TriPac Auxiliary

Heating/Cooling
Temperature
Management System
TK 53024-19-OD (Original, 10-05)

Diagnostic Manual

Copyright© 2005 Thermo King Corp., Minneapolis, MN USA

Printed in USA
Revision History TK 53024-19-OD
Release Date Description
Original 10/05 First release of this manual.

This manual is published for informational purposes only and the information so provided
should not 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 conditions
including, but not limited to, the THERMO KING LIMITED EXPRESS WARRANTY. Such
terms and conditions are available upon request.

Thermo King's warranty will not apply to any equipment which has been "so repaired or
altered outside the manufacturers plants as, in the manufacturers judgment, to effect it's
stability".

No warranties, express or implied, including warranties of fitness for a particular purpose

or merchantability, or warranties arising from course of dealing or usage of trade, are
made regarding the information, recommendations and descriptions contained herein.
Manufacturer is not responsible and will not be held liable in contract or in tort (including
negligence) for any special, indirect or consequential damages, including injury or
damage caused to vehicles, contents or persons, by reason of the installation of any
Thermo King product or its mechanical failure.
How to use this manual
Because not everyone is familiar with microprocessor based control systems, please take a
few minutes to read this page. It explains the content and structure of this manual. This will
make it easier for you to find the information you need.

Section 1 - Safety Information

This section contains the safety information for microprocessor control systems. Read this
material carefully before working on the unit.

Section 2 - Hardware Description

This section includes the microprocessor control system hardware description. It identifies and
locates system components and provides connector maps for all connectors.

Section 3 - Software Description

This section discusses the operation of the microprocecssor control system software,
programmable features and the sequence of operation. Each programmable feature is
discussed individually to illustrate how they are used.

Section 4 - Operation
This section shows you how to operate and program the microprocessor control system. This
information is referenced by material in Section 5 Diagnostics.

Section 5 - Diagnostics
This section explains how to diagnose TriPac units. It includes both alarm code diagnostics
and other symptom diagnostics. This section will reference material in Section 4 Operation
and Section 6 Service Procedures.

Section 6 - Service Procedures

This section includes Service Procedures to assist the technician when servicing units. These
procedrues are referenced by the diagnostic routines in Section 5 Diagnostics.

Section 7 - Service Information

This section offers Service Information on the basic components parts of the microprocessor
control system. It includes a software rervision history and a list of applicable bulletins.

Section 8 - Schematics and Wiring Diagrams

This section includes the control system electrical schematics and unit wiring diagrams.
 Changes and Comments
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your needs. Any corrections or comments are welcome. Please complete the following
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Thermo King Corporation

Return This Form To: 314 W. 90th Street
Mail Stop 38
Minneapolis, MN 55420-3603
Attn: Service Department
 Section 1 - Safety Information
Safety Definitions . . . . . . . . . . . . . . . . . . . . .1-1
Safety Precautions . . . . . . . . . . . . . . . . . . . .1-1
General Practices . . . . . . . . . . . . . . . . . . . .1-1
Auto Start Hazards . . . . . . . . . . . . . . . . . . .1-2
Refrigerant Hazards . . . . . . . . . . . . . . . . . .1-2
Refrigeration Oil Hazards . . . . . . . . . . . . . .1-2
Electrical Hazards . . . . . . . . . . . . . . . . . . . .1-2
Low Voltage . . . . . . . . . . . . . . . . . . . . . .1-2
Battery Removal . . . . . . . . . . . . . . . . . . . . .1-3
Welding Precautions . . . . . . . . . . . . . . . . . .1-3
Microprocessor Precautions . . . . . . . . . . . .1-3
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
First Aid: Refrigerants . . . . . . . . . . . . . . . . .1-4
First Aid: Refrigeration Oil . . . . . . . . . . . . . .1-4
First Aid: Engine Coolant . . . . . . . . . . . . . .1-4
First Aid: Electrical Shock . . . . . . . . . . . . . .1-4
 Section 1 - Safety Information
This section includes general safety
precautions, specific cautions, and first aid
information. Read this material carefully
before working on the unit.
Safety Definitions
The following types of safety precautions
appear in this manual:
DANGER: Denotes the possibility of
serious injury or death.
WARNING: Denotes the possibility of
serious damage to equipment and/or
serious injury to self.
CAUTION: Denotes the possibility of
minor to severe damage to
equipment and/or possible injury to
self.
Safety Precautions
NOTE: EPA Section 609 Certification is
needed to work on mobile vehicle air
conditioning systems.
General Practices
DANGER: Always turn the TriPac
unit off by pressing the HMI Main
Power On/Off key before refueling
the truck. Failure to do so can cause
fuel vapors to ignite or explode.
WARNING: Always wear goggles or
safety glasses when working on
TriPac. Refrigerant and battery acid
can permanently damage the eyes.
DANGER: Never apply heat to a
sealed refrigeration system or
container. This can cause an
explosion.
DANGER: Fluorocarbon refrigerants
in the presence of an open flame,
spark, or electrical short produce
toxic gases that are severe
respiratory irritants CAPABLE OF
CAUSING DEATH.
25 October 2005
DANGER: Keep your hands, clothing
and tools clear of moving parts when
the TriPac unit is running. Loose
clothing may become entangled in
moving parts, causing serious injury
or possible death.
DANGER: Do not breathe refrigerant.
Use caution when working with
refrigerant or a refrigeration system
in any closed or confined area with a
limited air supply. Refrigerant tends
to displace air and can cause oxygen
depletion, resulting in suffocation
and possible death.
WARNING: Make sure the gauge
manifold hoses are in good condi-
tion. Never let them come in contact
with a belt, fan, pulley, or any hot
surface. This will damage equipment
and can cause serious injury.
WARNING: Use caution when
working around exposed coil fins.
The fins can cause painful
lacerations.
WARNING: Use caution when using
ladders to install or service TriPac.
Always observe the manufacturer’s
safety labels and warnings.
CAUTION: Make sure all mounting
bolts are tight and are the correct
length for their particular
application. Improper torque and
incorrect bolt lengths can damage
equipment.
1-1
Section 1 - Safety Information
Auto Start Hazards
CAUTION: The TriPac can start and
run automatically any time the unit
is turned on. Always turn the TriPac
unit off by pressing the HMI Main
Power On/Off key before removing
covers or working on any part of the
TriPac unit.
Refrigerant Hazards
DANGER: Do not use a Halide torch.
When a flame comes in contact with
refrigerants, toxic gases are
produced. These gasses can cause
suffocation or even death.
DANGER: Store refrigerants in
proper containers out of direct
sunlight and away from intense heat.
Heat increases pressure inside
storage containers, which can cause
a container to explode.
DANGER: Do not use oxygen (O2 )
or compressed air for leak testing. A
mixture of oxygen (O2 ) and
refrigerant can be combustible.
WARNING: Always use butyl-lined
gloves when handling refrigerants,
in order to be protected from
frostbite.
CAUTION: Always be careful when
handling refrigerants. Refrigerants
can cause frostbite. When exposed
to the atmosphere in the liquid state,
refrigerants evaporate rapidly,
freezing anything they contact.
CAUTION: When removing any
refrigerant from a unit, use a
recovery process that prevents or
absolutely minimizes refrigerant
escape into the atmosphere.
Refrigerants can be harmful to the
Earth’s ozone layer.
1-2
Refrigeration Oil Hazards
WARNING: Avoid refrigeration oil
contact with the eyes. Refrigeration
oil can cause serious eye injury.
Avoid prolonged or repeated contact
of refrigeration oil with skin or
clothing. Wash thoroughly after
handling refrigeration oil to prevent
irritation.
CAUTION: Do not use the wrong
refrigeration oil. It will damage
equipment and void the warranty.
CAUTION: Do not mix refrigeration
oils. Mixing incompatible oils will
damage the system.
CAUTION: Use dedicated
equipment to prevent contaminating
the system with the wrong type of oil
or refrigerant.
CAUTION: Store refrigeration oil in
an approved sealed container to
avoid moisture contamination.
CAUTION: When adding oil to a
system, do not expose the
refrigeration oil to the air any longer
than necessary. Moisture in the oil
will increase evacuation times, and
can contaminate the system.
CAUTION: Wipe up spills
immediately. Oil can damage paints
and rubber materials.
Electrical Hazards
Low Voltage
WARNING: Control circuits are low
voltage (12 volts dc). This voltage
potential is not considered
dangerous, but a large amount of
current (over 30 amperes) can cause
severe burns if shorted or grounded.
25 October 2005
 Section 1 - Safety Information

WARNING: Do not wear jewelry, Microprocessor Precautions

watches or rings. These items can The following procedures must be followed
short out, damage equipment, and when working on microprocessor-based
cause severe burns to the wearer. control systems.
• Never use testers consisting of a battery
Battery Removal and a light bulb to test circuits on any
DANGER: When removing a battery, microprocessor-based equipment.
ALWAYS disconnect the negative • Always turn the TriPac unit off by pressing
battery terminal first. Then remove the HMI Main Power On/Off key before
the positive terminal. When connecting or disconnecting the truck
RECONNECTING THE BATTERY batteries. Read and follow all truck
TERMINALS, CONNECT THE instructions for removing batteries.
POSITIVE TERMINAL (+) FIRST, AND
CONNECT THE NEGATIVE (-) • Always use TriPac Service Procedure
TERMINAL LAST. B02A to replace the Interface Board.
• Always use TriPac Service Procedure
A03B to replace the HMI Controller.
This is done because the frame is grounded
to the negative battery terminal. If the
negative terminal is still connected, a
complete circuit exists from the positive
terminal of the battery to the frame. If a
conductive tool contacts the positive side and
the frame simultaneously, a spark or arcing
will occur. If there are sufficient hydrogen
gases emitted from the battery, a battery
explosion might occur, which can damage
equipment and cause serious injury or even
death.

Welding Precautions
Precautions must be taken before electric
welding is performed on any portion of the
unit or the vehicle to which unit is attached. It
is necessary to ensure that welding currents
are not allowed to flow through the electronic
circuits of the TriPac. For more information,
see TriPac Service Procedure A26A in
Section 6 of this manual.

25 October 2005 1-3

Section 1 - Safety Information
First Aid
First Aid: Refrigerants
In the event of frost bite, the objectives of
First Aid are to protect the frozen area from
further injury, to warm the affected area
rapidly, and to maintain respiration.
EYES: For contact with liquid, immediately
flush eyes with large amounts of water. Get
prompt medical attention.
SKIN: Flush area with large amounts of
lukewarm water. Do not apply heat. Remove
contaminated clothing and shoes. Wrap
burns with dry, sterile, bulky dressing to
protect from infection and injury. Get prompt
medical attention. Wash contaminated
clothing before reuse.
INHALATION: Move victim to fresh air and
use CPR (Cardio Pulmonary Resuscitation)
or mouth-to-mouth resuscitation, if
necessary. Stay with victim until emergency
medical personnel arrive.
First Aid: Refrigeration Oil
EYES: In case of eye contact, immediately
flush with plenty of water for at least 15
minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control
center or physician.
First Aid: Engine Coolant
EYES: In case of eye contact, immediately
flush with plenty of water for at least 15
minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control
center or physician.
1-4
First Aid: Electrical Shock
IMMEDIATE action must be initiated after a
person has received an electrical shock.
Obtain immediate medical assistance if
available.
The source of the shock must be immediately
removed by either shutting down the power
or removing the victim from the source.
If it is not possible to shut off the power, the
wire should be cut with either an insulated
instrument (e.g., a wooden handled axe or
cable cutters with heavy insulated handles) or
by a rescuer wearing electrically insulated
gloves and safety glasses. Whichever
method is used do not look at the wire while it
is being cut. The ensuing flash can cause
burns and blindness.
If the victim has to be removed from a live
circuit, pull the victim off with a
non-conductive material.
DO NOT TOUCH the victim! You can receive
a shock from current flowing through the
victim’s body.
Use the victim’s coat, a rope, wood, or loop
your belt around the victim’s leg or arm and
pull the victim off.
After separating the victim from power
source, check immediately for the presence
of a pulse and respiration.
• If a pulse is not present, start CPR (Cardio
Pulmonary Resuscitation) and call for
emergency medical assistance.
• If a pulse is present, respiration may be
restored by using mouth-to-mouth
resuscitation, but call for emergency
medical assistance.
25 October 2005
 Section 2 - Hardware Description
General Description. . . . . . . . . . . . . . . . . . . .2-2
TriPac Components . . . . . . . . . . . . . . . . . . . .2-3
TriPac HMI Controller . . . . . . . . . . . . . . . . .2-3
TriPac APU (Auxiliary Power Unit) . . . . . . .2-3
TriPac Control Box . . . . . . . . . . . . . . . . . . .2-4
TriPac Interface Board . . . . . . . . . . . . . . . .2-4
Interface Board Harness Terminals . . . .2-5
Smart FETs (Field Effect Transistors). . .2-5
CYCLE-SENTRY Module. . . . . . . . . . . .2-6
Control Relays . . . . . . . . . . . . . . . . . . . .2-6
Reset Switch . . . . . . . . . . . . . . . . . . . . .2-6
System Fuses and Fusible Links . . . . . .2-6
Unit Power . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Optional TriPac/Truck Integration . . . . . . . .2-7
Ignition Switch in the On or Start Position . .2-7
Ignition Switch in the Off or Accessory
Position. . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Optional Standby Switch . . . . . . . . . . . . . . .2-7
Optional Power Inverter . . . . . . . . . . . . . . . .2-7
Engine System Components . . . . . . . . . . . .2-7
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . .2-7
Engine On/Off Switch . . . . . . . . . . . . . . . . .2-7
Coolant Pump . . . . . . . . . . . . . . . . . . . . . . .2-7
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . .2-8
Pre-cooler . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Preheat Buzzer . . . . . . . . . . . . . . . . . . . . . .2-8
Preheat Thermistor . . . . . . . . . . . . . . . . . . .2-8
Starter Solenoid. . . . . . . . . . . . . . . . . . . . . .2-8
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Optional Arctic Package . . . . . . . . . . . . . . .2-8
Flywheel Sensor . . . . . . . . . . . . . . . . . . . . .2-8
High Coolant Temperature Switch. . . . . . . .2-9
Low Oil Pressure Switch . . . . . . . . . . . . . . .2-9
Air Conditioning Components . . . . . . . . . . .2-9
Compressor. . . . . . . . . . . . . . . . . . . . . . . . .2-9
Compressor Clutch . . . . . . . . . . . . . . . . . . .2-9
Condenser. . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Freeze-stat Switch . . . . . . . . . . . . . . . . . . .2-9
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . .2-9
Condenser Fan Motor . . . . . . . . . . . . . . . . .2-9
Evaporator Blower Motor . . . . . . . . . . . . . .2-9
Binary Switch . . . . . . . . . . . . . . . . . . . . . .2-10
High Pressure Cutout Switch (HPCO) .2-10
Low Pressure Cutout Switch (LPCO) . .2-10
Air Heater Components. . . . . . . . . . . . . . . .2-10
Air Heater Fuel Metering Pump. . . . . . . . .2-10
Air Heater . . . . . . . . . . . . . . . . . . . . . . . . .2-10
 Section 2 - Hardware Description

TriPac HMI Controller

Microprocessor
Software
Sleeper Cab Keypad
Temperature Sensor Display

Engine Components Air Conditioning

Engine On/Off Switch Components
Preheat Thermistor
TriPac Interface Board
Compressor Clutch
Glow Plugs and Evaporator Blower
Fuel Pump Control Box Condenser Fan
Fuel Solenoid Pull-In Microprocessor Binary Switch
Fuel Solenoid Hold Cycle Sentry Module HPCO
Starter Solenoid Run Relay LPCO
Starter Preheat Relay Freeze-stat
Flywheel Sensor Start Relay
Alternator Smart FET Outputs
Oil Pressure Switch Power Strip
Coolant Temp Switch Terminal Boards
High Water Temp Switch 5A Controller Fuse
Optional Artic
Pre-cooler Preheat Buzzer
Reset Switch Temperature Switch

