Thermo King TriPac Operator's Manual
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Thermo King TriPac Operator's Manual

Auxiliary heating/cooling temperature management system
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Operator's Manual
TriPac™
Auxiliary Heating/Cooling
Temperature Management System
TK 53035-19-OP (Rev. 6, 12/11)

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  • Page 1 Operator’s Manual TriPac™ Auxiliary Heating/Cooling Temperature Management System TK 53035-19-OP (Rev. 6, 12/11)
  • Page 3 TriPac Auxiliary Heating/Cooling Temperature Management System TK 53035-19-OP (Rev. 6, 12/11) Copyright© 2005 Thermo King Corp., Minneapolis, MN, USA Printed in USA...
  • Page 4 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.
  • Page 5 First Aid—Refrigerant Oil ....9 TriPac Unit) ....... . .21 Safety Decals .
  • Page 6 Standby Truck Integration ....33 TriPac Warranty ......55 Truck Integration Selector Switch .
  • Page 7 Table of Contents Recover Refrigerant ......64 CALIFORNIA Proposition 65 Warning ... 65...
  • Page 8 Table of Contents...

  • Page 9: Introduction

    Introduction There is nothing complicated about operating and maintaining IMPORTANT: This manual is published for informational your Thermo King unit, but a few minutes studying this purposes only and the information furnished herein should manual will be time well spent.
  • Page 10 Introduction...

  • Page 11: Safety Precautions

    Thermo King dealer. However, there are several general safety lacerations. Service work on the evaporator or practices you should be aware of: condenser coils is best left to a certified Thermo King technician. DANGER: Always turn the TriPac Main Power...

  • Page 12: Refrigerant Oil

    Safety Precautions Refrigerant Oil Refrigerant Observe the following precautions when working with or Although fluorocarbon refrigerants are classified as safe, around refrigerant oil: observe caution when working with refrigerants or around areas where they are being used in the servicing of your unit. WARNING: Always wear goggles or safety glasses to protect eyes from refrigerant oil contact.

  • Page 13: First Aid

    Safety Precautions First Aid First Aid—Refrigerant Oil Eyes: Immediately flush eyes with large amounts of water for First Aid—Refrigerant at least 15 minutes while holding the eyelids open. Get prompt medical attention. Eyes: For contact with liquid, immediately flush eyes with Skin: Remove contaminated clothing.

  • Page 14: Safety Decals

    Safety Precautions Safety Decals AMA690 AMA647 Figure 3: Shut Off Before Fueling Warning Figure 1: Caution - Unit May Start Automatically AMA646 Figure 2: Belt and Pulley Warning...

  • Page 15: Unit Description

    The TriPac is started to heat the coolant as required. By using TriPac, drivers can reduce fuel cost, rest comfortably during stops and comply with local, state and federal anti-idle laws.

  • Page 16: Unit Features

    7.5 hp 2 cylinder diesel engine - EPA Tier II TriPac System • Thermo King TM-15-XD compressor for air conditioning The TriPac system includes several major components: • Diesel fuel-fired sleeper compartment air heater • An APU (auxiliary power unit) •...

  • Page 17: Auxiliary Power Unit

    Figure 6: Condenser Figure 5: TriPac APU Condenser Auxiliary Power Unit The TriPac Air Conditioning Condenser is mounted on the The TriPac APU contains the diesel engine, air conditioning back of the truck cab. compressor, alternator and engine power switch.

  • Page 18: Evaporator

    (Evaporator installed under sleeper cab bunk) Heater Evaporator The TriPac Heater is typically installed in the cargo The TriPac air conditioning Evaporator is typically installed compartment under the truck cab sleeper compartment. It under the bunk in the truck cab sleeper compartment. Air ducts draws fuel from the truck’s diesel fuel tank and electric power...

  • Page 19: Hmi Controller

    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.

  • Page 20: Refrigerant

    9/06, it is part of the binary pressure closes to allow compressor operation. switch, mounted on the receiver-drier, typically near the TriPac condenser. On models manufactured during 9/06 and after, a High Pressure Cutout Switch (HPCO) is located at the receiver/drier.

  • Page 21: Engine Reset Switch

    The CLC option is designed for warm climate operation and switch opens the engine will shut down and an “Eng” Alarm also to isolate the TriPac system from the tractor engine Code will be displayed on the HMI. Typical causes for an open coolant if desired.
  • Page 22 Unit Description Fuses Fuse Number Amp Rating Component Protected / Circuit Starter / 8S Glowplugs / H HMI Controller / — Cab Heater / RED Standby Switch / 2A Standby Integration / IGN Fuel Solenoid / 8DP Engine Switch / 8FET Engine Start Signal / 7X/7A...
  • Page 23 Unit Description Fuse Number Amp Rating Component Protected / Circuit Fuse Number Amp Rating Component Protected / Circuit Pre-cooler Fan / PCF Condenser Fan / 7CF Evaporator Fan / PWM1/PWM2/7D Compressor Clutch / 7CL Heater On / 26/YLW Voltage Sense / SEN Main Power / 2 Ground / CH Hourmeter (Option) / 2...
  • Page 24 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.
  • Page 25 Coolant should be visible in coolant tank sight glass. 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.
  • Page 26 Manual Pretrip Inspection (Before Starting the TriPac Unit)

