Thermo King TriPac Envidia Installation Manual

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Installation ManualInstallation Manual

Installation ManualInstallation ManualInstallation Manual

Installation Manual

TriPac Envidia

Auxiliary Heating and Cooling

Temperature Management System

TK 56459-19-IM (Rev. 0, 12/17)

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Installation Manual

TriPac Envidia Auxiliary Heating and Cooling

Temperature Management System

TK 56459-19-IM (Rev. 0, 12/17)

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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 Cl ass 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 in stalle r with details to correc tly and safely install each of the APU components.

Before beginning the installatio n, the in stalle r should confirm with the customer the location for each of the APU’s component s by using the APU Installation Questionnaire. The customer should also be made aware that modifications to existing equipment might be necessary to complete the installation.

Modifications may include:

• Tractor’s engine must be fitted with an upgraded alternator of 270 amps or more and with upgraded alternator

wiring of OEM approved design.

• APU condenser may be directly mounted to the outside of the sleeper.

• APU evaporator, power inverter and/or converter may be installed in existing storage spaces under the bunk or in

the toolbox areas.

• APU heating and A/C duct work may to be routed with vents installed in existing closets or storage compartments.

• OEM components on the chassis may need to be relocated to accommodate the installation of the APU battery box.

• OEM fuel tank may need to be changed to a smaller size to accommodate the installation of the APU battery box.

• For base level performance - tractor battery box must have four 12Vdc batteries connected to provide 12Vdc output.

• For optimum level performance - tractor batteries may be upgraded to Thermo King NXT 1150 CCA absorbed glass

mat (AGM) batteries.

Due to its complexity, y ou should not attempt this installation unless you:

• Are an experienced mechanic.

• Can safely lift 34 kilos (75 lbs.)

• In the U.S., EPA 608 certified and trained in the repair and maintenance of transport refrigeration systems.

• Have a basic understanding of electricity and electrical wiring.

• Have the necessary tools and equipment to complete the installation.

• Have a truck body designed and built to meet the requirements of this installation.

This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or co vering all co ntingencies. If further information is required, Thermo King Corporation Service Department should be consulted. Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the manufacturer’s judgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect, special, or consequential damages whatsoever, arising out of the use of this manual or any information, recomm e ndations or d e scriptions contained herein.

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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) ............................................................................................. 15

D2/D4 Heater Dimensions (Option) ......................................................................................................................... 16

Required Tools and Additional Supplies .................................................................................................................. 18

Typical Component Locations ................................................................................................................................. 19

Tractor and APU Battery Recommendations ........................................................................................................... 20

Battery Box Installation ............................................................................................................................................ 22

Condenser and Receiver Drier Installation ............................................................................................................... 26

Evaporator/Control Box Installation ........................................................................................................................ 28

Fabricating Refrigeration Hoses ............................................................................................................................... 30

A/C Hose Installation ............................................................................................................................................... 34

A/C System Evacuation and Leak Check Procedures .............................................................................................. 36

D2/D4 Heater Installation (Heat Option) ................................................................................................................. 37

D2/D4 Heater Duct Installation (Heat Option) ......................................................................................................... 40

A/C Duct Installation ................................................................................................................................................ 42

Battery Box Harness Installation .............................................................................................................................. 44

Condenser Fan and Sensor Harness Installation ....................................................................................................... 46

Ignition Switch and Harness Installation .................................................................................................................. 47

HMI Installation ....................................................................................................................................................... 48

USB Service C om munication Cable .......................................................................................................................... 49

D2/D4 Heater Harness Installation (Heat Option) ................................................................................................... 50

Fuel Pickup Tube Installation (Heat Option) ........................................................................................................... 51

Heater Fuel Pump and Fuel Line Installation (Heat Option) .................................................................................... 55

Heater Fuel Pump Connections (Heat Option) ......................................................................................................... 57

Auxiliary AC Power Accessories (Option) .............................................................................................................. 58

Installing Battery Cables .......................................................................................................................................... 59

Priming the Heater Fuel Pump (Heat Option) .......................................................................................................... 61

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Heater Start-Up Procedure (Heat Option) ................................................................................................................ 62

A/C System Charging Procedure .............................................................................................................................. 66

Operation Checkout Procedures ............................................................................................................................... 67

Unit Setup ................................................................................................................................................................. 69

System Check List .................................................................................................................................................... 73

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Tips for a Successful In stallation

BEFORE BEGINNING THE INSTALLATION

• Read this manual t o understand where components are to be located and how they are to be installed.

• Review component location diagram and discuss with the customer where each component will be installed on his

tractor.

• Verify tools and special equipment required for the in stalla tion are available and in good working condition.

• Open all installation kits and inspect the contents before beginning installation.

• It is recommended that one person performs the installation of all the components outside the sleeper while a

second person installs all the components inside the sleeper. This will help minimize any damage to the sleeper’s interior from grease, dirt, etc.

TRACTOR ALTERNATO R

•

Tractor’s engine must be fitted with an upgraded alternator of 270 amps or more and with upgraded alternator wiring of OEM approved design.

TRACTOR’S BATTERIES

•

It is important not to allow the trac tor’s batteries to become discharged during the installation proc ess. A batte ry charger should be connected to the batteries while the installation is in process or shut the tractor’s battery power supply completely off using the OEM main battery disconnect switch, if available. See Tractor and APU Battery Recommendations section in t his manual for more information.

APU BATTERIES

•

Thermo King NXT AGM batteries are shipped fully charged and ready to use. See Tractor and APU Battery Recommend at io ns se ct io n in thi s ma nua l fo r mor e info r mati o n. .

APU BATTERY BOX INSTALLATION

IMPORTANT: DO NOT weld or dri l l h oles in the top or bottom flanges of the tractor’s frame. Seriou s structural

•

damage could occur to the frame! Consult your chassis manufacturer for further information.

• The battery box is designed to be mounted only to the existing truck frame rails. NO OTHER MOUNTING

LOCATION IS AC CEPTABLE!

• Safely relocate components on the chassis that interfere with the installation of the battery box.

• Check clearance around battery box before beginning t he installa tion.

• The use of a motorcycle/ATV lift or modified floor jack to raise battery box into position is recommended.

• Only the supplied spacer blocks and mounting claws must be used to install the battery box to the chassis frame rail.

• If diff erent mounting bol ts are u sed, they must be Grade 5 and of the correct length. DO NOT cut off excessive length

bolts.

• Verify the upper and lower battery box mounting bolts are square and flat with the chassis frame rail before

tightening.

• The mounting hardware securing the battery box to the tractor’s frame must be correctly positioned and torqued

using the fo ur-step tightening sequence described in this manual.

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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 extremel y hygroscopi c and a system left open for more than 5 minutes may requir e extensive evacuation/dehydration time to remove moisture.

• Verify all measurements before drilling any mountin g holes.

• Verify there is no interference with any OEM electrical wiring, internal supports, etc. before drilling mounting holes.

• Confirm the condenser location does not interfere with the service or operation of existing tractor components.

• Provide protection to the tractor’s interior and or exterior finish to prevent damage during the installation process.

• Use the stainless steel mounting hardware (supplied in the kit) to mount the condenser.

• Use the large fender washers (supplied in kit) inside the sleeper to provide additional support.

• All mounting holes must be sealed with silicone caulking to prevent Moisture or fumes from entering the sleeper.

A/C EVAPORATOR/C ONTROL BOX INSTALLATION

•

This installation requires a two-person or mechanically assisted lift.

• 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.

• Determine the best location for the A/C Evaporator/Con trol Box inside the sleeper, typically under th e bunk and f lush

to the front bulkhead.

• Allow adequate clearance for attac hi ng the t wo air out le t t ub es.

• Verify there is no interference with any OEM electrical wiring, internal floor supports, etc. before drilling any mounting

holes in the tractor.

• The Evaporator/Control Box should be mounted directly onto the floor mat inside the sleeper. Use the supplied

template to properly locate the drain and mounting holes.

• Always install the drain valves (kazoos) into drain holes located on the bottom pan of the evaporator.

• The A/C vents should be located and installed to provide maximum air circulation in the sleeper such as: MEDIUM

(above lower bunk level) and HIG H (above up per bunk level). NOTE: Locating a ve nt LOW (floor level) is not recommended. It will significantly reduce driver comfort and reduce maximum system run time.

• All mounting holes must be sealed with silicone caulk to prevent moisture or exhaust fume s from entering the

sleeper.

• All edges of access holes made in f iberglass and wood composite floors must be sealed correctly with fiberglass cloth

and resin.

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Tips for a Successful In stallation (continued)

D2/D4 HEATER INSTALLATION (Heat Option)

•

Determine the best location of the heater inside th e sleeper, typically un der the bunk. A llow clearance for dism antling 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.

• The heater must only be mounted on a flat horizo n tal sur face.

• Heater must be installed flush with the floor pan (i.e. sheet metal, fiberglass, etc.) to ensure proper sealing of the

mounting plate and gasket.

• All edges of access holes made in f iberglass and wood composite f loors must be sealed correctly with f iberglass cloth

and resin.

• Outside air intake and exhaust hoses must be installed correctly for the heater to operate safely.

• Exhaust hose should be mounted slightly downwards to help drain off condensation.

• Install exhaust hose so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or

flammable material.

• Inside air inlet and outlet ducts must be installed correctly for the heater to operate safely:

• Pulse type fuel pump outlet must be installed at a 15 to 35 degree angle up from horizontal to operate correctly.

• Fuel pickup tube must be installed correctly in the fuel tank or the heater will not operate.

• Fuel line from the pickup tube to the fuel pump to the heater should be routed at a continuous rise. Use a hose cutter

or sharp knife to cut plastic fuel lines. Do no t use a wire cutter as this will pinch the plastic fuel line closed.

• Do not route electrical wires, harness or battery cables together with fuel lines.

• BEFORE operating the heater, the fuel lines must be bled of air using the Heater Priming Harness (204-1144) or

damage to the fuel pump will result.

• The Diagnostic Code Reader (204-1143) must be used to setup and operate the heater in the run-in mode.