Optional Truck
Standby Switch
Diesel-Fueled
Air Heater

Figure 2-1: TriPac Control Block Diagram

25 October 2005 2-1

Section 2 - Hardware Description
General Description
The Thermo King TriPac Auxiliary
Heating/Cooling Temperature Management
System allows drivers to reduce unnecessary
truck engine idling to conserve diesel fuel,
reduce maintenance costs and save money.
TriPac provides truck cab sleeper
compartment climate control, truck battery
charging and truck engine preheating.
Available options include an Arctic Package
for additional truck engine preheating and a
power inverter to supply 120 vac.
By using TriPac, drivers can reduce fuel cost,
rest comfortably during stops and comply
with local, state and federal anti-idle laws.
Reducing unnecessary truck engine idling
also reduces engine wear and extends
engine maintenance intervals. TriPac’s own
diesel engine uses an automatic start/stop
feature for additional fuel efficiency.
• The APU (Auxiliary Power Unit) is
mounted on the truck frame. TriPac’s 7.5
HP two-cylinder diesel engine is EPA Tier
2 approved. A 65 amp alternator provides
power to operate the TriPac unit and
charge the truck batteries.
• Cooling in the truck cab sleeper
compartment is provided by an
evaporator coil and evaporator blower
(typically located under the bunk in the
truck cab sleeper compartment).
Conditioned air from the evaporator is
supplied through air vents installed in the
truck cab sleeper compartment wall. A
condenser coil and condenser fan are
mounted on the outside rear of the truck
cab sleeper compartment. The
compressor is located in the APU. R134a
refrigerant is utilized.
2-2
• Heating in the truck cab sleeper
compartment is provided by means of a
separate diesel fuel fired air heater.
Heated air is supplied by an internal fan in
the heater via an air vent in the truck cab
sleeper compartment. Diesel fuel for the
heater is drawn from the tractor fuel tank.
The evaporator blower can run during
heating operation for additional air flow if
desired.
• Truck battery charging is by means of the
TriPac alternator located in the APU. Low
battery voltage sensing is used to
automatically start the APU as required, to
maintain the truck batteries in a charged
condition.
• The optional Artic Package senses the
coolant temperature of the truck engine at
the APU . If the coolant temperature falls
below 30°F (-1°C) the TriPac engine
located in the APU will start. The TriPac
engine coolant is circulated through the
truck engine until the temperature of the
coolant at the APU reaches 90°F (32°C).
The TriPac engine will then shut down,
unless additional running is required for
temperature control or to charge the truck
batteries.
• The optional power inverter supplies 120
Vac to power small appliances in the
truck. The power inverter is connected
directly to the truck batteries. The TriPac
unit will start and stop as required to
charge the truck batteries, so long as the
TriPac Main Power is turned on and the
APU is enabled..
25 October 2005
 Section 2 - Hardware Description
TriPac Components TriPac APU (Auxiliary Power Unit)
The TriPac APU is mounted on the frame rail
TriPac HMI Controller of the truck. The APU contains the following
The microprocessor based HMI (Human components:
Machine Interface) Controller is the primary • 7.5 hp 2 cylinder - EPA Tier 2 engine
interface between the user and the TriPac
unit. The HMI Controller is typically mounted • 65-amp alternator
on a wall of the truck cab sleeper • Thermo King TM-15-XD compressor
compartment. A temperature sensor is
connected to the HMI Controller to measure • Electric compressor clutch
truck cab sleeper compartment temperature. • Engine On/Off switch
The control cable from the HMI Controller is
connected to the TriPac Interface Board. • Preheat buzzer
The HMI Controller allows the driver to turn
the unit on and off, adjust the temperature,
select cooling or heating operation, control
fan speed and program unit functions.

For complete operating details see Section 4

of this manual.

25 October 2005 2-3

Section 2 - Hardware Description
TriPac Control Box
The Control Box contains the Interface
Board. The Reset Switch is mounted on the
side of the control box. The Control Box is
typically located in a storage compartment
under the truck cab sleeper compartment. It
should be mounted so the Reset Switch is
accessible.
TriPac Interface Board
The Interface Board connects the HMI
Controller to the TriPac system control
components. The Interface Board utilizes a
board mounted microprocessor and a
CYCLE-SENTRY Module to control the
system as required by demand and
conditions.

PWM PWM
1 2
H 8S 8D 8 7A

BL1
PCF
BL2
8DP
FS2
26 Run Relay
Preheat
FS1
Relay
7D
CH
7CF
CH
8FET
Cycle Sentry Module L1
Starter
7CL Relay
H1
7X
W1
LWT
5

SBY 5A Fuse
Power Strip uP
DIM
J1
7CLA

D+

SEN

Figure 2-2: Interface Board (located inside the Control Box)

2-4 25 October 2005

 Section 2 - Hardware Description
Interface Board Harness Terminals Harness Terminals, Interface Board
The following table defines the Interface Terminal Wire Function
Board connections. / Socket #
Harness Terminals, Interface Board 7X 7X Low voltage or high truck
cab temperature start
Terminal Wire Function signal output
/ Socket # LWT LWT Pre-cooler fan control
PWM1 PWM Evaporator blower motor SBY SBY Standby Integration input
1 variable speed selector DIM DIM Not used
PWM2 PWM (not used) 7CLA 7CLA Air conditioning fault
2 input
H H Glow plugs D+ D+ Initial excitation and
8S 8S APU engine starter alternator charging
solenoid signal
8D 8D APU engine fuel SEN SEN Battery voltage sensing
solenoid, hold-in coil, 2A 2A Battery power
fuel pump, Reset Switch
8 8 APU engine-ready signal Smart FETs (Field Effect Transistors)
at interface board and
Run Relay contact The Smart FETs control power to the lower
7A 7A CYCLE-SENTRY current loads. A Smart FET will de-energize
Module start signal the circuit if the current flow is high or low, in
order to protect the connected device.
BL1 BL1 Preheat thermistor
BL2 BL2 Preheat thermistor Smart FET Descriptions
FS2 FS2 Flywheel (speed) sensor FET Location Description
FS1 FS1 Flywheel (speed) sensor No.
CH CH Ground Q1 PWM1 Output to evaporator
(GND) blower motor variable
CH CH Ground speed selector
(GND) Q2 PWM2 not used
L1 GRY/ Air heater temperature Q3 PCF Output to the
RED control wiring harness pre-cooler fan
H1 (not (not used) Q4 8DP Output to the fuel
used) solenoid pull-In coil
W1 BRN/ Air heater temperature Q5 7CL Output to the
WHT/ control wiring harness compressor clutch
BLK Q6 26 Output to the air heater
PCF PCF Pre-cooler fan output Q7 7X Output for low voltage
8DP 8DP APU engine fuel or high truck cab
solenoid, pull-in coil temperature start
output signal
26 YLW Air heater “on” output Q8 7D not used
7D 7D not used Q9 7CF Output to condenser
7CF 7CF Condenser fan motor fan motor
output Q10 8FET Output Power to Run
8FET 8FET TriPac Main Power to
the Engine On/Off switch
7CL 7CL Clutch output

25 October 2005 2-5

Section 2 - Hardware Description
CYCLE-SENTRY Module
The CYCLE-SENTRY Module controls the
three relays used to start and run the diesel
engine. These relays are the Preheat Relay,
Run Relay, and Starter Relay. The thermistor
supplies engine block temperature to the
CYCLE-SENTRY Module to determine
required preheat time. The flywheel sensor
supplies engine speed information to the
CYCLE-SENTRY Module to determine if the
engine has started.
Control Relays
The control relays are used to supply power
to high amperage loads. The are located on
the interface board.
Preheat Relay - The Preheat Relay is
energized to power the glow plugs and start
the buzzer via the “H” circuit. This preheats
the diesel engine. The CYCLE-SENTRY
Module energizes the Preheat Relay by
providing a path to ground for the Preheat
Relay coil.
Run Relay - The Run Relay is energized to
provide power to the 8D circuit. The
CYCLE-SENTRY Module energizes the Run
Relay by providing a path to ground for the
Run Relay coil.
Starter Relay - The Starter Relay is
energized to power the Starter Solenoid via
the 8S circuit. This cranks the diesel engine.
The CYCLE-SENTRY Module energizes the
Starter Relay by providing a path to ground
for the Starter Relay.
Reset Switch
The Reset Switch functions as an engine
safety shutoff circuit. It is located in the TriPac
control box. If the contacts close on either the
engine Coolant High Temperature Switch or
the Low Oil Pressure Switch a ground path is
created from the 20 wire through the Reset
Switch. As the resistor in the Reset Switch
heats, the contacts in the Reset Switch open.
Power is removed from the 8 circuit to shut
the engine down. The switch is reset by
pressing the Reset Switch button on the
outside of the TriPac control box.
System Fuses and Fusible Links
The table below describes the fuses and
fusible links used to protect the TriPac
electrical components.
Fuse Sizes and Descriptions:
Amps Location Description
20 Batteries Air heater
5 Interface HMI Controller
Board protection
---- Auxiliary 12 gauge fusible link in
Power Unit Main Power circuit (2
wire)
---- Auxiliary 20 gauge fusible link in
Power Unit Battery Sense circuit
(SEN wire)
30 Control 8S starter solenoid
Box
30 Control H wire to glow plugs
Box

2-6 25 October 2005

 Section 2 - Hardware Description
Unit Power
Electrical power is supplied to the TriPac unit
by the truck batteries. When the TriPac
engine starts the TriPac alternator provides
electrical power for TriPac operation. The
engine and alternator are mounted inside the
TriPac APU enclosure.
Optional TriPac/Truck
Integration
The TriPac unit typically does not operate
when the truck engine is running. This is
accomplished by placing TriPac in Standby
mode when the truck engine is running.
TriPac can also be forced to standby mode
with the optional Standby Switch.
Ignition Switch in the On or Start
Position
When the truck ignition switch is in the On or
Start position, power is routed to the interface
board SBY terminal via the SBY wire. When
this occurs, the TriPac unit is forced to
Standby mode and all outputs are
de-energized. The HMI Controller will display
[SBY].
Ignition Switch in the Off or
Accessory Position
When the truck’s ignition switch is in the Off
or Accessory position, power is removed from
the SBY terminal. TriPac will operate
normally.
Optional Standby Switch
The optional Standby Switch is mounted on
the truck dashboard.
• When the Standby Switch is in the On
position, TriPac operates as stated above.
• When the Standby Switch is in the Off
position, power is routed to the interface
board SBY terminal via the SBY wire.
When this occurs, the TriPac unit is forced
to Standby mode and all outputs are
de-energized. The HMI Controller will
display [SBY]. TriPac will remain in
standby until the Standby switch is placed
in the On position.
25 October 2005
Optional Power Inverter
An optional 12 Vdc to 120 Vac power inverter
is available. The inverter is normally
connected directly to the truck batteries.
Power inverter features will vary, depending
upon the brand and model used. Typically,
when the power inverter detects an AC load,
it automatically turns on to supply AC power.
IMPORTANT: If TriPac is enabled, the battery
voltage level is monitored. TriPac will start
and stop as necessary to charge the truck
batteries. If the TriPac is not enabled, the
inverter could drain the truck batteries below
the level required to start the truck or the
TriPac unit.
Engine System Components
Diesel Engine
TriPac power is provided by a 7.5 hp,
two-cylinder direct injection diesel engine that
is housed in the APU. A belt drive system
transfers engine power to the compressor
and the alternator.
Engine On/Off Switch
The Engine On/Off switch is located inside
the APU in the upper right corner. This switch
must be on for the TriPac diesel engine to
operate. The switch also functions as a
service safety switch. The Engine On/Off
switch must be turned off before maintenance
is performed on the TriPac APU. Turning this
switch off prevents the diesel engine from
starting. The HMI Controller will display [Eng].
Coolant Pump
The belt-driven centrifugal pump draws
coolant from the truck engine, through the
pre-cooler, circulates it through the TriPac
engine cylinder block and head, and sends it
back to the truck engine block.
Glow Plugs
The glow plugs are energized to preheat the
diesel engine to aid in quick starting. The
preheat time is determined by the
temperature sensed by the Preheat
2-7
Section 2 - Hardware Description
Thermistor. If the engine is warm the preheat
time might be only a few seconds. The glow
plugs are energized by the Interface Board
via the H wire.
Fuel Pump
The electric fuel pump supplies fuel from the
truck fuel tank, through an in-line fuel filter,
and to the injection pump. The fuel pump is
energized by the Interface Board Run Relay
via the 8D wire.
Fuel Solenoid
The fuel solenoid starts and stops fuel flow to
the TriPac diesel engine. The fuel solenoid
features two coils: a pull-in coil and a hold
coil. The pull-in coil draws approximately 40
amperes and the hold coil draws
approximately 1 ampere. The pull-in coil is
energized by the Interface Board for 1.4
seconds via the 8DP wire to shift the fuel
linkage. The hold coil is energized by the
Interface Board Run Relay via the 8D wire to
hold the solenoid open. Removing power
from the 8D wire shuts the Tripac engine
down.
Pre-cooler
The Pre-cooler reduces the temperature of
the hot coolant from the truck engine before
the coolant is circulated through the TriPac
diesel engine. This prevents the TriPac diesel
engine’s thermostat from opening
prematurely. The pre-cooler fan will turn on if
the coolant exceeds 120°F (49°C) and turns
off when the coolant temperature falls below
105°F (40°C). The Pre-cooler fan is
energized by the Interface Board via the PCF
wire.
Preheat Buzzer
An audible device that alerts the TriPac user
that the diesel engine is preheating and
preparing to start. It is energized during
preheat by the H wire.
2-8
Preheat Thermistor
The preheat thermistor is located in a bolt
hole in the engine block. It is a
variable-resistance device that reacts to
changes in temperature. It is connected to
the CYCLE-SENTRY Module to supply
engine block temperature information. The
CYCLE-SENTRY Module uses this
temperature information to determine preheat
time. The preheat thermistor is connected to
the Interface Board via the BL1 and BL2
wires.
Preheat time for a cold engine may be as
long as 120 seconds. Preheat time on a
warm engine might be only a few seconds.
Starter Solenoid
The starter solenoid is energized by the
Interface Board via the 8S wire to crank the
diesel engine.
Alternator
The 65 Amp TriPac alternator supplies power
to operate the TriPac unit and to charge the
truck batteries. Alternator output is via the B+
wire.
Optional Arctic Package
The Arctic Package starts and stops the
TriPac diesel engine to maintain the coolant
at a minimum temperature of 30°F (-1°C). An
Artic Package switch is mounted on the tube
between the pre-cooler and the water pump
inlet inside the APU. When the truck engine
coolant temperature falls below 30°F (-1°C)
the Artic Package switch closes and sends a
signal to the TriPac Interface Board via the
7A wire. The TriPac diesel engine will start
and run. When the truck coolant temperature
reaches 90°F (32°C) the Artic Package
switch opens to shut the Tripac engine down
if no other conditions require the engine to
run.
Flywheel Sensor
The flywheel sensor is a proximity sensor that
generates a pulse as each flywheel tooth
passes the sensor. The Interface Board
performs the calculations necessary to
25 October 2005
 Section 2 - Hardware Description
convert the pulses into engine RPM. This
RPM information is used by the Interface
Board and CYCLE-SENTRY Module to
determine if the engine has started and if it is
running.The sensor is connected to the
Interface Board via the FS1 and FS2 wires.
High Coolant Temperature Switch
The high coolant temperature switch closes if
the TriPac engine coolant temperature
exceeds 220°F (104°C). This completes a
ground path for the 20 wire through the Reset
Switch. When the Reset Switch trips it
removes power from the 8 wire and shuts the
engine down. [Eng] will appear in the HMI
Controller display and the red System Fault
LED will light. The fault code must be cleared
and the reset switch closed before further
operation is allowed.
Low Oil Pressure Switch
The low oil pressure switch closes if the
TriPac engine oil pressure drops below 15
psig (103 kPa). This completes a ground path
for the 20 wire through the Reset Switch.
When the Reset Switch trips it removes
power from the 8 wire and shuts the engine
down. [Eng] will appear in the HMI Controller
display and the red System Fault LED will
light. The fault code must be cleared before
further operation is allowed.
Air Conditioning Components
Compressor
The TriPac air conditioning compressor is
located in the TriPac APU and is driven by
the diesel engine when the compressor
clutch is engaged.
Compressor Clutch
The compressor clutch is mounted on the
compressor shaft. The compressor clutch is
energized by the Interface Board when truck
cab sleeper compartment cooling is required.
Any time the compressor clutch is energized
the condenser fan motor is also energized.
25 October 2005
Condenser
The condenser is typically mounted on the
exterior rear of the truck cab sleeper
compartment.
Evaporator
The evaporator is typically mounted under
the bunk inside the truck cab sleeper
compartment.
Freeze-stat Switch
This switch monitors the temperature of the
evaporator coil to prevent the coil from
freezing or icing. The Freeze-stat opens
when the evaporator coil temperature is at
31°F (-0.5°C) to de-energize the compressor
clutch. When the evaporator coil temperature
rises above the thermostat’s closing
temperature of 39°F (4°C) the Freeze-stat
switch closes to re-energize the compressor
clutch. Air conditioning resumes.
Receiver-Drier
Removes moisture, particles and minimal
amounts of acid from the refrigerant that
circulates through the system. It is located
near the condenser.
Condenser Fan Motor
The condenser fan moves air across the
TriPac condenser coil. The condenser fan
motor is energized any time the compressor
clutch is energized.
Evaporator Blower Motor
The evaporator blower moves air across the
TriPac evaporator coil and through the air
ducts to supply cooled air to the truck cab
sleeper compartment. The evaporator blower
features three speeds: Low, Medium, and
High. Blower speed is selected at the HMI
Controller. In addition, the evaporator blower
can be used to circulate cab air throughout
the truck cab sleeper compartment. The air
heater uses it’s own internal fan to circulate
heated air.
2-9
Section 2 - Hardware Description
Binary Switch HMI Controller, and Heat mode is turned on
or off at the HMI Controller. The heater shuts
The Binary Switch is mounted on the
down if its temperature exceeds an overheat
receiver-drier, typically near the TriPac
limit of 240°F (115°C).
condenser. The Binary Switch monitors
system pressure and incorporates two
The air heater, wiring harness, and ducting
separate switches.
are typically located in a storage
compartment under the truck cab sleeper
High Pressure Cutout Switch (HPCO)
compartment. The air heater combustion air
If refrigerant discharge pressure rises above inlet ducting, exhaust ducting, and the fuel
325 psi (22.4 bar) the normally closed switch inlet line are located below and outside of the
opens and removes power from the 7CLA truck cab sleeper compartment.
wire. The Interface Board will de-energize the
The evaporator blower can be run along with
compressor clutch and [AcS] will appear in
the heater for additional air circulation if the
the HMI Controller display and the red
TriPac APU is enabled.
System Fault LED will light.
The air heater receives electrical power from
When the discharge pressure falls below 230
the truck battery via the RED wire. This circuit
psi (22.4 bar) the switch closes. The System
is protected by a 20 amp fuse. The YLW wire
Fault code must be cleared by the operator
at the 26 terminal on the Interface Board
before further operation is allowed.
connects to the air heater. It provides a signal
to turn the air heater on. The GRY/RED and
Low Pressure Cutout Switch (LPCO)
BRN/WHT wires supply setpoint information
If refrigerant system pressure falls below 22.5 to the heater.
psi (16 bar) the normally closed switch opens
The air heater’s microprocessor monitors the
and removes power from the 7CLA wire. The
functions and operations of the air heater.
Interface Board will de-energize the
The air heater’s microprocessor is also
compressor clutch, [AcS] will appear in the
programmed to recognize air heater fault
HMI Controller display and the red System
codes. The five most-recent fault codes are
Fault LED will light. This prevents system
retained in the air heater’s microprocessor
damage should the refrigerant charge be lost.
memory. Older fault codes are deleted from
The fault code must be cleared before further
memory as new alarm codes occur. Fault
operation is allowed.
codes can be retrieved and read by using a
special Fault Reader. See Section 5,
Air Heater Components Diagnostics and Section 6 Service
Procedures for a description of air heater
Air Heater Fuel Metering Pump fault codes and how to use the Fault Reader.
A dedicated heater fuel metering pump
transfers diesel fuel from the truck fuel tank to
the air heater.

