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Trane Thermo King TriPac Envidia Installation Manual

Trane Thermo King TriPac Envidia Installation Manual

Auxiliary power unit edition
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Installation Manual
Auxiliary Power Unit Edition
TriPac® Envidia™ ™
Auxiliary Heating and Cooling Temperature Management
System
Revision B
T T K K 5 5 6 6 4 4 5 5 9 9 - - 1 1 9 9 - - I I M M - - E E N N
November 2020

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  • Page 1: A A U U X X I I L L I I A A R R Y Y A A C C P P O O W W E E R R A A C C C C E E S S S S O O R R I I E E S S ( ( O O P P T T I I O O N

    Installation Manual Auxiliary Power Unit Edition TriPac® Envidia™ ™ Auxiliary Heating and Cooling Temperature Management System Revision B T T K K 5 5 6 6 4 4 5 5 9 9 - - 1 1 9 9 - - I I M M - - E E N N November 2020...

  • Page 2: A A / / C C D D U U C C T T I I N N S S T T A A L L L L A A T T I I O O N

    Revision History Revision A (02/20) New manual format. Revision B (11/20) Added new HMI Controller. ©2018 Trane Technologies TK 56459-19-IM-EN...

  • Page 3: D D 2 2 / / D D 4 4 H H E E A A T T E E R R H H A A R R N N E E S S S S I I N N S S T T A A L L L L A A T T I I O O N N ( ( H H E E A A T T O O P P T T I I O O N

    I I n n t t r r o o d d u u c c t t i i o o n n Customer Satisfaction Survey Let your voice be heard! Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a web browser.

  • Page 4: Table Of Contents

    Table of Contents T T i i p p s s F F o o r r a a S S u u c c c c e e s s s s f f u u l l I I n n s s t t a a l l l l a a t t i i o o n n ..........................7 7 Before Beginning the Installation Recommendations .
  • Page 5 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Exhaust and Combustion Air Intake Installation ..........40 Return and Discharge Ducts and Vents Installation.

  • Page 6: A A / / C C H H O O S S E E I I N N S S T T A A L L L L A A T T I I O O N

    T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s A A / / C C S S y y s s t t e e m m C C h h a a r r g g i i n n g g P P r r o o c c e e d d u u r r e e s s ......................... . 7 7 1 1 O O p p e e r r a a t t i i o o n n C C h h e e c c k k o o u u t t P P r r o o c c e e d d u u r r e e s s .

  • Page 7: Before Beginning The Installation Recommendations

    Tips For a Successful Installation Before Beginning the Installation Recommendations I I m m p p o o r r t t a a n n t t : : Proper installation of each component onto the vehicle is critical! Refer to the Thermo King TriPac Installation Standards Guide (TK 56498) before beginning the installation.

  • Page 8: D D 2 2 / / D D 4 4 H H E E A A T T E E R R I I N N S S T T A A L L L L A A T T I I O O N N ( ( H H E E A A T T O O P P T T I I O O N

    T T i i p p s s F F o o r r a a S S u u c c c c e e s s s s f f u u l l I I n n s s t t a a l l l l a a t t i i o o n n I I m m p p o o r r t t a a n n t t : : 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).

  • Page 9: Battery Box Installation Requirements

    T T i i p p s s F F o o r r a a S S u u c c c c e e s s s s f f u u l l I I n n s s t t a a l l l l a a t t i i o o n n Battery Box Installation Requirements I I m m p p o o r r t t a a n n t t : : See “Battery Box Installation Standards”...

  • Page 10: A/C Hose Connections And Routing Requirements

    T T i i p p s s F F o o r r a a S S u u c c c c e e s s s s f f u u l l I I n n s s t t a a l l l l a a t t i i o o n n •...

