent personal injury during manipulation.

Installation
1. Place exactly the compressor in the unit frame on original position, set the compressor corners in
isolators.
2. Use flatwashers, spring washers and nuts and slightly fix the compressor.
3. Check the whole installation and tighten the fixing bolts with appropriate torque; see chapter 9.5 for
the value of torque, use torque wrench with extension bar if necessary.
4. Use a small brush and mark the threads/bolts/nuts with colour (for example nitrocellulose top
paint). It is simple signage if the thread is tight or loose or was loosen.

BEC556

Fixing Screw Marking (Example)

5. Put together all tubes, check if all tubes are in correct dimension and shape.
6. Use the nitrogen to purge and drying of tubing, clean the joints use brazing flux on joints.
7. Carefully braze all the joints, use any guard in case if heating can damage other parts, wet cloth can
will be also necessary to prevent from heating.
8. Check visually the joints (use a mirror for opposite or hidden sides).
9. Check all accessories (pressure switches, service ports) if all parts are present and connected.
10. Attach an evacuation station hoses to the service ports, use dry nitrogen to purge the system; see
chapter 11.2.6.
11. Pressurize the refrigeration system and check for leaks. See chapter 11.2.7.
12. Evacuate the system. See chapter 11.2.8.

96
13. Recharge the system. See chapter 11.2.9.
14. Connect compressor wires in junction box according valid electrical diagram.
15. Properly attach and fix the bushing, close the junction box, fix the covers be sure the sealing under
cover is present and in correct position. Fix all cables and wires with binders, no loosen parts are
acceptable.
16. Connect the XPOW and XLV1 connectors, restore the high voltage and low voltage power supply,
switch the control system ON and test the functionality.
17. Close and secure the top cover with locks. Use appropriate key only!
18. Return the HVAC unit into service, see chapter 11.1 for more information.

97
11.7. Low Pressure or High Pressure Switch Replacement

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Locate the non-functional pressure switch.
5. Remove the fixing binders from switch wiring or connectors, disconnect the connector from switch
wiring.
6. Unscrew and remove the switch.

NOTE: Install the new switch immediately to minimize the risk of refrigeration system pollution from
air/oxygen.

3 6

BEA711
4

1 Service port 4 Compressor

2 Compressor suction line (inlet pipe) 5 Pressure switch – LPCO
3 Compressor discharge line (outlet pipe) 6 Compressors junction box

Pressure Switch Installation (Example 1)

98
 1
4

BEA712

1 Pressure switch connector 4 Pressure switch – HPCO

2 Compressor discharge line (outlet pipe) 5 Service port
3 Safety relief valve 6 Junction box

Pressure Switch Installation (Example 2)

Installation
1. Apply compressor oil to the threads of the new switch.
2. Install new switch, connect the wires, fix the wires with binders.
3. Pressurize the refrigeration system and test for leaks. See chapter 11.2.7.
4. Release the cover support, close and secure the top cover with locks. Use appropriate key only!
5. Return the HVAC unit into service, see chapter 11.1 for more information.

99
11.8. Safety Relief Valve Replacement
The valve contains a spring loaded piston that lifts when the refrigerant pressure exceeds the spring
force. When pressure drops below setpoint, the valve will reset. The valve might leak refrigerant after it
has relieved excess pressure. Tapping the valve lightly may help the valve reseat and seal properly.
The valve is non-repairable and requires no adjustment. If the valve fails to reseat properly, the valve
must be replaced.
NOTE: Before starting replacement procedure, use your parts manual to identify the correct valve
for your unit.

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Recover the refrigerant from the system. See chapter 11.2 and refer to "Evacuation procedure".
5. Locate the relief valve, unscrew and remove the valve.

NOTE: Install the new switch immediately to minimize the risk of refrigeration system pollution from
air/oxygen. The recommended time is 30 minutes max. 1 hour.

1
4

BEA712

1 Pressure switch connector 4 Pressure switch – HPCO

2 Compressor discharge line (outlet pipe) 5 Service port
3 Safety relief valve 6 Junction box

Relief Valve Installation (Example)

100
Installation
1. Apply compressor oil to the threads of the new valve, install and tighten new valve.
2. Pressurize the refrigeration system and check for leaks. See chapter 11.2.7.
3. Evacuate the system. See chapter 11.2.8.
4. Recharge the system. See chapter 11.2.9.
5. Release the cover support, close and secure the top cover with locks. Use appropriate key only!
6. Return the HVAC unit into service, see chapter 11.1 for more information.

11.9. Solenoid Valve Replacement

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Locate the non-functional solenoid valve.
5. Disconnect solenoid valve connector.
6. Release bolt on top of solenoid valve cover, remove the cover.
7. Release the fixing binders from valve wiring where necessary.
8. Release bolt on top of valve/solenoid, remove the coil.