A/C HOSE CONNECTIONS AND ROUTING

• Keep all the A/C fittings capped and sealed

extremel y hygroscopi c and a system left open for more than 5 minutes may requir e extensive evacuation/dehydration time to remove moisture.

until the installation of the refrigeration hoses. Refrigerant oil is

• Only cut refrigerant hoses with the corr ect hose cutting tool (204-677). NEVER USE A SAW!

• Always use the correct hose fitting tool (204-1045) when assembling refrigeration hose s .

Always lubricate hose fittings with Alkyl Benzene Refriger ant Oil (670404TKA) when assembling to refrigeration

•

hoses.

• Always install and lubricate O-rings with Alkyl Benzene Refrigerant Oil (670404TKA) when connecting

refrigeration hose fittings to component connection fittings.

• Refrigeration hoses should be installed onto components in such a way as to allow for vibration and movement of

the cab. THEY SHOULD NEVER BE STRETCHED TIGHT!

• All refrigeration connections should be tightened securel y using two wr enches.

• Always keep refr igeration hose s from rubbing or chafing agai nst sharp meta l objects, rotating components or hot

components.

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Tips for a Successful Installation (continued)

• Protective covers or sleeves (installer supplied) for the refrigeration hoses may be required depending on the

installation.

• Always install the condenser’s receiver drier so refrigerant flow is in the direction indicated by the arrow.

• Thermo King Evacuation Station (20 4-725) and Evacuation Station Operatio n and Field Application Instr uctio ns

(TK-40612) are recommended.

• The oil in the evacuation station vacuum pump should be changed after each use.

• The A/C system must be leak free. Check for leaks by using an electronic leak detector.

• The A/C system will be charged with 2.0 lbs. of R134a refrigerant. NOTE: Accuracy is important. Over or under

charge by 3 ounces will reduce cooling capacity.

ELECTRICAL WIRING AND HMI CONTROLLER INSTALLATION

•

Electrical wiring s hould be inst alled and rout ed in such a way as to allow for vibrat ion and movement o f the cab. THEY SHOULD NEVER BE STRETCHED TIGHT!

• Always keep electrical wiring from rubbing or chafing against sharp metal objects, rotating components or hot objects.

• All electrical wiring should be neatly routed and secured with band wraps or clamps.

• Do note route or bundle 110Vac wires together with 12Vdc wires.

• Do not route electrical wires, harness or battery cables together with fuel lines.

• Excess length of battery cables should be cut off to reduce voltage drop.

• Superlube (203-524) or equivalent should be applied to a ll electric a l c onnections.

• All main power and ground accessory connections must be installed directly on top of the tractor’s battery terminal

posts and tightened securely. DO NOT INSTALL UNDER OEM BATTERY CABLES!

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Battery Box Dimensions

Figure 1: Battery Box Dimensions

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Battery Box Dimensions (continued)

Figure 2: Battery Box Dimensions (continued)

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Evaporator/Control Box Dimensions

Figure 3: Evaporator/Control Box Dimensions

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Condenser with Receiver Drier Dimensions

Figure 4: Condenser with Receiver Drier Dimensions

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HMI Dimensions

Figure 5: HMI Dimensions

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1000 Watt Power Inver ter Dimensions (Option)

Figure 6: 1000 Watt Power Inverter Dimensions

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AC/DC Shore Power Converter Dimensions (Option)

Figure 7: AC/DC Shore Power Converter Dimensions

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D2/D4 Heater Dimensions (Option)

Figure 8: Heater Dimension

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BLANK PAGE

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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. 2-1/2" dia. (for heater inlet/outlet louver) c. 2" dia. (access hole for evaporator hoses and elec tric al wiring) d. 3” dia. ( optiona l si ze acces s hole) e. 4-1/4" dia. (mounting A/C louver s, r outing A/C d uc ts through and heater mounting hole)

7. Reciprocating Saw (return air opening)

8. 1/2" Wrench

9. Level

10. Tape Measure

11. Utility Knife

12. Caulk Gun

13. Digital Meter (204-1079)

14. Refrigerant Leak Detector (204-712)

15. Hose Fitting Tool (204-1045)

16. Hose Cutting Tool (204-677)

17. Heater Priming Harness (204-1144)

18. Shop Vacuum

19. R-134a Gauge Manifold with automotive connectors

20. Vacuum Pump (204-713)

21. Micron Gauge (204-720)

22. Accurate Refrigerant Scale

23. AGM Battery Tester (204-1959)

24. Heavy Duty AGM Battery Charger (204-1923)

25. Laptop Computer (IBM Compatible) with Microsoft Internet Explorer 10.0 or higher installed.

26. USB Adapter Cable (204-2000)

Supplies (as required)

1. RTV Silicone sealant

2. Sealer Tape (203-391)

3. Alkyl Benzene Refrigerant Oil (670404TKA for lubricating hose fittings and O-rings)

4. Refrigerant 134a

5. Return air wall louver (approximately 11” x 10”)

6. Mounting Clamps #24 and #32 (to secure cables and hoses)

7. Band Wraps (assorted sizes and lengths)

8. Upholstery cleaner

9. Cardboard or blankets (to protect truck interior)

10. Fiberglass repair Kit (only used for fiberglass and wood composite floor)

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Typical Component Locations

Figure 9: Typical Component Locations

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Tractor and APU Battery Recommendations

Tractor’s Batteries

The tractor’s batteries should not be allowed to become discharged during the APU installation process. Always connect a battery charger to the tractor’s batteries before beginning the installation.

An alternative method is to shut the tractor’s battery power completely off using the OEM main battery discon nect switch if available.

For base level performance - tractor battery box must have four 12Vdc batteries connected in parallel to provide 12Vdc output.

For optimum level performance - Thermo King recommends the tractor batteries be upgraded to Thermo King NXT 1150 CCA absorbed glass mat (AGM) batteries.

NXT AGM Batteries 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 ye ars if ke pt be l ow 77 F (25 C ). NX T AGM batt e ries should be ch a rged w hen th e open circuit voltage (OCV) falls below 12.50 volts.

To charge the NXT AGM battery, use the following guidelin e s:

1. Verif y the output vo ltage of y our batter y charger is capable of maintaining 14.1 to 14.7 chargin g voltage. The

recommended charging voltage range for the NXT AGM battery is 14.1 to 14.7 volts. Voltages are to be measured at the battery terminals with the battery connected to the charger.

IMPORTANT: Never exceed 15 volts when charging the NXT AGM battery. Exceeding 15 volts will cause pressure relief valves to open and out-gas hydrogen and oxygen from inside the battery. This will shorten the life of the battery and could lead to premature battery failure.

2. Battery chargers with the batte ry type output setting should be set to AGM type battery. Do not set the output

type to gel cell or maintenance free settings.

3. Determine if your battery charger is an automatic or manual charger. Manual battery chargers must be closely

monitored during the charge period and for this reason an automatic battery charger is preferred over a manual charger.

a. Automatic battery chargers either charge up to a preset voltage and shut off, or charge to a present

voltage and then switch to a trickle charge mode. Either one of these battery chargers is acceptable: however, the automatic charger that shuts off may not fully charge the battery.

b. Manual battery chargers will have manual controls for setting the charge amperage rate. The charge

amperage rate will remain the same until the battery charger is manually shut off.

NOTE: When using a manual battery charger, set the charger to charge at 10 or 20 amps and limit the charging time based on the batteries state of charge (SOC). Use the chart below as a general guide to determine the amount of time necessary to charge the battery. DO NOT overcharge the battery.

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Tractor and APU Battery Recommendations

12.84 Volts

100%

0 Hours

12.50 Volts

75%

2 Hours

1 Hour

12.20 Volts

50%

4 Hours

2 Hours

11.88 Volts

25%

6 Hours

3 Hours

(continued)

Determining Maximum Charge Time Using a Manual Charger

Voltmeter Reading State of Charge Time @ 10 Amps Time @ 20 Amps

WARNING: Overcharging can damage the battery and possibly cause a fire or explosion. Follow the battery charger’s recommendations for monitoring batteries while charging. Batteries should be monitored while charging for signs of internal problems. Signs of internal problems include bulging cases, extreme gassing, pungent smell, and extreme heat. If you notice any of these signs turn the charger off and allow the battery to stabilize before handling or testing.

Cleaning a Battery

Use a damp cloth to clean the top of the battery to eliminate conductive paths created by dirt and dried or wet electrolyte, and to prevent corrosion. Use a battery terminal-cleaning tool that has nonco nductive (plastic or r ubber) cover to clean the battery terminals when corrosion is present. Replace any battery cables (or cable terminals) that are frayed, corroded, swelled, or damaged to the extent that they cannot be cleaned.

Battery Hold Down Hardware

Batteries are subjected to extreme shock loads and vibration. It is very important to make sure each battery is secured by the proper mounting hardware. Failure to secure each battery correctly can result in premature battery failure. Using a torque wrench, torque the hold down nuts in two step increments:

• STEP 1 - Torque ea ch ho ld down nut to 60 in-lbs. (6.8 N•m)

• STEP 2 - Torque each hold down nut to 120 to 144 in-lbs. (13.5 to 16.3 N•m)

Battery Cable Mo un tin g

On threaded stud type batteries, use only stainless steel nuts to fasten the cable to the battery. Torque the nut to 150 to 200 in-lbs. (17 to 22 .5 N•m).

On SAE post type batteries, use o nly stainless steel battery clamp bolts. Torque the nut to 60 in-lbs. (7 N•m).

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Battery Box Installation

Special Tools Required

Modified Floor Jack or Motorcycle/ATV Lift

½” Drive Torque Wrench

STANDARD INSTALLATION METHOD - MOUNTING CLAWS

WARNING: Installer supplie d lifting eyebolts must be forged stee l, 1/2"(12mm) diameter. WARNING: Use only locking lif ting hooks to attach to the lifting eyeb olts. WARNING: DO NOT connect any of the TriPac ENVIDIA battery cables to any b atteries at this time. NOTE: DO NOT OIL THE BOLT THREADS!

1. Remove the cover from the battery box to access and remove hardware that secures box to the shipping crate.

2. It is recommended that a modified floor jack or motorcycle/ATV lift be used to install the battery box.

Protection suc h as c ar db o ard, sho p ra gs, etc. sho uld be us ed und e r t he bo x to pr eve nt d amage d uri ng installation.

a. Install lifting eyebolts, wa shers and nuts securely into the two holes at the top of the battery box. b. Using locking lifting hooks, raise the battery box and place onto the lift then remove lifting eyebolts,

washers and nuts.

