Thermo King TriPac Envidia Installation Manual
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)
Installation Manual
TriPac Envidia
Auxiliary Heating and Cooling
Temperature Management System
TK 56459-19-IM (Rev. 0, 12/17)
Copyright© 2017 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
1
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.
2
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
3
Heater Start-Up Procedure (Heat Option) ................................................................................................................ 62
A/C System Charging Procedure .............................................................................................................................. 66
Operation Checkout Procedures ............................................................................................................................... 67
Unit Setup ................................................................................................................................................................. 69
System Check List .................................................................................................................................................... 73
4
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.
5
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.
6
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.
7
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!
8
Battery Box Dimensions
Figure 1: Battery Box Dimensions
9
Battery Box Dimensions (continued)
Figure 2: Battery Box Dimensions (continued)
10
Evaporator/Control Box Dimensions
Figure 3: Evaporator/Control Box Dimensions
11
Condenser with Receiver Drier Dimensions
Figure 4: Condenser with Receiver Drier Dimensions
12
HMI Dimensions
Figure 5: HMI Dimensions
13
1000 Watt Power Inver ter Dimensions (Option)
Figure 6: 1000 Watt Power Inverter Dimensions
14
AC/DC Shore Power Converter Dimensions (Option)
Figure 7: AC/DC Shore Power Converter Dimensions
15
D2/D4 Heater Dimensions (Option)
Figure 8: Heater Dimension
16
BLANK PAGE
17
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)
18
Typical Component Locations
Figure 9: Typical Component Locations
19
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.
20
Tractor and APU Battery Recommendations
12.84 Volts
100%
0 Hours
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).
21
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.
22
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