Diagnostic Manual

TriPac

TriPace Auxiliary
eTM

TM
Auxiliary Power Unit

Power Unit
TK 54294-19-OD (Rev. 2, 2/16)

TK 54294-19-OD
(Rev. 2, 2/16)
 DIAGNOSTIC MANUAL

TriPace™ Auxiliary Power Unit

TK 54294-19-OD (Rev. 2, 02/16)

Main Controller Software Revision 31 xx

HMI Control Panel Software Revision 32 xx

Smart Charger Module (SCM) Software Revision 33 xx

TK Monitor Software Revision 1.01

Copyright © 2011 Thermo King Corp. - Minneapolis, MN, USA

Printed in USA
Revision History – TriPace Auxiliary Power Unit Diagnostic Manual
Production Release TK 54294-19-OD (07/10)
Revision 1.1 Update (12/11)
Final Update (02/16)

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 manufacturer’s plants as, in the manufacturer’s judgment, to affect its 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.
 TriPace Hardware and Software

This manual covers the following hardware revisions:

Main Controller Board Version Rev C

Smart Charger Module (SCM) Rev 1

This manual covers the following software revisions:

Main Controller Software Revision 31 0 100 and 31 01

HMI Control Panel Software Revision 32 0 33 and 32 01
Smart Charger Module (SCM) Software Revision 42 0 13 and 33 01
TK Monitor Software Revision 1.0.B.6 and 1.01

See Section 7 of this manual for additional details.

 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 the TriPace control system. Read this material carefully
before working on the unit.

Section 2 - Hardware Description

This section describes the TriPace control system hardware. It identifies and locates controllers, relays,
LED’s, fuses and other components and provides connector maps for all connectors.

Section 3 - Software Description

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

Section 4 - System Operation

This section explains how to operate the TriPace control system. This information is referenced by material in
Section 5 Diagnostics.

Section 5 - Diagnostics
This section explains how to diagnose units equipped with the TriPace control system. 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 equipped with the
TriPace control system. These procedures are referenced by the diagnostic routines in Section 5
Diagnostics.

Section 7 - Service Information

This section offers Service Information on the basic component parts of the TriPace control system. It
includes hardware and software history as well as interchangeability information.

Section 8 – Schematics and Wiring Diagrams

This section includes the SR-2 control system electrical schematics and unit wiring diagrams.
Safety Information
 Section 1 – TriPace Safety Information

TABLE OF CONTENTS - SECTION 1

Safety Definitions .................................................................................................................................................... 2
General Practices .................................................................................................................................................... 2
Compressor.............................................................................................................................................................. 3
Refrigerant................................................................................................................................................................ 3
Refrigerant First Aid ........................................................................................................................................... 3
Refrigeration Oil....................................................................................................................................................... 4
Refrigeration Oil First Aid.................................................................................................................................. 4
Electrical Considerations ....................................................................................................................................... 4
Main Controller Service ..................................................................................................................................... 4
Welding................................................................................................................................................................ 4
Electrical Hazards .................................................................................................................................................... 4
Low Voltage ........................................................................................................................................................ 4
High Voltage (115 Vac)....................................................................................................................................... 4
High Voltage First Aid, Electrical Shock .......................................................................................................... 5
Battery Removal ................................................................................................................................................. 5
Heater Safety Precautions ...................................................................................................................................... 5

1-1
 Section 1 – TriPace Safety Information

WARNING: Always wear goggles or safety

SAFETY DEFINITIONS
glasses. Refrigerant liquid, refrigeration oil, and
DANGER: Addresses a circumstance that, if
battery acid can permanently damage the eyes
encountered, will lead to death or serious injury.
(see Refrigeration Oil First Aid).

WARNING: Addresses a circumstance that, if

WARNING: Keep your hands away from fans
encountered, might lead to death or serious
when the unit is running.
injury.

WARNING: Make sure all mounting bolts are

CAUTION: Addresses a circumstance that, if
tight and are of correct length for their particular
encountered, may cause damage to equipment
application.
or minor injury.

WARNING: Never drill holes into the unit. Holes

GENERAL PRACTICES drilled into the unit may weaken structural

DANGER: Always turn the TriPace unit off while components. Holes drilled into electrical wiring

refueling the truck. Fuel vapors could ignite if can cause fire or explosion.

they come in contact with TriPace electrical or

heater components. WARNING: When using ladders to install or
service refrigeration systems, always observe

DANGER: Never apply heat to a sealed the ladder manufacturer’s safety labels and

refrigeration system or container because it warnings. A work platform is the recommended

could explode, causing death or serious injury. method for installations.

DANGER: Fluorocarbon refrigerants, in the WARNING: Make sure your gauge manifold

presence of an open flame, spark or electrical hoses are in good condition before using them.

short produce toxic gases that are severe Never let them come in contact with moving

respiratory irritants. belts, fans, pulleys or hot surfaces. Defective

gauge equipment can damage components or

DANGER: Be careful when working with a cause serious injury.

refrigerant or refrigeration system in any

enclosed or confined area with a limited air WARNING: Turn the unit HMI Controller Off

supply (i.e., a trailer, container or the hold of a before opening the Battery Box or inspecting

ship). Refrigerant tends to displace air and can any part of the unit.

cause oxygen depletion which may result in

death by suffocation.

1-2
 Section 1 – TriPace Safety Information

CAUTION: Use caution when working around

exposed coil fins. The fins can cause painful When working on transport refrigeration systems, a
lacerations. recovery process that prevents or minimizes
refrigerant loss to the atmosphere is required by law.
NOTE: In the USA, EPA Section 609 Certification In addition, service personnel must be aware of the
is required to work on air conditioning systems. appropriate European Union, national, federal, state
and/or local regulations governing the use of
refrigerants and certification of technicians.
COMPRESSOR
WARNING: Immediately get away if you hear
When refrigerants are exposed to the atmosphere in
sounds of arching inside the compressor
liquid form, they evaporate rapidly, freezing anything
(sizzling, sputtering, or popping). Burns from
they contact. If they contact the skin severe frostbite
compressor venting with ignition may result.
can result. In the event of frostbite, the objectives of
first aid are to protect the frozen area from additional
WARNING: Improper servicing can lead to fire, injury and to warm it rapidly.
electrocution, or explosion. Never service,
repair, or troubleshoot a system unless you are Refrigerant First Aid
a professional service person.
● FROSTBITE: In the event of frost bite, the
objectives of First Aid are to protect the frozen
REFRIGERANT area from further injury, to warm the affected
area rapidly, and to maintain respiration.
WARNING: Although fluorocarbon refrigerants
are classified as safe refrigerants, certain
● EYES: For contact with liquid, immediately flush
precautions must be observed when handling
eyes with large amounts of water and get
them or servicing a unit in which they are used.
prompt medical attention.
When released to the atmosphere from the liquid
state, fluorocarbon refrigerants evaporator
● SKIN: Flush area with large amounts of
rapidly, freezing anything they contact.
lukewarm water. Do not apply heat. Remove
contaminated clothing and shoes. Wrap burns
At Thermo King we recognize the need to preserve
with dry, sterile, bulky dressing to protect from
the environment and limit the potential harm to the
infection/injury. Get medical attention. Wash
ozone layer that can result from allowing refrigerant
contaminated clothing before reuse.
to escape into the atmosphere.

● INHALATION: Move victim to fresh air and use

We strictly adhere to a policy that promotes the
CPR if necessary. Stay with victim until arrival of
recovery and limits the loss of refrigerant into the
emergency medical personnel.
atmosphere.

1-3
 Section 1 – TriPace Safety Information
REFRIGERATION OIL
WARNING: Avoid refrigeration oil contact with
the eyes. Avoid prolonged or repeated contact of
refrigeration oil with skin or clothing. Wash
thoroughly after handling refrigeration oil to
prevent irritation.
Refrigeration Oil First Aid
In case of eye contact, flush immediately with water
for at least 15 minutes. Obtain medical assistance
as soon as possible.
ELECTRICAL
CONSIDERATIONS
Main Controller Service
Precautions must be taken to prevent electrostatic
discharge when servicing the base controller and
related components. A potential difference less than
that required to create a small spark between a
finger and a doorknob can cause severe damage to
solid state components.
Welding
Precautions must be taken before welding on the
unit. Refer to Service Procedure A26A Welding on
Units Equipped with Solid State Control Systems in
Section 6 of this manual for additional information.
1-4
ELECTRICAL HAZARDS
Low Voltage
WARNING: Control circuits used in the TriPace
unit are low voltage (12 to 28 volts dc). This
voltage potential is not considered dangerous,
but the large amount of current available can
cause severe burns if shorted or grounded.
WARNING: Do not wear jewelry, watches or
rings when working on the unit. If these items
contact an electrical circuit, severe burns may
result.
CAUTION: Always disconnect power at the
battery before removing or repairing electrical
components. Failure to do so may result in
personal injury or damage to the equipment.
High Voltage (115 Vac)
DANGER: Lethal amounts of voltage are present
in some electrical circuits. Use extreme care
when working on an operating unit.
WARNING: Do not make rapid moves when
working on high voltage circuits in the unit. Do
not grab for falling tools because you might
accidentally touch a high voltage source.
WARNING: Use tools with well insulated
handles. Never hold uninsulated metal tools near
exposed, energized conductors.
 Section 1 – TriPace Safety Information
WARNING: Treat all wires and connections as if
they were high voltage until a meter and wiring
diagram indicate otherwise.
WARNING: Never work alone on high voltage
circuits in the unit. Another person should be
nearby to shut off the unit and provide aid in the
event of an accident.
WARNING: Safety glasses, rubber- insulated
gloves and cable cutters should be near your
work area, in the event of an electrical accident.
High Voltage First Aid, Electrical Shock
Take IMMEDIATE action after a person has
received an electrical shock. Get quick medical
assistance, if possible.
The source of the shock must be quickly stopped, by
either shutting off the power or removing the victim.
If the power cannot be shut off, the wire should be
cut with a non-conductive tool, such as a wood-
handle axe or thickly insulated cable cutters.
Rescuers should wear insulated gloves and safety
glasses, and avoid looking at wires being cut. The
ensuing flash can cause burns and blindness.
If the victim must be removed from a live circuit, pull
the victim away with a non-conductive material. Use
wood, rope, a belt or coat to pull or push the victim
away from the current. DO NOT TOUCH the victim.
You will receive a shock from current flowing
through the victim’s body. After separating the victim
from power source, immediately check for signs of a
pulse and respiration. If no pulse is present, start
CPR (cardio pulmonary resuscitation). If a pulse is
present, respiration might be restored by using
1-5
mouth-to-mouth resuscitation. Call for emergency
medical assistance.
Battery Removal
DANGER: Disconnect the negative battery
terminal (-) first when removing a battery.
Connect the positive terminal (+) first when
installing a battery.
This order is important 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. Metal objects contacting the positive
side and the frame simultaneously will cause sparks
or arcing. If there are sufficient hydrogen gases
emitted from the battery, an explosion might occur,
causing equipment damage, serious injury, even
death.
HEATER SAFETY
PRECAUTIONS
DANGER: EXPLOSION HAZARD or FIRE
HAZZARD! Failure to follow these instructions
could cause an explosion or fire resulting in
serious or fatal injury!
Heater must be turned off while re-fueling.
● Stored items in vehicle may shift while vehicle is
in operation and should be secured adequately
to prevent contact with the heater.
● Use a protective air intake grille on the air inlet
side of the heater to prevent objects from being
sucked in.
 Section 1 – TriPace Safety Information

● The heater must only be operated when the

maintenance cover is closed.

● Do not store or transport combustibles (road

flares, starting fluids, fuel containers, oil cans,
spray cans, gas cartridges, fire extinguishers,
cleaning rags, clothing, paper, etc.) in the same
compartment as the heater.

● Ensure that the fuel system is intact and there

are no leaks.

● Do not route electrical wires, harness or battery

cables together with fuel lines.

DANGER: ASPHYXIATION HAZARD! Failure to

follow these instructions could cause oxygen
depletion resulting in serious or fatal injury!

● Ensure an air tight seal will be maintained

between the heater and mounting surface and at
any exhaust connection points.

● The heater must not be operated in closed

areas such as garages, buildings, warehouses,
etc.

● Do not inhale exhaust fumes.

1-6
Hardware Description
 Section 2 – TriPace Hardware Description

TABLE OF CONTENTS - SECTION 2

General Description ................................................................................................................................................ 4

Major Components .................................................................................................................................................. 5
HMI Control Panel .............................................................................................................................................. 5
TriPace Battery Box ............................................................................................................................................ 6
Batteries ......................................................................................................................................................... 6
Smart Charger Modules (SCM) .................................................................................................................... 6
Current Sensor .............................................................................................................................................. 7
DC to DC Converter ...................................................................................................................................... 7
Fuse Block ..................................................................................................................................................... 7
Evaporator/Control Box ..................................................................................................................................... 8
Main Controller (1) ........................................................................................................................................ 9
Compressor Controller (2) ......................................................................................................................... 10
Compressor (3) ............................................................................................................................................ 10
Evaporator Coil (4) ...................................................................................................................................... 10
Evaporator Fan (5) ...................................................................................................................................... 10
Sensors ........................................................................................................................................................ 10
Condenser Housing ......................................................................................................................................... 10
Condenser Coil ............................................................................................................................................ 10
Condenser Fan ............................................................................................................................................ 11
Receiver/Drier .............................................................................................................................................. 11
Ambient Temperature Sensor .................................................................................................................... 11
Air Heater .......................................................................................................................................................... 11
Optional 115 Vac Components ....................................................................................................................... 12
AC to DC Power Converter ........................................................................................................................ 12
Power Inverter ............................................................................................................................................. 12
Truck Integration .............................................................................................................................................. 13
OEM Battery Pack ....................................................................................................................................... 13
Alternator ..................................................................................................................................................... 13
Ignition Switch ............................................................................................................................................. 13
Air Conditioning System ....................................................................................................................................... 13
Power Circuits ....................................................................................................................................................... 14
Main Fuse Block ............................................................................................................................................... 14
Smart Charger Modules (SCM) .................................................................................................................. 14

2-1
 Section 2 – TriPace Hardware Description

Truck Batteries ............................................................................................................................................ 14

115 Vac Converter (Optional) ..................................................................................................................... 14
Power to Controllers ........................................................................................................................................ 14
Main Controller / Interface Board .............................................................................................................. 14
DC to DC Converter .................................................................................................................................... 14
Compressor Controller ............................................................................................................................... 14
Power to Components ..................................................................................................................................... 14
Evaporator fan ............................................................................................................................................. 14
Condenser fan ............................................................................................................................................. 15
Compressor ................................................................................................................................................. 15
Heater ........................................................................................................................................................... 15
Fuses ...................................................................................................................................................................... 16
Fuse Block / Battery Box Connections Diagram ................................................................................................ 17
Plug Pinout and Location Diagrams .................................................................................................................... 18
Main Controller Interface Board Connector Locations ................................................................................ 18
Main Controller Interface Board Connector Usage ...................................................................................... 19
Main Controller Interface Board Connector Maps ........................................................................................ 20
J34 – HMI Control Panel Harness CAN Connector – arranged by pin number .................................... 20
J35 – Evaporator Sensor Harness Connector – arranged by pin number ............................................ 21
J36 – Main Controller Interface Board Connector ................................................................................... 21
J37 – Battery Box Harness Connector – arranged by pin number ........................................................ 22
J38 – J1939 Connector ............................................................................................................................... 22
J39 – Main Controller Data Port Connector ............................................................................................. 22
J52 – Spare RS-232 Serial Connector ....................................................................................................... 23
J53 – Spare I/O Connector ......................................................................................................................... 23
J54 – Heater Control Harness Connector – arranged by pin number ................................................... 23
J55 – Compressor Sensor Harness (HPCO) Connector – arranged by pin number ............................ 24
J56 – Compressor Control Harness Connector – arranged by pin number ......................................... 25
J58 – Evaporator Fan Harness Connector – arranged by pin number .................................................. 26
J59 – Condenser Fan Harness Connector ............................................................................................... 26
J65 – Heater Power Harness Connector – arranged by pin number ..................................................... 27
J70 – ING Wire to Truck Ignition Switch Connector ................................................................................ 27
Compressor Controller Board Connector Locations ................................................................................... 28
Compressor Controller Board Connector Usage ......................................................................................... 29

2-2
 Section 2 – TriPace Hardware Description

Compressor Controller Board Connector Maps ........................................................................................... 29

J1 – 28V Wire to DC to DC Converter........................................................................................................ 29
J2 – CH02 Wire to DC to DC Converter ..................................................................................................... 29
J3 – Blue Wire to Compressor ................................................................................................................... 29
J4 – Orange Wire to Compressor .............................................................................................................. 29
J5 – Orange Wire to Compressor .............................................................................................................. 29
JP3 – Compressor Control Harness Connector – arranged by pin number ......................................... 30
JP5 – Compressor Control Harness Connector – arranged by pin number ......................................... 30
JP6 – Compressor Overload Switch Harness Connector – arranged by pin number ......................... 31
Compressor Wire Connections ...................................................................................................................... 31
HMI Connector Map .......................................................................................................................................... 32
HMI Control Panel Harness CAN Connector – arranged by pin number .............................................. 32
Condenser Fan Connector Map ...................................................................................................................... 33
Condenser Fan Harness Connector – arranged by pin number ............................................................ 33
Current Sensor Connector Map ...................................................................................................................... 33
Battery Box Harness Current Sensor Connector – arranged by pin number ....................................... 33
Heater Connector Map ..................................................................................................................................... 34
Heater Control Harness Heater Connector – arranged by pin number ................................................. 34

2-3
 Section 2 – TriPace Hardware Description

● Drive time between layovers may be too short.

GENERAL DESCRIPTION
The TriPace™ APU system is designed to maintain
comfortable conditions in the truck cab without
running an engine. No engine means there are no
exhaust emissions and no fuel consumption. The
system is capable of cooling or heating the cab. It is
a battery powered solution that uses sophisticated
power management technology. When installed the
TriPace APU is integrated into the truck cab and
frame. It has a similar hardware footprint to the
There may not be adequate time to fully
recharge the system in preparation for the next
lay over.
If customer requirements do not fit within the TriPace
operating profile the customer may not be satisfied
with the performance of the system. There is still a
place for the TriPac engine solution.
Maximum climate control time is controlled by the

TriPac engine solution. The TriPace system goals total available power reserve in the TriPace

are to provide optimum HVAC performance while batteries. To achieve maximum run time, especially

achieving maximum battery life. The air conditioning when outside temperature is high, the operator

system will provide 7,200 Btu of cooling capacity at should take steps to conserve power reserve by

95 F ambient and 70 F cab temperatures. It should reducing power consumption. Suggested steps

be able to maintain this for about 10 to 12 hours include:

depending on driver accessory, Hotel Load, truck

● Keep window curtains closed to reduce radiant
battery type and battery condition.
heat that will increase cab temperature.

The TriPace solution works best under moderate

● Close curtain between cab and sleeper to
ambient conditions and may not be suitable for all
reduce air conditioning load.
customers or applications.

● Limit the on time and number of cab lights or

● In very cold ambient conditions the Espar heater
can maintain a comfortable cab temperature but
does not provide truck engine heating capability.
● In very hot ambient conditions the HVAC system
may run continuously, drawing power from the
batteries. This will reduce the potential total run
time and may be less than the layover time.
truck accessories to reduce battery power drain.
● Limit the on time and number of devices or
appliances connected to the optional AC Power
Inverter to reduce battery power drain.
● Connect to external Shore Power, if available, to
increase power reservoir.

● Driver layover of more than one night will

exhaust the battery reserve. The TriPace system
is intended for overnight driver comfort with
several hours of drive time to charge the
batteries before the next operation.

2-4
 Section 2 – TriPace Hardware Description

MAJOR COMPONENTS HMI Control Panel

The TriPace system is divided into several major The HMI (Human Machine Interface) is the driver
components that are installed on and in the truck control panel that is typically mounted in the bunk
structure. area. It is an easy to use control that allows the
driver to select the desired function of the system. It
● HMI Control Panel
will also provide driver feedback of alarms, battery
● TriPace Battery Box level and system status. The HMI has three selector
● Evaporator / Control Box knobs and a battery monitor display but no digital
display. The HMI also contains an integral Cab
● Condenser Housing
Temperature Sensor.
● Air Heater
The driver can select these basic functions from the
● 115 Vac Components HMI:

● System On/Off

● Mode (Cool, Fan, Heat)

● Desired Cab Temperature (Cooler-Warmer)

● Fan Speed (OFF, Auto, Variable)

HMI Control Panel

2-5
 Section 2 – TriPace Hardware Description

TriPace Battery Box ● +BATTA = Positive connection from one of the

two batteries. Terminal protected by a 60 amp
The Battery Box is the most obvious part of the
fuse.
system. It is mounted to the truck frame rail similar
to a TriPac APU. It contains the following ● +BATTB = Positive connection from one of the

components. two batteries. Terminal protected by a 60 amp

fuse.
Batteries
● CAN Plugs = Located on the bottom.
The battery box contains four Thermo King NXT Connection to system communication harness.
(green top) Absorbed Glass Mat (AGM) Deep Cycle
1
batteries. These batteries have been specifically 2
designed for the TriPace system to maximize battery 3
life and support deep discharge cycles. They provide
increased power storage capacity for the system.

Smart Charger Modules (SCM)

4
Each pair of batteries is connected to a Smart
Charger Module (SCM). The SCMs control current
flow to and from the batteries based on commands
from the Main Controller. An SCM can place a
battery in one of three modes. Charge Mode allows
current to flow into a TriPace battery. Discharge 5
Mode allows current to flow out of a TriPace battery.
Null Mode prevents flow of current in either direction. 1. -CH (Ground) Terminal
An SCM can charge or discharge only one battery at 2. 2 SCM to Fuse Block
3. +BATTA and +BATTB to Batteries
a time. The other will be in Null Mode. An SCM can
4. LEDs
isolate a battery from the system. 5. CAN Plugs on Bottom
There are four terminals on the top of each SCM. Smart Charger Module (SCM)

● -CH = Each battery negative cable is attached There are two LED indicators on the front of each
here. It is ground for the SCM. Connected to SCM. They display the status of the SCM in relation
Batt Box GND terminal. to each battery. Refer to Section 5, Diagnostics,
LED Indicators for additional details.
● 2SCM = Main input/output terminal. Connected
to the fuse block. Terminal protected by a 60
amp fuse.

2-6
 Section 2 – TriPace Hardware Description

Current Sensor 1 2 3

A current sensor is mounted on the battery cable

running to the OEM truck battery pack. It tells the
Main Controller when, how much and what direction 4
current is flowing between the truck batteries and
the TriPace system.

DC to DC Converter

The DC to DC Converter module is mounted on the

outside of the battery box. It converts the 12 Vdc
5
power from the batteries to 28 Vdc. This increased
voltage is used to run the air conditioning
compressor with reduced amperage.

Fuse Block 6

The Battery Box is also the central connection point

for all of the system 12 Vdc power sources. A fuse
1. DC to DC Converter
block on top of the batteries is connected to both of
2. Current Sensor
the SCM main input/output terminals, truck batteries, 3. Fuse Block
DC-DC converter and Main Controller. Several main 4. Smart Charger Module 1 (SCM1)
fuses are located on the fuse block. There is also a 5. Smart Charger Module 2 (SCM2)
6. Battery
main grounding stud on the upper battery support
plate. Battery Box (Cover Removed)

2-7
 Section 2 – TriPace Hardware Description

Evaporator/Control Box

The Evaporator/Control Box has combined the

electrical control system and much of the air
conditioning system into one enclosure. It will be
mounted in the cab under the bunk similar to a
TriPac evaporator box. It contains the following
components.

4
2

1
3

1. Main Controller 4. Evaporator Coil

2. Compressor Controller 5. Evaporator Fan
3. Compressor
Evaporator/Control Box

2-8
 Section 2 – TriPace Hardware Description

Main Controller (1) Controller contains plug connections and fuses. It

provides power outputs for the condenser and
The Main Controller is a combination of
evaporator fans and controls the speed of these
microprocessor and interface board. It contains the
fans. It also contains the data logger memory. The
operating logic for the system. The Main Controller
Main Controller is self protected against over voltage
receives and processes system information from the
up to 36 volts and reverse polarity for a short time.
sensors, SCMs and driver inputs through the HMI. It
sends operation commands to the SCMs,
compressor controller and heater. The Main

Main Controller

2-9
 Section 2 – TriPace Hardware Description
Compressor Controller (2)
The Compressor Controller module monitors and
controls the air conditioning compressor. It will
receive commands from the Main Controller to turn
the compressor On or Off and the desired
compressor speed. The Compressor Controller
receives 28 Vdc from the DC to DC Converter and
sends variable voltage to the compressor.
Compressor (3)
The air conditioning compressor is a variable speed
28 Vdc hermetic (sealed) unit. Its operation is
controlled by the Compressor Controller. The
compressor sends high pressure vapor refrigerant to
the condenser coil.
Evaporator Coil (4)
The evaporator coil, together with the expansion
valve, absorbs heat from the cab air flowing through
it. It receives high pressure liquid from the
condenser and sends low pressure vapor to the
compressor.
Evaporator Fan (5)
The evaporator fan circulates air from the cab, return
air, through the evaporator coil and back to the cab.
It is a variable speed fan that receives power and
speed commands from the Main Controller. The fan
contains an internal motor driver. Fan speed is
controlled using a Pulse Width Modulation (PWM)
signal through the speed control wire in the harness
to the motor.
2-10
Sensors
The Evaporator/Control Box contains two thermistor
type temperature sensors, Return Air Temperature
(RTS) and Evaporator Coil Temperature (CTS).
These sensors are not polarity sensitive. The Main
Controller uses the Return Air Temperature sensor
together with the Cab Temperature sensor located in
the HMI and the desired setpoint to control the air
conditioning system. The Evaporator Coil
Temperature sensor is primarily used to prevent
frost from forming on the evaporator coil. As coil
temperature approaches 32º F (0º C) compressor
speed will reduce and then stop at 32º F (0º C). It
will not restart until evaporator coil temperature rises
above about 45º F (7º C).
The Evaporator/Control Box will also contain
sensors that protect the Air Conditioning system. A
High Pressure Cutout (HPCO) switch is used to
monitor air conditioning system pressure and
generate an alarm for abnormally high system
pressure. A Compressor Overload Switch (OLS) will
monitor the temperature of the compressor to
protect against high compressor temperature.
Condenser Housing
The Condenser Housing will be mounted on the
outside of the cab similar to the TriPac system. It
contains the following components.
Condenser Coil
The condenser coil releases heat from the air
conditioning system. It converts high pressure vapor
refrigerant from the compressor to high pressure
liquid before going to the evaporator.
 Section 2 – TriPace Hardware Description
Condenser Fan
The condenser fan provides air circulation through
the condenser coil. It is a variable speed fan that
receives power and speed commands from the Main
Controller. High compressor RPM or high ambient
temperature will cause the fan to run in high speed.
Moderate ambient temperature or compressor RPM
may allow the fan to run slower. The fan contains an
internal motor driver. Fan speed is controlled using a
Pulse Width Modulation (PWM) signal through the
speed control harness to the motor driver.
Receiver/Drier
The receiver/drier will be mounted to condenser
housing. It acts as a temporary refrigerant storage
tank as system demands are changing. It also will
absorb a small amount of moisture to help prevent
system contamination. It will not have a pressure
switch.
Ambient Temperature Sensor
The Ambient Temperature (ATS) sensor provides
ambient air temperature information the Main
Controller. This information will assist in controlling
condenser fan and compressor speed. Sensor
mounted on the Receiver/Drier bracket.
Air Heater
The TriPace system uses an Espar diesel-fueled air
heater. It provides hot air through a heat outlet vent
to the truck cab. The vent is located near floor level
in the truck cab sleeper compartment. A return inlet
air vent is also located at floor level. The air heater
temperature setpoint is programmed at the HMI
2-11
Control Panel, and Heat mode is turned on or off at
the HMI Control Panel.
The Main Controller will provide the heater with
power, setpoint information and an On signal.
Heater operation will be controlled by the
microprocessor and return air sensor on the heater
control module inside the heater. The heater shuts
down if its heat exchanger temperature exceeds an
overheat limit of 240º F (115º C).
The air heater, wiring harness, and ducting are
typically located in a storage compartment under the
truck cab sleeper compartment. The air heater
combustion air inlet ducting, exhaust ducting, and
fuel inlet line are located below and outside of the
truck cab sleeper compartment. A dedicated heater
fuel metering pump transfers diesel fuel from the
truck fuel tank to the air heater.
The evaporator blower is defaulted off when Heat
mode is selected. However, the evaporator blower
can be operated along with the heater for additional
air circulation.
The air heater receives electrical power from the
main controller via the RED wire from the J65 plug.
The heater ground circuit is also connected to this
plug. This circuit is protected by a 20 amp fuse (F3)
on the Main Controller board. Information goes to
and from the heater through the J54 plug on the
Main Controller board. The YEL wire provides a
signal to turn the air heater on. The GRY/RED and
BRN/WHT wires supply setpoint information to the
heater. The RED wire provides a feedback signal
that power is available to the heater. The remaining
wires are for communication.
 Section 2 – TriPace Hardware Description
The microprocessor in the air heater monitors the
functions and operations of the air heater. The air
heater’s microprocessor is also programmed to
recognize air heater fault codes. The five most-
recent fault codes are retained in the air heater’s
microprocessor memory. Older fault codes are
deleted from memory as new alarm codes occur.
Fault codes can be retrieved and read by using the
EDiTH Diagnostic Tool or the Heater Diagnostic
Unit.
● See Section 5 of this manual for a description of
air heater fault codes.
● See Service Procedure H31A in Section 6 of this
manual for instructions regarding the use of the
EDiTH Diagnostic Tool.
● See Service Procedure H32A in Section 6 of this
manual for instructions regarding the use of the
Heater Diagnostic Unit.
Optional 115 Vac Components
If the following optional components are installed in
the system it may be capable of accepting and/or
providing 115 Vac.
AC to DC Power Converter
The AC to DC Power Converter is a 115 Vac to 12
Vdc power converter that provides up to 85 amps of
low voltage power to the system. With the optional
115 Vac Converter installed, when the truck is
parked and plugged into 115 Vac external or “Shore
Power” the Converter will help extend operation of
the system before the batteries are depleted. During
moderate ambient temperature conditions with
moderate air conditioning demand the converter will
2-12
support the system without draining the batteries.
During high ambient temperature conditions with
high air conditioning demand the converter will
extend the operating time before the batteries are
depleted. The Converter may also act as a
secondary battery charging method during periods
of low air conditioning or heating demand. The
Converter will be mounted in the cab, probably
under the bunk. If the AC to DC Power Converter is
plugged in while TriPace and all truck systems are
off the converter will charge the truck batteries.
NOTE: The converter should be connected to
shore power with a commercial grade, three
wire, grounded extension cord. Use a Type
SJOOW, 14 AWG cord up to 75 feet. Use a Type
SJOOW, 12 AWG cord up to 145 feet.
Power Inverter
The optional 1000 watt pure sine wave Power
Inverter provides 115 Vac “Hotel Power” for the
driver. It changes the low voltage DC available from
the system batteries to high voltage AC. The Inverter
will be mounted in the cab, possibly under the bunk.
NOTE: Use of the Power Inverter will reduce the
total time the air conditioning system is able to
operate. Some appliances or electronic devices
may not function properly when powered
through a DC to AC power inverter. Recommend
use of microwave ovens rated 800 watts or less.
 Section 2 – TriPace Hardware Description

Truck Integration power from the batteries. The time delay prevents
short cycling the system during short duration
The TriPace APU system is integrated with the
engine operation. If the truck engine is still running
following OEM Truck systems.
when the 3 minute timer expires the battery charging

OEM Battery Pack process will begin. When the truck ignition is turned
off the TriPace system is defaulted off (disabled) and
The OEM truck batteries provide part of the power
must be turned on (enabled) by the driver.
for the TriPace system. For base level system
performance there must be four 12 Vdc Group 31
AIR CONDITIONING SYSTEM
batteries connected to provide 12 Vdc output. For
Air Conditioning is provided by a basic four
optimum system performance the truck battery pack
component system. It will use two pounds of 134a
should be upgraded to four Thermo King NXT AGM
refrigerant. Automotive style quick connect service
type deep cycle batteries. These batteries have
ports are available near the compressor in the
been specifically designed for the TriPace system to
Evaporator/Control Box.
maximize battery life and support deep discharge
cycles. Shorter system runtime will be experienced
The compressor is a non-serviceable hermetic
without the battery upgrade.
compressor similar to those found in refrigerators
and residential A/C systems. It is a 28 Vdc variable
Alternator
speed rotary compressor that is controlled by a
The OEM truck alternator provides primary battery
separate Compressor Controller module. The
charging for the system while the truck is driving. It
electric drive motor is inside the compressor body. It
should be upgraded to a minimum of 185 amps.
is protected by an internal thermal compressor
With some applications or truck operation profiles,
overload switch (OLS). During normal operation the
such as short drive times or high system demand,
compressor speed may change depending on
increased battery charging capacity may be
required cooling capacity. To prevent the evaporator
required. To provide the additional charging capacity
coil from frosting the compressor may slow down or
the alternator and charging cables may need to be
stop as evaporator coil temperature nears 32º F
upgraded to 240 or 270 amps.
(0º C).

Ignition Switch The compressor will utilize PVE oil that is not
When the truck ignition switch is in the On or Run compatible with other types of refrigeration oil such
position a signal is sent to the Main Controller. After as PAG or POE. This oil is extremely hygroscopic
a 3 minute “Pull ahead” time delay the TriPace and will readily absorb moisture. Care must be taken
system will be turned off (disabled) and the system during installation and A/C system service to prevent
will begin a shutdown sequence. Once the moisture absorption. Allowing moisture into the
sequence is complete the system does not draw system will significantly increase the time required to

2-13
 Section 2 – TriPace Hardware Description

fully evacuate and dehydrate the system. The oil Power to Controllers
remains in the compressor and does not move with
Voltage from the main fuse block in the battery box
the refrigerant through the system. Replacement of
goes to these control devices.
refrigeration system components, such as
condenser or evaporator coils, should not affect Main Controller / Interface Board
system oil level. There will be no method available to
The Interface Board in the Evaporator/Control Box
check or adjust oil level.
contains the Main Controller microprocessor,
Refer to Maintenance Manual (TK 54499-19-MM) for communication circuits and power distribution to
additional details. components.

DC to DC Converter
POWER CIRCUITS
The DC to DC Converter mounted on the Battery
Main Fuse Block
Box will up convert 12 Vdc from the batteries to 28
e
The main fuse block is inside the TriPac battery Vdc. It sends this increased voltage to the
box. It provides the main power connections and Compressor Controller in the Evaporator/Control
main power fuses. Voltage for the system is fed to Box.
the main fuse block from these sources.
Compressor Controller
Smart Charger Modules (SCM)
The Compressor Controller in the
e
Inside the TriPac Battery Box there are two SCMs. Evaporator/Control Box provides variable voltage
They each transfer power to and from their pair of output to the compressor. It controls compressor
NXT batteries through a fuse on the main fuse block. speed based on input from the Main Controller.

Truck Batteries Power to Components

The four batteries in the truck battery box are
The Controllers send voltage to these operating
connected to the main fuse block. The interconnect
components.
cable will run through the Current Sensor (CS) as it
enters the TriPace Battery Box. Evaporator fan

This is a variable speed fan. The harness from the

115 Vac Converter (Optional)
Main Controller Board includes a speed control
If the optional 115 Vac AC to DC Power Converter is
circuit.
plugged in it will convert high voltage AC to low
voltage DC. This DC power is sent to the truck
batteries and is added to the total available battery
power.

2-14
 Section 2 – TriPace Hardware Description

Condenser fan

This is a variable speed fan. The harness from the

Main Controller Board includes a speed control
circuit.

Compressor

This is a variable speed motor. Variable control

voltage comes from Compressor Controller.

Heater

Power for the Espar heater is supplied by the Main

Controller Board.

2-15
 Section 2 – TriPace Hardware Description

FUSES
Fuse Location Amp Component Protected / Circuit –
Numbe Rating Connector
r
F1 Main Controller Interface Board 2 HMI / 2P – J34
F2 Main Controller Interface Board 2 HMI / 8XP – J34
F3 Main Controller Interface Board 20 Heater / RED – J65
F4 Main Controller Interface Board 15 Condenser Fan / CFPOS – J59
F5 Main Controller Interface Board 15 Evaporator Fan / EFPOS – J58
F6 Main Controller Interface Board 5 Main Controller / Controller, F1, F2
F7 Heater Harness 5 Heater / RED
F8 Vehicle Ignition Harness 1 Ignition Input / IGN
F9 Fuse Block in Battery Box 60 Smart Charger 2 / 2C
F10 Fuse Block in Battery Box 150 DC to DC Converter / 12V
F11 Fuse Block in Battery Box 40 Main Controller / 2
F12 Fuse Block in Battery Box 60 Smart Charger 1 / 2B
F13 Fuse Holder in Positive Battery Harness 175 Truck Batteries / RED
F14 Fuse Holder in Positive Inverter/Converter Harness 150 Inverter/Converter / RED
F15 Smart Charger 1 60 Smart Charger 1 / 2B
F16 Smart Charger 1 60 System Battery A / RED
F17 Smart Charger 1 60 System Battery B / RED
F18 Smart Charger 2 60 Smart Charger 2 / 2C
F19 Smart Charger 2 60 System Battery A / RED
F20 Smart Charger 2 60 System Battery B / RED

NOTE: Controller Outputs protected by F6

J35 to RTS and CTS
J37 to Current Sensor and CVEN
J56 to Compressor Controller
J58 to Evap Fan Speed Control
J59 to Cond Fan Speed Control

2-16
 Section 2 – TriPace Hardware Description

FUSE BLOCK / BATTERY BOX CONNECTIONS DIAGRAM

2-17
 Section 2 – TriPace Hardware Description

PLUG PINOUT AND LOCATION DIAGRAMS

Main Controller Interface Board Connector Locations

5
3 7
8 14

2
9
10
15
12
4

11

13
Main Controller Interface Board

2-18
 Section 2 – TriPace Hardware Description

Main Controller Interface Board Connector Usage

See the following pages for individual connector maps.

Number Connector Circuit

1 J34 Connection to HMI Control Panel Harness
2 J35 Connections to Evaporator Sensor Harness
3 J36 Debug – Not Used
4 J37 Connections to Battery Box Harness
5 J38 J1939 – Not Used
6 J39 Main Controller Data Port – Used to access TK Monitor by connecting to PC with USB
adapter harness.
7 J52 Spare RS-232 Serial Connection – Not Used
8 J53 Spare I/O – Not Used
9 J54 Connections to Heater Control Harness
10 J55 Connections to Compressor Sensor Harness (HPCO)
11 J56 Connections to Compressor Control Harness
12 J58 Connections to Evaporator Fan Harness
13 J59 Connections to Condenser Fan Harness
14 J65 Connections to Heater Power Harness
15 J70 Connection to IGN Wire to Truck Ignition Switch

2-19
 Section 2 – TriPace Hardware Description

Main Controller Interface Board Connector Maps

J34 – HMI Control Panel Harness CAN Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 CANL Red To HMI Control Panel Connector Pin 1
2 CANH Black To HMI Control Panel Connector Pin 2
3 SHLD Clear To HMI Control Panel Connector Pin 3
4 ON White To HMI Control Panel Connector Pin 4
5 2P White To HMI Control Panel Connector Pin 5 (Power)
6 8XP White To HMI Control Panel Connector Pin 6
7 OFF White To HMI Control Panel Connector Pin 7
8 CH White To HMI Control Panel Connector Pin 8

J34 – HMI Control Panel Harness CAN Connector – shown from pin side of harness connector

NOTE: Jumping pin 4 (ON) to pin 8 (CH) simulates pressing the On button of the HMI. Interface Board should
activate. Unit will be in Monitor Mode unless it is programmed NO, then unit may start in last known mode.

2-20
 Section 2 – TriPace Hardware Description

J35 – Evaporator Sensor Harness Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 RTS Black Output to Return Air Sensor
2 Not Used
3 CTS Yellow Output to Coil Temperature Sensor
4 Not Used
5 Not Used
6 RTS Black From Return Air Sensor
7 Not Used
8 CTS Yellow From Coil Temperature Sensor

J35 – Evaporator Sensor Harness Connector – shown from pin side of harness connector

J36 – Main Controller Interface Board Connector

Not Used

2-21
 Section 2 – TriPace Hardware Description

J37 – Battery Box Harness Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 CANL Red To Smart Charger 1 CAN Connector Pin A
2 Not Used
3 Not Used
4 1BATA2 Blue To Current Sensor Connector Pin A
5 BBA5V White To Current Sensor Connector Pin B
6 Not Used
7 Not Used
8 Not Used
9 Not Used
10 Not Used
11 CANH Black To Smart Charger 1 CAN Connector Pin B
12 SHLD Clear To Smart Charger 1 CAN Connector Pin C
13 CVEN White To DC to DC Converter ENABLE (CVEN) Terminal
14 1BATA1 Brown To Current Sensor Connector Pin D
15 BBACH Black To Current Sensor Connector Pin C
16 SHLD SHLD No Other End
17 Not Used
18 Not Used
19 Not Used
20 Not Used

J37 – Battery Box Harness Connector – shown from pin side of harness connector

J38 – J1939 Connector

Not Used

J39 – Main Controller Data Port Connector

Used to access TK Monitor by connecting to PC with USB adapter harness.

2-22
 Section 2 – TriPace Hardware Description

J52 – Spare RS-232 Serial Connector

Not Used

J53 – Spare I/O Connector

Not Used

J54 – Heater Control Harness Connector – arranged by pin number

Pin Wire Color Description

Number
1 Red To Heater Connector Pin 1 (Power)
2 Yellow To Heater Connector Pin 4 (Enable)
3 Blue/Yellow To Heater Connector Pin 3
4 Blue/White To Heater Connector Pin 8
5 Brown/White To Heater Connector Pin 6 (Setpoint/Remote Sensor)
6 Gray/Red To Heater Connector Pin 7 (Setpoint)
7 Gray To Heater Connector Pin 12 (Remote Sensor)
8 Brown To Heater Connector Pin 10 (Ground)
9 Not Used
10 Not Used
11 Not Used
12 Not Used
13 Not Used
14 Not Used

J54 – Heater Control Harness Connector – shown from pin side of harness connector

2-23
 Section 2 – TriPace Hardware Description

J55 – Compressor Sensor Harness (HPCO) Connector – arranged by pin number

Pin Circuit Code Description

Number (Wire Number)
1 Not Used
2 Not Used
3 Not Used
4 Not Used
5 HPC1 To HPCO, Low Voltage Signal (3-5 Vdc)
6 HPC2 From HPCO
7 Not Used
8 Not Used
9 Not Used
10 Not Used
11 Not Used
12 Not Used

J55 – Compressor Sensor Harness (HPCO) Connector – shown from pin side of harness connector

2-24
 Section 2 – TriPace Hardware Description

J56 – Compressor Control Harness Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 CMA Red To Compressor Controller Connector JP5 Pin 1
2 CCRET Black To Compressor Controller Connector JP5 Pin 2 (Ground)
3 CEN Yellow To Compressor Controller Connector JP5 Pin 3 (Power On/Off)
4 CVB1 Pink To Compressor Controller Connector JP5 Pin 4
5 CRXD Green To Compressor Controller Connector JP3 Pin 3 (Communication)
6 CTXD Blue To Compressor Controller Connector JP3 Pin 2 (Communication)
7 Not Used
8 Not Used
9 CSPD Gray From Compressor Controller Connector JP5 Pin 5 (Compressor
Speed)
10 CVB2 Violet From Compressor Controller Connector JP5 Pin 6 (+4 Vdc)
11 CSET Light Blue To Compressor Controller Connector JP5 Pin 7 (Speed Setpoint)
12 CFLT Orange From Compressor Controller Connector JP5 Pin 8 (Fault)
13 CRRET White To Compressor Controller Connector JP3 Pin 4 (Ground)
14 CVB3 Brown To Compressor Controller Connector JP3 Pin 1 (+4 Vdc)
15 Not Used
16 Not Used

J56 – Compressor Control Harness Connector – shown from pin side of harness connector

2-25
 Section 2 – TriPace Hardware Description

J58 – Evaporator Fan Harness Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 EFPOS Red To Evaporator Fan
2 EFNEG Blue To Evaporator Fan
3 EFRTN White To Evaporator Fan
4 EFCTL Yellow To Evaporator Fan

J58 – Evaporator Fan Harness Connector – shown from pin side of harness connector

J59 – Condenser Fan Harness Connector

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 CFNEG To Condenser Fan Connector Pin D
2 CFPOS To Condenser Fan Connector Pin A
3 ATS White Output to Ambient Air Temperature Sensor Black Wire
4 ATS White From Ambient Air Temperature Sensor Black Wire
5 CFCTL To Condenser Fan Connector Pin B
6 CFRTN To Condenser Fan Connector Pin C

J59 – Condenser Fan Harness Connector – shown from pin side of harness connector

2-26
 Section 2 – TriPace Hardware Description

J65 – Heater Power Harness Connector – arranged by pin number

Pin Wire Color Description

Number
1 Red To Heater Connector Pin 1
2 Brown To Heater Connector Pin 10

J65 – Heater Power Harness Connector – shown from pin side of harness connector

J70 – ING Wire to Truck Ignition Switch Connector

Circuit Code Description

(Wire Number)
IGN To F8 Fuse and then to Truck Ignition Switch

2-27
 Section 2 – TriPace Hardware Description

Compressor Controller Board Connector Locations

6 4

5
7

Compressor Controller Board

2-28
 Section 2 – TriPace Hardware Description

Compressor Controller Board Connector Usage

See the following pages for individual connector maps.

