TriPac - Thermo King Units, Parts And Service And .

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Operator’s ManualTriPac Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions fortemperature control and Trane, a provider of energy efficient heating, ventilating andAuxiliary Heating/CoolingTemperature Management SystemTK 53035-19-OP (Rev. 6, 12/11)Printed in U.S.A.Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions fortemperature control and Trane, a provider of energy efficient heating, ventilating andPrinted in U.S.A.

TriPac mTK 53035-19-OP (Rev. 6, 12/11)Copyright 2005 Thermo King Corp., Minneapolis, MN, USAPrinted in USA

DisclaimerThis manual is published for informational purposes only. Thermo King Corporation makes norepresentations or warranties, express or implied, with respect to the information, recommendationsand descriptions contained in this manual and such information, recommendations and descriptionsshould not be regarded as all-inclusive or covering all contingencies. In the event you have anyquestions or require further information, please contact your local Thermo King dealer.The procedures described herein should only be undertaken by suitably qualified personnel. Failure toimplement these procedures correctly may cause damage to the Thermo King unit or other property orpersonal injury.Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligenceand/or strict liability) or otherwise, to any person or entity for any personal injury, property damage orany other direct, indirect, special or consequential damage or liability whatsoever, arising out of orresulting from any actions by any person that are contrary to this manual or any of the information,recommendations or descriptions contained herein or the failure of any person to implement theprocedures described herein correctly or to follow caution and safety decals located on the ThermoKing unit.2

Table of ContentsTable of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9First Aid—Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 9First Aid—Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 9Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TriPac System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . .Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HMI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11111212131314141515Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Engine Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . .17Closed Loop Cooling Option . . . . . . . . . . . . . . . . . . . .17Manual Pretrip Inspection (Before Starting theTriPac Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21TriPac HMI Controller Description and .Operation 23TriPac HMI Controller Description . . . . . . . . . . . . .24HMI Controller Display . . . . . . . . . . . . . . . . . . . . .24Main Power Key . . . . . . . . . . . . . . . . . . . . . . . . . .24Mode Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24Up and Down Arrow Keys . . . . . . . . . . . . . . . . . . .24Fan Speed Key . . . . . . . . . . . . . . . . . . . . . . . . . . .25APU System Key . . . . . . . . . . . . . . . . . . . . . . . . . .25System Fault Indicator . . . . . . . . . . . . . . . . . . . . . .25Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Air Conditioning Mode . . . . . . . . . . . . . . . . . . . . . .261

Table of ContentsHeat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Fan Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Monitor (Null) Mode . . . . . . . . . . . . . . . . . . . . . . . 26Engine On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . 27TriPac HMI Controller Operation . . . . . . . . . . . . . . . . . 28Press HMI Controller Main Power Key . . . . . . . . . 28Enable APU System . . . . . . . . . . . . . . . . . . . . . . . 28Engine Hourmeter Display . . . . . . . . . . . . . . . . . . 29Select Mode of Operation . . . . . . . . . . . . . . . . . . . 29Select Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . 30Select Temperature Setpoint . . . . . . . . . . . . . . . . 30System Fault Indicator . . . . . . . . . . . . . . . . . . . . . 31Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32To Clear Alarm Codes . . . . . . . . . . . . . . . . . . . . . 32Optional Standby Operation . . . . . . . . . . . . . . . . . 33Options Used With Standby Operation . . . . . . . . . 33Standby Truck Integration . . . . . . . . . . . . . . . . . . . 33Truck Integration Selector Switch . . . . . . . . . . . . . 33Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .R-134a Refrigeration System . . . . . . . . . . . . . . . . . . .Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Truck Sleeper Compartment Heater (D2) . . . . . . . . .Optional Power Inverter . . . . . . . . . . . . . . . . . . . . . . .Optional Extreme Arctic Package Components . . . . .40404143444848Maintenance Inspection Schedule . . . . . . . . . . . . .Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Oil Change Intervals ( . . . . . . . . . . . . . . . . . . .Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49495051525353TriPac Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 57Optional Power Inverter . . . . . . . . . . . . . . . . . . . . . . 35Inverter Operation Warnings . . . . . . . . . . . . . . . . . 35Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 372TriPac Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . . 63

Table of ContentsRecover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 64CALIFORNIA Proposition 65 Warning . . . . . . . . . . . 653