4
1

2 5

3 6

BEC550

1 Solenoid coil fixing bolt 4 Solenoid valve connector

2 Solenoid coil 5 Solenoid valve
3 Bracket 6 Bracket

Solenoid Valve Installation

101
9. Release bushing and disconnect wires from terminals in valve enclosure, remove the solenoid coil
out of unit.
10. Recover the refrigerant from the system. See chapter 11.2 and refer to "Evacuation procedure ".
11. Unsolder the valve inlet and outlet line connections, use a guard to protect other parts against
damage from applied heat during this process (wet cloth can be also effective).
12. Release the bolts fixing the bracket to the bottom of unit.
13. Unscrew the bolt fixing the valve to bracket and remove the valve.

Installation
1. Clean tubing connections before installing the valve, clean the surfaces of joints, use brazing flux
on joints.
2. Position the valve in the unit, fix the valve to the bracket, install and tighten the bracket to bottom
of unit. See chapter 9.5 for appropriate torque.
3. Carefully solder inlet and outlet connections to new solenoid valve, use a guard to protect other
parts against damage from applied heat during this process (wet cloth can be also effective).

NOTE: Use dry nitrogen to purge the system during any solder operations; see chapter 11.2.6.

4. Check visually the joints (use a mirror for opposite or hidden sides).
5. Pressurize the refrigeration system and check for leaks. See chapter 11.2.7.
6. Evacuate the system. See chapter 11.2.8.
7. Recharge the system. See chapter 11.2.9.
8. Reinstall the solenoid valve coil, connect the cable to the coil terminal, tighten the bushing.
9. Fix the solenoid coil with bolt on top of the valve.
10. Fix the wires with binders where necessary.
11. Install the valve cover.
12. Connect the solenoid valve connector.
13. Close and secure the top cover with locks. Use appropriate key only!
14. Return the HVAC unit into service, see chapter 11.1 for more information.

102
11.10. Condenser Coil Replacement

CAUTION: Always use protective gloves when open the unit covers, the fins of
the condenser coil can be very sharp!

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Release and remove the grounding cable.
5. Remove the top cover.
6. Recover the refrigerant from the system. See chapter 11.2 and refer to "Evacuation procedure ".

WARNING: Adhere to all safety rules!

7. Unsolder the liquid lines before and after condenser coil, use a guard to protect other parts against
damage from applied heat during this process (wet cloth can be also effective).
8. Remove any accessories if necessary.

3 3

BEC558

BEC557

1 2 4

1 Unit frame 3 Condenser coil side fixing bolts

2 Condenser coil 4 Condenser coil bottom fixing bolts

Condenser Coil Installation

103
9. Release and remove the fixing bolts – the bolts are accessible from outside (4 on the side and 4 on
the bottom), condenser coil is fixed by 8 bolts.
10. Carefully pull out the condenser coil from unit.

Installation
1. Carefully insert and align new condenser coil in original position.
2. Fix the condenser coil with bolts from outside. Tighten the fixing bolts; see chapter 9.5 for
appropriate torque.
3. Solder inlet and outlet connections to new condenser coil, use a guard to protect other parts against
damage from applied heat during this process (wet cloth can be also effective).

NOTE: Use dry nitrogen to purge the system during any solder operations; see chapter 11.2.6.

4. Check visually the joints (use a mirror for opposite or hidden sides).
5. Pressurize the refrigeration system and check for leaks. See chapter 11.2.7.
6. Evacuate the system. See chapter 11.2.8.
7. Recharge the system. See chapter 11.2.9.
8. Install the condenser fan assembly.
9. Connect the condenser fan, install any other accessories if necessary.
10. Insert the cover, install/fix the hinges
11. Close and secure the cover with locks. Use appropriate key only!
12. Return the HVAC unit into service, see chapter 11.1 for more information.

104
11.11. Evaporator Coil Replacement

CAUTION: Always use protective gloves when open the unit covers, the fins of
the evaporator coil can be very sharp!

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Recover the refrigerant from the system. See chapter 11.2 and refer to "Evacuation procedure ".
5. Remove the gasket from side wall.
6. Dismount the side wall of the RAC unit.

WARNING: Adhere to all safety rules!

1
3

BEC559

1 Top cover 3 Evaporator coil

2 Side wall 4 Blower compartment

Evaporator Coil Installation – A

7. Disconnect the temperature sensor connector.

8. Remove the mixed air filter, see chapter 9.8.
9. Remove the heater, see chapter 12.4.
10. Carefully remove insulation from the evaporator coil inlet pipes, do not damage the temperature
sensor.

105
 1 3

BEC560

1 Evaporator coil 3 Heater

2 Insulation 4 Thermostatic expansion valve

Evaporator Coil Installation – B

11. Unsolder the liquid lines (the inlet line together with expansion valve), use a guard to protect other
parts against damage from applied heat during this process (wet cloth can be also effective).
12. Release the expansion valve, see chapter 11.5.
13. Release and remove the fixing bolts, save fixing bolts for reinstallation.
14. Carefully pull out the evaporator coil (assembly) from unit.

106
Installation
1. Carefully insert and align new or repaired evaporator coil in original position.
2. Fix the coil with all bolts to the central wall and unit frame.
3. Solder inlet and outlet connections, use a guard to protect other parts against damage from applied
heat during this process (wet cloth can be also effective).