3. Using a lift, carefully raise the battery box into position. Install the 3/4" bolts and washers through the

mounting claws and the rear of the b attery box.

4. Loosely install the retainers and locking nuts inside the battery box.

NOTE: Mounting bolt threads must extend into the battery box. IMPORTANT: The following steps are critical and must be followed to ensure the safe installation of the battery box

to the tractor’s frame.

5. With battery box still supported by a lift: a. Push battery box up tight to tractor’ s frame . b. Adjust height of box so top and bottom mounting claws and bolts are positioned flat on frame. c. Review (Detail A) - Lightly tighten mounting hardware only enough to remove excess p lay.

6. Using a torque wrench, torque mounting bolts in four step increments starting with top bolts, then bottom

bolts.

a. STEP 1 - Torque top then bottom mounting bolts to 25 ft-lb. (33.9 N•m). IMPORTANT: STOP and

verify all mounting claws and bolts remained flat on frame (Detail A). If they are not, loosen bolts, adjust as necessary and retighten again to 25 ft-lb. (33.9 N•m).

b. STEP 2- After first step is s uccessfully completed, tor que top, then bottom bolts to 50 ft-lb. (67.8

N•m).

c. STEP 3- Next, torque top, and then bottom bolts to 100 ft-lb. (135.6 N•m). d. STEP 4 - Finally, recheck all bolts to confirm they are at 100 ft-lb. (135.6 N•m)

7. Remove the support lift and visuall y inspect installation for the follo wi ng: a. Mounting claws and bolts are correctly installed. They should be square and flat on the frame (Detail

A).

b. If any mounting claws and bolts are improperly installed on the frame (i/e. they r e semble Details B

& C) - adjust as nec essary.

c. Damaged, deformed or cracked components during installation - must be replace immediately.

WARNING: DO NOT connect any of the TriPac Envidia battery cables to any batteries at this time.

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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

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Battery Box Installation (continued)

Special Tools Required

Modified Floor Jack or Motorcycle/ATV Lift

Large Drill (appropriate size to drill holes in frame rails)

25/32" or (20 mm) Drill Bit

1/2” or 3/4" Drive Torque Wrench

Direct Mount Bolt Kit (800461)

OPTIONAL INSTALLATI O N METHOD - DIRECT MOUNT

WARNING: Installer supplie d lifting eyebolts must be forged steel, 1/2" (12 mm) diameter. WARNING: Use only locking lif ting hooks to attach to the lifting eyeb olts. WARNING: DO NOT connect any of the TriPac ENVIDIA battery cables to any b atteries at this time. NOTE: DO NOT OIL THE BOLT THREADS!

1. Remove the cover from the battery box to access and remove hardware that secures box to the shipping crate.

2. It is recommended that a modified floor jack or motorcycle/ATV lift be u sed to install the battery box.

Protection such as cardboard, shop rags, etc. should be used under the box to prevent damage during installation. a. Install the lifting eyebolts, washers and nuts securely into the two holes at the top of the battery box. b. Using lock i ng lifting hooks, rai s e the battery box and pl ace onto the l ift then remove the lifting eyebolts,

washers and nuts.

c. The upper batteries must be removed.

NOTE: If the 1 1/2"or 2 ½” spacer options are being used refer to the installation instructions included with the option kit.

3. DETAIL A - Before installing the battery box to the tractor’s frame, insert the 3/4 x 3.00" long bolts and

washers through the slotted holes at the rear of the battery box. a. From inside the battery box, install the washers and locking nuts int o the inner frame channe l. Hand

tighten hard war e

b. Position the bolts at the bottom of the slots and tighten to 200 ft-lb. (270 N•m).

4. DETAIL B - IMPORTANT: Observe the positioning of existing OEM fasteners on the tractor’s frame. The

four fasteners used in this Direct -Mount Option need to be located on the tractor’s frame no higher and no lower than any existin g OEM faste ners.

a. Measure and mark the lo cation of the four mounting holes on the tractor’s frame. Drill four 25/32" (20

mm) holes in the frame.

5. Using the lift, carefully raise the battery box into position and align t he b a tte ry box mounting ho les wit h the

holes in the tractor’s frame. a. From the backside of the tractor’s frame, insert bolts and washers through the holes in the frame and then

into the battery box.

b. From inside the battery box, instal l the washers and locking nuts into the inner frame channel. Hand

tighten hardware.

6. With the battery box still supp orted by a lift and level with the tractor’s frame, use a torque wrench and torque

the four frame mounting bolts in three step increments as described below: a. STEP 1 - Torque top then bottom bolts to 50 ft-lb. (68 N•m).

b. STEP 2 - Torque top then bottom bolts to 100 ft-lb. (135 N•m). c. STEP 3 - Torque top then bottom bolts to 200 ft-lb. (270 N•m).

DO NOT OVER-TORQUE THE MOUNTING BOLTS!

7. Remove the support lift.

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Battery Box Installation (continued)

OPTIONAL INSTALLATI O N METHOD - DIRECT MOUNT

WARNING: DO NOT connect any of the TriPac ENVIDIA b attery cables to any batteries at this time.

Figure 11: Optional Installation Method – Direct Mount

Page 28

Condenser and Receiver Drier Installation

Special Tools Required

Hose Fitting Tool (204-1045)

Alkyl Benzene Refrigerant Oil (670404TKA)

Torque Wrench

Fitting Size

Torque Specifications

#6 (3/8”)

11-13 ft-lb (15-17 N•m)

Figure 12: Refrigeration hose I.D. and sizes shown

Sub-Assembly

IMPORTANT: Keep all the A/C fittings capped and sealed until the installa tion 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: Read and understand Fabricating Refrigeration Hoses on page 30 for proper hose fabrication requirements. Always use two wrenches while tightening refrigeration fittings.

Hose Cutting Tool (204-677)

Place the condenser coil onto a workbench and subassemble the following components:

• Loosely install the Ambient Temp Sensor

clamp to the receiver drier bracket.

• Install the receiver drier bracket onto the

condenser c oil housing with the Ambient Temp Sensor clamp to the back. Use supplied 1/4-20 mounting hardware and tighten securely.

• Attach the two large hose clamps to the

bracket.

• Install the receiver drier to the bracket with the

hose clamps and tighten s ecurely. Use arrow to verify correct direction of refrigerant flow.

• Fabricate and install a #4 hose (5.00 in. long)

with two 90 degree fittings onto the INLET fitting of the drier and the bottom OUTLET fitting on the co ndenser coil . Tighten fi ttings to the torque specs shown.

#8 (1/2”) 15-20 ft-lb (20-27 N•m)

Page 29

Condenser and Receiver Drier Installation

Special Tools Required

Template – Condenser Assembly

Tape Measure

Level

Drill Motor

3/8” Drill Bit

Caulk Gun and RTV Silicone Sealant

(continued)

Installation

CAUTION: Before drilling any holes in the trac tor, 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.

Locate an area on the exterior of the sleeper to install the condenser assembly that does not interfere with the operation of existing truck components. The condenser air inlets and fan outlet airflow must not be restricted. Obstr uctions must not cause recirculation of condenser out air.

If possible, mount the condenser below the bunk level. This allows easier access to 3/8” bolts with large fender washers inside the sleeper without disturbing interior panels.

1. Measure and mark the exterior center line of the sleeper.

2. Position the supplied template onto the exterior of the sleeper maki ng sure it is level and centered. Ma r k and

drill the 3/8” mounting holes and r emove the template.

3. Apply a bead of RTV silicone around each of the six mounting holes.

4. Install the condenser assembly with the supplied 3/8” stainless mounting hardware.

5. Assure all six mounting tabs a r e in contact with truck body. Use spacers as required.

6. Tighten hardware securely.

Page 30

Evaporator/Control Box Installation

Special Tools Required

Template – Evaporator/Control Box

Drill Motor

1/4” Drill Bit

7/8” Step Reamer

2” dia. Hole Saw (standard installation)

3” dia Hole Saw (optional installation)

Reciprocating Saw

Caulk Gun and RTV Silicone Sealant

Sealing Tape (203-391)

Fiberglass C loth a nd Re sin Ki t (if re qu ired)

Figure 13: Evaporator Template shown

PREFERRED LOCATION - FLUSH WITH FRONT BULK HEAD

Maximum cooling is obtained when evaporator inlet is installed flush with the bulkhead. This allows the hot air from the sleeper to be drawn directly into the return air inlet filter, through the evaporator coil and out the discharge air vents.

Template

The supplied template represent the amount of area needed to accommodate the Evaporator/Control Box and it also provides the locations for the mounting feet, drain holes and the two 2" access holes. One hole on each side of the Evaporator/Control Box. If there is not enough room for the hole near the Controller, an optional larger hole can be cut near the refrigeration hoses. The controller harnesses will wrap around the end of the Evaporator/Control Box.

IMPORTANT ACCESS HOLE INFORMATION:

• The actual location of the 2” access holes will be determined by your particular sleeper construction, including

OEM internal floor supports, electr ic a l wiring, etc.

• Before drilling any holes, check for interference with internal wires, supports or interior panels. Avoid drilling

into the truck’s support membe rs.

• Floors made from fiberglass covered wood construction require the edges of the access holes be completely

sealed with fiberglass and epoxy resin.

• An optional single 3” hole on the refrigerant line side may be used if mounting location does not permit a hole

on the controller side of the Evaporator/Control Box.

Page 31

Evaporator/Control Box Installation (continued)

Figure 14: Preferred Location Shown - Flush with Front Bulkhead

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.

1. Position template with RETURN AIR flush with bulkhead. Mark location of the 7/8” evaporator drain holes

and 2” access holes. Remove the template:

a. Drill a 1/4” pilot hole for drain holes followed by a 7/8” step reamer. b. Drill the 2” access holes. The holes may also be located outside the template area as shown.

2. Cut and install a piece of split loo m (or similar) around the inside edge of the 2” access holes to provide

protection for hoses and wiring.

