Operator`s Manual - Anderson Trucking Service, Inc.

Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
TriPac EVOLUTION
Auxiliary Heating/Cooling
Temperature
Management System
TK 55711-19-OP (Rev. 1, 03/14)
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2013 Ingersoll-Rand Company
Printed in U.S.A.
TriPac EVOLUTION
Auxiliary Heating/Cooling
Temperature
Management System
TK 55711-19-OP (Rev. 1, 03/14)
TriPac EVOLUTION
Auxiliary
Heating/Cooling
Temperature
Management System
TK 55711-19-OP (Rev. 1, 03/14)
Copyright© 2013 Thermo King Corp., Minneapolis, MN, USA
Printed in USA
Disclaimer
This manual is published for informational purposes only. Thermo King Corporation makes no representations or
warranties, express or implied, with respect to the information, recommendations and descriptions contained in this manual
and such information, recommendations and descriptions should not be regarded as all-inclusive or covering all
contingencies. In the event you have any questions or require further information, please contact your local Thermo King
dealer.
The procedures described herein should only be undertaken by suitably qualified personnel. Failure to implement these
procedures correctly may cause damage to the Thermo King unit or other property or personal injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence and/or strict
liability) or otherwise, to any person or entity for any personal injury, property damage or any other direct, indirect, special
or consequential damage or liability whatsoever, arising out of or resulting 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 the procedures described herein correctly or to follow caution and safety decals located on the Thermo King
unit.
2
Table of Contents
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Practices 7
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
First Aid—Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 9
First Aid—Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 9
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Battery Installation and Cable Routing . . . . . . . . . . . . 10
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TriPac System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Auxiliary Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HMI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Closed Loop Cooling Option . . . . . . . . . . . . . . . . . . . .21
Engine On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . .21
Manual Pretrip Inspection (Before Starting the
TriPac Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
TriPac HMI Controller Description and .Operation 25
HMI Control Panel Display . . . . . . . . . . . . . . . . . .25
On/Off Button . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Mode Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Temperature Selector . . . . . . . . . . . . . . . . . . . . . .27
Fan Speed Selector . . . . . . . . . . . . . . . . . . . . . . . .28
System Condition . . . . . . . . . . . . . . . . . . . . . . . . .28
3
Table of Contents
Standby Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 28
Alarm Icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Alarm Group Indicator . . . . . . . . . . . . . . . . . . . . . . 29
Clearing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Heat Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fan Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Standby Mode (Optional) . . . . . . . . . . . . . . . . . . . 31
Standby Truck Integration (Optional) . . . . . . . . . . 31
Truck Integration with Selector Switch (Optional) . 31
Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Activate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Deactivate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Engine Load Management . . . . . . . . . . . . . . . . . . 33
Engine On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . 33
Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Alarm Notification . . . . . . . . . . . . . . . . . . . . . . . . . 34
To Clear Alarm Codes . . . . . . . . . . . . . . . . . . . . . 36
Optional Power Inverter . . . . . . . . . . . . . . . . . . . . . . 37
Inverter Operation Warnings . . . . . . . . . . . . . . . . . 37
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Control System . . . . . . . . . . . . . . . . . . . . . .
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . .
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Truck Sleeper Compartment Heater (D2) . . . . . . . . .
Truck Sleeper Compartment Heater (D4 - Option) . . .
Optional Power Inverter . . . . . . . . . . . . . . . . . . . . . . .
39
39
39
41
42
43
43
45
46
Maintenance Inspection Schedule . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Change Intervals (Change oil and
filters hot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
47
48
49
50
51
51
TriPac Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 55
TriPac Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4
Table of Contents
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . . 61
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 62
CALIFORNIA Proposition 65 Warning . . . . . . . . . . . 63
5
Table of Contents
6
Introduction
Introduction
There is nothing complicated about operating and maintaining
your Thermo King unit, but a few minutes studying this
manual will be time well spent.
Performing pre-trip checks and enroute inspections on a
regular basis will minimize on-the-road operating problems. A
regular maintenance program will also help to keep your unit
in top operating condition. If factory recommended procedures
are followed, you will find that you have purchased the most
efficient and dependable temperature control system available.
IMPORTANT: This manual is published for informational
purposes only and the information furnished herein should
not be considered as all-inclusive or meant to cover all
contingencies. If more information is required, consult your
Thermo King Service Directory for the location and
telephone number of the local dealer.
All service requirements, major and minor, should be handled
by a Thermo King dealer for four very important reasons:
•
They are equipped with the factory recommended tools to
perform 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 the
repair and replacement of component parts is performed
by an authorized Thermo King dealer.
7
Introduction
8
Safety Precautions
Thermo King recommends all services be performed by a
Thermo King dealer. However, there are several general safety
practices you should be aware of that are listed in this Safety
Precautions chapter.
The warning symbol appears next to a point that is particularly
important:
DANGER: Addresses a circumstance that, if
encountered, will lead to death orserious injury.
WARNING: Addresses a circumstance that, if
encountered, might lead to death or serious injury.
CAUTION: Addresses a circumstance that, if
encountered, may cause damage to equipment or
minor injury.
General Practices
DANGER: Always turn the TriPac unit off while
refueling the truck. Fuel vapors could ignite if they
come in contact with TriPac electrical or heater
components.
WARNING: Always wear goggles or safety glasses
when working with or around the air conditioning
system or battery. Refrigerant or battery acid can
cause permanent damage if it comes in contact with
your eyes.
WARNING: Keep hands and loose clothing clear of
fans and belts at all times when the unit is operating
or when opening or closing compressor service
valves.
9
Safety Precautions
WARNING: Exposed coil fins can cause painful
lacerations. Service work on the evaporator or
condenser coils is best left to a certified Thermo King
technician.
CAUTION: Use extreme caution when drilling holes
in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Never drill into
structural components.
WARNING: Turn the unit HMI Controller Main Off
before inspecting any part of the unit.
Refrigerant Oil
Observe the following precautions when working with or
around refrigerant oil:
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact.
10
WARNING: Protect skin and clothing from
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended.
WARNING: Wash thoroughly immediately after
handling refrigerant oil to prevent irritation.