NOTE: Use dry nitrogen to purge the system during any solder operations; see chapter 11.2.6.

4. Check visually the joints (use a mirror for opposite or hidden sides).
5. Pressurize the refrigeration system and check for leaks. See chapter 11.2.7.
6. Evacuate the system. See chapter 11.2.8.
7. Recharge the system. See chapter 11.2.9.
8. Mount the expansion valve, see chapter 11.5.
9. Install the heater, see chapter 12.4.
10. Insert gasket on the side wall, correct gasket where necessary.
11. Install mixed air filter.
12. Close and secure the top cover with locks. Use appropriate key only!
13. Return the HVAC unit into service, see chapter 11.1 for more information.

107
12. Electrical Repairs
12.1. Introduction
CAUTION: Safety first! Always respect safety rules, follow “Safety Precautions”,
respect valid local laws and general Health & Safety prescripts.

WARNING: Make sure that HVAC unit and/or vehicle cannot start while servicing
the system.

CAUTION: Always use protective gloves when open the unit covers, the fins of
the condenser and evaporator coil can be very sharp!

Thermo King reserves the right to deny warranty coverage on claims due to lack of maintenance
or neglect. Claims in question must be supported by maintenance records.
If you are not really experienced in following actions please call for help Thermo King Service Centre
otherwise is here risk of damage or complications. The main repair procedures can be carried out in
specialized workshop only with trained and highly experienced technicians. In case of any question
or unclear situation please contact your supplier or directly Thermo King Manufacturer.
Before starting the replacement procedure, use most up-to-dated Parts Manual or Stocking Guide
to identify the correct spare part suitable for your unit.

BEFORE ANY SERVICE ACTIVITY STOP THE HVAC UNIT OPERATION WITH:
1. ON/OFF button on driver panel.
2. Turn all the power supply OFF.
3. Disconnection of all electrical connectors.

WARNING: The electrical disconnection is allowed only if all the power supply
cables are without voltage!

WHEN THE LAST SERVICE ACTIVITY IS FINISHED:

1. Check the HVAC unit top cover, check if all locking elements are at a proper position.
2. Connect all electrical connectors, check the proper connection.
3. Turn the power supply ON.
4. Enable the unit operation with ON/OFF button on driver panel.
5. Check the HVAC system functionality.

108
12.2. Evaporator Blower Replacement

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Open the locks, release and remove the switchboard box (electrobox) cover.
5. Disconnect wires from terminals.
6. Release and remove the evaporator blower cover.
7. Release the blower cable as much as possible, remove the fixing binders if applicably.
8. Remove the hardware and holder of the blower ring. Save the hardware for reinstallation.
9. Release and remove the hardware fixing the flange with cover. Save the hardware for reinstallation,
remove the cover.
10. Lift the evaporator blower assembly including the ring and the flange from the HVAC unit and
place on service bench.
11. Disassembly the blower body and flange.

4
1

BEA715

1 Blower power supply 4 Blower flange with cover

2 Sidewall of blower compartment 5 Blower ring holder and fixing hardware
3 Blower assembly

Evaporator Blower Installation (Example)

109
 1 4

BEB139

1 Blower assembly 3 Blower ring holder and fixing hardware

2 Blower ring 4 Blower flange with cover

Evaporator Blower Assembly

Installation
1. Assembly a new blower with flange, use original hardware.
2. Return the assembly and the blower ring into original position, fix the blower ring with original
hardware. Tighten the fixing bolts; see chapter 9.5 for appropriate torque.
3. Insert the flange cover into original position, fix the blower, flange and cover, use original
hardware. Use common sense and best practise for tightening.
4. Fix the blower cable with binders as necessary, no loosen parts are acceptable.
5. Connect the blower wires in a switchboard box (electrobox) according valid electrical diagram.
6. Properly attach and fix the cable bushing.
7. Insert the switchboard box (electrobox) cover and fix it with locks. Use appropriate key only!
8. Connect the XPOW and XLV1 connectors, restore the high voltage and low voltage power supply,
switch the control system ON and test the functionality.
9. Operate the evaporator blower to confirm correct direction of rotation.

WARNING: Extreme care must be used in this operation! Don't touch the rotating
parts neither by any tool!
DANGER: Keep your hands, clothing and tools clear of any rotating parts when
working on a unit that is running. Loose clothing might entangle moving fans, pulleys,
or belts, causing serious injury or possible death.

10. Switch the blower and the power supply OFF.

11. If the blower is working properly return the blower cover, fix the cover with original hardware.
12. Close and secure the top cover with locks. Use appropriate key only!
13. Return the HVAC unit into service, see chapter 12.1 for more information.

110
12.3. Condenser Fan Replacement

Removal
1. Switch the unit/control system OFF; turn all power supply OFF, disconnect the connectors.
2. Open and fix the top cover. Use appropriate key only!
3. Locate and unplug the sensor connector.