3. Install ret ur n air fil ter s upport to front of Evaporator/Control Box.

4. Set evaporator in place and determine where return air opening needs to be located on bulkhead. Leave

clearance for filter removal.

5. Mark return air opening (11.00 in. x 10.00 in.). a. Cut opening in bulkhead. b. A return air grille (installer supplied) can be installed to the bulkhead if desired.

6. Install the defrost drain tubes to the base of the evaporator before mounting to the floor.

7. Loosely install the three mounting tabs onto the evaporator.

8. Secure the evaporator to the floor with TEK screws.

9. Tighten the mounting ta b bolts.

10. From underneath the sleeper: a. Seal around drain tube access holes with sealing putty or silicone sealant. b. Apply silicone sealant around the three evaporator mounting screws. c. Seal any unused holes, cracks, or visible air gaps that might be found.

Page 32

Fabricating Refrigeration Hoses

Assembly Materials Checklist

Hose Cutting Tools (204-677)

Nipple Assembly

Alkyl Benzene refrigerant oil (670404TKA)

Nipple with internal O-ring

Figure 15: TK 2000 Components shown

TK 2000 Assembly System

The TK 2000 System is designed for assembly with Multi-Refrigerant hose only.

Hose Fitting Tool (204-1045)

TK 2000 Multi-Refrigerant Hose

Appropriately Sized Clips and Cage

NOTE: The two black O-rings on the nipple assembly are of a specific rubber compound and size. They should not be removed or replaced.

1. Hose

2. Cage

3. Clips

Page 33

Fabricating Refrigeration Hoses (continued)

Cut the Hose

1. 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.

Slip on Two Clamps

2. Install one or two proper- size clips, depending on hose size, onto the cut end of the hose. Orientation of the clips

does not affect the performance of the connection. However, for ease of assembly, both clips should have the same orientation.

CAUTION: Failure to slide the clips over the hose at this time will require the clips to be stretched over the

hose or fitting later. This

may permanently damage the clip.

Page 34

Fabricating Refrigeration Hoses (continued)

Oil the Nipple

3. 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.

4. Insert the nipple into the hose. To ensure that the nipple is full y inserted, check the gap between the cut end of the

hose and the shoulder o n the nippl e. Care should be taken to avoid kinking or othe r damage to the hose during nipple insertion.

NOTE: Be sure to wipe excess oil from the nipple and hose

Snap on the Cage

5. Snap the cage into the groove on the nipple. The arms should extend over the hose length. When the cage has been

carefully installed in the cage grove, the cage will be able to rotate in the grove. This step must be performed to ensure:

a. The clips will be located over the O-ring on the nipp le . b. The connection will be compatible with the connection’s pressure rating.

Slide the Clips

6. Slide the clips over the cage arms and into the channels on each arm.

Close the Clips

7. Use the fitting tool (204-1045 or 204-1128) to close the clips. The pliers should be positioned squarely on the

clip connection points and should remain square during the closi ng of the clip

NOTE: For easiest assembly, the clasp should be closed between the cage arms.

Page 35

Fabricating Refrigeration Hoses (continued)

Correct

Incorrect

Nose of the pliers should be firmly seated under the assembly bump and lock latch. If the pliers are not kept square during closing the clip, the clasp may have an offset. Use the piers to correct the clasp

alignment.

CAUTION: TK 2000 Speedy Clip System components should not be reused. Failure to follow these instructions and/or the use of 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 sy st ems.

Page 36

A/C Hose Installation

Special Tools Required

Hose Fitting Tool (204-1045)

Hose Cutting Tool (204-677)

Alkyl Benzene refrigerant oil (670404TKA).

Torque Wrench

Installation

NOTE: The Evaporator/Control Box system has a Nitrogen holding charge of 5 PSI. This holding charge can safely be vented into the atmosphere.

NOTE: Read and understand Fabricating Refrigeration Hoses section for proper hose fabrication requirements.

IMPORTANT: Always use two wrenches while tightening refrigeration fittings.

Condenser Coil to Evaporator/Control Box (Discharge Line)

1. Fabricate a #6 hose with a 90 degree fitting and connect to the fitting on the condenser coil inlet (top

connection). Tighten the fitting to 15-20 ft-lb (20-27 N•m). Use a backup wrench.

2. Route the ho s e up throu gh the 2” access hole in the tractor floor near the Evaporator/Control Box air

conditioning fittings.

3. Cut the hose to length, install a 90 degree fitting with service por t a nd a tta c h it to the large fitting o n the

Evaporator/Control Box. Tighten the fitting to 15 to 20 ft-lb (20 to 27 N•m). Use a backup wrench.

Receiver Drier to Evaporator/Control Box (Liquid Line)

4. Fabricate a #4 hose with a 90 degree fitting and attach onto the receiver liquid line outlet fitting on the

receiver drier. Tighten the fitting to 11 to 13 ft-lb (15 to 17 N•m). Use a backup wrench.

5. Route the hose up through the 2” access hole in the tractor floor near the Evaporator/Control Box air

conditioning fittings.

6. Cut the hose to length, install a 90 degree fitting and attach onto the small fitting on the Evaporator/Control

Box. Tighten the fitting to 11 to 13 ft-lb (15 to 17 N•m).

7. Secure all hoses adequately with clamps or band wraps.

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 sh o wn

Page 38

A/C System Evacuation and L eak Check Procedures

Special Tools Required

Vacuum Pump (204-713 or equivalent)

Micron Gauge (204-720)

Refrigerant Leak Detector (204-712)

Gauge Set with R134a Adapters

System Evacuation Procedures

IMPORTANT: Always use recommended vacuum equipment. Before each use, check that there are no leaks in the vacuum equipment e it he r in the pump itself or in the ho se s. The oil in the evacuation sta t ion vacuum pump sho ul d be changed after each use.

NOTE: While the system is being ev acuated, continue the installation with D2/D4 Heater if applicable.

1. Connect gauge manifold to suction and discharge service ports at the Evaporator/Control Box.

2. Connect service line of the gauge manifold to vacuum pump and micron gauge.

3. Open gauge manifold and vacuum p ump valves and gauge manifold hand valves.

4. Start vacuum pump and evacuate until system reaches 500 microns.

5. Once syste m reaches 500 microns, continue e vacuation for one additional hour.

6. Close vacuum pump isolation valve, switch off pump. Chec k that the gauge reading for the system does not

exceed 2000 microns in the following five minutes. If vacuum level exceeds 2000 microns before five minutes, and continues to rise, proceed to the Leak Check Procedures section. If it stops in a vacuum continue to evacuate for an additional 30 minutes.

7. If vacuum level remains below 2000 microns for 5 mi nutes the system is leak free and ready to be filled with

refrigerant.

8. Close mani fold hand valves and remove evacua tion equipment.

Leak Check Procedure

1. Add vapor R-134a to the unit until bottle pressure is reached.

2. Thoroughly leak check the system with an electronic leak detector.

3. If leak(s) are found, recover leak check charge.

4. Repair any leaks and re-evacuate system.

Page 39

D2/D4 Heater Installation (Heat Optio n)

Special Tools Required

Drill Motor

Utility Knife

Center Punch

4-1/4” dia. Hole Saw

Fiberglass Cloth and Resin Kit (if required)

Figure 17: Marking and Cutting the Hole.

Heater Location

IMPORTANT: Correct installa tion of this heater is necessary to ensure safe and proper operation. BEFORE installing the heater, thoroug hly re ad 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. However, the heater may be mounted anywhere inside the tractor provided you adhere to the following conditions:

• Install heater so it will maintain a mini mum distance of 2.00 inches (50.8 mm) from any heat sensitive or

flammable material.

• Combustion air intake, exhaus t a nd fuel inlet must be located outside the tra c tor.

• Install exhaust hose so it will maintain a minimum d istance of 2.00 inches (50.8 mm) fr om any hea t sensitive

or flammable material.

• Heater must be mounted on flat horizontal surface providing an air tight seal between heater and tractor.

• All floor matting, carpet, insulation, etc. must be removed to allow the heater to be mounted directly to the

bare floor.

• Heater harness may be repos itio ned to ei the r side of the heat er.

• Floors made of fiberglass covered wood construction require the edges of the access hole be sealed with

fiberglass and epoxy resin.

Drilling Hole in Floor

1. Position the heater’s metal

mounting plate onto the floor mat.

2. Use a utility knife to cut the

floor mat around the outside edges of the plate. Remove floor mat to access the bare floor.

3. With the mounting plate in

position, center punch the four outer holes. Re move the mounting plate and mark an “X” c onnecting the four center punched o ut er holes.

4. Center punch the center of

the “X” and drill a 4-1/4” hole with a hole saw.

Page 40

D2/D4 Heater Installation (continued)

Figure 18: Heater Subassembly and Installation.

Heater Subassembly

Turn the heater upside down and att ach the following co mponents:

1. Snap the air outlet hood onto the end of the heater.

2. Place the mounting plate onto the heater studs. Mounting hardware will be installed later.

3. Attach the short rubber hose and clamps onto the fuel inlet connection located at the base of the heater.

4. Insert the plastic fuel line all the way into the rubber hose until it bottoms o ut to prevent air gaps. Tighten both

hose clamps securely.

5. Attach the exhaust hose and metal clamp onto the fitting located under the OUTLET end of the heater. Turn

metal clamp to the center and tighten securely.

6. Insert the plastic air intake tube through the beveled opening of the small plastic mounting plate. Install the

plastic plate and tube onto studs located under the INLET end of the heater.

7. Install lock washers and nuts onto each of the mounting studs and tighten hardware securely.

8. Install gasket to mounting plat e .

9. The heater has two service data nameplates. Remove one a nd reinstall it onto the top of the heater so that it is

visible when the heater is installed.

Heater Installation

10. Position the heater over t he access hole with intake and exhaust hose and fuel line exiting t he tractor. Attach

the heater to the floor with TEK screws and tighten securely.

NOTE: Tighten TEK screws sufficiently to ensure a positive seal be tween mounting plate and mounting surface. Do not over tighten!

Page 41

D2/D4 Heater Installation (continued)

Figure 19: Exhaust and Combustion Air Intake Routing

Exhaust and Combustion Air Intake Routing

IMPORTANT: Correct installa tion 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.