Table of Contents4

IntroductionIntroductionThere is nothing complicated about operating and maintainingyour Thermo King unit, but a few minutes studying thismanual will be time well spent.Performing pre-trip checks and enroute inspections on aregular basis will minimize on-the-road operating problems. Aregular maintenance program will also help to keep your unitin top operating condition. If factory recommended proceduresare followed, you will find that you have purchased the mostefficient and dependable temperature control system available.IMPORTANT: This manual is published for informationalpurposes only and the information furnished herein shouldnot be considered as all-inclusive or meant to cover allcontingencies. If more information is required, consult yourThermo King Service Directory for the location andtelephone number of the local dealer.All service requirements, major and minor, should be handledby a Thermo King dealer for four very important reasons: They are equipped with the factory recommended tools toperform all service functions They have factory trained and certified technicians They have genuine Thermo King replacement parts The warranty on your new unit is valid only when therepair and replacement of component parts is performedby an authorized Thermo King dealer.5

Introduction6

Safety PrecautionsThermo King recommends all services be performed by aThermo King dealer. However, there are several general safetypractices you should be aware of:DANGER: Always turn the TriPac Main PowerOn/Off Key on the HMI Controller OFF whilerefueling the truck. Fuel vapors could ignite if theycome in contact with TriPac electrical or heatercomponents.WARNING: Always wear goggles or safety glasseswhen working with or around the air conditioningsystem or battery. Refrigerant or battery acid cancause permanent damage if it comes in contact withyour eyes.WARNING: Exposed coil fins can cause painfullacerations. Service work on the evaporator orcondenser coils is best left to a certified Thermo Kingtechnician.CAUTION: Use extreme caution when drilling holesin the unit. Drilling into electrical wiring orrefrigerant lines could cause a fire. Never drill intostructural components.WARNING: Turn the unit HMI Controller MainPower key to Off before opening the APU orinspecting any part of the unit.WARNING: Keep hands and loose clothing clear offans and belts at all times when the unit is operatingor when opening or closing compressor servicevalves.7

Safety PrecautionsRefrigerant OilRefrigerantObserve the following precautions when working with oraround refrigerant oil:Although fluorocarbon refrigerants are classified as safe,observe caution when working with refrigerants or aroundareas where they are being used in the servicing of your unit.WARNING: Always wear goggles or safety glasses toprotect eyes from refrigerant oil contact.WARNING: Protect skin and clothing fromprolonged or repeated contact with refrigerant oil.Rubber gloves are recommended.WARNING: Wash thoroughly immediately afterhandling refrigerant oil to prevent irritation.DANGER: Fluorocarbon refrigerants may producetoxic gases. In the presence of an open flame orelectrical short, these gases are severe respiratoryirritants CAPABLE OF CAUSING DEATH.DANGER: Fluorocarbon refrigerants tend todisplace air and can cause oxygen depletion whichcould result in DEATH BY SUFFOCATION. Provideadequate ventilation in enclosed or confined areas.WARNING: Fluorocarbon refrigerants evaporaterapidly, freezing anything they contact if accidentallyreleased into the atmosphere from the liquid state.8

Safety PrecautionsFirst AidFirst Aid—Refrigerant OilFirst Aid—RefrigerantEyes: Immediately flush eyes with large amounts of water forat least 15 minutes while holding the eyelids open. Get promptmedical attention.Eyes: For contact with liquid, immediately flush eyes withlarge amounts of water. Seek prompt medical attention.Skin: Flush areas with large amounts of warm water. Do notapply heat. Wrap burns with dry, sterile, bulky dressing toprotect from infection or injury. Seek prompt medicalattention.Inhalation: Move victim to fresh air and restore breathing ifnecessary. Stay with victim until emergency personnel arrive.Skin: Remove contaminated clothing. Wash thoroughly withsoap and water. Get medical attention if irritation persists.Inhalation: Move victim to fresh air and restore breathing ifnecessary. Stay with victim until emergency personnel arrive.Ingestion: Do not induce vomiting. Immediately contactlocal poison control center or physician.9

Safety PrecautionsSafety DecalsAMA647Figure 1: Caution - Unit May Start AutomaticallyAMA646Figure 2: Belt and Pulley Warning10AMA690Figure 3: Shut Off Before Fueling Warning