2
5

3
BEC561

6
5

BEA632
8

1 Fan assembly (motor, propeller, grille) 5 Top cover

2 Fan motor mounting bolts 6 Diffuser
3 Fan assembly mounting bolts 7 Grommet
4 Fan grille 8 Condenser fan connector

Condenser Fan Installation (Example)

111
4. Remove the fixing binder when necessary, loose the cable.
5. Partially release the four fan assembly mounting bolts – the bolts on grille perimeter only!
6. Hold the diffuser on internal side of cover, release the grommet, release more the mounting bolts,
remove the diffuser.
7. Hold the fan assembly, remove the mounting bolts, lift the entire fan assembly from the unit
and place on service bench.
8. Replace the damaged fan (the propeller wheel and motor is one un-detachable part) or grille.
9. For fan removal release the 4 fan motor mounting bolts, save the spacer for installation.
10. Cable of new fan assembly must be equipped with grommet.

Installation
1. Check the fan replacement for complete, after fan motor exchange check if all 4 spacers are
between fan motor and grille.
2. Carefully place the condenser fan assembly to the original position, insert the bolts into holes,
install the diffuser (don't forget for grommet) and fix the assembly with bolts.
3. Connect the connector on fan cable, fix the cable with fixing binders where necessary.
4. Connect the XPOW and XLV1 connectors.
5. Restore the high voltage and low voltage power supply, switch the control system ON and test
the functionality.
6. Close and secure the top cover with locks. Use appropriate key only!
7. Operate the condenser fan to confirm proper direction of rotation.
8. Return the HVAC unit into service, see chapter 12.1 for more information.

12.4. Heater Assembly Replacement

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Open the electrobox. Use appropriate key only!
5. Disconnect the heater power supply wiring from the contactor (KHTR).
6. Release the bushing on the rear side of electrobox use an appropriate tool for releasing.
7. Release and remove heater junction box cover.
8. Release the heater power supply electrical cable, remove the cable binders where necessary.
9. Disconnect (pull out) the wires/connectors from the temperature switches.
10. Release the temperature switches low voltage cable, remove the cable binders where necessary.
11. Release all bolts fixing:
 Hater to the evaporator coil.
 Heater to the evaporator blower bracket.
 Grounding cable.
112
12. Lift the heater from upwards and place it on service bench.
13. Remove or change the temperature switches as necessary.

5
1

6
2
7

4 BEC562 BEC563 8

1 Heater 5 Heater fixing bolts

Fixing bolt – common for heater and
2 Temperature switches 6
evaporator
3 Heater junction box cover 7 Temperature switches’ terminals
4 Bushing 8 Heater power cable

Heater Assembly Installation

Installation
1. Set up all parts of the heater assembly (the heater, temperature switches, insulation, cable).

NOTE: The temperature switches are different in case of montage carefully check the correct
position – the correct wiring.

2. Insert the heater assembly in original place.

3. Install all mounting bolts including flatwashers and lockwashers securely. Tighten the fixing bolts;
see chapter 9.5 for appropriate torque.
4. Reconnect the temperature switches wiring (refer to the actual schematic diagrams), check all
connections for tightness.
5. Fix the low voltage cable with fixing binders where necessary.
6. Reconnect the heater high voltage wiring, check all connections for tightness.

113
NOTE: Loose connection will cause terminal to overheat and cause damage and or fire.

7. Tighten the bushing on the rear side of electrobox, use an appropriate tool.
8. Fix the high voltage cable with fixing binders where necessary.
9. Insert the switchboard box (electrobox) cover and fix it with bolts.
10. Connect the heater power supply wiring to the contactor (KHTR).
11. Close the electrobox. Use appropriate key only!
12. Close and secure the top cover with locks. Use appropriate key only!
13. Return the HVAC unit into service, see chapter 12.1 for more information.

12.5. Heater Temperature Switch Replacement

Removal
1. Switch the unit/control system OFF.
2. Turn all power supply OFF, disconnect the XPOW and XLV1 connectors.
3. Open and fix the top cover. Use appropriate key only!
4. Disconnect (pull out) the wires/connectors from the temperature switches.
5. Release the temperature switches low voltage cable, remove the cable binders where necessary.
6. Release or remove the insulation (if necessary), unscrew the mounting screws.
7. Remove the temperature switch.

1
3

2
4

BEC564

1 Temperature switch fixing bolt 3 Connector

2 Cable binder 4 Temperature switch

Heater Temperature Switch

114
Installation
1. Fix the new temperature switch in original place, use both mounting screws.
2. Repair or reinstall the insulation.
3. Reconnect the switch wires, fix wires with fixing binders where necessary.
4. Check all connections for tightness.
5. Close and secure the top cover with locks. Use appropriate key only!
6. Return the HVAC unit into service, see chapter 12.1 for more information.