Air Heater
Several different diesel fueled air heaters are
available. The diesel-fueled air heater
provides hot air through a heat outlet grille
near floor level in the truck cab sleeper
compartment. The return inlet air vent is also
located at floor level, but some distance from
the discharge outlet vent. The air heater
temperature setpoint is programmed at the

2-10 25 October 2005

 Section 3 - Software Description
Software Operation . . . . . . . . . . . . . . . . . . . .3-1
Software Revisions and Changes . . . . . . . .3-1
HMI Controller: Program Features . . . . . . . .3-1
HMI Controller Program Structure. . . . . . . .3-1
Programming Aids. . . . . . . . . . . . . . . . . . . .3-1
Programming the HMI Controller Program
Features . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Entering Program Mode . . . . . . . . . . . . . . .3-2
Entering Program Features and Program
Selections. . . . . . . . . . . . . . . . . . . . . . . .3-2
Program Features Menu . . . . . . . . . . . . . . .3-4
Program Mode [ppp]. . . . . . . . . . . . . . . .3-4
HMI Controller Temperature Display
[ctd] . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Display Dimmer Level [ddL] . . . . . . . . . .3-4
HMI Controller Temperature Scale [ctS] .3-5
HMI Controller Dead Band Degrees
[dbd]. . . . . . . . . . . . . . . . . . . . . . . . . .3-5
HMI Controller Temperature Offset [cto].3-5
Optional Sensor Use [OSU] . . . . . . . . . .3-5
Optional Temperature Offset [oto] . . . . .3-6
Cool (A/C) Mode Enabled [C]. . . . . . . . .3-6
A/C Clutch Delay Timer [cdt] . . . . . . . . .3-6
Defrost Mode Enabled [d]. . . . . . . . . . . .3-6
Defrost Time Period [dtP] . . . . . . . . . . . .3-7
Defrost Time Ratio [dtr] . . . . . . . . . . . . .3-7
Heat Mode Enabled [H] . . . . . . . . . . . . .3-7
Espar Air Heater Control Enabled [EHC]3-7
Espar Air Heater Temperature Offset
[Eto] . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Fan Only Mode Enabled [F] . . . . . . . . . .3-8
Auto Fan Speed Enabled [AFS] . . . . . . .3-8
Engine High Speed Timer [HSS] . . . . . .3-8
Engine Low Speed Lockout [LSL] . . . . .3-8
Engine Delay Off Timer [Edo]. . . . . . . . .3-9
External Power Source [EPS] . . . . . . . .3-9
 Section 3 - Software Description
Software Operation
The software that operates the HMI
Controller and Interface Board
microprocessors contains a complex set of
instructions. The microprocessors examine
the conditions of all the inputs and compares
them to the instructions contained in the
software. The outputs are then energized, as
required, by the software instructions.
There is no way to determine from the
schematic or wiring diagrams exactly what
conditions will cause TriPac to operate in a
particular mode. This decision is made by the
microprocessors and software after analyzing
all the input conditions and the setpoint
temperature.
However, the operating mode can usually be
deduced from the existing conditions. For
example, if a 70 F (21.1 C) setpoint
temperature is selected and the truck cab
sleeper compartment temperature, as
indicated by the Control Sensor (thermostat),
is 80 F (26.7 C), the TriPac should operate in
A/C mode when selected.
Software Revisions and Changes
The HMI Controller software revision level
covered by this manual is revision level r20.
The Interface Board software revision level
covered by this manual is revision level CC.
25 October 2005
HMI Controller: Program
Features
TriPac operational settings and parameters
can be viewed or programmed using the HMI
Controller. See Figure 2-1 for an illustration of
the menu layout and programmable codes,
“HMI Controller Program Features Menu”.
HMI Controller Program Structure
The HMI Controller parameters that can be
programmed are indicated in Figure 2-1.
Using the HMI Controller, the TriPac operator
can enable A/C, Heat, and Fan Speed
modes, and modify other system operating
parameters.
Programming Aids
When programming the HMI Controller,
obtain and complete a copy of the Setup
Sheet shown in TriPac Service Procedure
A02A. Be certain that all customer-specified
settings are included when completing the
setup sheet. The sheet is used to confirm
each entry. It also assures that the correct
customer settings are programmed.
3-1
Section 3 - Software Description
Programming the HMI Controller Program Features
The setpoints for truck cab sleeper compartment temperatures (cooling or heating), and the
parameters for other TriPac operations, must be programmed into the microprocessor on the
HMI Controller. The TriPac user can choose from the currently used Program Features. Each
Program Feature can have one or more Program Selections that provides choices or defaults.
See the HMI Program Feature tables on the following pages for details.

Entering Program Mode • After a Program Feature selection is

entered, the HMI Controller Display
• Press the Main Power On/Off key to on.
advances to the next Program Feature in
• Simultaneously press and hold the Up the sequence.
Arrow Key and Down Arrow Key until
• After the Program Feature selections
the Program Feature menu [PPP]
have been entered and saved as desired,
appears in the HMI Controller Display.
press the Mode Key to return to the [PPP]
• If the Up Arrow Key and Down Arrow Program Feature.
Key are not pressed simultaneously and
• When [PPP] appears, press the Fan Key
[PPP] does not appear, wait until the
to save all of the entered Program
display dims before trying to press the
Selections. TriPac then returns to normal
keys again.
operation.
• If no key is pressed for 5 seconds during
See Figure 2-1 for the Program Features
Program mode, TriPac reverts back to
menu.
normal operation. No settings entered
during Program mode will be saved.
• If the Fan Key is pressed while [PPP] is
displayed, the Program mode settings are
saved.
• The Program Features appear on the HMI
Controller Display in the order indicated in
Figure 2-1. When the last feature is
reached, the list starts over from the
beginning.

Entering Program Features and

Program Selections
• From the [PPP] Program Feature menu,
press the Mode Key to advance through
the Program Features.
• At a desired Program Feature, press the
Up Arrow Key or Down Arrow Key once
to view the selections for that Program
Feature. Press the key again to change
the selection for the feature.
• Press the Fan Key to enter the desired
selection for a specific Program Feature.
Press the Mode Key to escape from a
Program Feature without saving the
change.

3-2 25 October 2005

 Section 3 - Software Description

HMI Controller
Programming Steps at the HMI Controller:
1. Press the Main Power On/Off Key to On.
2. Press the Up Arrow Key and Down Arrow Key simultaneously to access the Program Codes.
3. Press the Mode Key to advance through the Program Codes (the arrows below indicate the sequence of the
Program Codes)
Program Features 4. Press the Up Arrow Key or Down Arrow Key to view the Program Selections for a specific Program Code.
5. Press the Fan Speed Key to save a Program Selection. As required, press the Mode Key to escape from a
Menu
Program Selection without saving it.
Simultaneously 6. After all Program Codes are reviewed, press the Mode Key to return to the PPP Program Code.
press and hold Up 7. Press the Fan Speed Key to save all of the desired Program Selections.
and Down Arrow
Keys to access
Bold Underlined type = default setting
ctd
(HMI Controller
Temperature Display)
PPP ddL cts dbd
(Program Mode)
cts = Control Temperature (Display Dimmer (HMI Controller (HMI Controller
Sensor Level) Temperature Scale) Deadband Degrees)
A cXX = Controller
SPt = Setpoint
configuration
dbg = Debug 1 to 15 = Dimness F (Fahrenheit) or 1.0 to 10.0 degrees
(c01)
OFF = Off (unless setpoint levels (3) C (Celsius) (5 degrees)
rXX = Software
changed)
revision
ots = Optional temperature
number
sensor

OSU
cto (Optional Sensor Use) oto cdt
C
(HMI Controller (Optional (A/C Clutch Delay
(Cool Mode
Temperature Offset) OFF = Off Temperature Offset) Timer)
Enabled)
ctS = Control Temperature
-10 to 10 degrees Sensor -10 to 10 degrees 0 to 999 seconds
y (yes) or n (no)
(0 degrees) otS = Optional Temperature (0 degrees) (8 seconds)
Sensor

d dtp
dtr H
(Defrost Mode (Defrost Time
(Defrost Time Ratio) (Heat Mode
Enabled) Period)
Enabled)
10 to 100 % (50)
y (yes) or n (no) 1 to 10 minutes (1)
[do not change] y (yes) or n (no)
[do not change] [do not change]

Eto
EHC F AFS
(Air Heater
(Air Heater Control (Fan Only Mode (Auto Fan Speed
Temperature Offset)
Enabled) Enabled) Enabled)
-10 to 10 degrees
y (yes) or n (no) y (yes) or n (no) y (yes) or n (no)
(0 degrees)

HSS
LSL Edo
(Engine High Speed EPS
(Engine Low Speed (Engine Delay Off
Timer) (External Power
Lockout) Timer)
Source A
0 to 999 minutes
y (yes) or n (no) 0 to 999 minutes
(2 minutes) y (yes) or n (no)
[do not change] (15 minutes)
[do not change]

Figure 2-1: HMI Controller Program Features Menu

25 October 2005 3-3

Section 3 - Software Description
Program Features Menu HMI Controller Temperature Display [ctd]
The Program Features menu allows overall Program ctd
unit operation to be configured to specific end Feature
user requirements. These features are set to
HMI All
factory defaults when shipped, but can easily
Controller
be changed to suit the end user’s needs.
Rev
Interface All
Program Mode [ppp] Board Rev
Program PPP Program cts, SPt, dbg, OFF, otS
Feature Choices
HMI All Default SPt (Setpoint)
Controller Exceptions n/a
Rev Description Determines what temperature
Interface All information normally appears
Board Rev in the HMI Controller Display.
Program cXX (HMI Controller [cts] Displays the temperature
Choices Configuration). Choices for for the Control Sensor inside
cXX are: the truck cab sleeper
compartment.
[c01] = TriPac
[SPt] Displays the setpoint
temperature selected by the
[rXX] (Software revision
driver.
number)
[dbg] The Debug mode is for
Default
use only by Software
Exceptions n/a Engineers. Do not use this
Description Acknowledges that the setting.
Program Feature mode has [OFF] The display remains off
been entered. Allows software unless the driver is changing
revision to be displayed. the setpoint.
[otS] Displays the temperature
for the optional temperature
sensor.
Display Dimmer Level [ddL]
Program ddL
Feature
HMI All
Controller
Rev
Interface All
Board Rev
Program 1 to 15 (dimness levels)
Choices
Default 3
Exceptions n/a
Description Selects the brightness level of
the HMI Controller display
backlight.

3-4 25 October 2005

 Section 3 - Software Description
HMI Controller Temperature Scale [ctS] HMI Controller Temperature Offset [cto]
Program ctS Program cto
Feature Feature
HMI All HMI All
Controller Controller
Rev Rev
Interface All Interface All
Board Rev Board Rev
Program -10 to 10 (degrees)
Program F° (Fahrenheit), C° (Celsius)
Choices
Choices
Default 0
Default F
Exceptions n/a
Exceptions n/a Description Selects the number of degrees
Description Selects the temperature scale of offset that the HMI
used by the HMI Controller, Controller sensor uses to
either Fahrenheit or Celsius. calibrate the control
temperature sensor to another
device.
HMI Controller Dead Band Degrees [dbd]
Optional Sensor Use [OSU]
Program dbd
Feature Program OSU
HMI All Feature
Controller HMI All
Rev Controller
Rev
Interface All
Board Rev Interface All
Board Rev
Program 1.0 to 10.0 (degrees,
Program OFF
Choices incremented by 0.1 degrees)
Choices ctS
Default 5 otS
Exceptions n/a Default OFF
Description Dead band degrees (or Exceptions n/a
hysteresis) is the number of Description Selects how an optional
degrees above setpoint that sensor (if installed) is used.
the temperature in the truck [OFF] The OFF setting turns
cab sleeper compartment must the optional sensor off.
rise before cool mode
operation is started. [ctS] Not currently used.
[otS] The Optional
Temperature Sensor setting
allows an optional temperature
sensor outside the truck to be
enabled. If this feature is
enabled then the [ctd] feature
above must be set to [otS].
The display will then show
outside temperature instead of
setpoint.

