Thermo King TriPac Envidia Installation Manual

Auxiliary heating and cooling temperature management system

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Operator's manual (48 pages)

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Page 1 Installation Manual Installation Manual Installation Manual Installation Manual Installation Manual Installation Manual TriPac Envidia Auxiliary Heating and Cooling Temperature Management System TK 56459-19-IM (Rev. 0, 12/17)
Page 3 Installation Manual TriPac Envidia Auxiliary Heating and Cooling Temperature Management System TK 56459-19-IM (Rev. 0, 12/17) © Copyright 2017 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
Page 4: Introduction
Introduction This manual was written only to assist with the installation of the Thermo King TriPac Envidia Auxiliary Heating and Cooling Systems onto a typical Class 8 semi-tractor with sleeper. While it is not intended to be specific to a particular vehicle, the information in this manual will provide the installer with details to correctly and safely install each of the APU components.
Page 5: Table Of Contents
Table of Contents Introduction ................................2 Table of Contents ............................... 3 Tips for a Successful Installation..........................5 Battery Box Dimensions ............................. 9 Evaporator/Control Box Dimensions ........................11 Condenser with Receiver Drier Dimensions ......................12 HMI Dimensions ..............................13 1000 Watt Power Inverter Dimensions (Option) ...................... 14 AC/DC Shore Power Converter Dimensions (Option) .....................
Page 6 Heater Start-Up Procedure (Heat Option) ........................ 62 A/C System Charging Procedure ..........................66 Operation Checkout Procedures ..........................67 Unit Setup ................................. 69 System Check List ..............................73...
Page 7: Tips For A Successful Installation
Recommendations section in this manual for more information. APU BATTERIES • Thermo King NXT AGM batteries are shipped fully charged and ready to use. See Tractor and APU Battery Recommendations section in this manual for more information.. APU BATTERY BOX INSTALLATION •...
Page 8 Tips for a Successful Installation (continued) A/C CONDENSER INSTALLATION • Keep all the A/C fittings capped and sealed until the installation of the refrigeration hoses. Refrigerant oil is extremely hygroscopic and a system left open for more than 5 minutes may require extensive evacuation/dehydration time to remove moisture.
Page 9 Tips for a Successful Installation (continued) D2/D4 HEATER INSTALLATION (Heat Option) • Determine the best location of the heater inside the sleeper, typically under the bunk. Allow clearance for dismantling for service. • Install heater so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or flammable material.
Page 10 • Always install the condenser’s receiver drier so refrigerant flow is in the direction indicated by the arrow. • Thermo King Evacuation Station (204-725) and Evacuation Station Operation and Field Application Instructions (TK-40612) are recommended. • The oil in the evacuation station vacuum pump should be changed after each use.
Page 11: Battery Box Dimensions
Battery Box Dimensions Figure 1: Battery Box Dimensions...
Page 12 Battery Box Dimensions (continued) Figure 2: Battery Box Dimensions (continued)
Page 13: Evaporator/Control Box Dimensions
Evaporator/Control Box Dimensions Figure 3: Evaporator/Control Box Dimensions...
Page 14: Condenser With Receiver Drier Dimensions
Condenser with Receiver Drier Dimensions Figure 4: Condenser with Receiver Drier Dimensions...
Page 15: Hmi Dimensions
HMI Dimensions Figure 5: HMI Dimensions...
Page 16: 1000 Watt Power Inverter Dimensions (Option)
1000 Watt Power Inverter Dimensions (Option) Figure 6: 1000 Watt Power Inverter Dimensions...
Page 17: Ac/Dc Shore Power Converter Dimensions (Option)
AC/DC Shore Power Converter Dimensions (Option) Figure 7: AC/DC Shore Power Converter Dimensions...
Page 18: D2/D4 Heater Dimensions (Option)
D2/D4 Heater Dimensions (Option) Figure 8: Heater Dimension...
Page 19 BLANK PAGE...
Page 20: Required Tools And Additional Supplies
Required Tools and Additional Supplies Tools 1. Typical Mechanics Tools 2. Floor Jack or Motorcycle/ATV Lift 3. Drill Motor 4. Drill Bit Set 5. 7/8" dia. or 1" Step Reamer (for evaporator drain and controller holes) 6. Hole Saws a. 1" dia. (for fuel tank pickup tube) b.
Page 21: Typical Component Locations
Typical Component Locations Figure 9: Typical Component Locations...
