Thermo King Air Purification Solution (APS) Installation guide

Brand: Thermo King

Model: Air Purification Solution (APS)

Type: Installation guide

Kit 401623

A Merv-7 filter is required to ensure proper efficiency 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.

RCS1803

Tools Required:

7/16” socket, 3” extension and ratchet

7/16” open ended wrench

T–25 screwdriver

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 – The APS assembly installs directly onto the TK HVAC evaporator

using the existing hardware.

EElleeccttrriiccaall CCoonnnneeccttiioonnss – The 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 RLF Units

Installation Procedures

Step 1 – Bus HVAC Component Removal

IImmppoorrttaanntt:: DDiissccoonnnneecctt ppoowweerr ttoo tthhee bbuuss HHVVAACC uunniitt bbeeffoorree pprroocceeeeddiinngg..

1. Access evaporator via rooftop service panel.

2. Remove and retain the evaporator’s (6) 1/4” hardware on the roadside and curbside of the

evaporator as shown.

Figure 1. Evaporator’s hardware mounting locations shown.

RCS1804-1

2 2

Step 2 – APS Installation

1. Remove and discard the (2) 1/4” hardware securing control panel to APS assembly.

a. Move control panel off to the side of the APS during installation. This step is required to

allow the APS to slide in place along the coil.

Figure 2. Switch panel shown.

RCS1805

2. From the rooftop, place the APS assembly onto the evaporator and reinstall the following:

a. Roadside – Loosely reinstall (1) 1/4” hardware at top of evaporator and then reinstall

control panel along with the APS using the (2) ¼” hardware.

b. Curbside – Loosely reinstall (3) 1/4” hardware along with the (3) large washers supplied in

the kit.

NNoottee:: Lower hardware can be accessed from inside the bus.

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

Figure 3. Curbside and Roadside mounting bolts and control panel shown.

RCS1806-1

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 connector 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 4. Interface harness connections shown.

RCS1797-1

1a Interface Harness

4. PPoowweerr WWiirree – connect power wire to bus battery positive (+24VDC) source.

a. Fold rubber shield to access stud.

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.

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

6. EEddggee CClliipp – A edge clip is provided attached to harness. Install edge clip to sheet metal

bracket and secure harness to other harness with supplied band wraps.

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 5. Power and Ground locations shown.

RCS1826-2

Figure 6. Edge clip shown attached to sheet metal bracket.

RCS1825-1

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 unit before proceeding.

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:

• RLF Series Units:5

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 %:(RLF – 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 7. Main Module window (T–Series shown, RLF similar).

RAJ1281

1. Select: Read Data

2. APS Panel Count: Enter:

RLF-Series Units: 5

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 8. APS panels shown energized.

RCS1819

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.

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 Diagnostic 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 if the AC Fail option is selected.

Figure 9. Alarm 084 – Air Purification System fault shown.

RCS1802

Figure 10. RLF Series Air Purification Wiring Diagram

RCS1779

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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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