115
13. Temperature-Pressure Chart

Temperature pressure relationship – vapour pressure, kPa, psig

Temperature R-407C
kPa psig
°F °C
Shaded pressure values – Inches Hg below 1 ATM
-38 -38.9 23 3.4
-36 -37.8 13 1.9
-34 -36.7 2 0.3
-32 -35.6 4 0.6
-30 -34.4 10 1.5
-28 -33.3 16 2.3
-26 -32.2 22 3.2
-24 -31.1 29 4.2
-22 -30.0 36 5.2
-20 -28.9 43 6.2
-18 -27.8 50 7.2
-16 -26.7 57 8.3
-14 -25.6 66 9.5
-12 -24.4 74 10.7
-10 -23.3 82 11.9
-8 -22.2 91 13.2
-6 -21.1 100 14.5
-4 -20.0 110 15.9
-2 -18.9 120 17.4
0 -17.8 130 18.9
2 -16.7 141 20.4
4 -15.6 152 22.0
6 -14.4 163 23.7
8 -13.3 175 25.4
10 -12.2 187 27.1
12 -11.1 200 29.0
14 -10.0 212 30.8
16 -8.9 226 32.8
18 -7.8 240 34.8
20 -6.7 254 36.9
22 -5.6 270 39.1
24 -4.4 285 41.3
26 -3.3 301 43.6
28 -2.2 316 45.9
30 -1.1 334 48.4
32 0.0 351 50.9
34 1.1 369 53.5
36 2.2 387 56.1
38 3.3 406 58.9
40 4.4 425 61.7
42 5.6 445 64.6
44 6.7 466 67.6
46 7.8 487 70.7
48 8.9 509 73.8
50 10.0 532 77.1

116
 Temperature pressure relationship – vapour pressure, kPa, psig
Temperature R-407C
kPa psig
°F °C
Shaded pressure values – Inches Hg below 1 ATM
52 11.1 554 80.4
54 12.2 578 83.9
56 13.3 603 87.4
58 14.4 627 91.0
60 15.6 654 94.8
62 16.7 680 98.6
64 17.8 707 102.5
66 18.9 734 106.5
68 20.0 763 110.7
70 21.1 792 114.9
72 22.2 823 119.3
74 23.3 853 123.7
76 24.4 885 128.3
78 25.6 917 133.0
80 26.7 950 137.8
82 27.8 984 142.7
84 28.9 1019 147.8
86 30.0 1055 153.0
88 31.1 1091 158.3
90 32.2 1129 163.7
92 33.3 1167 169.2
94 34.4 1206 174.9
96 35.6 1246 180.7
98 36.7 1287 186.7
100 37.8 1329 192.8
102 38.9 1372 199.0
104 40.0 1415 205.3
106 41.1 1461 211.9
108 42.2 1507 218.5
110 43.3 1553 225.3
112 44.4 1602 232.3
114 45.6 1651 239.4
116 46.7 1701 246.7
118 47.8 1752 254.1
120 48.9 1804 261.7
122 50.0 1857 269.4
124 51.1 1913 277.4
126 52.2 1968 285.5
128 53.3 2025 293.7
130 54.4 2084 302.2

117
14. Index
A digital multimeter, 58
drain pan, 23
abbreviations, 10
acid, 11, 24, 77 E
acid test, 78
economic cool mode, 34
air filter, 26, 55, 67, 92
electrical circuit, 23
air pollution, 52
evacuation station, 76
alarm, 31, 42, 44
evaporator blower, 23, 24, 56, 72, 109, 110
alarm code, 42, 44
evaporator coil, 23, 24, 55, 57, 73, 91
ambient temperature, 85
expansion valve, 23, 29, 72, 77, 91, 92, 93, 94
ambient temperature sensor, 68
ATS, 45, 46, 47, 68 F
B filter-drier, 20, 23, 24, 29, 73, 80, 88, 90, 95
freeze protection, 45, 49
blower, 23, 48, 109, 110
fresh air filter, 26, 67
C fuse, 63
calibration, 35, 37 G
capillary, 92, 93, 94
gauge manifold, 11, 81, 87
charging, 13
circuit breaker, 21, 63, 64 H
clamp tester, 58
heat limiter, 26
cleaning, 57, 91
heater, 23, 24, 26, 73, 85
Climador, 57
heating elements, 24
clutch cycling, 45
hourmeter, 43
coil cleaner, 59
HPCO, 25, 44, 47, 76, 81, 85, 98, 100
coil temperature sensor, 68
communication connector, 46 I
compressor, 25, 48, 49, 73, 76, 77, 95
insulation, 92, 93, 94
compressor assembly, 23, 25
compressor overload protection, 25 J
compressor protection, 45, 49
junction box, 100
condenser coil, 11, 23, 24, 28, 54, 57, 103
condenser fan, 24, 28, 56, 57, 111, 112 L
contactor, 21, 63
leak detector, 56, 58
control diagram, 47
leak test, 75, 79, 102, 104, 107
control system, 51, 54, 93, 95
lock function, 41
controller, 23
LPCO, 25, 44, 47, 76, 81, 98
CTS, 45, 46, 47, 68
M
D
manifold gauge, 76
diagnostic system, 44
manual mode, 32
diffuser, 111, 112
mixed air filter, 26, 67
118
moisture, 24, 29, 76, 77, 78, 82, 84 sight glass, 20, 23, 25, 29
solenoid valve, 23, 48, 101
N superheat, 92, 93
nitrogen, 12, 79, 93, 96 switchboard, 23, 24, 56
normal operating mode, 44
T
O Technobond, 58
oil test kit, 58, 77 temperature sensor, 44, 47, 68
overheating, 26 temperature switch, 113, 114
overvoltage arrester, 21 theory of operation, 28
oxygen, 11, 13, 77 thermal overheat protection, 17, 26
thermometer, 93
P thermostatic expansion valve, 91
power supply, 51 thread locker, 58
pressure rise test, 75, 84 thread lubricant, 59
program number, 37 tightening torque, 60
torque special conditions, 61
R
receiver tank, 23, 24, 29 V
red alarm, 44 vacuum, 91
refrigerant circuit, 23 vacuum cleaner, 57
relay, 21, 63, 66 vacuum pump, 76, 80, 82, 85
relay test, 37 ventilation mode, 44
return air, 26 vibration eliminator, 23, 25
return air temperature sensor, 68
RTS, 45, 46, 47, 68 W
warranty, 2, 14
S water eliminator, 23
safety, 11, 74, 108 weights, 18
safety relief valve, 25, 86, 100 wiring diagram, 120
schematics diagram, 120 working mode, 48
sensor bulb, 91, 92, 93, 94
serial number, 27 Y
setpoint, 100 yellow alarm, 44
shut down, 51