Unit DescriptionIntroductionThe Thermo King TriPac Auxiliary Heating & CoolingTemperature Management System allows drivers to reduceunnecessary truck engine idling, conserve diesel fuel and savemoney. TriPac provides truck engine preheating, batterycharging and truck cab sleeper compartment climate control.By using TriPac, drivers can reduce fuel cost, rest comfortablyduring stops and comply with local, state and federal anti-idlelaws. Reducing unnecessary truck engine idling also reducesengine wear and extends engine maintenance intervals.TriPac’s own diesel engine uses an automatic start/stop featurefor additional fuel efficiency.TriPac’s two-cylinder diesel engine is EPA Tier 2 approved.An automotive type air conditioning compressor is used forsleeper compartment cooling. A fuel-fired air heater providessleeper compartment heat in cold conditions. Voltage sensingautomatically charges the truck batteries from TriPac’s 12-voltalternator. Noise dampening construction assures quietoperation. Truck engine preheating provides easier coldclimate starts by exchanging coolant between TriPac and thetruck engine. Optional Closed Loop Cooling allows the TriPacto operate independently of truck engine coolant. An optionalinverter provides 120-volt power to operate on-boardappliances. The optional Arctic package aids truck enginestartups in cold weather by sensing low coolant temperature.The TriPac is started to heat the coolant as required.AMA691Figure 4: TriPac11

Unit DescriptionUnit Features Optional Closed Loop Cooling (CLC) Optional Extreme Arctic Package Truck cab sleeper compartment cooling and heating fordriver comfort in all climatesOptional 12 Vdc to 120 Vac 1800 Watt inverter foron-board appliances Optional chrome plated exhaust pipe Truck engine preheating for easy starts in cold climates Optional stainless steel condenser shroud Truck battery charging with automatic low voltage sensing Optional Exhaust Diesel Particulate Filter (DPF) 7.5 hp 2 cylinder diesel engine - EPA Tier II Thermo King TM-15-XD compressor for air conditioningTriPac System Diesel fuel-fired sleeper compartment air heaterThe TriPac system includes several major components: 65 amp 12 VDC alternator An APU (auxiliary power unit) Noise-dampening construction for quiet operation Condenser Automatic start/stop operation for maximum fuelefficiency Evaporator Heater Optional Standby Truck Integration HMI Controller. Optional dash mounted Truck Integration Selector Switch(select normal or standby operation) Optional Arctic Package 12Easy to operate Human Machine Interface (HMI)Controller

Unit DescriptionAMA550AMA691Figure 5: TriPac APUFigure 6: CondenserAuxiliary Power UnitCondenserThe TriPac APU contains the diesel engine, air conditioningcompressor, alternator and engine power switch.The TriPac Air Conditioning Condenser is mounted on theback of the truck cab.13

Unit DescriptionAMA774AMA653AMA552Figure 7: TriPac Evaporator and Air Ducts(Evaporator installed under sleeper cab bunk)EvaporatorThe TriPac air conditioning Evaporator is typically installedunder the bunk in the truck cab sleeper compartment. Air ductsfrom the Evaporator carry conditioned air to the sleepercompartment14Figure 8: HeaterHeaterThe TriPac Heater is typically installed in the cargocompartment under the truck cab sleeper compartment. Itdraws fuel from the truck’s diesel fuel tank and electric powerfrom the truck’s batteries.

Unit DescriptionCompressorThe TriPac air conditioning compressor is mounted in theTriPac APU and is driven by the TriPac engine. Refrigerationlines connect the compressor to the TriPac air conditioningcondenser on the back wall of the truck cab and the evaporator,usually mounted under the truck sleeper compartment bunk.Figure 9: HMI ControllerCompressor operation is controlled by the TriPac InterfaceBoard. The Interface Board receives instructions from the HMIController. The HMI Controller will instruct the InterfaceBoard to start the TriPac engine and energize the compressorclutch when cab cooling is needed. The refrigeration system isprotected by high pressure and low pressure cutout switches.HMI ControllerControl CircuitsThe TriPac HMI (Human Machine Interface) Controller isinstalled in the truck cab, typically on a wall in the sleepercompartment. It is easily accessible to the driver and controlsTriPac operation. Standard, typically used operatingparameters are enabled in the HMI Controller when TriPac isinstalled. If necessary, HMI operating parameters can beadjusted through programming by your Thermo King dealer.The control circuits operate on 12V DC supplied by the truckbatteries.15

