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D2/D4 Heater Harness Installation (Heat Option)

Locate the

Heater Harness

supplied loose in the installation kit. Remove the two small plastic bags attached to the

harness containing the fuel pump electrical connector components and the in-line fuse assembly. Retain these for

installation later.

Connect the

14-pin

connector (with the locking tab) to the mating connector on the heater.

Use a large bladed screwdriver to pull the locking tab out

(to unlock)

from the connector body.

Connect the two connectors together.

Push locking tab back in

(to lock)

the connector body.

Connect the 10-pin connector to the Heater (J9) connector on the Evaporator/Control Box connector panel.

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.

Figure 28: D2/D4 Heater Harness Connection

Summary of Contents for TriPac Envidia

Page 1: ...on Manual Installation Manual Installation Manual Installation Manual Installation Manual Installation Manual TriPacEnvidia Auxiliary Heating and Cooling Temperature Management System TK 56459 19 IM R...

Page 2: ......

Page 3: ...1 Installation Manual TriPac Envidia Auxiliary Heating and Cooling Temperature Management System TK 56459 19 IM Rev 0 12 17 Copyright 2017 Thermo King Corp Minneapolis MN U S A Printed in U S A...

Page 4: ...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 t...

Page 5: ...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 In...

Page 6: ...4 Heater Start Up Procedure Heat Option 62 A C System Charging Procedure 66 Operation Checkout Procedures 67 Unit Setup 69 System Check List 73...

Page 7: ...e See Tractor and APU Battery Recommendations section in this manual for more information APU BATTERIES Thermo King NXT AGM batteries are shipped fully charged and ready to use See Tractor and APU Bat...

Page 8: ...ealed 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 rem...

Page 9: ...continuous rise Use a hose cutter or sharp knife to cut plastic fuel lines Do not use a wire cutter as this will pinch the plastic fuel line closed Do not route electrical wires harness or battery cab...

Page 10: ...educe cooling capacity ELECTRICAL WIRING AND HMI CONTROLLER INSTALLATION Electrical wiring should be installed and routed in such a way as to allow for vibration and movement of the cab THEY SHOULD NE...

Page 11: ...9 Battery Box Dimensions Figure 1 Battery Box Dimensions...

Page 12: ...10 Battery Box Dimensions continued Figure 2 Battery Box Dimensions continued...

Page 13: ...11 Evaporator Control Box Dimensions Figure 3 Evaporator Control Box Dimensions...

Page 14: ...12 Condenser with Receiver Drier Dimensions Figure 4 Condenser with Receiver Drier Dimensions...

Page 15: ...13 HMI Dimensions Figure 5 HMI Dimensions...

Page 16: ...14 1000 Watt Power Inverter Dimensions Option Figure 6 1000 Watt Power Inverter Dimensions...

Page 17: ...15 AC DC Shore Power Converter Dimensions Option Figure 7 AC DC Shore Power Converter Dimensions...

Page 18: ...16 D2 D4 Heater Dimensions Option Figure 8 Heater Dimension...

Page 19: ...17 BLANK PAGE...

Page 20: ...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 R...

Page 21: ...19 Typical Component Locations Figure 9 Typical Component Locations...

Page 22: ...tery 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 hydr...

Page 23: ...t and dried or wet electrolyte and to prevent corrosion Use a battery terminal cleaning tool that has nonconductive plastic or rubber cover to clean the battery terminals when corrosion is present Rep...

Page 24: ...ollowing 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 t...

Page 25: ...D 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...

Page 26: ...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...

Page 27: ...x Installation continued OPTIONAL INSTALLATION METHOD DIRECT MOUNT WARNING DO NOT connect any of the TriPac ENVIDIA battery cables to any batteries at this time Figure 11 Optional Installation Method...

Page 28: ...il onto a workbench and sub assemble the following components Loosely install the Ambient Temp Sensor clamp to the receiver drier bracket Install the receiver drier bracket onto the condenser coil hou...

Page 29: ...sting truck components The condenser air inlets and fan outlet airflow must not be restricted Obstructions must not cause recirculation of condenser out air If possible mount the condenser below the b...

Page 30: ...sent 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 Ev...

Page 31: ...r filter support 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 ai...

Page 32: ...ol 204 1045 Hose Cutting Tools 204 677 TK 2000 Multi Refrigerant Hose Nipple Assembly Appropriately Sized Clips and Cage Alkyl Benzene refrigerant oil 670404TKA NOTE The two black O rings on the nippl...

Page 33: ...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 per...

Page 34: ...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 s...

Page 35: ...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...

Page 36: ...Route the hose up through 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 port and at...