Number Connector Circuit

1 J1 Connection to DC to DC Converter 28V Terminal
2 J2 Connection to DC to DC Converter NEG Terminal
3 J3 Connection to Compressor Phase A Terminal (Blue Wire)
4 J4 Connection to Compressor Phase B Terminal (Orange Wire)
5 J5 Connection to Compressor Phase C Terminal (Yellow Wire)
6 JP3 Connections to Compressor Control Harness
7 JP5 Connections to Compressor Control Harness
8 JP6 Connections to Compressor Overload Switch Terminals

Compressor Controller Board Connector Maps

J1 – 28V Wire to DC to DC Converter

Circuit Code Description

(Wire Number)
28V To DC to DC Converter 28V Terminal

J2 – CH02 Wire to DC to DC Converter

Circuit Code Description

(Wire Number)
CH02 To DC to DC Converter NEG Terminal

J3 – Blue Wire to Compressor

Wire Color Description

Blue To Compressor Phase A Terminal

J4 – Orange Wire to Compressor

Wire Color Description

Orange To Compressor Phase B Terminal

J5 – Orange Wire to Compressor

Wire Color Description

Yellow To Compressor Phase C Terminal

2-29
 Section 2 – TriPace Hardware Description

JP3 – Compressor Control Harness Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 CVB3 Brown To Main Controller Interface Board Connector J56 Pin 14
2 CTXD Blue To Main Controller Interface Board Connector J56 Pin 6
3 CRXD Green To Main Controller Interface Board Connector J56 Pin 5
4 CRRET White To Main Controller Interface Board Connector J56 Pin 13

JP3 – Compressor Control Harness Connector – shown from pin side of harness connector

JP5 – Compressor Control Harness Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 CMA Red To Main Controller Interface Board Connector J56 Pin 1
2 CSRET Black To Main Controller Interface Board Connector J56 Pin 2
3 CEN Yellow To Main Controller Interface Board Connector J56 Pin 3
4 CVB1 Pink To Main Controller Interface Board Connector J56 Pin 4
5 CSPD Gray To Main Controller Interface Board Connector J56 Pin 9
6 CVB2 Violet To Main Controller Interface Board Connector J56 Pin 10
7 CSET Light Blue To Main Controller Interface Board Connector J56 Pin 11
8 CFLT Orange To Main Controller Interface Board Connector J56 Pin 12

JP5 – Compressor Control Harness Connector – shown from pin side of harness connector

2-30
 Section 2 – TriPace Hardware Description

JP6 – Compressor Overload Switch Harness Connector – arranged by pin number

Pin Wire Color Description

Number
1 Black To Compressor Overload Switch Terminal
2 Black To Compressor Overload Switch Terminals

JP6 – Compressor Overload Switch Harness Connector – shown from pin side of harness connector

Compressor Wire Connections

The following drawing shows the compressor wire connections.

1
2

4 3

1. Orange Wire – To Compressor Controller Board Phase B Terminal J4

2. Yellow Wire – To Compressor Controller Board Phase C Terminal J6
3. Black Wires – To Compressor Controller Board Connector J4 Pins 1 and 2
4. Blue Wire – To Compressor Controller Board Phase A Terminal J3
Compressor Wire Connections

2-31
 Section 2 – TriPace Hardware Description

HMI Connector Map

HMI Control Panel Harness CAN Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
1 CANL Red To Main Controller Interface Board Connector J34 Pin 1
2 CANH Black To Main Controller Interface Board Connector J34 Pin 2
3 SHLD Clear To Main Controller Interface Board Connector J34 Pin 3
4 ON White To Main Controller Interface Board Connector J34 Pin 4
5 2P White To Main Controller Interface Board Connector J34 Pin 5
6 8XP White To Main Controller Interface Board Connector J34 Pin 6
7 OFF White To Main Controller Interface Board Connector J34 Pin 7
8 CH White To Main Controller Interface Board Connector J34 Pin 8

HMI Control Panel Harness CAN Connector – shown from pin side of harness connector

2-32
 Section 2 – TriPace Hardware Description

Condenser Fan Connector Map

Condenser Fan Harness Connector – arranged by pin number

Pin Circuit Code Description

Number (Wire Number)
A CFPOS
B CFCTL
C CFRTN
D CFNEG
To Main Controller Interface Board Connector J59 Pin 2
To Main Controller Interface Board Connector J59 Pin 5
To Main Controller Interface Board Connector J59 Pin 6
To Main Controller Interface Board Connector J59 Pin 1

Condenser Fan Harness Connector – shown from pin side of harness connector

Current Sensor Connector Map

Battery Box Harness Current Sensor Connector – arranged by pin number

Pin Circuit Code Wire Color Description

Number (Wire Number)
A 1BATA2
B BBA5V
C BBACH
D 1BATA1
Blue To Main Controller Interface Board Connector J37 Pin 4
White To Main Controller Interface Board Connector J37 Pin 5
Black To Main Controller Interface Board Connector J37 Pin 15
Brown To Main Controller Interface Board Connector J37 Pin 14

Battery Box Harness Current Sensor Connector – shown from pin side of harness connector

2-33
 Section 2 – TriPace Hardware Description

Heater Connector Map

Heater Control Harness Heater Connector – arranged by pin number

Pin Wire Color Description

Number
1 Red To Main Controller Interface Board Connector J54 Pin 1, J65 Pin 1, Diagnostic
Harness Connector
2 Not Used
3 Blue/Yellow To Main Controller Interface Board Connector J54 Pin 3
4 Yellow To Main Controller Interface Board Connector J54 Pin 2, Diagnostic Harness
Connector
5 Green/Red To Fuel Pump Connector Pin 1
6 Brown/White To Main Controller Interface Board Connector J54 Pin 5
7 Gray/Red To Main Controller Interface Board Connector J54 Pin 6
8 Blue/White To Main Controller Interface Board Connector J54 Pin 4, Diagnostic Harness
Connector
9 Not Used
10 Brown To Main Controller Interface Board Connector J54 Pin 8, J65 Pin 2, Fuel Pump
Connector Pin 2, Diagnostic Harness Connector
11 Not Used
12 Gray To Main Controller Interface Board Connector J54 Pin 7
13 Not Used
14 Not Used
15 Pink Not Used
16 Not Used

Heater Control Harness Heater Connector – shown from pin side of harness connector

2-34
Software Description
 Section 3 – TriPace Software Description

TABLE OF CONTENTS - SECTION 3

Software Operation ................................................................................................................................................. 2

Software Revisions ................................................................................................................................................. 2
Compatibility ....................................................................................................................................................... 2
Main Controller Software ................................................................................................................................... 2
HMI Control Panel Software .............................................................................................................................. 2
Smart Charger Module (SCM) Software ........................................................................................................... 2
TK Monitor Software .......................................................................................................................................... 2
Programmable Features ......................................................................................................................................... 3
Tractor Battery Type .......................................................................................................................................... 3
Temperature Display .......................................................................................................................................... 3
Set Real Time Clock ........................................................................................................................................... 3
Auto Restart ........................................................................................................................................................ 4

3-1
 Section 3 – TriPace Software Description

SOFTWARE OPERATION SOFTWARE REVISIONS

The software is a very complex set of instructions Compatibility
used by the Main Controller, SCMs and HMI Control
Version 1.1 software is compatible with all current
Panel to control the HVAC system, manage system
TriPace hardware. Whenever an HMI, Main
power and interface with the driver. The Main
Controller or SCM is replaced, system software
Controller microprocessor examines the conditions
should be upgraded to Version 1.1. If the system
of all the available inputs and compares them to the
has already been upgraded the individual
instructions contained in the software. The outputs
component software should be upgraded to match.
are then energized or commands are sent as
specified by the software instructions.
Main Controller Software
There is no way to determine from the schematic The Main Controller software will make overall
diagram what conditions will cause the system system operation decisions based on current system
components to operate in a particular mode. These information from sensors, components, SCMs and
decisions are made by the software after examining HMI Control Panel. The Main Controller software
all the input conditions, HVAC mode selection and revision is 31 xx.
setpoint. System power should be automatically
managed to provide driver comfort for the longest HMI Control Panel Software
period of time. Battery power reserve will
The HMI Control Panel software interprets driver
automatically be managed to provide maximum
inputs and communicates them to the Main
battery life.
Controller. It also interprets information from the

All software for the TriPace system is flash loaded Main Controller and displays it to the driver. The HMI

using TK Monitor. Refer to Section 6, A51A, software revision is 32 xx.

Communication Using TK Monitor.

Smart Charger Module (SCM) Software
The TriPace system utilizes several different
The SCM software controls the charging and
software sets.
discharging of the TriPace batteries based on
commands from the Main Controller. The SCM also
For software revision detail refer to Section 7 of this
sends battery information to the Main Controller. The
manual.
SCM software revision is 33 xx.

TK Monitor Software

TK Monitor Software allows external communication

with the system using a PC computer. It will provide
system service and diagnostic tools. TK Monitor

3-2
 Section 3 – TriPace Software Description
software resides on the Main Controller board; it is
not loaded on the PC computer. The TK Monitor
software revision is 1.01.
PROGRAMMABLE FEATURES
Programmable feature settings are selected using
the Unit Setup function of TK Monitor. Refer to
Section 6, A51A, Communication Using TK Monitor.
Tractor Battery Type
Controller Rev – 31 01
HMI Rev – 32 00 or later
SCM Rev – 33 00 or later
TK Monitor Rev – 1.0 or later
Choices – All Others or NXT
Default – All Others
Description – Set during unit installation or if
truck battery type is changed. Changes the
maximum depth of discharge level for the system
depending on truck battery type.
[All Others] should be set if any battery type other
than NXT are installed in the tractor. The TriPace
HVAC system will shut down when system
voltage falls to 12.5 Vdc (12 Vdc with 31 00).
[NXT] should be set if four Thermo King NXT
batteries are installed in the tractor. The TriPace
HVAC system will shut down when system
voltage falls to 11.5 Vdc.
3-3
Temperature Display
Controller Rev – 31 00 or later
HMI Rev – 3 200 or later
SCM Rev – 33 00 or later
TK Monitor Rev – 1.0 or later
Choices – Celsius or Fahrenheit
Default – Fahrenheit
Description – Selects temperature scale to be
used by the system and displayed in TK Monitor.
Set Real Time Clock
Controller Rev – 31 00 or later
HMI Rev – 32 00 or later
SCM Rev – 33 00 or later
TK Monitor Rev – 1.0 or later
Choices – Check Box
Default – Current system time of the PC
computer connected.
Description – The Real Time Clock is used by
the data logger as the time stamp for logged
events. By selecting the check box and then
selecting Save Setup the TriPace Real Time Clock
will be reset to match the clock in the connected
computer. The Real Time Clock will display as a
24 hour clock. There is no method to enter a
different time.
 Section 3 – TriPace Software Description

Auto Restart
Controller Rev – 31 01 or later
HMI Rev – 32 01 or later
SCM Rev – 33 00 or later
TK Monitor Rev – 1.01 or later
Choices – Enabled or Disabled
Default – Disabled
Description – This setting defines the system
action when the truck ignition is turned from on to
off while the TriPace system is turned on. Refer to
Section 4, Truck Ignition On for details.

[Disabled] will cause the TriPace HVAC system to

remain off when the truck ignition is turned off.
Driver must turn system on and select an HVAC
mode at the HMI to begin climate control
operation. The system does not draw power from
the batteries when off. The [Disabled] setting
prevents batteries being depleted to climate
control a cab that is not occupied. This is the
recommended setting.

[Enabled] will cause the TriPace HVAC system to

automatically turn back on when the truck ignition
is turned off. Driver does not need to turn system
on at the HMI. System will operate in the last
selected mode. The system will draw power from
the batteries while maintaining the selected cab
temperature. This is not the recommended
setting.
NOTE: The [Enabled] setting creates the potential
of depleted batteries on an unoccupied truck. If
the driver does not turn the TriPace system off at
the HMI before exiting the truck it will continue to
draw battery power to climate control an
unoccupied truck.

3-4
System Operation
 Section 4 – TriPace System Operation

TABLE OF CONTENTS - SECTION 4

HMI ............................................................................................................................................................................ 3
On/Off Button ...................................................................................................................................................... 4
Mode Selector ..................................................................................................................................................... 4
Temperature Selector ........................................................................................................................................ 4
Fan Speed Selector ............................................................................................................................................ 4
Driver Selectable Settings ................................................................................................................................. 5
System Indicators .................................................................................................................................................... 6
Battery Monitor ................................................................................................................................................... 6
System Alarm Icon ............................................................................................................................................. 6
Battery Alarm Icon.............................................................................................................................................. 7
System Status Display ....................................................................................................................................... 7
Sequence of Operation ........................................................................................................................................... 8
Start Sequence in A/C mode ............................................................................................................................. 8
Temperature Control Sequence for Cool ......................................................................................................... 8
Start Sequence for Heat..................................................................................................................................... 9
Temperature Control Sequence for Heat ......................................................................................................... 9
Truck Ignition On ................................................................................................................................................ 9
TriPace Is On .................................................................................................................................................. 9
TriPace Is Off ................................................................................................................................................ 10
TriPace Turned On ....................................................................................................................................... 10
Power Sources ....................................................................................................................................................... 10
TriPace Battery Box .......................................................................................................................................... 11
Truck Batteries ................................................................................................................................................. 11
Shore Power ..................................................................................................................................................... 12
Power Flow ............................................................................................................................................................. 12
Smart Charger Modules ................................................................................................................................... 13
Discharge Mode .......................................................................................................................................... 13
Charge Mode................................................................................................................................................ 13
Null Mode ..................................................................................................................................................... 14
Shore Power ..................................................................................................................................................... 14
System Information Flow ...................................................................................................................................... 14
CAN (Controller Area Network)....................................................................................................................... 14
HMI ................................................................................................................................................................ 15

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 Section 4 – TriPace System Operation

Smart Charger Modules.............................................................................................................................. 15

Component Communication ........................................................................................................................... 15
Compressor Controller ............................................................................................................................... 15
DC to DC Converter .................................................................................................................................... 15
Fans .............................................................................................................................................................. 15
Heater ........................................................................................................................................................... 15
Sensors ............................................................................................................................................................. 15
Current Sensor (CS).................................................................................................................................... 15
Return Air Temperature (RTS) ................................................................................................................... 15
Evaporator Coil Temperature (CTS) .......................................................................................................... 16
Ambient Air Temperature (ATS) ................................................................................................................ 16
High Pressure Cutout Switch (HPCO) ...................................................................................................... 16
Truck Ignition Input (IGN) ........................................................................................................................... 16
TK Monitor......................................................................................................................................................... 16
Battery Charging.................................................................................................................................................... 16
Truck Running .................................................................................................................................................. 16
Shore Power ..................................................................................................................................................... 17
HVAC System On ........................................................................................................................................ 18
HVAC System Off ........................................................................................................................................ 18
12 Vdc to 115 Vac Power Inverter (Optional) ...................................................................................................... 18
115 Vac to 12 Vdc Shore Power Converter (Optional) ....................................................................................... 19
Operating Characteristics Summary ................................................................................................................... 19

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 Section 4 – TriPace System Operation

HMI Control Panel

HMI
The HMI (Human Machine Interface) is the driver control module that is typically mounted in the bunk area. The
driver can select the desired function of the system. It has three selector knobs and a battery monitor display. The
HMI contains the Cab Temperature Sensor. It communicates with the Main Controller using the Controller Area
Network (CAN).

The driver can select these functions from the HMI:

● System On/Off

● Mode (Cool, Fan, Heat)

● Desired Cab Temperature (Cooler-Warmer)

● Fan Speed (Off, Auto, variable)

● Driver Selectable Settings

When any change of settings is selected there is a two second delay before the controller will recognize the new
setting. This prevents momentary or accidental mode changes.

The HMI indicator LEDs will turn off after two minutes if no selections are made. Bump the On/Off button to
activate the display for an additional two minutes.

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 Section 4 – TriPace System Operation

On/Off Button
The On/Off Button is under the left knob on the HMI. It provides several functions depending on how long the
button is pressed.

● Turn system On: If the system is off, press the left knob for 1 second to turn the system on.

● Turn system Off: If system is on, press the left knob for 4 seconds to turn the system off.

● System Status Display: If the system is off, press the left knob for less than 1 second. Back light, battery
and alarm status will display. System does not turn on. The display will turn off in about three minutes.

● Pressing the left knob for less than 1 second is referred to as a “Bump”.

Other operation features can be accessed from the HMI. See Driver Selectable Settings in this section.

Mode Selector
Mode selection is accomplished by rotating the left knob. It selects between three operating modes. A mode icon
will flash then light indicating the selection. There will be a two second delay before the new mode is activated to
prevent momentary or accidental mode changes.

● A/C Mode

● Fan Only Mode

● Heat Mode

Temperature Selector
Temperature selection is accomplished by rotating the center knob. It adjusts the desired cab temperature cooler
(blue) or warmer (red). Adjust to driver comfort. Represented range is approximately 68º – 80º F (20º – 27º C) in
A/C Mode and 50º – 80º F (10º – 27º C) in Heat Mode.

Fan Speed Selector

Evaporator fan speed is variable. Rotating the selector clockwise will increase fan speed, counterclockwise will
decrease fan speed. As fan speed increases/decreases, LEDs will progressively turn on/off. The fan will continue
to run at the chosen speed. AUTO may be selected and is the preferred setting in air conditioning mode. This
allows the Main Controller to make fan speed decisions for optimum system performance. This is the default
mode when Air Conditioning is selected. OFF may be selected when in Fan or Heat mode. This is the default
mode when Fan or Heat is selected.

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 Section 4 – TriPace System Operation

Driver Selectable Settings

From the HMI the driver will have access to three additional selectable features. To access these features the
driver will use a sequence of “bumps” on the On/Off (left) button. Pressing the On/Off button for ½ second is a
bump. Important: The Selectable Settings Mode must be exited before the system will resume normal operation.

● Alarm Clearing: Most active system alarms can be cleared from the HMI.

o TriPace system is on and the alarm icon is on.

o Bump the On/Off button three times to enter the Selectable Settings Mode.

o Press the On/Off Button for 5 seconds to clear the alarms. The alarm icon should turn off. If the alarm
condition still exists the alarm will reoccur.

o Bump the On/Off button three additional times to exit the Selectable Settings Mode.

● HMI Dim: The brightness of the HMI display LEDs can be changed.

o The TriPace system is on.

o Bump the On/Off button three times to enter the Selectable Settings Mode.

o Rotate the Fan Speed knob to change display brightness.

o Bump the On/Off button three additional times to exit the Selectable Settings Mode.

● Shore Power Charging: Available if the optional AC to DC Power Converter is installed and plugged-in to an
external 115 Vac source. Can be used to charge system batteries while TriPace and truck systems are off.
The default setting will charge only the truck batteries. The driver may select to allow the TriPace batteries to
also charge if excess charging capacity is available from the converter. Shore Power Charging must be
selected each time the feature is desired.

o Turn the truck ignition and TriPace system off.

o Bump the On/Off button once to activate the System Status Display.

o Bump the On/Off button three times to enter the Selectable Settings Mode.

o Bump the On/Off Button an additional two times to toggle the feature.

o Bump the On/Off button three additional times to exit the Selectable Settings Mode.

o After about 20 seconds the green Battery Monitor bars should begin to scroll up. This indicates the
TriPace system is in charge mode. Refer to Battery Charging in this section.

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 Section 4 – TriPace System Operation

SYSTEM INDICATORS
The HMI provides the operator with some additional system information. In addition to the Mode and Fan Speed
indicators it also displays a Battery Monitor, System Alarm icon and Battery Alarm icon.

Battery Monitor
While the system is operating the six Battery Monitor bars indicate the remaining usable power reserve in the
truck batteries. The Battery Monitor information is based on the system voltage measured by the Main Controller
at the TriPace battery box bus bar. When the system is first turned on it will take approximately 20 seconds for the
Battery Monitor to accurately display.

● 6 Green Bars = Power above 90%

● 5 Green Bars = Power 70 – 90%

● 4 Green Bars = Power 50 – 70%

● 3 Yellow Bars = Power 30 – 50%

● 2 Yellow Bars = Power 15 – 30%

● 1 Red Bar = Power Less than 15%

● 0 Bars = No power available

Green bars will scroll up while truck ignition is on or Shore Power Charging is active. This indicates the TriPace
system is in charge mode. It does not indicate the TriPace batteries are charging. Refer to Battery Charging in this
section.

System Alarm Icon

The alarm icon will alert the driver that an abnormal condition exists. Most alarms may be cleared from the HMI.
While the system is on, bump the On/Off button three times then hold it for five seconds. Bump the On/Off button
three additional times to return to normal operation. The Alarm icon should go out. If it does not or immediately
returns the alarm condition still exists. The alarm code number must be retrieved using TK Monitor. Refer to
Section 6, A51A, Communication Using TK Monitor.

● Yellow = Check Alarm. This type of alarm indicates the system has an abnormal condition that should be
checked at the next opportunity. The system will continue to operate but may have reduced capacity.

● Red = Shutdown Alarm. This type of alarm indicates a system fault that should be checked by a technician
immediately. The system will not operate with this alarm active.

Refer to Section 5, Alarm Code Diagnostics.

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 Section 4 – TriPace System Operation

Battery Alarm Icon

● Red = System off due to low power reserve. System voltage has fallen below 12 Vdc. The SCMs have
switched to Null and HVAC systems have been disabled preventing further discharge of the system batteries.

If the system has turned off for low power reserve it may be turned on by pressing the On/Off button on the HMI
for one second. The system batteries should have been fully charged by running the truck before turning the
system on again. If the batteries are not charged, the system may immediately turn off for low power reserve or
have very short run time. Repeated partial charging then fully discharging the system batteries will reduce battery
life.

1. Battery Alarm Icon

HMI Control Panel Showing Battery Alarm Icon

System Status Display

When the TriPace HVAC system is off the HMI display will be dark. The operator may check the status of the
system without activating any HVAC function. Bump the On/Off button once to activate the System Status
Display. Pressing the On/Off button for ½ second is a bump. The HMI will display:

● The currently selected HVAC mode.

● Battery Monitor status. It will take approximately 20 seconds for the Battery Monitor to accurately display.

● Alarm Icon if active alarms are present.

The display will turn off in two minutes if no other action is taken.

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 Section 4 – TriPace System Operation

SEQUENCE OF OPERATION
NOTE: If System Voltage falls below 12 Vdc the HVAC system will shutdown.

Start Sequence in A/C mode

● Press On/Off button for 1 seconds or select A/C from another mode.

● Cool icon blinks then turns solid

● Fans do 1 second bump.

● Main Controller green LED begins blinking slowly, about once per second.

● Evaporator fan starts after 20 seconds.

● Compressor and condenser fan start after 5 additional seconds. Compressor will run at 3000 RPM for 30
seconds. Compressor and evaporator fan ramp up to high speed.

● After two minutes HMI indicators will turn off.

Temperature Control Sequence for Cool

● Minimum run time and minimum off time for A/C system is three minutes.

● Compressor is variable speed and will slow as temperature approaches setpoint. It will stop if temperature
falls below setpoint.

● Evaporator fan is variable speed and will slow as temperature approaches setpoint. When compressor stops
the fan will continue to run in low speed for ten minutes then stop.

● Minimum off time for the A/C compressor is three minutes.

● About a 5º F (3º C) cab temperature rise above setpoint will start the A/C compressor if the minimum off time
has elapsed. Compressor and evaporator fan speed will vary as required.

● Condenser fan speed will change with compressor speed.

● Evaporator Coil Temperature is used by the Main Controller to prevent a frosted evaporator coil. The
compressor will slowdown then stop as coil temperature nears 32º F (0º C). Once stopped it will not restart
until coil temperature rises above 45º F (7º C). The Cool icon on the HMI blinks. TK Monitor shows System
Mode NULL. Evaporator fan will continue to run.

● Ambient temperature sensor in combination with compressor speed will control condenser fan speed. High
ambient temperature and/or high compressor speed = high fan speed. Low ambient temperature and/or low
compressor speed = low fan speed.

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 Section 4 – TriPace System Operation

Start Sequence for Heat.

● Main Controller will activate the YEL circuit to the heater.

● Heater ramp up steps = about four minutes to boost level

o Slow fan

o Glow pin (60 seconds)

o Fuel pump (ignition)

o Fan and pump ramp up to Boost level

o Fan and fuel pump will begin to respond to setpoint and return air temperature

Temperature Control Sequence for Heat

● The internal heater controller will manage temperature control. It will use an internal return air sensor. It does
not use the Cab Temperature sensor.

● The Main Controller will send setpoint information to the heater controller as a variable resistance.

● As return air temperature nears setpoint fuel pump and fan speed will slow.

● When return air temperature achieves setpoint the fuel pump will stop and burner goes out. The fan will run in
low speed to circulate air through the heater.

● If return air temperature falls the heater will reignite.

● Minimum run time for the heater is five minutes.

● Minimum off time for the heater is three minutes.

● Heater cool down = about four minutes. When the heater is turned off the fuel pump stops and burner goes
out but the fan continues to run. This will cool down the heat exchanger. Cool down mode will occur even if
the system is turned off.

Truck Ignition On
The TriPace control system monitors the position of the truck ignition switch to determine if the truck engine is
running. This will affect the operation of the TriPace system. When the truck ignition switch is in the On or Run
position a signal is sent to the IGN terminal (J70) on the Main Controller board.

TriPace Is On
The truck ignition switch is turned on while the TriPace HVAC system is already on and running. A three minute
“Pull Ahead” time delay is activated. All TriPace batteries will be set to NULL mode. Power for the currently
running HVAC mode will be supplied by the truck alternator and batteries. If the ignition switch is turned off before

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 Section 4 – TriPace System Operation

three minutes has elapsed the system will continue in the current mode. The TriPace batteries will return to
DISCHARGE mode. The time delay prevents short cycling the HVAC system during short duration engine
operation. If the truck ignition is still on when the three minute time delay expires the TriPace HVAC system will be
turned off (disabled). The system will begin a shutdown sequence. Once the shutdown sequence is complete the
system does not draw power from the batteries. If the truck ignition remains on, the battery charging process will
begin. Refer to Battery Charging in this section.

When the truck ignition is turned off the TriPace HVAC system is defaulted off (disabled) and must be turned on
(enabled) by the driver at the HMI. This is the recommended setting and prevents depleted batteries caused by
controlling the cab temperature in an unoccupied truck.

If the Auto Restart feature is enabled the TriPace HVAC system will automatically resume operation when the
truck ignition is turned off. This is not the recommended setting. The driver must turn the system off at the HMI
when exiting the truck. NOTE: The Auto Restart [Enabled] setting creates the potential of depleted batteries on an
unoccupied truck. If the driver does not turn the TriPace system off at the HMI before exiting, the truck it will
continue to draw battery power while controlling cab temperature of an unoccupied truck.

TriPace Is Off
The ignition switch is turned on while the TriPace is turned off at the HMI or has cycled off after the “Pull Ahead”
timer has expired. Battery charging sequence will begin. Refer to Battery Charging in this section.

TriPace Turned On
The TriPace system was off but is turned on at the HMI while the truck ignition is already on. The selected mode
icon will flash continuously, but the HVAC system will remain in null. The battery monitor will scroll up. When the
truck ignition is turned off the TriPace system is defaulted off (disabled) and must be turned on (enabled) by the
driver at the HMI.

POWER SOURCES
All of the onboard batteries of a truck with the TriPace system can be thought of as a reservoir of electrical power.
When the truck is parked the TriPace system, and any other electrical devices in use, will consume the power in
this reservoir. The faster the power is consumed the sooner the reservoir will be empty.

To achieve maximum climate control run time the operator should takes steps to conserve power by reducing
consumption. This is especially important when outside temperature is high. Suggested steps include:

● Keep window curtains closed to reduce radiant heat that will increase cab temperature.

● Close curtain between cab and sleeper to reduce air conditioned space.

● Limit the on time and the number of lights and accessories to reduce battery power drain.

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 Section 4 – TriPace System Operation

● Limit the on time and number of devices or appliances connected to the optional AC Power Inverter to reduce
power drain.

● Connect the AC to DC Converter to Shore Power, if available, to increase power reservoir.

NOTE: Use of truck accessories such as lights, refrigerators, TVs, etc. draws power from the batteries
and will compete with the climate control electrical demand of the TriPace system. Heavy use of these
devices and/or use of the optional 12 Vdc to 115 Vac Power Inverter will reduce the potential run time of
the TriPace system. In addition, high ambient temperature will cause near continuous operation of TriPace
air conditioning system. This increased electrical demand will reduce the number of hours the system
can control cab temperature. In high ambient conditions the driver should reduce the use of electrical
accessories to a minimum to extend air conditioning time.

The TriPace power management technology will make the most efficient use of the available power. The system
will draw from the truck batteries and TriPace battery pack together. There is a Current Sensor in the interconnect
cable between the TriPace batteries and truck batteries. It provides the Main Controller with information to help
manage power flow. A pair of Smart Charger Modules (SCM) monitor and control power flow to and from the
TriPace batteries. The SCMs provide the Main Controller with battery status information. The TriPace system may
draw as in excess of 100 amps during full air conditioning demand.

Power for the TriPace system comes from the following three sources. All system power is sent to a main fuse
block in the TriPace battery box.

TriPace Battery Box

The TriPace Battery Box is the primary power source for the TriPace system. It has four 12 Vdc, Thermo King NXT
AGM (Absorbed Glass Mat) type Deep Cycle batteries. These batteries are specifically designed for the TriPace
system. Each pair of batteries is connected to the main fuse block through a Smart Charger Module (SCM) that
monitors the state of those batteries. An SCM in Discharge mode can provide up to 40 amps from one of its
batteries to the system. The combination of both SCMs and their batteries can provide up to 80 amps. These
batteries will be maintained at a charge level to promote optimum battery life. Each battery can be individually
isolated from the system by its SCM.

Truck Batteries
The OEM truck battery bank is the secondary power source for the TriPace system. For base level system
performance there must be four 12 Vdc group 31 batteries connected to provide 12 Vdc output. For optimum
performance and battery life recommend four Thermo King NXT AGM type Deep Cycle batteries be installed to
extend the maximum operating time of the system during high air conditioning demand conditions. These
batteries are specifically designed for the TriPace system. The type of truck batteries installed (lead acid or NXT)

4-11
 Section 4 – TriPace System Operation

must be programmed through TK Monitor - Unit Setup. High levels of driver Hotel Load may reduce available
reserve from these batteries.

Shore Power
The optional 115 Vac to 12 Vdc Power Converter is connected directly to the truck batteries. It will provide up to
an additional 85 amps of DC power to the system when plugged into external Shore Power. It will extend the
operating time before the system batteries are depleted. The AC to DC Power Converter should be plugged into a
115 Vac source when the batteries are near full charge. The Converter may not be able to support the system
demand alone if the batteries are already depleted. Driver may enable the Shore Power Charging function to
charge all the system batteries from the AC to DC Power Converter. The truck ignition and TriPace HVAC system
must be off. See Driver Selectable Settings.

The converter should be connected to shore power with a commercial grade, three wire, grounded extension
cord. Use a 14 AWG cord up to 75 feet. Use a12 AWG cord up to 145 feet.

POWER FLOW
The TriPace system automatically manages power flow into and out of the auxiliary batteries in the TriPace Battery
Box. The TriPace system also controls current flowing between the truck batteries and the TriPace Battery Box.
The TriPace battery box is the primary power reservoir for the HVAC system. The truck batteries are the primary
source of power for all electrical loads in the truck. This includes the optional DC to AC Power Inverter.

When HVAC demand is less than the maximum output of 80 amps the TriPace battery box will support most, if not
all, of the load. Power flow from the truck batteries to support HVAC operation is limited to 1 amp when HVAC
demand is less than 60 amps until all of the auxiliary batteries are depleted and unable to match the voltage
available in the truck batteries. When HVAC demand is greater than 60 amps the SCM will begin to transfer
increasing power from the truck batteries. When maximum output (80 amps) has been reached current will flow
from the truck batteries to make up the difference.

This power flow is controlled by the Smart Charger Modules (SCM) and is measured by the Current Sensor. At
some point the power level available in the TriPace auxiliary batteries and truck batteries may balance. The
reserve capacity of all the batteries will begin to fall together.

As each battery connected to an SCM falls below 11.5 Vdc it will be switched to Null. The second battery will
begin to discharge. When all the TriPace batteries are below 11.5 Vdc they will be disconnected from the system.
The TriPace HVAC system will continue to operate with the truck batteries as the power source until System
Voltage falls below the programmed depth of discharge, determined by the Tractor Battery Type setting, then stop
all HVAC operation. The depth of discharge limit is set to maintain sufficient charge for optimum battery life. If
Truck Battery Type is programmed to NXT batteries this is 11.5 Vdc, if programmed to All Others this will be 12
Vdc with early software or 12.5 Vdc with current software.

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 Section 4 – TriPace System Operation

Hotel Load for the driver is supported by the truck batteries. It is in competition for available electrical resources
with the TriPace HVAC demand. The Hotel Load may deplete the truck batteries faster than the TriPace batteries.
Current flow from the TriPace batteries to the truck batteries will be limited to 1 amp. The main function of the
TriPace batteries is to support HVAC functions.

Smart Charger Modules

There are two Smart Charger Modules (SCM) in the TriPace Battery Box. They are each connected to two
batteries. Only one battery is active at a time. The SCMs control the power flow of the TriPace batteries in one of
three modes: Discharge, Null or Charge. Two LEDs on the SCM will indicate the mode each battery connected to
the SCM is in. The Main Controller decides what mode should be used and communicates with the SCM through
the CAN (Controller Area Network) connection. The SCMs are self protected against over voltage up to 32 volts
and reverse polarity. They can read the voltage at each battery and the fuse block. They can also read and
control the amps flowing through the SCM in either direction. This information is reported to the Main Controller.

Discharge Mode
Truck ignition must be off. During Discharge mode current is allowed to flow out of one battery through its SCM to
the main fuse block. The SCM will first use the battery with the highest voltage. It will switch between its batteries
based on power demand and depth of discharge. Current is not allowed to flow backwards into the batteries. This
mode is used during TriPace HVAC operation. The SCM is capable of providing 12.8 volts to the system with
battery voltage as low as 10 volts. During normal operation when a battery falls below 11.5 Vdc it is put in Null.
From HMI On to SCM Discharge Mode takes 45 seconds. From HMI Off to SCM Null Mode takes 5 minutes.

Charge Mode
Truck ignition must be on. The Main Controller will check the status of the IGN input. If it is high the charging
sequence will start. During Charge mode current is allowed to flow into one of the TriPace batteries connected to
the SCM. The SCM will switch between its batteries based on charge level. Current is not allowed to flow
backwards out of the batteries. This mode will be used to charge the batteries when the truck is running,
alternator is charging and there is sufficient excess charging capacity. System Voltage must be above 13 Vdc
before the TriPace batteries will begin to charge. A battery must have at least 9 Vdc for an SCM to recognize the
battery and begin the charging process. Batteries below 9 Vdc will be ignored by the SCM and isolated from the
system. The SCM will charge its batteries in three stages.

Constant Current: Also known as Stage 1 or Bulk Charge. Charge partially depleted battery at a
constant high current of 40 amps. This brings the battery up to 80% state of charge. Voltage will rise to
about 14.7 volts.

Constant Voltage: Also known as Stage 2 or Absorption Charge. Finish charging from 80% to 100%
state of charge at a constant voltage of about 14.7 volts. Amperage will be decreasing.

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 Section 4 – TriPace System Operation

Float: Also known as Stage 3 or Maintenance Charge. After achieving 100% state of charge the batteries
are maintained with very low amperage at about 13.6 volts.

Null Mode
During Null mode current is not allowed to flow into or out of a TriPace battery. It is isolated from the system. One
of the batteries connected to an SCM will always be in Null. This mode will also be used if the TriPace HVAC
system has been turned off (disabled) and the truck ignition is off. This prevents TriPace battery drain by truck
systems.

Shore Power
The optional AC to DC Power Converter will provide up to 85 amps of additional system power when plugged into
external or “Shore Power”. It requires an external 115 Vac, 15 amp power source. The main function of the
Converter is to extend the maximum operating time of the system by providing an additional external power
source to the operating system. The Main Controller will monitor the power requirements of the system.

The TriPace batteries, truck batteries and AC to DC Power Converter will share in providing the required power.
The AC to DC Power Converter will extend the total operating time of the system. However, at some point the
available battery reserve will be depleted.

The AC to DC Power Converter will add to the capacity of the truck batteries only. This may help support Hotel
Load and HVAC system demand in excess of the current available from the TriPace batteries. The HVAC system
will use the TriPace battery box as the primary source of power. It would be possible for the TriPace auxiliary
batteries to become depleted. The system would then draw all power from the truck batteries.

NOTE: If shore power is available it should be connected when the batteries are near full charge to
receive the full extended run time benefit of the AC to DC Power Converter. It is not recommended to plug
into shore power after the batteries are already partially depleted.

SYSTEM INFORMATION FLOW

The TriPace Main Controller efficiently controls system operation based on operating conditions. System
information flows to and from the Main Controller in several ways.

CAN (Controller Area Network)

The CAN is an internal two way communication network between components in the system. The following
system components will communicate with the Main Controller through the CAN.

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 Section 4 – TriPace System Operation

HMI
The Main Controller receives driver input from the HMI (Human Machine Interface) for selected Mode, Setpoint
and Fan Speed. It also receives information from the integral Cab Temperature sensor. The Main Controller
sends system voltage information, evaporator fan speed and an alarm signal to the HMI control panel.

Smart Charger Modules

The SCMs are connected in series on the CAN to the Main Controller. The Main Controller receives information
from and sends commands to each of the SCMs.

Component Communication
The Main Controller communicates with many of the components in the TriPace system.

Compressor Controller
The Main Controller receives information from the Compressor Controller that includes compressor RPM,
amperage, compressor temperature and compressor faults. The Main Controller sends speed commands to the
Compressor Controller.

DC to DC Converter
The Main Controller sends an enable/disable signal to the DC to DC Converter.

Fans
The Main Controller sends speed commands to the condenser and evaporator fan controllers. It receives fan
speed feedback from the evaporator fan.

Heater
The Main Controller sends power, an On signal and setpoint information to the Espar heater.

Sensors
In addition to information provided to the Main Controller through the CAN and components there are several
other sensor inputs.

Current Sensor (CS)

The Current Sensor provides amperage information, amount and flow direction, to the Main Controller about the
connection between the OEM truck batteries and the TriPace battery box.

Return Air Temperature (RTS)

The Main Controller uses Return Air Temperature along with Cab Temperature from the HMI and Setpoint to
determine cooling demand.

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Evaporator Coil Temperature (CTS)

The Main Controller uses Evaporator Coil Temperature to prevent a frosted coil. The compressor will slowdown
then stop as coil temperature nears 32º F (0º C).

Ambient Air Temperature (ATS)

The Main Controller uses Ambient Air Temperature to assist in control of Compressor and Condenser Fan speed.
During moderate ambient conditions the Condenser Fan may slow down or even stop while cooling. The
Compressor speed may also be reduced.

High Pressure Cutout Switch (HPCO)

As in other Thermo King system the HPCO is a pressure switch that acts as a safety. It informs the Main
Controller if discharge pressure is abnormally high. Opens at 360 psig (2482 kPa) and closes at 240 psig (1655
kPa).

Truck Ignition Input (IGN)

This connection to the truck ignition switch provides a signal to the Main Controller when the switch is in the On
position, truck engine is running. The Main Controller will then initiate a system shut down sequence.

TK Monitor
TK Monitor is an external communication tool. It can be used by the technician to gather system information for
diagnostics. There is access to additional diagnostic tools. Refer to Section 5, Diagnostics.

BATTERY CHARGING
Truck Running
Charging amperage is provided by the truck alternator. A 185 amp alternator is the minimum recommended to
support the TriPace system. For many applications or truck operation profiles, such as high tractor duty load, high
driver “Hotel Load”, extended layover duration, high ambient temperature operation or short drive times between
layovers, increased battery charging capacity may be required. Undersized alternators will increase TriPace
charge time. The alternator will spend a higher percentage of operating time at maximum output. This may
shorten the life of the truck alternator. To provide the additional charging capacity the alternator and charging
cables may need to be upgraded to 240 or 270 amps.

Battery charging will take place in progressive stages (Refer to Charge Mode under Smart Charger Modules).
This prevents an extremely high charge rate. The process begins when the truck engine is started. The SCMs will
be put in Null mode. All TriPace batteries will be isolated. The truck batteries will begin charging first.

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 Section 4 – TriPace System Operation

NOTE: While the truck is idling there may not be enough amperage produced by the alternator to
effectively charge the batteries. Many alternators may require a minimum of 1,200 RPM before effective
battery charging is available.

If the TriPace system is on when the truck is started the four minute Pull Ahead timer must expire followed by a
four minute system check before the charging process will begin. If the TriPace system is off when the truck is
started the Main Controller checks IGN status every five minutes. If it is on, the charging process will begin.

The TriPace Main Controller will monitor System Voltage. When it rises above 12.5 Vdc the Main Controller will
begin adding one SCM at a time to the charging process if there is excess charging capacity available from the
alternator. Each SCM is capable of charging one battery at 40 amps. First the Main Controller will put one of the
SCMs in Charge mode. It will choose to charge the battery with the lowest state of charge. As a result, SCM1
battery A may not be the first to begin charging.

NOTE: A battery must be above 9 volts for the SCM to recognize it for charging. A battery below this
voltage should be externally charged then tested before adding it back into the system. A red flashing
LED on the SCM will indicate a battery that is under voltage.

If System Voltage does not drop significantly when a battery is added, the SCM will remain in Charge mode. If
System Voltage does drop there is insufficient reserve charging capacity, the truck batteries are not sufficiently
charged. The SCM will return to Null mode for 15 minutes then retry. The SCM will continue trying to engage
Charge mode until it is successful.

Once the first SCM is in Charge mode for a time the Main Controller will attempt to add the second SCM to the
charging process. It will perform the same steps described above until it has both SCMs charging one battery
each. The truck alternator is now charging six batteries; four in the truck and two in the TriPace battery box. The
SCMs will bring their first batteries to 80% state of charge then switch to their second batteries until all batteries
are at 80% state of charge. The SCMs will switch back to the first batteries to finish charging to 100% followed by
the second batteries. Once charging is started, if System Voltage falls below 11.5 Vdc then TriPace battery
charging will stop.

Total battery charging time is expected to be 6 – 10 hours depending on depth of discharge, traffic, driving profile
and alternator size. The six Battery Monitor bars will scroll up in green while the truck engine is running and
alternator is charging. Battery charge state can be read at the HMI while the HVAC system is off by bumping the
On/Off selector for less than one second.

Shore Power
Connect the optional 115 Vac to 12 Vdc Power Converter to external Shore Power. This requires a 115 Vac, 15
amp external power source. If the optional AC to DC Power Converter is installed and Shore Power is available it
should be connected to external power as soon as possible after the truck is parked. The converter will provide

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 Section 4 – TriPace System Operation

13.6 Vdc at up to 85 amps to the truck batteries. This additional amperage helps to keep the truck batteries at a
higher state of charge while supporting driver “Hotel Load”. The primary function of the AC to DC Power
Converter is to extend HVAC operating time.