25 October 2005 3-5

Section 3 - Software Description
Optional Temperature Offset [oto] A/C Clutch Delay Timer [cdt]
Program oto Program cdt
Feature Feature
HMI All HMI All
Controller Controller
Rev Rev
Interface All Interface All
Board Rev Board Rev
Program -10 to 10 (degrees) Program 0 to 999 (seconds)
Choices Choices
Default 0 Default 8
Exceptions n/a Exceptions n/a
Description Selects the number of degrees Description Selects the time delay
of offset that an optional between when the HMI
temperature sensor (if Controller determines that the
applicable) uses to “calibrate” A/C mode should be initiated
the optional temperature and when the A/C clutch is
sensor to another device. energized. This time interval
allows a delay between the
engine starting and the
Cool (A/C) Mode Enabled [C] compressor clutch engaging.
Program C
Feature Defrost Mode Enabled [d]
HMI All
Controller Program d
Rev Feature
Interface All HMI All
Board Rev Controller
Rev
Program y (yes)
Choices n (no) Interface All
Board Rev
Default y
Program y (yes)
Exceptions n/a Choices n (no)
Description Determines if A/C mode is Default n
accessible at the
HMI Controller. Exceptions n/a
Description Not currently used. Do not
change the default (factory)
setting.

3-6 25 October 2005

 Section 3 - Software Description
Defrost Time Period [dtP] Heat Mode Enabled [H]
Program dtP Program H
Feature Feature
HMI All HMI All
Controller Controller
Rev Rev
Interface All Interface All
Board Rev Board Rev
Program 1 to 10 (minutes) Program y (yes)
Choices Choices n (no)
Default 1 Default y
Exceptions n/a Exceptions n/a
Description Not currently used. Do not Description Determines if Heat mode is
change the default (factory) accessible at the
setting. HMI Controller.

Defrost Time Ratio [dtr] Espar Air Heater Control Enabled [EHC]
Program dtr Program EHC
Feature Feature
HMI All HMI All
Controller Controller
Rev Rev
Interface All Interface All
Board Rev Board Rev
Program 10 to 100 (percent) Program y
Choices Choices n
Default 50 Default y
Exceptions n/a Exceptions n/a
Description Not currently used. Do not Description Determines if Heat mode will
change the default (factory) be used to control the air
setting. heater. To control the air
heater, the heat output stays
on continuously and the digital
potentiometer is enabled.
The y (yes) setting must be
selected, in order for Heat
mode to control the air heater.
Do not change the default
(factory) setting.
Do not use the n (no) setting.

25 October 2005 3-7

Section 3 - Software Description
Espar Air Heater Temperature Offset [Eto] Auto Fan Speed Enabled [AFS]
Program Eto Program AFS
Feature Feature
HMI All HMI All
Controller Controller
Rev Rev
Interface All Interface All
Board Rev Board Rev
Program -10 to 10 (degrees) Program y (yes)
Choices Choices n (no)
Default 0 Default n
Exceptions n/a Exceptions n/a
Description Selects the number of degrees Description Not currently used. Do not
of offset that the digital change the default (factory)
potentiometer in the air heater setting.
uses to “calibrate” the air
heater to another device. Engine High Speed Timer [HSS]
Program HSS
Fan Only Mode Enabled [F]
Feature
Program F HMI All
Feature Controller
HMI All Rev
Controller Interface All
Rev Board Rev
Interface All Program 0 to 999 (minutes)
Board Rev Choices
Program y (yes) Default 2
Choices n (no) Exceptions n/a
Default y Description Not currently used. Do not
Exceptions n/a change the default (factory)
Description Determines if the fan-only setting.
mode is accessible at the HMI
Controller. Engine Low Speed Lockout [LSL]
Program LSL
Feature
HMI All
Controller
Rev
Interface All
Board Rev
Program y (yes)
Choices n (no)
Default n
Exceptions n/a
Description Not currently used. Do not
change the default (factory)
setting.

3-8 25 October 2005

 Section 3 - Software Description
Engine Delay Off Timer [Edo]
Program Edo
Feature
HMI All
Controller
Rev
Interface All
Board Rev
Program 0 to 999 (minutes)
Choices
Default 15
Exceptions n/a
Description The Engine Delay Off Timer
reduces the amount of engine
on/off cycling by operating the
engine for x-minutes beyond
the time when the setpoint is
attained. Delaying the engine
off function also ensures that
the desired temperature has
been reached.
External Power Source [EPS]
Program EPS
Feature
HMI All
Controller
Rev
Interface All
Board Rev
Program y (yes)
Choices n (no)
Default y
Exceptions n/a
Description Selects how the Climate
Control System integrates with
an external power source,
such as the truck’s Ignition or
Accessory switch.
If y (yes) is selected, the HMI
Controller is forced to Standby
when voltage is present on the
SBY input.
If n (no) is selected, the
external power source input is
ignored and normal TriPac
power operations are allowed.

25 October 2005 3-9

Section 3 - Software Description

3-10 25 October 2005

 Section 4 Operation
HMI Controller . . . . . . . . . . . . . . . . . . . . . . . .4-1
HMI Controller Keys and Icons/LEDs:
Detailed Descriptions . . . . . . . . . . . . . . . .4-2
Standby Operation (optional) . . . . . . . . . . . .4-4
Options Used with Standby Operation . . . .4-4
Standby Truck Integration (optional). . . .4-4
Truck Integration Selector Switch
(optional) . . . . . . . . . . . . . . . . . . . . . .4-4
Turning on the Engine On/Off Switch . . . . .4-5
HMI Controller Operations . . . . . . . . . . . . . .4-5
Turning Main Power On . . . . . . . . . . . . . . .4-5
Enabling the APU . . . . . . . . . . . . . . . . . . . .4-6
Viewing the APU Engine Hourmeter
Display . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Selecting Operating Mode. . . . . . . . . . . . . .4-6
Selecting Fan Speed . . . . . . . . . . . . . . . . . .4-7
Selecting Setpoint Temperature . . . . . . . . .4-7
System Fault Indicator . . . . . . . . . . . . . . . . .4-8
Alarm Codes. . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Alarm Codes: Clearing Alarms . . . . . . . . . .4-9
TriPac Operating Conditions . . . . . . . . . . .4-10
 Section 4 Operation
HMI Controller
The HMI Controller consists of a display, touch sensitive keys and LED indicators. It is used to
control the operation of the TriPac unit. It is typically mounted on a wall in the truck cab sleeper
compartment.

1 2 3 4 5 6 7 8 9 10 11 12

18 13

17 16 15 14

Figure 2-1: HMI Controller (wall-mounted in the truck cab sleeper compartment)

HMI Controller Callouts

Callout Description Callout Description
1 Fan Mode LED 10 Medium Speed Fan LED
2 Heat Mode LED 11 Low Speed Fan LED
3 Defrost Mode LED (not used) 12 System Fault LED
4 Air Conditioning Mode LED 13 APU On/Off Key and LED
5 Inside or outside temperature display 14 Fan Speed Selector key
LED (illuminated when the inside or
outside temperature appears in the
display)
6 HMI Controller Display 15 Down Arrow key
7 Setpoint temperature display LED 16 Up Arrow key
(illuminated only when the truck cab
sleeper compartment setpoint is
shown in the display)
8 Auto Fan Speed LED 17 Mode key
9 High Speed Fan LED 18 Main Power On/Off key and LED

25 October 2005 4-1

Section 4 Operation
HMI Controller Keys and Icons/LEDs: Detailed Descriptions
This section describes the functions of the keys, display and LEDs.

HMI Controller Key or Name of the Key or LED Description

LED

Main Power On/Off key The Main Power On/Off key is used to
and LED power up the HMI Controller and to turn
on the TriPac system. The green LED
indicator is illuminated when the TriPac
system is turned on.

Mode key and LEDs The Mode key is used to select the
desired operating mode. When the TriPac
is turned on the mode will default to the
last setting that was used. A/C
(air-conditioning), Heat and Fan modes
are selected by pressing the Mode key.
Defrost (DEF) is not used with TriPac.
The LEDs above the Mode key indicate
the current mode.
If the unit is on and no LEDs are lit, the
unit is in Null mode (neither cooling or
heating).

HMI Controller Display The HMI Controller Display is used to

indicate temperature setpoint, alarm
codes, hourmeter reading, and other
information.
The small LED in the lower right-hand
corner of the HMI Controller Display is
illuminated when a setpoint temperature
is indicated.
The small LED in the upper left-hand
corner of the HMI Controller Display is
illuminated when the inside or outside
temperature is indicated. The
temeprature displayed is determined by
the Program Features settings.

4-2 25 October 2005

 Section 4 Operation
HMI Controller Key or Name of the Key or LED Description
LED

Up Arrow key and Down The Up Arrow key and Down Arrow key
Arrow key are used to raise and lower the
temperature setpoint in the HMI Controller
Display. Each press of the Up Arrow key
or Down Arrow key will raise or lower the
setpoint temperature by one degree. The
alphanumeric readings in the HMI
Controller Display scroll up or down when
the Up Arrow key or Down Arrow key is
pressed continuously.
The HMI Controller setpoint temperature
range is 50 to 90 degrees.
Fan key and LEDs The Fan key is used to select the desired
evaporator blower speed. When the
TriPac system is turned on, the fan speed
defaults to the setting last used. High,
Medium and Low fan speeds are selected
with the Fan key. The Auto setting is not
currently used.

System Fault LED The red System Fault LED is illuminated

when an alarm condition has occurred
and an alarm code is displayed.
See Alarm Codes for detailed
descriptions.
APU On/Off key and LED The APU On/Off key is used to enable the
APU engine. The APU On/Off key must
be on for the TriPac engine to operate.
The APU provides truck cab sleeper
compartment air-conditioning, fans, truck
battery voltage sensing, and optional
engine coolant temperature sensing. This
key also allows access to the APU engine
hourmeter reading. The APU does not
have to be on to operate the truck cab
sleeper compartment air heater.
The hourmeter is briefly shown on the
HMI Controller Display when the APU is
turned on.

25 October 2005 4-3

Section 4 Operation
Standby Operation (optional)
The optional TriPac HMI Controller Standby Mode allows the system to be controlled by an
external source, typically the truck ignition. The display shows [Sby] when the controller is in this
mode. The following occurs when TriPac is in Standby mode:

• The HMI Controller is temporarily • Voltage sensing is disabled

disabled and none of the TriPac
• Optional engine coolant temperature
systems will operate
sensing functions are disabled.

Figure 2-2: HMI Controller in Standby Operation

Options Used with Standby Operation

Standby Truck Integration (optional)
• When the truck ignition switch is
rotated to the Off or Acc position, and
the TriPac Main Power and APU are
on, TriPac operates normally.
• When the truck ignition switch is
rotated to On or Start, the truck engine
will start and/or run but TriPac is
forced to Standby mode. The HMI
Controller Display shows [Sby].

Truck Integration Selector Switch (optional)

• When the dash-mounted selector
switch is in the On position, the TriPac
APU operates the same as the
Standby Truck Integration (see
above).
• When the dash-mounted selector
switch is in the Off position, the APU is
forced to continuous Standby mode.

Figure 2-3: Truck Integration Selector Switch

4-4 25 October 2005

 Section 4 Operation
Turning on the Engine On/Off Switch

DANGER: Always turn the Main Power On/Off key on the HMI Controller to off
while the truck is being refueled. Fuel vapors can ignite if they come in contact
with TriPac electrical or heater components.

WARNING: TriPac can start automatically without warning if the Engine On/Off
switch is in the On position.

WARNING: Immediately stand clear when the preheat buzzer sounds. This
indicates that the engine is preheating. If the engine is warm, the preheat time
might only be a few seconds.

The Engine On/Off switch is located inside the APU housing on the right side of the frame. This
switch must be in the On position for the TriPac system to operate. The On position is the
default position.

• If the Engine On/Off switch is off, there is no A/C operation, fan operation, or battery
charging available. Heat mode operation, however, is available.
• If the Engine On/Off switch is off when the APU On/Off key is on, an [Eng] alarm code
occurs.
The Engine On/Off switch also functions as a service switch. It allows maintenance personnel to
disable the APU engine, even if the Main Power On/Off key is on.

HMI Controller Operations

NOTE: The operating parameters for the HMI Controller come from the factory with
default settings. Individual parameters can be changed, in accordance with desired
operating conditions or customer practices. See Section 3 of this manual for details.

Turning Main Power On

1. Press the Main Power On/Off key on the HMI Controller. The green LED indicator is
illuminated when the HMI Controller is turned on.

Figure 2-4: Main Power On/Off key

25 October 2005 4-5

Section 4 Operation
Enabling the APU
2. Press the APU On/Off key to enable the APU diesel engine, and to also enable the truck cab
sleeper compartment air-conditioning, air circulation, truck battery voltage sensing, and
optional engine coolant temperature sensing. The APU On/Off key LED is illuminated while
the APU is enabled. When the APU On/Off key is initially pressed, the APU engine
hourmeter reading is displayed. (See the next step.)

Figure 2-5: APU On/Off key

Viewing the APU Engine Hourmeter Display

3. When the APU On/Off key is initially pressed, the APU engine hourmeter reading will be
displayed. The HMI Controller Display will flash three screens, starting with [HrS] “HrS” and
followed by [tXX] “tXX” for thousands of hours and then [XXX] “XXX” for hundreds of hours.
The example below shows 1,230 hours.

Figure 2-6: APU Engine Hourmeter Display

Selecting Operating Mode

4. Press the HMI Mode key to select the desired operating mode. Select A/C (air conditioning),
Heat, or Fan (air circulation) operations. (Def is not used.) When the TriPac is first started,
the HMI Controller defaults to the previous setting.

4-6 25 October 2005

 Section 4 Operation
Press the Mode key repeatedly to scroll through the selections. The operating mode
selected will be indicated by an illuminated LED.
A “Null” (fan off) status will occur when no LEDs are illuminated. If Heat is required, the air
heater can operate while the APU engine is off and the Fan key is off (no LED illuminated).

Figure 2-7: Mode key

Selecting Fan Speed

5. Press the Fan key to select the desired fan speed. Select Low, Med or High speed. When
the TriPac is first started, the HMI Controller defaults to the previous setting.
The fan speed selected will be indicated by an illuminated LED. Auto fan speed is not
currently used.
The air heater can operate while the fans are off (the Fan LED is not illuminated and the
evaporator blower is in a null status). If additional air circulation is desired for the truck cab
sleeper compartment, the fans can be turned on by enabling the APU.

Figure 2-8: FAN key

Selecting Setpoint Temperature

6. Press the HMI Controller Up Arrow key or Down Arrow key to raise or lower the setpoint
temperature. Each time an Up Arrow key or Down Arrow key is pressed, the degree number
in the HMI Controller Display increments up or down by one degree. If an Arrow key is
pressed and held, the degree number in the HMI Controller Display will scroll up or down.
The setpoint will be changed to the value shown in the HMI Controller Display. The HMI
setpoint temperature minimum is 50 degrees and the maximum is 90 degrees.

25 October 2005 4-7

Section 4 Operation
7. The lower right LED in the HMI Controller Display indicates that cab temperature setpoint is
displayed.

6 7

Figure 2-9: Up Arrow key and Down Arrow key

System Fault Indicator

8. The red HMI System Fault LED glows any time an alarm condition occurs and an alarm code
is displayed.

Figure 2-10: SYSTEM FAULT Indicator

4-8 25 October 2005

 Section 4 Operation
Alarm Codes
The following table indicates the alarm codes that the TriPac can experience. Alarm codes
appear on the HMI Controller Display and the red System Fault LED is illuminated. See Section
5 Diagnostics, for a detailed examination of alarm codes and equipment faults.

Alarm Alarm
Code Type Description Conditions Possible Causes
Eng Shutdown The engine failed to The Reset Switch has The Reset Switch has
start or should be tripped. tripped. This may be
running and is not. caused by low engine oil
pressure, high engine
coolant temperature, or an
engine start failure.
AcS Shutdown Air conditioning Unit not cooling. Can be caused by high
system failure. compressor discharge
pressure or low system
pressure.
ALt Shutdown Charging system The battery is not This alarm code is
failure. being charged. activated
2 minutes after no
alternator output occurs.
The alternator might be
malfunctioning or the
alternator belt may be
broken.