EXTREME CARE MUST BE TAKEN TO:

• Route the exhaust outlet hose and combustion air intake tube so they cannot be plugged by d ir t, water or snow.

• Ensure the exhaust outlet and air inlet d o not face into the tractor’s slip stream to prevent “ram air” effect.

• Keep exhaust outlet and air intake hoses a minimum of 12” apart.

• Install exhaust hose so it will mai ntain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive

or flammable material.

• The exhaust hose should be mounted slightly downwards to help drain off condensation.

• Install the protective cap onto the end of the exhaust hose.

• Route the exhaust hose to an open area to the rear or side of the tractor so fumes cannot build up and enter the

cab or the combustion air inlet tube to the heater.

• DO NOT mount the exhaust hose to the tra c tor’s frame. It must be installed to the cab to a llow for movement.

Installation

DANGER: The exhaust hose outlet must exit at least 3 feet from the A/C evaporator drains located under the tractor to prevent carbon monoxide poisoning or asphyxiation.

ALWAYS VERIFY the two water valves (kaz oos) ar e inst al led on to t h e evapor at or dr ain tube s and are secured with hose.

1. Route the ex haust hose to an open area to the rear or side of the tractor positioned slightly downwards to help

drain off condensation and secure with clamps .

a. Drill a 1/8” hole in exhaust hose if necessary to allow for water dra inage. b. Exhaust hos e can be shortened to a minimum of 8” if required.

2. Attach metal end cap to exhaust hose.

3. Position air intake tube

facing towards the rear of the tractor where it can pick up clean, fresh, moisture free air.

4. From underneath the

sleeper:

a. Apply silicone

sealant around ONLY the four heater mount in g screws.

b. DO NOT apply

any sealant around the access hole!

Page 42

D2/D4 Heater Duct Installation (Heat Opti o n)

Special Tools Required

Drill Motor

2-1/2” Hole Saw (for installing discharge return air vents)

3” dia. Hole Saw (for routing ducts through compartment walls if required)

Duct Locations

CAUTION:

• USE SUPPLIED HEATER DUCT H OSE ONLY! D o not use existing v ehicle ducts or o utlets.

Ducts and outlets must be capable of withstanding a minimum of 300F (148.9C) operating temperatures.

• Adjustable air vent must alway s b e insta lle d so it cannot blow hot air directly at liv ing creatures (people,

animals) or objects sensitive to temperature.

• Do not position outlet so that it will blow hot air directly at operator o r at thermostat.

• Position air outlet so that it cannot be obstructed.

• Use the supplied protective air intake grille on the air inlet side of the he ater to prevent objects from being

sucked in.

• Do not overtighten duct clamps.

• DO NOT lay or bundle the heater ducts with A/C ducts. They should not touch each other.

• Ensure provisions are mad e for proper air return v entilation.

The heater is equipped with a Return Inlet and Discharge Outlet for attaching the flexible heater duct hoses.

IMPORTANT: A return air duct to the heater should be provided for best heating efficiency.

• Return Inlet must be provided to return air to the heater. It is typically mounted at the base of the bunk

directly opposite the discharge outlet ve nt.

• Discharge Outlet should be located at floor level to provide maximum heating comfort in the sleeper. It is

typically installed at the base of the bunk on one end.

• Heater ducts should be installed and routed with smooth bends and no kinks to provide maximum airflow.

Installation

Page 43

D2/D4 Heater Duct Installation (continued)

Figure 20: Discharge and Return Air Duct Installation

Discharge Air

1. Find an appropriate locatio n f or the floor level discharge air vent and drill a 2-1/2” hole using the correct

hole saw.

a. Unsnap rotating outer louver assembly from the mounting base. b. Install the base into 2-1/2” hole and secure with supplied screws. c. Reinstall rotating outer louver assembly back into the mounting base ring. Verify that it rotates freely.

2. Attach one end of the heater duct to the dischar ge outlet hood on the heater and secure with supplied clamp.

3. Route the heater duct to the floor level discharge air vent, cut as needed, attach to the end of the plastic louver

vent and secure with sup plied hose c lamp.

Return Air

4. If a return air duct is not used, the protective grille must be installed onto the heater inlet.

5. Find an appropriate locatio n f or the floor level return air grille and drill a 2-1/2” hole usi ng the correct hole

saw.

a. Install the return air grille into the 2 -1/2” hole and secure with supplied screws.

6. Attach one end of the return air duct to the air inlet hood on the heater and secure with supplied clamp. a. Route the return air duct to the return air grille, cut as needed, attach to the end of the plastic

louver vent and secure with supplied hose clamp.

Page 44

A/C Duct Instal lation

Special Tools Required

Drill Motor

vents and routing ducts through compartment walls)

A/C Vent Locations

The evaporator is equipped with two air discharge outlets to a tta c h 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 ai r vents:

• MEDIUM (above lower bunk level)

• HIGH (above upper bu nk level)

A/C air ducts and vents are typically routed and installed through closets or storage compartments. Route air ducts as directly as possible with fewest number bends. Stretch out air ducts and cut off loose excess duct material. Verify all duct connections are leak free.

In some applications one of the Envidia air ducts may be connected to the truck OEM ducts. If this is done, a backflow damper must be installed in the duct near the truck’s under bunk OEM A/C unit. A back flow damper kit is provided along with installation instructions.

NOTE: When connecting to OEM duct work a backflow damper must be installed. This will prevent air from back flowing into the OEM HVAC ho using . Reduced maximum system runtime will result if damper is not installed.

NOTE: The A/C air duct adapter plate can be installed on either side of the Evaporator/Control Box. Optional adapters will allow one duct on each side.

IMPORTANT: Ex t reme care shou l d always be taken when drilling holes in the various types of material found in sleepers such as plastic, steel, a luminum, and upholstery.

Installation

4-1/4” dia. Hole Saw (for installing plastic A/C louver

1. Install the hose adapters into each air discharge outlet plate.

2. Find appropriate locations for the A/C vent(s) inside the sleeper and drill 4-1/4” diameter hole(s).

3. Attach the flexible air duct onto hose adapter(s) and secure with a supplied hose clamp.

4. Route the flexible air duct thro ugh the A/C ve nt hole. Cut excess duc t as needed .

5. Unsnap rotating outer louver assembly from the mounting base.

6. Attach to flexible air duct to the end of the hose adapter with band wraps.

7. Push the hose adapter back into 4-1/4” mounting hole and secure with supplied screws.

8. Reinstall rotating outer louver assembly back into the hose adapter and verify that it rotates freely.

9. Verify flexible ducts are installed and routed with smooth bends and no kinks to provide maximum airflow.

10. Secure flexible ducts with large band wraps to prevent excess movement.

Page 45

A/C Duct Instal lation (continued)

Figure 21: A/C Duct locations

FLUSH MOUNTED EVAPORATOR

Page 46

Battery Box Harness Ins tallation

Figure 22: Battery Box Harness Connections

From Envidia

Through

Controller

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 communication harness length should be doubled up and secured with band wraps. DO NOT CUT THE WIRE H ARNESS!

NOTE: Always check the male pins for straightness before attempting to mate connectors. If any resista nc e is f e lt when mating the connector: recheck the male pin alignment. Exercise care when mating the connections to circuit boards.

From TriPac ENVIDIA Battery Box

1. From the TriPac Envidia Battery Box route the Base Controller Communication harness and white (8 AWG)

power wires through the floor access hole. Route to the Evaporator/Control Box Connector Panel.

2. The Battery Box communication harness plugs into the 12-pin, (J8) connector on the Connector Panel.

3. Remove the Interconnect Harness cover plate.

4. Insert grommets into the two hol e s i n the Con ne c to r P a ne l .

5. Route the Ba se Co ntroller power wires through the holes in the Connector P a nel to the Base Controller.

6. Cut cables to length. Terminate with ¼” terminal lugs.

7. Connect the #2 power terminal lug to the stud marked +2. Co nnect the CH-0 1 ground te rminal lug to the stud

marked CH. Tighten the nuts to 1 8 in-lbs. (2.0 N•m).

IMPORTANT: Make sure the two terminal lugs are not touching each other!

8. Reinstall the Interconnect Harness cover plate.

9. Route the RED and BLA CK (2 AWG) cables from the TriPac ENVIDIA battery box to the truck battery box.

Do not connect at this time.

Battery Box

Connector Panel to

Page 47

Battery Box Harness Ins tallation (continued)

Figure 23: Battery Box harness connections

From Evaporator/Control Box

10. From the Evaporator/Control Box route the RED and BLACK (4 AWG) Co mpressor 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.

11. Route the posi t ive cable (RED) through the upper hole in the back of the battery box to the F10 (150 amp) fuse

in the holder.

12. Cut cable to length and install terminal with 1/4” hole.

13. Connect to F10 fuse holder terminal. Torque nut to 120 in-lb (13.5 N•m).

14. Route the negat ive (BLACK) cable through the lower hole in the back of the battery box to the chassis ground

stud.

15. Cut cable to length and install terminal with 3/8 ” ho le .

16. Secure to existing cables.

17. Connect to chassis ground stud.

Page 48

Condenser Fan and Sensor Harness Installation

Figure 24: Condenser and Sensor Harness Connections

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!

Evaporator/Control Box

1. Locate the Condenser Fan and Sensor harness supplied loose in the installation kit.

2. Locate the Connector Panel located outside the Evaporator/Control Box.

3. Connect the 6-pin connector to the Condenser (J6) connector.

4. Route the harness down through the 2” access hole in the tractor floor and out to the condenser fan.

Condenser Assembly

5. Connect the 4-pin connector to the matting connector from the condenser fan.

6. Attach the Ambient Air Sensor to the inside of the receiver drier bracket with the supplied clamp and

mounting hardware.

NOTE: Always install the sen sor to the inside of the drier bra cket for best temperature readings and to pro te c t it from damage.

7. Secure all harness adeq uately with insulated cla mp s or band wrap s.

Page 49

Ignition Switch and Harness Installation

Figure 25: Ignition Switch Harness Connections

IMPORTANT: Th e Ignition Sense h arness wire must be connec t ed to the ON or RUN position of t h e tractor’s ignition system. This will prev e nt the HVAC system from operating and allow battery charging when the tractor’s engine is running.