  • Page 11: Electrical Wiring And Hmi Controller Installation Requirements

    T T i i p p s s F F o o r r a a S S u u c c c c e e s s s s f f u u l l I I n n s s t t a a l l l l a a t t i i o o n n Electrical Wiring and HMI Controller Installation Requirements I I m m p p o o r r t t a a n n t t : : See “Electrical Standards“...

  • Page 12: Auxiliary Power Accessories Requirements

    T T i i p p s s F F o o r r a a S S u u c c c c e e s s s s f f u u l l I I n n s s t t a a l l l l a a t t i i o o n n Auxiliary Power Accessories Requirements Envidia installations may also include optional auxiliary power accessories such as: •...
  • Page 13 Required Tools and Additional Supplies N N o o t t e e : : While basic mechanics tools and refrigerant service equipment are a necessity, there are also special tools that are required when installing Thermo King TriPac Units. For a complete listing of special tools, See “Special Tool Requirements”...

  • Page 14: R R E E Q Q U U I I R R E E D D T T O O O O L L S S A A N N D D A A D D D D I I T T I I O O N N A A L L S S U U P P P P L L I I E E S

    R R e e q q u u i i r r e e d d T T o o o o l l s s a a n n d d A A d d d d i i t t i i o o n n a a l l S S u u p p p p l l i i e e s s A A D D D D I I T T I I O O N N A A L L S S U U P P P P L L I I E E S S ( ( a a s s r r e e q q u u i i r r e e d d ) ) 1.

  • Page 15: Battery Box Dimensions

    TriPac Envidia Component Dimensions Battery Box Dimensions TK 56459-19-IM-EN...
  • Page 16 T T r r i i P P a a c c E E n n v v i i d d i i a a C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s TK 56459-19-IM-EN...

  • Page 17: Condenser Dimensions

    T T r r i i P P a a c c E E n n v v i i d d i i a a C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s Condenser Dimensions TK 56459-19-IM-EN...

  • Page 18: Evaporator/Control Box Dimensions

    T T r r i i P P a a c c E E n n v v i i d d i i a a C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s Evaporator/Control Box Dimensions TK 56459-19-IM-EN...

  • Page 19: Hmi Controller Dimensions

    T T r r i i P P a a c c E E n n v v i i d d i i a a C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s HMI Controller Dimensions 203 mm (8.00 in.)

  • Page 20: Standard Heater Dimensions

    T T r r i i P P a a c c E E n n v v i i d d i i a a C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s Standard Heater Dimensions 311.15 mm (12.25 in.)

  • Page 21: High Output Heater Dimensions

    T T r r i i P P a a c c E E n n v v i i d d i i a a C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s High Output Heater Dimensions 376 mm (14.80 in.)

  • Page 22: Ac/Dc Shore Power Converter Dimensions

    T T r r i i P P a a c c E E n n v v i i d d i i a a C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s AC/DC Shore Power Converter Dimensions TK 56459-19-IM-EN...

  • Page 23: 1000 Watt Power Inverter Dimensions

    T T r r i i P P a a c c E E n n v v i i d d i i a a C C o o m m p p o o n n e e n n t t D D i i m m e e n n s s i i o o n n s s 1000 Watt Power Inverter Dimensions TK 56459-19-IM-EN...
  • Page 24 N N o o t t e e s s TK 56459-19-IM-EN...
  • Page 25 Typical Envidia Component Locations I I m m p p o o r r t t a a n n t t : : Proper installation of each component onto the vehicle is critical! Refer to the Thermo King TriPac Installation Standards Guide (TK 56498) before beginning the installation.

  • Page 26: Standard Installation Method - Mounting Claws

    Battery Box Installation I I m m p p o o r r t t a a n n t t : : See “Battery Box Installation Standards” in Section 6 of the Thermo King TriPac Installation Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED! Standard Installation Method –...
  • Page 27 B B a a t t t t e e r r y y B B o o x x I I n n s s t t a a l l l l a a t t i i o o n n Figure 2.