Alarm Codes: Clearing Alarms

Record the alarm code shown in the display. To clear an alarm code, use the Main Power
On/Off key to turn off the TriPac system. Then resolve the condition that caused the alarm.

Check the engine Reset Switch. If the alarm tripped the switch, the switch must be reset to allow
the TriPac engine to be restarted. The engine Reset Switch is located on the side of the Control
Box enclosure.

Typical causes for an open engine Reset Switch are low engine oil pressure, high engine
coolant temperature, or an engine start failure.

25 October 2005 4-9

Section 4 Operation
TriPac Operating Conditions
This table illustrates the conditions that will cause the unit engine to start, the engine start
sequence and the conditions that must be satisfied to allow the engine to shut down.

Conditions that Cause an Engine Start

Any single condition will cause an engine start

Optional Artic HMI Controller Battery Voltage

Switch Cab temperature Battery voltage is
Coolant Temp > 5°F above setpoint < 12.15 Vdc for 60
< 30°F (Air Conditioning Only) seconds

Engine Start Engine Start

TriPac
Block Temp
Interface Board
Thermistor
Determines preheat time

Preheat Relay Run Relay Starter Relay

Time determined by
Block Temp Thermistor

Hold Pull-in

Reset Switch Fuel Pump Fuel Solenoid Starter

Engine Supplies fuel to Features hold Solenoid
protection fuel solenoid and pull-in coils

Flywheel Starter
Sensor

Conditions that Shut the Engine Down

All conditions must be satisfied before the engine will shut down

Optional Artic HMI Controller Battery Voltage

Switch Cab temperature at Battery voltage is
Coolant Temp > 90°F setpoint for 15 minutes > 13.56 Vdc for 15
(Air Conditioning Only) minutes

4-10 25 October 2005

 Section 4 Operation
The following table indicates the relationship between the HMI Controller keys and the TriPac
modes, whether fans are on or off, whether voltage sensing is enabled or not available, and
whether the optional Arctic Package (Engine Coolant Temperature Sensor) is enabled or not
available.

HMI Controller Keys TriPac Operations

Main
Power APU Air Arctic
On/Off Mode Fan On/Off A/C heaterf Voltage Package
key key key key fans an sensing (optional) Comments
Off --- --- --- --- --- --- --- TriPac is off, no system
functions are available
On A/C Not Off Off Off Not Not Delayed A/C mode.
available available available Waiting for APU to be
turned on.
On A/C Operator On On Off Enabled Enabled A/C mode. Normal A/C
selectable operation, with voltage
sensing active.
On Heat Not Off Off On Not Not Heat mode. Normal air
available available available heater operation.
On Heat Operator On On On Enabled Enabled Heat mode. The A/C
selectable fans can be run for
additional circulation.
Voltage sensing active.
On Fan Not Off Off Off Not Not Delayed Fan mode.
available available available Waiting for APU to be
turned on.
On Fan Operator On On Off Enabled Enabled Fan mode. Normal
selectable fan-only operation, with
voltage sensing active.
On Null Not Off Off Off Not Not Delay Null mode.
available available available Waiting for APU to be
turned on.
On Null Not On Off Off Enabled Enabled Null mode. HMI
available Controller Display only,
with voltage sensing.

25 October 2005 4-11

Section 4 Operation

4-12 25 October 2005

 Section 5 — TriPac Diagnostics

TriPac Service Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Part 1 - Corrective Actions As A Result Of Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . 5-2
TriPac Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Clearing Alarm Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
[Eng] Engine Alarm Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
[AcS] Air Conditioning System Alarm Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
[ALt] Alternator Alarm Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Part 2 - Corrective Actions As A Result Of other symptoms . . . . . . . . . . . . . . . . . . . . 5-11
HMI Controller Remains Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
HMI Controller Powers Up But The APU Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . 5-11
Symptoms Caused by Defective Preheat Thermistor -
TriPac Units using a Cycle Sentry Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Part 3 – Diagnosing the Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Basic Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Heater Does Not Ignite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Heater Ignites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Espar Heater Diagnostic Unit - Service Part Number 204-1143 . . . . . . . . . . . . . . . . . . . 5-15
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Fault Code Retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Displaying Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Deleting Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Ending Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Espar Heater Diagnostic Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Resistance Values for the Overheat Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Resistance Values for the Flame Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Fuel Quantity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Fuel Quantity Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
 Section 5 — TriPac Diagnostics
Section 5 is devoted to diagnostic routines designed to help the technician quickly identify the
cause of a problem and repair it using the correct tools, information and procedures. It is
important that the required procedures be followed exactly. Failure to do so may result in an
incomplete repair.
The remaining material is divided into three parts. The first part suggests corrective actions as a
result of alarm codes. The second part suggests corrective actions as a result of symptoms
other than alarm codes. The third part suggests corrective actions for the air heater.
The following hints will prove helpful.
• Operators should record all alarm codes for reference.
• Clear any alarm codes before performing diagnostic routines.
• Be certain all connectors on the interface board and HMI control panel are completely
seated.
• Be certain all harness connectors are securely in place.
• Make sure all programmable features are set to the customer’s specifications before
releasing the unit for service.

TRIPAC SERVICE NOTES

The following procedures must be followed when working on TriPac units.
• Never use testers consisting of a battery and a light bulb to test circuits on any
microprocessor-based device.
• Any time the TriPac HMI Controller is replaced, these Service Procedures must be used:
A02A - Recording TriPac HMI Controller Programmable Feature Settings
A03B - Replacing the TriPac HMI Controller
A04A - TriPac HMI Controller Programmable Feature Setup
• Any time welding is necessary, Service Procedure A26A must be followed.

ELECTROSTATIC DISCHARGE
The following electrostatic precautions must be taken.
• Keep all TriPac interface boards and HMI controllers in anti-static bags at all times.
• Protect any defective TriPac interface boards and HMI controllers from physical damage by
placing them in the shipping carton supplied with the replacement. They will be returned for
failure analysis and possible re-manufacture.

25 October 2005 5-1

Section 5 — TriPac Diagnostics
PART 1 - CORRECTIVE ACTIONS AS A RESULT OF
ALARM CODES
TriPac Alarm Codes
There are 3 possible TriPac alarm codes. They are all shutdown alarms – if they occur the unit
will shut down and the alarm code will appear in the TriPac HMI Controller display.
• [Eng] Engine Alarm
• [AcS] Air Conditioning System Alarm
• [Alt] Alternator Charging System Alarm

Clearing Alarm Codes

Alarm codes are cleared by pressing the HMI Controller On/Off key to turn the unit off. Correct
the alarm condition and restart the unit. If the condition still exists the alarm will re-occur.

5-2 25 October 2005

 Section 5 — TriPac Diagnostics

[Eng] Engine Alarm Code

Alarm Type Shutdown Alarm

Component Description and Location

Circuit Description
The 8FET output from the Interface Board is energized when the TriPac unit is turned on.
8FET power is supplied to the Engine On/Off switch located inside the APU. If the Engine
On/Off switch is closed power is supplied by the 8X wire to the normally closed contacts in
the Reset switch. As long as the Reset switch is closed power is supplied on the 8 wire to the
8 terminal on the Interface Board.
See the drawing on the next page for details.

Considerations

How Alarm is Set

Any time the 8FET output is energized, power must also be present on the Interface Board 8
Terminal. If power is not present at the 8 terminal when the 8FET output is energized, one of
three events has occurred. Any of these events will prevent the engine from starting or shut
the engine down if it is running.
1. The Engine On/Off switch is not turned on.
2. The Reset switch has tripped due to low engine oil pressure or high engine coolant
temperature.
3. The Reset switch has tripped because the engine failed to start.
The [Eng] alarm code is set and no further operation is possible until the alarm condition is
cleared.

How Alarm is Cleared

The alarm is cleared by pressing the HMI Controller Main Power On/Off switch. Turning the
unit off clears the alarm.
Resolve the condition that caused the alarm and press the Reset switch if necessary. Failure
to resolve the alarm condition will cause the alarm to re-occur.

25 October 2005 5-3

Section 5 — TriPac Diagnostics
Partial Schematic Diagram - [Eng] Alarm Code
Note 1 When the engine is required
to run and the 8FET output is
8D 8
energized, power is supplied thru the
Engine On/Off Switch and NC Reset
Note 3 8D 8 Note 2 Switch to the 8 terminal on the
Interface Board.
RUN
RELAY Note 2 If the 8FET output is
energized and power is not present at
the 8 terminal on the Interface Board
then Alarm Code [Eng] is set.

Note 3 When the engine is required

TRIPAC to run the Run Relay is energized.
INTERFACE This supplies power on the 8D circuit
BOARD to the Reset Switch resistor and the
8FET hold coil on the Fuel Solenoid. If high
water temperature or low engine oil
Note 1 pressure occur, current flows thru the
20 circuit to ground. This heats the
reset switch causing it to open. Power
is removed from the 8 terminal on the
Interface Board and Alarm Code [Eng]
is set.
ENGINE RESET
ON/OFF SWITCH If the engine fails to start the normally
SWITCH closed Low Oil Pressure switch will
cause the reset switch to trip and set
8FET 8X 8 the [Eng] alarm code.
HWT

8D 20

Note 3
LOP

5-4 25 October 2005

 Section 5 — TriPac Diagnostics

[Eng] Engine Alarm Code

Diagnostic Procedure
1. Verify the Engine On/Off switch is turned on. It is located inside the APU enclosure in
the upper right hand corner. Turn on if necessary.
2. Press the button on the Reset switch.
3. Check the engine oil level. Add oil if necessary.
4. Check coolant level. Add coolant if necessary.
5. Attempt an engine start. If the engine does not start troubleshoot and correct the cause
as necessary.
6. If the engine starts but the Reset switch trips again, check the Low Oil Pressure Switch
and High Water Temperature switch.
7. Check the associated circuitry for continuity and shorts using the diagram on the
previous page.
8. Check the 20 circuit for a short to ground.
9. Check the reset switch for continuity.

25 October 2005 5-5

Section 5 — TriPac Diagnostics

5-6 25 October 2005

 Section 5 — TriPac Diagnostics

[AcS] Air Conditioning System Alarm Code

Alarm Type Shutdown Alarm

Component Description and Location

Circuit Description
The 7CL output from the Interface Board is energized to engage the compressor clutch when
the TriPac unit requires air conditioning. 7CL power is supplied to the Binary switch which
includes the High Pressure Cutout Switch and Low Pressure Cutout Switch. As long as these
switches are closed 7CLA power is supplied to the Freeze-stat switch. 7CLA power is also
supplied to the Interface Board 7CLA terminal.
The Freeze-stat is a normally closed temperature switch that opens at 31°F (-1°C) and closes
at 39°F (4°C). It is used to prevent the evaporator coil from icing. As long as the Freeze-stat is
closed 7CLB power is supplied to the compressor clutch to allow cooling operation.
See the drawing on the next page for details.

Considerations

How Alarm is Set

Any time the 7CL output is energized power must also be present on the Interface Board
7CLA Terminal. If power is not present at the 7CLA terminal when the 7CL output is
energized, one of two events has occurred. Any of these events will prevent the compressor
clutch from engaging.
1. The High Pressure Cutout switch has opened due to high discharge pressure.
2. The Low Pressure Cutout switch has opened due to low system pressure.
The [AcS] alarm code is set and no further operation is possible until the alarm condition is
cleared.

How Alarm is Cleared

The alarm is cleared by pressing the HMI Controller Main Power On/Off switch. Turning the
unit off clears the alarm.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause
the alarm to re-occur.

25 October 2005 5-7

Section 5 — TriPac Diagnostics

[AcS] Air Conditioning System Alarm Code

Partial Schematic Diagram - [AcS] Alarm Code

A/C
Binary Switch Freeze-Stat
Note 3 Clutch
7CL 7CLA 7CLB
Note 1

HPCO LPCO Note 2

Note 1 +12 Vdc from the 7CL output on the Interface Board to energize the compressor clutch
when cooling is required.

Note 2 +12 Vdc to the 7CLA input on the Interface Board. If the 7CL output is +12 Vdc then the
7CLA input must also be +12 Vdc. If it is not, the HPCO or LPCO switch is open and Alarm Code
[AcS] is set.

Note 3 The Freeze-Stat opens at 31°F (-1°C) and closes at 39°F (4°C) to prevent ice buildup on
the evaporator coil.

Diagnostic Procedure
1. Connect a gauge set to determine if the problem is caused by high discharge pressure
or low system pressure.
2. If discharge pressure is high check for dirty or blocked condenser coil.
3. Verify proper operation of the Condenser Fan Motor.
4. If system pressure is low check refrigerant level and correct as required.
5. Check the associated circuitry for continuity using the diagram above.

5-8 25 October 2005

 Section 5 — TriPac Diagnostics

[ALt] Alternator Alarm Code

Alarm Type Shutdown Alarm

Component Description and Location

Circuit Description
On engine startup initial excitation voltage is supplied from the D+ terminal on the Interface
Board to the alternator excite terminal. After 2 minutes the Interface Board monitors the D+
terminal as an input.
12.6 Vdc or more must be present after 2 minutes to indicate that the alternator is functioning
properly. If this voltage is low or missing, Alarm Code [Alt] is set.
See the drawing on the next page for details.

Considerations

How Alarm is Set

12.6 Vdc or more must be present after 2 minutes to indicate that the alternator is functioning
properly. If this voltage is low or missing, Alarm Code [Alt] is set.
The [AcS] alarm code is set and no further operation is possible until the alarm condition is
cleared.

How Alarm is Cleared

The alarm is cleared by pressing the HMI Controller Main Power On/Off switch. Turning the
unit off clears the alarm.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause
the alarm to re-occur.

Diagnostic Procedure
1. Check alternator output with a meter. With the engine running the voltage at the
alternator output should be approximately 13.8 to 14.2 Vdc. If the voltage is less than
12.6 Vdc or greater than 15 Vdc with the engine running test and repair the alternator.
2. Check for broken or slipping alternator belt.
3. Check that all alternator connections are secure.
4. Check the associated circuitry for continuity and shorts using the diagram on the next
page.

25 October 2005 5-9

Section 5 — TriPac Diagnostics

Partial Schematic Diagram - [ALt] Alarm Code

Note 1 On engine startup initial

excitation voltage is supplied from the
D+ terminal on the Interface Board to
the alternator excite terminal.

TRIPAC After 2 minutes the Interface Board

INTERFACE monitors the D+ terminal as an input.
BOARD 12 Vdc or more must be present after
2 minutes to indicate that the alternator
is functioning properly. If this voltage
D+ is low or missing, Alarm Code [ALt] is
set.

D+ B+
Note 1

EXC SENSE
W

GND

To Fusible
OUTPUT F2
Links, Starter
and Battery
B+

5-10 25 October 2005

 Section 5 — TriPac Diagnostics
PART 2 - CORRECTIVE ACTIONS AS A RESULT OF OTHER
SYMPTOMS

HMI Controller Remains Blank

Cause Corrective Action

The Main Power is not turned on. Press the HMI Controller Main Power key
to turn the unit on.

Faulty power circuits from the battery.
Disconnected HMI Controller.
Wiring problem.
Defective HMI Controller.
Check the battery circuits using the Wiring
Diagram as a reference.
Check to be sure the HMI Controller
harness is securely connected at the HMI
Controller and at the Interface Board.
Check the associated circuitry for continuity
using the wiring diagram.
Replace the HMI Controller.

HMI Controller Powers Up But The APU Does Not Operate

Cause Corrective Action

The Engine On/Off switch is turned off.
The Reset Switch is open.
Wiring problem.
Turn the Engine On/Off switch on.
Check for the [Eng] Alarm Code. If present
see the [Eng] Alarm Code in this section for
diagnostic details.
Check the associated circuitry for continuity
using the wiring diagram.

25 October 2005 5-11

Section 5 — TriPac Diagnostics

Symptoms Caused by Defective Preheat Thermistor -

TriPac Units using a Cycle Sentry Module

Symptom Cause and Corrective Action

Extremely long preheat time – 5 minutes or The preheat thermistor circuit is open and
more. must be replaced.

Very short preheat time – 3 to 5 seconds. The preheat thermistor is shorted and must
be replaced.
Unit sticks in preheat – will not crank. The preheat thermistor circuit is shorted to
ground and must be replaced.