Refrigerant
Although fluorocarbon refrigerants are classified as safe,
observe caution when working with refrigerants or around
areas where they are being used in the servicing of your unit.
DANGER: Fluorocarbon refrigerants may produce
toxic gases. In the presence of an open flame or
electrical short, these gases are severe respiratory
irritants CAPABLE OF CAUSING DEATH.
DANGER: Fluorocarbon refrigerants tend to
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
Safety Precautions
WARNING: Fluorocarbon refrigerants evaporate
rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.
First Aid—Refrigerant Oil
Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
medical attention.
First Aid
Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
First Aid—Refrigerant
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Seek prompt medical attention.
Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Seek prompt medical
attention.
Inhalation: Move victim to fresh air and use CPR if
necessary. Stay with victim until arrival of emergency medical
personnel.
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
Low Voltage
CAUTION: Control circuits used in the TriPac unit
are low voltage (12 volts dc). This voltage potential is
not considered dangerous, but the large amount of
current available can cause severe burns if shorted or
grounded.
11
Safety Precautions
WARNING: Do not wear jewelry, watches or rings
when working on the unit. If these items contact an
electrical circuit, severe burns may result.
CAUTION: Always disconnect power at the battery
before removing or repairing electrical components.
Failure to do so may result in personal injury or
damage to the equipment.
Battery Installation and Cable
Routing
Although fluorocarbon refrigerants are classified as safe,
observe caution when working with refrigerants or around
areas where they are being used in the servicing of your unit.
WARNING: Improperly installed battery could result
in a fire or explosion! A Thermo King approved
battery must be installed and properly secured to the
battery tray.
12
WARNING: Improperly installed battery cables could
result in fire or explosion! Battery cables must be
installed, routed and secured properly to prevent them
from rubbing, chaffing or making contact with hot,
sharp or rotating components.
WARNING: Do not attach fuel lines or any
additional wiring harnesses to the battery cables as
this could cause an electrical fire!
CAUTION: Do not connect other manufacturer’s
equipment or accessories to the Thermo King unit.
This could result in severe damage to equipment and
void the warranty!.
CAUTION: Set all unit electrical controls to the OFF
position before connecting battery cables to the
battery to prevent unit from starting unexpectedly
and causing personal injury.
Safety Precautions
CAUTION: Always wear protective clothing, gloves
and eye wear when handling and installing batteries.
Battery acid can cause serious burns when exposed to
eyes or skin. If battery acid contacts skin or clothing,
wash immediately with soap and water. If acid enters
your eye, immediately flood it with running cold
water for at least twenty minutes and get medical
attention immediately.
CAUTION: Always cover battery terminals to prevent
them from making contact with metal components
during battery installation. Battery terminals
grounding against metal could cause the battery to
explode.
Safety Decals
AMA647
Figure 1: Caution - Unit May Start Automatically
AMA646
Figure 2: Belt and Pulley Warning
13
Safety Precautions
AMA690
Figure 3: Shut Off Before Fueling Warning
14
Unit Description
Introduction
The Thermo King TriPac EVOLUTION Auxiliary Heating &
Cooling Temperature Management System allows drivers to
reduce unnecessary truck engine idling, conserve diesel fuel
and save money. TriPac EVOLUTION provides truck engine
preheating, battery charging and truck cab sleeper
compartment climate control.
By using TriPac, drivers can reduce fuel cost, rest comfortably
during stops and comply with local, state and federal anti-idle
laws. Reducing unnecessary truck engine idling also reduces
engine wear and extends engine maintenance intervals.
TriPac’s own diesel engine uses an automatic start/stop feature
for additional fuel efficiency.
TriPac’s two-cylinder diesel engine is EPA Tier 4 approved.
An automotive type air conditioning compressor is used for
sleeper compartment cooling. A fuel-fired air heater provides
sleeper compartment heat in cold conditions. Voltage sensing
automatically charges the truck batteries from TriPac’s 12-volt
alternator. Noise dampening construction assures quiet
operation. Truck engine preheating provides easier
cold-climate starts by exchanging coolant between TriPac and
the truck engine. An optional inverter provides 120-volt power
to operate on-board appliances.
An optional Arctic package aids truck engine startups in cold
weather by sensing low coolant temperature. The TriPac is
started to heat the coolant as required.
Figure 1: TriPac
15
Unit Description
Unit Features
•
Optional 1000 Watt pure sine inverter for on-board
appliances
•
Easy to operate Human Machine Interface (HMI)
Controller
•
•
Truck cab sleeper compartment cooling and heating for
driver comfort in all climates
Optional 1800 Watt inverter plus 120 amp alternator for
on-board appliances
•
Optional stainless steel condenser shroud
•
Truck engine preheating for easy starts in cold climates
•
Optional Exhaust Diesel Particulate Filter (DPF)
•
Truck battery charging with automatic low voltage sensing
•
Optional Closed Loop Cooling System
•
9.0 hp 2 cylinder diesel engine - EPA Tier 4
•
Optional 120 amp alternator
•
Thermo King TK 15 compressor for air conditioning
•
Diesel fuel-fired sleeper compartment air heater
TriPac System
•
65 amp alternator standard
The TriPac system includes several major components:
•
Noise-dampening construction for quiet operation
•
An APU (auxiliary power unit)
•
Automatic start/stop operation for maximum fuel
efficiency
•
Condenser
•
Evaporator
•
Optional Standby Truck Integration
•
Optional Truck Integration with Selector Switch
(select normal or standby operation)
•
Heater
•
HMI Controller.
•
Optional Arctic Package
•
Optional Closed Loop Cooling (CLC)
16
Unit Description
AMA550
Figure 2: TriPac APU
Figure 3: Condenser
Auxiliary Power Unit
Condenser
The TriPac APU contains the diesel engine, air conditioning
compressor, alternator and engine power switch.
The TriPac Air Conditioning Condenser is mounted on the
back of the truck cab.
17
Unit Description
ARA1421
AMA653
AMA552
Figure 4: TriPac Evaporator and Air Ducts
(Evaporator installed under sleeper cab bunk)
Evaporator
The TriPac air conditioning Evaporator is typically installed
under the bunk in the truck cab sleeper compartment. Air ducts
from the Evaporator carry conditioned air to the sleeper
compartment
18
Figure 5: Heater
Heater
The TriPac Heater is typically installed in the cargo
compartment under the truck cab sleeper compartment. It
draws fuel from the truck’s diesel fuel tank and electric power
from the truck’s batteries.