Page 22: Tractor And Apu Battery Recommendations
Charge Maintenance Thermo King NXT AGM batteries are shipped fully charged. Fully charged NXT AGM batteries that are kept in stock should not require charging for 2 years if kept below 77 F (25 C). NXT AGM batteries should be charged when the open circuit voltage (OCV) falls below 12.50 volts.
Page 23 Tractor and APU Battery Recommendations (continued) Determining Maximum Charge Time Using a Manual Charger Voltmeter Reading State of Charge Time @ 10 Amps Time @ 20 Amps 12.84 Volts 100% 0 Hours 0 Hours 12.50 Volts 2 Hours 1 Hour 12.20 Volts 4 Hours 2 Hours...
Page 24: Battery Box Installation
WARNING: Installer supplied lifting eyebolts must be forged steel, 1/2"(12mm) diameter. WARNING: Use only locking lifting hooks to attach to the lifting eyebolts. WARNING: DO NOT connect any of the TriPac ENVIDIA battery cables to any batteries at this time. NOTE: DO NOT OIL THE BOLT THREADS!
Page 25 Battery Box Installation (continued) STANDARD INSTALLATION METHOD - MOUNTING CLAWS WARNING: DO NOT connect any of the TriPac Envidia battery cables to any batteries at this time. NOTE: Mounting bolt threads must extend into the battery box. Figure 10: Standard Installation Method – Mounting Claws...
Page 26 WARNING: Installer supplied lifting eyebolts must be forged steel, 1/2" (12 mm) diameter. WARNING: Use only locking lifting hooks to attach to the lifting eyebolts. WARNING: DO NOT connect any of the TriPac ENVIDIA battery cables to any batteries at this time. NOTE: DO NOT OIL THE BOLT THREADS!
Page 27 Battery Box Installation (continued) OPTIONAL INSTALLATION METHOD - DIRECT MOUNT WARNING: DO NOT connect any of the TriPac ENVIDIA battery cables to any batteries at this time. Figure 11: Optional Installation Method – Direct Mount...
Page 28: Condenser And Receiver Drier Installation
Condenser and Receiver Drier Installation Sub-Assembly IMPORTANT: Keep all the A/C fittings capped and sealed until the installation of the refrigeration hoses. Refrigerant oil is extremely hygroscopic and a system left open for more than 5 minutes may require extensive evacuation / dehydration time to remove moisture.
Page 29 Condenser and Receiver Drier Installation (continued) Installation CAUTION: Before drilling any holes in the tractor, check for interference with internal wires, supports or interior panels. Avoid drilling into any interior support members as this could void the tractor’s OEM warranty. IMPORTANT: Use a backup wrench whenever tightening refrigerant hose fittings.
Page 30: Evaporator/Control Box Installation
Evaporator/Control Box Installation PREFERRED LOCATION - FLUSH WITH FRONT BULKHEAD IMPORTANT: Keep all the A/C fittings capped and sealed until the installation of the refrigeration hoses. Refrigerant oil is extremely hygroscopic and a system left open for more than 5 minutes may require extensive evacuation/dehydration time to remove moisture.
Page 31 Evaporator/Control Box Installation (continued) NOTE: It is not necessary to remove the Evaporator/Control Box cover to complete a system installation. NOTE: This installation requires a two-person or mechanically assisted lift. Position template with RETURN AIR flush with bulkhead. Mark location of the 7/8” evaporator drain holes and 2”...
Page 32: Fabricating Refrigeration Hoses
Fabricating Refrigeration Hoses TK 2000 Assembly System The TK 2000 System is designed for assembly with Multi-Refrigerant hose only. Assembly Materials Checklist Hose Fitting Tool (204-1045) Hose Cutting Tools (204-677) TK 2000 Multi-Refrigerant Hose Nipple Assembly Appropriately Sized Clips and Cage Alkyl Benzene refrigerant oil (670404TKA) NOTE: The two black O-rings on the nipple assembly are of a specific rubber compound and size.
Page 33 Fabricating Refrigeration Hoses (continued) Cut the Hose Cut the hose to proper length with an appropriate cutting tool. Hand-held hose cutter (204-677) has been specially designed for cutting all non-wire reinforced hose, such as TK 2000 Multi-Refrigerant hose. Be sure the cut is made square to the hose length.
Page 34 Fabricating Refrigeration Hoses (continued) Oil the Nipple Lubricate the nipple with a generous amount of the Alkyl Benzene refrigerant oil (670404TKA). This MUST be done to lower the force of nipple insertion. Insert the nipple into the hose. To ensure that the nipple is fully inserted, check the gap between the cut end of the hose and the shoulder on the nipple.