Locate the Ignition Sense harness supplied loose in the installation kit.

1. Connect the 2-pin connector to the I gnition (J10) connector on the Evaporator/Control Box connector panel.

2. Route the harness towards the tr a c tor’s ignition switch.

3. Connect the end with the diode and fuse to the ON or RUN position of the tractor’s ignition switch.

4. Secure the harness adequately with band wraps.

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 sys tem may not function correctly. In this case locate the truck ignition module and connect to the ON or RUN outpu

Page 50

HMI Installation

Special Tools Required

Level

Drill Motor

Drill Bits

Figure 26: HMI Controller 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

Locate the HMI Controller Harness with the 8-pin conne c tors on each end supplied loose in the installation kit. The connectors are not the same. Connect the white end to the HMI.

1. Route the harness to the Evaporator/Control Box.

2. Connect the black 8-pin connector to the HMI (J7) connector on the Evaporator/Control Box connector panel.

3. From the Evaporator/Control Box , route th e harness behind the in terior walls (if applicable) to the location chosen

to install the HMI controller.

4. Unsnap the r ear mounti ng base from the controller and route the harness connector through the access hole. a. Positio n and le vel the mo un ting base a nd i ns ta l l s e c ur e l y.

5. Push the white connector firmly into the plug on the rear of the controller.

6. Snap the controller back onto the mounting base.

7. Secure harness.

Page 51

USB Service Communi catio n C ab l e

Figure 27: USB Cable Connection

The USB Service Communication Cable will allow installation and service technicians to ea sily access the communication application.

1. On the Base Controller, remove the cover over the USB Communication Port.

2. Plug the USB Mini-B connector into the communicatio n port.

3. Route the cable to a protected area that is accessible without raising the bunk. Recommend inside truck tool

box door.

4. Secure communication cable to other harnesses or cab structure.

Page 52

D2/D4 Heater Harness Installation (Heat Option)

Figure 28: D2/D4 Heater Harness Connection

Locate the Heater Harness supplied loose in the installation kit. Remove the two small plastic bags attached to the harness cont aining the fuel pump electrical connector components and the in-line fuse assembly. Retain these for installation later.

1. Connect the 14-pin connector (with the locking tab) to the mating connector on the heater. a. Use a large bladed screwdriver to pull the locking tab out (to unlock) from the connector body. b. Connect the two connectors together. c. Push locking tab back in (to lock) the connector body.

2. Connect the 10-pin connector to the Heater (J9) connector o n t he Evaporator/Control Box connector panel.

3. Route the fuel pump harness out of the sleeper through the 2” access hole. It will be assembled and connected

to the fuel pump in a later step.

NOTE: The Diagnostic Connector near the heater is only used for diagnostic purposes.

Page 53

Heater Fuel Pickup Tube Installation (Heat Option)

Special Tools Required

Tape Measure

Tubing Cutter

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" NPT connections factory installed . These fitting eliminate the need to drill into the f ue l tank to install the heater’s fuel pickup tube.

• OEM Fuel Connections - Route and connect the heater’s fue l sup ply line to one of these fittings.

• OEM 1/4" NPT Fitting - See following installation instructions.

Important Installation Tips

• Remove the protective cap from the e nd of the pickup tube prior to installatio n.

• Do not apply any type of sealant material to the fuel pickup tube assembly. Doing so will result in plu gged fuel

lines.

Installation

NOTE: The tank mounted fuel pump bracket cannot be used on direct tank installations. The supplied remote mounted L-bracket must be used.

1. Remove the nut, washers and b us hing assembly from the fuel pic kup tube as shown. The nut, washers and

bushing assembly will not be used.

2. Remove the 1/4" NPT fitting from fuel pickup tube and install it into the fuel tank’s 1/4" NPT fitting securely.

3. Measure the fuel tank diameter and cut the pickup tube 3” shorter.

4. Install the pickup tube with the fer rule nut into the tank. a. Position the pickup tube as needed to facilitate fuel line connections and tighten ferrule nut securely.

5. Install the supplied warning n ameplate onto the fuel tank in a visible area near the fuel cap.

Page 54

Heater Fuel Pickup Tube Installation (continued)

Figure 29: Fuel Pickup Tube Installation – No Drilling

Direct Tank Installation – No Drilling

Page 55

Heater Fuel Pickup Tube Installation (continued)

Special Tools Required

Tape Measure

Drill Motor

¼” Drill Bit

1” Hole Saw

Tubing Cutter

Alternative Instal la t ion – 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. Use nitrogen or an inert gas to purge the diesel fuel vapors from the tank. Keep the diesel tank filled with inert gas while drilli ng.

DANGER: Use extreme ca ution when drilling into a diesel fuel tank . Sparks from an electric drill or drill bit could cause an explosion.

Important Installation Tips

• Check for i nt ernal baffles inside the fuel tank BEFORE drilling any holes.

• Remove protective caps from ends of pic kup tube prior to installation.

• Do not apply any type of sealant material to the fuel pickup tube assembly. Doing so will result i n plugged f uel

lines.

• The ferrule nut and 1/4" NPT fitting must be tightened securely into the bushing before installing the pickup

tube into the tank. Failure to tighten the fittings will allow the bushing and washer assembly to slide down the pickup tube and drop into the fuel tank.

Installation

1. Measur e a nd ma rk the mo u nt i n g h o l es o n t he fu e l ta n k as sho wn.

2. Drill (2) 0.25" outer holes first followed by the 1.00" center hole. a. Thoroughly cle an a nd flus h the tank t o remove any chips.

3. Measure the fuel tank diameter and cut the pickup tube 3” shorter. a. With the pickup tube positioned at the correct height, place a wrench on the flats of the bushing and

tighten the 1/4" NPT fitting and the ferrule nut securely.

4. Remove the large nut, metal cupped washer and rubber washer from the bushing assembly. a. Insert the fuel pickup tube (with the reinforcing washer) into the tank using the slot created by the two

0.25" holes.

b. Lift the pickup tube and bushing into positio n through the 1.00" ho le. c. Hold the pickup tube in place and reinstall the rubber washer, metal cupped washer, fuel pump

bracket and large nut ont o the bushing. Hand tighten the large nut.

d. Position the pickup tube as needed to facilitate fuel line connections. e. Place a wrench on the flats of the bushing and tighten the large nut securely.

5. Install the supplied warning nameplate onto the fuel tank in a visible area near the fuel cap.

Page 56

Heater Fuel Pickup Tube Installation (continued)

IMPORTANT: The ferrule nut and 1/4" NPT fitting must be tightened securely into the bushing before

Figure 30: Fuel Pickup Tube Installation – Drilling Hole in Tank

Alternative Installation – Drilling hole in Fuel Ta nk

installing the pickup tube into the tank.

Page 57

Heater Fuel Pump and Fuel Line Installation

Special Tools Required

Utility Knife

Hose Cutting Tool (204-677)

(Heat Option)

Tank Mounted Fuel Pump

1. Install the fuel pump and rubber clamp onto t he tank mounted bracket securel y.

2. 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.

3. Attach the short rubb er hose connection to the outlet end of the fuel pump and secure with supplied hose

clamps.

4. Route the plastic fuel line (installed earlier on the heater) to the fuel pump and cut to length. Insert the fuel line

into the rubber hose connection until it butts up tight with the fuel pump’s outlet pipe. Secure with supplied hose clamp.

NOTE: The fuel line must be installed c orrectly to prevent air bubbles (DETAIL A). The fuel line from the pickup tube, to fuel pump, to heater should be routed at a continuous rise. CAUTION: Only use a hose cutter o r utility knife to cut plastic fuel lines. Do not use a wire cutter as this will pinch the

plastic fuel line closed.

Remote Mounted Fuel Pump with L-Bracket

Choose a protected lo ca tion under t h e cab close to the f uel pick-up tube and heater and install the supplied L-bracket securely with TEK screws.

1. Install the fuel pump into the rub ber mounting clamp and t hen onto the L-bracket.

2. Position the fuel pump at a 15 to 35 degree angle with the outlet end facing up (outlet end has connector and

smaller ba rb fitting) a nd tighten mounting hardware sec urely.

3. Attach the short rubb er hose connection to the outlet end of the fuel pump and secure with supplied hose

clamp.

4. Route the plastic fuel line (installed earlier on the heater) to the fuel pump and cut to length. Insert the fuel line

into the rubber hose connection until it butts up tight with the fuel pump ’s ou tle t pipe. Secure with supplied hose clamp.

NOTE: The fuel line must be installed c orrectly to prevent air b u bbles (DETAIL A). The fuel line from the pickup tube, to fuel pump, to heater should be routed at a continuous rise. CAUTION: Only use a hose cutter o r utility knife to cut plastic fuel lines. Do not use a wire cutter as this will pinch the

plastic fuel line closed

5. Attach fuel line 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 Instal l ation

Tank Mounted

Fuel Pump Bracket

Remote Mounted

L-Bracket

Figure 31: Heater Fuel Pump and Fuel Line Installation

(continued)

Page 59

Heater Fuel Pump Connections (Heat Option)

Special Tools Required

Wire Cutters

Terminal Crimping Tool

Figure 32: Heater Fuel Pump Connections

CAUTION: To prevent the heate r f ro m starting unexpectedly, set all electrical controls to the OFF position BEFORE connecting wires to battery.

1. Route the heater fuel pump harness (installed earlier) to the heater fuel pump and cut the wires to the correct

length.

a. Strip wire ends, slide on rubber sealing boots and attach pin terminals securely with crimping tool. b. Insert pin terminals into connector body until they lock in place. c. NOTE: The pump is not polarity sensitive. T he wires can be installed in either lo c ation of the

connector body

d. Snap locking cover closed on connector body.

e. DO NOT connect the fuel pump harness to the fuel pump at this time. The fuel pump harness will be

attached later after the fuel pump has been primed

Page 60

Auxiliary AC Power Accessories (Option)

Figure 33: Auxiliary AC Power Accessories Connections

DC/AC Power Inverter Only

• Follow the installation instruct ions supplied with the Power Inverter.

• Connect tractor’s batteries directly to inverter as shown.

AC/DC Shore Power Converter Only

• Follow the installation instruct ions supplied with the AC/DC Power Converter.