Unit Description
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,
usually mounted under the truck sleeper compartment bunk.
ARA2100
Figure 6: HMI Controller
Compressor operation is controlled by the TriPac Interface
Board. The Interface Board receives instructions from the HMI
Controller. The HMI Controller will instruct the Interface
Board to start the TriPac engine and energize the compressor
clutch when cab cooling is needed. The refrigeration system is
protected by high pressure and low pressure cutout switches.
HMI Controller
Control Circuits
The TriPac HMI (Human Machine Interface) Controller is
installed in the truck cab, typically on a wall in the sleeper
compartment. It is easily accessible to the driver and controls
TriPac operation. If necessary, system operating parameters
can be adjusted through programming by your Thermo King
dealer.
The control circuits operate on 12 Volt DC supplied by the
truck batteries.
Refrigerant
The TriPac air conditioning system uses R-134a refrigerant.
19
Unit Description
Protection Devices
The High System Pressure Cutout Switch is a normally
closed system pressure sensitive switch. If the discharge
pressure rises above the switch’s opening pressure, the switch
opens the circuit to stop the unit and Alarm Code 10 will be
logged. When the discharge pressure falls below the switch’s
closing pressure, the switch closes to allow compressor
operation. System sensors are continuously monitored and
alarms will be generated to protect the system.
The Low System Pressure Cutout Switch is a normally
closed pressure sensitive switch. If the pressure falls below the
switch’s opening pressure, the switch opens the circuit to stop
the compressor. and Alarm Code 93 will be logged. When the
pressure rises above the switch’s closing pressure, the switch
closes to allow compressor operation.
The electrical system is protected by a number of Fuses. Most
of the fuses are located on the interface board shown in Figure
10. Other fuses are located in fuse holders in wire harnesses.
See the list of fuses on page 19.
20
Figure 7: Interface Board
Unit Description
Fuses
Fuse Number
Amp Rating
Component Protected / Circuit
F1
30
Starter
F2
2
HMI Controller
F3
30
Glowplugs
F4
2
HMI Controller
F5
5
Optional Standby Switch
F6
5
Logic Power (main controller)
F7
40
Fuel Solenoid
F8
7.5
Engine Switch
F9
5
Engine Start Signal
21
Unit Description
Fuse Number
Amp Rating
Component Protected / Circuit
Fuse Number
Amp Rating
Component Protected / Circuit
F10
15
Pre-cooler Fan
F11
20
Condenser Fan
F12
20
Evaporator Fan
F13
7.5
Compressor Clutch
F14
5
Heater On
F15
2
Real Time Clock
F16
50
System Power
F17
2
Ground
F18
3
Voltage Sense
F19
1
Truck Ingnition Input
F24
150
Main DPF Power (option)
F25
10
SECM Power
F26
1
Truck Ignition Input to SECM
22
Unit Description
Fuse Number
Amp Rating
Component Protected / Circuit
F28
5
Heater Power Sense
F29
200
Main Power Cable
F30
3
Alternator Sense
F90
20
Cab Heater
CAUTION: Use fuel suitable for the climate you operate in (see truck engine manufacturer’s recommendations).
Blending used engine oil with diesel fuel is not permitted in the TriPac system. It will plug the filters and will not allow
the air heater to run properly. Thermo King reserves the right to void all warranty on the unit.
Closed Loop Cooling Option
The CLC option is designed for warm climate operation and
also to isolate the TriPac system from the tractor engine
coolant if desired. The TriPac will run independently of the
tractor engine coolant while providing battery charging and
cab comfort options.
Engine On/Off Switch
DANGER: Always turn the TriPac Main Power
On/Off Key on the HMI Controller OFF while
refueling the truck. Fuel vapors could ignite if they
come in contact with TriPac electrical or heater
components.
The APU Engine On/Off Switch is located inside the TriPac
APU housing on the right side of the frame. This switch must
be in the ON position for the TriPac system to operate.
23
Unit Description
ARA2124
1.
Engine On/Off Switch
Figure 8: Engine On/Off Switch
24
Manual Pretrip Inspection
(Before Starting the TriPac Unit)
Pretrip inspections are an important part of a preventative
maintenance program designed to minimize operating
problems and breakdowns. Perform this pretrip inspection
before every trip.
Structural: Visually inspect the unit for leaks, loose or
broken parts, and other damage.
NOTE: Pretrip inspections are not intended to take the place
of regular maintenance inspections.
Heater: Check exhaust pipe and intake tube.
Engine: Check engine oil level. Check coolant level if
equipped with optional closed loop cooling. Coolant should be
visible in coolant tank sight glass.
Coils: Make sure the condenser, evaporator and pre-cooler
coils are clean and free of debris.
General: Listen for unusual noises and vibrations.
Belts: Make sure the TriPac APU belts are in good condition
and adjusted to the proper tension. For more information about
belt tension, see the Specifications chapter.
Electrical: Check the electrical connections to make sure
they are securely fastened. Wires and terminals should be free
of corrosion, cracks, and moisture.
25
Manual Pretrip Inspection (Before Starting the TriPac Unit)
26
TriPac HMI Controller Description and Operation
The HMI (Human Machine Interface) is the operator control
module that is typically mounted in the bunk area of the truck
cab. The operator can select the desired function of the system.
It has three selector knobs and system condition display. The
HMI contains the Cab Temperature Sensor. It communicates
with the Controller using the Controller Area Network (CAN).
HMI Control Panel Display
The operator can select these functions from the HMI:
•
System On/Off
•
Mode (Cool, Fan, Heat)
•
Cab Temperature (Cooler/Blue-Warmer/Red)
•
Fan Speed (Off, Low, Medium, High)
When any change of settings is made there is a two second
delay before the controller will recognize the new setting. This
prevents momentary or accidental mode changes.
The HMI indicator LEDs will dim after 90 seconds if no
selections are made. Bump the On/Off button to activate bright
display for an additional 90 seconds.