Page 35 TK 2000 Speedy Clip System hose with fittings supplied by other manufactures could result in sudden or unintended escape of refrigerant gases. Personal injury and/or violations of EPA regulations may occur as a consequence. NOTE: Thermo King recommends adherence to all guidelines, including EPA guidelines concerning the service of refrigerant systems.
Page 36: A/C Hose Installation
A/C Hose Installation Installation IMPORTANT: Keep all the A/C fittings capped and sealed until the installation of the refrigeration hoses. Refrigerant oil is extremely hygroscopic and a system left open for more than 5 minutes may require extensive evacuation/dehydration time to remove moisture. NOTE: The Evaporator/Control Box system has a Nitrogen holding charge of 5 PSI.
Page 37 A/C Hose Installation (continued) #4 Liquid Line from Drier Outlet #6 Discharge Line from Condenser Figure 16:A/C Hose I.D. and routing shown...
Page 38: A/C System Evacuation And Leak Check Procedures
A/C System Evacuation and Leak Check Procedures System Evacuation Procedures Special Tools Required Vacuum Pump (204-713 or equivalent) Micron Gauge (204-720) Refrigerant Leak Detector (204-712) Gauge Set with R134a Adapters IMPORTANT: Always use recommended vacuum equipment. Before each use, check that there are no leaks in the vacuum equipment either in the pump itself or in the hoses.
Page 39: D2/D4 Heater Installation (Heat Option)
D2/D4 Heater Installation (Heat Option) Heater Location IMPORTANT: Correct installation of this heater is necessary to ensure safe and proper operation. BEFORE installing the heater, thoroughly read and understand the heater manufacturer’s manual included with the heater. The location for mounting the heater will vary depending on the type of tractor. Typically, the heater is mounted inside the sleeper, under the bunk in a storage compartment.
Page 40 D2/D4 Heater Installation (continued) Heater Subassembly Turn the heater upside down and attach the following components: Snap the air outlet hood onto the end of the heater. Place the mounting plate onto the heater studs. Mounting hardware will be installed later. Attach the short rubber hose and clamps onto the fuel inlet connection located at the base of the heater.
Page 41 D2/D4 Heater Installation (continued) Exhaust and Combustion Air Intake Routing IMPORTANT: Correct installation of this heater is necessary to ensure safe and proper operation. BEFORE installing the heater, thoroughly read and understand the heater manufacturer’s manual included with the heater. DANGER: The correct installation of the exhaust and combustion air intake hoses is extremely important to prevent carbon monoxide poisoning or asphyxiation.
Page 42: D2/D4 Heater Duct Installation (Heat Option)
D2/D4 Heater Duct Installation (Heat Option) Duct Locations CAUTION: • USE SUPPLIED HEATER DUCT HOSE ONLY! Do not use existing vehicle ducts or outlets. Ducts and outlets must be capable of withstanding a minimum of 300F (148.9C) operating temperatures. • Adjustable air vent must always be installed so it cannot blow hot air directly at living creatures (people, animals) or objects sensitive to temperature.
Page 43 D2/D4 Heater Duct Installation (continued) Discharge Air Find an appropriate location for the floor level discharge air vent and drill a 2-1/2” hole using the correct hole saw. Unsnap rotating outer louver assembly from the mounting base. Install the base into 2-1/2” hole and secure with supplied screws. Reinstall rotating outer louver assembly back into the mounting base ring.
Page 44: A/C Duct Installation
A/C Duct Installation A/C Vent Locations The evaporator is equipped with two air discharge outlets to attach the supplied flexible air ducts. The ducts will be attached to plastic air vents that should be located and installed to provide maximum air circulation in the sleeper. Suggested locations of the air vents: •...
Page 45 A/C Duct Installation (continued) FLUSH MOUNTED EVAPORATOR Figure 21: A/C Duct locations...
Page 46: Battery Box Harness Installation
IMPORTANT: Make sure the two terminal lugs are not touching each other! Reinstall the Interconnect Harness cover plate. Route the RED and BLACK (2 AWG) cables from the TriPac ENVIDIA battery box to the truck battery box. Do not connect at this time.
Page 47 10. From the Evaporator/Control Box route the RED and BLACK (4 AWG) Compressor Drive Module power cables through the floor access hole with the refrigerant lines. Route cables to the back of the TriPac Envidia Battery Box. NOTE: These cables are pre-connected to the Compressor Drive Module inside the Evaporator/Control Box.