5-12 25 October 2005

 Section 5 — TriPac Diagnostics
PART 3 – DIAGNOSING THE AIR HEATER
Basic Diagnostics

Heater Does Not Ignite

Symptom Corrective Action

Blower motor does not run. 1. Check fuse in the Power Harness.
2. Check power to control unit.
3. Check power to and from switch.
4. Check electrical connections.
Blower motor runs approximately 20 seconds 1. Ensure that voltage at the control unit
and shuts off. remains above 10 Vdc during startup
with the glow plug circuit energized.
Blower motor runs and fuel metering pump 1. Check fuel lines and fuel filter.
starts and then shuts down after two start 2. Check fuel level.
attempts.
3. Check for combustion air or exhaust
tube blockage.
Blower motor runs but fuel metering pump 1. Check for electrical pulses at the fuel
does not. metering pump.
2. Check for frozen fuel metering pump.
3. Check for blocked fuel line.

25 October 2005 5-13

Section 5 — TriPac Diagnostics

Heater Ignites

Symptom Corrective Action

Heat shuts down at random. 1. Check fuel metering pump quantity.

2. Check for possible overheat
condition.
3. Check control unit input voltage.

Heater smokes and carbons up. 1. Check for blocked exhaust pipe.
2. Check for blocked combustion air
intake.
3. Check for exhaust entering
combustion air intake pipe.
4. Check for short cycling – rapid on/off
operation.
5. Check fuel system.
6. Check fuel metering pump quantity.
7. Check motor RPM.

5-14 25 October 2005

 Section 5 — TriPac Diagnostics
Espar Heater Diagnostic Unit - Service Part Number 204-1143

The Diagnostic Unit is used for reading, displaying and deleting fault codes saved in the
electronic control unit of the heater. The electronic control unit can save up to 5 fault codes,
labeled F1 to F5. The most recent fault code is in memory location F1. The current or actual
fault code is shown as “AF” and is always written into the F1 memory location. Previous fault
codes are transferred to memory locations F2 to F5.

The Diagnostic Unit allows three functions to be performed:

1. Access the current fault which is affecting the heater.
2. Access the four previous faults which affected the heater.
3. Clear the fault memory to erase previous fault history.

Connection
Connect the Heater Diagnostic Tool cable to the diagnostic pigtail (8-pin black connector) on the
heater’s main wiring harness as shown below.

25 October 2005 5-15

Section 5 — TriPac Diagnostics

When correctly connected, the Diagnostic Unit display shows [dIA].

Fault Code Retrieval

Press the “D” key on the Diagnostic Unit to switch on the heater. The display
shows [ -:- -].

After 8 seconds the display will show [AF:00] if there are no fault codes set.

If fault codes are set, the display will show [AF:xx], where xx = the current fault
code. Fault Code 64 is shown here.

If the display shows [ - - - ] the fault codes can not be read. Possible causes
are:
Adaptor cable not connected properly.
Defective heater control unit.

Displaying Fault Codes

Press the Left Arrow or Right Arrow keys to scroll forward or backward through
the existing fault codes. In the example shown here the display indicates that
the second fault code set (F2:) is Fault Code 10 (10).
Up to 5 fault codes may be shown. However, only existing codes will be
shown. For example, if only three fault codes are set, then only three fault
codes will be displayed.

Deleting Fault Codes

Eliminate the cause of the fault. Be sure to correct the root cause, not just the
symptom.
Press and hold both “L” keys until the display shows [ - : - - ].
When the fault codes are deleted, the last current fault code is still shown. The
last current fault code is not reset to [ AF:00 ] until the next restart of the
heater, provided no other fault code has occurred.

After the next heater start, the display will show [ AF:00 ]. No fault codes are
set.

Ending Fault Code Display

Press the “D” key to turn the heater off. The display will show [ dIA ]. Wait for
the end of the heater cool down period and then remove the Heater Diagnostic
Unit cable from the harness.

5-16 25 October 2005

 Section 5 — TriPac Diagnostics
Espar Heater Diagnostic Fault Codes
Not all codes apply to all heater models. For additional diagnostic information see Diagnosing
the Air Heater in Section 5 of this manual.

Fault
Fault Description Causes/Repair
Code
000 Normal operation If there are no heater faults, the heater will go
through a normal start cycle and regulate
based on thermostat setting.
004 Warning – short circuit in Disconnect the connection S1/B1 at the
controller, fresh air outlet AIRTRONIC heater. At connector B1 pin 16
check for a short between the pin and the
blower relay. If no short exists then replace
the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
005 Warning – short circuit at Check the line through to the relay isolating
controller, anti theft alarm output switch or theft warning in line for a short circuit
to chassis. If no short exists then replace the
control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
009 TRS – shutdown The unit switched off due to a signal change.
Check for a change of signal from (+) to (-) at
pin 13 (S1) or a (+) signal at pin 14 (S1).
010 Over voltage shutdown Start the vehicle engine. Check the voltage at
(B1) between terminals 1 and 10. This voltage
must be less than 16 volts (15.2 volts with
glow plug on).
Check the vehicle charging system.
011 Under voltage shutdown Start the vehicle engine. Check the voltage at
connector (B1) between terminals 1 and 10.
This voltage must be more than 10 volts.
Check the vehicle charging system.
Check the batteries and battery connections.

25 October 2005 5-17

Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
012 Overheat at overheating sensor The Overheating sensor has detected
excessive temperatures.
Check for clogged hot air ducting.
Check that the total number of ducting pieces
in unison is not too large. Re-route if
necessary.
Check the overheat sensor resistance values.
(See the Resistance Values for the Overheat
Sensor table at the end of this section).
Measure fuel quantity.
013 Overheat at flame sensor The Flame sensor has detected excessive
temperature at the heat exchanger.
Check for clogged hot air ducting.
Check that the total number of ducting pieces
in unison is not too large. Re-route if
necessary.
Measure fuel quantity.
Check flame sensor resistance. (See the
Resistance Values for the Flame Sensor table
at the end of this section).
014 Potential overheat detected – Check for clogged hot air ducting.
temperature difference between Check that the total number of ducting pieces
the flame sensor and overheating in unison is not too large.
sensor too large
Check the flame sensor.
If O.K. check the overheating sensor. If the
over-heating sensor is defective replace the
combi-sensor.
If the overheating sensor is O.K. measure fuel
quantity. (See the Fuel Quantity Test at the
end of this section).
If fuel quantity is O.K. replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.

5-18 25 October 2005

 Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
015 Too many overheat shutdowns Fault code 015 is shown when the
AIRTRONIC is switched on again after fault
Overheat with excessive
code 017.
temperature
The hardware limit value for the overheating
sensor has been exceeded – the control unit
is damaged.
Check sensor.
Replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
017 Overheat with excessive The hardware limit value for the overheating
temperature sensor, has been exceeded because the
control unit has not detected fault code 012,
013.The control unit is locked. If AIRTRONIC
is switched on again, fault code
015 is displayed.
Check the overheat sensor.
Replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
020 Open circuit – glow pin Check continuity of glow pin while still
installed. The resistance values should be as
shown below.
AIRTRONIC 12 volt - approximately
0.5 Ω ± 0.05 Ω
Replace open glow pin.

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Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
021 Short circuit – glow pin / glow plug Check functions of glow pin in installed
condition. To do so disconnect connector from
Caution!
controller.
For AIRTRONIC 12 volt
AIRTRONIC 12 Volt. Apply voltage of 8 volts
applications, check functions
to glow pin respectively, and measure current
with max. 8 volt
after 40 seconds. Glow pin is O.K. with the
If voltage values are exceeded the following values:
component will be destroyed.
Glow pin 8 volt - current = 9 amps + 1.5 / - 1.2
amps
If the values differ, replace glow pin.
If the values of the continuity test and function
test are O.K., check glow pin cable harness
for damage and continuity.
If harness O.K., replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
031 Open circuit – blower motor Check the blower motor cable harness for
interrupted correct routing and damage.
If O.K., disconnect the cable harness from the
control unit and check for continuity.
If O.K., replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
032 Short circuit – blower motor Check the functions of the blower motor. To
do so, disconnect connector from control unit.
Caution!
Apply voltage of 8 volts ± 0.1 to the blower
For AIRTRONIC 12 volt motor and measure the current after 40
applications, check functions seconds.
with max. 8 volt
Current < 6.5 amp – blower motor O.K.,
If voltage values are exceeded replace controller.
the component will be
Current > 6.5 amp, replace blower.
destroyed.

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 Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
033 Blower motor speed deviation Motor speed varies from specification by more
(>10%) or blower motor does not than 10% for longer than 30 seconds.
turn If too slow, check for air flow restriction, and
check for short in motor circuit or control unit.
If none found, replace blower.
If too fast, check for damaged or missing
magnetic sensor on the control unit. Replace
blower motor if damaged.
Replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
047 Short circuit – fuel metering pump Disconnect the connector from the fuel
metering pump. If fault code 048 (interruption)
is displayed then the fuel metering pump is
defective and must be replaced.
If fault code 047 is still displayed, then
disconnect connection S1/B1. At connector
B1, Pin 5, check line1 (green/red) through to
FMP for short circuit to (pin 10). If O.K.
replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
048 Open circuit – fuel metering pump Disconnect connector from fuel pump and
measure the resistance value of fuel pump.
12 volt pumps should measure 10 + 0.5
ohms. If the resistance values are O.K.
reconnect the cable harness to the fuel pump.
Disconnect the connection S1/B1, and
measure the resistance value between pin 5
and pin 10. If O.K., replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.

25 October 2005 5-21

Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
050 Too many failed start attempts The control unit is locked after too many
unsuccessful start attempts.
Check the fuel, glow plug, combustion air and
exhaust flow.
Use the Diagnostic Unit to unlock the control
unit. Maximum “No Start” attempts = 255
051 Faulty flame recognition If the resistance value of the flame sensor is
1274 Ω after switching on (> 70°C), then the
blower of the AIRTRONIC runs for
approximately 15 minutes to cool down. If
resistance does not fall below the above value
within 15 minutes a fault shut down occurs.
Check the flame sensor, diagrams and
values. (See the Resistance Values for the
Flame Sensor table at the end of this section).
If O.K., replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
052 No start safety time exceeded No flame detected on start attempt.
Check the exhaust and combustion air lines.
Check the fuel supply. Measure fuel quantity.
(See the Fuel Quantity Test at the end of this
section).
Check the glow pin (see Fault Codes 20 and
21).
Check the flame sensor. (See the Resistance
Values for the Flame Sensor table at the end
of this section). If O.K., replace the control
unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.

5-22 25 October 2005

 Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
053 Flame cutout in boost mode Heater has started successfully but the flame
has extinguished.
Check exhaust and combustion air lines.
Check fuel supply and measure fuel quantity.
(See the Fuel Quantity Test at the end of this
section).
Check the flame sensor. (See the Resistance
Values for the Flame Sensor table at the end
of this section).
If O.K., replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
054 Flame cutout in high mode Flame cutout in high mode.
See corrective action for Fault Code 053.
055 Flame cutout in medium mode Flame cutout in medium mode.
See corrective action for Fault Code 053.
056 Flame cutout in low mode Flame cutout in low mode.
See corrective action for Fault Code 053.
060 Open circuit – external Disconnect connection S1/B1 (main harness)
temperature control sensor and measure resistance value at connector
B1, pins 6 & 12. If there is an open circuit, the
resistance value between the pins is > 7175
Ω. If the resistance value is O.K., then the
control unit is defective.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.

25 October 2005 5-23

Section 5 — TriPac Diagnostics
Fault
Fault Description
Code
061 Short circuit – external
temperature control sensor
062 Open circuit – Thermostat,
Rheostat, Timer
The temperature setpoint control
used by the heater is a simulated
digital potentiometer located on
the TriPac Interface Board. It is
connected to the Interface Board
via the Gry/Red and Brn/Wht wires
from the heater via the S1/B1
connector.
063 Short circuit – Switch Control
Fault recognition only works in
heating mode. However, if a short
circuit already exists and the
AIRTRONIC is subsequently
switched on, ventilating mode will
be active (no fault code).
5-24
Causes/Repair
Disconnect connection S1/B1 (main harness)
and measure the resistance value at
connector B1, between pins 6 & 12. If there is
a short circuit, the resistance value between
the pins is < 486 Ω.
If Fault Code 061 continues to be displayed,
then the control unit is defective.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
The digital potentiometer values are out of
range on Thermostat switch.
Disconnect connection S1/B1 (main harness)
and check the resistance between pins 6 and
7 at B1.
The resistance value for interruption between
pins is > 7175 Ω. The normal value is 1740 Ω -
2180 Ω (± 80 Ω).
If the resistance value is O.K. replace the
control unit. See the “Sleeper Cab Air Heater
Service Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
If the resistance value is not O.K. replace the
TriPac Interface Board.
If a ventilating switch has been built in,
disconnect and check function. If faulty,
replace switch.
Disconnect the wires from thermostat or
switch. If Fault Code 062 is displayed, replace
the switch.
If the switch is O.K., check connection lines
grey/red and brown/white for short-circuit. If
O.K., reconnect the wires to the
thermostat/switch.
Disconnect connection B1. If fault 063 is still
displayed, replace the control unit. The
resistance value for a short circuit between
pins 6 and 7 is < 486 Ω. The normal value is
1740 Ω - 2180 Ω (± 80 Ω).
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
25 October 2005
 Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
064 Open circuit – flame sensor Sensor is sensing value outside of range.
Open the Airtronic shell and remove the
control unit from the casing.
Disconnect the green connector from control
unit. At the green connector measure the
resistance value between the green wire and
the brown/white wire. Resistance value for an
open circuit is > 7175 Ω. (See the Resistance
Values for the Flame Sensor table at the end
of this section).
If the flame sensor is O.K., replace the control
unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
065 Short circuit – flame sensor Open the Airtronic shell and remove the
control unit from the casing.
Disconnect the green connector from the
control unit. If Fault Code 64 is displayed,
replace the combination sensor
(flame/temperature).
If Fault Code 65 is still displayed, replace the
control unit. See the “Sleeper Cab Air Heater
Service Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
The resistance value for a short circuit is <
486 Ω. (See the Resistance Values for the
Flame Sensor table at the end of this section).
071 Open circuit – overheat sensor Open the Airtronic shell and remove the
control unit from the casing.
Disconnect the blue and green connectors
from the control unit. Measure the resistance
value at the blue connector (pin 1- blue wire)
and at the green connector pin 2 (brown/white
wire).
If O.K., replace the control unit. See the
“Sleeper Cab Air Heater Service Operations”
procedure in the TriPac Maintenance manual,
TK 53036, for the air heater control unit
replacement procedure.
The resistance value for an open circuit is >
223 Ω. (See the Resistance Values for the
Flame Sensor table at the end of this section).

25 October 2005 5-25

Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
072 Short circuit – overheat sensor Open the Airtronic shell and remove the
control unit from the casing.
Disconnect the blue connector from control
unit. If Fault Code 071 is displayed, replace
the combination sensor (flame/temperature).
If Fault Code 072 is still displayed, replace the
control unit. See the “Sleeper Cab Air Heater
Service Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
The resistance value for a short circuit is <
183 Ω.
090 Control unit defect – internal fault Internal failure. Replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
091 External voltage disturbance Check the vehicle charging system. Look for a
poor battery, or a connected battery charger.
092 Control unit defect – ROM error Internal failure. Replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
094 Control unit defect – EEPROM Replace the control unit.
error See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
096 Control unit defect – internal Replace the control unit or use external
temperature sensor temperature sensor.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.

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 Section 5 — TriPac Diagnostics

Fault
Fault Description Causes/Repair
Code
097 Control unit defect – power failure Internal failure. Replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.