Figure 1: HMI Controller
27
TriPac HMI Controller Description and Operation
On/Off Button
The On/Off Button is behind the left knob on the HMI. It
provides several functions depending on how long the button is
pressed.
Turn system On: If the system is off, press the Mode
Selector knob for a minimum of 1 second to turn the system
on. The mode icon will flash for 10 seconds while the
controller completes a boot process. Once the system has been
turned on the system mode, temperature or fan speed may then
be selected. If no selection is made the system will be in
Monitor Mode. See Monitor Mode later in this section.
NOTE: Pressing the Mode Selector knob for less than 1
second will not turn the TriPac system on.
Turn system Off: If system is on, press the Mode Selector
knob for a minimum of 2 seconds to turn the system off.
Display System Status: If system is on but display has
dimmed, press the Mode Selector knob for less than 1 second
to restore display to full brightness. The display will
automatically dim again in about 90 seconds. Pressing the
Mode Selector knob for less than 1 second is referred to as a
“Bump”.
28
Figure 2: Press Button for ON or OFF
Mode Selector
Mode selection is accomplished by rotating the left Mode
Selector knob. It selects between three operating modes. A
mode icon will flash then light indicating the selection. There
will be a two second delay before the new mode is activated to
prevent momentary or accidental mode changes. When the
system is first turned on at the HMI there will be a 10 second
delay before the selected mode is activated.
•
Cool Mode
•
Fan Only Mode
•
Heat Mode
TriPac HMI Controller Description and Operation
1
1
2
Temperature Selector
3
Cool Mode 2
Temperature selection is accomplished by rotating the center
Temperature Selector knob. It adjusts the desired cab
temperature cooler (blue) or warmer (red). Adjust to operator
comfort. The default represented range is approximately 65 80 F (20 - 27 C) in Cool Mode and 50 - 80 F (10 - 27 C) in
Heat Mode.
Fan Only Mode
3
Heat Mode
Figure 3: Mode Selection
NOTE: When the system is turned on for the first time after
replacing or disconnecting the main controller from power
the mode icon will flash for approximately 60 seconds. This is
initial boot of the micro processor.
Figure 4: Center Knob Adjusts Temperature
29
TriPac HMI Controller Description and Operation
Fan Speed Selector
System Condition
Evaporator fan speed selections are Off, Low, Medium and
High. Rotating the Fan Speed Selector knob clockwise will
increase fan speed, counterclockwise will decrease fan speed.
As fan speed increases/decreases, groups of four LEDs will
progressively turn on/off. The fan will continue to run at the
chosen speed. When Air Conditioning mode is selected and
Fan Speed is selected OFF, the fan speed will default to LOW.
When Fan Only or Heat mode are selected Fan Speed will
default to OFF.
Display Several LED indicators are on the left side of the HMI.
These provide additional System Condition information.
1
Standby Indicator
STBY is illuminated when the system is in Standby or Monitor
mode.
1
2
2
3
4
5
1
FAN Selector
2
LEDs
Figure 5: Right Knob Adjusts Fan Speed
30
1
ENG Icon
2
Alarm Icon
4
STBY Icon
5
ACS Icon
3
ALT Icon
Figure 6: System Condition Display Icons
TriPac HMI Controller Description and Operation
Alarm Icon
If the system has an active alarm the Alarm Icon will
illuminate. It will be Red for shutdown alarms and Yellow for
Check alarms.
Alarm Group Indicator
System shutdown alarms have been organized into three
general groups to help diagnosis. When a shutdown alarm is
generated the red Alarm Icon and the corresponding Alarm
Group name will illuminate.
•
[ENG] are APU engine related alarms.
•
[ALT] are alternator or charging system alarms.
•
[ACS] are air conditioning system related alarms.
Clearing Alarms
Alarm codes can be cleared by turning the controller off and
back on again. If the condition that caused the alarm still exists,
the alarm will return. Refer to the TriPac EVOLUTION
Diagnostic Manual TK 55739 for more information about
alarm codes. Contact the nearest Thermo King dealer if alarms
continue to appear.
Operating Modes
Cool Mode
When Cool Mode is selected at the Mode Selector knob, the
HMI Control Panel uses the Cab Temperature Sensor to
measure sleeper compartment temperature. If it is above the
temperature selected by the Setpoint Selector knob, the APU
engine will begin a start sequence (if not already running). The
evaporator fan is defaulted ON and will run in low or the speed
selected by the Fan Speed Selector knob. The compressor
clutch will engage 60 seconds after a successful engine start.
The system will cool the sleeper compartment until it falls to
the selected setpoint temperature. The compressor clutch will
disengage but the APU engine will continue to run for several
minutes based on the Engine Delay Timer setting (default 8
minutes). The evaporator fan will continue to run at the
31
TriPac HMI Controller Description and Operation
selected speed. If sleeper compartment temperature rises above
setpoint by more than the Dead Band setting (default 3 F)
during this time the compressor clutch will re-engage.
During normal air conditioning operation the compressor
clutch may cycle on and off with no alarm. The evaporator fan
will continue to run. The system is monitoring the Evaporator
Coil Temperature sensor to prevent frost buildup on the
evaporator coil. If coil temperature falls below 32 F the
compressor clutch is de-energized. When coil temperature rises
above 45 F the compressor clutch is energized.
The APU engine will shut down when the sleeper compartment
temperature remains near setpoint and the truck batteries are
charged. The evaporator fan will continue to run. If sleeper
compartment temperature rises above setpoint by more than
the Dead Band setting (default 3 F) the APU engine will restart
and compressor clutch will re-engage. Battery voltage sensing
and engine coolant temperature sensing are enabled for the
APU. Refer to Monitor Mode.
32
Heat Mode
The air heater is a separate module that heats the sleeper
compartment to the setpoint selected with the Temperature
Selector knob. Sleeper compartment temperature is sensed
inside the air heater, it does not use the Cab Temperature
Sensor on the HMI. All heater function is controlled by a
separate module inside the heater. The TriPac evaporator fan is
defaulted to OFF when Heat Mode is selected. It can be turned
on to provide additional air circulation. Battery voltage sensing
and engine coolant temperature sensing are enabled for the
APU. Refer to Monitor Mode.