  • Page 28: Optional Installation Method - Direct Mount

    B B a a t t t t e e r r y y B B o o x x I I n n s s t t a a l l l l a a t t i i o o n n Optional Installation Method –...
  • Page 29 B B a a t t t t e e r r y y B B o o x x I I n n s s t t a a l l l l a a t t i i o o n n Figure 3.
  • Page 30 Receiver Drier Installation I I m m p p o o r r t t a a n n t t : : See “Receiver Drier Installation Standards” and “Refrigeration Hose and Fittings Standards” in Section 8 of the Thermo King TriPac Installation Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED! Special Tools Required Hose Fitting Tool (204–1045)

  • Page 31: R R E E C C E E I I V V E E R R D D R R I I E E R R I I N N S S T T A A L L L L A A T T I I O O N

    R R e e c c e e i i v v e e r r D D r r i i e e r r I I n n s s t t a a l l l l a a t t i i o o n n 4.

  • Page 32: A/C Condenser Installation

    R R e e c c e e i i v v e e r r D D r r i i e e r r I I n n s s t t a a l l l l a a t t i i o o n n A/C Condenser Installation I I m m p p o o r r t t a a n n t t : : A properly installed condenser onto the truck’s cab is critical.
  • Page 33 A/C Evaporator / Control Box Installation I I m m p p o o r r t t a a n n t t : : See “Evaporator/Control Box Installation Standards” in Section 6 of the Thermo King TriPac Installation Standards Guide (TK 56498).

  • Page 34: A A / / C C E E V V A A P P O O R R A A T T O O R R / / C C O O N N T T R R O O L L B B O O X X I I N N S S T T A A L L L L A A T T I I O O N

    A A / / C C E E v v a a p p o o r r a a t t o o r r / / C C o o n n t t r r o o l l B B o o x x I I n n s s t t a a l l l l a a t t i i o o n n N N o o t t e e : : This installation requires two-persons or mechanically assisted lift.
  • Page 35 A A / / C C E E v v a a p p o o r r a a t t o o r r / / C C o o n n t t r r o o l l B B o o x x I I n n s s t t a a l l l l a a t t i i o o n n N N o o t t e e : : A 12”...
  • Page 36 A/C Hose Installation I I m m p p o o r r t t a a n n t t : : See “Refrigerant Hose and Fittings Standards” in Section 8 of the Thermo King TriPac Installation Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED! N N o o t t e e : : The Evaporator/Control Box system has a Nitrogen holding charge of 5 PSI.
  • Page 37 A/C System Evacuation and Leak Check Procedures I I m m p p o o r r t t a a n n t t : : See “System Evacuation Standards” in Section 12 of the Thermo King TriPac Installation Standards Guide (TK 56498).

  • Page 38: Heater Location

    D2/D4 Heater Installation (Heat Option) I I m m p p o o r r t t a a n n t t : : Correct installation of the TriPac diesel-fired heater system is critical to ensure safe and proper operation. B B E E F F O O R R E E installing the heater, read the heater manufacturer’s manuals included with the heater and the “Heater Installation Standards”...

  • Page 39: Heater Subassembly And Installation

    D D 2 2 / / D D 4 4 H H e e a a t t e e r r I I n n s s t t a a l l l l a a t t i i o o n n ( ( H H e e a a t t O O p p t t i i o o n n ) ) Heater Subassembly and Installation Turn the heater upside down and attach the following components: 1.

  • Page 40: Exhaust And Combustion Air Intake Installation

    D D 2 2 / / D D 4 4 H H e e a a t t e e r r I I n n s s t t a a l l l l a a t t i i o o n n ( ( H H e e a a t t O O p p t t i i o o n n ) ) Exhaust and Combustion Air Intake Installation I I N N S S T T A A L L L L A A T T I I O O N N P P R R O O C C E E D D U U R R E E S S 1.
  • Page 41 D D 2 2 / / D D 4 4 H H e e a a t t e e r r I I n n s s t t a a l l l l a a t t i i o o n n ( ( H H e e a a t t O O p p t t i i o o n n ) ) Special Tools Required Drill Motor 2-1/2”...