Resistance Values for the Overheat Sensor

The following tables contain data for the minimum and maximum resistance (in kW) at specific
temperatures (in degrees C) for the Overheat Sensor and Flame Sensor.
Temperature vs. Resistance Values, Overheat Sensor
Temp F Temp C Resistance (kΩ) Minimum Resistance (kΩ) Maximum
-40 -40 C 1597 kΩ 1913.0 kΩ
-4 -20 C 458.80 kΩ 533.40 kΩ
32 0C 154.70 kΩ 175.50 kΩ
68 20 C 59.30 kΩ 65.84 kΩ
104 40 C 25.02 kΩ 28.04 kΩ
140 60 C 11.56 kΩ 13.16 kΩ
176 80 C 5.782 kΩ 6.678 kΩ
212 100 C 3.095 kΩ 3.623 kΩ
248 120 C 1.757 kΩ 2.081 kΩ
284 140 C 1.050 kΩ 1.256 kΩ
320 160 C 0.6654 kΩ 0.792 kΩ
356 180 C 0.4253 kΩ 0.5187 kΩ
392 200 C 0.2857 kΩ 0.3513 kΩ

25 October 2005 5-27

Section 5 — TriPac Diagnostics
Resistance Values for the Flame Sensor
The following tables contain data for the minimum and maximum resistance (in kW) at specific
temperatures (in degrees C) for the Overheat Sensor and Flame Sensor.
Temperature vs. Resistance Values, Flame Sensor
Temp F Temp C Resistance (kΩ) Minimum Resistance (kΩ) Maximum
-40 -40 C 825.90 kΩ 859.60 kΩ
32 0C 980.00 kΩ 1020.00 kΩ
104 40 C 1132.30 kΩ 1178.50 kΩ
176 80 C 1282.80 kΩ 1335.10 kΩ
248 120 C 1431.50 kΩ 1489.90 kΩ
320 160 C 1578.30 kΩ 1642.80 kΩ
392 200 C 1723.40 kΩ 1793.70 kΩ
464 240 C 1866.60 kΩ 1942.80 kΩ
536 280 C 2008.10 kΩ 2090.00 kΩ
608 320 C 2147. 70 kΩ 2235.40 kΩ
680 360 C 2285.50 kΩ 2378.80 kΩ
752 400 C 2421.50 kΩ 2520.30 kΩ

5-28 25 October 2005

 Section 5 — TriPac Diagnostics
Fuel Quantity Test
Fuel Quantity Test
The fuel quantity should be tested if the heater has difficulty starting or maintaining a flame.
Check the following before measuring fuel quantity.
• Check the filter in the fuel pump
• Check that the fuel lines are correctly routed
• Check that the fuel lines don’t leak.
• Check and tighten hose connections
• Does fuel withdrawal comply with the data in the technical description

Preparation
• Detach the fuel line from the AIRTRONIC.
• Insert the fuel line into a measuring glass (25 cm3).
• Switch the AIRTRONIC on and allow fuel system to bleed out air for approximately
60 seconds.
• Switch the AIRTRONIC off and drain the measuring glass.

Measurement
• Switch the AIRTRONIC on
• The fuel is pumped approximately 60 seconds after switching on.
• Hold the fuel line in the measuring glass level with the glow pin while fuel is being delivered.
• The pump will stop automatically after delivering fuel for 90 seconds. (110 seconds for AIR-
TRONIC 4)
• Once fuel pump stops, switch off the heater.

Evaluation
• Read out the quantity of fuel in measuring glass.
• Fuel quantity should be between
3.7 ml and 4.3 ml. on AIRTRONIC 2
5.4 ml and 6.3 ml. on AIRTRONIC 4
• If the fuel quantity is outside this range, check for and remove any restriction in fuel system
or replace the fuel metering pump.
NOTE: The fuel quantity is not affected by voltage variances.

25 October 2005 5-29

Section 5 — TriPac Diagnostics

5-30 25 October 2005

 Section 6 - Service Procedures
A02A Recording TriPac HMI Controller Programmable Feature Settings
A03B Replacing the TriPac HMI Controller
A04A TriPac HMI Controller Programmable Feature Setup
A26A Welding on Units Equipped with Microprocessors
B02A TriPac Interface Board Removal and Replacement
D01A TriPac Control Sensor Test
F09A Flywheel Sensor Test and Adjustment
H04A Checking Harness Continuity
 TriPac Service Procedure A02A
A02A Recording TriPac HMI Controller Programmable Feature
Settings
Where Used
All TriPac units.

Purpose
This procedure should be used to retrieve and record the programmable feature settings of an
HMI Controller. These settings will then be duplicated in the replacement HMI Controller. This
must be done prior to replacement of the HMI Controller.

Use a copy of the Programmable Features Setup Sheet at the end of this service procedure to
record the existing settings.

Important Information
The settings at the HMI Controller vary in accordance with the TriPac user’s personal choices
for the truck cab sleeper compartment cooling, heating, and ventilation flow.

HMI Controller Hourmeter Screens

STEP No. ACTION
1 NOTE: It may not be possible to
2 Obtain a copy of the Setup
Sheet at the end of this
procedure.
3 Press the Main Power On/Off
key to turn the unit on.
4 Press the APU On/Off key.
RESULTS COMMENTS
accomplish part or all of this
process with a defective HMI
Controller. If so, the information
must be obtained from customer
records.
This copy will be used to record the
information as it is retrieved.
The hourmeter screens Hourmeter information will not be
appear. entered into the new HMI Controller
1. The HrS screen flashes. but should be recorded in the
This indicates hourmeter customers records for future
information is about to be reference.
displayed.
2. The tXX screen appears.
This 2 digit number
represents thousands of
engine hours. Record this
number on the setup sheet.
3. The XXX screen appears.
This 3 digit number
represents hundresds of
engine hours. Record this
number on the setup sheet.

1 P41PA02A - 25 October 2005

TriPac Service Procedure A02A
HMI Controller Program Features
STEP NO. ACTION
1 Press and hold both the Up Arrow
and Down Arrow keys until [PPP]
appears in the display.
2 Press the Mode key to advance to
the first Program Feature.
3 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
4 Press the Mode key to advance to
the next Program Feature.
5 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
6 Press the Mode key to advance to
the next Program Feature.
7 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
8 Press the Mode key to advance to
the next Program Feature.
9 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
10 Press the Mode key to advance to
the next Program Feature.
11 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
12 Press the Mode key to advance to
the next Program Feature.
13 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
14 Press the Mode key to advance to
the next Program Feature.
15 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
16 Press the Mode key to advance to
the next Program Feature.
17 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
18 Press the Mode key to advance to
the next Program Feature.
19 Press the Up Arrow key or Down
Arrow key once to display the
feature setting.
20 Press the Mode key to advance to
the next Program Feature.
P41PA02A - 25 October 2005
RESULTS COMMENTS
[PPP] appears in the
display.
[ctd] appears. Controller Temperature Display
Record the feature
setting [cts, SPt,
dbg, OFF or otS].
[ddL] appears. Display Dimmer Level
Record the feature
setting [1 to 15].
[cts] appears. Controller Temperature Scale
Record the feature
setting [F or C].
[dbd] appears. Dead Band Degrees
Record the feature
setting [1.0 to 10.0].
[cto] appears. Controller Temperature Offset
Record the feature
setting [-10 to 10].
[OSU] appears. Optional Sensor Use
Record the feature
setting [OFF, ctS or
otS].
[oto] appears Optional Temperature Offset
Record the feature
setting [-10 to 10].
[C] appears A/C Mode Enabled
Record the feature
setting [y or n].
[cdt] appears Clutch Delay Timer
Record the feature
setting [0 to 999].
[d] appears Defrost Mode Enabled
2
 TriPac Service Procedure A02A
HMI Controller Program Features
STEP NO. ACTION RESULTS COMMENTS
21 This feature is not currently used
with TriPac. Do not change the
factory default setting.
22 Press the Mode key to advance to [dtP] appears Defrost Time Period
the next Program Feature.
23 This feature is not currently used
with TriPac. Do not change the
factory default setting.
24 Press the Mode key to advance to [dtr] appears Defrost Time Ratio
the next Program Feature.
25 This feature is not currently used
with TriPac. Do not change the
factory default setting.
26 Press the Mode key to advance to [H] appears Heat Mode Enabled
the next Program Feature.
27 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [y or n].
feature setting.
28 Press the Mode key to advance to [EHC] appears Heater Control Enabled
the next Program Feature.
29 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [y or n].
feature setting.
30 Press the Mode key to advance to [Eto] appears Heater Temperature Offset
the next Program Feature.
31 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [-10 to 10].
feature setting.
32 Press the Mode key to advance to [F] appears Fan Only Mode Enabled
the next Program Feature.
33 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [y or n].
feature setting.
34 Press the Mode key to advance to [AFS] appears Auto Fan Speed Enabled
the next Program Feature.
35 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [y or n].
feature setting.
36 Press the Mode key to advance to [HSS] appears Engine High Speed Timer
the next Program Feature.
37 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [0 to 999].
feature setting.
38 Press the Mode key to advance to [LSL] appears Engine Low Speed Lockout
the next Program Feature.
39 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [y or n].
feature setting.

3 P41PA02A - 25 October 2005

TriPac Service Procedure A02A
HMI Controller Program Features
STEP NO. ACTION RESULTS COMMENTS
40 Press the Mode key to advance to [Edo] appears Engine Delay Off Timer
the next Program Feature.
41 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [0 to 999].
feature setting.
42 Press the Mode key to advance to [EPS] appears External Power Source
the next Program Feature.
43 Press the Up Arrow key or Down Record the feature
Arrow key once to display the setting [y or n].
feature setting.
44 All programmable feature settings
have been recorded. Pressing the
Mode key again will start the menu
over with the [ctd] feature.

P41PA02A - 25 October 2005 4

 TriPac Service Procedure A02A
HMI Controller Hourmeter Screens Setup Sheet
Hourmeter Screens Typical or Default
Hourmeter Hours Function Setting Recorded Setting
txx Engine hours in
thousands of hours
XXX Engine hours in
hundreds of hours

HMI Controller Program Feature Setup Sheet

Program Typical
Feature Function Program Settings Recorded Setting
ctd HMI Controller cts, dbg, OFF, ots
Temperature Display
default = SPt
ddL Display Dimmer Level 1 to 15 [dimness
levels]
default = 3
cts HMI Controller Temperature F or C [degrees]
Scale
default = F
dbd HMI Controller 1.0 to 10.0 [degrees]
Dead Band [hysteresis] Degrees
default = 5
cto HMI Controller -10 to 10 [degrees]
Temperature Offset
default = 0
OSU Optional Sensor Use OFF, ctS, otS

default = OFF
oto Optional Temperature Offset -10 to 10 [degrees]
default = 0
C A/C Mode Enabled y or n
default = y
cdt A/C Clutch Delay Timer 0 to 999 [seconds]
default = 8

5 P41PA02A - 25 October 2005

TriPac Service Procedure A02A
HMI Controller Program Feature Setup Sheet
Program Typical
Feature Function Program Settings Recorded Setting
d Defrost Mode Enabled not used

dtP Defrost Time Period not used

dtr Defrost Time Ratio not used

H Heat Mode Enabled y or y or n

default = y
EHC Air Heater Control Enabled y or n

default = y
Eto Air Heater Temperature -10 to 10 [degrees]
Offset
default = 0
F Fan Only Mode Enabled y or n
default = y
AFS Auto Fan Speed Enabled y or n
default = n
HSS Engine High Speed Timer 0 to 999 [minutes]
default = 2
LSL Engine Low Speed y or n
Lockout
default = n
Edo Engine Delay Off Timer 0 to 999 [minutes]

default = 15
EPS External Power Source y or n
default = y

P41PA02A - 25 October 2005 6

 TriPac Service Procedure A03B
A03B Replacing the TriPac HMI Controller
Where Used
All TriPac units.

Purpose
This procedure should be used to remove and replace a TriPac HMI Controller.

Important Information
After the replacement HMI Controller is installed, see TriPac Service Procedure A04A to set up
the Program Codes.

Procedure

STEP ACTION RESULTS COMMENTS

1 Obtain a copy of the Setup
Sheet at the back of TriPac
Service Procedure A02A.
2 Record the existing HMI NOTE: It may not be possible
Controller settings using to accomplish part or all of this
TriPac Service Procedure process with a defective HMI
A02A on the Setup Sheet. Controller. If so, the
information must be obtained
from customer records.
3 Press the Main Power On/Off
key to turn the unit off.
4 Remove the screws that mount
the HMI Controller to the wall
of the truck cab sleeper
compartment.
5 Disconnect the HMI Controller
cable from the HMI Controller.
6 Disconnect the sensor leads The sensor leads are not
SP-1 and SP-2 from the HMI polarity sensitive.
Controller.
7 Connect the sensor leads
SP-1 and SP-2 to the
replacement HMI Controller.
8 Connect the HMI Controller
cable to the replacement HMI
Controller.
9 Position the replacement HMI
Controller over the screw holes
and mount it. Tighten the
screws securely.

1 P41PA03B - 25 October 2005

TriPac Service Procedure A03B
STEP ACTION RESULTS COMMENTS
10 Press the Main Power On/Off
key to turn the unit on.
11 Verify that the HMI Controller
powers up.
12 Obtain the completed Setup
Sheet.
13 Set up the Programmable
Features using TriPac Service
Procedure A04A.
14 Start and run the unit to verify
operation.

P41PA03B - 25 October 2005 2

 TriPac Service Procedure A04A
A04A TriPac HMI Controller Programmable Feature Setup
Where Used
All TriPac units.

Purpose
This procedure should be used to set up the programmable feature settings of a new or
replacement HMI Controller.

Use a completed copy of the Programmable Features Setup Sheet from Service Procedure
A02A or customer specifications to set the programmable features. For additional
programmable feature details see Section 3 of this manual.

Important Information
The settings at the HMI Controller vary in accordance with the TriPac user’s personal choices
for the truck cab sleeper compartment cooling, heating, and ventilation flow.

HMI Controller Program Features

STEP ACTION RESULTS COMMENTS
1 Press the Main Power On/Off key
to turn the unit on.
2 Pressing the Mode key scrolls forward
to the next Programmable Feature.
Pressing the Fan key loads the setting
shown in the display and then scrolls
forward to the next Programmable
Feature.
This Service Procedure will verify and
load each setting using the Fan key.
3 Press and hold both the Up Arrow [PPP] appears in the
and Down Arrow keys until [PPP] display.
appears in the display.
4 Press the Mode key to advance to [ctd] appears. Controller Temperature Display
the first Program Feature.
5 Press the Up Arrow key or Down Possible settings are The default setting is [SPt].
Arrow key once to display the [cts, SPt, dbg, OFF
current feature setting. If or otS].
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
6 When the correct setting is shown [ddL] appears. Display Dimmer Level
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
7 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [1 to 15].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.

1 P41PA04A - 25 October 2005

TriPac Service Procedure A04A
HMI Controller Program Features
STEP ACTION RESULTS COMMENTS
8 When the correct setting is shown [cts] appears. Controller Temperature Scale
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
9 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [F or C].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
10 When the correct setting is shown [dbd] appears. Dead Band Degrees
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
11 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [1.0 to 10.0].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
12 When the correct setting is shown [cto] appears. Controller Temperature Offset
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
13 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [-10 to 10].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
14 When the correct setting is shown [OSU] appears. Optional Sensor Use
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
15 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [OFF, ctS or otS].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
16 When the correct setting is shown [oto] appears Optional Temperature Offset
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
17 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [-10 to 10].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
18 When the correct setting is shown [C] appears A/C Mode Enabled
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.

P41PA04A - 25 October 2005 2

 TriPac Service Procedure A04A
HMI Controller Program Features
STEP ACTION RESULTS COMMENTS
19 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [y or n].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
20 When the correct setting is shown [cdt] appears Clutch Delay Timer
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
21 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [0 to 999].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
22 When the correct setting is shown [d] appears Defrost Mode Enabled
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
23 This feature is not currently used
with TriPac. Do not change the
factory default setting.
24 Press the Mode key to advance to [dtP] appears Defrost Time Period
the next Program Feature.
25 This feature is not currently used
with TriPac. Do not change the
factory default setting.
26 Press the Mode key to advance to [dtr] appears Defrost Time Ratio
the next Program Feature.
27 This feature is not currently used
with TriPac. Do not change the
factory default setting.
28 Press the Mode key to advance to [H] appears Heat Mode Enabled
the next Program Feature.
29 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [y or n].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
30 When the correct setting is shown [EHC] appears Heater Control Enabled
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
31 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [y or n].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
32 When the correct setting is shown [Eto] appears Heater Temperature Offset
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.