HVAC System On
If the combined amp draw of the TriPace HVAC system, truck systems and DC to AC Power Inverter is less than
the available 85 amp output of the AC to DC Power Converter, the truck battery pack may begin charging. The
TriPace batteries will not charge with the HVAC system on.

HVAC System Off

If the TriPace system and truck ignition are off, by default only the truck batteries will charge. This is because the
SCMs are defaulted to NULL with the TriPace and truck ignition off, preventing current from flowing to or from the
TriPace batteries. If the Shore Power Charging feature (refer to Driver Selectable Settings) is selected by the
driver, when the truck batteries become sufficiently charged and there is excess Converter charging capacity the
Main Controller may command the SCMs to begin charging the TriPace batteries. It will use the same charging
process as when the truck is running.

12 VDC TO 115 VAC POWER INVERTER (OPTIONAL)

A 1000 watt 12 Vdc to 115 Vac pure sine wave inverter is available as an option for the TriPace. The inverter is
normally connected directly to the truck batteries.

● Pure Sine Wave Inverter

● 900 watt Continuous Output

● 1000 watt Peak Output for five minutes

● 2000 watt Momentary Surge Output

● GFCI Protected

● Inverter is connected directly to the truck batteries

● Alarm Codes and Automatic Shutdown Protection

When the inverter detects an AC load, it automatically turns on and converts DC to AC to power onboard 115 Vac
devices. If the TriPace is enabled and the inverter draws system battery voltage down below the voltage limit
established for the installation, the TriPace system will shut down.

Heavy use of the inverter will reduce air conditioning run time.

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 Section 4 – TriPace System Operation

Use of the inverter may draw the truck batteries below the TriPace voltage limit. If the voltage level continues to
fall, the tractor low voltage disconnect alarm will turn off the truck accessory circuit. If the driver continues to use
the inverter it will activate an alarm at 11 Vdc and will shut down at 10.5 Vdc.

The inverter is designed to handle a variety of applications including compact microwaves, TVs, VCRs, coffee
makers, and small power tools. Thermo King recommends that 800 watt or smaller microwave ovens be used
with the Thermo King Pure Sine Wave Inverter.

115 VAC TO 12 VDC SHORE POWER CONVERTER (OPTIONAL)

To effectively extend HVAC operating time the converter should be connected to Shore Power whenever
available and as soon as possible while the batteries are fully charged.

Converter is connected directly to the truck batteries.

System support mode will provide up to 85 amps to the system at 13.6 Vdc. Plug in as soon as possible for most
effective extension of HVAC run time.

Battery charging mode will charge the batteries at 13.6 Vdc with decreasing amperage. To charge the TriPace
batteries Shore Power Charging must be selected by the driver. Refer to Driver Selectable Settings.

The 115 Vac to 12 Vdc Power Converter should be connected to an external 115 Vac, 15 amp outlet. Use a
commercial grade, three wire, grounded extension cord. Use a 14 AWG cord up to 75 feet. Use a12 AWG cord
up to 145 feet.

OPERATING CHARACTERISTICS SUMMARY

Technicians should understand basic system operating characteristics. This understanding will be helpful during
system diagnostics.

● High electrical accessory use and high ambient temperature will shorten operating time.

● TriPace System is defaulted off. When the truck ignition is turned off the driver must re-enable the system by
pressing the On Button of the HMI.

● When changing between operating modes the new mode will not initiate immediately. A 2 second delay will
prevent system short cycling. It allows changing back, or to another selection to avoid momentary or
accidental mode starts.

● Evaporator fan mode is defaulted to Auto when A/C is selected and Off when Fan or Heat is selected.

● Once the A/C system has started it will run for a minimum of 3 minutes. After the minimum run time has
expired, if the A/C system cycles off or is turned off it will not restart for a minimum of 3 minutes.

● Once the air heater receives an On signal it will run for a minimum of 5 minutes.

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 Section 4 – TriPace System Operation

● The heater cool down cycle is about 4 minutes.

● While the TriPace system is operating, if the truck ignition is turned on the system will initiate a 3 minute “Pull
Ahead” timer. If the ignition is turned off before the end of three minutes the system will continue the current
operating mode. If the truck ignition is still on when the timer expires the system will enter a shutdown
sequence.

● When the system is turned on after a non-standard shutdown, such as loss of power, it takes 60 seconds for
the control system to boot up and start running in application mode. The green LED on the Main Controller
will blink rapidly during this time.

● During A/C operation the compressor is limited to five On events per hour. This will prevent short cycling of
the system. The system will reset one hour after the first event.

● During Heat operation the heater is limited to five On events per hour. This will prevent short cycling of the
system. The system will reset one hour after the first event.

● System Voltage must rise above 13 Vdc before TriPace batteries will begin charging.

● A TriPace battery that falls below 9 Vdc will not be charged by the system.

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 Section 5 – TriPace Diagnostics

TABLE OF CONTENTS - SECTION 5

TriPace Diagnostics ................................................................................................................................................. 6

TriPace Service Notes.............................................................................................................................................. 6
Electrostatic Discharge........................................................................................................................................... 7
System Checkout Procedure.................................................................................................................................. 7
Physical Inspection ............................................................................................................................................ 8
System Function During Discharge Mode ....................................................................................................... 9
Standard Discharge Mode Testing .............................................................................................................. 9
Extended Discharge Mode Testing ........................................................................................................... 10
System Function During Charge Mode .......................................................................................................... 11
Standard Charge Mode Testing ................................................................................................................. 11
Extended Charge Mode Testing ................................................................................................................ 12
Truck Battery and Charging System Condition ............................................................................................ 13
TriPace Battery and Connection Condition ................................................................................................... 14
Batteries ................................................................................................................................................................. 15
Jump Starting ................................................................................................................................................... 15
NXT AGM Battery Charge Maintenance ......................................................................................................... 15
Parasitic Drain .................................................................................................................................................. 16
Test for Parasitic Drain:.............................................................................................................................. 17
Battery Cable Connections ............................................................................................................................. 17
Battery Testing ................................................................................................................................................. 18
Open Circuit Voltage (OCV) ....................................................................................................................... 18
Battery System Test .................................................................................................................................... 19
Voltage Drop Test ....................................................................................................................................... 19
Alarm Code Diagnostics ....................................................................................................................................... 19
Clearing Alarms ................................................................................................................................................ 19
Alarm Types ...................................................................................................................................................... 19
Log Alarms................................................................................................................................................... 19
Check Alarms .............................................................................................................................................. 20
Prevent Alarms ............................................................................................................................................ 20
Shutdown Alarms........................................................................................................................................ 20
Alarm Codes........................................................................................................................................................... 21
02, Evaporator Coil Sensor ............................................................................................................................. 21
03, Return Air Sensor ....................................................................................................................................... 22

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 Section 5 – TriPace Diagnostics

05, Ambient Air Sensor .................................................................................................................................... 23

10, High Discharge Pressure........................................................................................................................... 24
11, Unit Controlling on Alternate Sensor ....................................................................................................... 27
12, Sensor Shutdown ....................................................................................................................................... 28
54, Test Mode Timeout ..................................................................................................................................... 29
61, Low Battery Voltage ................................................................................................................................... 30
70, Hourmeter Failure ...................................................................................................................................... 31
180, Compressor Fault..................................................................................................................................... 32
Fault Conditions .................................................................................................................................................... 33
Low Battery Fault ............................................................................................................................................. 33
HMI Communication Fault ............................................................................................................................... 33
Compressor Fault ............................................................................................................................................. 33
Compressor Faults Indicated by Flashing Red Fault LED on Compressor Controller Board ............ 34
LED Indicators ....................................................................................................................................................... 37
Main Controller ................................................................................................................................................. 37
Compressor Controller .................................................................................................................................... 37
SCM .................................................................................................................................................................... 37
Diagnostic Information - TK Monitor ................................................................................................................... 38
Dash Board ....................................................................................................................................................... 38
System Monitoring ........................................................................................................................................... 38
Service Test Mode ............................................................................................................................................ 38
System Diagnosis .................................................................................................................................................. 39
Battery Icon On ................................................................................................................................................. 39
Low Power Reserve or Short Operation ........................................................................................................ 39
Battery Condition ........................................................................................................................................ 39
Charging System Evaluation ..................................................................................................................... 40
Truck Batteries Become Depleted .................................................................................................................. 41
HMI Diagnosis ........................................................................................................................................................ 42
HMI dark and system not responding ............................................................................................................ 42
Mode icon flashing but system not responding ........................................................................................... 42
HMI Circuits....................................................................................................................................................... 43
SCM Diagnosis....................................................................................................................................................... 44
Indicator LEDs Off ............................................................................................................................................ 44
Indicator LED Flashing Red ............................................................................................................................ 44
Indicator LED Amber ........................................................................................................................................ 44

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 Section 5 – TriPace Diagnostics

Incorrect Operating Mode................................................................................................................................ 44

Compressor Controller Diagnosis ....................................................................................................................... 45
Compressor Does Not Run ............................................................................................................................. 45
Compressor Running Slow ............................................................................................................................. 45
Service Test Mode – Cool with TK Monitor ................................................................................................... 46
12 Vdc to 28 Vdc Power Converter Diagnosis .................................................................................................... 47
Variable Speed Fans ............................................................................................................................................. 49
Fan Motor Does Not Run ................................................................................................................................. 49
115 Vac to 12 Vdc Power Converter (Optional Shore Power) ........................................................................... 50
Check Converter Operation............................................................................................................................. 50
Power Output is Surging or Inconsistent ...................................................................................................... 51
Converter Does Not Charge Tractor Batteries .............................................................................................. 51
Converter Does Not Charge TriPace Batteries .............................................................................................. 52
Temperature Sensors ............................................................................................................................................ 53
Values ................................................................................................................................................................ 53
Test Procedure ................................................................................................................................................. 53
Air Heater Diagnostics .......................................................................................................................................... 54
Heater Does Not Ignite ..................................................................................................................................... 54
Air Heater Ignition and Random Shutdown Problems ................................................................................. 55
Diagnosing TriPac Heater Units for Excessive White Smoke and/or Heater Alarm Code 52 – Safety
Time Exceeded ................................................................................................................................................. 56
Diagnosing TriPac Heater Units with a Dirty or Carboned Glow Pin, Glow Pin Screen or
Burner/Combustion Chamber ......................................................................................................................... 58
Air Heater Fault Codes..................................................................................................................................... 60
Fault Code: 0 No Fault ........................................................................................................................... 60
Fault Code: 4 Short circuit in electronic control unit fresh air output ............................................. 61
Fault Code: 5 Short circuit in electronic control unit car alarm output ........................................... 62
Fault Code: 6 Inexplicable atmospheric altitude information ........................................................... 63
Fault Code: 9 ADR Shutdown ............................................................................................................... 64
Fault Code: 10 Overvoltage shut down ............................................................................................... 66
Fault Code: 11 Under voltage shut down ............................................................................................ 67
Fault Code: 12 Overheating at the Overheating Sensor .................................................................... 69
Fault Code: 13 Overheating at the Flame Sensor ............................................................................... 71
Fault Code: 14 Delta T between Flame Sensor and Overheating Sensor too large ....................... 73
Fault Code: 15 Electronic Control Unit locked ................................................................................... 75

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 Section 5 – TriPace Diagnostics

Fault Code: 17 Overheating .................................................................................................................. 76

Fault Code: 18 Starting energy of the glow pin is too low................................................................. 77
Fault Code: 19 Ignition Energy too Low .............................................................................................. 78
Fault Code: 20 Glow Pin Interruption ................................................................................................... 79
Fault Code: 21 Glow Pin Overload or Short Circuit to Ground ......................................................... 80
Fault Code: 22 Glow Pin Output Short Circuit to Power (+) .............................................................. 81
Fault Code: 31 Blower Motor Open Circuit.......................................................................................... 82
Fault Code: 32 Blower Motor Short Circuit ......................................................................................... 83
Fault Code: 33 Blower Motor Does Not Turn ...................................................................................... 84
Fault Code: 34 Blower Motor Output Short Circuit ............................................................................ 85
Fault Code: 47 Fuel Metering Pump Overload or Short Circuit to Ground ...................................... 86
Fault Code: 48 Fuel Metering Pump Interruption ............................................................................... 87
Fault Code: 49 Fuel Metering Pump Output Short Circuit to Power (+) ........................................... 89
Fault Code: 50 Electronic Control Unit Locked .................................................................................. 90
Fault Code: 51 Flame detected when switching on............................................................................ 91
Fault Code: 52 Safety Time Exceeded ................................................................................................. 92
Fault Code: 53 Flame Cutout in Power Mode ...................................................................................... 95
Fault Code: 54 Flame Cutout in High Mode......................................................................................... 95
Fault Code: 55 Flame Cutout in Medium Mode ................................................................................... 95
Fault Code: 56 Flame Cutout in Low Mode ......................................................................................... 95
Fault Code: 57 Flame Cutout in Start Phase ....................................................................................... 98
Fault Code: 60 External Temperature Sensor Open Circuit ............................................................ 101
Fault Code: 61 External Temperature Sensor Short Circuit ............................................................ 102
Fault Code: 62 Setpoint Control Open Circuit .................................................................................. 103
Fault Code: 63 Setpoint Control Short Circuit .................................................................................. 104
Fault Code: 64 Flame Sensor Open Circuit ....................................................................................... 106
Fault Code: 65 Flame Sensor Short Circuit ....................................................................................... 107
Fault Code: 71 Overheat Sensor Open Circuit .................................................................................. 108
Fault Code: 72 Overheat Sensor Short Circuit ................................................................................. 109
Fault Code: 74 Control Unit Defective ............................................................................................... 110
Fault Code: 90 Control Unit Defective ............................................................................................... 111
Fault Code: 91 External Interference Voltage ................................................................................... 112
Fault Code: 92 Control Unit Defective ............................................................................................... 113
Fault Code: 93 Control Unit Defective ............................................................................................... 114
Fault Code: 94 Control Unit Defective ............................................................................................... 115

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 Section 5 – TriPace Diagnostics

Fault Code: 95 Control Unit Defective ............................................................................................... 116

Fault Code: 96 Internal Temperature Sensor Defective. .................................................................. 117
Fault Code: 97 Control Unit Defective ............................................................................................... 118
Fault Code: 98 Control Unit Defective or Low Voltage Supply under load .................................... 119
Fault Code: 99 Too many resets in sequence or Transistor Error in ECU..................................... 120
12 Vdc to 115 Vac Power Inverter (Optional) .................................................................................................... 121

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 Section 5 – TriPace Diagnostics

TriPace DIAGNOSTICS
Section 5 is devoted to diagnostic information and procedures designed to help the technician quickly and
accurately diagnose a problem and efficiently repair the problem 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 or
ineffective diagnosis and repair.

Use the following hints to help with diagnostics.

● Check system for physical damage.

● Be certain all connectors on the Main Controller Board, Compressor Controller, SCMs and HMI Control
Panel are completely and securely seated.

● Be certain all harness connectors are completely and securely in place.

● Be certain all battery connections, including those in the truck, are clean and tight.

● Record the Open Circuit Voltage at each battery, including those in the truck. Turn off all systems.
Measure voltage at battery posts, not cable ends.

● Note the condition of all LED indicators on the HMI, SCMs, Main Controller and Compressor Controller.

● Using TK Monitor record and clear any alarm codes before performing diagnostic routines. Refer to
Section 6, Communication Using TK Monitor, A51A.

TriPace SERVICE NOTES

Follow these procedures when working on TriPace units:

● The condition and function of the truck batteries and charging system should be verified first when
diagnosing TriPace power issues.

● AGM batteries must be tested with a Battery System Tester, such as 204-1924, designed for use with
AGM batteries. Conventional battery load testing is unreliable.

● Never use circuit testers consisting of a bulb light bulb and ground lead or battery and a light to test the
circuits on any microprocessor-based device unless specifically stated in a diagnostic procedure. A
quality digital multi-meter is required.

● Any time welding is necessary; Service Procedure A26A must be followed.

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 Section 5 – TriPace Diagnostics

ELECTROSTATIC DISCHARGE
Electrostatic Discharge will occur when static electricity in your body causes a high voltage electrical charge to
transfer to system components. This discharge can damage control system microprocessor circuits. Follow these
electrostatic precautions to prevent system or component damage:

● Use an approved anti-static wrist strap, such as 204-622, connected to chassis ground when handling or
servicing microelectronic components.

● Keep all new TriPace Controller/Interface Boards and HMI Control Panels in anti-static bags at all times.
Remove from bag only when component is ready to be installed.

● Protect any defective TriPace Controller/Interface Boards and HMI Control Panels 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.

SYSTEM CHECKOUT PROCEDURE

A common complaint about the TriPace system is short run time in air conditioning mode. A TriPace system that is
unable to maintain air conditioning for at least eight hours is considered to have short run time. This is generally
caused by an abnormal reduction in the available battery power reserve. The cause of this problem usually falls
into one of four areas:

● Incorrect system functions during Discharge Mode.

● Incorrect system functions during Charge Mode.

● Poor truck battery or charging system condition.

● Poor TriPace battery or connection condition.

To diagnose a short run time problem you may need to verify system function or condition in each of the four
areas. The Discharge Mode and Charge Mode checkout procedures are divided into Standard testing and
Extended testing.

Standard Testing verifies base system operation. These tests should always be performed. However, they do not
check some functions.

Extended Testing primarily verifies the system ability to switch between batteries. It also verifies that all batteries
are participating in system operation. These tests should be performed if time and space permit. They should
definitely be performed if the system passed all of the Standard tests but still has complaints about operation.

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 Section 5 – TriPace Diagnostics

Physical Inspection

Before beginning a system checkout procedure a physical inspection should be performed.

1. Verify truck ignition is off.

2. Remove the TriPace battery box cover. Inspect general condition of batteries, SCMs, fuses and connections.
Repair as required. NOTE: Blown fuses are a symptom of a problem. Find and repair cause before
continuing.

3. Check indicator LEDs on the SCMs.

a. All blinking GREEN = Normal, go to next step.

b. One or more blinking RED = Voltage of battery is very low (below 9 Vdc), system has disabled the
battery. Go to TriPace Battery and Connection Condition.

c. One or more solid AMBER = Battery is disconnected from SCM. Check connections and fuses.

d. LEDs dark = Power lost to the 2SCM terminal of SCM. If both SCMs are dark, voltage from the truck
batteries has been lost to the main fuse block.

4. Verify TriPace cable connections at truck batteries are clean and tight.

5. Turn TriPace system on at HMI. Select Fan Mode.

6. Check for alarm indicator on HMI.

a. No alarms = Go to next step.

b. Alarm indicator On = Retrieve and record alarm codes before continuing. Repair as required. Refer to
Diagnostic Manual, Section 6, A51A, Communication Using TK Monitor and Section 5, Alarm Code
Diagnostics.

7. Check for Low Battery Fault indicator on HMI.

a. No fault = Go to next step.

b. Low Battery Fault indicator On = Go to System Function during Charge Mode procedure.

8. Remove compressor/electrical access cover from evaporator box.

9. Check green LED on Main Controller.

a. Blinking once per second = Normal, continue system checkout.

b. Blinking twice per second but slows down within 60 seconds = Normal, continue system checkout.

c. Blinking twice per second for more than 60 seconds = Stuck in Boot Mode. Refer to Diagnostic Manual,
Section 6, A57A, Power Cycle Main Controller.

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 Section 5 – TriPace Diagnostics

System Function During Discharge Mode

These steps will verify the TriPace system software and components are capable of providing power to the
system. It will also verify the system power sources are sharing the load in the correct proportions.

NOTE: The optional Shore Power Converter must not be plugged into 115 Vac.

NOTE: If the TriPace Auxiliary batteries are already low (depleted) at the beginning of this procedure it may be
quicker and more effective to go directly to the System Function during Charge Mode procedures before
performing these Discharge Mode tests.

Standard Discharge Mode Testing

These steps should always be used to evaluate TriPace Discharge Mode function.

1. Verify truck ignition is off.

2. Verify the TriPace system is on at the HMI and green LED on Main Controller is blinking once per second.

3. Connect PC computer to the TriPace Main Controller using a USB Adapter cable (204-1926) and start TK
Monitor. Refer to Diagnostic Manual, Section 6, A51A, Communication Using TK Monitor.

4. Select Service Test Mode from the menu. Select Cool Test. Click Run Test button. The evaporator fan,
compressor and condenser fan should ramp up to high speed.

5. Select System Monitoring from the menu. Select the SCM batteries tab.

6. Check [Number of Connected TriPac SCMs].

a. 2 = Normal. Go to next step.

b. 1 or 0 = System not communicating with both SCMs. Determine cause of lost function.

7. Check and record [System Voltage].

a. Above 12.5 Vdc = Go to next step.

b. Below 12.5 Vdc = Go to System Function during Charge Mode.

8. Check and record [Aux Battery Voltage] for each of the four TriPace batteries. Four batteries with nearly even
voltage suggest the system components are working and can use all batteries equally. A battery below 11
Vdc will not be used by the system to provide power.

a. All batteries above 11.5 Vdc = Go to next step.

b. Any battery below 11.5 Vdc = Go to System Function during Charge Mode.

9. Check [Requested Mode] for each of the four TriPace batteries. One battery from each SCM should be in
Discharging Mode. The other battery should be in Null Mode.

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 Section 5 – TriPace Diagnostics

10. Verify the LED on each SCM for the Discharging battery is flashing green once per second and the LED for
the Null battery is flashing green twice per second. This indicates the SCMs have responded to the Main
Controller commands.

11. Check and record [Aux Battery Current] for each of the four TriPace batteries. Abnormal readings indicate the
system is not correctly responding to existing load conditions. Normal readings indicate the system
components are capable of providing the proper level of current to the HVAC system. Total output from the
TriPace battery box should be about 80 amps.

a. Each SCM has a Discharging battery showing about -40 amps and Null battery showing 0 amps = Go to
next step.

b. Only one or neither SCM is providing normal current to the system = Exit System Checkout Procedure.
Determine why SCMs are not functioning correctly.

12. Check and record [Current Sensor (Low Range)] in the upper part of the TK Monitor page. This represents
the current flowing from the truck batteries to the TriPace system. An abnormal high reading indicates too
much current coming from the truck batteries. A normal reading indicates the system components are
capable of restricting current flow from the truck and use the TriPace batteries as primary power.

a. Current Sensor shows less than -20 amps = Go to next step.

b. Current Sensor shows more than -20 amps = Return to previous step.

13. Select Service Test Mode from the TK Monitor menu. Click Cancel Test button. System should return to the
mode selected by the HMI.

Extended Discharge Mode Testing

The steps are time consuming and require the truck be available for several hours, perhaps through a second
shift. If truck will not be available proceed to System Function during Charge Mode.

The following additional steps will verify the TriPace system ability to switch between batteries. They will also
demonstrate the TriPace system will shut down before killing the truck batteries. Tests need only periodic
monitoring. Computer and TK Monitor may be disconnected then reconnected during test.

14. Set HMI to Cool Mode with setpoint at minimum. Allow system to operate normally.

15. Record which SCM indicator LEDs are blinking once per second (Discharge Mode) or which SCMs are in
Discharge Mode according to TK Monitor.

16. Periodically check the LED blink pattern on SCMs or which SCMs are in Discharge Mode according to TK
Monitor to determine when it changes. This indicates the system has switched batteries.

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 Section 5 – TriPace Diagnostics

17. With TK Monitor check and record [Aux Battery Voltage] for each of the four TriPace batteries. Note the
reading of the battery that had been in Discharge Mode. It should be near 11 Vdc. Can wait until both SCMs
have switched before checking voltage.

18. Periodically check the HMI Battery Monitor. Note when the green bars begin to turn off.

19. With TK Monitor check and record [Aux Battery Voltage] for each of the batteries that are in Discharge Mode.
Should be nearing 11 Vdc. If voltage is below 11 Vdc the battery should have changed to Null.

20. With TK Monitor periodically check and record [System Voltage]. Reading should be falling as Battery Monitor
bars drop.

21. With TK Monitor periodically check and record [Current Sensor]. Reading should be increasing as TriPace
batteries become depleted and system requires more power from the truck batteries.

22. Periodically check the HMI Battery Monitor. Note when down to red bars.

23. With TK Monitor periodically check and record [System Voltage]. Reading should be approaching 12 Vdc.
When reading drops to 12 Vdc the red battery alarm icon should illuminate and all TriPace HVAC function
should stop. NOTE: Truck battery drain may continue in support of driver convenience loads (cab lights, DC-
AC inverter, refrigerator, etc.). The TriPace system has no control of these loads.

24. Proceed to System Function during Charge Mode unless already completed.

System Function During Charge Mode

These steps will verify the TriPace system software and components are capable of charging the TriPace
batteries. The truck alternator is normally used to charge all the batteries. Depending on battery state this may
require running the truck engine for several hours. If this is not possible a battery charger connected to truck
batteries and an energized IGN circuit can simulate the running truck. The optional Shore Power Converter may
be plugged into 115 Vac to provide additional charging capacity.

Standard Charge Mode Testing

These steps should always be used to evaluate TriPace Charge Mode function.

1. Verify truck ignition is off.

2. Verify the TriPace system is on at the HMI and green LED on Main Controller is blinking once per second.
Select Fan Mode.

3. Connect PC computer to the TriPace Main Controller using a USB Adapter cable (204-1926) and start TK
Monitor. Refer to Diagnostic Manual, Section 6, A51A, Communication Using TK Monitor.

4. Start Truck engine or energize the IGN circuit.

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5. In TK Monitor select System Monitoring from the menu. Select the SCM batteries tab.

6. Verify [Ignition State] is on.

7. After 4 minutes all TriPace HVAC functions should stop. [TriPac Auxiliary Battery Charge Status] should show
Charging.

8. Check and record [System Voltage].

a. Below 12.5 Vdc = Allow truck batteries to charge until System Voltage rises above 12.5 Vdc. All TriPace
batteries should show [Requested Mode] of Null. SCM indicator LEDs all blinking twice per second.

b. Above 12.5 Vdc = TriPace charging process may begin.

9. Monitor the SCM indicator LEDs. Solid green indicates a TriPace battery in charge mode.

a. Two TriPace batteries in charge mode within 30 minutes = Normal. Go to next step.

b. Two TriPace batteries are not in charge mode after 30 minutes = Go to Truck Battery and Charging
System Condition.

10. In TK Monitor one battery from each SCM should show [Requested Mode] as Charging. The other still in Null.

11. In TK Monitor the charging batteries should show the following. Normal readings indicate the SCMs are
capable of controlling the proper level of charge current.

a. [Stage of Operation] as CC Bulk Charge.

b. [Aux Battery Current] about +40 amps.

c. [Aux Battery Voltage] should be rising.

d. [Current Sensor (high range)] should be about +80 amps. It shows the total input to the TriPace battery
box from the truck.

Extended Charge Mode Testing

The steps are time consuming and require the truck be available for several hours, perhaps through a second
shift. If truck will not be available proceed to Truck Battery Condition.

The following additional steps will verify the TriPace system ability to switch between batteries. It will also validate
the correct charging profile. Tests need only periodic monitoring. Computer and TK Monitor may be disconnected
then reconnected during test.

12. Check and record which SCM indicator LEDs are solid green.

13. Periodically check battery charging status in TK monitor. Verify [Aux Battery Voltage] continues rising toward
14.7 Vdc in the charging batteries.

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14. Periodically monitor the SCM indicator LEDs looking for a change of the solid green LED. This should occur
when the first charging batteries reach 14.7 Vdc.

15. In TK Monitor the second charging batteries should show the following.

a. [Stage of Operation] as CC Bulk Charge.

b. [Aux Battery Current] about +40 amps.

c. [Aux Battery Voltage] should be rising.

16. Periodically monitor the SCM indicator LEDs looking for a change of the solid green LED. This should occur
when the second charging batteries reach 14.7 Vdc. The SCMs have switched back to the first batteries.

17. In TK Monitor the first charging batteries should show the following.

a. [Stage of Operation] as CV Absorption Charge.

b. [Aux Battery Current] falling.

c. [Aux Battery Voltage] should be 14.7 Vdc.

Proceed to System Function during Discharge Mode unless already completed.

Truck Battery and Charging System Condition

The truck batteries and charging system are an integral part of the TriPace system power reserve. System voltage
from the truck batteries must hold above 12.5 Vdc before the TriPace batteries will charge.

1. Turn all truck and TriPace systems off.

2. Determine truck alternator size.

a. 185 amps or higher = Adequate for most TriPace applications. Bigger is better.

b. Less than 185 amps = Too small for most TriPace applications.

3. Physically inspect truck batteries for damage and loose or corroded connections.

4. Verify all four truck batteries are connected in parallel to provide 12+ Vdc.

5. Test each truck battery with a load tester or Battery System Analyzer. Follow manufacturer’s instructions.
Replace defective batteries as required.

6. Repair loose or dirty connections as required.

7. Start truck engine.

8. Test truck alternator charging capacity. Follow truck OEM test instructions.

9. Measure and record voltage at alternator output terminal.

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10. Measure and record voltage at truck battery pack.

11. Stop truck engine.

12. Compare readings from steps 9 and 10.

a. Less than 0.5 Vdc difference = Normal.

b. More than 0.5 Vdc difference = Abnormal high resistance causing voltage drop. Find and repair as
required.

13. Turn on TriPace system. Enable air conditioning mode.

14. Measure and record voltage in the TriPace battery box at the truck battery cable connection on the fuse block.

15. Measure and record voltage at truck battery pack.

16. Compare readings from steps 14 and 15.

a. Less than 0.5 Vdc difference = Normal.

b. More than 0.5 Vdc difference = Abnormal high resistance causing voltage drop. Find and repair as
required.

17. Turn off TriPace at HMI.

TriPace Battery and Connection Condition

After performing all other system checks the customer complaint is still short run time. One or more of the TriPace
batteries may be defective and not able to maintain power output.

1. Turn TriPace system off at the HMI.

2. Disconnect power cable from truck at the TriPace fuse block.

3. Disassemble TriPace battery connections.

4. Verify battery cable and fuse connections to SCMs are clean and tight.

5. Individually charge batteries to 12.5 Vdc or higher.

6. Test each TriPace battery using an AGM Battery Tester (204-1959 or 204-1960). Replace defective batteries
as required.

7. Clean battery cable connections and reassemble.

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BATTERIES
Refer to Service Bulletin T&T 445 - Lead Acid Battery Safety and Best Practices for more information. The
TriPace battery box contains four Thermo King NXT, AGM, deep cycle type batteries. These batteries have been
specifically designed for the TriPace system to maximize battery life and support deep discharge cycles. They
provide increased power storage capacity for the system. Thermo King recommends that the tractor’s batteries
also be of the same type as the TriPace batteries for optimum performance and battery life.

Jump Starting
To avoid potential damage to batteries and charging systems jump starting is not recommended. It is
recommended that low or dead batteries be charged using an external battery charger. They should then be
tested before being returned to service.

CAUTION: The TriPace battery box is not designed to Jump Start the truck engine or provide power to the
truck while driving. Serious system damage may result.

NOTE: If a system utilizing a Thermo King AGM battery has just been jump-started due to a dead battery,
be aware that the battery may use the entire output of the alternator to charge. This is normal, and the
alternator voltage output may be lower during the charge period due to the high current draw of the
battery.

NXT AGM Battery Charge Maintenance

Thermo King NXT AGM batteries are shipped fully charged. Fully charged NXT AGM batteries that are kept in
storage should not require charging for 2 years if keep below 77 F (25 C). NXT AGM batteries should be charged
when the open circuit voltage (OCV) falls below 12.50 volts.

To charge the NXT AGM battery, use the following guidelines:

1. Verify the output voltage of your battery charger is capable of maintaining 14.1 to 14.7 volts charging voltage.
The recommended charging voltage range for the NXT AGM battery is 14.1 to 14.7 volts. Voltages are to be
measured at the battery terminals with the battery connected to the charger.

NOTE: Never exceed 15 volts when charging the NXT AGM. Exceeding 15 volts will cause pressure
relief valves to open and out-gas hydrogen and oxygen from inside the battery. This will shorten the
life of the battery and could lead to premature battery failure.

2. Battery chargers with the battery type output setting should be set to AGM type battery. Do not set the output
type to gel cell or maintenance free settings.

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3. Determine if your battery charger is an automatic or manual charger. Manual battery chargers must be
closely monitored during the charge period and for this reason an automatic battery charger is preferred over
a manual charger.

a. Automatic battery chargers either charge up to a preset voltage and shut off, or charge to a preset
voltage and then switch to a trickle charge mode. Either one of these battery chargers is acceptable:
however the automatic charger that shuts off may not fully charge the battery.

b. Manual battery chargers will have manual controls for setting the charge amperage rate. The charge
amperage rate will remain the same until the battery charger is manually shut off.

NOTE: When using a manual battery charger, set the charger to charge at 10 or 20 amps and limit the
charging time based on the batteries state of charge (SOC). Use the chart below as a general guide to
determine the amount of time necessary to charge the battery. DO NOT overcharge the battery.

Determining Maximum Charge Time Using a Manual Charger

Voltmeter Reading State of Charge Time @ 10 Amps Time @ 20 Amps
12.75 Volts 100% 0 Hours 0 Hours
12.50 Volts 75% 2 Hours 1 Hour
12.30 Volts 50% 4 Hours 2 Hours
12.00 Volts 25% 6 Hours 3 Hours
WARNING: Overcharging can damage the battery and possibly cause a fire or explosion. Follow the
battery charger’s recommendations for monitoring batteries while charging. Batteries should be
monitored while charging for signs of internal problems. Signs of internal problems include bulging
cases, extreme gassing, pungent smell, and extreme heat. If you notice any of these signs turn the
charger off and allow the battery to stabilize before handling or testing.

Parasitic Drain
Batteries are low or dead when the truck has not run for a few days. This may be caused by Parasitic Drain on
the batteries. Dirt, water, oil, coolant or battery electrolyte can combine to provide a conductive path across the
surface of a battery between the posts. This parasitic drain may discharge a battery even when system loads are
turned off.

NOTE: TriPace batteries may become depleted if the truck is not used for an extended period. The TriPace
control system is still active even when the system is turned off. If TriPace battery voltage falls below 9
Vdc, batteries must be externally charged to 11 Vdc or higher before the system will recognize and
charge them. Refer to NXT AGM Battery Charge Maintenance in this section.

IMPORTANT: If a truck with a TriPace will not be used for more than 30 days the system should be
prepared for Long Term Storage. Refer to the TriPace Maintenance Manual (TK 54499), Electrical
Maintenance, Long Term Storage.

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Test for Parasitic Drain:

4. Turn all systems off.

5. Place the positive lead of a voltmeter on the positive battery terminal.

6. Place the negative lead of the voltmeter on the top surface of the battery case near the negative terminal.
Pick a spot that looks dirty.

7. Read the meter.

8. There should be no voltage reading. Any voltage reading indicates parasitic drain across the battery case.

9. Clean the battery to remove conductive path.

Parasitic Drain may also be caused by an electrical load that remains connected when all systems are turned off.
Check for:
● Cab lights left on.

● Convenience lights in glove box or under bunk stuck on.

● Trailer interior lights left on.

● Power Inverter on with device plugged in.

● Any other device that is connected directly to the batteries and not controlled by the ignition switch.

Battery Cable Connections

Battery cable connections that are loose, dirty or corroded add resistance to the power circuit. This will reduce the
voltage and amperage available from the battery to the system. It will also reduce the amperage that can flow to
the battery during charging. Check the following:

● Battery cable connections that can be rotated by hand are too loose and should be tightened.

● Battery cable connections that are obviously corroded must be disassembled and cleaned.

● Incorrect terminal hardware can cause corrosion and increased resistance. Use stainless steel nuts and
washers. Torque to 150-200 in-lb (16.9-22.6 N•m).

● Frayed cables or loose cable to terminal connection will cause high resistance and reduced current.

● High resistance in cables and connections can be located and measured using a Voltage Drop Test.
Refer to Section 6, H24A.

● Superlube (P/N 203-524) or equivalent should be applied to all electrical connections.

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Battery Testing
Use the Open Circuit Voltage (OCV) test and Battery System Tester to determine if a battery should be charged
or replaced. TriPace battery voltage may be checked with TK Monitor using the System Monitoring, SCM batteries
screen. Refer to Communication Using TK Monitor, Section 6, A51A. To find high resistance in battery cables and
connections use Voltage Drop Test, Section 6, H24A.

NOTE: The tractor batteries are an important part of the TriPace power reservoir. The condition of these
batteries should also be tested when diagnosing a power reserve problem. On a truck with NXT batteries,
the alternator must charge at 14.2 volts or more. This voltage must actually be delivered to the batteries.
High resistance in cables or connections can prevent this. At lower voltage the batteries will never
achieve full charge and will sulfate. Battery life will be shortened

Open Circuit Voltage (OCV)

OCV is the voltage available in the battery with no other circuits or loads connected. The OCV test is used to
determine a battery’s State Of Charge (SOC). A good quality digital multi-meter or a dedicated Battery System
Tester should be used.

Test OCV:

1. Electrically isolate the battery or disconnect the battery cables from the battery. When reconnecting cables to
the TriPace system connect the negative cable first. A small spark may occur when connecting the positive
cable. This is normal.

2. Check the voltage between the battery terminals. Connect the tester leads to the battery posts. Do not
connect to cable terminals.

3. Read the OCV. The voltage reading corresponds to the SOC as shown in the following table.

Open Circuit Voltage State of Charge

(OCV) (SOC)
12.75 Volts 100%
12.50 Volts 75%
12.30 Volts 50%
12.00 Volts 25%
NOTE: A battery that has an OCV of less than 12.5 volts should be charged before further testing. When
reconnecting cables to the TriPace system connect the negative cable first. A small spark may occur
when connecting the positive cable. This is normal.

Absorbed Glass Mat (AGM) batteries, such as Thermo King NXT, should not be allowed to fall below 10 Vdc. A
battery left below this level or is repeatedly discharged to below this level may be permanently damaged. It may
not be able to provide normal output or take a full charge.

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Battery System Test

It is not recommended to use traditional load testing on systems with Absorbed Glass Mat (AGM) batteries, such
as Thermo King NXT. This type of test is not reliable. A Battery System Tester designed for AGM batteries, such
as Thermo King P/N 204-1959 or 204-1960, should be used. Battery System Testers may also be used on
regular lead acid and gel type batteries. Follow the manufacture instructions for the tester being used. If a battery
fails the system test it should be replaced.

In general, before testing a battery it should be disconnected from the system. When reconnecting cables to the
TriPace system connect the negative cable first. A small spark may occur when connecting the positive cable.
This is normal. Open circuit voltage should be above 12.5 Vdc. A battery below this voltage should be charged
before further testing. A battery that cannot be charged to this level is probably defective.

Voltage Drop Test

Voltage drop in wire and cable connections can significantly reduce the power that can be transferred to and from
batteries. It is caused by abnormally high resistance from loose or corroded connections. This resistance can be
located using a Voltage Drop Test. Refer to Section 6, H24A.

ALARM CODE DIAGNOSTICS

The alarm icon on the HMI will alert the operator that an abnormal condition exists. The alarm code number must
be retrieved using TK Monitor. Refer to Communication Using TK Monitor, Section 6, A51A.

NOTE: Alarms are a symptom of a problem. They should not be considered as diagnosis of the problem.
A logical step-by-step diagnostic process should be used to identify the actual cause.

Clearing Alarms
Most alarms may be cleared from the HMI. With the HMI on, bump the On/Off button three times then hold it for
five seconds. The Alarm icon should go out. If it does not or immediately returns the alarm condition may still exist
or the alarm is not clearable from the HMI. System should be checked by a qualified technician.

All alarms can be viewed and cleared using the TK Monitor Alarm screen. Refer to Communication Using TK
Monitor, Section 6, A51A.

Alarm Types

Log Alarms
Log Alarms are indicated by a yellow HMI alarm icon for 30 seconds each time the HMI is turned on. This level of
alarm serves as notice to take corrective action before a problem becomes severe. The system will usually
continue to operate with a Log Alarm but some features and functions may be inhibited or disabled. Alarm code is
logged in the data logger.

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Check Alarms
Check Alarms are indicated by a steady yellow HMI alarm icon. This level of alarm serves as notice to take
corrective action at the earliest convenience before a problem becomes severe. The system will continue to
operate but some features and functions may be inhibited or disabled. Alarm code is logged in the data logger.

Prevent Alarms
Prevent Alarms are indicated by a steady yellow HMI alarm icon and the system will not be operating. This level
of alarm serves as notice that the system has detected an abnormal operating condition or potential system
problem and has shutdown. The system will remain shut down for a timed restart interval. System will reactivate
at the end of this interval. If the alarm condition does not reoccur during a probation period of 60 minutes the
alarm will self-clear. If the condition occurs two additional times before clearing the 60 minute probation timer the
alarm will become a shutdown. Alarm code is logged in the data logger.

Shutdown Alarms
Shutdown alarms are indicated by a flashing red HMI alarm icon and the system will not be operating. This level
of alarm serves as notice to take immediate corrective action. System has detected a potentially severe problem
and shutdown. Unit will not restart until the alarm is manually cleared. Alarm code is logged in the data logger.

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ALARM CODES

02, Evaporator Coil Sensor

Alarm Type Check Alarm TriPace APU

Associated Alarm Codes Alarm Code 12 Sensor Shutdown

Component Description and Location

This sensor is a thermister style sensor that can be tested with an ohmmeter. It is not polarity sensitive. The
sensor is located in the evaporator coil.

Circuit Description
The evaporator coil temperature sensor circuit is a two wire circuit. The two yellow (CTS) wires are connected
to the Main Controller Interface Board 8 pin evaporator sensor connector J35 Pin 3 and Pin 8. The sensor
wires are routed in the Evaporator Sensor Harness. The sensor is hard-wired to the sensor harness.

Considerations
Sensors should be positioned to minimize the potential for moisture entry where the wires enter the sensor
shell.

How Alarm is Set

If the sensor reading is outside of the allowable limit (-38° F to 170° F [-39° C to 77° C]) and does not return
within 10 seconds then Alarm Code 02, Evaporator Coil Sensor is set as a check alarm. Typically generated by
an open or very high resistance in the sensor circuit. The compressor will stop but evaporator fan will continue
to operate. Has no effect on heat mode.

How Alarm is Cleared

This alarm can be cleared manually from the HMI. Bump the On/Off button three times then hold it for five
seconds. Bump the On/Off button three additional times to return to normal operation. All alarms can be viewed
and cleared using the TK Monitor Alarm screen. Refer to Service Procedure A51A, Communication Using TK
Monitor.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause the alarm to
reoccur.

Diagnostic Procedure
In TK Monitor an open sensor circuit will display as DISABLED. Check the sensor circuit for an open wire or
connection. A shorted sensor circuit will display about 30º F that does not change. Check for a shorted sensor
and harness or a short to ground. Check resistance of the CTS circuit (yellow wires) at the J35 plug. See
Service Procedure D01A Unit Temperature Sensor Test. Verify 2.5 Vdc is available at J35 pin 3.

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03, Return Air Sensor

Alarm Type Check Alarm TriPace APU

Associated Alarm Codes Alarm Code 12 Sensor Shutdown

Component Description and Location

This sensor is a thermister style sensor that can be tested with an ohmmeter. It is not polarity sensitive. The
sensor is located in the evaporator return air flow.

Circuit Description
The return air temperature sensor circuit is a two wire circuit. The two black (RTS) wires are connected to the
Main Controller Interface Board 8 pin evaporator sensor connector J35 Pin 1 and Pin 6. The sensor wires are
routed in the Evaporator Sensor Harness. The sensor is hard-wired to the sensor harness.

Considerations
Sensors should be positioned to minimize the potential for moisture entry where the wires enter the sensor
shell. Mount sensors with the barrel up and the wires down wherever possible.

How Alarm is Set

If the sensor reading is outside of the allowable limit (-38° F to 170° F [-39° C to 77° C]) and does not return
within 10 seconds then Alarm Code 03, Return Air Sensor is set as a check alarm. Typically generated by an
open or very high resistance in the sensor circuit. The Cab Air sensor will control the system. Has no effect on
heat mode.

How Alarm is Cleared

This alarm can be cleared manually from the HMI. Bump the On/Off button three times then hold it for five
seconds. Bump the On/Off button three additional times to return to normal operation. All alarms can be viewed
and cleared using the TK Monitor Alarm screen. Refer to Service Procedure A51A, Communication Using TK
Monitor.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause the alarm to
reoccur.