  • Page 42: Discharge Air Outlet Options

    A/C Duct Installation I I m m p p o o r r t t a a n n t t : : Maximum cooling is obtained when the evaporator air discharge ducts and vents are installed and routed correctly in the bunk area. Proper air distribution from the A/C system provides maximum driver comfort.

  • Page 43: Discharge Air Duct Installation

    A A / / C C D D u u c c t t I I n n s s t t a a l l l l a a t t i i o o n n Discharge Air Duct Installation N N o o t t e e : : It is important that the flexible air discharge air ducts are installed and routed properly for maximum air conditioning performance.
  • Page 44 A A / / C C D D u u c c t t I I n n s s t t a a l l l l a a t t i i o o n n Figure 17. Typical A/C Duct locations shown. TK 56459-19-IM-EN...

  • Page 45: Backflow Damper Installation

    A A / / C C D D u u c c t t I I n n s s t t a a l l l l a a t t i i o o n n Backflow Damper Installation I I m m p p o o r r t t a a n n t t : : The back flow damper must be installed when connecting TriPac Envidia A/C discharge hose into OEM ducts.
  • Page 46 Battery Box Harness Installation I I m m p p o o r r t t a a n n t t : : See “Electrical Standards” in Section 10 of the Thermo King TriPac Installation Standards Guide (TK56498). THESE STANDARDS MUST BE FOLLOWED! I I m m p p o o r r t t a a n n t t : : 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.

  • Page 47: B B A A T T T T E E R R Y Y B B O O X X H H A A R R N N E E S S S S I I N N S S T T A A L L L L A A T T I I O O N

    B B a a t t t t e e r r y y B B o o x x H H a a r r n n e e s s s s I I n n s s t t a a l l l l a a t t i i o o n n Figure 19.
  • Page 48 B B a a t t t t e e r r y y B B o o x x H H a a r r n n e e s s s s I I n n s s t t a a l l l l a a t t i i o o n n 8.
  • Page 49 Condenser Fan and Sensor Harness Installation I I m m p p o o r r t t a a n n t t : : See “Electrical Standards” in Section 10 of the Thermo King TriPac Installation Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED! I I m m p p o o r r t t a a n n t t : : 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.
  • Page 50 Ignition Switch and Harness Installation I I m m p p o o r r t t a a n n t t : : See “Electrical Standards” in Section 10 of the Thermo King TriPac Installation Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED! N N o o t t e e : : The Ignition Sense harness wire must be connected to the ON or RUN position of the truck’s ignition system.
  • Page 51 HMI Installation I I m m p p o o r r t t a a n n t t : : See “HMI Controller Installation Standards” in Section 10 of the Thermo King TriPac Installation Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED! Special Tools Required Level Drill Motor...
  • Page 52 USB Service Communication Cable Installation The USB Service Communication Cable allows technicians to easily access the communication application. I I N N S S T T A A L L L L A A T T I I O O N N P P R R O O C C E E D D U U R R E E S S 1.
  • Page 53 D2/D4 Heater Harness Installation (Heat Option) I I m m p p o o r r t t a a n n t t : : See “Electrical Standards” in Section 10 of the Thermo King TriPac Installation Standards Guide (TK 56498). THESE PROCEDURES MUST BE FOLLOWED! I I N N S S T T A A L L L L A A T T I I O O N N P P R R O O C C E E D D U U R R E E S S 1.

  • Page 54: Direct Tank Installation - With Oem Fuel Tank Fittings

    Heater Fuel Pickup Tube Installation (Heat Option) Direct Tank Installation – with OEM Fuel Tank Fittings I I m m p p o o r r t t a a n n t t : : See “Fuel Pickup Tube Installation Standards“ in Section 7 of the Thermo King TriPac Installation Standards Guide (TK 56498).
  • Page 55 H H e e a a t t e e r r F F u u e e l l P P i i c c k k u u p p T T u u b b e e I I n n s s t t a a l l l l a a t t i i o o n n ( ( H H e e a a t t O O p p t t i i o o n n ) ) Figure 26.

