Related Manuals for Carrier Transport Air Conditioning
Summary of Contents for Carrier Transport Air Conditioning
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Page 1: Installation Procedures
Transport Air Conditioning INSTALLATION PROCEDURES SPLIT SYSTEMS Generation 4 & 5 T--311 Rev B Change 06/10... - Page 2 INSTALLATION MANUAL SPLIT- -SYSTEMS GEN 4 & 5 POLICY AND PROCEDURES...
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Page 3: Safety Summary
Always use a DOT (Department of Transportation) approved cylinder for storing used and recycled refrigerant. Approved cylinders will be stamped DOT 4BW or DOT 4BA. Carrier recommends a MACS (Mobile Air Conditioning Society) certification in Recovery/Recycling to gain more information on handling and using refrigerants. - Page 4 SPECIFIC WARNINGS AND CAUTIONS WARNING Do not attempt to modify the EM-3 evaporator top panel. Modifications to the top panel could struc- turally weaken the evaporator assembly, causing system failures and/or injuries to passengers. WARNING Do not use a nitrogen cylinder without a pressure regulator WARNING Never use air for leak testing.
- Page 5 CAUTION Because of the limited access to the block valve, start the fittings by hand (finger tightening) making sure that there is no cross-threading before tightening. When tightening the fittings, make sure that the Block Valve does not move. CAUTION Never route refrigerant hose, electrical cable or drain lines in any location where driver’s visibality would be impaired.
- Page 6 CAUTION Condenser assemblies must be properly installed using graded hardware. The CM-2 condenser as- sembly requires at least 4 bolts and the CM-3 requires at least 6 bolts. CAUTION When drilling into the vehicle wall, always use a drill stop to help protect against damaging any wir- ing that might be located behind the wall.
- Page 7 TABLE OF CONTENTS Section ................Page SAFETY SUMMARY .
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Page 8: Table Of Contents
TABLE OF CONTENTS - - Continued: Section ................Page CONDENSERS . - Page 9 TABLE OF CONTENTS - - Continued: Section ................Page ELECTRICAL .
- Page 10 10-1 10.2.1 Authorized Carrier Transport A/C Dealers ..........
- Page 11 LIST OF ILLUSTRATIONS Figure ................. Page Figure 2-14 Installed GEN 4 Evaporator .
- Page 12 LIST OF ILLUSTRATIONS Figure ................. Page Figure 2-57 In-Wall Cut-Out (TBB) .
- Page 13 LIST OF ILLUSTRATIONS Figure ................. Page Figure 4--23 Hose Routing (Chassis) .
- Page 14 ........... . Table 1-2 CARRIER TRANSPORT AIR CONDITIONING SYSTEMS (GEN 4/5) .
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Page 15: Condensers
BTU”s to the nearest 10 This manual contains instructions for the proper thousand. (Example - 26,000 BTU’s would be rounded preparation of and installation of Carrier Transport Air off to 30,000 BTU’s, or the number 3.) Conditioning split systems. This manual does not... -
Page 16: Figure 1-1 Condenser Model Cm2/3 - Serial Number Location
Table 1-2 CARRIER TRANSPORT AIR CONDITIONING SYSTEMS (GEN 4/5) SYSTEM TYPE EVAP (S) COND (S) COMP (S) AC-3140 26,000 (1) EM-14 AC-360 30,000 (1) EM-6 AC-3142 26,000 (1) EM-14 (1) CM-2 (1) 10 CID AC-362 30,000 (1) EM-6 (1) CM-2... -
Page 17: Figure 1-3 Gen 5 Evaporator Model (All) - Serial Number Location
Figure 1-3 GEN 5 Evaporator Model (All) - Serial Number Location Figure 1-4 GEN 4, IW-2 & IW-7 - Serial Number Location Figure 1-5 GEN 4, IW-1 - Serial Number Location T--311 1--3... -
Page 18: Figure 1-6 Cm-7/11 Rooftop Condensers (No Longer Offered) - Serial Number Location
Obsolete Tag Figure 1-6 CM-7/11 Rooftop Condensers (No Longer Offered) - Serial Number Location Figure 1-7 KR-2/KR-3 Rooftop Condensers - Serial Number/PID Location Serial/Model- Number Plate Figure 1-8 KR-4 Rooftop Condenser - Serial Number/PID Location T--311 1--4... -
Page 19: Figure 1-9 Typical Component Locations
from the refrigerant. The receiver/drier also stores liquid 1.4 SYSTEM COMPONENTS refrigerant (See Figure 1-9). 1. Thermostat - A thermostat is a temperature 6. Expansion Valve/Block Valve - Meters the sensitive device, which when activated, signals the refrigerant flow into the evaporator coil. electro-magnetic clutch to engage. -
Page 20: Figure 1-10 Refrigerant Flow Diagram
1.5 COOLING CYCLE then flows to the block type expansion valve. The expansion valve reduces pressure and temperature of the liquid and meters the flow of liquid refrigerant to the The unit operates as a vapor compression system using evaporator to obtain maximum use of the evaporator R-134a as the refrigerant (See Figure 1-10). -
