Thermo King Air Purification Solution (APS) Installation guide

Brand: Thermo King

Model: Air Purification Solution (APS)

Type: Installation guide

Kit 401622

A Merv-7 filter is required to ensure proper efficacy of the air purification device over the course

of the product life. Please contact your Thermo King representative to identify the applicable

part number for your application.

RCS1785

Tools Required:

7/16” socket, 3” extension and ratchet

7/16” open ended wrench

T-25 Torx screw driver

Side cutters

Terminal crimper

Laptop with CANDiag kit (Flash load firmware version 4.02.05 or later into main module is required.)

Installation Overview

CCoommppoonneenntt IInnssttaallllaattiioonn – APS assembly installs directly onto the TK HVAC evaporator using

the existing hardware. Depending on the bus air inlet opening size, it can be installed as a

complete assembly, or disassembled, installed in two sections and reassembled.

EElleeccttrriiccaall CCoonnnneeccttiioonnss – APS interface harness connects to the IntelligAIRE III controller and to

a bus battery positive (+24VDC) and chassis ground (-) source.

SSyysstteemm PPrrooggrraammmmiinngg – After the APS is installed, the IntelligAIRE III controller will need to be

programmed to operate the system.

Installation Instructions

Air Purification Solution (APS) for T14/T15

Series Bus Units

Installation Procedures

Step 1 – Bus HVAC Component Removal

IImmppoorrttaanntt:: Disconnect power to the bus HVAC unit before proceeding.

1. Access evaporator via bus interior return air inlet grille. Remove filter from coil face (if

applicable).

Figure 1. Access HVAC Evaporator.

RCS1786-1

1 1

2. Remove and retain the evaporator’s 1/4” hardware per your particular APS installation

below:

a. AAPPSS iinnssttaalllleedd aass aa ccoommpplleettee aasssseemmbbllyy — remove the evaporator’s (6) 1/4” hardware as

shown below.

b. AAPPSS iinnssttaalllleedd aass ttwwoo sseeppaarraattee ppiieecceess — remove only the evaporator’s upper (4) 1/4”

hardware and just loosen (do not remove) the lower (2) 1/4” hardware.

3. Remove and retain the (2) filter clips (not shown, if applicable).

IImmppoorrttaanntt:: Drill out only the rivet heads securing the filter clips. Drilling through the rivet

hole could damage the evaporator coil.

Figure 2. Evaporator’s hardware mounting locations shown.

RCS1787-1

Step 2 – APS Installation

NNoottee:: When installing the APS as a complete assembly through the bus return air opening,

follow Step 2 – APS Installation. If the bus return air opening is too small the APS will need

to be disassembled and installed as individual pieces, go to Step 2a - APS Disassembly

Procedures.

1. Temporarily remove the (2) 1/4” hardware securing control panel to APS assembly. This will

allow access to the center mounting bolt when installing APS onto the evaporator.

2. Position APS assembly onto evaporator, reinstall (6) 1/4” hardware (removed earlier) and

tighten to 6 ft-lbs (8.2 Nm).

3. Reinstall control panel onto APS assembly and tighten the (2) 1/4” hardware to 6 ft-lbs (8.2

Nm).

Figure 3. Remove control panel to access center mounting bolt.

RCS1788

Figure 4. APS shown installed onto evaporator.

RCS1789

Continue to Step 3 – Electrical Connections

Step 2a – APS Disassembly Procedures

NNoottee:: If the return air opening is too small, the APS assembly will need to be disassembled and

installed in two sections by following Step 2a - APS Disassembly Procedures and Step 2b –

APS Panel Installation and Reassembly Procedures.

1. Place APS assembly onto a flat surface, cut band wraps securing curbside and roadside

electrical connectors, unplug connectors and remove from holders.

Figure 5. Unplug electrical connectors and remove from holders.

RCS1790-1

Roadside

Curbside

2. Remove 1/4” hardware securing connector bracket to panel assembly

3. Loosen 1/4” hardware securing top channel to panel assembly and hardware securing

retaining plates. Rotate retainer plates and retighten hardware.

4. Remove 1/4” hardware securing control panel bracket to panel assembly.

Figure 6. Remove electrical connector brackets, retainer brackets and control panel bracket.

RCS1791-1

Roadside Curbside

5. Remove 1/4” hardware and T-25 Torx screws.

Figure 7. Remove hardware shown.

RCS1792

6. Separate APS upper and lower panels as shown.

7. Remove 1/4” hardware and separate both side brackets from upper panel.

Figure 8. APS panels shown separated.

RCS1793-2

Upper Panel

End Panels

Lower Panel

Step 2b – APS Installation and Reassembly Procedures

1. Position both side panels onto evaporator and loosely reinstall 1/4” hardware removed

earlier.

2. Position upper panel onto evaporator and loosely reinstall 1/4” hardware removed earlier.

3. Position lower panel onto evaporator and rotate retainer plates back 180 degrees.

4. Reinstall center bracket and hand tighten the T25 Torx screws securely. DDOO NNOOTT OOVVEERR

TTIIGGHHTTEENN SSCCRREEWWSS!! Tighten all 1/4” hardware to 6 ft-lbs (8.2 Nm).

Figure 9. Position panels onto evaporator and reinstall hardware shown.

RCS1794-1

5. Reinstall control panel, roadside connector bracket and the retainer brackets back onto APS

assembly and tighten 1/4” hardware to 6 ft-lbs (8.2 Nm).

6. Reconnect all electrical connectors and secure with band wraps as they were originally.

Figure 10. Reinstall switch panel, electrical and retainer brackets and all electrical connectors.