  • Page 56: Alternative Installation - Drilling Hole In Fuel Tank

    H H e e a a t t e e r r F F u u e e l l P P i i c c k k u u p p T T u u b b e e I I n n s s t t a a l l l l a a t t i i o o n n ( ( H H e e a a t t O O p p t t i i o o n n ) ) Alternative Installation –...
  • Page 57 H H e e a a t t e e r r F F u u e e l l P P i i c c k k u u p p T T u u b b e e I I n n s s t t a a l l l l a a t t i i o o n n ( ( H H e e a a t t O O p p t t i i o o n n ) ) Figure 27.

  • Page 58: Tank Mounted Fuel Pump

    Fuel Pump and Fuel Line Installation (Heat Option) I I m m p p o o r r t t a a n n t t : : See “Heater Fuel Pump Installation Standards” and “ Heater Fuel Line Installation Standards” in Section 7 of the Thermo King TriPac Installation Standards Guide (TK 56498).

  • Page 59: Remote Mounted Fuel Pump With L-Bracket

    F F u u e e l l P P u u m m p p a a n n d d F F u u e e l l L L i i n n e e I I n n s s t t a a l l l l a a t t i i o o n n ( ( H H e e a a t t O O p p t t i i o o n n ) ) Remote Mounted Fuel Pump with L-Bracket Choose a protected location under the cab close to the fuel pick-up tube and heater and install the supplied L-bracket securely with TEK screws.
  • Page 60 Heater Fuel Pump Connections (Heat Option) I I m m p p o o r r t t a a n n t t : : See “Heater Fuel Pump Connector” in Section 10 — Electrical Standards of the Thermo King TriPac Installation Standards Guide (TK 56498).

  • Page 61: Dc/Ac Power Inverter Only

    Auxiliary AC Power Accessories (Option) DC/AC Power Inverter Only • Follow the installation instructions supplied with the Power Inverter. • Connect tractor’s batteries directly to inverter as shown. I I m m p p o o r r t t a a n n t t : : D D O O N N O O T T connect auxiliary power accessories to the TriPac ENVIDIA batteries. Figure 31.

  • Page 62: Ac/Dc Shore Power Converter Only

    A A u u x x i i l l i i a a r r y y A A C C P P o o w w e e r r A A c c c c e e s s s s o o r r i i e e s s ( ( O O p p t t i i o o n n ) ) AC/DC Shore Power Converter Only •...

  • Page 63: Dual System - Dc/Ac Power Inverter And Ac/Dc Shore Power Converter

    A A u u x x i i l l i i a a r r y y A A C C P P o o w w e e r r A A c c c c e e s s s s o o r r i i e e s s ( ( O O p p t t i i o o n n ) ) Dual System –...
  • Page 64 Battery Cable Installation I I m m p p o o r r t t a a n n t t : : See “Terminal Lug Standards” and “Fused Power Connection Standards” in the Electrical Standards” in Section 10 of the Thermo King TriPac Installation Standards Guide (TK 56498). THESE PROCEDURES MUST BE FOLLOWED! T T R R U U C C K K B B a a t t t t e e r r y y B B o o x x C C a a b b l l e e C C o o n n n n e e c c t t i i o o n n s s N N o o t t e e : : Refer to the illustration on the following page.

  • Page 65: B B A A T T T T E E R R Y Y C C A A B B L L E E I I N N S S T T A A L L L L A A T T I I O O N

    B B a a t t t t e e r r y y C C a a b b l l e e I I n n s s t t a a l l l l a a t t i i o o n n d.
  • Page 66 Priming the Heater Fuel Pump (Heat Option) I I m m p p o o r r t t a a n n t t : : It is important the heater fuel pump be primed before attempting to operate the heater for the first time. Failure to prime the pump will cause the unit to shutdown, set diagnostic codes and cause damage to the fuel pump.