Fan Mode
The TriPac evaporator fan can be turned on with the Fan Speed
Selector knob to provide additional air circulation in the
sleeper compartment and truck cab. Three fan speeds can be
selected (Low, Medium, High). LEDs around the Fan Speed
Selector will indicate the selected speed. Battery voltage
sensing and engine coolant temperature sensing are enabled for
the APU. Refer to Monitor Mode.
TriPac HMI Controller Description and Operation
Standby Mode (Optional)
The optional TriPac Standby Mode allows the system to be
controlled by an external switch input. This is typically the
truck ignition using the optional Standby Truck Integration.
The feature is used to disable the TriPac APU when the truck
engine is running. When the truck ignition switch is in the run
position, a voltage signal is sent to the controller. The TriPac
system will enter Standby Mode. The following occurs when
the TriPac system is in Standby Mode:
•
The STBY indicator on the HMI will illuminate.
•
Air conditioning, fan or heat operation will terminate.
•
The APU engine will stop.
•
The TriPac controller remains on but will not respond to
any operation requests, such as low battery voltage or low
coolant temperature.
Standby Truck Integration (Optional)
An optional wire harness connects the truck ignition switch to
an input connection on the TriPac interface board. The board
monitors voltage on this circuit.
•
Truck ignition switch is in the Off or Acc position. If the
TriPac system is turned on the unit operates normally.
•
Truck ignition switch is in the Start or On position. The
TriPac unit is forced to Standby mode. The HMI
Controller STBY indicator will illuminate.
Truck Integration with Selector Switch
(Optional)
An optional wire harness connects the truck ignition switch
and dash mounted selector switch to an input connection on the
TriPac interface board. The board monitors voltage on this
circuit.
•
Dash-mounted selector switch is in the Normal position. If
the TriPac system is turned on the unit operates normally.
The system will respond to the truck ignition as with the
Standby Truck Integration option.
•
Dash-mounted selector switch is in the Standby position.
The TriPac system will enter Standby Mode. This allows
the operator to disable the TriPac system without
accessing the HMI Control Panel in the sleeper.
33
TriPac HMI Controller Description and Operation
Deactivate
Monitor Mode will be deactivated and system will begin
HVAC operation if the operator presses the On/Off button at
the HMI, moves the Mode selector or moves the Fan Speed
selector. The selected HVAC mode will activate. The STBY
indicator on the HMI will turn off. System will continue to
monitor battery voltage and engine coolant temperature.
Figure 7: Standby Select Switch
Monitor Mode
Activate
By default Monitor Mode is active when the TriPac system is
turned on at the HMI Control Panel but a mode has not been
selected by the operator. Monitor Mode is also activated when
the truck ignition has been turned on (Standby) then turned off.
The STBY indicator on the HMI will illuminate.
34
Operation
While Monitor Mode is active the APU will continue to start
and stop as necessary to maintain battery voltage and engine
coolant temperature (if the Arctic Option is installed). While in
Monitor Mode the system will not react to changes in cab
temperature. TriPac Cool, Heat and Fan modes will remain off.
Battery voltage sensing is enabled. When battery voltage falls
to the level set by Battery Voltage Restart Value (default 12.1
Vdc) the APU engine will start so it can charge batteries. It will
continue to run until the Charge Current Shutoff Value setting
has been reached (default 20 amps).
TriPac HMI Controller Description and Operation
If the Arctic Option is installed and enabled, truck engine
coolant temperature sensing will occur. If engine coolant
temperature at WT2 falls below 35 F the APU engine will start
to warm the truck engine. It will continue to run until returning
coolant temperature rises to 55 F.
Monitor Mode may be disabled. If disabled the system will
return to the mode it was in when the truck ignition was turned
on.
NOTE: This is not the recommended setting. Refer to the
TriPac EVOLUTION Diagnostic Manual TK 55739 Section
3, Software Settings, Switch to Monitor for more information.
Engine Load Management
To maintain Tier 4 engine emission levels, engine load may be
reduced under some conditions.
Engine On/Off Switch
DANGER: Always turn the TriPac Main Power
On/Off Key on the HMI Controller OFF while
refueling the truck. Fuel vapors could ignite if they
come in contact with TriPac electrical or heater
components.
WARNING: The unit may start automatically without
warning if the Engine On/Off Switch is in the On
position.
WARNING: Immediately stand clear when the
preheat buzzer sounds. This indicates that the engine
is preheating. If the engine is hot, preheat time will
only be a few seconds.
The Engine On/Off Switch is located inside the TriPac APU
housing on the right side of the frame. This switch must be in
the On position for the TriPac engine to operate.
35
TriPac HMI Controller Description and Operation
•
If the TriPac system is ON but the APU engine is not
running, a shutdown alarm (code 35) will generate in the
[ENG] group. The engine will not start.
•
If the TriPac engine is running, the engine will stop and a
shutdown alarm (code 35) will generate in the [ENG]
group. The engine will not restart.
Alarm Codes
ARA2124
Alarm Notification
Figure 8: Engine On/Off Switch
The APU Engine On/Off Switch functions as a service switch.
It allows maintenance personnel to disable the APU engine.
This assures the engine will not crank even if the HMI On/Off
button is pressed on.
When the Engine On/Off switch is placed in the Off position:
•
36
If the TriPac system is OFF and the TriPac HMI On/Off
button is pressed, a shutdown alarm (code 35) will
generate in the [ENG] group. The engine will not start.
The TriPac control system continually monitors operation and
can generate several alarm codes. If the unit has an alarm
condition the operator will be notified by an illuminated Alarm
Icon on the HMI Control Panel. The icon can be Yellow or
Red.
TriPac HMI Controller Description and Operation
Yellow = Check Alarm: This indicates one or more of the
system Check Alarms are active. This level of alarm serves as
notice to take corrective action at the earliest convenience
before a problem becomes severe. The system will continue to
operate but some features and functions may be inhibited or
disabled.