3 P41PA04A - 25 October 2005

TriPac Service Procedure A04A
HMI Controller Program Features
STEP ACTION RESULTS COMMENTS
33 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [-10 to 10].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
34 When the correct setting is shown [F] appears Fan Only Mode Enabled
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
35 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [y or n].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
36 When the correct setting is shown [AFS] appears Auto Fan Speed Enabled
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
37 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [y or n].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
38 When the correct setting is shown [HSS] appears Engine High Speed Timer
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
39 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [0 to 999].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
40 When the correct setting is shown [LSL] appears Engine Low Speed Lockout
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
41 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [y or n].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
42 When the correct setting is shown [Edo] appears Engine Delay Off Timer
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
43 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [0 to 999].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.

P41PA04A - 25 October 2005 4

 TriPac Service Procedure A04A
HMI Controller Program Features
STEP ACTION RESULTS COMMENTS
44 When the correct setting is shown [EPS] appears External Power Source
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
45 Press the Up Arrow key or Down Possible settings are
Arrow key once to display the [y or n].
current feature setting. If
necessary, press the Up Arrow or
Down Arrow keys again to select
the desired setting.
46 When the correct setting is shown
in the display, press the Fan key to
load the setting and advance to the
next Program Feature.
47 All programmable feature settings
have been made. Pressing the
Mode key will scroll thru the menu
to verify the settings are correct.

5 P41PA04A - 25 October 2005

TriPac Service Procedure A04A

P41PA04A - 25 October 2005 6

 TriPac Service Procedure A26A
A26A Welding on Units Equipped with Microprocessors
Where Used
All TriPac units.

Purpose
To prevent damage to the microprocessor during welding operations. Electric welding generates
extremely high amperage currents which can damage electrical and electronic components. In
order to minimize the possibility of damage the following procedures must be followed.

STEP ACTION RESULTS COMMENTS

Before Welding
1 Press the Main Power On/Off key
to turn the unit off.
2 Remove the TriPac battery
cables from the truck batteries.
3 Connect the welder ground cable
as close as possible to the area
where the welding is to be
performed. Move the welder
ground cable, as required.
After Welding is Completed
1 Reconnect the battery cables to
the truck batteries.
2 Press the Main Power On/Off key
to turn the unit on.
3 Start and run the unit to verify
operation.

1 P41PA26A - 25 October 2005

TriPac Service Procedure A26A

P41PA26A - 25 October 2005 2

 TriPac Service Procedure B02A
B02A TriPac Interface Board Removal and Replacement
Where Used
All TriPac units.

Purpose
This procedure should be followed when replacing the Interface Board.

STEP ACTION RESULTS COMMENTS

Remove the Interface Board from the Control Box
1 Press the Main Power On/Off key
to turn the unit off.
2 Remove the TriPac battery cables
from the truck batteries.
3 Open the storage compartment in
the truck cab sleeper compartment
and locate the TriPac Control Box.
4 Remove the screws that attach the
Control Box to the bunk
compartment.
5 Position the Control Box for easy
access.
6 Remove the screws that attach the
cover to the Control Box.
7 Remove all of the wiring harness
wires from the Interface Board
terminal boards.
8 Disconect the HMI Controller cable
from the Interface Board.
9 Disconnect the "2" wires from the Note the hardware stack when
power bus bar on the Interface removing the wires.
Board.
10 Remove the screws that attach the
Interface Board to the bottom of
the Control Box.
11 Lift and remove the Interface
Board from the Control Box.
Replace the Interface Board in the Control Box
1 Position the replacement Interface
Board in the Control Box.

1 P41PB02A - 25 October 2005

TriPac Service Procedure B02A
STEP ACTION RESULTS COMMENTS
2 Install the screws that secure the
Interface Board to the bottom of
the Control Box.
3 Connect all of the wiring harness Be certain all connections are to
wires to the Interface Board the correct terminals and are
terminal boards. tightened securely. See the
TriPac wiring diagram for
reference.
4 Connect the HMI Controller cable
to the Interface Board.
5 Connect the "2" wires to the power Connect the wires using the
bus bar on the Interface Board. hardware in the same order as
it was removed.
6 Position the cover on the Control
Box. Insert the screws and tighten
them.
7 Position the Control Box inside the
storage compartment. Insert the
screws that attach the Control Box
to the bunk compartment and
tighten.
8 Start and run the unit to confirm
operation.

P41PB02A - 25 October 2005 2

 TriPac Service Procedure D01A
D01A TriPac Control Sensor Test
Where Used
All TriPac units.

Purpose
This procedure is used to confirm the proper operation of the Control Sensor used with the HMI
Controller. The HMI Controller and Control Sensor are mounted in the truck cab sleeper
compartment.

STEP ACTION RESULTS COMMENTS

1 Press the Main Power On/Off key
to turn the unit off.
2 Remove the HMI Controller from
the sleeper compartment wall.
3 Disconnect the wall-mounted
control sensor at its plug.
4 Using a high quality digital
multimeter, check the resistance
between the sensor wires SP-1
and SP-2.
5 Considering the temperature at
the sensor, compare the
resistance reading obtained
above to the Temperature vs.
Resistance Table on the following
page.
6 If the sensor resistance does not
match the values shown in the
table within + 10% the sensor is
defective and must be replaced.

1 P41PD01A - 25 October 2005

TriPac Service Procedure D01A

Te m p Re s is tance Te m p Re s is tance
(de g. C) (Ohm s ) (de g. C) (Ohm s )
-25 86,430 45 4,911
-20 67,770 50 1,460
-15 53,410 55 3,536
-10 42,470 60 3,020
-5 33,900 65 2,588
0 27,280 70 2,228
5 22,050 75 1,924
10 17,960 80 1,668
15 14,690 85 1,451
20 12,090 90 1,266
25 10,000 95 1,108
30 8,313 100 9,731
35 6,940 105 8,572
40 5,827 110 7,576

P41PD01A - 25 October 2005 2

 TriPac Service Procedure F09A
F09A Flywheel Sensor Test and Adjustment
Where Used
All TriPac units.

Purpose
To test and adjust the Flywheel Sensor.

Materials Required
Fluke digital multimeter.

Operation
The Flywheel Sensor rarely fails, but might require adjustments for proper operation.

Procedure

STEP ACTION RESULTS COMMENTS

1 Press the Main Power On/Off key
to turn the unit off.
2 Turn the Engine On/Off switch to The Engine On/Off switch is
off. located in the upper right corner
of the APU.
3 Remove the FS1 and FS2 wires
from the sensor.
4 Check the sensor resistance The sensor resistance should be
using a Fluke digital multimeter. 250 to 300 ohms with the wires
removed. If not, the sensor
should be replaced.
5 Loosen the lock nut, turn the
sensor in until it contacts the ring
gear on the flywheel, then back it
out 1/4 turn and tighten the lock
nut.
6 Reattach the FS1 and FS2 wires Polarity is not important.
to the sensor.
7 If a problem still exists, check
circuit continuity from the
flywheel sensor to the interface
board using Service Procedure
H04A.

1 P41PF09A - 25 October 2005

TriPac Service Procedure F09A

P41PF09A - 25 October 2005 2

 TriPac Service Procedure H04A
H04A Checking Harness Continuity
Where Used
All TriPac units.

Purpose
To illustrate the correct procedures for checking harness continuity on equipment utilizing solid
state devices.

STEP ACTION RESULTS COMMENTS

CAUTION STATEMENTS
1 Do not use battery and light Using such devices might
combinations to check continuity. present excessive voltage or
current to solid state devices. In
most cases the device will be
damaged or destroyed.
2 Use a high quality digital Older analog (needle type meter
multimeter such as that illustrated movement) meters and some
or an analog meter with high inexpensive “mechanic tool box”
input impedance. meters present a large load to the
circuit being tested. This can
significantly alter the meter
reading, especially when
measuring small voltages or
currents.
3 Never test a circuit to see if it is Causing a spark will damage
energized by tapping the circuit solid state components or blow a
wire to ground and watching for a fuse.
spark.

1 P41PH04A - 25 October 2005

TriPac Service Procedure H04A
STEP ACTION
4 Locate the suspect circuit on the
appropriate electrical schematic
diagram.
5 Isolate both ends of the circuit
using the following methods, as
required.
• Disconnect the appropriate
connector at the Interface
Board.
• Disconnect the device
connector at the device.
• Remove the wire from the
device terminal.
6 Using jumpers as required,
connect each end of the circuit to low resistance (less than 1.0
a high quality multimeter.
7 After determining that the circuit
passes a continuity test, remove
one lead and connect it to
chassis ground to check for a
short to ground.
P41PH04A - 25 October 2005
RESULTS COMMENTS
Harness connections can be
determined by consulting the
electrical schematics and
harness diagrams.
CAUTION: Failure to isolate
both ends might cause
misleading results.
The multimeter must show a very Be certain the ohmmeter battery
is good and the meter zeros with
ohm), indicating circuit continuity. the leads held together.
If not, the circuit is open or has
excessive resistance.
Troubleshoot the circuit to
determine the cause, using the
electrical schematic diagrams.
The meter should indicate an
open circuit. If continuity is
indicated, the circuit is shorted to
ground. Troubleshoot the circuit
to determine the cause of the
short using the electrical
schematic diagrams.
2
 TriPac Service Procedure H14A
H14A Smart FET Test Procedure
Where Used
All TriPac units

Purpose
This procedure is used to confirm the proper operation of the Smart FETs on the Interface
Board.

Materials
• Fluke digital MultiMeter
• Test leads with alligator clips
• 1000 Ohm Resistor, 1/2 watt or larger

Procedure
A Smart FET (Field Effect Transistor) is a solid state device used to apply and remove power to
various circuit devices such as solenoids. If the device draws too much current when
energized, the Smart FET will turn off to prevent damage to the connected device and related
circuitry. When the problem is resolved the Smart FET will resume normal operation. Smart
FET outputs typically do not use a fuse to protect the output device.
Care must be taken to insure that a load is present in order to properly check the operation of
Smart FET outputs. If there is no load connected to the output, the output will read +12 Vdc
even though the output is actually turned off. The Smart FET output is functioning properly. The
+12 Vdc reading is caused by the lack of a load on the Smart FET output. The Interface Board
should not be replaced.
To ensure accurate readings when checking Smart FET outputs, connect a 1000 ohm resistor
from the positive meter lead to chassis ground. This provides a load to the Smart FET output,
even if the actual load is disconnected or open. The meter will read +12 Vdc when the output is
turned on and 0 Vdc when the output is turned off.

COMPLETE CIRCUIT
Here the circuit is complete, with a load connected to M
TriPac the Smart FET output. Current flows from the Smart Vdc
Interface FET output, through the solenoid coil to chassis
Board ground. When the Smart FET output is "on", the meter
(M) will indicate 12 Vdc. When the Smart FET output
Smart FET
is "off", the meter (M) will indicate 0 Vdc.
Output
Solenoid
Coil

1 P41PH14A-19 October 2005

TriPac Service Procedure H14A

OPEN CIRCUIT
OPEN CIRCUIT
Here the circuit is open. There is no load connected to
Here
the theFET
Smart circuit is open.
output. WhenThere
the is no load
Smart FETconnected
output is to M
TriPac the Smart FET output. When the Smart FET output M
Vdc
TriPac "on", the meter (M) will indicate 12 Vdc. When the FETis Vdc
Interface "on", the meter (M) will indicate 12 Vdc. When the
Interface output is "off", the meter (M) may still indicate 12 Vdc
Board FET
due to output
the open is "off",
circuit.theThe
meter (M) FET
Smart will still
outputindicate
is 12
Board Vdc due to the open circuit. The Smart FET output
working properly. The Interface Board should not
Smart FET beisreplaced.
working properly. The Interface Board should
Smart
OutputFET not be replaced.
Output Open
Open Solenoid
Solenoid
Coil
Coil

OPEN CIRCUIT with LOAD RESISTOR on METER

OPEN CIRCUIT with LOAD RESISTOR on METER
Here the circuit is still open but a 1000 ohm resistor is M
TriPac Here the from
connected circuitthe
is +
still openlead
meter but to
a 1000 ohm
chassis resistor is
ground. M
Vdc
TriPac connected from the + meter lead to chassis ground. Vdc
Interface This provides a load for the Smart FET output. When
Interface This
the provides
Smart a loadisfor"on",
FET output the the
Smart FET
meter output.
(M) will When 1000 Ohm
Board 1000 Ohm
Board indicate 12 Vdc. When the Smart FET output iswill
the Smart FET output is "on", the meter (M) "off",
indicate
the 12 Vdc.
meter (M) When the
will indicate Smart FET output is "off",
0 Vdc.
Smart FET the meter (M) will indicate 0 Vdc.
Smart
OutputFET
Output Open
Connecting a Resistor to Ground Open Solenoid
Connecting
Connect a 1000a ohmResistor to in
resistor Ground
a clip-on lead. Clip Solenoid
Coil
Connect
one end of athe
1000
leadohm resistorground.
to chassis in a clip-on
Clip lead. Clip
the other Coil
end of the lead to the positive meter probe. This other
one end of the lead to chassis ground. Clip the
end of the
provides lead load
a circuit to thetopositive
assure anmeter probe.indication
accurate This
ofprovides
Smart FETa circuit
outputload to assure an accurate indication
operation.
of Smart FET output operation.

Diagnosing a Smart FET circuit

When testing a Smart FET circuit the following steps are suggested.
• Disconnect the circuit load at the Interface Board. Check the load resistance with an
ohmmeter to determine if the circuit is shorted, open or shorted to ground. Correct as
required.
• Reconnect the circuit load.
• Determine what conditions will turn the Smart FET on and duplicate those conditions.
• Check the output with a good quality multimeter set to read DC volts. 12 Vdc should be
present.
• Determine what conditions will turn the Smart FET off and duplicate those conditions.
• Check the output with a good quality multimeter set to read DC volts. 0 Vdc should be
present.If any question exists, confirm the readings using a 1000 ohm resistor from the
positive meter probe to chassis ground as shown above.

P41PH14A-19 October 2005 2

 Section 7 - TriPac Information

TriPac Software Features and

Interchange . . . . . . . . . . . . . . . . . . . . . . . .7-1
HMI Controller Software . . . . . . . . . . . . . . .7-1
Interface Board Software . . . . . . . . . . . . . .7-1
TriPac Hardware Features and
Interchange . . . . . . . . . . . . . . . . . . . . . . . .7-1
Interface Board . . . . . . . . . . . . . . . . . . . . . .7-1
HMI Controller . . . . . . . . . . . . . . . . . . . . . . .7-1
TriPac Bulletins . . . . . . . . . . . . . . . . . . . . . . .7-1
TriPac Service Bulletins . . . . . . . . . . . . . . .7-1
 Section 7 - TriPac Information

TriPac Software Features and Interchange

To identify the software version used with your TriPac Interface Board and HMI Controller, see
Service Procedure A06A in Section 6 of this manual.

CAUTION: The software of a replacement component should always be checked to

be certain that it is the current software revision.

HMI Controller Software

Software Revision Number Features Interchange With:
r20 Production release n/a

Interface Board Software

Software Revision Number Features Interchange With:
CC Production release n/a

TriPac Hardware Features and Interchange

Interface Board
Item Features TK Part Number Interchange With:
Interface Board Production release 41-6848 n/a

HMI Controller
Item Features TK Part Number Interchange With:
HMI Controller Production release 45-2126 n/a

TriPac Bulletins
TriPac Service Bulletins
Service Bulletin Title Date
Number
T&T 386 TriPac Evaporator Wiring Harness 08/29/05
T&T 387 TriPac Governor Spring—Tier 2 Engines 09/16/05

25 October 2005 7-1

Section 7 - TriPac Information

7-2 25 October 2005

 Section 8 - Schematics and Wiring Diagrams
The following schematic and wiring diagrams are for the TriPac system.

Diagram, Schematic and Wiring

TK Part Number Description
1E34010 Rev A Diagram, Schematic, TriPac
1E34011 Rev A Diagram, Wiring, TriPac
8-1
8-2