Unit DescriptionRefrigerantThe TriPac uses R-134a refrigerant.Protection DevicesThe High System Pressure Cutout Switch is a normallyclosed system pressure sensitive switch. On modelsmanufactured prior to 9/06, it is part of the binary pressureswitch, mounted on the receiver-drier, typically near the TriPaccondenser. On models manufactured during 9/06 and after, aHigh Pressure Cutout Switch (HPCO) is located at thereceiver/drier.If the discharge pressure rises above the switch’s openingpressure, the switch opens the circuit to stop the unit andgenerates an AcS Alarm Code. When the discharge pressurefalls below the switch’s closing pressure, the switch closes toallow compressor operation.The Low System Pressure Cutout Switch is a normallyclosed pressure sensitive switch.16On models manufactured prior to 9/06, it is part of the binarypressure switch, mounted on the receiver-drier, typically nearthe TriPac condenser. On models manufactured during 9/06and after, a Low Pressure Cutout Switch (LPCO) is installed atthe evaporator coil.If the pressure falls below the switch’s opening pressure, theswitch opens the circuit to stop the compressor. When thepressure rises above the switch’s closing pressure, the switchcloses to allow compressor operation.

Unit DescriptionEngine Reset SwitchClosed Loop Cooling OptionThe engine is protected by a reset switch. When the resetswitch opens the engine will shut down and an “Eng” AlarmCode will be displayed on the HMI. Typical causes for an openengine reset switch are low oil pressure, high watertemperature or an engine start failure. The engine reset switchis located on the side of the Interface Board control boxenclosure.The CLC option is designed for warm climate operation andalso to isolate the TriPac system from the tractor enginecoolant if desired. The TriPac will run independently of thetractor engine coolant while providing battery charging andcab comfort options.1On units with Interface BoardRevision 1.5 and earlier, thebutton on the engine reset switchpops out when the switch opens.You can also feel it click and stayin when you push it to reset it.On units with Interface BoardRevision 1.6, the reset switchbutton does not pop out when thereset circuit opens. Also, you willnot feel a click when you pushthe button to reset the circuit.Figure 10: Engine Reset Switch2AMA7831.Coolant Tank2.Coolant Tank Sight GlassAMA618Figure 11: Closed Loop Cooling Option17

Unit DescriptionFusesFuse NumberAmp RatingComponent Protected / CircuitF130Starter / 8SF230Glowplugs / HF35HMI Controller / —F420Cab Heater / REDF55Standby Switch / 2AF61Standby Integration / IGNF740Fuel Solenoid / 8DPF87.5Engine Switch / 8FETF95Engine Start Signal / 7X/7A18

Unit DescriptionFuse NumberAmp RatingComponent Protected / CircuitFuse NumberAmp RatingComponent Protected / CircuitF1015Pre-cooler Fan / PCFF1120Condenser Fan / 7CFF1220Evaporator Fan / PWM1/PWM2/7DF137.5Compressor Clutch / 7CLF145Heater On / 26/YLWF153Voltage Sense / S

by an authorized Thermo King dealer. IMPORTANT: This manual is published for informational . consult your Thermo King Service Directory for the location and telephone number of the local dealer. Introduction 6. 7 Safety Precautions Thermo King recommends all services be performed by a Thermo King dealer. . The TriPac APU contains the diesel .

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adjusted through programming by your Thermo King dealer. Compressor The TriPac air conditioning compressor is mounted in the TriPac APU and is driven by the TriPac engine. Refrigeration lines connect the compressor to the TriPac air conditioning condenser on the back wall of the truck cab and the evaporator,

Thermo King already builds the best selling diesel APU in the industry, and with TriPac Envidia, brings you the longest all-electric runtime in the industry* along with superior battery life. See why TriPac Envidia is the right choice for you! TriPac *Based on testing against leading competitive all-electric APU system.

This Thermo King User’s Manual contains confidential information of Thermo King, and is intended solely for the use and support of persons who are registered users of the Thermo King iService System. If you are not a registered user of iService , please call the Thermo King iService Support Center at 1-877-272-7877, or email .

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