1
2
3
4
1
ENG Icon
2
Alarm Icon
1
ALT Icon
2
ACS Icon
Figure 9: System Condition Display Alarm Icons
Red = Shutdown Alarm: This indicates one of the system
Shutdown Alarms is active. This level of alarm serves as notice
that a potentially severe system problem exists. Immediate
corrective action should be taken. The system will not be
operating. Along with the Red Alarm Icon, one of the
shutdown alarm group names (ENG, ALT, ACS) will
illuminate. This indicates the alarm falls into one of the three
categories, helping to focus diagnosis and repair.
ENG: Alarms in this group are engine related.
ALT: Alarms in this group are alternator, battery or system
voltage related.
ACS: Alarms in this group are air conditioning system
related.
37
TriPac HMI Controller Description and Operation
To Clear Alarm Codes
If the alarm icon is Red, first note the alarm group that is
illuminated on the HMI display (ENG, ALT, ACS). Use the
HMI Control Panel System On/Off button to turn the TriPac
unit off. Resolve the condition that caused the alarm. Use the
HMI Control Panel System On/Off button to turn the TriPac
unit on. Any active alarms will be cleared.
NOTE: If the alarm condition still exists the alarm will
return.
Active alarms and those recently cleared by the operator can be
read and cleared by a Thermo King service technician.
38
Optional Power Inverter
Inverter Operation Warnings
DANGER: Do not use an inverter in life support or
health care applications where a malfunction or
failure of the inverter could cause failure of a life
support device or medical equipment or significantly
alter the performance of that equipment.
DANGER: Potentially lethal voltages exist within the
inverter as long as the battery supply is connected.
During any service work, the battery supply should be
disconnected.
DANGER: Do not connect or disconnect batteries
while the inverter is operating from the battery
supply. Dangerous arcing may result.
CAUTION: Protect against possible electrical shock
hazards. If the inverter is operated in wet or damp
conditions a user-supplied, portable GFCI (ground
fault circuit interruptor) must be connected between
each inverter receptacle and the equipment it powers.
CAUTION: You may experience uneven performance
results if you connect a surge suppressor, line
conditioner or UPS system to the output of the
inverter.
A 12 Vdc to 120 Vac inverter is available as an option for
TriPac. The inverter is normally connected directly to the truck
batteries.
Inverter features will vary, depending upon the brand and
model used. Typically, when the inverter detects an AC load, it
automatically turns on and converts DC to AC power for
onboard 120 Vac devices. If the TriPac is enabled and the
39
Optional Power Inverter
inverter draws truck battery voltage down below the voltage
limit established for the installation, the TriPac will start and
attempt to recharge the truck batteries back to the level
specified. If the TriPac is not enabled, the inverter could drain
the truck batteries below the level required to start the truck or
the TriPac.
Manufacturer’s instructions for the optional inverter are
provided separately. It is important to read and follow those
instructions for proper use of the inverter.
40
Specifications
Engine
Engine Model
TK 270F (Tier 4)
Fuel Type
No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Caution: Use fuel suitable for the climate you operate in (see truck engine
manufacturer’s recommendations). Blending used engine oil with diesel fuel is not
permitted in the TriPac system. It will plug the filters and will not allow the air heater
to run properly. Thermo King reserves the right to void all warranty on the unit.
Oil Capacity: Crankcase & Oil Filter
6.5 quarts (6.2 liters) maximum.
IMPORTANT: The fill port on top of the engine
should not be used to add engine oil. To prevent
engine lock-up and/or serious internal damage
after TriPac engine oil is added or changed,
always add oil through the lower port on the timing
gear cover. Approximately 1.5 quarts (1.4 liters) is
required to move the oil level from the lower line
(5.1 quarts [4 .8 liters]) to the upper line (6.5
quarts [6.2 liters]) on the dipstick.
41
Oil Type*
API Type CJ-4 or better multigrade oil
API Synthetic Type CJ-4 or better multigrade oil is
required for units equipped with the optional DPF
(Diesel Particulate Filter)
Oil Viscosity
5 to 104 F (-15 to 40 C): SAE 15W-40
-4 to 86 F (-20 to 30 C): SAE 10W-30
Engine rpm:
No Load Operation, compressor clutch disengaged and alternator 2400 rpm ± 25 RPM
not charging.
2350 rpm ± 25 RPM
Loaded Operation, compressor clutch engaged and alternator
charging.
Engine Oil Pressure
50 psig (345 kPa) at rated output. 18 psig (128
kPa) at low idle.
Low Oil Pressure Switch (Normally Closed)
15 ± 2 psig (103 ± 14 kPa)
Coolant System Capacity (TriPac engine only)
0.6 quarts (0.6 liters)
2.75 quarts (2.6 liters) with Closed Loop Cooling
Engine Thermostat
160 F (71 C)
42
Compressor
Compressor
TM-15 HD
Compressor Oil Charge
8 oz. (236.5 ml)*
Compressor Oil Type (R134a Refrigerant Used)
Refrigerant Charge
Oil Viscosity
100
Polyalkylene glycol (PAG 100) TK P/N 203-502
1.5 lbs. (0.69 Kg)
Electrical Control System
Control System Voltage
12 Vdc
Alternator (Standard)
12 V 65 amp brush type integral regulator
Fuses (see Fuse list in Unit Description Chapter)
43
Electrical Components
Current Draw (Amps) at 12.5 Vdc
Glow Plugs (Each)
StarterMotor
CondenserFan
4.3
11.8 to 12.4
3.6 to 4.2
Pre‐CoolerFan
6.5 to 6.6
EvaporatorBlower
16.5 (high
speed)
FuelSolenoid:PullIn
HoldIn
3.0 to 3.5
1.4
35 to 45
0.2 to 0.3
0.5
24 to 29
NOTE: Disconnect components from unit circuit to check resistance.
44
2.3 ± 0.2
90 to 105 (cranking)
CompressorClutch
FuelPump
Resistance—(Ohms)
Belt Tension
Tension No. on TK
Gauge P/N 204-427
Engine/Compressor/Alternator Belt
75
Note: A deflection of 0.25 in. (7 mm) between the
alternator and compressor (longest free span of belt)
may be used if a gauge is not available to test tension.