Diagnostic Procedure
In TK Monitor an open sensor circuit will display as DISABLED. Check the sensor circuit for an open wire or
connection. A shorted sensor circuit will display about 30º F that does not change. Check for a shorted sensor
and harness or a short to ground. Check resistance of the RTS circuit (black wires) at the J35 plug. See
Service Procedure D01A Unit Temperature Sensor Test. Verify 2.5 Vdc is available at J35 pin 1.

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05, Ambient Air Sensor

Alarm Type Check Alarm TriPace APU

Component Description and Location

This sensor is a thermister style sensor that can be tested with an ohmmeter. It is not polarity sensitive. The
sensor is located on or near the condenser assembly.

Circuit Description
The ambient air temperature sensor circuit is a two wire circuit. The two white (ATS) wires connect the Main
Controller Interface Board 6 pin condenser fan connector J59 Pin 5 and Pin 6 to the black sensor wires. The
sensor wires are routed in the Condenser Fan Harness. The sensor is hard-wired to the harness.

Considerations
Sensors should be positioned to minimize the potential for moisture entry where the wires enter the sensor
shell. Mount sensors with the barrel up and the wires down wherever possible. A failed Ambient Air Sensor will
force the condenser fan to run high speed.

How Alarm is Set

If the sensor reading is outside of the allowable limit (-38° F to 170° F [-39° C to 77° C]) and does not return
within 10 seconds then Alarm Code 05, Ambient Air Sensor is set as a check alarm. Typically generated by an
open or very high resistance in the sensor circuit. The condenser fan will be forced to high speed during air
conditioning mode. Has no effect on heat mode.

How Alarm is Cleared

This alarm can be cleared manually from the HMI. Bump the On/Off button three times then hold it for five
seconds. Bump the On/Off button three additional times to return to normal operation. All alarms can be viewed
and cleared using the TK Monitor Alarm screen. Refer to Service Procedure A51A, Communication Using TK
Monitor.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause the alarm to
reoccur.

Diagnostic Procedure
In TK Monitor an open sensor circuit will display as DISABLED. Check the sensor circuit for an open wire or
connection. A shorted sensor circuit will display about 30º F that does not change. Check for a shorted sensor
and harness or a short to ground. Check resistance of the ATS circuit (white wires) at the J59 plug. See
Service Procedure D01A Unit Temperature Sensor Test. Verify that 2.5 Vdc is available at J59 pin 3.

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10, High Discharge Pressure

Alarm Type Prevent or Shutdown Alarm TriPace APU

Component Description and Location

The high pressure cutout switch (HPCO) is located in the discharge line near the compressor.

Circuit Description
The Code 10 circuit is complex and passes through the Main Controller and Compressor Controller boards.
Voltage is supplied by the Main Controller from J56 pin 14. This is a low voltage circuit (3-5 Vdc). The CVB3
wire sends voltage to and through the Compressor Controller. Circuit continues from JP5 pin 6 with the CVB2
wire to the Main Controller J56 pin 10. Circuit continues through the Main Controller to J55 pin 5. The high
pressure cutout is connected to the Main Controller by two wires. The HPC1 and HPC2 wires connect to the
Main Controller Interface Board 12 pin compressor sensor connector J55 Pins 5 and 6. If voltage is lost on
HPC2 to pin 6 the code 10 will generate. The switch wires are routed in the Compressor Sensor Harness. The
switch is hard-wired to the harness.

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How Alarm is Set

HPCO Switch: Open = 360 psig (2482 kPa) Close = 240 psig (1655 kPa). If voltage is lost to J55 pin 6 the
alarm will be set.
Prevent: If the HPCO switch opens Alarm Code 10 is set as a prevent alarm. The air conditioning compressor
will stop. Cool icon will flash. Evaporator and condenser fans will run. Compressor operation will be delayed for
3 minutes, and then the switch position is checked. If the switch is closed, the system will restart. The alarm
icon will remain on for 15 minutes indicating an alarm condition had occurred. If the switch is still open, a new 3
minute delay will begin. The alarm icon will remain on.
Shutdown: If the HPCO switch opens two additional times before clearing the 60 minute probation timer or the
switch stays open the alarm will become a shutdown. Alarm will also generate if the Compressor Controller
harness connected to the Main Controller at J56 is open or unplugged.
NOTE: If the Code 10 circuit opens anywhere while operating in Cool mode, code 10 will be set.
NOTE: If the HPCO switch or Code 10 circuit is open anywhere when the system is turned on, code 10
shutdown will set. System will not run in any mode.

How Alarm is Cleared

This alarm can be cleared manually from the HMI. Bump the On/Off button three times then hold it for five
seconds. Bump the On/Off button three additional times to return to normal operation. All alarms can be viewed
and cleared using the TK Monitor Alarm screen. Refer to Service Procedure A51A, Communication Using TK
Monitor.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause the alarm to
reoccur.

Diagnostic Procedure
1. Check the refrigeration system for high discharge pressure and correct as required.
2. Disconnect the HPCO and Compressor Controller harness plugs. Inspect plug connections. Reconnect
harness plugs and verify they are fully seated. Recheck operation.
3. Unplug HPCO harness from J55. Measure voltage at J55 pin 5 (HPC1).
a. 3-5 Vdc = Alarm circuit is complete to this point. Go to next step.
b. Less than 3 Vdc = go to step 6
4. Jump J55 pin 5 (HPC1) to pin 6 (HPC2). Clear code 10 using TK Monitor.
a. Alarm does not return = HPCO switch or harness is open. Go to next step.
b. Alarm returns = Replace Main Controller board.
5. Check the High Pressure Cutout Switch circuit for proper operation (closed under normal conditions).
Connect ohmmeter to J55 harness connector. Check the switch and harness for excessive resistance.
a. Less than 1 ohm = HPCO circuit is normal. Reconnect harness. Restart Diagnostic Procedure.
b. More than 1 ohm = HPCO or circuit is open or resisted. Retest at HPCO.
6. Check voltage with Compressor Controller harness connected, Back probe J56 pin 10 (CVB2).
a. 3-5 Vdc = open or high resistance connection at pin 10 or board trace. Repair connection or
replace Main Controller.
b. Less than 3 Vdc = go to next step.

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7. Check voltage with Compressor Controller harness connected, Back probe J56 pin 14 (CVB3).
a. 3-5 Vdc = open or high resistance connection in Compressor Controller harness connections or
Compressor Controller. Repair connection or replace Compressor Controller.
b. Less than 3 Vdc = replace Main Controller.
General Conditions:
• Back probe J55 pin 6. The presence of 3-5 volts at this input verifies the HPCO and code 10 circuit
is complete.
• With compressor controller harness and HPCO unplugged, jump J56 pin 14 to J55 pin 6. If code 10
can be cleared and not return the interface board logic is working.
• Low resistance between J56 pin 10 and J55 pin 5 indicates the Interface Board pass-through
circuit is complete.

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11, Unit Controlling on Alternate Sensor

Rev. 31 01 and later
Alarm Type Check Alarm TriPace APU

Associated Alarm Codes None

Component Description and Location

Cab Temperature Sensor in HMI

Circuit Description
HMI internal connections

How Alarm is Set

While operating in air conditioning mode using the Cab Temperature Sensor the sensor reading is outside the
normal range of 158º F to -40º F continuously for 10 seconds. Temperature control will be switched to the
Return Air Sensor. Code 11 will set as a check alarm.
Alarm will also generate if communication with the HMI is lost.

How Alarm is Cleared

This alarm is cleared automatically when the Cab Temperature Sensor returns to the normal range. Control is
shifted back to the Cab Temperature Sensor.

Diagnostic Procedure
Cab temperature control will be affected. Use TK Monitor to evaluate the Cab Temperature Sensor reading.
Refer to Service Procedure A51A, Communication Using TK Monitor. If it is out of range replace the HMI.

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12, Sensor Shutdown

Alarm Type Shutdown or Check Alarm TriPace APU

Associated Alarm Codes Alarm Code 02 Evaporator Coil Sensor

Alarm Code 03 Return Air Sensor

Component Description and Location

See Alarm Codes indicated above.

Circuit Description
See Alarm Codes indicated above.

How Alarm is Set

If Alarm Codes 02 and 03 are set together then Alarm Code 12 Sensor Shutdown is set as a shutdown alarm.
Will switch to Check alarm when Heat mode is activated.

How Alarm is Cleared

This alarm is cleared automatically when the associated sensor Alarm Codes 02 or 03 are cleared.
Resolve the condition that caused the associated alarms. Failure to resolve the alarm condition will cause the
alarm to reoccur.

Diagnostic Procedure
See the diagnostic procedures for the associated sensor Alarm Codes 02 and 03.

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54, Test Mode Timeout

Alarm Type Shutdown Alarm TriPace APU

How Alarm is Set

If the unit has been in the same Service Test Mode function for 15 minutes then Alarm Code 54 Test Mode
Timeout is set as a shutdown alarm.

How Alarm is Cleared

Exit the Service Test Mode and clear the alarm manually from the HMI. Bump the On/Off button three times
then hold it for five seconds. Bump the On/Off button three additional times to return to normal operation. All
alarms can be viewed and cleared using the TK Monitor Alarm screen. Refer to Service Procedure A51A,
Communication Using TK Monitor.

Diagnostic Procedure
Clear the alarm and re-enter the test mode as necessary to complete the diagnosis or repair.

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61, Low Battery Voltage

Alarm Type Log, Check, or Shutdown Alarm TriPace APU

Circuit Description
System Voltage is measured at the Main Controller board #2 terminal.

How Alarm is Set

TriPace HVAC system has shutdown at 11.5 Vdc. Driver has continued to draw hotel power from batteries.
Log: If System Voltage falls below alarm threshold of 11.2 Vdc for three minutes Alarm Code 61 Low Battery
Voltage is logged in data logger.
Check: If System Voltage falls below check alarm threshold of 10.9 Vdc for three minutes, Alarm Code 61 Low
Battery Voltage is set as a check alarm.
Shutdown: If System Voltage falls below alarm threshold of 10.5 Vdc for three minutes, Alarm Code 61 Low
Battery Voltage is set as a shutdown alarm.
System Voltage is measured at the Main Controller board #2 terminal. No further alarms will set after code 61.

How Alarm is Cleared

This alarm can be cleared manually from the HMI. Bump the On/Off button three times then hold it for five
seconds. Bump the On/Off button three additional times to return to normal operation. All alarms can be viewed
and cleared using the TK Monitor Alarm screen. Refer to Service Procedure A51A, Communication Using TK
Monitor.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause the alarm to
reoccur.

Diagnostic Procedure
Refer to Batteries earlier in this section.
Test TriPace and truck batteries.
Charge batteries as required.
Determine the cause of the abnormal battery drain.

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70, Hourmeter Failure

Alarm Type Log Alarm TriPace APU

Circuit Description
System Voltage is measured at the Main Controller board #2 terminal.

How Alarm is Set

If one or more hourmeters exceeds 499,999 hours the Alarm Code 70 Hourmeter Failure is set as a log alarm.

How Alarm is Cleared

This alarm can be cleared manually from the HMI. Bump the On/Off button three times then hold it for five
seconds. Bump the On/Off button three additional times to return to normal operation. All alarms can be viewed
and cleared using the TK Monitor Alarm screen. Refer to Service Procedure A51A, Communication Using TK
Monitor.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause the alarm to
reoccur.

Diagnostic Procedure
Verify the hour meter reading. Refer to Service Procedure A51A, Communication Using TK Monitor.
Replace the Main Controller.

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180, Compressor Fault

Rev. 31 01 and later
Alarm Type Check or Shutdown Alarm TriPace APU

How Alarm is Set

Check: The Main Controller detected a Compressor Controller fault.
Shutdown: The Main Controller has detected 5 Compressor Controller faults within 60 minutes.

How Alarm is Cleared

Alarm may automatically clear based on Compressor Controller input. This alarm can be cleared manually from
the HMI. Bump the On/Off button three times then hold it for five seconds. Bump the On/Off button three
additional times to return to normal operation. All alarms can be viewed and cleared using the TK Monitor
Alarm screen. Refer to Service Procedure A51A, Communication Using TK Monitor.
Resolve the condition that caused the alarm. Failure to resolve the alarm condition will cause the alarm to
reoccur.

Diagnostic Procedure
Refer to Compressor Fault under Fault Conditions later in this section.

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FAULT CONDITIONS
There are several system fault conditions that affect system operation but do not directly generate an alarm code.
They may be indicated by the fault display in TK Monitor, icons on the HMI or LED indicators at the device itself.

Low Battery Fault

HMI Battery Icon is red. System is off due to low power reserve. System Voltage has fallen below 12 Vdc or 11.5
Vdc when NXT batteries are installed in the truck. The SCMs have switched to Null and HVAC systems have
been disabled preventing further discharge of the auxiliary and truck batteries. Truck should be run to recharge
the batteries. The fault will self-clear when System Voltage rises above 12 Vdc or 11.5 Vdc when NXT batteries
are installed in the truck. This event is logged but is not an alarm.

HMI Communication Fault

The HMI is not able to communicate with the Main Controller. The system is not responding to HMI mode
changes and Battery Monitor does not display. Selected mode icon is flashing. After about 5 minutes a red alarm
icon will display. No alarm is recorded by the Main Controller and will not be listed in TK Monitor. Check TK
Monitor – System Monitoring – HMI & Controller - HMI Online. If NO, check HMI harness and connections. If TK
Monitor cannot communicate then check green LED on Main Controller. If it is flashing twice per second for more
than 60 seconds the Main Controller is stuck in boot mode and not communicating. Power Cycle the Main
Controller. Refer to Section 6, A57A.

Compressor Fault
The Compressor Controller monitors the operation of the hermetic compressor. If a Compressor Fault occurs the
compressor may be shutdown. The evaporator fan will continue to run. The Compressor Controller will signal a
fault condition by outputting a volt high value to J56, CFLT input on the Main Controller. The alarm icon on the
HMI will light. An alarm code 180 will generate. Refer to Alarm Code Diagnostics in this section. TK Monitor will
indicate an active fault under System Monitoring – HVAC. Refer to Communication Using TK Monitor, Section 6,
A51A.

The Compressor Controller will indicate a fault condition by flashing the red fault LED on the Compressor
Controller board. The Flashing pattern will be ¼ second on and ¼ second off for each count, it then waits 2 1/2
seconds and repeats until the fault(s) are cleared. Most compressor faults will automatically clear when the fault
condition is no longer active. Listed below are the fault codes.

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Compressor Faults Indicated by Flashing Red Fault LED on Compressor Controller Board
Flashes Fault Description/Diagnostic Procedure
1 Over Description
Current Hard current limit – if the Compressor Controller detects an over-current condition it
will shut down the compressor and activate the fault indicator. The Compressor
Controller will delay 60 seconds then attempt to restart. After 10 over current faults
the compressor will not restart. Power must be cycled to clear this fault.
Diagnostic Procedure
1. Check for short circuits in the Blue, Orange, and Yellow wires between the
compressor controller board connections (J3, J4, and J5) and the
compressor.
2. Check for a defective compressor. Measure compressor motor resistance.
Should be 0.2 ohm between terminals and OL between terminals and
compressor case.
2 Over Description
Voltage If the motor voltage is above 60 volts, the Compressor Controller will shut down the
motor and will delay for 10 seconds. After the delay period, the Compressor
Controller will recheck the voltage conditions. If the voltage has fallen below 59
volts the motor will restart.
Diagnostic Procedure
1. Check DC to DC Converter for correct output.
3 Under Description
Voltage If the motor voltage is below 19 volts, the Compressor Controller will shut down the
motor and will delay for 10 seconds. After the delay period, the Compressor
Controller will recheck the voltage conditions. If the voltage is above 20 volts the
motor will restart.
Diagnostic Procedure
1. Check for open or high resistance circuits between the compressor
controller board and DC to DC Converter.
2. Check DC to DC Converter for correct output.
4 Controller Description
Overheat If the Compressor Controller (heat sink) temperature rises above 185° F (85° C) the
Compressor Controller will shut down the motor and delay for 10 seconds. The
Compressor Controller will indicate a fault condition by activating the fault indicator.
After the delay period the Compressor Controller will recheck the module
temperature. If the temperature has fallen below 185° F (85° C) the Compressor
Controller will restart the motor and clear the fault.
Diagnostic Procedure
1. Check for something blocking the air flow over the compressor controller
heat sink, which is located on the outside of the Evaporator/Control Box.
2. Turn system off for 15 minutes to allow controller to cool then retest.

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Compressor Faults Indicated by Flashing Red Fault LED on Compressor Controller Board
Flashes Fault Description/Diagnostic Procedure
5 Compressor Description
Overheat If the internal thermal Compressor Overload Switch (OLS) opens, above 195° F
(90º C), the Compressor Controller will shut down the motor and delay for 5
seconds. After 10 attempts the Compressor Controller will indicate the fault
condition by activating the fault indicator. The Compressor Controller will
periodically recheck the Compressor Overload Switch state. If the switch is closed,
below 135°F (57ºC), the controller will restart the motor and deactivate the fault
indicator.
Diagnostic Procedure
1. Check for open circuit in the Black wires between the compressor controller
board connector JP6 (pins 1 and 2) and the OLS on the compressor.
2. Check for a defective OLS that opens to early.
3. Check for conditions that cause a higher than normal load on the
compressor such as high ambient temperature, poor or restricted air flow
through the condenser, and higher than normal discharge pressure.
4. Check for a defective compressor. Measure compressor motor resistance.
Should be 0.2 ohm between terminals and OL between terminals and
compressor case.
6 Stalled Description
If the Compressor Controller detects a locked rotor it will shut down the motor, delay
for 20 seconds and attempt to restart the motor. The Compressor Controller will
continually attempt to restart the motor. After ten attempts the fault indicator will be
activated. The Compressor Controller will continue attempting to start the motor.
The fault will deactivate if the motor starts.
Diagnostic Procedure
1. Check for open, short or high resistance circuits in the Blue, Orange, and
Yellow wires between the compressor controller board connections (J3, J4,
and J5) and the compressor.
2. Check for conditions that cause a higher than normal load on the
compressor such as high ambient temperature, poor or restricted air flow
through the condenser, and higher than normal discharge pressure.
3. Check for a defective compressor. Measure compressor motor resistance.
Should be 0.2 ohm between terminals and OL between terminals and
compressor case.

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Compressor Faults Indicated by Flashing Red Fault LED on Compressor Controller Board
Flashes Fault Description/Diagnostic Procedure
7 Low Speed Description
The compressor must maintain a minimum speed of 1500 RPM for proper
lubrication. If the Compressor Controller detects a low speed condition, it will shut
down the motor, delay for 20 seconds and attempt to restart the motor. If the motor
does not restart and maintain over 1500 RPM after 10 attempts, the Compressor
Controller will activate the fault indicator. The Compressor Controller will continue
attempting to restart the motor. If the Compressor Controller is successful in
restarting the motor and maintaining a speed above 1500 RPM for 30 seconds, the
fault indicator will be deactivated.
Diagnostic Procedure
1. Check for open, short or high resistance circuits in the Blue, Orange, and
Yellow wires between the compressor controller board connections (J3, J4,
and J5) and the compressor.
2. Check for conditions that cause a higher than normal load on the
compressor such as high ambient temperature, poor or restricted air flow
through the condenser, and higher than normal discharge pressure.
3. Check for a defective compressor. Measure compressor motor resistance.
Should be 0.2 ohm between terminals and OL between terminals and
compressor case.
8 Startup Description
Failed The Compressor Controller will detect if the motor has failed to start. After a 20
second pause the Compressor Controller will attempt to restart the motor. The
Compressor Controller will continually attempt to restart the motor. After ten
attempts the fault indicator will be activated. The Compressor Controller will
continue attempting to start the motor. The fault will deactivate if the motor starts.
Diagnostic Procedure
1. Check for open, short or high resistance circuits in the Blue, Orange, and
Yellow wires between the compressor controller board connections (J3, J4,
and J5) and the compressor.
2. Check for a defective compressor. Measure compressor motor resistance.
Should be 0.2 ohm between terminals and OL between terminals and
compressor case.

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LED INDICATORS
Main Controller
A green Heartbeat LED will turn on and flash about once per second when the controller recognizes the system is
turned on at the HMI or the truck ignition is on. If the system experiences a non-standard shutdown, such as a
loss of power, the green LED will fast flash, twice per second, for about 60 seconds. The system is rebooting and
looking for possible external software. When the HMI is off the LED will blink momentarily every five minutes while
the Main Controller is checking the state of the IGN input. No other active LEDs on the board.

If the LED continues to fast flash beyond 60 seconds the controller is locked in rebooting mode. This is usually
caused by connecting power to the Main Controller before connecting ground. Power Cycle the system to reset.
Refer to Power Cycle Main Controller, Section 6, A57A.

An open CH circuit in the HMI harness will stop Main Controller function, the LED will not blink.

Compressor Controller
A red LED on the compressor controller indicates a compressor fault. It will flash indicating the fault code. Refer
to Compressor Fault under Fault Conditions earlier in this section.

SCM
Two LEDs on each SCM will indicate the mode (charge, null, discharge) of each battery connected to the SCM.
The LEDs will be labeled BATT A and BATT B corresponding to the battery terminals on the top of the SCM.

LED Indication
Off Loss of power to the 2 SCM terminal from the fuse block. (F9/F18, F12/F15)
Green (solid) Charging Mode
Green Short Flash Null Mode
(twice per second)
Green Flashing Discharge Mode
(once per second)
Red (solid) Thermally Limited, SCM internal board temperature has exceeded 185 F (85 C). Will
continue to operate at reduced capacity. Will return to full capacity as SCM cools.
Red Flashing Battery under voltage (9 Vdc or less) or over voltage (16 Vdc or more). The SCM will
(once per second) disconnect this battery from the system. It cannot charge or discharge until the voltage
is in range.
Amber (solid) Battery input voltage less than 1 Vdc. Battery disconnected, removed or fuse blown
(F16, F17, F19, F20).
Amber Flashing Battery polarity reversed.
(once per second)

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DIAGNOSTIC INFORMATION - TK MONITOR

When connected to the TriPace system through TK Monitor, technicians will have access to system information
that may be helpful during system diagnosis. TK Monitor software resides on the TriPace Main Controller Board. It
is not loaded on the service computer. For additional information refer to Communication Using TK Monitor,
Section 6, A51A.

Dash Board
Dash Board provides the technician quick access to basic operating information such as hourmeters, system
temperatures, battery status, SCM mode and alarms. It also allows the technician to change operating modes
without access to the HMI and initiate a Data Logger Download.

System Monitoring
System Monitoring screens provide the technician with detailed real time system information. Information is
divided into three screens; HMI & Controller, HVAC and SCM Batteries. This expanded system information can
be helpful when diagnosing system issues.

Service Test Mode

Service Test Mode allows the technician to force the system into a known operating condition. Diagnostic testing
can then be performed under controlled conditions for more reliable test results. The following tests can be
performed.

Cool Test
The compressor, evaporator fan and condenser fan are turned on and set to 100%. Evaporator coil frost
prevention is disabled.

Heat Test
The Main Controller heat output is turned on. Setpoint is set to maximum of 95º F.

Fan Only Test

Evaporator fan on and set to 100%. Other HVAC functions are disabled.

Battery Charged Test

Individual SCM and battery can be set to Charge Mode. A dropdown will allow selection of the active battery. The
LEDs on the SCM should indicate the active battery is in Charge Mode.

Battery Discharged Test

Individual SCM and battery can be set to Discharge Mode. A dropdown will allow selection of the active battery.
The LEDs on the SCM should indicate the active battery is in Discharge Mode.

Battery Null Test

The SCMs and their batteries are set to Null Mode. The TriPace batteries are isolated from the system.

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SYSTEM DIAGNOSIS
The following may be used as a guide when diagnosing general system issues.

Battery Icon On
System Voltage measured by the Main Controller is falling below the system cutoff threshold; typically 12 Vdc.
TriPace batteries are depleted. SCMs have batteries in NULL mode. System Voltage is being supplied by truck
batteries only.
1. Truck ignition off, TriPace system on.
2. Measure voltage at TriPace battery box fuse F11.
a. Less than 12 Vdc = Insufficient voltage is reaching the TriPace system. Go to next step.
b. More than 12 Vdc = Go to step 4.
3. Check truck batteries, connections and cable condition. Refer to Batteries in this section. Repair and retest
system operation.
4. Measure voltage at Main Controller board 2 terminal.
a. Less than 12 Vdc = Circuit between TriPace battery box fuse F11 and Main Controller is open or
has high resistance. Repair as required.
b. More than 12 Vdc = Record voltage, go to next step.
5. Connect computer to Main Controller and open TK Monitor. Refer to Communication Using TK Monitor,
Section 6, A51A.
6. TK Monitor – Dashboard – System Voltage.
a. Less than voltage recorded in step 4b = Main Controller is not reading available System Voltage.
i. Clean and tighten 2 and CH terminals on Main Controller board.
ii. Check CH01 circuit from Main Controller to TriPace battery box ground terminal.
iii. System Voltage does not increase to match voltage recorded in step 4b = Replace Main
Controller.
b. Same as voltage recorded in step 4b = Connect battery charger to truck batteries. Increase
System Voltage to above 13 Vdc and retest.
i. Battery Icon turns off, system operates = System responding to change in System
Voltage. Charge all batteries and return to service. Refer to Section 4, Battery Charging.
ii. Battery Icon does not turn off = System is not responding. Replace Main Controller.

Low Power Reserve or Short Operation

The TriPace HVAC system depletes the available power reserve in less than eight hours.
Battery Condition
The condition of system batteries, both truck and TriPace, is central to the operation of the TriPace system.
Batteries that are unable to accept a charge or provide power to the system will reduce operating time. Follow
these steps to evaluate system batteries.
1. Truck ignition off. TriPace off.
2. Inspect truck batteries, connections and cable condition. Check each battery with a Battery System Tester.
Repair or replace as required. Refer to Batteries in this section.
3. Check truck battery Open Circuit Voltage.
a. Above 13 Vdc = OK for further testing. Go to next step.
b. Below 13 Vdc = Charge batteries to 13 Vdc or higher. Go to next step.
4. Inspect TriPace batteries, connections and cable condition. Check each battery with a Battery System Tester.
Repair or replace as required. Refer to Batteries in this section.
5. TriPace on.

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6. Measure the voltage of the TriPace batteries. May use TK Monitor – System Monitoring – SCM batteries.
Refer to Communication Using TK Monitor, Section 6, A51A.
a. All batteries above 10 Vdc = System should recognize batteries for charging. Go to Charging
System Evaluation.
b. Battery or batteries less than 10 Vdc = System will not recognize battery for charging. Test
battery with a Battery System Tester. Replace defective batteries as required. Externally charge
low batteries to above 11.5 Vdc. Refer to Batteries in this section. Go to Charging System
Evaluation.

Charging System Evaluation

System batteries, both truck and TriPace, that are found to be undercharged are not being effectively charged.
This may be caused by defective battery charging components or insufficient time available to effectively
recharge depleted batteries. Use the following steps to evaluate battery charging components.
Truck Components
1. Truck ignition off. TriPace off.
2. Turn off optional 12 Vdc to 115 Vac Power Inverter.
3. Measure and record truck battery Open Circuit Voltage.
4. Start truck engine.
5. Measure and record voltage at truck alternator output terminal.
a. Higher than battery voltage before starting truck = Alternator is charging. Go to next step.
b. Same or lower than battery voltage before starting truck = Alternator is not charging. Diagnose
alternator per truck manufacturer recommendation.
6. Measure and record voltage at truck batteries.
7. Compare recorded charging voltages from steps 5 and 6.
a. Less than 1 volt difference = Cable connections are good. Charging voltage is reaching the
batteries. Go to next step.
b. More than 1 volt difference = High resistance in cable connections. Locate and repair as
required. May use Voltage Drop Test, Section 6, H24A.
8. Use an amp clamp to measure the truck alternator output amperage.
a. More than 100 amps = Alternator is charging. Go to next step.
b. Less than 100 amps = Alternator may not have enough charging capacity to support truck duty
load and charge batteries. Diagnose alternator per truck manufacturer recommendation.
TriPace Components
9. Check LED indicators on the Smart Charger Modules (SCMs) in the TriPace battery box.
a. All LEDs are flashing green = Normal. Go to next step.
b. One or more LEDs are not green = Refer to LED Indicators – SCM and SCM Diagnosis in this
section.
10. After the truck has been running for a minimum of 7 minutes, check the green LED on the Main Controller.
a. Flash once per second = Normal. Go to next step.
b. Flash twice per second = Main Controller stuck in boot mode. Refer to Power Cycle Main
Controller, Section 6, A57A.
c. Not flashing = No IGN signal or no power at 2 terminal of Main Controller. Refer to Section 2,
Plug Pinout and Location Diagrams or Section 8, Schematics and Diagrams.
11. Connect computer to Main Controller and open TK Monitor. Refer to Communication Using TK Monitor,
Section 6, A51A.
12. Open the System Monitoring screen. Select the SCM batteries tab.
13. Read Number of Connected TriPac SCMs.
a. 2 = Normal. Go to next step.
b. 1 or 0 = One or both of the SCMs are not communicating with the Main Controller. Check CAN
port connections.

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14. Read TriPac Auxiliary Charge Status.

a. Charging = Normal. Go to next step.
b. Null or Discharging = No IGN signal to Main Controller. Refer to Section 2, Plug Pinout and
Location Diagrams or Section 8, Schematics and Diagrams.
15. Read System Voltage.
a. Higher than truck battery voltage recorded in step 6 = Normal because the truck alternator has
been charging. Go to next step.
b. Same or lower than truck battery voltage recorded in step 6 = Alternator is not charging or
voltage is not reaching the TriPace system.
16. Allow truck batteries to continue charging until System Voltage rises above 13 Vdc.
a. May allow truck engine to continue running.
b. May turn truck engine off. Turn ignition switch on. Connect a battery charger to truck batteries
and set for high output.
c. May turn truck engine off. Turn ignition switch on. Plug in the optional Shore Power Converter if
present.
d. May turn truck engine off and ignition switch off. Plug in the optional Shore Power Converter if
present. Enable Shore Power Charging feature. Refer to Section 4, Driver Selectable Settings.
17. Read Requested Mode under each of the 4 batteries.
a. One of the batteries has switched from Null Mode to Charge Mode = Normal, the TriPace system
has successfully initiated the charging process. The SCM LED Indicator for the corresponding
battery should change to solid green.
b. All batteries are in Null Mode = Wait 30 minutes to allow truck battery charge level to improve
then recheck.
c. TriPace battery charging has not initiated.
i. Truck charging system is not able to support charging additional batteries. Diagnose
alternator per truck manufacturer recommendation.
ii. Truck batteries are defective and absorbing alternator output. Check each battery with a
Battery System Tester. Replace defective batteries as required. Refer to Batteries in this
section.
iii. Cable connection between truck batteries and TriPace battery box has high resistance.
Refer to Voltage Drop Test, Section 6, H24A.

Truck Batteries Become Depleted

Driver complains that the TriPace system has drained the truck batteries. The system is designed to stop HVAC
operation when System Voltage falls to about 12 Vdc to prevent depletion of the truck batteries. Use the following
steps to evaluate if the system is correctly managing battery usage. NOTE: Power for DC to AC inverters and
other accessories in the cab are directly connected to the truck batteries and not controlled by the TriPace
system.
1. Truck ignition off. TriPace off.
2. Inspect truck batteries, connections and cable condition. Check each battery with a Battery System Tester.
Repair or replace as required. Refer to Batteries in this section.
3. Connect a volt meter to the truck batteries to allow voltage monitoring.
4. Check truck battery Open Circuit Voltage.
a. Above 13 Vdc = OK for further testing. Go to next step.
b. Below 13 Vdc = Charge batteries to 13 Vdc or higher. Go to next step.
5. Turn TriPace system on.
6. Select A/C mode at the HMI. Rotate Temperature Control Knob to the coldest setpoint. Open cab doors to
keep system in full cool.
7. Connect computer to Main Controller and open TK Monitor. Refer to Communication Using TK Monitor,
Section 6, A51A.
8. Open the System Monitoring screen. Select the SCM batteries tab.

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9. Read Requested Mode for each of the batteries. One or two batteries should be Discharging.
10. Monitor Aux Battery Voltage for each of the batteries.
a. As reading falls to 11.5 Vdc for a battery the system should place it in Null mode. The other
battery in the pair will switch to Discharging mode if it is above 11.5 Vdc.
b. When all batteries are in Null mode at 11.5 Vdc there is no power being supplied by the TriPace
battery box to the system.
11. Monitor System Voltage. This now represents the voltage supplied by the truck batteries. It should be going
down.
12. Check HMI Battery Monitor bars. Should be going down.
13. Monitor meter voltage at the truck batteries. It should be within 0.5 Vdc of System Voltage and going down at
the same rate. Note when it is getting close to 12 Vdc.
14. Monitor HMI Battery Alarm Icon and A/C system operation.
15. Check meter voltage at the truck batteries.
a. Voltage 12 Vdc (11.5 Vdc when programmed for NXT) when Battery Alarm Icon lights and A/C
system stops = Normal.
i. TriPace HVAC system has stopped drawing power from truck batteries.
ii. Check for other sources of battery drain.
b. Voltage falls below 12 Vdc (11.5 Vdc when programmed for NXT) but Battery Alarm Icon does
not light and A/C system continues to run = Verify System Voltage reading also falls below 12
Vdc (11.5 Vdc when programmed for NXT).
i. No = Determine why System Voltage reads higher than battery voltage.
ii. Yes = Main Controller is not correctly controlling at the low voltage limit. Replace Main
Controller.

HMI DIAGNOSIS
HMI dark and system not responding
1. Check voltage at Main Controller 2 terminal.
a. 12 Vdc = Normal. Go to next step.
b. 0 Vdc = No power to Main Controller. Open 2 circuit from TriPace battery box.
2. Unplug harness at HMI.
3. Check voltage on 2P.
a. 12 Vdc = Normal. Go to step 5.
b. 0 Vdc = No power to HMI. Go to next step.
4. Unplug HMI harness from Main Controller (J34). Check voltage on pin 5.
a. 12 Vdc = Open in HMI harness. Repair or replace as required.
b. 0 Vdc = No output. Replace Main Controller.
5. Check voltage between 2P and CH in the HMI harness plug.
a. 12 Vdc = Controller and harness are good. Replace HMI.
b. 0 Vdc = No ground for HMI. Go to next step.
6. Unplug HMI harness from Main Controller (J34). Check voltage between pins 5 and 8.
a. 12 Vdc = Open in HMI harness. Repair or replace as required.
b. 0 Vdc = No ground through Main Controller. Go to next step.
7. Check voltage between 2 and CH stud terminals on Main Controller.
a. 12 Vdc = Ground trace on Main Controller open. Replace Main Controller.
b. 0 Vdc = Open connection to chassis ground. Repair as required.

Mode icon flashing but system not responding

1. Check green LED on Main Controller.
a. Flashing once per second = Normal. Main Controller responding to ON signal. CAN
communication issue. Check:

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 Section 5 – TriPace Diagnostics

i. HMI harness plug connections

ii. CAN plugs connections
iii. CAN terminator in bottom SCM
iv. Defective HMI harness
v. Defective HMI
b. Flashing twice per second for more than 60 seconds = Main Controller stuck in boot mode. Refer
to Power Cycle Main Controller, Section 6, A57A.
c. LED not on = On signal not received by Main Controller. Go to next step.
2. Unplug harness at HMI.
3. Check voltage at pin4, ON circuit.
a. 9.3 Vdc = Normal. Go to step 5.
b. 0 Vdc = No ON circuit signal from Main Controller.
4. Unplug HMI harness from Main Controller (J34). Check voltage on pin 4.
a. 9.3 Vdc = ON circuit open in HMI harness. Repair or replace as required.
b. 0 Vdc = No output. Replace Main Controller.
5. Jump HMI harness plug pin 4 to pin 8 at the HMI.
a. Main Controller LED begins flashing = Main Controller and HMI harness good. Replace HMI.
b. Main Controller LED not on = Go to next step.
6. Unplug HMI harness from Main Controller (J34).
7. Jump plug J34 pin 4 to pin 8.
a. Main Controller LED begins flashing = Main Controller good. Open CH circuit in harness. Repair
or replace as required.
b. Main Controller LED not on = Not responding to ON signal. Replace Main Controller.

HMI Circuits
The HMI harness is connected to the Main Controller at J34. Refer to connector maps in Section 2.

● ON: Signal from the HMI to the Main Controller to enable the HVAC system. This is 9.3 Vdc circuit. When
the On/Off button is pressed the ON circuit at the HMI is grounded and pulled low indicating to the Main
Controller to activate HVAC or display mode.

● OFF: This circuit is designed to shutdown the system when activated. When the On/Off button is pressed
for three seconds the OFF circuit is pulled low indicating to the Main Controller to deactivate HVAC
modes and turn off.

● 2P: Direct connection to the Main Controller power circuit. It is powered whenever voltage is available to
the #2 terminal on the Main Controller. This is source of voltage for all HMI functions and indicators.

● 8XP: Controller feedback is a response signal from the Main Controller ON relay contacts. Not used at
this time. Future expansion.

● CH: Chassis ground for all HMI circuits.

● CANL, CANH, SHLD: Communication with Main Controller on the CAN. Sends setpoint, cab
temperature, mode selection, fan speed selection. Receives mode and fan speed feedback, battery
monitor information and alarm status. Loss of communication will affect these functions.

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 Section 5 – TriPace Diagnostics

SCM DIAGNOSIS
The SCMs control current flow to and from the TriPace batteries based on commands from the Main Controller.
Before beginning SCM diagnosis note the current operating mode. Refer to LED Indicators – SCM earlier in this
section.

Additional operating information for the SCMs can be read using TK Monitor – System Monitoring – SCM
batteries. Service Test Mode through TK Monitor can be used to force an SCM into a known mode to assist in
diagnosis. Refer to Communication Using TK Monitor, Section 6, A51A.

Indicator LEDs Off

1. Lost voltage to the 2 SCM terminal. Should match system voltage.
a. Open F15/F18 fuse on SCM.
b. Open F9/F12 at fuse block for 2C/2B circuits to SCM.
c. No power to fuse block from truck batteries.
i. Open battery terminal connections at truck batteries.
ii. Open F13 power fuse in truck battery box.
2. Terminal connection into SCM defective. Replace SCM.

Indicator LED Flashing Red

1. Low voltage (below 9 Vdc) at +BATTA/+BATTB terminal on SCM. System has disconnected battery. TK
Monitor will show battery in null.
a. Check voltage at TriPace battery.
b. High resistance between battery and SCM. Clean and tighten connections.
2. Low voltage (below 9 Vdc) in TriPace battery. System has disconnected battery. TK Monitor will show battery
in null.
a. Clean and tighten battery terminal connection.
b. Charge battery with AGM type battery charger to 11.5 Vdc or higher then test with AGM Battery
System Tester.

Indicator LED Amber

1. Solid = Battery disconnected or below 1 Vdc.
2. Flashing = Battery polarity reversed.

Incorrect Operating Mode

SCM mode does not agree with TK Monitor.
1. Failed/poor CAN communication with Main Controller.
a. Check Main Controller J37 plug.
b. Check all CAN connections.
2. Verify terminator plug in in place on lower SCM.

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 Section 5 – TriPace Diagnostics

COMPRESSOR CONTROLLER DIAGNOSIS

The Compressor Controller is powered by 28 Vdc provided by the DC to DC Converter. It does not use the 12
Vdc from the system. The Compressor Controller provides power and speed control to the air conditioning
compressor based on commands from the Main Controller. Check for flashing red LED on Compressor
Controller. Refer to Fault Conditions – Compressor Fault earlier in this section.

Compressor Does Not Run

NOTE: Compressor will not start,
- When ambient temperature reading is low.
- When evaporator coil temperature has fallen below 32 F and not risen above 45 F.
- When Cabin Temperature is less than 5 F above Setpoint.
1. Verify A/C demand is present.
a. Change HMI setpoint to lowest setting.
b. Use Service Test Mode – Cool to force A/C operation. Refer to Communication Using TK
Monitor, Section 6, A51A.
2. Check for flashing red LED on Compressor Controller. May have shutdown alarm. Refer to Fault Conditions –
Compressor Fault earlier in this section.
3. Verify 28V and CH02 wires are connected to the correct terminals. Refer to Section 2.
4. Check available voltage of the 28V circuit at the power input terminal (J1+).
a. 28 Vdc = normal. Go to next step.
b. Less than 28 Vdc = Check for high resistance in 28V circuit from DC to DC Converter. Refer to
Voltage Drop Test, Section 6, H24A.
c. 0 Vdc = Refer to 12 Vdc to 28 Vdc Power Converter Diagnosis.
5. Verify CH02 circuit is a good ground.
6. Controller output voltage to compressor should be 20 Vac. Must be read with an AC meter.
7. Compressor motor windings should have a resistance of 0.1 - 0.3 Ohms. Measured Leg-to-Leg they should
be equal.

Compressor Running Slow

1. Verify cab temperature is more than 5 F above setpoint. Cooling demand may be low.
2. Determine if A/C system pressures are high causing increased compressor load.
a. Ambient temperature at condenser coil very high.
b. Condenser fan not running or running slow.
c. Cab temperature very high.
3. Check available voltage of the 28V circuit at the power input terminal (J1+).
a. 28 Vdc = normal. Go to next step.
b. Less than 28 Vdc = Check for high resistance in 28V circuit from DC to DC Converter.
4. Check compressor current draw on the orange, blue and yellow wires to compressor.
a. Less than 45 amp = Normal. Use Service Test Mode – Cool to force high speed operation. Refer
to Communication Using TK Monitor, Section 6, A51A.
b. 45 amps or higher = Exceeding current limit. Compressor speed will be reduced to control amps.

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 Section 5 – TriPace Diagnostics

Service Test Mode – Cool with TK Monitor

When Service Test Mode – Cool is enabled with TK Monitor the compressor, condenser fan and evaporator fan
should run in high speed. Refer to Communication Using TK Monitor, Section 6, A51A.
1. Fans run but compressor does not.
a. Check voltage on Main Controller J56 pin 11 (CSET)
i. 5 Vdc = Normal. Go to next step.
ii. 0 Vdc = Replace Main Controller.
b. Disconnect JP5 harness plug at Compressor Controller.
c. Check voltage on Compressor Controller harness plug JP5 pin 7 (CSET).
i. 5 Vdc = Replace Compressor Controller.
ii. 0 Vdc = Open circuit in harness. Repair as required.
2. Fans and compressor do not run.
a. Verify TK Monitor communication by selecting a different test mode or monitoring system
information.
b. Replace Main Controller.

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 Section 5 – TriPace Diagnostics

12 Vdc to 28 Vdc POWER CONVERTER DIAGNOSIS

The DC to DC Converter module is mounted on the outside of the battery box. It converts the 12 Vdc power from
the batteries to 28 Vdc. This increased voltage is used to run the air conditioning compressor with reduced
amperage. The output voltage should be 27.5 to 28.5 Vdc when enabled with an input voltage of 8.0 to 15.5 Vdc.
When the HVAC system is on the Main Controller will send an Enable signal to the CVEN terminal on the
converter. The CVEN circuit at or near 12 Vdc will enable the converter.

1 2 3 4

1. 28 Vdc Output Terminal

2. 12 Vdc Input Terminal
3. CH (Ground) Terminal
4. CVEN Enable/Disable Push On Terminal
DC to DC Converter (Front View)

Short circuit and current limiting protection is provided by monitoring the output current. Detection of a short circuit
or current above 45 amps turns the output off. The converter will turn the output on every 1.5 seconds to
determine if the high current still exists. If not the output voltage will return to normal level.

The converter is also thermally protected. A heat sink temperature above 220º F will shut the converter off. When
the temperature falls the converter automatically turns back on.

A green LED status indicator is located near the converter terminals. It indicates when the converter is producing
current. As output current approaches 0 amps or the converter senses an overload the LED will go out.

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 Section 5 – TriPace Diagnostics

● No voltage to Compressor Controller.

o Input voltage at 12V terminal of converter below 9.5 Vdc.

 Verify System Voltage at F10 on Fuse Block.

o Input voltage at CVEN terminal below 8 Vdc.

 Verify System Voltage at #2 terminal of Main Controller is above 11 Vdc.