• Connect tractor’s batteries directly to converter as shown.

Dual System DC/AC Power Inverter and AC/DC Shore Power Converter

• Follow the installation instruct ions supplied with the Power Inverter and AC/DC Power Converter.

• Connect tractor’s batteries directly to inverter, then connect the converter to the inverter as shown.

IMPORTANT: The tractor battery power cables must always be connected directly to the DC/AC POWER INVERTER.

DC/AC Power Inverter Connect to Tractor Batteries

AC/DC Shore Power Converter Connect to Tractor Batteries

Dual System IMPORTANT: Connect Tractor Batteries directly to the DC/AC POWER INVERTER.

Page 61

Installing Battery Cables

TriPac Envidia Battery Box

1. POSITIVE BATTERY CABLES

a. Inside the TriPac Envidia battery box, route and connect each positive battery cable to each

corresponding positive battery post and tighten securely.

b. Apply Superlube (PN 203-524) or equivalent onto the battery’s connections. c. Position the protective boots over the terminal lugs.

2. NEGATIVE BATTERY CABLES

a. They are pre-connected.

Tractor Battery Box

NOTE: If truck batteries are being replaced that should be done now. NOTE: Do not attach both the positive and the negative cables to a single battery. For best results, attach the positive cable to the first battery a nd the negative cable to the last battery as shown.

1. FUSE HOLDER a. Mount fuse holder securely with (installe r supplied) 1/4-20 hardware and within 12.0 inches (304.8

mm) of the tractor batteries positive terminal.

b. DO NOT install the fuse at this ti me.

2. POSITIVE BATTERY CABLE a. Route the positive cable from the TriPac ENVIDIA battery box to the fuse holder, cut t o length and

strip 1/2 to 3/4 in. (13 to 19 mm) of insulation from cable end.

b. Slide the supplied RED heat shrink tubing and terminal ring onto the end of the cable. Attach the

terminal ring firmly to the cable.

c. Position heat shrink t ubing to cover exposed wires on the te rminal ring and use a heat gun to shrink

the tubing in place.

d. Install the positive cable terminal lug onto the fuse holder stud and hand tighten the nut.

3. SHORT PO S ITI V E B A TT ER Y C AB L E a. This cable has two different size battery lugs. Install cable lug with small hole onto the other fuse

holder stud and hand tighten the nut.

b. Install the ring connec tor with the large hole onto the battery’s POSITIVE (+) connection and tighte n

securely.

c. Apply Superlube (PN 203-524) or equivalent onto the battery’s connection.

Page 62

Installing Battery Cables (continued)

Figure 34: Installing Battery Cables and Fuse

4. NEGATIVE BATTERY CABLE

NOTE: Do not attach both the positive and the negative cables to a single b attery. For best results, attach the positive cable to the first battery and the negative cable to the last ba tte ry as shown.

a. 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.

b. Slide the supplied BLACK heat shrink tubing and terminal ring onto the end of the cable. Attach the

terminal rin g firmly to end of cable.

c. Position hea t shrink tubing to cove r exposed wires on the terminal ring and use a heat gun to shrink

the tubing in place.

d. Install the negative cable terminal lug onto the battery’s NEGATIVE (-) connection and tighten

securely.

e. Apply Superlube (PN 203-524) or equivalent onto the battery’s connection.

5. TriPac Envidia BATTERY BOX

a. Connect po sitive cab le ter mi nals to each o f t he batter ies. b. Connect negative cable terminals to eac h of the ba tterie s.

6. INSTALL FUSE (F13) a. Remove the nuts from the fuse holder, place the 175 amp fuse onto the studs, and on top of the

battery cables lugs and reinstall the nuts. Tighten the nuts to 120 in-lb (13.5 N•m).

b. Close the fuse holder cover securely. c. The TriP ac ENVIDIA s ys te m is no w p o wer ed .

Page 63

Priming the Heater Fuel Pump (Heat O ptio n )

Special Tools Required

Heater Priming Harness (204-1144)

Wire

Battery Connection

Black

Negative

Figure 35: Priming the Heater Fuel Pu m p

Priming the Heater Fuel System

The heater uses a pulse style fuel pump. You must use the heater priming harness to operate the fuel pump to prime the system. Applying continuous power to the pump will not work.

NOTE: Verify there is a sufficient amount of fuel in the fuel tank.

1. Attach the Hea t er Priming Harness connector to the heater fuel pump.

2. Attach the alligator clips to the battery:

Red Positive

3. Turn the priming harness switch t o the “ON” position.

4. The flasher unit will operate the fuel p ump (ON/OFF/ON/OFF) to prime the system.

5. Allow the system to operate for approximately 5 minutes to bleed air from the fuel lines.

NOTE: Running the fuel pump longer than 5 minutes will cause the heater to emit excessive white smoke when operated.

6. Check fuel lines and s ystem for l eaks.

7. Turn the priming harness switch t o the “OFF” position. Disco nnect the po s i tive and then the negative battery

connections.

8. Disconnect the priming harness connector from the heater fuel pump.

9. Attach the heater fuel pump harness onto the heater fuel pump.

Page 64

Heater Start-Up Procedure (Heat Option)

Figure 36: Heater Diagnostic Connections

Heater Start-Up Procedures

NOTE: See Operating and Diagnostic Manual TK 56464-19-OD for further diag n osis 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 sto red in the heater's electronic control box. It may also be used to start and run the heater.

• The test duration is limited to a maximum of 120 minutes.

• The electronic control box can store up to 5 faults.

• The current fault is displayed as “AF” and a 2-digit number and is always written in memory location F1.

• The stored fa ults “F1” to “F5” can be queried.

Connect th e Diagnostic Unit

1. Verify the Heater harness is plugged into the J9 plug at the Evaporator/Control Box connector panel.

2. Connect the adapter harness to the Diagnost ic Tool .

3. Connect the 8-pin diagnostic connector to the mating connector located on t he heat er ha rness inside the sleeper

near the heat er.

NOTE: The two remaining adapter harness connectors shown in the illustration are not used .

Page 65

Heater Start-Up Procedure (continued)

Perform the Start-Up

Automatic Detection

Five seconds after the diagnostic tool has been conne cted to the heater using the adapter cable, the automatic detec tion starts to determine the type of heater to which the diagnostic unit is connected.

NOTE: If the automatic dete ction was successful, if necessary, the heater is briefly started and the n switches off again.

• Display until the automatic detection is completed.

• Heater Icon will display when heater has been detected.

Confirm flashing symbol with OK key.

Possible Displays:

• If no errors/faults exist go to Heater Start-up.

• If errors/faults exist go to Clearing Faults.

• Communication error. Go to Unable to Perform the Diagnosis

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:

• Exhaust and intake hoses are installed a nd functioning correctly.

• Heat is blowing out of the heat duct inside the sleeper.

Press OK key to stop heater.

• Heater will begin a four-minute cool-down mode.

Disconnect Diagnostic Unit from the heat er harness.

Clearing Faults

Display current fault in fault memory

1. Press Left and Right arrow keys simultaneously to display active or current faults in memory. a. Displa y: e.g. AF: 12

Display fault memory F1 – F5

2. Press Left or Right arrow keys to display any faults in memory. a. Display: e.g. F1: 20

Record all fault codes. Refer to the diagnostic manual for an explanation of fault code diagnosis.

Page 67

Heater Start-Up Procedure (continued)

Display current fault in the fault memory again

3. Simultaneously press Left and Right arrow keys. a. Displa y: 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 – F5 Clear all faults and cancel control box lock by pressing OK key. dEL will display.

Press OK key again to confirm deletion. The fault memory is deleted and the control box is unlocked.

Continue with Heater Start-Up or Diagnosis.

Quit Start-Up

Switch off heater

Press the OK key, heater is switched off.

Perform the diagnosis again

Press the ON/OFF key, display is activated.

Unable to perform the diagnosis

Automatic detection was unsuccessful

Display if the automatic detection was not successfully completed.

Possible causes:

• Diagnostic harness not connected to heater harness

• Adapter plug not seated in diagnostic harness

• Defective diagnos tic cable

• Defective heater.

Page 68

A/C System Charging Procedure

Special Tools Required

R-134a Refrigerant

Accurate Scale

Figure 37: A/C Charging connections shown

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: Refrigera nt charge is sensitive. Use smallest practical ref rigerant bottle with accurate and reliable scale. IMPORTANT: Keep all the A/C fittings capped and sealed until the installa tion of the refrigeration hoses.

Refrigerant oil is extremely hygroscopic and a system left open for more than 5 minutes may require extensive evacuation time to remove moisture.

1. Connect the refrigerant bottle to the gauge manifold and place it on a scale.

2. Open the refrigerant bottle valve for liquid and purge the charging line.

3. Keep the low pressure side valve of the gauge manifold closed. Open the high pressure side valve.

4. Slowly add refrigerant until reaching 2 lbs. of R-134a. NOTE: The system never uses more than 2 lbs. of

refrigerant. Accuracy is important. Over or under charging by 3 oz will reduce cooling capacity and reduce maximum system run time.

5. Close the refr igerant bo ttle valve and the high si de valve of the gauge manifold.

6. Remove the gauge manifold.

7. Reinstall only the access cover over the evaporator coil.

Page 69

Operation Checkout Procedures

Overview

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 E nvidia 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 Step 2 -Use a laptop PC connected directly to the TriPac Envidia

Tool and Service Test Mode to ver ify system operation in more detail.

The Envidia Service Tool communication software is service computer This software provides the technician with system interface, flash load system upgrades, real ti me system information retrieval, Service Test Mode and Alarm clearing capabilities. The following tools will be require d:

• Laptop Computer (IBM Compatible).

• USB Adapter Harness (204-2000 or USB Mini-B).

• Envidia Service Tool software.

HMI controller to verify basic system operation.

Base Controller module using the Envidia Service

and will export information directly to a laptop PC.

batteries are

Step 1 – Checkout Procedures Using the HMI Controller

The following operation checkout procedures will be performed using the TriPac Envidia HMI controller. NOTE: Make sure the tractor’s engine is off and ignition switch is in the o f f position.