RCS1795-2

Continue to Step 3 – Electrical Connections

Step 3 – APS Electrical Connections

Air Purification Grid Connections

1. Unplug 4-pin connector ((PP33)) on ECM and connect to mating connector on APS interface

harness.

a. Connect 4-pin APS interface harness connector to ECM connector ((PP33)).

2. Unplug 18-pin connector ((PP66)) on ECM and connect to APS interface harness.

a. Connect 18-pin on interface harness to ECM connector ((PP66))

3. Remove ECM 24-pin connector ((PP11)) and add single CSEN wire from interface harness into

correct cavity as shown below:

a. Insert the single CSEN wire into cavity 14 of connector P1 and reconnect to the ECM.

NNoottee:: The large photo below shows connector P1 with the CSEN wire already installed. The

small inset photo shows the single CSEN wire in cavity 14 of connector P1.

Figure 11. Interface harness connections shown.

RCS1797-1

1a Interface Harness

4. PPoowweerr WWiirree – Remove 1/4-20 hardware holding control panel assembly to unit frame.

a. Rotate control panel assembly to gain access to the back of the Bussmann fuse block.

NNoottee:: Harness band wraps may need to be removed to gain full access.

b. Remove 1/4-20 nut, split lock washer and flat washer. Retain nut.

c. Add 1/4 ring terminal of APS power harness on top of the main power lug. Add bronze

internal lock washer. Secure with nut. Torque nut to 48-53 in.- lb.

NNoottee:: The supplied bronze internal tooth lock washer is required to be used in place of the

existing flat washer and split lock washer to account for the additional stack up at the

fuse block stud due to the APS terminal.

RCS1813

44a

RCS1817

5. GGrroouunndd WWiirree - connect ground wire from panel ground stud to a chassis ground (-) source.

One example shown, other examples include:

• ¼” or #10 ground stud located on the main HVAC control panel.

• 5/16” ground stud located on the brushless motor drive if equipped.

• 3/8” ground studs located on the control box.

NNoottee:: Long and short ground wires are provided to accommodate the various ground locations

found on T-series bus HVAC systems. Various size terminal rings are also included to be

used to match the stud sizes. Use side cutters and terminal crimper to cut wire to

appropriate length and attach correct size terminal ring.

6. Secure APS harness with supplied band wraps to existing harnesses.

NNoottee:: When installing band wraps, use proper tensioning/cutting tool or use care to trim ties

in a way that eliminates sharp edges that can cut and scratch.

Figure 12. Typical power and ground wires shown connected and secured.

RCS1798-1

Step 4 – Setup Procedures

NNoottee:: See the IntelligAIRE III Diagnostic Manual TK 54650 for detailed information on flash

loading and connecting using the CANDiag software.

1. Reconnect power to the bus HVAC.

2. Flash load firmware version 4.02.05 or later into main module.

3. Connect CANDiag and open Main Module window.

4. Go to Setup Parameter tab and click Read Data.

5. When upload is complete, the Customized Configuration box will show the current

configuration number loaded in the module.

6. Go to the APS Panel Count parameter and select the correct number of panels installed:

• T-Series Units: 4

7. Go to Cont Evap Blower parameter and click the check box to enable.

8. Go to APS Fail Indicator – This is an optional selection:

•IIff bbooxx iiss sseelleecctteedd:: the AC Fail Indicator lamp on the control panel wwiillll iilllluummiinnaattee when

aallaarrmm ccooddee 008844 is detected.

•IIff bbooxx IISS NNOOTT sseelleecctteedd:: The AC Fail Indicator lamp on the control panel wwiillll nnoott

iilllluummiinnaattee when aallaarrmm ccooddee 008844 is detected. This is the default setting.

9. Go to Basic Parameters and adjust the following evaporator speed value %:(Y—Series units

with brushless motors only).

• Evap Max Speed: Values % set to 9955

• Evap Max Speed H: Values % set to 9955

• Evap Med Speed: Values % set to 8800

• Evap Min Speed: Values % set to 6677

10.Click Send Data to download the modified configuration back into the module.

11.The configuration process for Air Purification is now complete.

12.Reinstall air filter and grille and return bus to service.

Figure 13. Main Module window shown.

RAJ1281

1. Select: Read Data

2. APS Panel Count: Enter:

T-Series Units: 4

3. Cont Evap Blower: Select Check Box

4. APS Fail Indicator (optional)

5. Basic Parameters — Evaporator Blower Speed Value %

6. Select: Send Data

APS System Operation

When the bus is started and the RUN signal becomes active, the air purification panels will

energize and the IntelligAIRE III controller will wake up.

Figure 14. APS panels shown energized.

RCS1800

The evaporator blowers will start automatically and operate in low speed unless being

commanded to a higher speed by the HVAC.

The air purification panels may be temporarily disabled (for example during service procedures,

flash loading, etc.) by using the service ON / OFF switch in the return air section.

Figure 15. APS Service Switch shown.

RCS1801

IImmppoorrttaanntt:: The screen mesh of the air purification system must only be cleaned with a low

power vacuum equipped with a soft bristle dust brush attachment. Do not use liquids,

chemicals, cleaners, cleaning agents, compressed air, water, or a high power vacuum

to clean the mesh or damage may occur.

APS Diagnostics Procedures

• The IntelligAIRE III controller monitors voltage and current to determine total power drawn

by the air purification system.

• If the air purification system power drops more than the threshold amount below the

expected power, an alarm code 084 is generated.

• This alarm code is also broadcast through the DM1 messaging on the vehicle J1939 network

and will light the AC Fail indicator at the driver panel.

Figure 16. Alarm 084 – Air Purification System fault shown.

RCS1802

Figure 17. T-Series Wiring Diagram.

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Thermo King Air Purification Solution (APS) Installation guide

Thermo King Air Purification Solution (APS) Installation guide

Thermo King Air Purification Solution (APS) Installation guide

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