 Verify CVEN circuit output from J37 Main Controller plug is near System Voltage. Refer to connector
maps in Section 2.

o 28V circuit improperly connected to Compressor Controller.

 Verify 28V wire is connected to the + terminal of the Compressor Controller. Refer to connector maps
in Section 2.

 Remove wire from 28V terminal at DC-DC Converter. Recheck voltage output.

● Normal output – 28V circuit grounded or high draw through Compressor Controller.

● No output – DC to DC Converter defective.

o Open CH05 ground circuit for converter.

o Possible defective DC to DC Converter.

● Pulsing voltage to Compressor Controller or Green LED blinking.

o Output above 45 amps or 28V circuit shorted to ground.

 Compressor pulsing – test compressor for shorted windings. Measure compressor motor resistance.
Should be 0.2 ohm between terminals and OL between terminals and compressor case.

 Compressor not pulsing – test 28V circuit for dead short to ground.

● Low voltage to Compressor Controller.

o Input voltage at 12V terminal of converter less than 11 Vdc.

o High resistance in CH05 converter ground circuit.

 Perform Voltage Drop Test, refer to Section 6, H24A.

o Converter output voltage at 28V terminal normal (near 28 Vdc).

 High resistance in 28V circuit to Compressor Controller

● Perform Voltage Drop Test, refer to Section 6, H24A.

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 Section 5 – TriPace Diagnostics

VARIABLE SPEED FANS

The condenser and evaporator fan motors are variable speed fans that contain fan motor drivers. These drivers
respond to a pulse width modulation (PWM) speed control signal provided by the Main Controller. An ohmmeter
reading cannot be used to diagnose an inoperative motor of this type. When the fan plug is disconnected the
motor driver will open the motor circuit, causing an OL reading.

Refer to Plug Pinout and Location Diagrams in Section 2, Hardware Description.

Fan Motor Does Not Run

1. Verify there are no alarms.

2. Using TK Monitor Service Test Mode energize Cool Test. The compressor and both fan motors should be
forced to high speed.

3. Verify that the compressor and other fan operate.

4. Disconnect the fan motor connector.

a. Condenser fan – harness plug near the condenser housing.

b. Evaporator fan – J58 plug on Main Controller board. Evaporator fan plug can be back-probed while
connected.

5. Check DC voltage between the power and ground circuits at the connection. It should be near source voltage.
If not, diagnose cause of lost power or ground. Check fuses F4 and F5. Possible defective Main Controller.

a. Condenser fan – CFPOS and CFNEG

b. Evaporator fan – EFPOS/RED and EFNEG/BLU

6. Read the voltage between the speed control circuit and ground. It should be about 10 Vdc. If not, diagnose
cause of lost control voltage. Possible defective Main Controller.

a. Condenser fan – CFCTL and CFNEG (8-10 Vdc)

b. Evaporator fan – EFCTL/YEL and EFNEG/BLU (11 Vdc)

7. If test results are good replace the fan motor.

NOTE: If necessary, connector pins can be removed using a P/N 204-737 pin remover tool.

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 Section 5 – TriPace Diagnostics

115 Vac to 12 Vdc Power Converter (Optional Shore Power)

The 115 Vac to 12 Vdc Power Converter is connected to the tractor batteries. It adds up to 85 amps DC to the
tractor batteries when connected to 115 Vac Shore Power. This additional power may be used by the TriPac-e
system or help support driver “hotel load”. The Shore Power Converter should be plugged in at the beginning of
the driver rest period when all batteries are charged. This will extend system operating time. The Shore Power
Converter is not intended to fully support system operating load.

WARNING: AC voltage measurements should be taken leg to leg, not leg to ground.

IMPORTANT: By default the Shore Power Converter will charge only the tractor batteries when the TriPace
system is off. Charging the TriPace batteries can occur if selected. See Driver Selectable Settings in Section 4.

Check Converter Operation

1. Verify extension cord is in good condition and the correct gauge for the length of cord (14 AWG up to 75 feet,
12 AWG up to 145 feet).

2. Verify 110 – 120 Vac is available from the external Shore Power source receptacle and extension cord.

3. Disconnect the 115 Vac adapter harness from the converter. Plug the extension cord into the tractor Shore
Power plug.

4. Measure voltage in the supply side of the adapter harness.

a. 110 – 120 Vac = Go to next step.

b. Zero or low volts = Open or high resistance in power circuit or connections. Locate and repair as
required.

5. Disconnect the Shore Power cord.

6. Reconnect the adapter harness.

7. Turn off the TriPace system at the HMI and turn off the 12 Vdc to 115 Vac Power inverter.

8. Measure and record DC voltage at the truck batteries.

9. Measure and record DC voltage between the converter output terminals.

a. Voltage at batteries and converter terminals are equal = Go to next step.

b. Voltage at the converter terminals is 0 Vdc = Locate and repair the open circuit in the power cables to the
converter.

10. Reconnect the Shore Power Cord.

11. Measure and record DC voltage between the converter output terminals.

5-50
 Section 5 – TriPace Diagnostics

a. At least 1 volt rise above previous reading or 13.6 Vdc = Normal converter output.

b. Less than 1 volt rise above previous reading = Low converter output, replace converter.

c. 0 Vdc = No converter output. Check fuses on back of converter.

i. Fuses open = Check for reverse polarity of battery connections. Replace fuses and retest.

ii. Fuses not open = Replace converter.

Power Output is Surging or Inconsistent

The converter is overheating and cycling on thermal protection. Normal cooling fan operation is variable and
controlled by temperature.

1. Verify airflow to and from the converter is not restricted.

a. Fans not blocked.

b. Not installed in enclosed space.

2. Verify driver belongings are not in contact with converter.

3. Verify converter fans are operating. If converter feels warm to the touch the fans should be running.

a. Yes = Disconnect from shore power. Allow converter to cool then retest.

b. No = Replace converter.

Converter Does Not Charge Tractor Batteries

1. Verify truck ignition key is in the off position.

2. Verify the TriPac-e HVAC system has been turned off at the HMI.

3. Verify the 12 Vdc to 115 Vac Power Inverter is turned off.

4. Perform the Check Converter Operation procedure.

5. With converter connected to shore power, measure and record DC voltage between the converter terminals.

6. Measure and record DC voltage at the truck batteries.

a. Voltage at tractor batteries is less than 0.5 Vdc lower than at converter = Cable connections are good =
Test batteries for ability to take and hold charge

b. Voltage at tractor batteries is more than 0.5 Vdc lower than at the converter = High resistance in cables
or connections are preventing charging current from reaching the batteries.

i. Check for open or high resistance cables or connections to truck batteries.

ii. Check for high current demand, possibly a bad battery.

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 Section 5 – TriPace Diagnostics

Converter Does Not Charge TriPace Batteries

NOTE: By default the Shore Power Converter will charge only the tractor batteries when the TriPace system is off.
Charging the TriPac-e batteries can occur if selected. See Driver Selectable Settings in Section 4.

1. Verify truck ignition key is in the off position.

2. Verify the TriPac-e HVAC system has been turned off at the HMI.

3. Verify the 12 Vdc to 115 Vac Power Inverter is turned off.

4. Verify Shore Power Charging has been enabled at the HMI. Refer to Driver Selectable Settings in Section 4.

5. Perform the Check Converter Operation procedure.

6. Verify truck battery voltage (System Voltage). Note: TriPac-e batteries will not begin charging until System
Voltage rises above 13 Vdc.

a. Above 13 Vdc = Go to next step.

b. Below 13 Vdc = Allow truck batteries to continue charging until above 13 Vdc.

7. Wait 30 minutes. Verify at least one SCM has entered Charge Mode. Refer to LED Indicators – SCM in this
section.

a. Yes = TriPac-e charge process has begun.

b. No = Go to System Checkout Procedure in this section.

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 Section 5 – TriPace Diagnostics

TEMPERATURE SENSORS
The system uses several temperature sensors to monitor and control the air conditioning function. If the air
conditioning system is not functioning as expected it is possible that one or more of the temperature sensors are
not providing correct information to the Main Controller. A failed temperature sensor or circuit will generate an
alarm. The sensor readings and alarms can be viewed with TK Monitor. Refer to Communication Using TK
Monitor, Section 6, A51A.

The system sensors are thermistor type that change resistance as the temperature changes. Resistance values
can be measured using a high quality ohmmeter. The value may be compared to a table to directly determine the
represented temperature.

NOTE: The Cab Temperature Sensor is integral with the HMI and cannot be individually tested. Readings
are sent to the Main Controller by the CAN. If the Cab Temperature Sensor is defective the HMI must be
replaced.

NOTE: The Return Air, Ambient Air and Evaporator Coil temperature sensors are not used to control Heat
Mode. A failed sensor will generate an alarm but will not affect heater operation.

Values
An open sensor or circuit will read DISABLED in TK Monitor.

A shorted sensor or circuit will read about 32º F (0º C) in TK Monitor.

Normal sensor resistance values can be found in Unit Temperature Sensor Test, Section 6, D01A.

Test Procedure
Use TK Monitor – Dash Board to get temperature readings. Use TK Monitor – Alarm to record and clear alarm
codes. Refer to Unit Temperature Sensor Test, Section 6, D01A for sensor circuit testing.

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 Section 5 – TriPace Diagnostics

AIR HEATER DIAGNOSTICS

The air heater receives electrical power from the main controller via the RED wire from the J65 plug. The heater
ground circuit is also connected to this plug. This circuit is protected by a 20 amp fuse (F3) on the Main Controller
board. Information goes to and from the heater through the J54 plug on the Main Controller board. The YEL wire
provides a signal to turn the air heater on. The GRY/RED and BRN/WHT wires supply setpoint information to the
heater. The RED wire provides a feedback signal that power is available to the heater. The remaining wires are
for communication.

The microprocessor in the air heater monitors the functions and operations of the air heater. The air heater’s
microprocessor is also programmed to recognize air heater fault codes. The five most-recent fault codes are
retained in the air heater’s microprocessor memory. Older fault codes are deleted from memory as new alarm
codes occur. Fault codes can be retrieved and read by using the EDiTH Diagnostic Tool or the Heater Diagnostic
Unit.

Heater Does Not Ignite

Symptom Corrective Action

Blower motor does not run.
Blower motor runs approximately 20 seconds
and shuts off.
Blower motor runs and fuel metering pump
starts and then shuts down after two start
attempts.
Blower motor runs, but fuel metering pump does
not.
1. Verify Heat mode is selected at HMI.
2. Check RED wire for power to heater control unit.
3. Check YEL wire for on signal to heater control unit.
4. Check system for alarms.
Ensure that voltage at the control unit remains above 10
Vdc during startup with the glow plug circuit energized.
1. Check fuel lines and fuel filter.
2. Check fuel level.
3. Check for combustion air or exhaust tube blockage.
1. Check for electrical pulses at the fuel metering
pump.
2. Check for gelled fuel.
3. Check for blocked fuel line.

5-54

Air Heater Ignition and Random Shutdown Problems
Symptom
Heat shuts down at random.
Heater smokes and carbons up.
Section 5 – TriPace Diagnostics
Corrective Action
1. Check metering pump fuel quantity using Service
Procedure H30A.
2. Check for possible overheat condition.
3. Check YEL wire for intermittent control unit input
voltage.
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 metering pump fuel quantity using Service
Procedure H30A.
7. Check motor RPM.
5-55

Diagnosing TriPac Heater Units for Excessive White Smoke and/or Heater Alarm Code
52 – Safety Time Exceeded
IMPORTANT: If the heater is used regularly at high altitudes (above 5000 feet) a High Altitude Kit (P/N 80-0115)
should be installed. Failure to use a high altitude kit at higher elevations may result in excessive white smoke,
Alarm Code 52 and/or carbon buildup.
Symptom
Excessive white smoke on
startup
and/or
Heater Alarm Code 52 –
Safety Time Exceeded
Section 5 – TriPace Diagnostics
Cause
Dirty or poor quality fuel.
Excessive fuel in the burner
combustion chamber.
Restricted intake or exhaust
tubes.
Restricted fuel delivery
system.
Dirty or Plugged Glow Pin
Screen.
5-56
Corrective Action
Be sure the diesel fuel used is clean and of
good quality. The fuel must be appropriate for
the climate in the region where the unit is
used. Fuel that is more than 5% biodiesel
should not be used.
Start and run the heater to determine if the
white smoke clears. If it does the heater may
be experiencing difficulty starting.
Troubleshoot as required to determine the
reason for difficult starts.
Check the intake and exhaust tubes for any
restrictions. Reduced air flow due to tube
restrictions can result in an incorrect air to fuel
ratio.
Check the fuel delivery system to be sure
there are no damaged or restricted fuel lines
or connections. Be sure the fuel pump is
installed at least 15° to 35° from horizontal
with the pump outlet port higher than the
pump inlet port.
Check the Glow Pin Screen for dirt or carbon
and replace if necessary. Do not attempt to
clean the Glow Pin Screen. Also check the
small ventilation hole on the side of the
chamber where the glow pin screen is
mounted to make sure it is clear. Clean the
glow pin screen chamber before installing the
replacement screen. The glow pin screen
should be replaced at least once a year.
Check more often if dictated by local
conditions.
 Section 5 – TriPace Diagnostics
Symptom Cause
Excessive white smoke on Dirty, Old or Damaged Glow
startup Pin
and/or
Heater Alarm Code 52 –
Safety Time Exceeded
Incorrect fuel quantity
supplied to
burner/combustion chamber.
Defective flame sensor.
5-57
Corrective Action
Check the glow pin for damage to the ceramic
tip and carbon build up on the tip. Check the
glow pin wires. The glow pin should be
inspected at least once a year while changing
the glow pin screen. Check more often if
dictated by local conditions.
Perform a Fuel Quantity Test using Service
Procedure H30A to be sure the correct
volume of fuel is supplied to the
burner/combustion chamber.
Check the flame sensor resistance values
Using Service Procedure D05A.
 Section 5 – TriPace Diagnostics

Diagnosing TriPac Heater Units with a Dirty or Carboned Glow Pin, Glow Pin Screen or
Burner/Combustion Chamber
Correcting a symptom (such as replacing a dirty or carboned burner) may result in a temporary fix but will seldom
result in a permanent solution. The heater must be diagnosed to determine and correct the root cause of the
carbon buildup and dirt problems. The Diagnostic Procedure below will help the technician determine and correct
the root cause.

IMPORTANT: If the heater is used regularly at high altitudes (above 5000 feet) a High Altitude Kit (P/N 80-0115)
should be installed. Failure to use a high altitude kit at higher elevations may result in excessive white smoke,
Alarm Code 52 and/or carbon buildup.

IMPORTANT: Do not attempt to clean the glow pin screen.

IMPORTANT: Mechanically clean the burner/combustion chamber using a soft metal brush. Do not sand blast
the burning chamber. A combustion chamber with severe carbon buildup should be replaced.

NOTE: The glow pin and glow pin screen should be inspected at least annually or as local conditions dictate.
When Ultra Low Sulfur Diesel (ULSD) fuel is used the glow pin and glow pin screen may need to be inspected
more often.

NOTE: If the glow pin and glow pin screen show excessive dirt or carbon buildup the burner/combustion chamber
may also need to be checked for excessive carbon buildup.

NOTE: The exhaust outlet of the heater and the glow pin screen chamber may also provide an indication of
excessive carbon buildup in the burner / combustion chamber.

NOTE: A burner/combustion chamber with slight carbon buildup should correct itself once the root cause of the
problem is corrected and the heater is operating efficiently.

NOTE: When removing the burner/combustion chamber, the thermal insulator between the burner/combustion
chamber and the heater body will likely be cracked into several pieces. This is normal and does not contribute to
carbon buildup in the burner/combustion chamber. However, the thermal insulator must be replaced when the
burner/combustion chamber and the heat exchanger are disassembled. For additional information see Thermo
King Service Bulletin TT462 TriPac Air Heater Cracked Thermal Insulator.

5-58

Symptom
Excessive dirt or carbon
buildup on the Glow Pin,
Glow Pin Screen or the
Burner/Combustion Chamber.
This may result in excessive
white smoke during
operation.
Section 5 – TriPace Diagnostics
Cause
Dirty or poor quality fuel.
If the heater is always running
in high or low operating
modes excessive carbon
buildup may result.
Restricted intake or exhaust
tubes.
Restricted fuel delivery
system.
Incorrect fuel quantity
supplied to
burner/combustion chamber.
5-59
Corrective Action
Be sure the diesel fuel used is clean and of
good quality. The fuel must be appropriate for
the climate in the region where the unit is
used. Fuel that is more than 5% biodiesel
should not be used.
If the heater is equipped with a Hella Control
Unit, use the EDiTH Diagnostic Tool to
examine the hours of operation in high and
low mode. For additional information see
Service Procedure H31A Air Heater
Diagnostics using the EDiTH Diagnostic Tool.
Check the intake and exhaust tubes for any
restrictions. Reduced air flow due to tube
restrictions can result in an incorrect air to fuel
ratio.
Check the fuel delivery system to be sure
there are no damaged or restricted fuel lines
or connections. Be sure the fuel pump is
installed at least 15° to 35° from horizontal
with the pump outlet port higher than the
pump inlet port.
Perform a Fuel Quantity Test using Service
Procedure H30A to be sure the correct
volume of fuel is supplied to the
burner/combustion chamber.
 Section 5 – TriPace Diagnostics

Air Heater Fault Codes

Fault Code: 0 No Fault
Fault Type Not a Fault
Requirements Applies to all TriPac D2 and D4 Airtronic Heaters.
Related Fault Codes
How Fault Code is Set
When switching on the heater and the Fault Code 0 is shown as the AF or Actual Fault there is no Fault
occurring with the heater at that time. When the F1 to F5 Memory Locations show 0 there are no stored fault
codes in the memory of the ECU.
The ability to retrieve the Fault Code 0 indicates that the Fault Code Retrieval System works.
How Fault Code is Cleared
Fault Code 0 indicates there is no fault so it cannot be cleared.
To permanently delete any the fault codes that may be in the Heater’s Electronic Control Unit memory the
EDiTH Diagnostic Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A
and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Reported problem not ● Verify that the reported problem is with the heater and not with another
related to the heater. TriPac or vehicle system.
No Active Fault. ● Check for any previous Fault Codes in the ECU memory locations F1 to F5
and troubleshoot the heater according to the most recent fault code which is
When the AF is 0 there is
F1.
no Active Fault. A fault that
● Check to make sure the heaters power supply is good. Sudden losses in
happened previously will
power may not allow the heater to detect or record a fault code to the ECU
be stored in the memory
Memory. Refer to Fault Code 11 for instructions on checking the power
and may be the reason a
supply.
problem was reported.
● The only Fault Code that is not stored in the ECU Memory after it occurs is
the F-9. This Fault Code can only be detected when it occurs. Refer to
Fault Code 9 for further details.
Problem is Temperature ● Test the temperature set-point as outlined in F-62 to make sure it is
Control Related. accurate.
● Test the Internal Temperature Sensor as outlined in F96 to make sure it is
The reported problem may
accurate.
be that the truck sleeper
● If the optional External Temperature Sensor is installed then test it as
temperature is too hot or
outlined in F-60 and F-61.
too cold. If the
● Make sure the Control Sensor, either the internal one or the optional
temperature set- point is
external one is able to detect the sleeper temperature properly. You may
out of tolerance or the
need to modify the installation by installing a return air duct or relocate the
control temperature sensor
location of the external temperature sensor if there is one.
cannot detect the sleeper
● Using EDiTH Diagnostics is the best way to check the set-point the ECU is
temperature accurately the
receiving as well as the temperature the control sensor is detecting.
heater may not regulate to
the desired set-point.
Unless the temperature
set-point or control sensor
is too far out of range a
Fault Code will not be set.

5-60
 Section 5 – TriPace Diagnostics

Fault Code: 4 Short circuit in electronic control unit fresh air output
Fault Type Warning
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
After switching on the heater the ECU has detected a short circuit between the wire going to Pin 16 of the
Heater Harness connector and power or while the heater is in the Low Regulation Mode it has detected a short
circuit to ground.
When using EDiTH Diagnostics the Vehicle Blower Measured Value will be highlighted in Green when the
heater is in Low Regulation Mode, this is normal since the fresh air output is only turned on in Low Regulation
Mode.
The fresh air output is not normally used in North America or when the heater is installed with a TriPac. The
fresh air output could be used to activate a relay which in turn would activate an auxiliary fan or vehicle blower
if this option were used.
How Fault Code is Cleared
The fault does not show up as an Actual Fault or AF so it does not need to be cleared in order for the heater to
function.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Wire Connected to Pin 16
on the Harness Connector.
If this wire has a short
circuit to or is connected to
power or ground it will
cause the fault.
Short Circuit in ECU
Harness or Connectors.
Damage to the ECU
harness wires can cause
them to short circuit.
Short Circuit inside ECU.
It is not possible to check
for this short circuit if it is
inside the ECU.
● If there is a wire connected to the Pin 16 of the Harness Connector check it
for a short circuit to ground or power.
● Find out why the wire is connected since it may be an error since this option
is not used on the TriPac. Remove it if no reason for wire is found.
● Check the harness between the ECU and the Heater Connector for damage
since this could cause a short circuit between the black/grey wire going to
Pin 16 on the Heater Connector and power or ground in the ECU Harness.
If it is not possible to repair the harness then the whole ECU will have to be
replaced.
● Check if there is any damage to the Heater Harness Connectors or
terminals and repair or replace.
● After confirming there is nothing connected to Pin 16 of the Harness
Connector and there is no short circuit in the ECU wires or connector, delete
the fault codes and try running the heater again.
● If the Fault Code 4 is set again then the short circuit is inside the ECU and it
should be replaced.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 5 Short circuit in electronic control unit car alarm output
Fault Type Warning
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
After switching on the heater the ECU has detected a short circuit between the wire going to Pin 15 of the
Heater Harness connector and ground.
When using EDiTH Diagnostics the Anti-theft alarm Measured Value will be highlighted in Green to indicate it
is active, this is normal. If the short circuit exists the Measured Value will no longer be highlighted in Green.
The car alarm output is not normally used in North America or when the heater is installed with a TriPac. The
car alarm output could be used as a signal to deactivate a car alarm while the heater is running if the option
was used. The ECU produces a signal voltage on Pin 16 of the Heater Harness Connector when the heater is
on and no voltage when the heater is off.
How Fault Code is Cleared
The fault does not show up as an Actual Fault or AF so it does not need to be cleared in order for the heater to
function.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Wire Connected to Pin 15
on the Harness Connector.
If this wire has a short
circuit to or is connected to
ground it will cause the
fault.
Short Circuit in ECU
Harness or Connectors.
Damage to the ECU
harness wires can cause
them to short circuit.
● If there is a wire connected to the Pin 15 of the Harness Connector check it
for a short circuit to ground.
● Find out why the wire is connected since it may be an error since this option
is not used on the TriPac. Remove it if no reason for wire is found.
● Check the harness between the ECU and the Heater Connector for damage
since this could cause a short circuit between the Pink wire going to Pin 15
on the Heater Connector and ground in the ECU Harness. If it is not
possible to repair the harness then the whole ECU will have to be replaced.
● Check if there is any damage to the Heater Harness Connectors or
terminals and repair or replace.

Short Circuit inside ECU.
It is not possible to check
for this short circuit if it is
inside the ECU.
● After confirming there is nothing connected to Pin 15 of the Harness
Connector and there is no short circuit in the ECU wires or connector, delete
the fault codes and try running the heater again.
● If the Fault Code 5 is set again then the short circuit is inside the ECU and it
should be replaced.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

5-62
 Section 5 – TriPace Diagnostics

Fault Code: 6 Inexplicable atmospheric altitude information

Fault Type Warning
Requirements Only High Altitude Compatible D2 and D4 Airtronic ECUs
Related Fault Codes High Altitude Sensor specific Fault Codes F-0, F-11, F12, F-13
How Fault Code is Set
The Electronic Control Unit has not received any understandable information from the optional High Altitude
Sensor.
The optional High Altitude Sensor has a separate Fault Code Memory and Fault Code List. The High Altitude
Sensor Fault Code List is available in the EDiTH Diagnostics Program Version S3V7-F and higher. Refer to
Service Procedure H31A for instructions to download and install the latest version. When the EDiTH Program
is opened, go to the Help tab and select Help Topics from the drop down, then under the Contents Tab select
the + sign next to the EDiTH folder to open it. Within the EDiTH Folder there is a Folder named Air Pressure
Sensor, select the Air Pressure Sensor Folder to open it and view the Fault Code List.
Refer to Service Bulletin TT499 to identify high altitude sensor compatible Electronic Control Units.
How Fault Code is Cleared
The fault does not show up as an Actual Fault or AF so it does not need to be cleared in order for the heater to
function.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Fault with High Altitude
Sensor.
● Retrieve the Fault Codes from the High Altitude Sensor memory using the
EDiTH Diagnostic Tool. A high altitude sensor adaptor (Espar Part Number
22 1000 33 3100) is required.
● Correct the fault according to the instructions for the specific Fault Code
retrieved from the High Altitude Sensor Memory.
● Refer to Air Heater Diagnostics using the EDiTH Diagnostic Tool, Section 6,
H31A.

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 Section 5 – TriPace Diagnostics

Fault Code: 9 ADR Shutdown

Fault Type Warning with shut down
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
The ADR function is not normally used in North America or with TriPacs unless it was specially modified. ADR
is a European agreement on the international transport of dangerous on the road which the heater, installation
and operation must comply with on vehicles that transport dangerous goods.
If power is detected upon start up at the Pin 14 of the Heater Connector the heater will not start and will
indicate an F-9. If the power to Pin 14 or short to power is detected after the heater is running it will
immediately generate the F9 and then shut down with only a 40 Second Cool Down.
If a power signal is detected at Pin 13 upon switching on the heater it will still start. If however this power signal
is lost after having been applied the heater will generate the F-9 and then shut down with only a 40 second
Cool Down.
This does not necessarily indicate a true failure but is a warning that indicates the heater cannot start or was
shut down by a signal. These signals are used to shut down the heater in certain applications where ADR
regulations require it.
The F-9 is not stored in the Memory of the ECU. It will only be detected if either a Diagnostic Retrieval Tool or
EDiTH Diagnostics is connected when it occurs. When using EDiTH it is possible to view the signal inputs and
operating status in more detail. Generator D+ highlighted indicates Pin 13 has power, Auxiliary Drive
highlighted indicates Pin 14 has power.
Refer to the Airtronic / Airtronic M – ADR Circuit Diagrams in the Airtronic / Airtronic M Troubleshooting and
Repair Instructions published by Eberspaecher for more information. Document Number 25 2115 95 19 01
dated 04 2009.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the shut down may cause it to re-occur.
The fault does not show up as an Actual Fault or AF and is not recorded in the Fault Code Memory so it does
not need to be deleted from the Heater’s Electronic Control Unit Memory.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Short Circuit in ECU
Harness or Connectors.
Damage to the ECU
harness wires can cause
them to short circuit which
could replicate the signal
which would set this fault.
● Check the harness between the ECU and the Heater Connector for damage
since this could cause the Blue wire going to Pin 13 or the Blue/Black wire
going to Pin 14 on the Heater Connector to short circuit to and power in the
ECU Harness. If it is not possible to repair the harness then the whole ECU
will have to be replaced.
● Check if there is any damage to the Heater Harness Connectors or
terminals and repair or replace.

5-64

Pin 13 at the Harness
Connector has a wire
inserted and that signal
changed from Positive to
Off or was grounded.
The Pin 13 may be used
as a mechanism to
automatically shut the
heater down quickly in
areas such as a fuel
transfer station where the
Engine of a vehicle must
also be shut off due to
safety concerns.
Pin 14 at the Harness
Connector has a wire
inserted and the signal was
powered with a positive
power signal.
The Pin 14 is used as a
mechanism for shutting off
the heater quickly when a
positive voltage signal is
provided at Pin 14.
Section 5 – TriPace Diagnostics
● If there is a wire inserted in Pin 13 of the Harness connector, remove it and
test run the heater to find out if the signal that caused the F-9 was from this
wire.
● If there is a wire inserted at Pin 13 check what the wire is connected to. It
may be connected to a Generator or Alternator on an Engine so that the
heater receives a positive voltage signal to Pin 13 when the Engine is on.
This would allow the Engine to start while the heater is on and the heater to
start while the Engine is on but it will shut the heater off when the Engine is
turned off after it was running.
● If the wire going to Pin 13 is connected there for legitimate reasons do not
remove it. The system may have been modified so the heater can only run
at certain times due to safety concerns and this should not be deactivated if
it was installed.
● If there is a wire inserted in Pin 14 of the Harness connector, remove it and
test run the heater to find out if the signal that caused the F-9 was from this
wire.
● If there is a wire inserted at Pin 14 check what the wire is connected to. It
may be connected to something that generates a positive voltage sign when
it is turned on. This may be an emergency shut off switch or a fuel transfer
pump on a Fuel Tanker Truck which should not have a heater running near
it when the transfer pump is activated.
● If the wire going to Pin 14 is connected there for legitimate reasons do not
remove it. The system may have been modified so the heater cannot start
and will shut off when the device it is connected to is activated. This could
be for safety or emergency reasons and this should not be deactivated if it
was installed.
5-65
 Section 5 – TriPace Diagnostics

Fault Code: 10 Overvoltage shut down

Fault Type Warning with shut down.
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
After switching on the heater the ECU has detected a voltage higher than 16 Volts DC between Pin 1 and Pin
10 of the Heater Harness connector for a minimum of 20 seconds. Maximum voltage applied to heater must be
less than 16 Volts DC.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.

To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Overvoltage supplied to
Heater.
● Disconnect the Heater Harness connector and check the voltage between
Pin 1 (Power +) and Pin 10 (Ground -) at the Harness Connector.
● TriPac APU system: Check while Engine/Alternator is running. If the
Voltage is higher than 16 Volts then check the TriPac APU charging system
including voltage regulators.
● TriPace system: Check System Voltage at the fuse block inside the TriPace
battery box while the HVAC system is set to heat. If the voltage is higher
than 16 Volts then batteries are over charged. Check the Tractor charging
system and voltage regulators.

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 Section 5 – TriPace Diagnostics

Fault Code: 11 Under voltage shut down

Fault Type Warning with shut down
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-91, F-98, F- 99
How Fault Code is Set
After switching on the heater the ECU has detected a voltage lower than 10.5 V between Pin 1 and Pin 10 of
the Heater Harness connector for at least 20 seconds without interruption. Minimum voltage applied to heater
has to be more than 10.5 V.
During Start Up while the Glow Pin is on the lower voltage limit is 9.5 Volts to compensate for the high current
the Glow Pin draws.
It is possible to get a low voltage code if the Blower Motor is jammed when the heater is first turned on. If the
Blower Motor is jammed the heater will attempt to turn it and draw a lot of power which can cause a voltage
drop.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair
Possible Causes What to inspect or test and how to correct.
Low Battery Voltage ● Disconnect the Heater Harness connector and check the voltage between
Make sure that the TriPac Pin 1 (Power +) and Pin 10 (Ground -) on the Harness connector. This
APU Engine/Alternator voltage must be more than 10.5 Volts.
and tractor ● If the voltage is below 10.5 Volts then check system voltage at the #2
Engine/Alternator are terminal of the TriPac controller. If the system voltage is less than 10.5 Volts
turned off when checking then test the batteries. Charge or replace the batteries as required.
for low voltage. ● If the voltage at the Harness Connector is less than at the TriPac interface
board/controller then check all the connections and fuses from the interface
board/controller to the Harness Connector for damage, corrosion or poor
connection and repair or replace them.
Voltage drop occurs ● If the Voltage at the Harness Connector and TriPac interface
between the Battery and board/controller are the same and above 10.5 Volts then check the Power
the Heater ECU when Supply between Pin 1 (Power +) and Pin 10 (Ground -) at the Harness
under load. Connector under a 10 amp load to see if the voltage drops below 9.5 Volts.
● If the voltage drops below 9.5 Volts then measure the voltage at the system
When a load is applied to batteries. If the voltage does not drop at the system batteries then there is
the power supply the voltage drop in the circuit caused by high resistance between the batteries
voltage may drop if there and the Harness Connector. Refer to Voltage Drop Test, Section 6, H24A. If
is a poor connection or the battery voltage drops then test the batteries. Charge or replace the batteries
battery is weak. The as required.
Airtronic uses up to 100 ● If there is no Voltage drop up to the Harness Connector then check the ECU
Watts when starting or Harness and the Heater and Harness Connector and Terminals for damage
about 8.3 Amps at 12 or corrosion since that could cause a voltage drop. Make sure the Heater
Volts. Harness Terminals are locked in and cannot be pushed back when the
connector is closed. Repair if possible. If the ECU Harness is damaged
and cannot be repaired the ECU must be replaced.
● Perform a Function Test with the EDiTH Diagnostic Tool to check for a
Voltage Drop in the complete Power Supply circuit while the Glow Pin is on

5-67
 Section 5 – TriPace Diagnostics

when starting the heater. This is the only way to check the entire power
supply circuit right up the ECU and to confirm the ECU is measuring the
voltage properly. Refer to Air Heater Diagnostics using the EDiTH
Diagnostic Tool, Section 6, H31A.

5-68
 Section 5 – TriPace Diagnostics

Fault Code: 12 Overheating at the Overheating Sensor

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-13, F14, F15
How Fault Code is Set
Temperature at the overheating sensor is too high. The heater will generate the Fault Code 12 and Shut
Down. The overheat sensor measures the Air Temperature just above the heater exchanger.
The normal overheat limit at the overheating sensor is 120°C (248°F) for the D2 Airtronic and 150°C (302°F)
for the D4 Airtronic.
In the latest Model ECU the overheat limit can temporarily increase to avoid unnecessary overheats. Please
refer to Thermo King Service Bulletin TT499 for details on the latest ECU. The increased overheat limits and
the measured sensor values can be viewed by using EDiTH Diagnostics.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Restriction in Ducting.
When the air flow is
restricted the air
temperature above the
heat exchanger can rise
too high and can cause an
overheat at the Overheat
Sensor.
When trying to recreate an
overheat make sure that
the layout and conditions
of the sleeper are not
altered too much from
normal since changes in
layout can affect the
airflow.
● Check the air inlet and outlet for blockage and make sure the ducting is not
crushed. Remove any blockage and test run heater.
● When the heater does not have a return air duct then make sure the under
bunk area is not too tightly sealed when the bed is down. Install a return air
duct or cut ventilation holes to make sure the heater has enough return air.
● When the area under the bed is too tightly sealed and the heater does not
get enough return air the overheating may be intermittent and it will not
happen if the heater is tested with the bed raised.
● When test running the heater to see if it will overheat you must make sure
the bunk is down and the set-point is high and all the doors and windows are
closed.
● The overheat might only happen when the sleeper has reached a high
temperature and then the heater cycles down. This is due to the fact that
when the heater is cycling down and the air flow is decreasing the Overheat
Sensor temperature temporarily rises. If the Overheat Sensor was already
running at a temperature close to the limit then it may overheat as it cycles
down.

A restriction to air flow

may be unknowingly
removed and then the
cause cannot be found.

5-69

Air Flow restriction due to
exceeding the ducting
rating guide.
If the ducting rating guide
is exceeded the heater
could overheat even
though there is no
apparent blockage.
Overheat Sensor out of
tolerance.
If the Overheat Sensor is
out of tolerance it may be
reading a temperature that
is higher than actual and
trigger a false overheat.
Fuel Quantity is out of
specification.
If the heater is running too
lean it could overheat.
Section 5 – TriPace Diagnostics
● Add up the ratings for all the components of the ducting system to see if it
goes over the heaters ducting limit. Refer to the Ducting Rating Guide in the
Espar Product Catalogue for ducting ratings and component values.
● Modify the ducting system so that it does not exceed the permissible ducting
rating for the heater and test run the heater again to make sure it does not
overheat.
● Check the resistance value of the Overheat Sensor as outlined in Service
Procedure D05A.
● Use EDiTH Diagnostics to verify that the Overheat Sensor temperature is
accurate. Refer to Service Procedure H31A.
● When reading the Overheat Sensor temperature with EDiTH it is possible to
see if the sensor is accurate by performing a Function Test when the heater
is completely cooled off and there is no residual heat left since the sensor
will then read the approximate room temperature.
● Perform Fuel Quantity Test as outlined in Service Procedure H30A.
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 Section 5 – TriPace Diagnostics

Fault Code: 13 Overheating at the Flame Sensor

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-12, F14, F15
How Fault Code is Set
Temperature at the flame sensor is too high. The heater will generate the Fault Code 13 and Shut Down. The
Flame Sensor measures the surface temperature of the heat exchanger. The overheat limit at the flame
sensor is 280°C (536°F) for the D2 Airtronic and 290°C (554°F) for the D4 Airtronic.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Restriction in Ducting.
When the air flow is
restricted the temperature
of the heat exchanger can
rise too high and cause an
overheat at the Flame
Sensor.
When trying to recreate an
overheat make sure that
the layout and conditions
of the sleeper are not
altered too much from
normal since changes in
layout can affect the
airflow.
● Check the air inlet and outlet for blockage and make sure the ducting is not
crushed. Remove any blockage and test run heater.
● When the heater does not have a return air duct then make sure the under
bunk area is not too tightly sealed when the bed is down. Install a return air
duct or cut ventilation holes to make sure the heater has enough return air.
● When the area under the bed is too tightly sealed and the heater does not
get enough return air the overheating may be intermittent and it will not
happen if the heater is tested with the bed raised.
● When test running the heater to see if it will overheat you must make sure
the bunk is down and the set-point is high and all the doors and windows are
closed.
● The overheat might only happen when the sleeper has reached a high
temperature and then the heater cycles down. This is due to the fact that
when the heater is cycling down and the air flow is decreasing the Flame
Sensor temperature temporarily rises. If the Flame Sensor was already
running at a temperature close to the limit then it may overheat as it cycles
down.

A restriction to air flow

may be unknowingly
removed and then the
cause cannot be found.
Air Flow restriction due to ● Add up the ratings for all the components of the ducting system to see if it
exceeding the ducting goes over the heaters ducting limit. Refer to the Ducting Rating Guide in the
rating guide. Espar Product Catalogue for ducting ratings and component values.
● Modify the ducting system so that it does not exceed the permissible ducting
If the ducting rating guide rating for the heater and test run the heater again to make sure it does not
is exceeded the heater overheat.
could overheat even
though there is no
apparent blockage.

5-71

Flame Sensor out of
tolerance or plugged in
wrong.
If the Flame Sensor is out
of tolerance it may be
reading a temperature that
is higher than actual and
trigger a false overheat.
If the Flame Sensor wires
are reversed the Overheat
Sensor has lost its proper
ground and the ECU
cannot read it properly
anymore and the ECU will
read that the Flame
Sensor is hotter than it
actually is which could
trigger a Fault Code 13.
Overheat Sensor out of
tolerance.
Fuel Quantity is out of
specification.
If the heater is running too
lean it could overheat.
Section 5 – TriPace Diagnostics
● Check the green Flame Sensor Connector to make sure the green wire from
the combination sensor is plugged into Terminal 1 in the green connector
and that the brown wire is plugged into Terminal 2 in the green connector.
The terminal numbers are on the connectors and inside the ECU socket.
● Check to make sure the green flame sensor connector was not forced into
the ECU the wrong way. The connector is keyed but if forced enough it can
go in the wrong way.
● Also make sure that the connector is plugged into the middle socket on the
ECU between the Glow Pin and the Overheat Sensor.
● Check the resistance value of the Flame Sensor as outlined in Service
Procedure D05A.
● Use EDiTH Diagnostics to verify that the Flame Sensor temperature is
accurate.
● When reading the Flame Sensor temperature with EDiTH it is possible to
see if the sensor is accurate by performing a Function Test when the heater
is completely cooled off and there is no residual heat left since the sensor
will then read the approximate room temperature.
● Check the resistance value of the Overheat Sensor as outlined in Service
Procedure D05A.
● Use EDiTH Diagnostics to verify that the Overheat Sensor temperature is
accurate.
● When reading the Overheat Sensor temperature with EDiTH it is possible to
see if the sensor is accurate by performing a Function Test when the heater
is completely cooled off and there is no residual heat left since the sensor
will then read the approximate room temperature.
● Perform Fuel Quantity Test as outlined in Service Procedure H30A.
5-72
 Section 5 – TriPace Diagnostics

Fault Code: 14 Delta T between Flame Sensor and Overheating Sensor too large
Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-12, F13, F15
How Fault Code is Set
After switching on the heater the ECU has detected that the temperature difference between the flame sensor
and overheating sensor is too large.
This may indicate there is a problem with one of the sensors. This is another back up to make sure the heater
could not overheat at either sensor and not detect it because a sensor did not work properly.
If the temperature difference between the two sensors is more than 200°C (360°F) for the D2 Airtronic or
190°C (342°F) for the D4 Airtronic and either the Flame or Overheat Sensor is over 100°C (212°F) on a D2
Airtronic and over 20°C (68°F) on a D4 Airtronic the Fault Code 14 will be set.

How Fault Code is Cleared

The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Flame Sensor out of
tolerance or plugged in
wrong.
If the Flame Sensor is out
of tolerance it may be
reading a temperature that
is lower or higher than
actual.
If the Flame Sensor wires
are reversed the Overheat
Sensor has lost its proper
ground and the ECU
cannot read it properly
anymore and the ECU will
read that the Flame
Sensor is hotter than it
actually is which could
trigger a Fault Code 14.
Overheat Sensor out of
tolerance.
If the Overheat Sensor is
out of tolerance it may be
reading a temperature that
is lower or higher than
actual.
● Check the green Flame Sensor Connector to make sure the green wire from
the combination sensor is plugged into Terminal 1 in the green connector
and that the brown wire is plugged into Terminal 2 in the green connector.
The terminal numbers are on the connectors and inside the ECU socket.
● Check to make sure the green flame sensor connector was not forced into
the ECU the wrong way. The connector is keyed but if forced enough it can
go in the wrong way.
● Also make sure that the connector is plugged into the middle socket on the
ECU between the Glow Pin and the Overheat Sensor.
● Check the resistance value of the Flame Sensor as outlined in Service
Procedure D05A.
● Use EDiTH Diagnostics to verify that the Flame Sensor temperature is
accurate.
● When reading the Flame Sensor temperature with EDiTH it is possible to
see if the sensor is accurate by performing a Function Test when the heater
is completely cooled off and there is no residual heat left since the sensor
will then read the approximate room temperature.
● Check the resistance value of the Overheat Sensor as outlined in Service
Procedure D05A.
● Use EDiTH Diagnostics to verify that the Overheat Sensor temperature is
accurate.
● When reading the Overheat Sensor temperature with EDiTH it is possible to
see if the sensor is accurate by performing a Function Test when the heater
is completely cooled off and there is no residual heat left since the sensor
will then read the approximate room temperature.

