TriPac Auxiliary Heating/Cooling Temperature Management System PDF

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TriPac AuxiliaryHeating/CoolingTemperatureManagement SystemTK 53036-19-MM (Rev. 1, 09/08)Copyright 2005 Thermo King Corp., Minneapolis, MN, USA.Printed in USA.

The maintenance information in this manual covers unit models:TriPac (900217)For further information, refer to:TriPac Operating ManualTK 53035TriPac Parts ManualTK 53037TriPac Diagnostic ManualTK 53024TriPac Installation ManualTK 53120International Components Engineering (ICE) Compressor Service ManualICE No. 51068Diagnosing Thermo King Refrigeration SystemsTK 5984Evacuation Station Operation and Field ApplicationTK 40612Tool CatalogTK 5955Electrostatic Discharge Training GuideTK 40282The information in this manual is provided to assist owners, operators and service people in the properupkeep and maintenance of Thermo King units. The above manuals may be purchased from your localThermo King dealer.This manual is published for informational purposes only and the information so provided shouldnot be considered as all-inclusive or covering all contingencies. If further information is required,Thermo King Corporation should be consulted.Sale of product shown in this manual is subject to Thermo King’s terms and conditionsincluding, but not limited to, the Thermo King Limited Express Warranty. Such terms andconditions are available upon request. Thermo King’s warranty will not apply to anyequipment which has been “so repaired or altered outside the manufacturer’s plants as,in the manufacturer’s judgment, to effect its stability.”No warranties, express or implied, including warranties of fitness for a particularpurpose or merchantability, or warranties arising from course of dealing or usage oftrade, are made regarding the information, recommendations, and descriptionscontained herein. Manufacturer is not responsible and will not be held liable in contractor in tort (including negligence) for any special, indirect or consequential damages,including injury or damage caused to vehicles, contents or persons, by reason of theinstallation of any Thermo King product or its mechanical failure.

Recover RefrigerantAt Thermo King, we recognize the need to preserve the environmentand limit the potential harm to the ozone layer that can result fromallowing refrigerant to escape into the atmosphere.We strictly adhere to a policy that promotes the recovery and limitsthe loss of refrigerant into the atmosphere.In addition, service personnel must be aware of Federal and Stateregulations concerning the use of refrigerants and the certification oftechnicians. For additional information on regulations and techniciancertification programs, contact your local THERMO KING dealer.R-134a and PAG Compressor OilWARNING: Use only PAG-based refrigeration compressor oil in theTriPac R-134a air conditioning system. See Thermo King Parts Manualfor part number.WARNING: With HVAC systems and the use of PAG, it is very importantthat oil mixing does not take place. PAG and POE oil CANNOT be mixed.Mixing these oils will cause serious system contamination, especially withchlorine based refrigerants.NOTE: When servicing Thermo King R-134a units, use only thoseservice tools certified for and dedicated to R-134a refrigerant and PAGcompressor oils. Residual non-HFC refrigerants or oils will contaminateR-134a systems. The proper compressor oil is determined by therefrigerant used and specific air conditioning application requirements.Verify both serial nameplates on the unit and compressor for correct oil touse in a particular system. Because of the many variables in oils,particularly in HVAC systems, compressors may be delivered with an oilthat is not specified for the particular unit it is to be fitted to. Unless it is100% clear it is the correct oil, Thermo King recommends the oil ischanged to the correct type.PAG oil is very hygroscopic. Only use oil taken from a fresh container.

About This ManualPurposeThe purpose of this manual is to provide general maintenance information necessary to maintain theTriPac unit at peak operating standards. This includes safety information, unit information such as bills ofmaterial and kit numbers, general unit information, maintenance procedures and related information(such as wiring and schematic diagrams), and some diagnostic and troubleshooting information.NOTE: This manual may cover more than one unit. Therefore, it may contain information notapplicable to your unit.ContentsThis manual is organized into the following chapters:ChapterPurposeSafety PrecautionsProvides detailed safety information. You should be familiar with thesafety precautions before working on any unit.Model Systems and UpdateMatricesThese tables list the bills of material and kit options that make up yourunit. Use them for the following purposes:1. To determine if you have the right manual for your unit: the bill ofmaterial (B/M) number on your unit serial plate should match one of thebill of material numbers listed in this publication. If you cannot find yourunit B/M, call TK Service for more information.)2. To communicate with TK Service Department: If you need to call TKService, you must know your model number so that the servicerepresentative to help you.SpecificationsLists unit specifications.General DescriptionGives an overview description of your unit including standard andoptional features, illustrations, and general heating and air conditioninginformation.Operating InstructionsProvides unit operating instructions.Maintenance Inspection ScheduleTable of routine maintenance procedures.Maintenance ChaptersProvide detailed maintenance procedures required for your unit.(Electrical, Air Conditioning, Compressor, Engine, Structural)Wiring and Schematic DiagramsWiring and Schematic diagrams applicable to the unit.5

About This ManualBefore You Call Thermo King Service!Who to call: Your Thermo King Service Representative.Before you call Thermo King Service, have the following information on hand: Bill of Material - usually located on the unit serial plate. Model Number - found on frame inside the APU unit.Blank PagesThis manual may contain blank pages at the end of chapters. This is normal. There is no informationmissing from the manual.Roadside/Curbside TerminologyRoadside/Curbside terminology: These terms can be confusing because of differences between NorthAmerica and Europe. Please note:Curbside:The side of the truck to the driver’s right when the driver is in his seat and facing forward.Roadside:The side of the truck to the driver’s left when the driver is in his seat and facing forward.Using the Model Tables in “About this Unit”The model tables in this section (called “About this Unit,” “Model Systems and Update Matrices,” orsomething similar) list important unit information that you will need to communicate with the ThermoKing Service Department. See the table on the previous page for a description of how to use these tables.6

Table of ContentsAbout This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Before You Call Thermo King Service! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Blank Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Roadside/Curbside Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Using the Model Tables in “About this Unit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Refrigeration Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Model Systems (System Designations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17TriPac Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17R-134a Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Truck Sleeper Compartment Heater (D2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Truck Sleeper Compartment Heater (D4 - Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Optional Power Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Optional Extreme Arctic Package Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Specifications—Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25TriPac System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Auxiliary Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26HMI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27High System Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Low System Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Fuse Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Engine Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31TriPac HMI Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31HMI Controller Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Main Power Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Mode Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Up and Down Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Fan Speed Key . . . . . . . . . . . . . . . . . . . . . . . . . . .

TriPac Operating Manual TK 53035 TriPac Parts Manual TK 53037 TriPac Diagnostic Manual TK 53024 TriPac Installation Manual TK 53120 International Components Engineering (ICE) Compressor Service Manual ICE No. 51068 Diagnosing Thermo King Refrigeration Systems TK 5984 Evacuation Station Operation and Field Application TK 40612 Tool Catalog TK 5955