Page 37: ...35 A C Hose Installation continued 4 Liquid Line from Drier Outlet 6 Discharge Line from Condenser Figure 16 A C Hose I D and routing shown...

Page 38: ...pump valves and gauge manifold hand valves 4 Start vacuum pump and evacuate until system reaches 500 microns 5 Once system reaches 500 microns continue evacuation for one additional hour 6 Close vacuu...

Page 39: ...ensitive 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...

Page 40: ...ghten 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 hea...

Page 41: ...t 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...

Page 42: ...the heater ducts with A C ducts They should not touch each other Ensure provisions are made for proper air return ventilation The heater is equipped with a Return Inlet and Discharge Outlet for attac...

Page 43: ...the floor level discharge air vent cut as needed attach to the end of the plastic louver vent and secure with supplied hose clamp Return Air 4 If a return air duct is not used the protective grille m...

Page 44: ...lled 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 Extreme care should always be taken...

Page 45: ...43 A C Duct Installation continued FLUSH MOUNTED EVAPORATOR Figure 21 A C Duct locations...

Page 46: ...s 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 pla...

Page 47: ...ide the Evaporator Control Box 11 Route the positive 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 w...

Page 48: ...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 Conde...

Page 49: ...ector on the Evaporator Control Box connector panel 2 Route the harness towards the tractor s ignition switch 3 Connect the end with the diode and fuse to the ON or RUN position of the tractor s ignit...

Page 50: ...s 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 the harness behind the...

Page 51: ...lication 1 On the Base Controller remove the cover over the USB Communication Port 2 Plug the USB Mini B connector into the communication port 3 Route the cable to a protected area that is accessible...

Page 52: ...n 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...

Page 53: ...emove the protective cap from the end of the pickup tube prior to installation Do not apply any type of sealant material to the fuel pickup tube assembly Doing so will result in plugged fuel lines Ins...

Page 54: ...52 Heater Fuel Pickup Tube Installation continued Direct Tank Installation No Drilling Figure 29 Fuel Pickup Tube Installation No Drilling...

Page 55: ...ng 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 M...

Page 56: ...lternative Installation Drilling hole in Fuel Tank IMPORTANT The ferrule nut and 1 4 NPT fitting must be tightened securely into the bushing before installing the pickup tube into the tank Figure 30 F...

Page 57: ...mote 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 1 Install the fuel...

Page 58: ...56 Heater Fuel Pump and Fuel Line Installation continued Tank Mounted Fuel Pump Bracket Remote Mounted L Bracket Figure 31 Heater Fuel Pump and Fuel Line Installation...

Page 59: ...s 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...

Page 60: ...Inverter and AC DC Shore Power Converter Follow the installation instructions supplied with the Power Inverter and AC DC Power Converter Connect tractor s batteries directly to inverter then connect t...

Page 61: ...12 0 inches 304 8 mm of the tractor batteries positive terminal b DO NOT install the fuse at this time 2 POSITIVE BATTERY CABLE a Route the positive cable from the TriPac ENVIDIA battery box to the fu...

Page 62: ...cable c Position heat shrink tubing to cover 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...

Page 63: ...ction Red Positive Black Negative 3 Turn the priming harness switch to the ON position 4 The flasher unit will operate the fuel pump ON OFF ON OFF to prime the system 5 Allow the system to operate for...

Page 64: ...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 faults F1 to F5 can...

Page 65: ...gnostic unit is connected NOTE If the automatic detection was successful if necessary the heater is briefly started and then switches off again Display until the automatic detection is completed Heate...

Page 66: ...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 heater harness Clearing Faults Display current fault in...

Page 67: ...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 of...

Page 68: ...cial Tools Required R 134a Refrigerant Accurate Scale 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 chargi...

Page 69: ...ng tools will be required Laptop Computer IBM Compatible USB Adapter Harness 204 2000 or USB Mini B Envidia Service Tool software Step 1 Checkout Procedures Using the HMI Controller The following oper...

Page 70: ...ding on cab temperature the heater may start Note If the heater ignites it will run for a minimum of 5 minutes The blower will then run through a cool down cycle 9 Rotate Mode Selection knob back to F...

Page 71: ...nter 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 d...

Page 72: ...ature of the heater 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 Cance...

Page 73: ...ery charger or Shore Power Converter if applicable 26 Turn the truck ignition switch to the ON position Note Truck engine not required to run There is a 3 minute delay before entering Charge Mode 27 S...

Page 74: ...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...

Page 75: ...d 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...

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Page 80: ...2200 Thermo King Corporate Distributed by Ingersoll Rand s Climate Solutions sector delivers energy ef cient HVACR solutions for customers globally Its world class brands include Thermo King the lead...

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