5-73

Restriction in Ducting.
When the air flow is
restricted the air
temperature above the
heat exchanger can rise
too high and can cause an
overheat at the Flame
Sensor.
When trying to recreate an
overheat make sure that
the layout and conditions
of the sleeper are not
altered too much from
normal since changes in
layout can affect the
airflow.
A restriction to air flow
may be unknowingly
removed and then the
cause cannot be found.
Air Flow restriction due to
exceeding the ducting
rating guide.
If the ducting rating guide
is exceeded the heater
could overheat even
though there is no
apparent blockage.
Fuel Quantity is out of
specification.
If the heater is running too
lean it could overheat.
Section 5 – TriPace Diagnostics
● Check the air inlet and outlet for blockage and make sure the ducting is not
crushed. Remove any blockage and test run heater.
● When the heater does not have a return air duct then make sure the under
bunk area is not too tightly sealed when the bed is down. Install a return air
duct or cut ventilation holes to make sure the heater has enough return air.
● When the area under the bed is too tightly sealed and the heater does not
get enough return air the overheating may be intermittent and it will not
happen if the heater is tested with the bed raised.
● When test running the heater to see if it will overheat you must make sure
the bunk is down and the set-point is high and all the doors and windows are
closed.
● The overheat might only happen when the sleeper has reached a high
temperature and then the heater cycles down. This is due to the fact that
when the heater is cycling down and the air flow is decreasing the Flame
Sensor and Overheat Sensor temperatures temporarily rise. If the Flame
Sensor was already running at a temperature close to the limit then it may
overheat as it cycles down.
● Add up the ratings for all the components of the ducting system to see if it
goes over the heaters ducting limit. Refer to the Ducting Rating Guide in the
Espar Product Catalogue for ducting ratings and component values.
● Modify the ducting system so that it does not exceed the permissible ducting
rating for the heater and test run the heater again to make sure it does not
overheat.
● Perform Fuel Quantity Test as outlined in Service Procedure H30A.
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 Section 5 – TriPace Diagnostics

Fault Code: 15 Electronic Control Unit locked

Fault Type Operating Lockout
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-12, F-13, F-14, F-17, F-74
How Fault Code is Set
This fault code can be set in one of two ways.
The first possible reason the Fault Code 15 may be set is if the heater has overheated too many times in a
row. This could include all the overheat Fault Codes 12, 13 and 14.
For the older style Wehrle ECUs the maximum number of overheats allowed consecutively is 10 and for the
new style Hella ECUs it is 255.
Please refer to the Service Bulleting TT 461-1 to identify the difference between the older Wehrle and newer
Hella ECUs.
The second possible reason the Fault Code 15 may be set is if the Heater was switched back on after the
Fault Code 17 was set.
How Fault Code is Cleared
It is not possible to clear this fault code by turning the heater on and then back on again or by disconnecting
the power.
The Operating Lockout can only be cleared by permanently deleting the fault code from the Heater’s Electronic
Control Unit memory by using the EDiTH Diagnostic Tool or the Heater Diagnostic Unit. Refer to Service
Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Too many consecutive ● Check if there are any overheat fault codes including F-12, F-13 and F-14 in
overheats. the ECU memory prior to the F-15.
● If there are other Fault Codes then diagnose and correct the root cause of
the overheat by referring to the most recent overheat fault code first.
Failed Flame or Overheat ● If there is a Fault Code 17 in the ECU memory then check the Overheat and
Sensor. Flame Sensor resistance using Service Procedure D05A.
Failed ECU ● If there is a Fault Code 17 in the ECU memory and the Overheat and Flame
Sensor resistance values are in tolerance then replace the ECU.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 17 Overheating

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters.
Related Fault Codes F-15, F-74
How Fault Code is Set
This fault code is set because the hardware threshold value (180° C or 356°F) of the overheating sensor has
been exceeded because the ECU Failed to detect the Fault Code 12 (Overheating at the Overheating Sensor)
or Fault Code 13 (Overheating at the Flame Sensor).
If the heater is switched on again after the Fault Code 17 was set it will set the Fault Code 15.
How Fault Code is Cleared
It is not possible to clear this fault code by turning the heater on and then back on again or by disconnecting
the power.
The Operating Lockout can only be cleared by permanently deleting the fault code from the Heater’s Electronic
Control Unit memory by using the EDiTH Diagnostic Tool or the Heater Diagnostic Unit. Refer to Service
Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Failed Flame or Overheat ● If there is a Fault Code 17 in the ECU memory then check the Overheat and
Sensor. Flame Sensor resistance using TriPac Service Procedure D05A.
Failed ECU ● If there is a Fault Code 17 in the ECU memory and the Overheat and Flame
Sensor resistance values are in tolerance then replace the ECU.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 18 Starting energy of the glow pin is too low

Fault Type Error
Requirements Only High Altitude Compatible D2 and D4 Airtronic ECUs.
Related Fault Codes F-19, F-52, F-57
How Fault Code is Set
After switching on the heater the ECU has detected a low starting energy at the glow pin.
The current draw of the glow pin is checked in preheat mode before the start of the fuel supply. If the glow pin
current is found to be insufficient the ECU will increase the preheat time of the glow pin by 20 seconds. If the
glow pin current is still found insufficient after the extended preheat the start sequence will be repeated. If the
glow pin current is still insufficient the fault code 18 will be set.
This will help prevent fuel delivery / flooding if there is little chance of ignition due to a weak glow pin.
Refer to Service Bulletin TT499 to identify a high altitude compatible Electronic Control Unit.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Glow Pin Resistance too
High.
Damaged Glow Pin
Harness or connections.
Low Power Supply
Voltage.
Failed ECU.
● Check the resistance value of the Glow Pin at the black 2 pin connector
when the glow pin is at a room temperature of 20°C or (68°F).
● The resistance must be between 0.42Ω and 0.7 Ω at 20°C or (68°F). If the
resistance value is out of range, replace the glow pin
● Check the glow pin harness for damage such as being pinched or missing
insulation and for fraying at the glow pin connection points. Replace Glow
Pin if damaged.
● Check the black 2 pin connector and terminals on the Glow Pin for damage.
Make sure the terminals are locked in the connector and cannot be pushed
back. Replace the Glow Pin if damaged.
● Check the terminals in the ECU where the Glow Pin plugs in to see if they
are bent or corroded. Clean or straighten if possible.
● Check the Voltage as outlined in Fault Code 11.
● Replace the Glow Pin and test run the heater to see if the Fault Code
happens again. If it does then replace the ECU and test run the heater with
the old Glow Pin to make sure it works.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 19 Ignition Energy too Low

Fault Type Error
Requirements All Hella Type D2 and D4 Airtronic ECUs
Related Fault Codes F-18, F-52, F-57
How Fault Code is Set
If the heater fails to ignite the flame during the start phase the ECU will check the Glow Pin Power
Consumption. If the Power Consumption is too low, the heater will set a Fault Code 19.
If the Glow Pin Power Consumption is at a sufficient level then the Heater will Generate a Fault Code 52
instead. The Fault Code 19 indicates that the most likely reason the heater could not start was the Glow Pin.
Note: On some early Hella type ECUs when the Fault Code 19 was set that it was due to incorrect software
and not a failed Glow Pin. The Week and Year of production are shown in a small box on the Silver ECU Part
Label. The Week is at the top of the box and the year at the bottom. When 24 is in the top of the box and 05
is in the bottom of the box it indicates Week 24 Year 2005. Any Hella ECU up to Week 24 2005 which sets a
Fault Code 19 the ECU must be replaced and not the Glow Pin. When the Hella ECU has a week after 24 and
year after 2005 the Glow Pin is the problem.
Refer to TriPac Service Procedure H31A to identify a Hella and Wehrle ECU.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Glow Pin Resistance too
High.
Damaged Glow Pin
Harness or connections.
Failed ECU.
Refer to Note in the How
Fault Code is Set section
above to see if you have
an older ECU where it is
known to be faulty when it
gets this Fault Code.
● Check the resistance value of the Glow Pin at the black 2 pin connector
when the glow pin is at a room temperature of 20°C or (68°F).
● The resistance must be between 0.42Ω and 0.7 Ω at 20°C or (68°F). If the
resistance value is out of range, replace the glow pin.
● Check the glow pin harness for damage such as being pinched or missing
insulation and for fraying at the glow pin connection points. Replace Glow
Pin if damaged.
● Check the black 2 pin connector and terminals on the Glow Pin for damage.
Make sure the terminals are locked in the connector and cannot be pushed
back. Replace the Glow Pin if damaged.
● Check the terminals in the ECU where the Glow Pin plugs in to see if they
are bent or corroded. Clean or straighten if possible.
● Replace the Glow Pin and test run the heater to see if the Fault Code
happens again. If it does then replace the ECU and test run the heater with
the old Glow Pin to make sure it works.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 20 Glow Pin Interruption

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-18, F-19, F-21, F-22
How Fault Code is Set
After switching on the heater the ECU has detected that the Glow Pin circuit is open or that the resistance in
the circuit is too high.
On Heaters with the older Wehrle Style ECUs the Fault Code 20 will be generated if the Glow Pin output has a
short circuit to Power (+). With a New Style Hella this would generate a Fault Code 22. Refer to Service
Bulletin 461-1 to identify the difference between an older Wehrle ECU and the new Hella ECU.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Glow Pin circuit is open.
Glow Pin Resistance too
High.
Damaged Glow Pin
Harness or connections.
Glow Pin output has a
short circuit to Power.
Only on Heaters with older
Wehrle Type ECUs. Refer
to TriPac Service
Procedure H31A to
identify Wehrle. ECU.
Failed ECU.
● Check to make sure the Glow Pin is plugged all the way into the ECU.
● Check the Glow Pin for Continuity at the black 2 Pin connector and replace
the Glow Pin if it is open.
● Check the resistance value of the Glow Pin at the black 2 pin connector
when the glow pin is at a room temperature of 20°C or (68°F).
● The resistance must be between 0.42Ω and 0.7 Ω at 20°C or (68°F). If the
resistance value is out of range, replace the glow pin.
● Check the glow pin harness for damage such as being pinched or missing
insulation and for fraying at the glow pin connection points. Replace Glow
Pin if damaged.
● Check the black 2 pin connector and terminals on the Glow Pin for damage.
Make sure the terminals are locked in the connector and cannot be pushed
back. Replace the Glow Pin if damaged.
● Check the terminals in the ECU where the Glow Pin plugs in to see if they
are bent or corroded. Clean or straighten if possible.
● When the Heater has a Wehrle ECU it is possible that this fault code can be
caused by a short circuit between the FMP Output which is the white wire on
the Glow Pin and a power source.
● Refer to the How Fault Code is Set section above.
● Refer to Fault Code 22 for instruction on diagnosis and repair if the heater
has a Wehrle ECU.
● Complete all previous checks to make sure the problem is not external of the
ECU.
● Also complete all steps in F-22 if it is a Wehrle ECU.
● Replace the Glow Pin and test run the heater to see if the Fault Code
happens again. If it does then replace the ECU and test run the heater with
the old Glow Pin to make sure it works.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 21 Glow Pin Overload or Short Circuit to Ground

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-18, F-19, F-20, F-22
How Fault Code is Set
After switching on the heater the ECU has detected a short circuit between the Glow Pin output and ground or
the Glow Pin resistance is too low.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Glow Pin output has short
circuit to ground.
Glow Pin Resistance too
Low.
Failed ECU.
● Check the glow pin harness for damage such as being pinched or missing
insulation and for fraying at the glow pin connection points. This could
cause a short circuit between the white Glow Pin output and a ground.
● Check the black 2 pin connector and terminals on the Glow Pin for damage.
Make sure the terminals are locked in the connector and cannot be pushed
back. Replace the Glow Pin if damaged.
● Check the terminals in the ECU where the Glow Pin plugs in to see if they
are bent or corroded. Clean or straighten if possible.
● Check the resistance value of the Glow Pin at the black 2 pin connector
when the glow pin is at a room temperature of 20°C or (68°F).
● The resistance must be between 0.42Ω and 0.7 Ω at 20°C or (68°F). If the
resistance value is out of range, replace the glow pin
● Replace the Glow Pin and test run the heater to see if the Fault Code
happens again. If it does then replace the ECU and test run the heater with
the old Glow Pin to make sure it works.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 22 Glow Pin Output Short Circuit to Power (+)

Fault Type Error
Requirements All Hella Type D2 and D4 Airtronic ECUs
Related Fault Codes F-18, F-19, F-20, F-21
How Fault Code is Set
After switching on the heater the ECU has detected a short circuit between the Glow Pin output and Power (+).
When the heater has an older Wehrle style ECU the Fault Code 20 will be generated if the Glow Pin output
lead has a short to Power (+). Refer to TriPac Service Procedure H31A to identify the Wehrle and Hella ECUs.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Glow Pin output has short
circuit to power.
Failed ECU.
● Check the glow pin harness for damage such as being pinched or missing
insulation and for fraying at the glow pin connection points. This could
cause a short circuit between the white Glow Pin output and a Power
source.
● Make sure the Glow Pin Harness is routed correctly so it cannot short circuit
to Power.
● Replace the Glow Pin and test run the heater to see if the Fault Code
happens again. If it does then replace the ECU and test run the heater with
the old Glow Pin to make sure it works.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 31 Blower Motor Open Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-32, F-33, F-34
How Fault Code is Set
After switching on the heater the ECU has detected that the Blower Motor circuit is open or that the resistance
in the circuit is too high.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Blower Motor circuit is ● Check the blower motor cable harness for correct routing and damage.
open. ● If acceptable disconnect the cable harness from the control unit and check
the harness for continuity.
Failed ECU. ● If test results above are acceptable replace the ECU.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 32 Blower Motor Short Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-31, F-33, F-34
How Fault Code is Set
After switching on the heater the ECU has detected that the Blower Motor circuit has a short circuit.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Blower Motor circuit has a
short circuit.
Failed ECU or Blower
Motor.
● Check the blower motor wiring for a short circuit.
● Check the functions of the blower motor. Disconnect the connector from the
control unit. Apply DC voltage as shown below and measure the motor
current flow after 40 seconds.
Caution! The power source used must be capable of delivering at least 20
Amps minimum.
For 12 volt applications, check functions with maximum 10 ± 0.1 Vdc.
For 24 volt applications, check functions with maximum 18 ± 0.1 Vdc for the
D2 Airtronic and 18.5 ± 0.1 Vdc for the D4 Airtronic.
Caution! If the above voltage values are exceeded the component will
be destroyed.
o If the current is less than 6.5 amps the blower motor is acceptable, replace
the ECU.
o If the current is more than 6.5 amps, replace the blower motor.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 33 Blower Motor Does Not Turn

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-31, F-32, F-34
How Fault Code is Set
After switching on the heater the ECU has detected that the blower motor speed has varied from specification
by more than 10% for longer than 30 seconds. This can be checked using a non-contact RPM counter. Refer
to the heater manual for correct RPM values for each control stage.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Blower Motor circuit has a
short or open circuit.
Restrictions prevent free
running of the motor
Blower.
Damaged or missing
magnetic insert on blower
wheel.
Failed Blower Motor or
ECU.
● Check the blower motor wiring for a short circuit, open circuit, or damage.
● If the motor speed is too low: Check for restrictions that prevent free running
of the motor such as a warped case caused by something pressing on the
heater housing or an over-tightened intake duct clamp. If interference is
found, correct and function test the heater.
● If the motor speed is too high: Check for a damaged or missing magnetic
insert on blower wheel. Replace the blower motor if the magnetic insert is
missing or damaged.
● Manually Test Motor Speed: First make sure the motor is free spinning and
the fan is not rubbing against housing. Apply 10 ± 0.1 Vdc to the motor.
Measure motor speed in rpms with a non-contact rpm counter. Motor speed
should be 5000 rpms ± 1250 rpms for the D2 Airtronic and 4400 rpms ±
1100 rpms for the D4Airtronic.
Caution! The power source used must be capable of delivering at least 20
Amps minimum.
For 12 volt applications, check functions with maximum 10 ± 0.1 Vdc.
For 24 volt applications, check functions with maximum 18 ± 0.1 Vdc for the
D2 Airtronic and 18.5 ± 0.1 Vdc for the D4 Airtronic.
Caution! If the above voltage values are exceeded the component will
be destroyed.
o If the motor speed is incorrect then replace the blower motor.
o If motor speed is correct then replace the control unit.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 34 Blower Motor Output Short Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-31, F-32, F-33
How Fault Code is Set
After switching on the heater the ECU has detected that the Blower Motor output circuit has a short circuit.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Blower Motor output circuit
has a short circuit.
Failed ECU.
● Check the blower motor harness for correct routing and damage.
● If acceptable disconnect the cable harness from the ECU and check the
harness for continuity.
● If test results above are acceptable replace the ECU.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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 Section 5 – TriPace Diagnostics

Fault Code: 47 Fuel Metering Pump Overload or Short Circuit to Ground

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-48, F-49
How Fault Code is Set
A short circuit to ground has been detected in the Fuel Metering Pump or between the green / red cable at Pin
5 at the Heater Harness Connector and ground.
The short circuit will not be detected by the ECU until the Fuel Metering Pump is supposed to start. Normally
the Fuel Metering Pump will start about a minute after the heater is turned on unless the heater is performing a
pre-cool or it was just turned off and is still performing a shut down phase.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Short Circuit in the Fuel
Metering Pump.
Short Circuit in the Fuel
Metering Pump Harness.
Since this harness is
exposed it is could be
damaged more easily and
have a short circuit.
Short Circuit in ECU
Harness between Heater
Connector and ECU.
Short Circuit in ECU.
● Disconnect the connector at the Fuel Metering Pump and turn the heater on
again.
● If the Fault Code 48 is shown then the short circuit is in the fuel metering
pump and it must be replaced.
● If the Fault Code 47 is displayed when the fuel metering pump is
disconnected then the short is not in the metering pump.
● Disconnect the Heater Harness Connector at the heater and check the
green / red wire from Pin 5 at the Harness Connector up to the fuel metering
pump for a short circuit to ground at Pin 10 on the Harness connector.
● Check green / red wire between Pin 5 at the Harness Connector and Fuel
Metering Pump for short to chassis ground.
● Repair the short circuit to ground.
● Check the ECU Harness for damage which may have caused a short circuit
between the green red cable at Pin 5 and the Ground at Pin 10 or chassis
ground.
● If the ECU harness is damaged and cannot be repaired the ECU must be
replaced.
● Complete all previous steps to make sure the short circuit is not external of
the ECU.
● Test run the heater with new ECU to make sure the F47 does not appear
again. Make sure to run it until the fuel metering pump starts since the fault
is not detected until the pump starts.
● If the F47 does not appear again after testing until the Fuel Metering Pump
is running the short circuit was in the ECU and it must be replaced.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 48 Fuel Metering Pump Interruption

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters.
Related Fault Codes F-47, F-49
How Fault Code is Set
An interruption has been detected in either the Fuel Metering Pump or between the green / red cable at Pin 5
at the Heater Harness Connector and ground at Pin 10 on the Heater Harness Connector.
This fault could be due to an open circuit or too high of a resistance in the fuel metering pump circuit.
This fault will normally be detected when the heater is first turned on and then the heater will not try to start
and set the Fault Code 48.
With a heater with an older style Wehrle ECU this fault can also be caused by a short circuit between the Fuel
Metering Pump output at Pin 5 on the Heater Harness Connector and Power (+). Refer TriPac Service
Procedure H31A to identify Wehrle ECU.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Open Circuit or too high of
a resistance in the Fuel
Metering Pump.
The FMP Connector is
exposed and therefore can
be damaged or corroded
which can cause an open
circuit or high resistance
due to poor contact. Make
sure the weather seals at
the FMP are installed
properly to protect against
moisture.
Open Circuit or too high of
a resistance in the Fuel
Metering Pump Harness.
● Make sure the FMP Connector is securely plugged into the FMP and locked
on with the metal clip for that connector. If loose, then repair and reconnect
and then run the heater again.
● Remove the connector from the Fuel Metering Pump and measure the
resistance value of the Fuel Metering Pump. The resistance should be 9.5Ω
± 0.50Ω. Make sure the Terminals in the FMP are clean and not corroded.
● Check the FMP Connector and Terminals to see if they are loose, damaged
or corroded. Make sure the terminals are locked in place so they do not get
pushed back when connected. Replace the Terminals and weather seals if
the connector is corroded or damaged.
● Reconnect the FMP before this check.
● Disconnect the Heater Harness Connector at the heater and measure the
resistance value of the FMP Circuit between the Pin 5 and Pin 10 at the
Harness Connector. The resistance should be the same as it was at the
Fuel Metering Pump in the previous check or there is an open circuit in the
FMP harness and it must be repaired.
● Make sure the Terminals at Pin 5 and Pin 10 on the Harness Connector are
locked in and cannot be pushed back when the connector is locked closed.

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Open Circuit in ECU ● Check the Heater Harness Connector for damage and corrosion and make
Harness between Heater sure the Pin 5 and Pin 10 as well as the other pins are locked in and cannot
Connector and ECU. be pushed back when the Heater Harness Connector is locked closed.
● Check the ECU Harness for damage which may have caused an open
circuit in the green / red wire between the Heater Connector and the ECU.
● If the ECU harness is damaged and cannot be repaired the ECU must be
replaced.
FMP output has a short ● When the Heater has a Wehrle ECU it is possible that this fault code can be
circuit to Power. caused by a short circuit between the FMP Output which is the green / red
wire from Pin 5 at the Harness connector and a power source.
Only on Heaters with older ● Refer to the How Fault Code is Set section above.
Wehrle Type ECUs. Refer ● Refer to Fault Code 49 for instruction on diagnosis and repair if the Heater
to TriPac Service has a Wehrle ECU.
Procedure H31A to
identify Wehrle. ECU.
Failed ECU. ● Complete all previous steps to make sure the open circuit is not external of
the ECU.
● Also complete all steps in F-49 if it is a Wehrle ECU.
● Test run the heater with new ECU to make sure the F-48 does not appear
again. Make sure to run it until the Fuel Metering Pump starts since the F-49
or F-47 may not be detected until the pump starts.
● If no Fault Code appears again after testing until the Fuel Metering Pump is
running the open circuit was in the ECU and it must be replaced.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 49 Fuel Metering Pump Output Short Circuit to Power (+)
Fault Type Error
Requirements All Hella Type D2 and D4 Airtronic ECUs
Related Fault Codes F-47, F-48
How Fault Code is Set
After switching on the heater the ECU has detected a short circuit to Power (+) in the glow pin output lead.
The Fuel Metering Pump output is Green with a Red Stripe and comes from the ECU to the Pin 5 on the
Heater Harness connector and then goes to the fuel metering pump.
Refer to TriPac Service Procedure H31A to identify the Hella ECU.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Fuel Metering Pump output
short circuit to Power in the
Fuel Pump Harness.
Fuel Metering Pump output
short circuit to Power in the
ECU Harness.
Failed ECU.
● Check the Fuel Metering Pump harness for any signs of damage and that it
is routed properly from the heater to the FMP.
● Make sure that the FMP Harness is not shorted to any power source.
● Check the ECU Harness for damage which may have caused a short circuit
from the green / red wire at Pin 5 to power at Pin 1 at the Heater Connector.
● If the ECU harness is damaged and cannot be repaired the ECU must be
replaced.
● Complete all previous steps to make sure the short circuit is not external of
the ECU.
● Test run the heater with new ECU to make sure the F-49 does not appear
again. Make sure to run it until the Fuel Metering Pump starts since the F-49
may not be detected until the pump starts.
● If the Fault Code 49 does not appear again after testing until the Fuel
Metering Pump is running the short circuit was in the ECU and it must be
replaced.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 50 Electronic Control Unit Locked

Fault Type Operating Lockout
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-52
How Fault Code is Set
This fault code is set it the heater had too many consecutive failed start attempts.
For the older style Wehrle ECUs the maximum number of failed start attempts allowed consecutively is 10 and
for the new style Hella ECUs it is 255.
Refer to the TriPac Service Procedure H31A to identify the difference between the older Wehrle and newer
Hella ECUs.
How Fault Code is Cleared
It is not possible to clear this fault code by turning the heater on and then back on again or by disconnecting
the power.
The Operating Lockout can only be cleared by permanently deleting the fault code from the Heater’s Electronic
Control Unit memory by using the EDiTH Diagnostic Tool or the Heater Diagnostic Unit. Refer to Service
Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Too many failed start ● Unlock the ECU by permanently deleting the fault codes and try starting the
attempts. heater.
● If the heater does not start, troubleshoot and repair according to the most
recent fault code.

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Fault Code: 51 Flame detected when switching on

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-13, F-64, F-65
How Fault Code is Set
If, after being switched on the flame sensor indicates a temperature above 70°C (158°F) on a D2 Airtronic and
60°C (140°F) on a D4 Airtronic the heater will run the blower motor to cool the heat exchanger down. If the
flame sensor temperature reading does not fall below 70°C (158°F) on a D2 Airtronic and 60°C (140°F) on a
D4 Airtronic after about 15 minutes the heater will set a Fault Code 51 and shut down.
It is normal for the heater to pre-cool the heat exchanger when it is turned on if it is too hot which may be the
case if the heater was turned on shortly after it was running. After the heater exchanger cools down the heater
will perform it normal start up. This could be a reason why the heater start up is delayed in some cases.
This fault is most likely due to a failed or damaged flame sensor or wires or a poor connection.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Flame Sensor Resistance
too High
A poor or damaged
connection could cause an
increase in the Flame
Sensor circuit resistance.
A higher resistance of the
flame sensor would
indicate the temperature is
higher and the heater
would try to cool it down
before starting.
Failed ECU
● Check to make sure the Flame Sensor is plugged all the way into the ECU.
● Check the flame sensor harness, connector and terminals for any damage
or corrosion. Make sure the terminals are locked in the connector and
cannot be pushed back.
● Check the resistance value of the flame sensor as outlined in Service
Procedure D05A. If the resistance is over approximately 1274 Ω when on a
D2 (1232 Ω on a D4) when the sensor is at room temperature it is the
reason for the fault code and must be replaced.
● When possible use EDiTH Diagnostics to view the Temperature that the
Flame Sensor is reading when the heater is started to see if it stays above
70°C (158°F) on a D2 Airtronic and 60°C (140°F) on a D4 Airtronic even
when it has cooled down.
● Test the heater with a new Flame Sensor to see if the Fault Code happens
again. If it does then reinstall the old sensor. It can take over 15 minutes to
set this fault since the heater attempts to cool off for about 15 minutes
before the Fault Code is set.
● Replace the ECU and run it with the old Flame Sensor to confirm the fault
does not happen again. Make sure when test running the heater that the
Fuel Metering Pump Starts and the Flame Starts and that the heater is not
just doing another pre-cool since it may appear the heater is working when
the fan is running.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 52 Safety Time Exceeded

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-18, F-19, F-50, F-57
How Fault Code is Set
No flame was detected during the heater start up phase.
The heater is allowed two start attempts to ignite while delivering fuel. The Airtronic D2 has two 90 second
start attempts. The Airtronic D4s first start attempt is 105 or 110 seconds while the second is about 70
seconds.
If no flame is detected during the first start attempt the heater will automatically do a second start attempt after
a short preheat. If a flame is not detected in the second start attempt, the heater will shut off the Fuel Metering
Pump and set a Fault Code 52. The glow pin will continue to be on for a short period and the blower motor will
also stay on for about 4 minutes to cool the heater off.
The heater detects a flame with the flame sensor that is mounted on top of the heat exchanger. During the
start up attempt the flame sensor must detect a 4° C (7.2° F) rise in the temperature of the heat exchanger
within 10 seconds to recognize that a flame has started.
For the D4 Airtronic the first start attempt times are dependent on which type of ECU it has. For the Wehrle
ECU the first start attempt is about 110 Seconds and for the Hella ECU the first start attempt is about 105
seconds. Refer to TriPac Service Procedure H31A to identify the Hella and Wehrle ECUs.
On Heaters with a Hella Electronic Control Unit a Fault Code 19 could be set instead of a Fault Code 52 when
the heater does not detect a flame during the start phase. Refer to TriPac Service Procedure H31A to identify
the Hella and Wehrle ECUs.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Restricted combustion air
intake or exhaust.
If the combustion air
intake or the exhaust is
restricted in any way, the
heater may not get
enough combustion air to
start or sustain the flame.
● Check the combustion air intake hose and the exhaust pipe to see if they are
crushed, damaged or restricted.
● Check to make sure the air intake and exhaust are installed correctly
according to the TriPac Installation Manual.
● The Exhaust and the Air Intake should not be shorter than 12 inches each or
longer than 6.5 Feet each.
● Avoid excessive bends in the air intake or exhaust since they can cause
restriction. A general guideline is to not have more than 180° to 270° worth
of bends in either the exhaust or air intake pipes.

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Fuel supply problem. ● Check the fuel delivery system to be sure there are no loose, damaged or
restricted fuel lines or connections.
If there is not enough fuel
● Check the fuel system installation to make sure it is installed correctly
or too much fuel the heater
according to the TriPac Installation Manual.
may not start or be able to
● Perform a Fuel Quantity Test. Refer to TriPac Service Procedure H30A.
sustain the flame since it
does not have the right
amount of fuel for proper
ignition and combustion.
The Fuel Quantity Test is
the most effective way to
test the entire fuel system
from the tip of the pickup
pipe to the heater inlet
pipe.
Problem with the glow pin, ● Check the glow pin tip to see if it is dirty or deformed. If it cannot be wiped
which is the ignition clean with a soft cloth it must be replaced.
source. ● Check the Glow Pin as outline in Fault Codes 20 and 21. Replace if
necessary.
If the glow pin is dirty or not
working properly, it may
not be able to ignite the
flame.
Problem with the ● Check the glow pin ventilation hole to make sure it is completely open and
combustion air supply or not restricted.
fuel supply inside the ● Check to see if the glow pin screen has build-up on it or looks dirty. If it is
heater. dirty or has build up remove and replace it.
● Make sure to clean the glow pin screen chamber before installing new glow
If the glow pin ventilation
pin screen. Use a small brush to loosen any build up in the Glow Pin
hole is restricted or
chamber and a vacuum to remove any loose particles. Do not blow loose
blocked the heater may not
particles into the Burner Chamber with compressed air.
be able to ignite the flame
● Make sure to that the glow pin screen insertion tool bottoms out when
because the small amount
inserting the glow pin screen so that the ventilation hole is completely clear.
of air going through the
hole is critical for ignition
and helps atomize the fuel
for proper combustion. If
the glow pin screen is dirty
or plugged it will not be
able to atomize the fuel
well which is equivalent to
a fuel restriction.

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Failed or incorrectly ● Check to make sure the flame sensor is not damaged and is correctly and
installed flame Sensor. securely clamped into the indent on top of the heat exchanger with the
smooth silver side completely touching the heat exchanger.
If the Flame Sensor has
● Check to make sure the flame sensor wires are securely connected to the
failed or is not mounted
sensor and are routed properly and not damaged.
properly it may not detect
● Check the green connector to make sure that the terminals are locked into
the heater exchanger
the connector and cannot be pushed back.
temperature properly and
● Check the flame sensor resistance values. Refer to TriPac Service
therefore it may detect the
Procedure D05A.
flame went out even if it did
● Use EDiTH Diagnostics to perform a Function Test and view the measured
not or it may detect a flame
temperature of the Flame Sensor. If the heater has not been running the
started even if it did not.
flame sensor will read the approximate room temperature when the Function
EDiTH Diagnostics is the Test is first started. To see if the sensor is reading properly when the heater
most effective way to is warm then you will have to remove the flame sensor and perform a
check the flame sensor for Function Test with it in the ambient air. If the flame sensor is not reading
function and accuracy. accurately it must be replaced. Refer to TriPac Service Procedure H31A.
Carbon Build Up in the ● Look inside the Glow Pin Chamber to see if you can see a blockage or
Burner. restriction in the bottom.
● Take off the exhaust and look into the exhaust port on the heater to see if
In some cases when there there is soot build up.
has been a partial ● If you are able to get the heater started after making a correction or repair
restriction in the then first try to start it a couple of times and run it in high to see if it will burn
Combustion Air Supply or off the carbon.
a problem with the Fuel ● If it will not start well or does not run smoothly or without smoke then refer to
Supply over a period of Espar Technical Bulletin 282 to see how to clean a burner.
time, there could be carbon
build up in the burner that
needs to be cleaned. In
many cases if the error
was not present for too
long or it was not too
severe, the heater will burn
off the carbon after the
problem is corrected.
Elevation is too high. ● Find out if the elevation at your location is close to or higher than 5000 feet
and if the truck is used at elevations above 5000 feet more than on a rare
If the heater is being run at
occasion.
5000 Feet above sea level
● If the heater will be used at elevations above 5000 feet then install either a
or higher it may not be
High Altitude Sensor on later model heaters or install a secondary high
starting because the air to
altitude fuel pump and selector switch on older model heaters. Refer to TK
fuel ratio could be too low.
Service Bulletin TT500 for details.

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 Section 5 – TriPace Diagnostics

Fault Code: 53 Flame Cutout in Power Mode

Fault Code: 54 Flame Cutout in High Mode
Fault Code: 55 Flame Cutout in Medium Mode
Fault Code: 56 Flame Cutout in Low Mode
Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters.
Related Fault Codes F-52, F-57
How Fault Code is Set
After the heater has reached regulation mode and is in one of the controlled heat output levels the ECU
has detected the flame has gone out and after restarting successfully has gone out again within 15
minutes.
The ECU detects the flame cutout by evaluating the dropping temperature trend of the Flame Sensor
which reads the surface temperature of the heat exchanger.
Which of the four Flame Cutout Fault Codes is set depends on which heat output level the heater was in
when the flame cutout occurred the second time in 15 minutes. It is not based on the heat output level
the heater was in when the first flame cutout occurred which is followed by the automatic restart.
After a flame-out the heater will only perform one automatic start attempt and not two start attempts as it
may on an initial start up. In this restart attempt the flame must ignite within 90 seconds after the start of
the fuel pump for a D2 Airtronic and about 70 seconds for a D4 Airtronic. In this restart the heater will
first go into the Medium Mode before controlled regulation starts and not into Power Mode as it does on
an initial start.
If the automatic restart attempt after a flame-out is not successful the heater will not set one of the
Flame Cutout in Regulation Fault Codes but instead another Fault Code such as F-52 or F-57 which
indicates why the heater was not able to start.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the
condition that caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH
Diagnostic Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A
and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Restricted combustion air
intake or exhaust.
If the combustion air
intake or the exhaust is
restricted in any way, the
heater may not get
enough combustion air to
start or sustain the flame.
● Check the combustion air intake hose and the exhaust pipe to see if
they are crushed, damaged or restricted.
● Check to make sure the air intake and exhaust are installed correctly
according to the TriPac Installation Manual.
● The Exhaust and the Air Intake should not be shorter than 12 inches
each or longer than 6.5 Feet each.
● Avoid excessive bends in the air intake or exhaust since they can
cause restriction. A general guideline is to not have more than 180°
to 270° worth of bends in either the exhaust or air intake pipes.

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 Section 5 – TriPace Diagnostics

Fuel supply problem. ● Check the fuel delivery system to be sure there are no loose,
damaged or restricted fuel lines or connections.
If there is not enough fuel
● Check the fuel system installation to make sure it is installed correctly
or too much fuel the heater
according to the TriPac Installation Manual.
may not start or be able to
● Perform a Fuel Quantity Test. Refer to TriPac Service Procedure
sustain the flame since it
H30A.
does not have the right
amount of fuel for proper
ignition and combustion.
The Fuel Quantity Test is
the most effective way to
test the entire fuel system
from the tip of the pickup
pipe to the heater inlet
pipe.
Problem with the ● Check the glow pin ventilation hole to make sure it is completely open
combustion air supply or and not restricted.
fuel supply inside the ● Check to see if the glow pin screen has build-up on it or looks dirty. If
heater. it is dirty or has build up remove and replace the glow pin screen.
● Make sure to clean the glow pin screen chamber before installing new
If the glow pin ventilation
glow pin screen. Use a small brush and a vacuum to loosen and
hole is restricted or
remove any build up in the Glow Pin chamber. Do not blow loose
blocked the heater may not
particles into the Burner Chamber with compressed air.
be able to keep the flame
● Make sure that the glow pin screen insertion tool bottoms out when
going because the small
inserting the new glow pin screen so that the ventilation hole is not
amount of air going
blocked.
through the hole is critical
for ignition and helps
atomize the fuel for proper
combustion. If the glow pin
screen is dirty or plugged it
will not be able to atomize
the fuel well which is
equivalent to a fuel
restriction.
Failed or incorrectly ● Check to make sure the flame sensor is not damaged and is correctly
installed flame Sensor. and securely clamped into the indent on top of the heat exchanger
with the smooth silver side completely touching the heat exchanger.
If the Flame Sensor has
● Check to make sure the flame sensor wires are securely connected to
failed or is not mounted
the sensor and are routed properly and not damaged.
properly it may not detect
● Check the green connector to make sure that the terminals are locked
the heater exchanger
into the connector and cannot be pushed back.
temperature properly and
● Check the flame sensor resistance values. Refer to TriPac Service
therefore it may detect the
Procedure D05A.
flame went out even if it did
● Use EDiTH Diagnostics to perform a Function Test and view the
not or it may detect a flame
measured temperature of the Flame Sensor. If the heater has not
started even if it did not.
been running the flame sensor will read the approximate room
EDiTH Diagnostics is the temperature when the Function Test is first started. To see if the
most effective way to sensor is reading properly when the heater is warm then you will have
check the flame sensor for to remove the flame sensor and perform a Function Test with it in the
function and accuracy. ambient air. If the flame sensor is not reading accurately it must be
replaced. Refer to TriPac Service Procedure H31A.

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Failed ECU ● Before replacing the ECU, try to run the heater with a new Flame
Sensor and view the temperature it is reading with EDiTH.
If the ECU is not
● If after replacing the Flame Sensor, the ECU still does not measure
measuring the flame
the Flame Sensor correctly according to EDiTH then replace the ECU
sensor properly it may not
and reinstall the old Flame Sensor. Confirm the new ECU reads the
recognize when the flame
proper temperature with the old Flame Sensor.
is on or off.

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Fault Code: 57 Flame Cutout in Start Phase

Fault Type Error
Requirements Only High Altitude Compatible D2 and D4 Airtronic ECUs.
Related Fault Codes F-18, F-19, F-52, F-53, F-54, F-55, F-56
How Fault Code is Set
A flame was detected during the start phase but then went out some time before reaching the regulation
mode.
The heater is allowed two start attempts to ignite while delivering fuel. The Airtronic D2 has two 90
second start attempts. The Airtronic D4s first start attempt is 105 or 110 seconds while the second is
about 70 seconds.
If a flame is detected during one or both of these start attempts and then goes out and is not started
again before the end of the second start attempt and then stays on until it reaches regulation mode the
Heater will shut off the Fuel Metering Pump and set a Fault Code 57. The glow pin will continue to be
on for a short period and the blower motor will also stay on for about 4 minutes to cool the heater off.
The heater detects a flame with the flame sensor that is mounted on top of the heat exchanger. During
the start up attempt the flame sensor must detect a 4° C (7° F) rise in the temperature of the heat
exchanger within 10 seconds to recognize that a flame has started. The ECU detects the flame cutout
by evaluating the dropping temperature trend of the Flame Sensor.
For the D4 Airtronic the first start attempt times are dependent on which type of ECU it has. For the
Wehrle ECU the first start attempt is about 110 Seconds and for the Hella ECU the first start attempt is
about 105 seconds. Refer to TriPac Service Procedure H31A to identify the Hella and Wehrle ECUs.
Refer to Service Bulletin TT499 to identify a high altitude compatible Electronic Control Unit.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the
condition that caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH
Diagnostic Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A
and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Restricted combustion air
intake or exhaust.
If the combustion air
intake or the exhaust is
restricted in any way, the
heater may not get
enough combustion air to
start or sustain the flame.
● Check the combustion air intake hose and the exhaust pipe to see if
they are crushed, damaged or restricted.
● Check to make sure the air intake and exhaust are installed correctly
according to the TriPac Installation Manual.
● The Exhaust and the Air Intake should not be shorter than 12 inches
each or longer than 6.5 Feet each.
● Avoid excessive bends in the air intake or exhaust since they can
cause restriction. A general guideline is to not have more than 180°
to 270° worth of bends in either the exhaust or air intake pipes.

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 Section 5 – TriPace Diagnostics

Fuel supply problem. ● Check the fuel delivery system to be sure there are no loose,
damaged or restricted fuel lines or connections.
If there is not enough fuel
● Check the fuel system installation to make sure it is installed correctly
or too much fuel the heater
according to the TriPac Installation Manual.
may not start or be able to
● Perform a Fuel Quantity Test. Refer to TriPac Service Procedure
sustain the flame since it
H30A.
does not have the right
amount of fuel for proper
ignition and combustion.
The Fuel Quantity Test is
the most effective way to
test the entire fuel system
from the tip of the pickup
pipe to the heater inlet
pipe.
Problem with the glow pin, ● Check the glow pin tip to see if it is dirty or deformed. If it cannot be
which is the ignition wiped clean with a soft cloth it must be replaced.
source. ● Check the Glow Pin as outline in Fault Codes 20 and 21. Replace if
necessary.
If the glow pin is dirty or not
working properly, it may
not be able to establish a
stable flame even though it
was able to ignite it initially.
Problem with the ● Check the glow pin ventilation hole to make sure it is completely open
combustion air supply or and not restricted.
fuel supply inside the ● Check to see if the glow pin screen has build-up on it or looks dirty. If
heater. it is dirty or has build up remove and replace it.
● Make sure to clean the glow pin screen chamber before installing new
If the glow pin ventilation
glow pin screen. Use a small brush to loosen any build up in the
hole is restricted or
Glow Pin chamber and a vacuum to remove any loose particles. Do
blocked the heater may not
not blow loose particles into the Burner Chamber with compressed
be able to ignite the flame
air.
because the small amount
● Make sure to that the glow pin screen insertion tool bottoms out when
of air going through the
inserting the glow pin screen so that the ventilation hole is completely
hole is critical for ignition
clear.
and helps atomize the fuel
for proper combustion. If
the glow pin screen is dirty
or plugged it will not be
able to atomize the fuel
well which is equivalent to
a fuel restriction.

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Failed or incorrectly ● Check to make sure the flame sensor is not damaged and is correctly
installed flame Sensor. and securely clamped into the indent on top of the heat exchanger
with the smooth silver side completely touching the heat exchanger.
If the Flame Sensor has
● Check to make sure the flame sensor wires are securely connected to
failed or is not mounted
the sensor and are routed properly and not damaged.
properly it may not detect
● Check the green connector to make sure that the terminals are locked
the heater exchanger
into the connector and cannot be pushed back.
temperature properly and
● Check the flame sensor resistance values. Refer to TriPac Service
therefore it may detect the
Procedure D05A.
flame went out even if it did
● Use EDiTH Diagnostics to perform a Function Test and view the
not or it may detect a flame
measured temperature of the Flame Sensor. If the heater has not
started even if it did not.
been running the flame sensor will read the approximate room
EDiTH Diagnostics is the temperature when the Function Test is first started. To see if the
most effective way to sensor is reading properly when the heater is warm then you will have
check the flame sensor for to remove the flame sensor and perform a Function Test with it in the
function and accuracy. ambient air. If the flame sensor is not reading accurately it must be
replaced. Refer to Service Procedure H31A.
Carbon Build Up in the ● Look inside the Glow Pin Chamber to see if you can see a blockage
Burner. or restriction in the bottom.
● Take off the exhaust and look into the exhaust port on the heater to
In some cases when there
see if there is soot build up.
has been a partial
● If you are able to get the heater started after making a correction or
restriction in the
repair then first try to start it a couple of times and run it in high to see
Combustion Air Supply or
if it will burn off the carbon.
a problem with the Fuel
● If it will not start well or does not run smoothly or without smoke then
Supply over a period of
refer to Espar Technical Bulletin 282 to see how to clean a burner.
time, there could be carbon
build up in the burner that
needs to be cleaned. In
many cases if the error
was not present for too
long or it was not too
severe, the heater will burn
off the carbon after the
problem is corrected.
Elevation is too high. ● Find out if the elevation at your location is close to or higher than
5000 feet and if the truck is used at elevations above 5000 feet more
If the heater is being run at
than on a rare occasion.
5000 Feet above sea level
● If the heater will be used at elevations above 5000 feet then install
or higher it may not be
either a High Altitude Sensor on later model heaters or install a
starting because the air to
secondary high altitude fuel pump and selector switch on older model
fuel ratio could be too low.
heaters. Refer to TK Service Bulletin TT500 for Details.