  • Page 27: Tripac Hmi Controller Description And .Operation

    TriPac HMI Controller Description and Operation The TriPac is operated using an HMI (Human Machine Interface) Controller which is typically mounted on a wall in the truck cab sleeper compartment. The HMI Controller includes a display screen, operation keys and indicator LEDs.

  • Page 28: Tripac Hmi Controller Description

    Up and Down Arrow Keys The HMI Controller Main Power Key is The HMI Controller Up and Down Keys used to turn the TriPac system on and off are used to raise and lower the temperature from the sleeper compartment. The green setpoint in the display.

  • Page 29: Fan Speed Key

    ON to provide sleeper compartment air conditioning, air circulation, truck battery voltage sensing and engine coolant temperature sensing. This key also allows access to the diesel engine hourmeter reading. The APU does not have to be On to operate the TriPac sleeper compartment heater.

  • Page 30: Operating Modes

    TriPac HMI Controller Description and Operation Operating Modes Fan Mode The fans can be turned on for air circulation in the truck cab. Air Conditioning Mode Fan speed is selected and battery voltage sensing is enabled. The APU must be enabled..

  • Page 31: Engine On/Off Switch

    Figure 13: Engine On/Off Switch 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.

  • Page 32: Tripac Hmi Controller Operation

    TriPac HMI Controller Description and Operation TriPac HMI Controller Operation Enable APU System The Engine On/Off Switch (inside the TriPac APU) must Press HMI Controller Main Power Key be on for the engine to run. Press the HMI Controller APU Key to enable the diesel power unit and also enable sleeper Press the Main Power Key.

  • Page 33: Engine Hourmeter Display

    TriPac HMI Controller Description and Operation Engine Hourmeter Display Select Mode of Operation When the APU Key is initially pressed, the TriPac unit Press the HMI Mode Key to select the desired operating engine hourmeter reading will be displayed. The display mode.

  • Page 34: Select Fan Speed

    The HMI setpoint temperature minimum is 50 degrees and the maximum is 90 degrees. The TriPac heater will operate while the Fans are off (no fan LED is illuminated – fan is in “Null”). If additional air...

  • Page 35: System Fault Indicator

    [with the Arctic option]) the TriPac will shut down. The TriPac will restart if the TriPac system is on and any of these conditions require a restart. (The truck’s ignition switch must be in the Off or Accessory position.) No alarm codes will...

  • Page 36: Alarm Codes

    To Clear Alarm Codes TriPac HMI Controller alarm codes are: Record the alarm code shown in the display. To clear an alarm code, use the HMI Main Power Key to turn off the TriPac Eng: • This code indicates that the that the “8” circuit has a system.

  • Page 37: Optional Standby Operation

    Standby Truck Integration system to be controlled by an external source which is typically the truck’s ignition system. This is used to disable the TriPac When the truck’s ignition switch is in the Off or Accessory system when the truck’s engine is running. The display will position, the TriPac APU will operate normally if the APU show “Sby”...
  • Page 38 TriPac HMI Controller Description and Operation...

  • Page 39: Optional Power Inverter

    Typically, when the inverter detects an AC load, it supply. Dangerous arcing may result. automatically turns on and converts dc to ac to power onboard 120 volt ac devices. If the TriPac is enabled and the inverter...
  • Page 40 Optional Power 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.

  • Page 41: Specifications

    No. 1 Diesel fuel is acceptable cold weather fuel 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.
  • Page 42 Specifications Oil Type* API Type CI-4 or better multigrade oil API Synthetic Type CI-4 or better after first 1000 hours (optional) API Type CJ-4 or better multigrade oil is required for units equipped with the optional DPF (Diesel Particulate Filter) Oil Viscosity Multigrade Oil Ambient Temperature...
  • Page 43 Specifications Coolant System Capacity (TriPac engine only) 0.6 quarts (0.6 liters) 2.75 quarts (2.6 liters) with Closed Loop Cooling Engine Coolant Type: Conventional Conventional coolant (antifreeze) is green or blue-green. Units equipped with conventional coolant do not have an ELC nameplate on the expansion tank.

  • Page 44: Compressor

    Specifications 10 psig (69 kPa) Radiator Cap Pressure, Closed Loop Cooling Drive Belts to compressor, 12 V alternator, water pump Compressor Compressor TM-15-XD Compressor Oil Charge 8 oz. (236.5 ml)* Compressor Oil Type (R134a Oil Viscosity Refrigerant Used) Polyalkylene glycol (PAG 100) TK P/N 203-502 R-134a Refrigeration System Refrigerant Charge 1.2 lbs.