1. Rotate Mode Selection knob to Fan Mode.

2. Rotate Temperature Selection knob so white dot is at the top.

3. Press Mode Selection knob for at least one second to turn the TriPac Envidia a. Fan icon should flash for several s econds then stay on. b. Evaporat or fan may not start. c. Battery level bars should illuminate steady green. It may take up to 30 seconds for the battery level bars to

illuminate steady green.

4. Rotate Fan Speed Selection knob clockwise.

NOTE: There will be a two second delay in response to changes made using the HMI Controller.

a. Fan speed LED indicators should increase. b. Evaporator fan speed should increase.

5. Rotate Fan Speed Selection knob counterclockwise. a. Fan speed LED indicators should decrease. b. Evaporator fan speed should decrease.

6. Rotate Temperature Selection knob counterclockwise to the blue stop.

system ON.

Page 70

Operation Checkout Procedures (continued)

7. Rotate Mode Selection knob to Air Conditioning Mode. a. Snowflake ic on should flash for s everal seconds then stay on. b. Fan speed LEDs should turn off and AUTO indi cator LED should come o n. The fan s hould run in low. c. If cab temperature is above 68 F the compressor may start and evaporator fan speed may increase.

8. Rotate Mode Selection knob to Heat Mode. a. Heat icon s hould flash for sever al seconds then stay on. b. Evaporator fan should stop or remain off. c. The fan OFF i ndicator LED should come on. d. Depending on cab temperature the heater may start.

Note: If the heater ignites it will run fo r a minimum of 5 minutes. The blower will t he n run through a cool down cyc le .

9. Rotate Mode Selection knob back to Fan Mode. a. Evaporator fan should not run. b. Rotating the fan speed knob will start the evaporator fan.

10. Battery Monitor Display. a. Watch battery level display for approximately 30 seconds. b. At least four green battery level bars should illuminate steady green.

11. Press Mode Selection knob for at least three seconds to turn system OFF. a. All indicator LEDs should turn off. b. Evaporator fan should stop if running.

THIS COMPLETES STEP 1 – VERIFYING BASIC SYSTEM OPERATIONS

DO NOT TURN THE SYSTEM OFF

CONTINUE TO STEP 2 – VERIFYING DETAILED SYSTEM OPERATIONS

Page 71

Step 2 - Procedures using Laptop PC and Envidia Service Tool

The following Unit Setup and Function Check procedures will be performed using a laptop PC connected to the Base Controller module of the TriPac E nvidia.

1. Verify the Envidia Service Tool program is installed on the service computer.

2. Verify the USB Adapter Harness is installed. It was connected to the USB Communication Port on the Base

Controller module located on the Evaporator/Control box. The harness should have been routed to an easily accessible location. Do not connect to the computer at this time.

3. Press the HMI Mode Selection knob for at least one second to turn the TriPac Envidia system ON. a. The green Heart Beat LED on the Base Controller module should blink once per second.

4. Start the laptop PC.

5. Connect the USB Adapter Harness to a USB port on the laptop PC.

6. Start the Envidia Service Tool. a. The Dashboard page should appear.

Unit Setup

1. From the Service Tool tabs select Unit Setup.

2. Enter the Unit Serial number.

3. Enter the Unit ID number. a. Any six alphanumeric characters b. Typically truck number

4. Verify Programmable Settings are correct for this installation. Recommend accepting default settings.

5. Select the check box next to Set Real Time Clock.

6. Select Save Setup. a. The system will restart b. The Service Tool must be restarted

HVAC Function Check

Air Conditioning Test

7. From the Envidia Service Tool tabs select Service Test.

NOTE: The Service Test Mode allows the technician to force the system into a specific operating mode for a maximum of 15 minutes. After 15 minutes, the system will shut down and alarm 54 will be set indicating the Servic e T e st M ode has been active for 15 minutes. Most tests can be accomplished in under 10 minutes.

8. In the Service Test Screen, select Cool Test, then click Run Test. This test will verify the operation of the air

conditioning components.

NOTE: When you choose to run a test, “Running Se rv ice Test” will appear in the upper right on the scree n. When you cancel a test, always allow the system time to respond before continuing.

a. Evaporator fan should run in high s peed. b. A/C compressor should ramp up to high speed.

Page 72

Step 2 – Procedures (continued)

c. Condenser fan should run in high speed. d. Discharge vent temperature should begin getting cooler.

IMPORTANT: If inside cab temperature is below F (18.3 C) do not operate the COOL TEST for more than two minutes or the evaporator coil may freeze up.

9. In the Service Test screen, click Canc el Test.

Heat System Check

10. In the Service Test Screen, select Heat Test, then click Run Test. This test will verify the operation of the heating

components.

a. Evaporator fan should turn off. b. Heater blower should start slo wly then begin to ramp up. c. After one minute the heater fuel pump near the fuel tank should begin clicking. d. After two mi nutes the heater should have ignited. e. Discharge vent temperature should begin rising. f. Blower speed should begin r ising. g. Outside the cab, the velocity and temperature of the heate r’s exhaust should begin rising. h. After four minutes the heater should be in high heat (Boost) mode. i. At the end of five minutes exit the test.

11. In the Service Test screen, click Cancel Test. a. The fuel pump and burner should stop. b. The blower will continue to run for a four-minute cool down cycle. c. Blower speed will ramp down. d. Discharge vent temperature will decrease.

NOTE: Selecting another operating mode or turning the system off will not terminate the cool down cycle . Y ou may continue with the test procedures while in the cool down cycle.

Fan Only Check

This function was alrea dy 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.

14. Verify that AUX BATTERY VOLTAGE for all batteries reads above 11.5 Volts. a. If voltage is lower the batteries must be charged before proceeding.

Battery Discharge

15. Select Service Test tab.

16. In the Service Test screen select Battery Discharge Test.

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). a. Note the value of Requested Mode. It should indicate DISCHARGING. b. Note the value of Stage of Operation. It should be GOOD. c. All others should be NULL.

21. At the HMI, rotate the Fan Speed Selection knob to highest speed setting. a. Note the Aux Battery Current for the selected battery. b. Should indicate minus 2 or more amps.

22. In the Service Test screen, click Cancel Test.

23. Repeat the Battery Discharge Test for each remaining battery (1B, 2A and 2B).

24. At the HMI, rotate the Fan Speed Selection knob to OFF.

Battery Charge

25. Connect battery charger or Shore Power Converter (if applicable).

26. Turn the truck i gnition switch to the O N position. Note: Truck engine not required t o run. Ther e is a 3-minute delay

before entering Charge Mode.

27. Select Service Test tab.

28. In the Service Test screen select Battery Charge Test.

29. From the drop down menu select 1A then click Run Test.

30. Select System Monitoring tab.

31. Select SCM/Batteries at the top of screen.

32. Locate the data group associated with selected battery (example: 1A = SCM1 Battery A). c. Note the value of Requested Mode. It should indicate CHARGING. d. Note the value of Stage of Operation. It should not be NULL. e. All others s hould be Null.

33. Note the value of Aux Battery Current after one minute. a. Aux Battery Current should indicate positive amps.

34. Select Service Test tab.

35. In the Service Test Screen select Cancel Test.

36. Repeat test for each remaining battery (1B, 2A and 2B).

37. Turn truck ign ition OFF.

38. Disconnect battery charger or Shore Power Converter (if applicable).

Page 74

Step 2 – Procedures (continued)

Alarms

ALARM CODE CHART

CODE NUMBER CODE TYPE CODE DESCRIPTION

02 CHECK

03 CHECK

05 CHECK

10 SHUTDOWN

11 CHECK

12 SHUTDOWN

23 SHUTDOWN

49 CHECK

54 SHUTDOWN

61 LOG CHECK

SHUTDOWN

70 LOG

155 CHECK

Evaporator Coil Sensor

Return Air Sensor

Ambient Air Sensor

High Discharge Pressure

Unit Controlling on Alternate Sensor

Sensor Shutdown

Cooling Cycle Fault

Cab Temperature Sensor

Test Mode Timeout

Low Battery Voltage

Hourmeter Failure

Lost CAN Communication

180

CHECK,

SHUTDOWN

Compressor Fault

39. Select Alarm tab.

40. Record any alarms shown. Refer to the Alarm Code Chart to diagnose and repair all alarm conditions.

41. Clear all alarms.

This completes the TriPa c Envidia operation checkout procedures.

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.

For further diagnostic procedures see TriPac Envidia Maintenance Manual (TK 56458-19-MM) and TriPac Envidia Operation and Diagnostic Manual (TK 56464-19-OD).

Page 75

System Check List

 BATTERY BOX - Mounting claws (or

direct frame mounted bolts) positioned correctly and torqued to specifications.

 CONDENSER - Mounting bolts tightened

securely and sealed with silicone.

 RECEIVER DRIER - Mounting bands

tightened securely.

 EVAPORATOR / CONTROL BOX -

Mounting bolts tightened securely and sealed with silicone.

 EVAPORATOR DRAIN TUBES -

Installed and access holes in floor sealed with silicone.

 REFRIGERATION HOSES - Routed

and secured to allow for movement and vibration.

 REFRIGERATION FITTINGS -

Tightened to proper torque specifications.

 ELECTRICAL - Electrical w ir ing and

battery cables connected tightly, properly routed and secured.

 A/C SYSTEM - Properly charged and

free of leaks.

 HEATER INTAKE AND EXHAUST -

Heater intake and exhaust hoses routed safely and secured.

 HEATER FUEL LINES - All fuel lines

are routed safely and secured.

 HEATER FUEL LINE

CONNECTIONS - All fuel line

connections are tight and leak free.

 SAFETY GUARDS - All covers and

grilles Installed securely.

 AIR GAPS - Verif ied an y unused hol es

in the sleeper floor are completely sealed closed with caulking and the 3” access hole inside the sleeper floor is completely caulked from both inside and underneath.

 SYSTEM OPERATION - The

Operation Checkout Procedures were run, all system components operate correctly with no error codes.

 TRACTOR INTERIOR - Thoroughly

cleaned and vacuumed.

 RELEASE TO CUSTOMER.

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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.

Distributed by:

Thermo King Corporate

314 West 90th Street

314 West 90th Street Minneapolis, MN 55420

Minneapolis, MN 55420

Direct (952) 887-2200