119
15. Appendix
15.1. Schemes, Diagrams and Drawings Index

Dwg No. Diagram / Drawing Title Pages

1E10861 Piping Schematic Diagram RAC 1

2E43411 Electric Wiring Diagram RAC 1

3E10039 Diagram Installation RAC 60 BRI 1

3E13495 Electric Schematic Diagram RAC 60 BRI 2

15.2. Recommended Publications

Following documents are available on ESA Info Central or contact your local Thermo King dealer
or directly Thermo King Representative, please.
http://iservice.thermoking.com/esa
NOTE: These www pages are protected for TK people & dealers only, you need to have login name
and password.

Title Nr.

A Evacuation station operation and field application TK 40612

B Silver brazing and soft soldering TK 7949

C Tool catalog TK 5955

D Electrostatic discharge training guide TK 40282

E Transport temperature control systems TK 50951

120
Page 1/1
 8 7 6 5 4 3 2 1
RELEASED 22/Jan/2014

REVISIONS
CHANGE ORDER REV DESCRIPTION DATE APPROVED
1 CEFM-1

WACS1

WACS2

WACS3
738571 A RELEASED 01-JUL-13 HORKY
W24N_4 2 CEFM-2
F 772885 B A D D E D P U L L - U P R E S I S T O R , D E L E T 17-DEC-13
ED GND_TS HORKY F
WPM_2 3 CEFM-3 1 3 5
QHTR ELECTROBOX

W24PI_2

W24PI_2
W24PI_1
W24P_6

W24P_4
WEFM1 4 CEFM-4

W108

W101
W117_1

W24P_5

W103_1

W103_2

WEFM1
W113

W112

W116

W107

W109
W103_4 5 YLL-1
C1 21 11 1 13 21 A
W102 6 YLL-2
11 14 12 11 14 12 23 24 13 14 24 14 1E38457G01 XPOW
XTB-1

QHTSR
22 12 HEATER POWER
W109 7 HTS-1

F1
QCFM QCOM QHTR QEFM
W110_1
8 HTS-2 KEFM
W110_3
C2 A2 A1 2 1422 B 1E38458G01
E
W107 9 HTS-3 COMPRESSOR POWER
E

W105_2 (D1)
W105_1

W105_1
W101
10

W106_2

W24P_3
W24N_6
W108 HTS-4
1E38460G01,1E38461G01
11 LV HEATER, SOLENOID

W117_2 (D2)

W110_2 (D3)
ATS-1 12 WATSA_2
1E38462G01,1E38463G01,1E40188G01

W24N_5
W117_1

W110_1

W110_3
BLP, BHP, CTS
XPOW
W116
W113
WSCR2 ATS-SCR
13 CTS-SCR
2E40813G01
WACS1 1 A
WRTSA_2 14 RTS-1
1 3 5 13A1 1 3 5 13A1 1 3 5 13A1 1 3 5 13A1 WACS2 2 1E41328G01 FADM
(OPTION)
WACS3 3 EVAPORATOR FAN MOTOR
WCTSA_2 15 CTS-1
KCFM KCOM KHTR1 KHTR2
D WTSB_2 RTS-2
1E40186G01
RTS
D
ATS_2 16 CTS-2
2 4 6 14A2 2 4 6 14A2 2 4 6 14A2 2 4 6 14A2 WGPOW 1E41301G01
CONDENSER FAN MOTOR
XLV1
HTR-1
CCFM-1