Page 48: Condenser Fan And Sensor Harness Installation
Condenser Fan and Sensor Harness Installation IMPORTANT: Before making any electrical connections, confirm the battery cables in the TriPac Envidia battery box and truck battery box are not connected to the batteries. NOTE: Excessive harnesses lengths should be doubled up and secured with band wraps. DO NOT CUT THE WIRE HARNESSES! NOTE: Always check the male pins for straightness before attempting to mate connectors.
Page 49: Ignition Switch And Harness Installation
NOTE: On some truck models the ignition switch acts only as a selector device connected to an ignition module. There may not be system power available at the switch. The TriPac Envidia system may not function correctly. In this case...
Page 50: Hmi Installation
HMI Installation HMI Controller Location Choose a location inside the tractor’s sleeper for the HMI controller that is easily accessible and visible from the driver’s bunk Installation Special Tools Required Level Drill Motor Drill Bits Locate the HMI Controller Harness with the 8-pin connectors on each end supplied loose in the installation kit. The connectors are not the same.
Page 51: Usb Service Communication Cable
USB Service Communication Cable The USB Service Communication Cable will allow installation and service technicians to easily access the communication application. On the Base Controller, remove the cover over the USB Communication Port. Plug the USB Mini-B connector into the communication port. Route the cable to a protected area that is accessible without raising the bunk.
Page 52: D2/D4 Heater Harness Installation (Heat Option)
D2/D4 Heater Harness Installation (Heat Option) Locate the Heater Harness supplied loose in the installation kit. Remove the two small plastic bags attached to the harness containing the fuel pump electrical connector components and the in-line fuse assembly. Retain these for installation later.
Page 53: Fuel Pickup Tube Installation (Heat Option)
Heater Fuel Pickup Tube Installation (Heat Option) Direct Tank Installation – No Drilling OEM Fuel Tank Fittings DANGER: Use caution when working in or around the area of the diesel fuel tank. Diesel fuel vapors are potentially explosive. Do not smoke while working near the diesel fuel tank. NOTE: Some fuel tanks may have auxiliary fuel connections or 1/4"...
Page 54 Heater Fuel Pickup Tube Installation (continued) Direct Tank Installation – No Drilling Figure 29: Fuel Pickup Tube Installation – No Drilling...
Page 55 Heater Fuel Pickup Tube Installation (continued) Alternative Installation – Drilling hole in Fuel Tank Installing the Fuel Pickup Tube DANGER: Use caution when working in or around the area of the diesel fuel tank. Diesel fuel vapors are potentially explosive. Do not smoke while working near the diesel fuel tank. DANGER: Before drilling into a fuel tank, drain all fuel from the tank.
Page 56 Heater Fuel Pickup Tube Installation (continued) Alternative Installation – Drilling hole in Fuel Tank IMPORTANT: The ferrule nut and 1/4" NPT fitting must be tightened securely into the bushing before installing the pickup tube into the tank. Figure 30: Fuel Pickup Tube Installation – Drilling Hole in Tank...
Page 57: Heater Fuel Pump And Fuel Line Installation (Heat Option)
Heater Fuel Pump and Fuel Line Installation (Heat Option) Special Tools Required Utility Knife Hose Cutting Tool (204-677) Tank Mounted Fuel Pump Install the fuel pump and rubber clamp onto the tank mounted bracket securely. Attach a fuel line hose from the fuel pick-up supply to the inlet end of the fuel pump and secure with supplied hose clamps.
Page 58 Heater Fuel Pump and Fuel Line Installation (continued) Tank Mounted Remote Mounted Fuel Pump Bracket L-Bracket Figure 31: Heater Fuel Pump and Fuel Line Installation...
Page 59: Heater Fuel Pump Connections (Heat Option)
Heater Fuel Pump Connections (Heat Option) CAUTION: To prevent the heater from starting unexpectedly, set all electrical controls to the OFF position BEFORE connecting wires to battery. Special Tools Required Wire Cutters Terminal Crimping Tool Route the heater fuel pump harness (installed earlier) to the heater fuel pump and cut the wires to the correct length.
Page 60: Auxiliary Ac Power Accessories (Option)
Auxiliary AC Power Accessories (Option) DC/AC Power Inverter Only • Follow the installation instructions supplied with the Power Inverter. • Connect tractor’s batteries directly to inverter as shown. AC/DC Shore Power Converter Only • Follow the installation instructions supplied with the AC/DC Power Converter. •...