  • Page 67: Diagnostic Tool Overview

    Heater Start-Up Procedures (Heat Option) N N o o t t e e : : See Operating and Diagnostic Manual TK 56464-19-OD for further diagnosis and service procedures if needed. Special Tools Required Heater Diagnostic Tool (204-1143) Diagnostic Tool Overview The diagnostic tool is used to read out, display and delete faults stored in the heater's electronic control box.
  • Page 68 H H e e a a t t e e r r S S t t a a r r t t - - U U p p P P r r o o c c e e d d u u r r e e s s ( ( H H e e a a t t O O p p t t i i o o n n ) ) Five seconds after the diagnostic tool has been connected to the heater using the adapter cable, the automatic detection starts to determine the type of heater to which the diagnostic unit is connected.

  • Page 69: Heater Start-Up

    H H e e a a t t e e r r S S t t a a r r t t - - U U p p P P r r o o c c e e d d u u r r e e s s ( ( H H e e a a t t O O p p t t i i o o n n ) ) Heater Start-Up 1.

  • Page 70: Quit Start-Up

    H H e e a a t t e e r r S S t t a a r r t t - - U U p p P P r r o o c c e e d d u u r r e e s s ( ( H H e e a a t t O O p p t t i i o o n n ) ) D D i i s s p p l l a a y y c c u u r r r r e e n n t t f f a a u u l l t t i i n n t t h h e e f f a a u u l l t t m m e e m m o o r r y y a a g g a a i i n n 4.
  • Page 71 A/C System Charging Procedures I I m m p p o o r r t t a a n n t t : : See “System Charging Standards” in Section 14 of the Thermo King TriPac Installation Standards Guide (TK 56498).

  • Page 72: Step 1 - Basic Operation Checkout Procedures

    Operation Checkout Procedures An operation checkout procedure must be performed after the TriPac Envidia installation has been completed. This procedure will confirm the operation of the heating and air conditioning systems, and will verify the TriPac Envidia batteries are charging and discharging properly. Any alarm codes that may have been set can also be checked and cleared.

  • Page 73: Step 2 - Detailed Operation Checkout Procedures

    O O p p e e r r a a t t i i o o n n C C h h e e c c k k o o u u t t P P r r o o c c e e d d u u r r e e s s a.

  • Page 74: Envidia Hvac Function Check Procedures

    O O p p e e r r a a t t i i o o n n C C h h e e c c k k o o u u t t P P r r o o c c e e d d u u r r e e s s 5.
  • Page 75 O O p p e e r r a a t t i i o o n n C C h h e e c c k k o o u u t t P P r r o o c c e e d d u u r r e e s s a.

  • Page 76: Envidia Battery Check Procedures

    O O p p e e r r a a t t i i o o n n C C h h e e c c k k o o u u t t P P r r o o c c e e d d u u r r e e s s Envidia Battery Check Procedures B B a a t t t t e e r r y y C C o o n n d d i i t t i i o o n n 1.
  • Page 77 O O p p e e r r a a t t i i o o n n C C h h e e c c k k o o u u t t P P r r o o c c e e d d u u r r e e s s A A l l a a r r m m s s ALARM CODE CHART CODE NUMBER...

  • Page 78: Envidia Hvac Function Check Procedures

    O O p p e e r r a a t t i i o o n n C C h h e e c c k k o o u u t t P P r r o o c c e e d d u u r r e e s s Envidia HVAC Function Check Procedures A A i i r r C C o o n n d d i i t t i i o o n n i i n n g g T T e e s s t t 1.
  • Page 79 N N o o t t e e s s TK 56459-19-IM-EN...
  • Page 80 Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938.

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