COM-1

HTR-3

HTR-5
W111_2
CCFM-3

COM-3

HTR-2

HTR-4

HTR-6
CCFM-2

COM-2
W115
W114_3

W114_3
W114_2

W118_2
W102

WSCR RTS-SCR 1E53276G01

17 WSCR2 ATS

W103_4 W103_3
W103_1 18 BLP-1

BLP-2
19 BHP-1 CFM EFM
CABLE CABLE
W115 BHP-2
C 20 JBOX C

CFM-GRN/YELL
XHEAT
W103_2 W103_3
21 XLV1 HTRS1_1 HTS-1

CFM-WHITE

CFM-WHITE

EFM-WHITE
CCFM-5

EFM-BLUE

EFM-YELL
HTRS1_2 HTS-2 CABLE TO

EFM-RED
CFM-U1

CFM-V1

CFM-W1

CFM-U2
CFM-V2
W112 CCFM-6
W24PI_1 1 A HTRS2_1 HTS-3 ELECTROBOX
22 2 HTRS2_2 HTS-4 1E38460G01
W24N_1 3
WPM_2 4
W24N_4 W24N_1
W24N_3 (FADM OPTION)
23 W24N_2 5
1 2 3 4 5 6 7 8 9 10 11
W24P_2 6
7
W24N_5
24 DM (FADM OPTION) 8

CEFM-1
CCFM-1

WGPOW
CEFM-3
W24N_6 W24N_2

CEFM-2

CEFM-4
CCFM-3

CCFM-5
CCFM-2

CCFM-4

CCFM-6
B

CFM-W2
W106_2 1

B 25
W114_2
W104_2
2
3 B
WATSA_2 4
WRTSA_2 5
W24P_1 (FADM OPTION) W24P_2
W24P_3 26 WTSB_2 6
W111_2 7
1E41301G01 1E41328G01
W118_2 8
W24P_4 CCFM CEFM
27 9
WCTSA_2 10
B 11 INGERSOLL-RAND IS THE SOLE OWNER OF THIS DRAWING CAD GENERATED DRAWING,
W24P_5
W24P_6 28 PULL-UP RESISTOR 3k9 2.0W 12
AND ALL INFORMATION IN IT, WHICH ARE PROTECTED BY
COPYRIGHT AND OTHER LAWS AND MAY BE SUBJECT TO LAWS
DO NOT MANUALLY UPDATE
Thermo King
-ITEM 6A10516H03 FROM ASSY 1E38424G04 WSCR REGARDING EXPORTING INFORMATION OUTSIDE OF THE U.S.
THIS DRAWING MAY BE USED ONLY BY ITS RECIPIENTS FOR DRAWN DATE
THE PURPOSE FOR WHICH IT IS PROVIDED AND ONLY BY TITLE
D1-W105_2 HORKY 01-JUL-13
29 THE RECIPIENT, WHO AGREES THAT IT WILL NOT, ELECTRIC WIRING
A A
WITHOUT INGERSOLL-RAND'S PRIOR WRITTEN PERMISSION: CHECKED
1) DISCLOSE NOR USE THIS DRAWING OR THE INFORMATION DIAGRAM
HAVELKA 01-JUL-13
IN IT EXCEPT AS SPECIFIED ABOVE; OR 2) MAKE ANY RAC
D3-W110_2 COPIES OF OR EXTRACTS, REVISIONS, OR UPDATES FROM APPROVED
W104_2 30 D2-W117_2
THE DRAWING. ALL COPIES MUST BE RETURNED TO
LESAK 01-JUL-13 SIZE CODE IDENT NO DWG NO REV
INGERSOLL-RAND UPON COMPLETION OF THE WORK FOR
WHICH THEY HAVE BEEN PROVIDED OR UPON ANY EARLIER ENG APPVL A2 2E43411 B
REQUEST.
- - SCALE: NONE REF DWG: - SHEET 1 OF 1

8 7 6 5 4 3 2 1
RELEASED 29/Jun/2016 10:07:02 GMT
 8 7 6 5 4 3 2 1
RELEASED 29/Jun/2016 10:07:01 GMT

REVISIONS
CHANGE ORDER REV DESCRIPTION DATE APPROVED

1045589 A RELEASED 21-JUN-16 HORKY

F XLV1
A1 24V DC
F
W24PI_1
A3 0V DC ClimaAIRE
W24N_1
F1/T4A 26 A6
W24P_3 W24P_2 W24P-1 W24P-4 P1-14
A B
ON/OFF SW

XJB
MEFM RED(BROWN) 11
CEFM-4
4
WEFM1
14
KEFM
11
W101
2
QEFM
1
W24PI_2
23
24 A5
10A W24N_2 W24N-1 P1-13
9 2
E M BLUE

YELLOW(BLACK) 10
CEFM-2
3
W24N_4
A4
E
CEFM-3 WPM_2 WPM-1 P1-08
WHITE(GREY) 8 1 QEFM KEFM
CEFM-1 27
YLL KCOM A1 A2 B1
24V 5 6 14 13
W24P_4
13 14
W105_1 W106_2 W106-1 P1-06
135W W103_4 YLL-1 YLL-2 W102 W24N_5 D1 29
W105_2