Page 61: Installing Battery Cables
DO NOT install the fuse at this time. POSITIVE BATTERY CABLE Route the positive cable from the TriPac ENVIDIA battery box to the fuse holder, cut to length and strip 1/2 to 3/4 in. (13 to 19 mm) of insulation from cable end.
Page 62 Route the negative cable from the TriPac ENVIDIA battery box to the tractor’s negative battery terminal, cut to length and strip 1/2 to 3/4 in. (13 to 19 mm) of insulation from cable end.
Page 63: Priming The Heater Fuel Pump (Heat Option)
Priming the Heater Fuel Pump (Heat Option) Priming the Heater Fuel System Special Tools Required Heater Priming Harness (204-1144) The heater uses a pulse style fuel pump. You must use the heater priming harness to operate the fuel pump to prime the system.
Page 64: Heater Start-Up Procedure (Heat Option)
Heater Start-Up Procedure (Heat Option) Heater Start-Up Procedures NOTE: See Operating and Diagnostic Manual TK 56464-19-OD for further diagnosis and service procedures if needed. Special Tools Required Heater Diagnostic Tool (204-1143) Diagnostic Unit The diagnostic unit is used to read out, display and delete faults stored in the heater's electronic control box. It may also be used to start and run the heater.
Page 65 Heater Start-Up Procedure (continued) Perform the Start-Up Automatic Detection Five seconds after the diagnostic tool has been connected to the heater using the adapter cable, the automatic detection starts to determine the type of heater to which the diagnostic unit is connected. NOTE: If the automatic detection was successful, if necessary, the heater is briefly started and then switches off again.
Page 66 Heater Start-Up Procedure (continued) Heater Start-Up The heater will begin a four minute start up process. • Blower will start slow and heater will ignite. • Heat and blower will ramp up to high boost mode. With the heater operating check the following: •...
Page 67 Heater Start-Up Procedure (continued) Display current fault in the fault memory again Simultaneously press Left and Right arrow keys. Display: e.g. AF: 12 Delete the fault memory and as a result, at the same time cancel the control box lock Current fault or fault F1 –...
Page 68: A/C System Charging Procedure
A/C System Charging Procedure Adding Refrigerant NOTE: The system should be charged with refrigerant only after following A/C System Evacuation and Leak Check Procedures on page 36. NOTE: Refrigerant charge is sensitive. Use smallest practical refrigerant bottle with accurate and reliable scale. IMPORTANT: Keep all the A/C fittings capped and sealed until the installation of the refrigeration hoses.
Page 69: Operation Checkout Procedures
An operation checkout procedure must be performed after the TriPac Envidia installation has been completed. This procedure will confirm the operation of the heating and air conditioning systems, and will verify the TriPac Envidia batteries are charging and discharging properly. Any alarm codes that may have been set can also be checked and cleared. This checkout procedure will be done in two steps: Step 1 -Use the TriPac Envidia HMI controller to verify basic system operation.
Page 70 Operation Checkout Procedures (continued) Rotate Mode Selection knob to Air Conditioning Mode. Snowflake icon should flash for several seconds then stay on. Fan speed LEDs should turn off and AUTO indicator LED should come on. The fan should run in low. If cab temperature is above 68 F the compressor may start and evaporator fan speed may increase.
Page 71: Unit Setup
Do not connect to the computer at this time. Press the HMI Mode Selection knob for at least one second to turn the TriPac Envidia system ON. The green Heart Beat LED on the Base Controller module should blink once per second.
Page 72 Fan Only Check This function was already tested during the HMI Function Check. TriPac Envidia Battery Check Battery Condition 12. Select System Monitoring tab. 13. Select SCM/Batteries at the top of the screen.
Page 73 Step 2 – Procedures (continued) 17. From the drop down menu select 1A then click Run Test. 18. Select System Monitoring tab. 19. Select SCM/Batteries at the top of the screen. 20. Locate the data group associated with selected battery (example: 1A = SCM1 Battery A). Note the value of Requested Mode.
Page 74 Exiting Envidia Service Tool 42. Close the Envidia Service Tool on the computer. 43. Press the Mode Selection knob on the HMI for approximately three seconds to turn the TriPac Envidia system OFF. 44. Disconnect the USB Adapter Harness from the PC.
Page 75: System Check List
System Check List BATTERY BOX - Mounting claws (or HEATER INTAKE AND EXHAUST - direct frame mounted bolts) positioned Heater intake and exhaust hoses correctly and torqued to specifications. routed safely and secured. CONDENSER - Mounting bolts tightened HEATER FUEL LINES - All fuel lines securely and sealed with silicone.
Page 80 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.