Thermo King ThermoLite T-Series Installation Manual

The Thermo King ThermoLite T-Series is a line of advanced, lightweight transport refrigeration units designed for medium-duty trucks and vans. It features precise temperature control, robust construction for demanding environments, and energy-efficient operation. This manual covers safety procedures, pre-installation checks, mounting instructions, electrical and refrigerant connections, system commissioning, and post-installation verification. Always refer to the latest technical documentation and local regulations before proceeding.

Safety Precautions

Installation must be performed by qualified personnel trained in refrigeration systems and vehicle electrical work.

Unit Overview & Components

Key components included in the shipment: Refrigeration Unit, Mounting Kit (brackets, bolts, shims), Electrical Harness, Drain Tube Kit, User Control Panel, and Documentation Pack.

1. Refrigeration Unit: Contains compressor, condenser, evaporator, and control module.
2. Mounting Kit: All hardware for securing the unit to the vehicle chassis.
3. Electrical Harness: Pre-wired harness for connection to vehicle battery and control panel.
4. Control Panel: Digital interface for temperature setpoint, mode selection, and diagnostics.
5. Drain Tube: For condensate removal from the evaporator coil.

WARNING! Inspect all components for shipping damage before installation. Do not install damaged parts.

Pre-Installation Requirements

Ensure the vehicle and site are prepared.

1. Vehicle Check: Verify chassis is rated for the additional weight. Check mounting surface is clean, flat, and free of corrosion.
2. Power Supply: Confirm vehicle electrical system (battery, alternator) meets unit's voltage and amperage requirements (see Specifications).
3. Clearance: Ensure adequate clearance around the unit for airflow (min. 6 inches) and service access.
4. Tools: Gather required tools: torque wrench, socket set, wire strippers/crimpers, multimeter, refrigerant manifold gauges, vacuum pump.

CAUTION! Failure to meet pre-installation requirements can void warranty and cause system failure.

Specifications

• Model Series: ThermoLite T-300, T-400, T-500.
• Voltage: 12V DC or 24V DC (model dependent).
• Max Current Draw: 45-80 Amps (see model-specific datasheet).
• Refrigerant: R-452A (or as specified on unit label).
• Temperature Range: -10°F to +70°F (-23°C to +21°C) adjustable.
• Dimensions (LxWxH): Varies by model. Refer to unit label.
• Weight: 150-220 lbs (68-100 kg).
• Airflow: High-efficiency evaporator and condenser fans.
• Control: Microprocessor-based with digital display and diagnostic codes.

Mounting the Unit

Position the unit on the vehicle's front wall or chassis as per the mounting diagram.

Procedure:

1. Position mounting brackets onto the vehicle frame using provided template. Mark drill holes.
2. Drill holes to specified diameter. Deburr holes and treat with anti-corrosion paint.
3. Lift unit into position using a hoist. Align with bracket holes.
4. Insert mounting bolts with washers. Hand-tighten initially.
5. Torque all bolts to specification (typically 50-60 ft-lbs / 68-81 Nm) in a criss-cross pattern.
6. Install vibration isolators (if provided) between unit and brackets.
7. Verify unit is level and secure. No movement should be present.

Tip: Use a second technician to guide the unit during lowering.

Electrical Connection

Connect the main power harness and control panel.

1. Disconnect Battery: Negative terminal first.
2. Route Harness: Run the main power cable from the unit to the vehicle battery, securing it away from heat and moving parts. Use grommets through firewall.
3. Battery Connection: Connect RED wire to battery positive (+) terminal via an appropriately rated fuse (80A-150A, see spec). Connect BLACK wire to battery negative (-) terminal or a clean chassis ground.
4. Control Panel: Mount the control panel in the cab. Plug its connector into the designated port on the main harness.
5. Seal & Secure: Weatherproof all external connections. Secure all wiring with zip ties.

WARNING! Incorrect polarity will damage the control module. Double-check connections.

Refrigerant System Connection

For split systems or units requiring field connections. (Some T-Series models are pre-charged).

1. Leak Check: Before connecting, inspect factory-installed Schrader valves and fittings.
2. Connect Lines: Using clean, refrigerant-grade tools, connect the liquid and suction lines between the unit and the evaporator coil (if remote). Use new seals.
3. Evacuation: Connect a vacuum pump to the service port. Evacuate the system to a minimum of 500 microns. Hold for 15 minutes to check for leaks.
4. Charging: Using a calibrated scale, add the exact amount of refrigerant specified on the unit's nameplate. Use vapor charge for final ounces.
5. Final Leak Check: Use an electronic leak detector on all connections.

WARNING! Only EPA-certified technicians should perform refrigerant work. Follow all local regulations.

Control System Setup

Power on and configure the control system.

1. Reconnect vehicle battery (negative terminal last).
2. Turn the vehicle ignition to ON (or as required per model).
3. The control panel display should illuminate. Navigate the menu using the arrow keys.
4. Set the desired temperature setpoint.
5. Configure operating parameters if needed (e.g., defrost cycle interval, alarm thresholds). Default settings are typically suitable.
6. Set clock and date for event logging.

Commissioning & Initial Startup

Perform a full system test.

1. Start the vehicle engine to ensure stable voltage.
2. On the control panel, select COOL mode and set a temperature below ambient.
3. The compressor and fans should engage. Listen for unusual noises.
4. Monitor the suction and discharge pressures (if gauges are installed). Compare to typical operating pressures for the ambient temperature.
5. Allow the unit to run for at least 15 minutes. Check that cold air is discharging from the evaporator.
6. Verify the drain tube is ejecting condensate.
7. Test HEAT mode (if equipped) and DEFROST cycle.

CAUTION! Do not run the unit for extended periods with the vehicle doors closed without ventilation.

Performance Verification

Confirm the unit meets performance criteria.

Troubleshooting & Support

Reset: Power cycle the unit by disconnecting the battery for 60 seconds.

Service & Support: For technical assistance, contact Thermo King at 1-800-XXX-XXXX or visit www.thermoking.com. Have the model and serial number ready.