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Fault Code: 60 External Temperature Sensor Open Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-61
How Fault Code is Set
The external temperature sensor is detecting an out of range temperature.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

External Temperature
Sensor circuit is open.
Failed ECU.
● Disconnect the Heater Harness connection (main harness) and measure the
resistance value at the Harness connector Pins 6 & 12. Refer to TriPac
Service Procedure D06A.
● If there is an open circuit, the resistance value between the pins will be more
than 7175 Ω.
● Disconnect the sensor from the harness and test the sensor. If the
resistance is the same as the previous test, replace the sensor. If the
resistance value is normal locate and repair open in the harness.
● If the resistance value is acceptable replace the ECU.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 61 External Temperature Sensor Short Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-60
How Fault Code is Set
The external temperature sensor is detecting an out of range temperature.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

External Temperature
Sensor circuit is shorted.
Failed ECU.
● Disconnect the Heater Harness connection (main harness) and measure the
resistance value at the Harness connector Pins 6 & 12. Refer to TriPac
Service Procedure D06A.
● If there is a short circuit, the resistance value between the pins will be less
than 486 Ω.
● Measure the resistance value between Pin 12 and chassis ground. Any
reading indicates the harness is shorted to ground. Locate and repair short.
● Disconnect the sensor from the harness and test the sensor. If the
resistance is low, replace the sensor. If the resistance value is normal locate
and repair short in the harness.
● If the resistance value is acceptable and Alarm Code 061 continues to occur
then replace the ECU.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 62 Setpoint Control Open Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-63
How Fault Code is Set
The digital temperature control potentiometer values are out of range high for the TriPac digital temperature
control potentiometer (thermostat). Heater will ignite then run in high speed.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Setpoint Control circuit is ● Disconnect the Heater Harness connector.
open, failed ECU, or failed ● Turn the TriPac system on and set for heat.
Interface/Controller Board. ● Check the resistance between Pins 6 and 7 at the Harness connector. The
normal value is from 1740 Ω to 2180 Ω ± 80 Ω. Typical TriPac values for
The TriPac temperature
setpoint settings with heat mode selected are as follows:
setpoint is supplied to the
50° F (10° C) Setpoint 1775 Ω ± 80 Ω
heater by a digitally
77° F (25° C) Setpoint 2000 Ω ± 80 Ω
simulated potentiometer.
90° F (32° C) Setpoint 2175 Ω ± 80 Ω
This digital potentiometer is
The resistance value for an open circuit between Pins 6 and 7 is more than
located on the TriPac
7175 Ω.
Interface Board or the
● If the values are correct replace the ECU.
TriPace Main Controller
● If the values are not correct then disconnect the GRY/RED wire from
Board. The digital
terminal L1 and the BRN/WHT wire from the W1 terminal on the TriPac
potentiometer is connected
Interface Board, or unplug connector J54 on the TriPace Main Controller
to the heater via the Heater
Board. Measure the values at the board for the setpoints shown above.
Harness connector.
● If the values are correct at the Interface/Controller Board but incorrect at the
The Grey/Red wire from heater then check the wiring harness from the heater to the Interface/
the heater is connected to Controller Board.
terminal L1 on the TriPac ● If the values are incorrect at the Interface/Controller Board then replace the
Interface Board or Interface/Controller Board.
connector J54 Pin 6 on the ● Do not clear or erase the Fault Code in the old ECU if it is being
TriPace Main Controller returned under Warranty.
Board. The Brown/White
wire from the heater is
connected to the W1
terminal on the TriPac
Interface Board or
connector J54 Pin 5 on the
TriPace Main Controller
Board.

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Fault Code: 63 Setpoint Control Short Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-62
How Fault Code is Set
The digital temperature control potentiometer values are out of range low (Less than 1740 ohm) for the TriPac
digital temperature control potentiometer (thermostat).
This Alarm Code is only active in Heat Mode. If the short circuit has already occurred and the heater is
switched on then Ventilation Mode will be active.
NOTE: If a short circuit already exists before the heater is turned on, the heater will run in vent mode
but no alarm will occur. EDiTH will report Parking Ventilation Mode.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Setpoint Control circuit has
a short circuit, or failed
Interface/Controller Board.
The TriPac temperature
setpoint is supplied to the
heater by a digitally
simulated potentiometer.
This digital potentiometer is
located on the TriPac
Interface Board or the
TriPace Main Controller
Board. The digital
potentiometer is connected
to the heater via the Heater
Harness connector.
The Grey/Red wire from
the heater is connected to
terminal L1 on the TriPac
Interface Board or
connector J54 Pin 6 on the
TriPace Main Controller
Board. The Brown/White
wire from the heater is
connected to the W1
terminal on the TriPac
Interface Board or
connector J54 Pin 5 on the
TriPace Main Controller
Board.
● Disconnect the Heater Harness connector.
● Turn the TriPac system on and set for heat.
● Check the resistance between Pins 6 and 7 at the Harness connector. The
normal value is from 1740 Ω to 2180 Ω ± 80 Ω. Typical values for setpoint
settings with heat mode selected are as follows:
50° F (10° C) Setpoint 1775 Ω ± 80 Ω
77° F (25° C) Setpoint 2000 Ω ± 80 Ω
90° F (32° C) Setpoint 2175 Ω ± 80 Ω
● The resistance value for a short circuit between Pins 6 and 7 is less than
486 Ω.
● Resistance below 1700 ohm (32 F, 0 C) will cause heater to be stuck in
Parking Ventilation Mode.
● If the values are not correct then disconnect the GRY/RED wire from
terminal L1 and the BRN/WHT wire from terminal W1 on the TriPac Interface
Board, or unplug connector J54 on the TriPace Main Controller Board Pins 5
and 6. Measure the values at the board for the setpoints shown above.
● If the resistance values are incorrect at the Interface/Controller Board with
the wires disconnected then replace the Interface/Controller Board.
● If the resistance values are correct check the resistance between Pins 6 and
7 at the Harness connector.
● If the value is anything other than OL the short circuit is between the
GRY/RED or BRN/WHT wires in the wiring harness from the heater to the
Interface/Controller Board. Locate short and repair the harness as
necessary.
● Measure the resistance value between Pin 6 and chassis ground then Pin 7
and chassis ground. Any reading other than OL indicates the harness is
shorted to ground. Locate short and repair the harness as necessary.
● If the short circuit cannot be found then replace the wiring harness from the
heater to the Interface/Controller Board.

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Reversed Harness ● The GRY/RED and BRN/WHT wire connections are reversed.
Connection ● EDiTH will report Parking Ventilation Mode.
● Blower will run.
● Burner will not ignite.
● No alarm will generate.
Failed ECU. ● If the resistance values are correct replace the ECU.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 64 Flame Sensor Open Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-65
How Fault Code is Set
The Flame Sensor is sensing an out of range value.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Flame Sensor circuit is ● Disconnect the green connector from the ECU. Check the Flame Sensor
open. resistance using Service Procedure D05A.
Failed ECU. ● If the Flame Sensor is acceptable then replace the ECU. The resistance
value for interruption is more than 7175 Ω.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 65 Flame Sensor Short Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-64
How Fault Code is Set
The Flame Sensor is sensing an out of range value.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Flame Sensor circuit has a ● Disconnect the green connector from the ECU and run the heater. If Alarm
short circuit. Code 064 is displayed then replace the combination flame/overheat sensor.
Failed ECU. ● If Alarm Code 065 is still displayed then replace the ECU. The resistance
value for a short circuit is less than 486 Ω. For Flame Sensor resistance
values see Service Procedure D05A.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 71 Overheat Sensor Open Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-72
How Fault Code is Set
The Overheat Sensor value is out of range.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Overheat Sensor circuit is ● Disconnect the green and blue connectors from the ECU. Measure the
open. resistance value from the blue connector Pin 1- (blue wire) to the green
connector Pin 2 (brown/white wire). For Overheat Sensor resistance values
see Service ProcedureD05A.
Failed ECU. ● If the resistance value is acceptable then replace the ECU. The resistance
value for interruption is more than 223 k Ω.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 72 Overheat Sensor Short Circuit

Fault Type Error
Requirements All D2 and D4 Airtronic ECUs
Related Fault Codes F-71
How Fault Code is Set
The Overheat Sensor value is out of range.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Overheat Sensor circuit
has a short circuit.
Failed ECU.
● Disconnect the blue connector from the ECU and run the heater. If Alarm
Code 071 is displayed then replace the combination Flame/Overheat
Sensor.
● If Alarm Code 072 is still displayed then replace the ECU. The resistance
value for a short circuit is less than 183 Ω. For Overheat Sensor resistance
values see Service Procedure D05A.
● Do not clear or erase the Fault Code in the old ECU if it is being
returned under Warranty.

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Fault Code: 74 Control Unit Defective

Fault Type Error
Requirements All D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
The overheat threshold value is not detected by the ECU.
How Fault Code is Cleared
The fault code does not need to be cleared since the ECU needs to be replaced.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Failed ECU ● Replace the ECU and Function Test the heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 90 Control Unit Defective

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
The Electronic Control Unit (ECU) inside the heater has failed and is defective.
How Fault Code is Cleared
The fault code does not need to be cleared since the ECU needs to be replaced.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Failed ECU ● Replace the ECU and Function Test the heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 91 External Interference Voltage

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes F-10, F-11, F-98, F-99
How Fault Code is Set
An error has occurred in the ECU due to an interference voltage from either the TriPac or tractor electrical
system.
This Fault Code can be caused by a battery charger being connected to the electrical system.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Battery Charger
Connected to Truck
Batteries.
Voltage interference from
vehicle electrical system.
● Remove the Battery Charger.
● Clear the Fault Code from the ECU Memory and Function Test the Heater
without the Battery Charger connected to confirm the fault does not happen
again and was due to the Battery Charger.
● Check the truck and TriPac charging systems and repair any problems.
● Test the Heater Power Supply as outline in Fault Codes 10 and 11.

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Fault Code: 92 Control Unit Defective

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
The Electronic Control Unit (ECU) inside the heater has failed and is defective.
How Fault Code is Cleared
The fault code does not need to be cleared since the ECU needs to be replaced.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Failed ECU ● Replace the ECU and Function Test the heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 93 Control Unit Defective

Fault Type Error
Requirements All Hella Type D2 and D4 Airtronic ECUs
Related Fault Codes
How Fault Code is Set
The Electronic Control Unit (ECU) inside the heater has failed and is defective.
Refer to TriPac Service Procedure H31A to identify the Hella ECU.
How Fault Code is Cleared
The fault code does not need to be cleared since the ECU needs to be replaced.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Failed ECU ● Replace the ECU and Function Test the heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 94 Control Unit Defective

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
The Electronic Control Unit (ECU) inside the heater has failed and is defective.
How Fault Code is Cleared
The fault code does not need to be cleared since the ECU needs to be replaced.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Failed ECU ● Replace the ECU and Function Test the heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 95 Control Unit Defective

Fault Type Error
Requirements All Hella Type D2 and D4 Airtronic ECUs
Related Fault Codes
How Fault Code is Set
The Electronic Control Unit (ECU) inside the heater has failed and is defective.
Refer to TriPac Service Procedure H31A to identify the Hella ECU.
How Fault Code is Cleared
The fault code does not need to be cleared since the ECU needs to be replaced.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Failed ECU ● Replace the ECU and Function Test the heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 96 Internal Temperature Sensor Defective.

Fault Type Warning
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
The internal temperature sensor on the Electronic Control Unit has failed.
The internal temperature sensor is located on the outside of the ECU in the path of the return air and is used to
read the return air temperature to the heater in order to regulate the heater output so that it heats to the
temperature setpoint. On the Hella ECUs it has Blue Wires leading to it and on the Wehrle ECU is it just a
black sensor with small black shield protruding out the same side of the ECU that the Blower Motor plugs into.
If the internal temperature sensor has failed and there is no optional external temperature sensor installed the
heater will still function in an emergency mode so not to leave someone stranded without heat. When the
internal temperature sensor has failed the heater is not able to measure the sleeper temperature so it cannot
regulate the heater. In this case the heater will run only in High heat output which could lead to a sleeper
temperature rising higher than the temperature set point.
By default the ECU will control to the internal temperature sensor unless an optional, normally not used
external temperature sensor is connected.
How Fault Code is Cleared
The fault does not show up as an Actual Fault or AF so it does not need to be cleared in order for the heater to
function.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Damage to the Internal
Temperature Sensor on
the ECU.
Internal Temperature
Sensor is too far out of
Tolerance.
● Check the temperature sensor on the ECU to see if it is damaged or if the
wires leading to it are damaged. The damage could be from pulling on the
wires or if the ECU was dropped or crushed somehow.
● If the sensor or the wires are damaged an External Temperature Sensor will
have to be installed or the ECU replaced.
● Failure of the Sensor due to external physical damage is not covered
by Warranty. If the Heater is out of Warranty or the sensor was
physically damaged it would likely be more cost effective to install an
external temperature sensor than to replace the whole ECU.
● It is not possible to do a resistance check on the Internal Temperature
Sensor or to replace it.
● If the Fault Code 96 is in the ECU Memory the Internal Temperature Sensor
has failed and it does not need to be proven, only a decision on the best way
to correct it must be made.
● If the Heater is under Warranty and the Sensor did not fail due to
physical damage, the whole ECU should be replaced under Warranty.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 97 Control Unit Defective

Fault Type Error
Requirements All TriPac D2 and D4 Airtronic Heaters
Related Fault Codes
How Fault Code is Set
The Electronic Control Unit (ECU) inside the heater has failed and is defective.
How Fault Code is Cleared
The fault code does not need to be cleared since the ECU needs to be replaced.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Failed ECU ● Replace the ECU and Function Test the heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 98 Control Unit Defective or Low Voltage Supply under load
Fault Type Error
Requirements All Hella Type D2 and D4 Airtronic ECUs
Related Fault Codes F-11, F- 91, F-99
How Fault Code is Set
The voltage supply to the heater dropped excessively low during start up or the Electronic Control Unit is
defective.
Refer to TriPac Service Procedure H31A to identify the Hella ECU.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Low Voltage Supply or
Voltage drop occurs
during start up.
Failed ECU
● Check all power supply connections and lines at both ground and power for
a loose, damaged or corroded connections and make necessary repairs.
● Since this voltage drop may be intermittent it may only occur when the truck
is vibrating so the bad connection may be hard to find and the power supply
must be checked very thoroughly.
● Check the Voltage Supply according to the instructions in Fault Code 11.
● After confirming the Power Supply is good by making all the checks in Fault
Code 11, clear the Fault Codes from the ECU and Perform a Function Test
to repeat the Fault Code 98.
● If the Fault Code is repeated then replace the ECU and Function Test the
Heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

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Fault Code: 99 Too many resets in sequence or Transistor Error in ECU

Fault Type Error
Requirements All Hella Type D2 and D4 Airtronic ECUs
Related Fault Codes F-11, F-91, F-98
How Fault Code is Set
The voltage supply to the heater dropped excessively low to less than 5 – 6 Volts for a short period of time
repeatedly or the Electronic Control Unit Transistor has failed.
Refer to TriPac Service Procedure H31A to identify the Hella ECU.
How Fault Code is Cleared
The fault can be cleared by turning the heater off and then back on again. Failure to resolve the condition that
caused the fault may cause it to re-occur.
To permanently delete the fault code from the Heater’s Electronic Control Unit memory the EDiTH Diagnostic
Tool or the Heater Diagnostic Unit can be used. Refer to TriPac Service Procedures H31A and H32A.
How to Diagnose and Repair

Possible Causes What to inspect or test and how to correct.

Intermittent and repeated
Voltage Drop in Heater
Power Supply.
An intermittent and
repeated voltage drop is
likely due to a loose
connection or fuse.
Failed ECU
● Check all power supply connections and lines at both ground and power for
a loose, damaged or corroded connections and make necessary repairs.
● Since this voltage drop is intermittent it may only occur when the truck is
vibrating so the bad connection may be hard to find and the power supply
must be checked very thoroughly.
● Check the Voltage Supply according to the instructions in Fault Code 11.
● After confirming the Power Supply is good by making all the checks in Fault
Code 11, clear the Fault Codes from the ECU and Perform a Function Test
to repeat the Fault Code 99.
● If the Fault Code is repeated then replace the ECU and Function Test the
Heater.
● Do not clear or erase the fault code in the old ECU if it is being
returned under Warranty.

5-120
 Section 5 – TriPace Diagnostics

12 Vdc TO 115 Vac POWER INVERTER (OPTIONAL)

Use the following table to help diagnose problems with the optional power inverter.

Digital Display Code and/or Possible Cause Solution

Condition
E01 Under Voltage (low input) Recharge the battery. Check cables and
shutdown connection if secure.
E01 Poor DC wiring and/or poor Use proper cable and make secure
with persistent low battery battery condition connections. Charge the battery or install a
alarm new battery.

E02 Over Voltage (high input) Make sure the inverter is connected to a 12
shutdown Vdc battery. Should not be connected to a
battery charger or alternator supplying above
15 Vdc.
E03 Overload shutdown Reduce the load to within the inverter’s
continuous power rating.
E04 Over temperature shutdown Allow the inverter to cool off and reduce the
Heavy load is connected then load if continuous operation is required.
AC output becomes
unavailable.
E04 Over temperature shutdown Improve ventilation and make sure the
Normal load is connected inverter’s ventilation openings are not
then AC output becomes obstructed. Reduce the ambient temperature,
unavailable. if possible.

E10 Short circuit Check the AC wiring for a short circuit.

No output voltage.
No output voltage; no voltage
indication.
The unit is on and running but
there is no AC output.
Very heavy load
Output circuit overheat
The unit is off. No power to
the inverter. Inverter fuse
open. Reverse DC polarity.
The GFCI device tripped.
Remove the load.
Turn the unit off. Let the unit cool down, check
the fan for any obstructions and clear it, or
reduce the load. Turn the unit back on.
Turn the inverter on. Check wiring to the
inverter. Have a qualified service technician
check and replace the fuse if necessary. Have
a qualified service technician check and
replace the fuse, making sure to observe
correct polarity.
Reset the GFCI.

5-121
Service Procedures
 Section 6 – TriPace Service Procedures

TABLE OF CONTENTS - SECTION 6

A02A Recording Existing Programmable Feature (Refer to Communication Using TK Monitor, A51A)
A03A Main Controller Board Removal and Replacement
A03B Replacement of the HMI Control Panel
A03D Smart Charger Module (SCM) Removal and Replacement
A03E Compressor Controller Removal and Replacement
A03F DC to DC Converter Removal and Replacement
A04A Programmable Feature Setup (Refer to Communication Using TK Monitor, A51A)
A05A Clock Set (Refer to Communication Using TK Monitor, A51A)
A06A Checking Software Revision (Refer to Communication Using TK Monitor, A51A)
A07A Performing Main Controller Cold Start (Refer to Communication Using TK Monitor, A51A)
A26A Welding on Systems Equipped with Microprocessors
A34A Operating Service Test Mode (Refer to Communication Using TK Monitor, A51A)
A46A Upgrading System Software (Refer to Communication Using TK Monitor, A51A)
A50A Data Logger
A51A Communication Using TK Monitor
A57A Power Cycle Main Controller
D01A Unit Temperature Sensor Test
D05A Checking the Air Heater Overheat Sensor and Flame Sensor
D06A Checking the Air Heater External Temperature Sensor
H04A Checking Harness Continuity
H24A Voltage Drop Test
H25A Available Voltage
H30A Performing a TriPac Air Heater Fuel Quantity Test
H31A Air Heater Diagnostics using the EDiTH Diagnostic Tool
H32A Air Heater Diagnostics using the Heater Diagnostic Unit

6-1
 Section 6 – TriPace Service Procedure A03A

Main Controller Board Removal and Replacement

Where Used
All TriPace Units

Purpose
To remove and replace the Main Controller board in the Evaporator/Control Box.

Important Notes
● System information contained in the data logger will be lost if the Main Controller is replaced. When
possible download the data logger before disconnecting the Main Controller. Refer to procedure A51A,
Communication Using TK Monitor.

● System hour meters in the new Main Controller will begin at zero hours. The hour meters cannot be reset.
When possible use TK Monitor – Dash Board to view and record the hour meter readings before
disconnecting the Main Controller. Refer to procedure A51A, Communication Using TK Monitor.

● If required, harness pins for the white Mate-N-Lock connectors may be removed using TK tool P/N 204-
1120.

Procedure
Whenever a Main Controller is replaced system software should be upgraded to Version 1.1 or higher. If the
system has already been upgraded the individual component software should be upgraded to match.
Step Action Result Comments
Main Controller Removal
1 Download data logger, record Refer to procedure A51A.
hour meter readings and
programmable feature settings.
2 Turn the unit off at the HMI. All icons and indicators should
be off.
3 Unplug the 115 Vac to 12 Vdc
Shore Power Converter if
present.

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 Section 6 – TriPace Service Procedure A03A

Step Action Result Comments

4 At the TriPace battery box fuse Disconnect battery voltage There should be no voltage to
block remove the F11 fuse. supply to the 2 terminal. any device inside the
Evaporator/Control box.
5 Remove Evaporator/Control Box
cover.
6 Beginning at the top of the
board, disconnect each plug
connector.
7 Remove the wires from the CH
terminal.
8 Remove the wire from the 2
terminal.
9 Remove six mounting screws.
Lift board from control box.
Main Controller Installation
1 Install Main Controller board with
six mounting screws.
2 Connect the 2 wire to the 2
terminal.
3 Connect the CH01 and WHT
wires to the CH terminal.
4 Beginning at the bottom of the
board, reconnect each plug
connector.
5 At the TriPace battery box fuse
block install the F11 fuse.
6 Turn the unit on at the HMI. Green LED on the Main Main Controller is going
Select Fan mode. Controller board should blink through a boot-up process.
rapidly for 60 seconds then blink
about once per second.

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 Section 6 – TriPace Service Procedure A03A
Step Action
7 Connect a PC computer to the
Main Controller and start TK
Monitor.
8 In TK Monitor – Software
Upgrade screen verify that the
system and Controller software
is the most recent revision.
9 In TK Monitor – Unit Setup select
Set Real Time Clock.
10 In TK Monitor – Service Test
select Cool Test then click Run
Test.
11 In TK Monitor – Service Test
click Cancel Test.
12 Close the TK Monitor application.
Disconnect computer from the
Main Controller.
13 Verify proper unit operation in all
modes from the HMI.
14 Install Evaporator/Control Box
cover.
P41wA03A
Result Comments
Refer to A51A.
System software should be Refer to A51A.
upgraded to Version 1.1 or
higher. If the system has already
been upgraded the individual
component software should be
upgraded to match.
Refer to A51A.
Condenser Fan, Evaporator Fan Refer to A51A. Indicates the
and Compressor should start Main Controller is
and run in high speed. communicating and able to
control system components.
Condenser fan and compressor
should stop. Evaporator fan may
continue to run because Fan was
earlier selected at the HMI.
Refer to A51A.
Determine that original
problem has been fixed.
Page 3
 Section 6 – TriPace Service Procedure A03B

Replacing the HMI Control Panel

Where Used
All TriPace Units

Purpose
This procedure is used to remove and replace the TriPace HMI Control Panel.

Procedure
Whenever an HMI is replaced system software should be upgraded to Version 1.1 or higher. If the system has
already been upgraded the individual component software should be upgraded to match.
Step Action Result Comments
HMI Removal
1 Turn the unit off at the HMI. All icons and indicators should
be off.
2 Unplug the 115 Vac to 12 Vdc
Shore Power Converter if
present.
3 At the TriPace battery box fuse Disconnect battery voltage The Main Controller and the
block remove the F11 fuse. supply to the Main Controller 2 HMI are powered down.
terminal and 2P circuit to the
HMI.
4 Place a screw driver in the The HMI will swing out and up The selector knobs do not
locking tabs on the bottom of the from the bottom. need to be removed.
HMI. Pull forward on the HMI
while applying downward
pressure on a locking tab. The
latch should release that end of
the HMI from the mounting base.
Repeat with the other locking
tab.

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 Section 6 – TriPace Service Procedure A03B

Step Action Result Comments

5 Unplug the harness connector
from the HMI.
HMI Install
1 Plug the harness into the new
HMI.
2 Place the top of the HMI onto the
mounting base.
3 Press the bottom of the HMI onto
the mounting base until the
latches click.
4 At the TriPace battery box fuse Provides battery voltage supply The Main Controller and the
block install the F11 fuse. to the Main Controller 2 terminal HMI have power available.
and 2P circuit to the HMI.
5 Turn the unit on with the HMI. Determine that original
problem has been fixed.
6 Connect a PC computer to the System software should be Refer to Communication
Main Controller and start TK upgraded to Version 1.1 or Using TK Monitor, A51A.
Monitor. Verify correct system higher. If the system has already
and component software been upgraded the individual
revision. component software should be
upgraded to match.

Page 2

P41wA03B
 Section 6 – TriPace Service Procedure A03D

Smart Charger Module (SCM) Removal and Replacement

Where Used
All TriPace Units

Purpose
To remove and replace a SCM in the Battery Box.

Procedure
Whenever a Smart Charger Module (SCM) is replaced system software should be upgraded to Version 1.1 or
higher. If the system has already been upgraded the individual component software should be upgraded to match.
Step Action Result Comments
SCM Removal
1 Turn the unit off at the HMI. All icons and indicators should
be off.
2 Remove the battery box cover.
3 Remove fuses F9 and F12 from Truck batteries have been Take care to avoid grounding
the fuse block to isolate the isolated from TriPace SCMs. your tools while removing the
SCMs from the fuse block. Indicator LEDs should turn off. fuses.
4 Disconnect the Black battery
wires and White CH03 or CH04
wires from the -CH terminal on
the SCM.
5 Disconnect the 2B or 2C wire
from the 2 SCM terminal on the
SCM.

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P41wA03D
 Section 6 – TriPace Service Procedure A03D

Step Action Result Comments

6 Disconnect the Red wires from Take care to avoid grounding
the +BATT A and +BATT B your tools when
terminals on the SCM. Note disconnecting cables.
which Red wire is connected to
which terminal or mark the wires
so they will be attached to same
terminal when reconnected.
Secure the ends of these wires
so they do not contact anything
that is grounded.
7 Remove the SCM mounting
screws from the outside of the
battery box.
8 Disconnect the CAN harness(es) The SCM in the lower battery
from the CAN connector(s) on bay has a CAN termination
the bottom of the SCM and plug in the second connector.
remove the SCM from the This must be transferred to
battery box. the replacement SCM.
SCM Installation
1 Place the SCM in the battery box The SCM in the lower battery
and connect the CAN bay requires that a CAN
harness(es) to the CAN termination plug be installed
connector(s) on the bottom of the in the second connector.
SCM. Transfer it from the replaced
SCM.
2 Place the SCM in position and
install and tighten the mounting
screws.

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P41wA03D
 Section 6 – TriPace Service Procedure A03D

Step Action Result Comments

3 Connect the Red wires to the Take care to avoid grounding
+BATT A and +BATT B terminals your tools when connecting
on the SCM. Make sure the Red cables.
wires are connected to the same
terminals from which they were
removed. It is recommended that
the +BATT A wire be connected
to the left battery.
4 Connect the 2B or 2C wire to the
2 SCM terminal on the SCM.
5 Connect the Black battery wires
and White CH03 or CH04 wires
to the -CH terminal on the SCM.
6 Install fuses F9 and F12 in the Take care to avoid grounding
fuse block. Replace the fuse your tools while installing the
covers after installing the fuses. fuses.
7 Verify the indicator LEDs on the Refer to LED Indicators,
SCMs are blinking green. SCM, Section 5.
8 Turn system on and verify proper Determine that original
operation. problem has been fixed.
9 Install the battery box cover.
10 Connect a PC computer to the System software should be Refer to Communication
Main Controller and start TK upgraded to Version 1.1 or Using TK Monitor, A51A.
Monitor. Verify correct system higher. If the system has already
and component software been upgraded the individual
revision. component software should be
upgraded to match.

Page 3

P41wA03D
 Section 6 – TriPace Service Procedure A03E

Compressor Controller Removal and Replacement

Where Used
All TriPace Units

Purpose
To remove and replace the Compressor Controller in the Evaporator/Control Box.

Procedure
Step Action Result Comments
Compressor Controller Removal
1 Turn the unit off at the HMI. All icons and indicators should
be off.
2 Remove fuse F10 from the fuse Remove power from DC to DC Take care to avoid grounding
block. Converter and Compressor your tools while removing the
Controller. fuse.
3 Remove fuse F11 from the fuse Remove power from Main Take care to avoid grounding
block. Controller. your tools while removing the
fuse.
4 Remove the Evaporator/Control
Box cover.
5 Unplug the harness connectors
from Compressor Controller
beginning at the top. Note where
they go so they will be attached
in the same places when
reconnected.
6 Disconnect the Blue (Phase A),
Orange (Phase B), and Yellow
(Phase C) wires from the three
phase output terminals.

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 Section 6 – TriPace Service Procedure A03E

Step Action Result Comments

7 Disconnect the CH02 wire from
the NEG terminal.
8 Disconnect the 28V wire from the
POS terminal.
9 Remove the mounting screws
from the Compressor Controller
and remove it from the
Evaporator/Control Box.
Compressor Controller Installation
1 Place the Compressor Controller
in the Evaporator/Control Box
and install the mounting screws.
2 Connect the 28V wire to the POS Left terminal.
terminal.
3 Connect the CH02 wire to the IMPORTANT: Make sure the
NEG terminal. lugs on the 28V and CH02
wires do not touch each
other.
4 Connect the Blue (Phase A),
Orange (Phase B), and Yellow
(Phase C) wires to the three
phase output terminals. The Blue
wire goes to the top terminal, the
Orange wire goes to the middle
terminal, and the Yellow wire
goes to the bottom terminal. See
the drawing on the next page.
5 Plug the harness connectors
onto the Compressor Controller
beginning at the bottom. Make
sure to they go to the same
places from which they were
unplugged.

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P41wA03E
 Section 6 – TriPace Service Procedure A03E

Step Action Result Comments

6 Install fuses F10 and F11 in the Take care to avoid grounding
fuse block. Replace the fuse your tools while installing the
cover after installing the fuse. fuse.
7 Operate system in cool mode. Determine that original
Verify proper unit operation. problem has been fixed.
8 Install the Evaporator/Control
Box cover.

1. Blue Wire (Phase A) 4. CH02 Wire (Negative –)

2. Orange Wire (Phase B) 5. 28V Wire (Positive +)
3. Yellow Wire (Phase C)
Compressor Controller

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P41wA03E
 Section 6 – TriPace Service Procedure A03F

DC to DC Converter Removal and Replacement

Where Used
All TriPace Units

Purpose
To remove and replace the DC to DC Converter on the Battery Box.

Procedure
Step Action Result Comments
DC to DC Converter Removal
1 Turn the unit off at the HMI. All icons and indicators should
be off.
2 Remove the battery box cover.
3 Remove fuse F10 from the fuse Remove power from DC to DC Take care to avoid grounding
block. Converter. your tools while removing the
fuse.
4 Remove terminal cover at DC to
DC Converter.
5 Disconnect the wires from the
DC to DC Converter.
6 Remove the DC to DC Converter
mounting hardware from the
outside of the battery box.
DC to DC Converter Installation
1 Place the DC to DC Converter in
position and install the mounting
hardware.
2 Connect the wires to the DC to Refer to diagram on next
DC Converter and apply page.
Superlube (P/N 203-524) to the
connections.

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P41wA03F
 Section 6 – TriPace Service Procedure A03F

Step Action Result Comments

3 Install terminal cover at DC to
DC Converter.
4 Install fuse F10 in the fuse block. Provides power to DC to DC Take care to avoid grounding
Replace the fuse cover after Converter. your tools while installing the
installing the fuse. fuse.
5 Operate system in cool mode. Determine that original
Verify proper operation. problem has been fixed.
6 Install the battery box cover.

1 2 3 4

1. 28 Vdc Output Terminal 3. CH (Ground) Terminal

2. 12 Vdc Input Terminal 4. CVEN Enable/Disable Push On Terminal
DC to DC Converter

Page 2

P41wA03F
 Section 6 – TriPace Service Procedure A26A

Welding on Systems Equipped with Microprocessors

Where Used
All TriPace Units

Purpose
To prevent damage to the base controller during welding operations

Materials Required
● None

Operation
Electric welding generates high amperage currents that can damage electrical and electronic components. In
order to minimize the possibility of damage the following procedures should be followed.

Before Welding
Step Action Result Comments
1 Turn the unit off.
2 Remove the TriPace 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.

Page 1
P41wA26A
 Section 6 – TriPace Service Procedure A26A

After Welding
Step Action Result Comments
1 Reconnect the battery cables.
2 Turn the unit off.
3 Start and run the unit to verify
operation.

Page 2
P41wA26A
 Section 6 – TriPace Service Procedure A50A

Data Logger
This is a function of TK Monitor. Refer to Communication Using TK Monitor, A51A.

There is a data logger built into the TriPace controller. It logs the system operating condition every five minutes
and should contain about 30 days of information. This information may be downloaded and saved using TK
Monitor.

At this time these downloads are being used by Thermo King to better understand customer use and system
operation. TK Monitor does not currently have the ability to display this data. Downloads can be attached to an
email and sent to the Minneapolis Service Department for evaluation. Contact David Palm at 952-887-2353
before sending downloads.

Page 1
P41wA50A
 Section 6 – TriPace Service Procedure A51A

Communication Using TK Monitor

Where Used
All TriPace Units

Purpose
External communication with the Main Controller is available through the TK Monitor interface. It will use the USB
plug (J39) on the Main Controller board and a TK Monitor Adapter Harness (P/N 204-1926). Communication will
require the use of an IBM compatible PC computer with Microsoft Internet Explorer 8.0 or higher. TK Monitor
communication software is in the Main Controller and will export information to the computer. No additional
software must be installed on the computer to retrieve and view this information. It will provide system interface,
flashload system upgrades, real time system information retrieval, Service Test Mode and Alarm clearing
capabilities.

Menus
The Main TK Monitor home screen will display the following menu choices on the left side of the TK Monitor
screen:

Dashboard

Provides the technician quick access to basic operating information such as hourmeters, system temperatures,
battery status, SCM mode and alarm status. It displays current HMI settings and allows the technician to change
operating modes without access to the HMI. It may also initiate a Data Logger Download.

Software Upgrade

Allows software upgrades to be flash loaded into the Main Controller, SCMs or HMI. TK Monitor software can also
be upgraded through this menu. The currently installed software revisions will be listed. For detailed information
about specific System Software Upgrades refer to the Service Bulletin published at the time of software release.

System Monitoring

The TriPace system is based on controlling power flow and communication between system components. System
Monitoring provides the technician with detailed real time system information to evaluate this power and
information flow. This expanded system information can be helpful when diagnosing system issues. System

Page 1

P41wA51A
 Section 6 – TriPace Service Procedure A51A

Monitoring used in combination with Service Test can provide diagnostic information based on known operating
conditions.

System Monitoring is divided into three sections. They can be selected using the buttons across the top of the
information box. Red numbers indicate values that are changing.

HMI & Controller

This screen provides HMI status along with Unit voltage and amperage levels.

HVAC
This screen displays information about the climate control system components. This includes temperature
sensors, fan speeds, compressor information, fault conditions and control outputs to the heater.

SCM Batteries
The SCMs and batteries are central to the operation of the system. A large amount of information is displayed
about general system power. Detailed information about the status of each SCM and battery is also displayed.

Service Test Mode

Service Test Mode is accessible through TK Monitor. It allows the technician the ability to force the system into a
specific operating mode for up to 15 minutes. This ability can be helpful when diagnosing system issues.
Available modes are; Cool, Heat, Null, Fan Only, Battery Charging, Battery Discharging and Battery Null. The
current test must be canceled before selecting a new one. If a Service Test is initiated while the system is running
the current operation will terminate and the selected mode will begin.

Once selected, a test will be active for 15 minutes. “Running Service Test” will display in the upper right of the
screen while a test is active. Once a test is selected the “Run Test” button will change to “Cancel Test”. To
change to a new test the current test must first be canceled. If the test is not canceled before the timer has
expired, an alarm code 54 shutdown will generate. If a shutdown alarm occurs during the test the unit will record
the alarm, exit Service Test Mode and shut down. When the alarm is cleared the unit will return to operation with
the settings stored prior to entering Service Test Mode. Following is a description of the available modes.

While operating in a Service Test Mode the System Monitor screens are available. This will allow the technician to
gather real time diagnostic information. Shutdown alarms are still actively protecting the system.

NOTE: Operator should wait for system response before selecting new setting or changing to a new screen.

Cool Test: The DC to DC Converter is turned on. The compressor, evaporator fan and condenser fan are turned
on. They will be set to 100%. Setpoint and cab temperature are not monitored. The evaporator coil anti-frost
algorithm is disabled.

Page 2

P41wA51A
 Section 6 – TriPace Service Procedure A51A

Heat Test: The Main Controller heat output is turned on. Setpoint is set to maximum. If cab temperature is higher
than the maximum setpoint (80º F [27º C] in 3100, 95º F [35º C] in 3101) the heater will not start.

Fan Only Test: Evaporator fan on and set to 100%. Fan speed can be changed at the HMI. Other HVAC
functions are disabled.

Battery Charging Test: Individual SCM and battery can be set to Charge Mode. A dropdown list will allow
selection of the active battery. The LEDs on the SCM should indicate the active battery is in Charge Mode. The
inactive batteries should be in Null Mode. Current will be allowed to flow through the SCM into the active battery
but not out. The truck ignition switch must be on or Shore Power Charging enabled with the AC to DC Converter
plugged-in.

Battery Discharging Test: Individual SCM and battery can be set to Discharge Mode. A dropdown menu will
allow selection of the active battery. The LEDs on the SCM should indicate the active battery is in Discharge
Mode. The inactive batteries should be in Null Mode. Current will be allowed to flow through the SCM out of the
active battery but not in. System functions may be activated using the HMI.

Battery Null Test: The SCMs are set to Null Mode. The TriPace batteries are isolated from the system. Current
should not flow in or out of the batteries through SCMs.

Alarm

Allows the technician to view and clear alarms. Alarms that are not clearable from the HMI can be cleared through
the Alarm menu. The menu will indicate the level of each alarm. It will also allow alarms to be cleared individually
or as a complete list.

Unit Setup

Provides access to unit configuration settings and programmable features. Also allows system time to be set.
Time will be set to match the connected computer.

Tools

There is a technician access Tools Menu that does not display in the TK Monitor standard screens. It provides
access to advanced system functions.

NOTE: During normal system monitoring and diagnosis it is not necessary to enter this menu.

Access
While in TK Monitor press and hold the Ctrl-Shift-T keys together. An additional item labeled Tools will appear in
the menu on the left. Selecting this item will open the Tools screen.

Page 3

P41wA51A
 Section 6 – TriPace Service Procedure A51A

Restart
Warm Restart: Performing a Warm Restart will reboot the Main Controller. This is a “soft” restart that is
equivalent to power cycling the Main Controller (removing power from #2 terminal). Hour meters, data logger and
programmable settings are retained. A Warm Restart may be required after installing a software update.

Cold Restart: Performing a Cold Restart will reboot the Main Controller and reset all software parameters to their
default setting. Data logger information will be lost. Programmable settings will return to default value. Hour
meters are retained. Before performing a Cold Restart the programmable feature settings should be recorded and
data logger downloaded if possible.

Connect To TK Monitor
Step Action
1 Remove Compressor cover from
the Evaporator/Control Box
2 Connect the TK Monitor Adapter
Harness (P/N 204-1926) to the
J39 plug on the Main Controller.
3 Turn system on at HMI.
4 Verify the green LED indicator on
the Main Controller is flashing.
5 Start the PC computer. Delete
Temporary internet Files from
computer.
6 Connect the TK Monitor Adapter
Harness to a USB port on the
computer.
7 Use “My Computer” or “Windows
Explorer” to locate and open the
new data drive.
Result
Wait for selected mode icon to
stop flashing.
Should be flashing about once
per second.
The computer will recognize the
TriPace system as a new
external data drive.
Comments
Leave the Evaporator Coil
cover in place.
Do not connect to PC
computer at this time.
If LED is flashing rapidly the
Main Controller is restarting
after a loss of power. After 60
seconds the rate should
return to normal.
Wait for the computer to
complete the startup process.
Usually drive letter “E” named
TK Monitor.

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 Section 6 – TriPace Service Procedure A51A

Step Action Result Comments

8 In the new drive locate and open
the AUTORUN.BAT file.
An Internet Explorer window
should open and display the TK
Monitor screen.
The computer does not need
to be connected to the
Internet. AUTORUN.BAT
should be the first of the three
autorun files.

Adapter Harness (P/N 204-1926) Main Controller Connection (J39)

Disconnect From TK Monitor

Step Action Result Comments
e
1 If operating in Service Test Mode Returns TriPac system to
select Cancel Test in the Service normal operation.
Test screen.
2 Exit TK Monitor by closing the Terminates communication with
Internet Explorer window. the TriPace system.
3 Disconnect the Adapter Harness TK Monitor data drive will
from the computer. terminate.
4 Disconnect the Adapter Harness
from the Main Controller.
5 Shutdown the PC computer.
6 Replace the Evaporator/Control
Box cover.
7 Verify proper unit operation.

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P41wA51A
 Section 6 – TriPace Service Procedure A51A
View and Clear Alarms
Step Action
1 Connect to TK Monitor.
2 In the menu on the left side of
the TK Monitor screen select
Alarm.
3 Record the listed alarms.
4 Clear individual alarms by
selecting a Clear button in the
Action column.
5 Clear all alarms by selecting the
Clear All button.
6 Alarms have been cleared.
P41wA51A
Result Comments
Alarm screen should open. It will If there are no alarms the
display the Alarm Code, Type screen will show “No Active
and Title of the active alarms. Alarms”. The grid will not
display.
Refer to Alarm Code
Diagnosis, Section 5.
The alarm will be removed from
the list.
Select a new function from the
left menu or refer to Disconnect
From TK Monitor.
Page 6
 Section 6 – TriPace Service Procedure A51A

Record or Setup Programmable Features

Step Action Result Comments
1 Connect to TK Monitor.
2 In the menu on the left side of Unit Setup screen should open.
the TK Monitor screen select
Unit Setup.
3 Note the software feature If correct: select a new function Refer to Software
settings. from the left menu or refer to Description, Section 3.
Disconnect From TK Monitor.

If incorrect: proceed to next step.

4 To change setting: Do not select Save Setup
Select the desired setting. until all desired changes have
been selected.
5 Note Real Time Clock. If correct: proceed to next step.

If incorrect: refer to Set System

Clock.
6 Select Save Setup The system will perform a Warm The internet Explorer window
Restart to initialize the saved should close.
settings.

Main Controller will exit TK

Monitor.
7 Disconnect the Adapter Harness Refer to Disconnect From TK
from the computer. Monitor steps 4 – 7.

Page 7

P41wA51A
 Section 6 – TriPace Service Procedure A51A
Set System Clock
Step Action
1 Connect to TK Monitor.
2 In the menu on the left side of
the TK Monitor screen select
Unit Setup.
3 Note Real Time Clock.
4 Select the check box next to Set
Real Time Clock.
5 Select Save Setup
6 Disconnect the Adapter Harness
from the computer.
Check Software Revision
Step Action
1 Connect to TK Monitor.
2 In the menu on the left side of
the TK Monitor screen select
Software Upgrade.
3 Under Current Version, note the
installed component software
revisions.
At the bottom of the screen, note
the installed TK Monitor revision.
P41wA51A
Result Comments
Unit Setup screen should open.
If correct: select a new function
from the left menu or refer to
Disconnect From TK Monitor.
If incorrect: proceed to next step.
The Real Time Clock will be Refer to Software
reset to match the connected Description, Section 3.
computer.
The system will perform a Warm The Internet Explorer window
Restart to initialize the new time. should close.
Main Controller will exit TK
Monitor.
Refer to Disconnect From TK
Monitor steps 4 – 7.
Result Comments
Software Upgrade screen should
open.
If correct: select a new function Refer to Software
from the left menu or refer to Description, Section 3.
Disconnect From TK Monitor.
If incorrect: proceed to Upgrade
System Software.
Page 8
 Section 6 – TriPace Service Procedure A51A
Upgrade System Software
Step Action
1 Download software upgrade file
from Info Central.
2 Connect to TK Monitor.
3 In the menu on the left side of
the TK Monitor screen select
Software Upgrade.
4 Verify current software revisions
to determine if a software
upgrade is required.
5 Under Select The File For
Upgrade select the Browse
button.
6 Open the selected software
upgrade file.
7 Select “Start Flashload”. “Flash
loading in progress” will display
in the upper right of the screen.
8 A prompt will display telling you
that TK Monitor has been
disconnected.
P41wA51A
Result Comments
Save software upgrade file to the Recommendation: Create a
PC computer. When the zip file file folder dedicated to TriPace
is expanded it will create new software upgrade files.
files: app.bin, hmi.bin, scm.bin
and pcmonz.bin. They are the
actual flash load files.
Software Upgrade screen will
open.
A file search dialog box will Note: Only the software for
open. one component; Main
Controller, HMI, SCM or TK
Locate the software upgrade file
Monitor can be flash loaded
saved in step 1.
at one time. When flash
loading multiple upgrades, TK
Monitor (pcmonz.bin) should
be done first.
A “File Validation Successful”
window should open. Select OK.
Green LED on Main Controller Flash load should take 20 to
may flash rapidly. The LEDs on 45 seconds for pcmonz, app
the SCMs will flash Red/Green and hmi.bin. SCM.bin will
during SCM flash load. take about 4 minutes.
The TK Monitor window will still
display but is not connected to
the Main Controller.
Page 9
 Section 6 – TriPace Service Procedure A51A

Step Action Result Comments

9 Close the TK Monitor window.
Restart TK Monitor to verify
updated revision.
10 Repeat steps 5 – 9 until all
upgrades have been flash
loaded.
11 Perform a Cold Restart after all
upgrades have been flash
loaded.
12 Close TK Monitor or continue
with other tasks.
Note: If HMI software was Refer to Connect To TK
updated the HMI will Monitor.
automatically be turned off.
System must be turned back on
at the HMI.
Refer to Main Controller Cold
Restart.
Refer to Disconnect From TK
Monitor.