Truck Sleeper Compartment Heater (D2)
Heat Output (±10%)
7,500 BTU/hr Boost (2.2 kW)
6,150 BTU/hr High (1.8 kW)
4,100 BTU/hr Medium (1.2 kW)
2,900 BTU/hr Low (0.85 kW)
Current at 12v (±10%)
8.3 amps - Start
2.8 amps - Boost
1.9 amps - High
1.0 amps - Medium
0.7 amps - Low
45
Fuel Consumption (±10%)
Boost 0.07 gal/hr (0.28 liter/hr.)
High 0.06 gal/hr (0.23 liter/hr.)
Medium 0.04 gal/hr. (0.14 liter/hr.)
Low 0.03 gal/hr (0.10 liter/hr.)
Air Flow (±10%)
48 cfm Boost
40 cfm High
27 cfm Medium
19 cfm Low
Motor Speed
4800 ± 140 RPM - Boost
4000 ± 120 RPM - High
2800 ± 80 RPM - Medium
2000 ± 60 RPM - Low
600 ± 20 RPM - Adjustment in circulation mode with
temperature sensor, internal.
0 RPM - Adjustment in fresh air mode with temperature
sensor, external.
4800 ± 140 RPM - Ventilation
46
Truck Sleeper Compartment Heater (D4 - Option)
Heat Output (±10%)
13,600 BTU/hr Boost (4.0 kW)
10,200 BTU/hr High (3.0 kW)
6,800 BTU/hr Medium (2.0 kW)
3,400 BTU/hr Low (1.0 kW)
Current at 12v (±10%)
8.3 amps - Start
3.3 amps - Boost
2.0 amps - High
1.1 amps - Medium
0.6 amps - Low
Fuel Consumption (±10%)
Boost 0.13 gal/hr (0.51 liter/hr.)
High 0.10 gal/hr (0.38 liter/hr.)
Medium 0.07 gal/hr. (0.25 liter/hr.)
Low 0.03 gal/hr (0.13 liter/hr.
Air Flow (±10%)
85 cfm Boost
69 cfm High
50 cfm Medium
30 cfm Low
47
Motor Speed
4400 ± 130 RPM - Boost
3600 ± 100 RPM - High
2800 ± 80 RPM - Medium
1600 ± 50 RPM - Low
600 ± 20 RPM - Adjustment in circulation mode with
temperature sensor, internal.
0 RPM - Adjustment in fresh air mode with temperature
sensor, external.
3600 ± 100 RPM - Ventilation
Optional Power Inverter
1,000 or 1,800 Watts; see manufacturer’s specifications
48
Maintenance Inspection Schedule
Pre-Trip 500 Hrs
Annual
2,000 Hrs
Inspect/Service These Items
Engine
•
•
•
Check engine oil level.
•
•
•
If equipped with Closed Loop Cooling option: Check coolant level;
coolant should be visible in coolant tank sight glass.
•
•
•
Inspect belts for condition and proper tension.
•
•
•
Listen for unusual noises, vibrations, etc.
•
•
Check air cleaner hose for damage.
•
•
Inspect air cleaner. Change as needed or annually. 2,000 hours max.
•
•
Inspect fuel pre-filter. Change as required or annually.
•
Change fuel filter. Thermo King brand fuel filter is required.
•
Drain water from fuel tank and check vent.
•
•
Check and adjust engine speed.
•
•
Check condition of engine mounts.
49
Maintenance Inspection Schedule
Pre-Trip 500 Hrs
Annual
2,000 Hrs
Inspect/Service These Items
•
Maintain year-round anti-freeze protection at –30° F (-34° C).
Change coolant every two years, or with truck coolant. For units with
optional Closed Loop Cooling system and ELC (red) engine coolant,
change ELC coolant every 5 years or 12,000 hours.
•
Adjust engine valves.
---
Test fuel injection nozzles at least every 3,000 hours. (Based on EPA
40 CFR Part 89.)
---
Replace fuel return lines between fuel injection nozzles every 10,000
hours or sooner, as required.
Engine Oil Change Intervals (Change oil and filters hot)
2,000
Hour
Intervals
500 Hour
Intervals
2,000 Hour Interval - Oil change interval is every 2,000 hours of
operation only when using a Thermo King brand oil filter and CI-4 or
better oil. Units with optional DPF require CJ-4 or better oil.
500 Hour Interval - Oil change interval is every 500 hours of
operation when using any other brand oil filter and CI-4 or better oil.
Units with optional DPF require CJ-4 or better oil.
IMPORTANT: The fill port on top of the engine should not be used to add engine oil. To prevent engine
lock-up and/or serious internal damage after TriPac engine oil is added or changed always add oil through the
lower port on the timing gear cover.
50
Maintenance Inspection Schedule
Pre-Trip 500 Hrs
Annual
2,000 Hrs
Inspect/Service These Items
Electrical
•
•
Check operation of protection shutdown circuits.
•
•
Check alternator voltage.
•
Check alternator bearings. See Note 1
•
•
Inspect battery terminals.
•
•
Inspect electrical connections.
•
•
Inspect wire harness for rubbing or damage.
•
Check electric condenser, evaporator and pre-cooler fans.
•
Note 1 - With belt removed spin alternator by hand. Listen for noise and ensure that bearings roll
freely.
51
Maintenance Inspection Schedule
Pre-Trip 500 Hrs
Annual
2,000 Hrs
Inspect/Service These Items
Structural
52
•
•
•
Visually inspect unit for fluid leaks (coolant, oil, refrigerant).
•
•
•
Visually inspect unit for damaged, loose or broken parts.
•
•
Inspect, clean and (if necessary) replace evaporator air filter. It may
be necessary to check or replace it more often if conditions require it.
•
•
Inspect evaporator drain valves (kazoos) to ensure that they are in
place, in good condition and are sealing.
•
Steam clean condenser coil, APU pre-cooler coil. Do not bend over
coil fins.
•
Blow out evaporator coil and evaporator water drains with air. Do not
bend over coil fins.
•
Check APU mounting bolts and brackets for cracks. damage and
poor aligment.Verify tightness and torque to 100 ft/lbs (135.6 N•m) for
the claw mount, or 200 ft/lbs (271.2 N•m) for the direct frame mount.