  • Page 45: Fuses

    Specifications Fuses Component Protected / Circuit Voltage Starter/8S Glowplugs/H HMI Controller / — Cab Heater/RED Standby Switch/2A Standby Integration/IGN Fuel Solenoid/8DP Engine Switch/8FET Engine Start Signal/7X/7A Pre-cooler Fan/PCF Condenser Fan/7CF Evaporator Fan / PWM1/PWM2/7D Compressor Clutch / 7CL...
  • Page 46 Specifications Heater On / 26/YLW Voltage Sense / SEN Main Power / 2 Ground / CH Hourmeter (Option) / 2 Hourmeter (Option) / 8D Hourmeter (Option) / 26 Supplemental Heater Contactor (Extreme Arctic Option) / SHR Supplemental Heater (Extreme Arctic Option) / SH Oil Pan Heater (Extreme Arctic Option) / OPH...

  • Page 47: Belt Tension

    Specifications Fusable Link, 12 Gauge, APU Main (Prior To Power 9/06) Belt Tension Field Reset Engine/Compressor/Alternator Belt The belt tension should be set at 95 lbs force. A deflection of 1/4” between the alternator and compressor (longest free span of belt) may be used if a guage is not available to test tension.

  • Page 48: Truck Sleeper Compartment Heater (D2)

    Specifications 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...
  • Page 49 Specifications Motor Speed 800 ± 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.
  • Page 50 Specifications 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...
  • Page 51 Specifications 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.

  • Page 52: Optional Power Inverter

    Specifications Optional Power Inverter 1800 Watts; see manufacturer’s specifications Optional Extreme Arctic Package Components Approximate Approximate Current Draw Resistance— (Amps) at 12.5 (Ohms) Coolant Heater (800 Watts) 0.25 Oil Pan Heater (300 Watts) 0.65 Supplemental Heater Contactor Coil 13.5 NOTE: Disconnect components from unit circuit to check resistance.

  • Page 53: Maintenance Inspection Schedule

    Inspect air cleaner. Change as needed, or annually. • • 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. • •...

  • Page 54: Engine Oil Change Intervals

    1,000 1,000 Hour Interval - Oil change interval is every 1,000 hours of Hour operation only when using a Thermo King brand oil filter and CI-4 or Intervals better oil. Units with optional DPF require CJ-4 or better oil. •...

  • Page 55: Electrical

    Maintenance Inspection Schedule Pre-Trip 500 Hrs Annual Inspect/Service These Items 2,000 Hrs ELECTRICAL • • Check operation of protection shutdown circuits. • • Check alternator voltage. • Check alternator bearings. See Note 1 • • Inspect battery terminals. • • Inspect electrical connections.

  • Page 56: Structural

    Maintenance Inspection Schedule Pre-Trip 500 Hrs Annual Inspect/Service These Items 2,000 Hrs STRUCTURAL • • • 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.

  • Page 57: A/C System

    Maintenance Inspection Schedule Pre-Trip 500 Hrs Annual Inspect/Service These Items 2,000 Hrs A/C SYSTEM • • Check refrigerant level. • • Check refrigerant lines for rubbing or damage. HEATER • • • Start and run for at least 20 minutes each month. •...
  • Page 58 Maintenance Inspection Schedule...

  • Page 59: Tripac Warranty

    TriPac Warranty Terms of the Thermo King Warranty are available on request. Please reference document TK 50046 for the Thermo King TriPac Warranty.
  • Page 60 TriPac Warranty...

  • Page 61: Serial Number Locations

    (APU cover must be removed 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.
  • Page 62 Serial Number Locations...

  • Page 63: Tripac Glossary

    TriPac Glossary This glossary is published for informational purposes only and CFC: Chlorofluorocarbon. A chlorine-based refrigerant the information being furnished herein should not be consisting of chlorine, fluorine and carbon. Example: R12. In considered as all-inclusive or meant to cover all contingencies.
  • Page 64 HCFC refrigerants are not normally due to moisture in the refrigerant and the formation used in modern Thermo King units. of ice at the expansion valve. The expansion valve may be Hertz: A unit of frequency equal to one cycle per second.
  • Page 65 LPCO (Low Pressure Cut Out Switch): A receiver tank: A refrigerant storage device included in pressure-operated switch that opens to stop unit operation nearly all Thermo King units. when suction pressure reaches a predetermined minimum. refrigerant: The medium of heat transfer in a refrigeration no.
  • Page 66 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.

  • Page 67: Emergency Cold Line

    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.
  • Page 68 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.
  • Page 69 CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer.
  • Page 72 Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

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