28
W24P_6 R/3k9/2.0W
W24P_5

QHTR QHTSR
D 23 24
W107
9
HTS-3
3
HTRS2_1 HTRS2_2
4
HTS-4
10
W108
C1 C2
W24N_6
D
F2HTR
130
$C

KEFM QCFM KCFM

21 24
21 5 WHITE FCFM WHITE 6 22 14 11 A1 A2 B2
18 W103_2 CCFM-5 CCFM-6 W112 W113 W114_2 W114-1 P1-04
W103_3
KCFM QCOM KCOM
BLP 19 BHP 20 14 13 14 11 A1 A2
BLP-1 BLP-2 BHP-1 BHP-2 W115 W116 W117_1 W114_3
D2 30
p< p>
W117_2
B3
W104_2 W104-1 P1-12
QHTR KHTR1
7 1 FHTR1,2 2 8 B7
C W103_1
13 14
W109 HTS-1 HTRS1_1
90
$C
HTRS1_2 HTS-2 W110_1
A1 A2
W111_2
D3
W111-1 P1-05 C
W110_2

XATS KHTR2
BATS A1 A2 B8
A W110_3 W118_2 W118-1 P1-01
12 B4
B ATS-1 CATS WATSA_2 WATSA-1 P1-09
XRTS ATS-2
BRTS 14
A B5
RTS-1 CRTS WRTSA_2 WRTSA-1 P1-10
B 16 B6
RTS-2 WTSB_2 WTSB-1 P1-07
B BCTS
XCTS
15
B
A B10
CTS-1 CCTS WCTSA_2 WCTSA-1 P1-11
B
CTS-2 17 SCR
RTS-SCR WSCR CCTRL-SCR
ATS_SCR 13
CTS_SCR
INGERSOLL-RAND IS THE SOLE OWNER OF THIS DRAWING CAD GENERATED DRAWING,
AND ALL INFORMATION IN IT, WHICH ARE PROTECTED BY
1 COPYRIGHT AND OTHER LAWS AND MAY BE SUBJECT TO LAWS
DO NOT MANUALLY UPDATE
XTB1 REGARDING EXPORTING INFORMATION OUTSIDE OF THE U.S.
THIS DRAWING MAY BE USED ONLY BY ITS RECIPIENTS FOR DRAWN DATE
Thermo King
1 THE PURPOSE FOR WHICH IT IS PROVIDED AND ONLY BY
HORKY 07-APR-16 TITLE
XHEAT THE RECIPIENT, WHO AGREES THAT IT WILL NOT, ELECTRIC SCHEMATIC
A A
WITHOUT INGERSOLL-RAND'S PRIOR WRITTEN PERMISSION: CHECKED
1 1) DISCLOSE NOR USE THIS DRAWING OR THE INFORMATION DIAGRAM
HAVELKA 07-APR-16
XJB IN IT EXCEPT AS SPECIFIED ABOVE; OR 2) MAKE ANY
COPIES OF OR EXTRACTS, REVISIONS, OR UPDATES FROM APPROVED
RAC 60 BRI
THE DRAWING. ALL COPIES MUST BE RETURNED TO SIZE CODE IDENT NO DWG NO REV
LESAK 07-APR-16
INGERSOLL-RAND UPON COMPLETION OF THE WORK FOR
WHICH THEY HAVE BEEN PROVIDED OR UPON ANY EARLIER ENG APPVL A2 3E13495 A
REQUEST.
- - SCALE: NONE REF DWG: - SHEET 1 OF 2

8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1
RELEASED 29/Jun/2016 10:07:01 GMT

F F

HEATER
QHTR KHTR1
1 2 1 2
HTR-1

3 4 3 4
2,5 kW
HTR-2

E 5
9.5A
6 5 6
HTR-3 E
(7-10A) KHTR2
1 2
HTR-4

3 4
2,5 kW
HTR-5

5 6
HTR-6

HTR-GND

D D
XPOW XJB

L1
A1
WACS1
1
QCFM
2 1
KCFM
2
CCFM-1
1 U1 - BROWN MCFM
3 x 400V A2 2 V1 - BLUE M
0,2 kW
3 4 3 4
L2 WACS2 CCFM-2
50Hz 3
3
A3 5 6 5 6 W1 - BLACK
L3 WACS3 CCFM-3
0.6A
(0.8A) 4 GREEN/YELLOW
WGPOW CCFM-4
7 W2 - ORANGE
C V2 - GREY
U2 - RED
C

1
QCOM
2 1
KCOM
2
COM-1
MCOM
M
2,5 kW
3 4 3 4
COM-2
3
5 6 5 6
COM-3
6.5A
(5.5-8A)
COM-GND

B B

A Thermo King
A
SIZE CODE IDENT NO DWG NO REV
A2 3E13495 A
SCALE: NONE REF DWG: - SHEET 2 OF 2

8 7 6 5 4 3 2 1