Maintenance Inspection Schedule
Pre-Trip 500 Hrs
Annual
2,000 Hrs
Inspect/Service These Items
A/C System
•
•
Check refrigerant level.
•
•
Check refrigerant lines for rubbing or damage.
Heater
•
•
•
Start and run for at least 20 minutes each month.
•
•
•
Inspect combustion air intake tube and exhaust pipe for restrictions
or blockage.
•
•
•
Inspect the ducting, the air intake screen and air outlet for restrictions
or blockage.
•
Remove the glow pin and inspect for carbon build up. Clean.
•
Remove the glow pin screen and inspect for carbon build up.
Replace.
•
Change fuel pump screen.
53
Maintenance Inspection Schedule
54
TriPac Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50046 for the Thermo King
TriPac Warranty.
55
TriPac Warranty
56
Serial Number Locations
Serial Number Locations
APU: Unit nameplate is located on front right edge of APU
frame near the Engine Switch (APU service access door must
be opened to view the nameplate).
Engine: Nameplate located on the top of the engine. The
engine is mounted in the TriPac APU housing.
Compressor: Nameplate located on compressor body. The
engine driven compressor is located in the TriPac APU
housing.
Heater: Sticker located on the side of the heater (Fabrik No.).
57
Serial Number Locations
58
TriPac Glossary
This glossary is published for informational purposes only and
the information being furnished herein should not be
considered as all-inclusive or meant to cover all contingencies.
NOTE: Additional terms not found in the glossary may be
located in the index section of this manual.
APU: Auxiliary Power Unit.
ambient air temperature: Temperature of the air
surrounding an object.
amp: Abbreviation for ampere. The basic measuring unit of
electrical current.
Btu (british thermal unit): The quantity of heat required to
raise the temperature of one pound of water by one degree
Fahrenheit. 1 Btu = 252 calories.
Celsius: The metric unit of temperature measurement. The
preferred alternate to the term centigrade. Abbreviated “C.”
centigrade. See Celsius.
CFC: Chlorofluorocarbon. A chlorine-based refrigerant
consisting of chlorine, fluorine and carbon. Example: R12. In
many countries it is illegal to release this type of refrigerant to
the atmosphere because chlorine damages the earth’s
atmosphere. CFC refrigerants are not used in modern Thermo
King units.
circuit breaker: A thermal device that automatically
interrupts an electrical circuit when the current in the circuit
exceeds the predetermined amperage rating of the breaker. See
amp.
coil: A cooling or heating element made of pipe or tube,
formed into a helical or serpentine shape, that may be equipped
with thin metal fins to aid heat transfer.
compressor: The refrigeration component that compresses
refrigerant vapor and creates refrigerant flow.
condenser: An arrangement of tubing in which the
vaporized and compressed refrigerant is liquefied as heat is
removed.
59
TriPac Glossary
cycles per second: See Hertz.
dehydrator: A device used to remove moisture from
refrigerant. Also called a drier.
discharge air temperature: The temperature of air leaving
the evaporator.
drier: See dehydrator.
evaporator: The part of the refrigeration system that absorbs
heat during the cooling cycle.
F: See Fahrenheit.
Fahrenheit: A unit of temperature measurement used in the
United States. Abbreviated “F.”
freeze up: 1) Failure of a refrigeration system to operate
normally due to moisture in the refrigerant and the formation
of ice at the expansion valve. The expansion valve may be
frozen shut or open, causing improper unit operation in either
case. 2) The formation of a solid ice mass over the evaporator
coil reducing air flow.
60
fuse: An electrical safety device (typically a cartridge)
inserted into an electrical circuit. It contains material that will
melt or break when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
fusible link: An electrical safety device (typically a short
piece of wire) inserted into an electrical circuit. The wire melts
or breaks when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
HCFC: Hydrochlorofluorocarbon. A chlorine-based
refrigerant containing hydrogen, chlorine, fluorine and carbon.
Example: R22. Because chlorine damages the earth’s
atmosphere, in many countries, it is illegal to release this type
of refrigerant to the atmosphere. HCFC refrigerants are not
used in modern Thermo King units.
Hertz: A unit of frequency equal to one cycle per second.
Abbreviated “Hz.”
HFC: A refrigerant consisting of hydrogen, fluorine and
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered “safe” for the
environment.
TriPac Glossary
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the
system if pressure exceeds a predetermined value.
pre-heat: The heating of diesel engine glow plugs prior to
start-up. Some engines use an intake manifold heater rather
than glow plugs.
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
HPCO (High Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when discharge pressure reaches a predetermined maximum.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
LPCO (Low Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
square inch as displayed by a gauge calibrated to zero when
open to the atmosphere.
receiver tank: A refrigerant storage device included in
nearly all Thermo King units.
no. 1 diesel fuel: A grade of diesel fuel formulated to
prevent “jelling” in low ambient temperatures.
refrigerant: The medium of heat transfer in a refrigeration
system which absorbs heat by evaporating at a low temperature
and releases heat by condensing at a higher temperature.
no. 2 diesel fuel: A grade of diesel fuel formulated for
moderate to warm ambient temperatures.
refrigerant oil: A special oil used to lubricate compressors in
refrigeration systems.
ohm: An electrical unit measuring the amount of resistance
(opposition to the current flow) in an electrical circuit.
rpm: Revolutions per minute.
61
TriPac Glossary
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
short cycling: When a refrigeration unit cycles between the
heat and cool modes more often than normal.
sight glass: A system component that permits visual
inspection of oil or refrigerant level and condition.
Vac (volts alternating current): An electric current that
reverses direction at regularly recurring intervals.
Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
volts: The basic measuring unit of electrical potential.
watt: The basic measuring unit of electrical power.
62
Emergency Cold Line
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AMA1585
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
63
Recover Refrigerant
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.
64
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
65
66
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
TriPac EVOLUTION
Auxiliary Heating/Cooling
Temperature
Management System
TK 55711-19-OP (Rev. 1, 03/14)
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2013 Ingersoll-Rand Company
Printed in U.S.A.
TriPac EVOLUTION
Auxiliary Heating/Cooling
Temperature
Management System
TK 55711-19-OP (Rev. 1, 03/14)
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