Page 10

P41wA51A
 Section 6 – TriPace Service Procedure A51A

Operate Service Test Mode

Step Action
Enter Service Test Mode
1 Connect to TK Monitor.
2 In the menu on the left side of
the TK Monitor screen select
Service Test.
3 From the list select the desired
test.
4 Select the Run Test button.
View System Information During Service Test
1 Enter Service Test Mode
2 In the menu on the left side of
the TK Monitor screen select
System Monitoring.
Result
Service Test screen will open.
The system should operate in
the selected test mode.
“Running Service Test” will
appear in the upper right of the
screen.
The screen will open.
“Running Service Test” will
appear in the upper right of the
screen.
Comments
For details of test function
refer to Service Test Mode in
the description above.
System will operate in
selected mode for 15
minutes. Alarm code 54
shutdown will then generate.
All sections of System
Monitoring are available and
displaying current
information.

System will continue to operate

in the selected test mode.
3 In the menu on the left side of Returns to the Service Test
the TK Monitor screen select when done reviewing
Service Test. information.

Page 11

P41wA51A
 Section 6 – TriPace Service Procedure A51A
Step Action
Change Test or Exit Service Test Mode
1 In the menu on the left side of
the TK Monitor screen select
Service Test.
2 Select the Cancel Test button.
3 To exit Service Test screen: In
the menu on the left side of the
TK Monitor screen select a new
function.
4 To change to a new test: From
the list select the desired new
test.
5 Select the Run Test button.
P41wA51A
Result
Returns to the Service Test
when done reviewing
information.
The currently running test is
terminated.
The system should operate in
the selected test mode.
“Running Service Test” will
appear in the upper right of the
screen.
Page 12
Comments
System will return to normal
operation.
Exiting the Service Test
screen will not terminate a
running test. Refer to step 2.
A running test must be
terminated before a new test
can be started. Refer to step
2.
System will operate in
selected mode for 15
minutes. Alarm code 54
shutdown will then generate.
 Section 6 – TriPace Service Procedure A51A
Main Controller Cold Restart
Step Action
1 Connect to TK Monitor.
2 Press the Ctrl + Shift + T keys
together.
3 In the menu on the left side of
the TK Monitor screen select
Tools.
4 Select Cold Restart
5 Select the Restart button.
6 Reconnect to TK Monitor.
7 Reset programmable settings.
8 Verify proper system operation.
9 Exit TK Monitor by closing the
Internet Explorer window.
10 Disconnect the Adapter Harness
from the computer.
P41wA51A
Result
In the menu on the left side of
the TK Monitor screen Tools will
be added to the menu list.
Main Controller will exit TK
Monitor.
Terminates communication with
the TriPace system.
Page 13
Comments
A Cold Restart will reboot the
Main Controller and reset all
software parameters to their
default setting. Data logger
information will be lost.
Close the Internet Explorer
window.
Refer to Record or Setup
Programmable Features.
Refer to Disconnect From TK
Monitor steps 3 – 7.
 Section 6 – TriPace Service Procedure A51A
Download Data Logger
Step Action
1 Connect to TK Monitor.
2 In the Dash Board screen locate
the Data Logger box.
3 Select the Download button.
4 Wait 20 – 45 seconds.
5 “File Download” box will display.
Select Save.
6 A “Save As” box will display.
Choose a file name and save
location.
7 System Restart box will appear.
Select OK.
8 Close the TK Monitor window.
9 Re-launch TK Monitor or
disconnect computer.
P41wA51A
Result
Button will turn gray.
Data is being downloaded.
Rename file with a short
descriptive name with no spaces.
File extension must remain .bin.
Save to a location that you can
find again.
Controller will perform a Warm
Restart.
Page 14
Comments
Wait for screen information to
refresh before proceeding.
Recommendation: Create a
dedicated Download folder.
Default file name is
DATALOG.bin.
TK Monitor window will
remain open but is no longer
communicating with Main
Controller.
Refer to Connect To TK
Monitor steps 7 and 8.
Refer to Disconnect From TK
Monitor steps 3 – 7.
 Section 6 – TriPace Service Procedure A57A

Power Cycle Main Controller

Where Used
All TriPace Units

Purpose
This procedure is used to remove power from the TriPace Main Controller to cause a system reset.

Procedure
Step Action
1 Turn the unit off at the HMI.
2 Unplug the 115 Vac to 12 Vdc
Power Converter from shore
power if present.
3 At the TriPace battery box fuse
block, disconnect the RED cable
attached to the bus bar. This
cable comes from the truck
batteries.
CAUTION: Do not allow this
terminal to touch ground.
4 Reconnect the RED cable to the
fuse block terminal.
5 Turn the unit on at the HMI.
Result Comments
All icons and indicators should
be off.
Disconnects battery voltage The Main Controller, HMI and
supply to the Main Controller 2 SCMs are powered down.
terminal, 2P circuit to the HMI SCM LEDs and Green LED
and 2 SCM terminals on both on the Main Controller should
SCMs. be off.
Reconnects battery voltage LEDs on the SCMs should
supply to the Main Controller 2 begin flashing green.
terminal, 2P circuit to the HMI
and 2 SCM terminals on both
SCMs.
NOTE: There will be a spark
when the cable is reconnected.
Selected mode icon should flash.

Page 1

P41wA57A
 Section 6 – TriPace Service Procedure A57A

Step Action Result Comments

6 Check green LED on the Main
Controller.
7 Check HMI display.
8 Check system operation.
● Will flash twice per second ● Main Controller is
for about 60 seconds. resetting. Main Controller
● After a successful reset the will not communicate with
green LED will flash once the HMI, SCMs or TK
per second. Monitor during reset.
● The Main Controller may
now communicate.
● Mode icon should stop
flashing.
● Battery monitor should
display.
● System should start in
selected mode.

Page 2

P41wA57A
 Section 6 – TriPace Service Procedure D01A

Unit Temperature Sensor Test

Where Used
All TriPace Units

Purpose
To confirm the proper operation of the unit temperature sensors and circuits.

Materials Required
Quality digital multimeter capable of reading DC volts and ohms.

Operation
The system sensors are thermistor type that change resistance as the temperature changes. They are not polarity
sensitive. Resistance values can be measured using a high quality ohmmeter. Value may be compared to a table
to directly determine the represented temperature. The following table represents normal sensor resistance value
vs. temperature.

Sensor Resistance vs Temperature

ºF ºC Ohms
-20 -29 166,356
-10 -23 115,757
0 -18 86,501
10 -12 61,737
20 -7 47,070
30 -1 34,374
32 0 32,650
40 4 26,688
50 10 19,904
60 16 15,002
70 21 11,994
80 27 9,166
90 32 7,402
100 38 5,775

Page 1

P41wD01A
 Section 6 – TriPace Service Procedure D01A

Return Air Sensor

This sensor monitors the temperature of the air returning to the evaporator coil. The sensor is located in the return
air flow and is connected directly to the Main Controller connector J35 pins 1 and 6. The Return Air Sensor is
connected to the Main Controller via the BLK wires. J35 pin 1 should output 2.5 Vdc.

Ambient Air Sensor

This sensor monitors the outside air temperature. The sensor is located on the condenser coil housing and is
connected directly to the Main Controller connector J59 pins 3 and 4. The Ambient Air Sensor is connected to the
Main Controller via the WHT wires. J59 pin 3 should output 2.5 Vdc.

Evaporator Coil Sensor

This sensor monitors the temperature of the evaporator coil. The sensor is located in the Evaporator coil and is
connected directly to the Main Controller connector J35 pins 3 and 8. The Evaporator Coil Sensor is connected to
the Main Controller via the YEL wires. J35 pin 3 should output 2.5 Vdc.

Sensor Failure
A failure is defined by an out of range sensor reading that is greater than 170º F (77º C) or less than -38º F (-39º
C). This is typically caused by an open or shorted sensor or sensor circuit. If this occurs the alarm code for that
sensor will be set. Use TK Monitor to check the sensor reading and clear the alarm.

A sensor that is reading high will have abnormally high resistance in the circuit. An open or disconnected sensor
circuit will read DISABLED in TK Monitor and generate a sensor alarm.

A sensor that is reading low will have abnormally low resistance in the circuit. It may be shorted. A shorted or
bypassed sensor circuit will read about 30º F in TK Monitor and will not generate a sensor alarm.

Page 2

P41wD01A
 Section 6 – TriPace Service Procedure D01A
Diagnostic Procedure
Step Action
1 Locate the plug connector for the
sensor. Disconnect the sensor to
be tested from the Main
Controller.
2 Using a high quality meter check
the resistance of the sensor
harness and sensor.
3 If circuit resistance is normal,
check continuity from each wire
to chassis ground.
4 If circuit resistance is not normal,
disconnect and bypass the
sensor and retest.
5 If the sensor harness and sensor
resistance is normal place a
voltmeter on the sensor
terminals of the plug on the Main
Controller board.
P41wD01A
Result
The resistance should match the
table.
The meter should read OL.
If resistance is near 0 ohms
replace the sensor. If resistance
is high or reads OL, then test
and repair the harness as
required. See Service Procedure
H04A for additional information.
If output voltage is 2.5 Vdc retest
harness.
If output voltage is near 0 Vdc
the Main Controller is defective.
Page 3
Comments
Refer to Plug Pinout and
Location Diagrams in Section
2, Hardware Description.
This verifies a complete
sensor circuit and checks the
accuracy of the sensor.
This verifies that the circuit is
not shorted to chassis
ground.
This isolates a defective
harness from a defective
sensor.
This verifies the Main
Controller sensor circuit has
power and ground.
Refer to Plug Pinout and
Location Diagrams in Section
2, Hardware Description.
 Section 6 – TriPac Service Procedure D05A

Checking the Air Heater Overheat Sensor and Flame Sensor

Where Used
All TriPac Air Heaters

Purpose
To confirm the proper operation of the TriPac Air Heater Overheat Sensor and Flame Sensor

Materials Required
• Fluke Digital Multi-meter.

TriPac Air Heater Over-heat Sensor and Flame Sensor

These sensors change resistance as the temperature changes. The tables at the back of this procedure show the
minimum and maximum resistance (in Ω) at specific temperatures (in degrees F and C) for the Overheat Sensor
and Flame Sensor. The resistance can be measured directly using a high quality multi-meter.

Sensor Assembly Both sensors are part of a common assembly located at the rear of the heater body behind
the glow pin. To access the sensors, open the heater housing and remove the control unit. The sensor leads are
routed to connectors on the control unit. To replace the sensors, release the wire sensor clamp and remove the
sensors.

Sensor Connectors There are three wires terminated in two connectors at the control unit. The green and
brown wires terminate at a green connector shell and are connected to the flame sensor. The brown wire is
common to both sensors. The single blue wire terminates at a blue connector shell.

Diagnostic Procedure
Step Action Result Comments
1 Remove the heater cover and
remove the control unit.

2 Disconnect the sensor to be

tested from the control unit.

Page 1
P41VD05A
 Section 6 – TriPac Service Procedure D05A

3 Using a high quality meter, check
the sensor resistance.
To measure the Overheat Sensor
measure between the
brown/white wire and the blue
wire.
To measure the Flame Sensor
measure between the brown wire
and the green wire.
The sensor resistance is Be sure to consult the correct
dependant on the sensor table for resistance values.
temperature as shown by the two
tables at the back of this
procedure. The measured
sensor resistance should
approximate the value shown for
that sensor temperature (within 5-
10%).

4 If the resistance measured in the

previous step is correct the
control unit may be defective. If
the resistance measured is not
correct replace the sensor.

5 When reattaching the sensor

connectors to the control unit, the
green connector is attached to
the center port on the control unit.
The blue connector is attached to
the other small port. The glow
pin is attached to the large port.

Page 2
P41VD05A
 Section 6 – TriPac Service Procedure D05A

Resistance Values vs. Temperature, Overheat Sensor

Temp °F Temp °C Minimum Resistance in Ω Maximum Resistance in Ω
-40 -40 1597.00 kΩ 1913.00 kΩ
-4 -20 458.80 kΩ 533.40 kΩ
32 0 154.70 kΩ 175.50 kΩ
68 20 59.30 kΩ 65.84 kΩ
104 40 25.02 kΩ 28.04 kΩ
140 60 11.56 kΩ 13.16 kΩ
176 80 5.782 kΩ 6.678 kΩ
212 100 3.095 kΩ 3.623 kΩ
248 120 1.757 kΩ 2.081 kΩ
284 140 1.050 kΩ 1.256 kΩ
320 160 655 Ω 792 Ω
356 180 425 Ω 518 Ω
392 200 285 Ω 351 Ω

Resistance Values vs. Temperature, Flame Sensor

Temp °F Temp °C Resistance (Ω) Minimum Resistance (Ω) Maximum
-40 -40 825.90 Ω 859.60 Ω
-4 -20 903.20 Ω 940.00 Ω
32 0 980.00 Ω 1020.00 Ω
68 20 1056.40 Ω 1099.50 Ω
104 40 1132.30 Ω 1178.50 Ω
140 60 1207.80 Ω 1257.10 Ω
176 80 1282.80 Ω 1335.10 Ω
212 100 1357.40 Ω 1412.80 Ω
248 120 1431.50 Ω 1489.90 Ω
284 140 1505.10 Ω 1566.60 Ω
320 160 1578.30 Ω 1642.80 Ω
392 200 1723.40 Ω 1793.70 Ω
464 240 1866.60 Ω 1942.80 Ω
536 280 2008.10 Ω 2090.00 Ω
608 320 2147.70 Ω 2235.40 Ω
680 360 2285.50 Ω 2378.80 Ω
752 400 2421.50 Ω 2520.30 Ω

Page 3
P41VD05A
 Section 6 – TriPac Service Procedure D06A

Checking the Air Heater External Temperature Sensor

Where Used
All TriPac Air Heaters

Purpose
To confirm the proper operation of the TriPac Air Heater External Temperature Sensor

Materials Required
• Fluke Digital Multi-meter.

TriPac Air Heater External Temperature Sensor Resistance Values vs Temperature

The TriPac Air Heater External Temperature Sensor changes resistance as the temperature changes. The
following table contains data for the minimum and maximum resistance (in Ω) at specific temperatures (in degrees
F and C) for the External Temperature Sensor. The resistance can be measured directly using a high quality
multi-meter.

Diagnostic Procedure
Step Action Result Comments
1 To isolate the External Sensor
circuit disconnect the Heater
Harness Connector near the
heater and Heater Control
Connector (J54) on the Main
Controller.

2 Using a high quality digital

multimeter, check the sensor
resistance from Heater Control
Connector (J54) pin 5
(BRN/WHT) to pin 7 (GRY).

Page 1
P41VD06A
 Section 6 – TriPac Service Procedure D06A

Step Action Result Comments

3 The sensor resistance is
dependant on the sensor
temperature as shown by the
table on the following page. The
measured sensor resistance
should approximate the value
shown for that sensor
temperature.
4 If the sensor resistance does not
match the values shown in the
table within + 10% the sensor is
defective and must be replaced.

Page 2
P41VD06A
 Section 6 – TriPac Service Procedure D06A

SENSOR TEMPERATURE vs RESISTANCE IN OHMS

TEMPERATURE RESISTANCE IN OHMS

°C °F MIN. TYP. MAX.
-55 -67 952 980 1009
-50 -58 1000 1030 1059
-40 -40 1105 1135 1165
-30 -22 1218 1247 1277
-20 -4 1338 1367 1396
-10 14 1467 1495 1523
0 32 1603 1630 1656
10 50 1748 1772 1797
20 68 1901 1922 1944
25 77 1980 2000 2020
30 86 2057 2080 2102
40 104 2217 2245 2272
50 122 2383 2417 2451
60 140 2557 2597 2637
70 158 2737 2785 2832
80 176 2924 2980 3035
90 194 3118 3182 3246
100 212 3318 3392 3466
110 230 3523 3607 3691
120 248 3722 3817 3912
125 257 3815 3915 4016
130 266 3901 4008 4114
140 284 4049 4166 4283
150 302 4153 4280 4407

Page 3
P41VD06A
 Section 6 – TriPac Service Procedure 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.

Materials Required
• Fluke Digital Multi-meter or equivalent

FLUKE 23 MULTIMETER

OFF V
V

300mV

A
A

10A VW

300mA COM

Cautions
• Do not use battery and light combinations to check continuity. Using such devices might present
excessive voltage or current to solid state devices. In most cases the device will be damaged or
destroyed.

• Use a high quality digital multimeter such as that illustrated or an analog meter with high input
impedance. Older analog (needle type meter movement) meters and some inexpensive "mechanic tool
box" meters present a large load to the circuit being tested. This can significantly alter the meter reading,
especially when measuring small voltages or currents.

• Never test a circuit to see if it is energized by tapping the circuit wire to ground and watching for a
spark. This will damage solid state components or blow a fuse or circuit.

Page 1
P41VH04A
 Section 6 – TriPac Service Procedure H04A
Step Action
General Procedures
1 Locate the suspect circuit on the
appropriate electrical schematic
diagram.
2 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.
3 Using jumpers as required,
connect each end of the circuit
to a high quality multimeter.
4 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.
P41VH04A
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 Be certain the ohmmeter
very low resistance (less than battery is good and the meter
1.0 ohm), indicating circuit zeros with the leads held
continuity. If not, the circuit is together.
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.
Page 2
 Section 6 – TriPace Service Procedure H24A

Voltage Drop Test

Where Used
All TriPace Units

Purpose
This test is used when diagnosing a circuit that is suspected of having high resistance. High resistance in a circuit
may cause a device to be slow or weak by reducing the voltage and amperage available to the device
experiencing the problem. High circuit resistance may also prevent batteries from supplying sufficient current or
properly charging.

The Voltage Drop Test is used to locate resistance in a circuit without disassembling connections. Dirty, corroded
or loose terminals or cable connections add unwanted resistance to the circuit. The Voltage Drop Test can be
used to test a single connection point such as a single wire or cable terminal, plug connection or switch contact. It
can also be used to check an entire circuit for high resistance. The Voltage Drop Test can also be used to locate
high resistance in ground circuits.

Test Applications
● Battery connections

● Battery cables

● Control circuits

● Resisted ground

● Control points (switch contacts, relay contacts, fuses

● Long circuits (voltage at A – voltage at B = voltage drop)

Test Conditions
To measure Voltage Drop the circuit must have current flowing. Make sure the circuit being tested is:

● Complete: A circuit that is disconnected or open has no current flowing and will not show voltage drop.

● Powered: A circuit that is not on or does not have voltage available will not show voltage drop.

● Loaded: The circuit being tested must have an operating load. This may be a solenoid coil, relay coil,
motor, resistor or other electrical load. The load must be on and trying to work during the test.

Page 1

P41wH24A
 Section 6 – TriPace Service Procedure H24A

Test Procedure #1
Used when testing a single electrical connection, component or circuit with ends that can be reached with the
leads attached to the multimeter. This is the preferred procedure because the reading can be taken in one step.

● Power the circuit. (For this test to work, the circuit must be complete, powered and trying to do work.)

● Set the meter for Vdc.

● Connect your meter leads in parallel with the circuit or component being tested, as shown in the example.

● Connect the red lead to the power side of the circuit or component being checked.

● Connect the black lead to the ground side of the circuit or component being checked.

● Read the meter.

Test Procedure #2
Used when testing long circuits that cannot be reached by the leads attached to the multimeter.

● Power the circuit. (For this test to work, the circuit must be complete, powered and trying to do work.)

● Set the meter for Vdc.

● Make an Available Voltage reading at the end of the circuit segment being tested that is nearest to the
power source. Record reading “A”.

● Make an Available Voltage reading at the end of the circuit segment being tested that is nearest to
ground. Record reading “B”.

● Subtract reading B from reading A. The difference is the Voltage Drop between the test points.

Page 2

P41wH24A
 Section 6 – TriPace Service Procedure H24A

Results
● In a normal circuit a single wire connection, switch contact, relay contact or circuit segment should drop
less than 0.5 Vdc.

● In a normal circuit the entire circuit from battery to operating load should drop less than 10% of source
voltage. This should be the same for the ground side from the load back to the battery.

● Voltage Drop through the operating load in a circuit should be very close to source voltage. The operating
load could be devices like an electric motor, resistor, solenoid or relay coil.

The Volt Drop Test can also be used to locate high resistance in the ground circuit.

REMINDER: Only the device or load that is trying to do work should have volt drop near source voltage.

TIP: To perform the Volt Drop Test the circuit must be complete, powered and trying to work.

Page 3

P41wH24A
 Section 6 – TriPace Service Procedure H25A

Available Voltage

Where Used
All TriPace Units

Purpose
This test is used to see how much voltage is available at specific points in a circuit. Available voltage is probably
the most common electrical diagnostic test. It is a quick, easy test to perform that provides helpful data to
determine the next steps in a diagnostic process.

Typical Uses
The primary purpose of this test is to find open faults in circuits.

Choose this test first whenever a device is not working at all.

This test may be part of a Voltage Drop test when hunting for unwanted resistance in a circuit.

Choosing a Test Point

Use a schematic diagram to determine how the circuit works and choose the best test point. Possible test points
are:

● At the component if it is a single problem

● At the common point if there are multiple problems

● The easiest to reach location that gives the best information

● Experience will guide you to likely test points.

Power Circuit Test

Procedure

Connect your volt meter between a good chassis ground and the test point you have chosen.

This example shows a fuel solenoid circuit.

● Energize the circuit you are testing.

● Set your meter to read Vdc.

Page 1

P41wH25A
 Section 6 – TriPace Service Procedure H25A

● Connect the black lead from your meter to a good chassis ground.

● Connect the red lead from your meter to the power side of the device. In this example your red meter lead
would be positioned the same as the solid red arrow shown below.

● Read the available voltage on the meter.

Result

Battery voltage = complete power circuit

0 Vdc = open power circuit

Any reading above 0 Vdc but less than battery voltage = high resistance in the power circuit.

Ground Circuit Test

The ground circuit can also be checked. If the component does not have a good ground, it will not work properly.

Procedure

First, verify that there is voltage reaching the component as described earlier. If there is adequate voltage on the
power side, then:

● Place the red meter lead on the ground terminal of the component. Your red lead would be positioned the
same as the dotted red arrow in the example.

● Connect the black lead from your meter to a good chassis ground.

● Read the voltage on the meter.

Result

0 Vdc = open component

Battery voltage = open ground

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 Section 6 – TriPace Service Procedure H25A

Any reading above 0 Vdc but less than battery voltage = high resistance in the ground circuit.

REMINDER: In a normal circuit the component will use up all the volts. If volts are left over, there is an additional
unwanted resistance in the ground that is using the remaining volts.

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 Section 6 – TriPac Service Procedure H30A

Performing a TriPac Air Heater Fuel Quantity Test

Where Used
All TriPac Air Heaters

Purpose
To confirm the proper operation of the TriPac Air Heater Fuel Pump. The fuel quantity should be tested if the
heater has difficulty starting or maintaining a flame. Check the following before measuring fuel quantity.

Materials Required
• Measuring Glass – TK 89-593

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.

Diagnostic Procedure
Step Action Result Comments
IMPORTANT: The fuel quantity
is not affected by voltage
variances.

1 Check the filter in the fuel pump. The filter must be clean and in
good condition.

2 Check that the fuel lines are See the Installation Manual TK
correctly routed, are securely 53120 for details.
tightened and do not leak.
3 Verify that the fuel complies with
the data in the technical
description.

4 Detach the fuel line from the air Measuring Glass Service Part #
heater and insert it into the 89-593
measuring glass.

5 Switch the air heater on for

approximately 60 seconds to
allow the fuel system to bleed out
any air.

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 Section 6 – TriPac Service Procedure H30A

6 Switch the air heater off and

drain the fuel from the measuring
glass.

7 Insert the fuel line back into the

measuring glass. Hold the
measuring glass level with the
heater glow pin while fuel is
being delivered in the next step.

8 Switch the air heater back on.
Fuel will begin to pump about 60
seconds after the heater is turned
on. The pump will stop
automatically after delivering fuel
for 90 seconds. Allow the fuel to
pump until the pump turns off
automatically.

9 When the pump stops, turn the

heater off.

Test Evaluation and Corrective

Actions
10 Read the quantity of fuel in the Fuel quantity should be as
measuring glass in milliliters (ml). follows:

D2 Heaters = 3.7 ml to 4.3 ml

D4 Heaters = 5.4 ml to 6.3 ml

11 If the fuel quantity is outside the Possible fuel system restrictions

range specified for the heater, may include:
check the fuel system for
restrictions and correct as • Dirty fuel pump inlet screen.
necessary. • Poorly cut fuel lines – using a
side cutter instead of a tubing
cutter or razor blade.
• Fuel lines not fully inserted in
fittings.

12 If the fuel quantity is still outside

the range specified replace the
fuel pump.

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 Section 6 – TriPac Service Procedure H31A

TriPac Air Heater Diagnostics using the EDiTH Diagnostic Tool

Where Used
All TriPac units

Purpose
This procedure is used to diagnose the TriPac Air Heater using the EDiTH Diagnostic Tool. When properly
connected to a TriPac heater the EDiTH Diagnostic Tool and software offers the following benefits:
• The technician can display and clear heater alarm codes.
• The technician can display the heater run time.
• The technician can turn individual heater components on and off to aid in diagnostics.
• The technician can monitor and record real time heater operating conditions to aid in diagnostics.

The TriPac EDiTH Diagnostic Tool consists of a Basic ISO Adapter and the required cables. A USB Serial
Adaptor can be used if the PC computer is not equipped with a serial port, but is not supplied with the EDiTH
Diagnostic Tool. The EDiTH software must be installed on a PC computer.

NOTE: An EDiTH General Data printout showing all alarm codes must accompany any ECU submitted for
warranty. Refer to Warranty Bulletin WB406 for details.

Availability:
Hardware: The EDiTH Diagnostic Tool is available as Service Part Number 84-1158. The tool is supplied with
two cables as shown on page 3. The grey serial cable is used to connect the EDiTH Diagnostic Tool to the PC
computer. The black coiled cable is used to connect the EDiTH Diagnostic Tool to the test pigtail on the TriPac
heater cable.

An adapter cable as shown on page 3 is required to complete the connection to the heater. The EDiTH
Diagnostic Tool Adapter is available as Service Part Number 89-0322. The TriPac heater harness is equipped
with a test pigtail to allow the Diagnostic Tool to be connected to the heater. The adapter is used to connect the
black Diagnostic Tool cable to the pigtail on the TriPac heater harness.

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 Section 6 – TriPac Service Procedure H31A

Software: The TriPac EDiTH Diagnostic Tool software is available on TSA Info Central. Go to:

HTTP://WWW.THERMOKING.COM. Choose iService login, then select TSA Info Central - Software &
Downloads - TriPac - EDiTH Software - EDiTH_S3V11_Setup EN.zip. (The most recent version software will be
listed here and should be used)

EDiTH Diagnostic Tool and Software

Important EDiTH Diagnostic Tool Notes:

• All temperatures are displayed in Celsius only. The software does not allow temperatures to be displayed
in Fahrenheit. Temperature conversion charts are shown where appropriate.

• If an earlier version of EDiTH software is installed, it must uninstalled and removed before installing a
newer version.

• If used, the USB adapter must be connected before starting the computer. If the USB adapter is removed
while EDiTH is active, it may cause unstable system behaviour.

• Always install and remove the Diagnostic Tool in the specified order.

• A defective Diagnostic Tool circuit connection can result in an alarm code.

EDiTH Diagnostic Tool Hardware System Requirements:

• Computer Hardware = Pentium 133 or better with minimum 100 MByte hard drive space, 32 MByte RAM
and an available serial port. A USB Serial Adaptor can be used in place of a serial port.

• Operating Systems = Windows 98, NT, 2000, Me, XP, Vista and 7.

EDiTH Diagnostic Tool Software Installation:

• Download and save the latest EDiTH software zip file from the Thermo King TSA Info Central web site.

• Unzip the downloaded file.

• If the installation does not start automatically, double click on the “Setup.Exe” file to start the installation.

• Follow the setup instructions to complete the installation. AN EDiTH Diagnostic Tool Icon will be placed
on the desktop.

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 Section 6 – TriPac Service Procedure H31A

EDiTH Diagnostic Tool:

The EDiTH Diagnostic Tool is available as Service Part Number 84-1158. The tool is supplied with two cables as
shown below. The grey serial cable is used to connect the EDiTH Diagnostic Tool to the PC computer. The
black coiled cable is used to connect the EDiTH Diagnostic Tool to the test pigtail on the on the TriPac heater
cable. The ISO Adapter Module is available individually as 84-1670.

EDiTH Diagnostic Tool – Service Part Number 84-1158

EDiTH Diagnostic Tool Adapter:

The TriPac heater harness is equipped with a test pigtail to allow the Diagnostic Tool to be connected to the
heater. An adapter cable is required to complete the connection to the heater. The EDiTH Diagnostic Tool
Adapter is available as Service Part Number 89-0322. The adapter is used to connect the black Diagnostic Tool
cable to the pigtail on the TriPac heater harness.

EDiTH Diagnostic Tool Adapter – Service Part Number 89-0322

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 Section 6 – TriPac Service Procedure H31A

USB 2.0 Serial Adapter:

If the PC computer to be used does not have a serial port, a USB 2.0 Serial Adapter is required. A USB 2.0
Serial Adapter can be obtained at a local computer store. Be sure to purchase a USB 2.0 Serial Adapter. A
software driver will be supplied with the adapter. Install the software driver as instructed by the USB 2.0 Serial
Adapter documentation.

USB 2.0 Adaptor

EDiTH Diagnostic Tool Connections using a Serial Cable:

Always connect the Diagnostic Tool in the order shown here. See the illustration below for details.

• Locate the heater diagnostic pigtail. It is located in the TriPac heater harness near the heater. Note the 6
digit heater model number. Also note if the cable from the heater is covered with smooth plastic or is
wrapped with fabric tape. This information is necessary to select the heater test.

• Connect the Adaptor Cable to the heater diagnostic pigtail connector.

• Connect the other end of the black coiled cable to the EDiTH Diagnostic Tool.

• Connect the EDiTH Diagnostic Tool to the serial port on the PC computer using a serial cable.

EDiTH Diagnostic Tool Adapter

Serial Cable Application

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 Section 6 – TriPac Service Procedure H31A

EDiTH Diagnostic Tool Connections using a USB 2.0 Serial Adaptor Cable:
Always connect the Diagnostic Tool in the order shown here. See the illustration below for details.

• Locate the heater diagnostic pigtail. It is located in the TriPac heater harness near the heater. Note the 6
digit heater model number. Also note if the cable from the heater is covered with smooth plastic or is
wrapped with fabric tape. This information is necessary to select the heater test.

• Connect the Adaptor Cable to the heater diagnostic pigtail connector.

• Connect the other end of the black coiled cable to the EDiTH Diagnostic Tool.

• Connect the EDiTH Diagnostic Tool to a USB 2.0 port on the PC computer using a USB 2.0 Serial
Adapter.

EDiTH Diagnostic Tool Adapter

USB 2.0 Serial Adapter Cable Application

Starting the EDiTH Software:

• Double click the EDiTH icon on the desktop.

• The EDiTH software will start and the EDiTH Main Menu will appear.

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 Section 6 – TriPac Service Procedure H31A

Selecting the COM Port:

The correct COM port must be selected. If the EDiTH Diagnostic Tool fails to operate the reason is likely that the
wrong COM port has been set. To change the COM port used by the EDiTH Diagnostic Tool, proceed as follows.

• From the EDiTH Main Menu select the “Options” drop down menu at the top of the display. Choose
“Serial Interface” from the drop down menu as shown below

• A COM Port Selection menu will appear. Choose the appropriate COM port as shown below. Once the
COM port for the computer is selected it will remain selected and should not need to be changed.

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 Section 6 – TriPac Service Procedure H31A

Determining the Heater Model Number and Type:

The heater tests are selected using the 6 digit heater model number. Some models also require the heater
control type.

• The 6 digit model number is located on the heater serial number plate. Typical heater model numbers
are 25 2440, 25 2441, 25 2069 and 25 2113.

In addition, these heaters use one of two different control units. The heater control unit type can be determined
by checking the cable coming from the heater enclosure.

• Earlier heaters used a Wehrle heater control unit. The Wehrle heater control unit can be identified by the
smooth black plastic covering on the cable coming from the heater. Note that not all tests are available
with the earlier Wehrle heater control units.

Early Wehrle Heater Control Unit

with smooth black plastic covering on the cable

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 Section 6 – TriPac Service Procedure H31A

• Later heaters (after Feb. 2006) use a Hella heater control unit. The Hella heater control unit can be
identified by the black cloth wrapping on the cable coming from the heater.

Later Hella Heater Control Unit

with black cloth wrapping on the cable

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 Section 6 – TriPac Service Procedure H31A

Selecting a Heater to Test:

• From the EDiTH Main Menu select the “Heater” drop down menu at the top of the display. Choose
“Select Heater” from the drop down menu as shown below.

The heater to be tested is selected using the left and center columns of the menu display as shown below.

• A Heater and Test Selection menu will appear. Choose “Airtronic / Airtronic M / L” as shown below.

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 Section 6 – TriPac Service Procedure H31A

• A list of heaters will appear in the center of the display. Select the correct heater model number as
shown below.

• Some universal model numbers show two versions of heater control units – Wehrle and Hella – such as
the model 25 2069 heater shown below. Be sure to select the correct version.

Wehrle Heater Control Units - Smooth black plastic covering on the cable coming from the heater.

Hella Heater Control Units - Black cloth wrapping on the cable coming from the heater,

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 Section 6 – TriPac Service Procedure H31A

Selecting a Heater Test:

The desired test is selected using the right column of the menu display as shown below.

• A list of Tests will appear on the right side of the display. Select the desired test, and then select Start
Test as shown below. The following tests are available.

General Data – This test will display general data of the selected heater including hardware and software
versions, hours of operation and other general details as shown below. The Error Codes in the heater
memory can also be displayed.

Functional Check – This test will allow the heater to be test run. The operating details will be displayed.

Switch on Component – This test will allow the individual components to be turned on and off. This test
is only available with new style Hella Control Units.

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General Data Test

The General Data Test will display general data of the selected heater including hardware and software versions,
hours of operation and other general details as shown below. The Error Codes in the heater memory can also be
displayed. Select the General Data Test, and then select Start Test as shown below.

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 Section 6 – TriPac Service Procedure H31A

The first General Data Test display that appears is the General Data menu for the selected heater. The data will
be displayed as shown below.

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 Section 6 – TriPac Service Procedure H31A

To display the Alarm Codes (Error Codes) held in the heater memory click the Error button as shown below.

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 Section 6 – TriPac Service Procedure H31A

Any Alarm Codes (Error Codes) held in the heater memory will be displayed. Record any alarm codes for future
use.

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 Section 6 – TriPac Service Procedure H31A

Choosing Delete will clear the Alarm Codes (Error Codes). Choosing Stop will exit the General Data Test but
allow the Alarm Codes and other data to be saved for future reference.

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 Section 6 – TriPac Service Procedure H31A

If Stop is selected, a Save Changes prompt will appear as shown below. To exit the General Data Test without
saving the data select No. To exit the General Data test and save the data select Yes.

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 Section 6 – TriPac Service Procedure H31A

If Yes is selected, a Save As prompt will appear as shown below. Choose the desired Save In location on the PC
computers local hard drive and enter the File Name. When the desired location and file name have been
selected click Save to exit the General Data Test and save the data to the selected location.

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 Section 6 – TriPac Service Procedure H31A

Functional Check Test

This test allows the heater to be operated to verify proper operation. Select the Functional Check test, and then
select Start Test as shown below.

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 Section 6 – TriPac Service Procedure H31A

The first Functional Check test display that appears allows the desired operating mode to be selected. Choose
the desired operating mode and click OK.
• Heating Setpoint Input Control – the heater will control to the setpoint determined by the TriPac controls.
• Heating Setpoint Input Via EDiTH – the heater will control to the setpoint selected by the EDiTH software.
• Ventilate – the heater will operate in ventilation mode with the fan running but no heat operation.

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 Section 6 – TriPac Service Procedure H31A

The next Functional Check test display that appears shows the measured values for the heater under test as
shown below.

IMPORTANT: All temperatures are displayed in Celsius only. The software does not allow temperatures to be
displayed in Fahrenheit. See the conversion table on the next page.

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 Section 6 – TriPac Service Procedure H31A

Temp Sensor Conversions Setpoint Conversions

Temp °F Temp °C Temp °F Temp °C
-40 -40 50 10
-4 -20 54 12
32 0 57 14
68 20 61 16
104 40 64 18
140 60 68 20
176 80 72 22
212 100 75 24
248 120 79 26
284 140 82 28
320 160 86 30
392 200 90 32
464 240
536 280
608 320
680 360
752 400

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 Section 6 – TriPac Service Procedure H31A

To Graph Heater Values - Note that some of the values have a check box next to them as shown by the lower
arrow below. Clicking on the check box will select that value. Only values that have been selected will be
graphed.

To view the graph, click the Graphic button as shown by the upper arrow below. The selected values will be
presented in graphic form as shown on the next page.

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 Section 6 – TriPac Service Procedure H31A

The selected values will be presented in graphic form.

Each value is identified by color. The definitions of each color are shown in the table to the right of the graphed
values.

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 Section 6 – TriPac Service Procedure H31A

Any stored error codes can also be displayed from the Functional Check test. To display the Error Codes held in
the heater memory click the Error button as shown below. Any error codes will be displayed as shown under
General Test above.

To exit the Functional Check test click Stop.

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 Section 6 – TriPac Service Procedure H31A

Switch On Component Test

This test allows various heater components to be switched on and off to verify proper operation. Select the
Switch On Component test, and then select Start Test as shown below.

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 Section 6 – TriPac Service Procedure H31A

The Switch On Component test menu will appear. First, select the desired component as shown by arrow # 1
below. Then select the amount of time the device is to be energized (if applicable) as shown by arrow # 2.
Finally, select Execute to switch the component on as shown by arrow # 3.

2 3

IMPORTANT: Do not run the dosing pump (heater fuel pump) for more than 10 seconds or excess fuel may be
pumped into the heater and effect operation.

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 Section 6 – TriPac Service Procedure H31A

Any stored Alarm Codes (Error Codes) can also be displayed from the Switch On Component test. To display the
Alarm Codes (Error Codes) held in the heater memory click the Error button as shown below. Any alarm codes
will be displayed as shown under General test above.

To exit the Switch On Component test click Stop.

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 Section 6 – TriPac Service Procedure H31A

Stopping the EDiTH Software:

• Click the red “X” at the upper right of the larger EDiTH display.

Additional Information:
• For additional information on using the EDiTH Diagnostic Tool and Software see the EDiTH Help Menu.

• For complete Espar/Airtronic Air Heater alarm code descriptions including causes and suggested
diagnostics see Section 5 of this manual.

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 Section 6 – TriPac EVOLUTION Service Procedure H32A

Air Heater Diagnostics using the Heater Diagnostic Unit

Where Used
All TriPac units.

Purpose
The Heater Diagnostic Unit is used to read out, display and delete faults stored in the heater’s electronic
control box. The electronic control box can store up to 5 faults (exception: auxiliary heater D 3 W Z). The
current fault is displayed as “ AF” and a 2-digit number and is always written in memory location F1. The
stored faults “F1” to “F5” can be queried.

Operating Instructions

backwards control button

forwards control button

activation button

confirmation button

Connect diagnostic unit

•  Disconnect the plug-in connection in the “Hea ter / Cable harness” cable loom.

•  Connect the adapter cable to the “Heater” cable loom and to the cable harness.

•  Connect the 6-pin push-on sleeve housing of the adapter cable with the 6-pin tab connector housing of
the diagnostic unit.

Note: Before starting the diagnosis, the controller of all air heaters operated with a control unit or a mini-
controller must be set to maximum heat output.

01/30/2014 Page 1
 Section 6 – TriPac EVOLUTION Service Procedure H32A

Perform the Diagnosis

Automatic Detection
Five seconds after the diagnostic unit has been connected to the heater using the adapter cable, the automatic
detection starts to determine the type of heater the diagnostic unit is connected to.

Note: If the automatic detection was successful, if necessary, the heater is briefly started and then switches off
again.

Display until the automatic Delete the fault memory and as

detection is completed. a result, at the same time cancel
the control box lock.
Current fault or fault F1 – F5
Display if Air Heater is detected. Confirm with

Confirm display dEL again with

or

The fault memory is deleted and

the control box is unlocked.

Confirm flashing symbol with

Possible displays:
Quit Diagnosis
If no errors/faults exist:
Switch off heater.
Further action –> display fault
memory, delete fault memory.
Press , the heater is switched off.

If errors/faults exist: Perform the Diagnosis Again

Further actions –> display current
fault and fault memory, delete fault
Press ; the heater is switched off.
memory.
Repeat the procedure on this page.
Display current fault in fault
memory:
Unable to Perform the Diagnosis
Automatic detection was
Simultaneously press and
unsuccessful.
Display: e.g. aF : 12 Display if the automatic detection
Display fault memory f1 – f5 was not successfully completed.

Press or

Display: e.g. F1 : 20 Possible causes:

Display current fault in the fault •  bl/ws diagnostic cable not connected
memory again •  bl/ws diagnostic cable is defective
–> check for continuity, short circuit and damage.
Simultaneously press and
•  Heater was not detected.
Display: e.g. aF : 12
01/30/2014 Page 2
Service Information
 Section 7 – TriPace Information

TABLE OF CONTENTS - SECTION 7

Hardware Revisions ................................................................................................................................................ 2

Main Controller Board ........................................................................................................................................ 2
Smart Charger Module (SCM) ........................................................................................................................... 2
Software Revisions ................................................................................................................................................. 2
System Software ................................................................................................................................................ 2
Main Controller Software ................................................................................................................................... 2
HMI Control Panel Software .............................................................................................................................. 2
Smart Charger Module (SCM) Software ........................................................................................................... 2
TK Monitor Software .......................................................................................................................................... 2

7-1
 Section 7 – TriPace Information

HARDWARE REVISIONS
Main Controller Board
There is currently one version of the TriPace Main Controller Board and that is Revision C.

Smart Charger Module (SCM)

There is currently one version of the TriPace Smart Charger Module (SCM) and that is Revision 1.

SOFTWARE REVISIONS
System Software
As a group the current component software versions are referred to as Version 1.1. This software revision is
compatible with all current TriPace hardware. Whenever an HMI, Main Controller or SCM is replaced system
software should be upgraded to Version 1.1. If the system has already been upgraded the individual component
software should be upgraded to match.

Main Controller Software

There are currently two versions of the TriPace Main Controller Software.
● The original version is Revision 31 0 100.
● The current version is Revision 31 01. Used with TK Monitor Revision 1.01 or later.

HMI Control Panel Software

There are currently two versions of the TriPace HMI Software.
● The original version is Revision 32 0 33.
● The current version is Revision 32 01. Used with TK Monitor Revision 1.01 or later.

Smart Charger Module (SCM) Software

There are currently two versions of the TriPace SCM Software.
● The original version is Revision 42 0 13.
● The current version is Revision 33 01. Used with TK Monitor Revision 1.01 or later.

TK Monitor Software
There are currently two versions of the TriPace TK Monitor Software.
● The original version is Revision 1.0.B.6
● The current version is Revision 1.01. Used with Main Controller Software 31 01 or higher.

7-2
Schematics & Wire
Diagrams
 Section 8 – Schematics and Diagrams

TABLE OF CONTENTS - SECTION 8

TriPace Schematic Diagram – 1H22507

TriPace Wiring Diagram – 1H22508

8-1
Section 8 – Schematics and Diagrams

8-2
 Section 8 – Schematics and Diagrams

CHANGES AND COMMENTS

You are invited to comment on this manual so it can be updated and improved to better meet
your needs. Any corrections or comments are welcome. Please complete the following
information:

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Corrections and Comments __________________________________________________

__________________________________________________________________________

__________________________________________________________________________

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__________________________________________________________________________

__________________________________________________________________________

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Return to: THERMO KING CORPORATION

314 West 90th Street
Mail Stop 38
Minneapolis, MN, USA
55420
Attn: Service Department

8-3