Page 21: Table 1-3 Gen 4 Evaporators
Evaporators are located in the interior of the vehicle. Their primary function is to transfer heat contained in the Refer to Table 1-3 (Gen 4) and Table 1-4 (Gen 5) for passenger compartment into the refrigerant. The Carrier Transport Conditioning evaporator... -
Page 22: Table 1-5 Gen 5 Evaporators -- Variable Speed
(2) CM-2’s or two (2) CM-3’s can be Condensers are normally located on the outside of the stacked on each other with a kit available from Carrier vehicle. Their primary function is to reject heat absorbed Transport Air Conditioning. Carrier Transport Air by the refrigerant from the passenger compartment to Conditioning condensers are listed in Table 1-7. -
Page 23: Pre-Installation Inspection
1.8 PRE-INSTALLATION INSPECTION Check contents of cartons against the enclosed packing lists. If any parts are missing, incomplete, or defective, Immediately upon receipt of your Carrier Transport Air call Carrier Transport Air Conditioning customer service Conditioning system: for assistance. Check the number/amount of cartons and skids/pallets Before installing any evaporator assembly, spin the against the shipping company’s “Bill of Lading”... -
Page 24: Location
Before attempting to install any evaporator, always must be removed in order to accomodate and install insure that the evaporator will fit in the location of choice. these type evaporators. Some of Carrier Transport A/C 2.1.3 Cap Plugs In-Wall evaporators assemblies are “OEM” specific. -
Page 25: Figure 2-1 Template For Em-1 And Em-2 (Gen 4)
This panel can be trimmed to compensate for EM-7 26.64 inch 7.62 inch 19.13 inch the ceiling curve. Contact the Carrier Transport NOTE Air Conditioning Technical Service Hot Line (1--800-450-2211) for assistance in obtaining Except for the EM-3, all the evaporators listed in these panels. -
Page 26: Figure 2-2 Measurement To Wall (Gen 4)
Table 2-3 DISTANCE TO BACK WALL (GEN 4) GEN 4 Evaporator Distance to back wall EM-1 7 Inches EM-2 7 Inches EM-3 4.5 Inches EM-6 7 Inches EM-14 8.75 Inches Figure 2-4 7/16 Inch Holes in Bus Roof Table 2-4 DISTANCE TO BACK WALL (GEN 5) Matching holes in reinforcing rails to holes in bus roof, drop 3/8 inch carriage bolts through mounting rails and the roof. -
Page 27: Figure 2-7 Carriage Bolt Sealing
CAUTION When installing any GEN 5 Evaporator as- sembly, be very careful not to push against the blower wheel (s). The blower wheel can easily be distorted and will have to be re- placed. Figure 2-7 Carriage Bolt Sealing Figure 2-9 Locking Pliers & GEN 4 Evaporator Figure 2-10 Evaporator Mounted to Flat Ceiling Figure 2-8 Locking Pliers Clamped to Carriage Bolts... -
Page 28: Figure 2-12 Block Valve Insulation
Figure 2-14 Installed GEN 4 Evaporator With the cover removed, note the distance between the top of the unit and the contour of the bus ceiling. If this distance is more than 1 inch, it must be closed off to prevent any recirculation over top of the evaporator. -
Page 29: Figure 2-17 Gen-4/5 Front/Rear (Em-1, 2, 6, & 14) Evaporator & Installation Hardware
7/6 inch holes Snap Cap h. Mounting Channel Pan Head Screw Carriage Head Bolt 3/8-16 x 4 Snap Cap washer Optional Spacers Trim Strip k. Drain Line Flexible Trim Drain Line Clamp Evaporator Cover m. Condensate Valve (Kazoo) Evaporator n. Locking Nut 3/8-16 Figure 2-17 GEN-4/5 Front/Rear (EM-1, 2, 6, &... -
Page 30: Figure 2-19 Rear Mount Evaporator (Gen-5) - Installed
If 2.2.2 Luggage Compartment Evaporator assistance is needed, please contact the Carrier If installing an evaporator assembly in an enclosure Transport Air Conditioning Technical Service Hot Line such as a rear luggage compartment, you must insure (1--800-450-2211). Change 07/09... -
Page 31: Figure 2-21 Em-3 Installation Diagram
2.2.3 EM-3 EVAPORATOR GEN 4 OR GEN 5 bus roof and/or evaporator from distorting when tightening the lock nuts. To install the EM-3 utilize the installation procedures outlined in Paragraph 2.2 except as noted below. See Figure 2-21 for a typical EM-3 installation drawing. WARNING NOTE Threaded rod (3/8-16) is supplied with the EM-3... -
Page 32: Figure 2-22 Side-Mount Template
2.3 SIDE MOUNTED EVAPORATOR - EM-1, EM-2, Loosely install evaporator assembly onto the front EM-6, EM-7, & EM-14 and rear mounting brackets. Tighten rear mounting hardware. To install a side mounted evaporator assembly utilize the following installation procedures: m Level evaporator assembly front to rear using a small level and the 3/8-16 jam-nuts (See Figure 2-23). -
Page 33: Figure 2-24 Side Mount Installation Instructions (Typical)
Top Panel Top Panel Front Hanger Detail Front Hanger Assembly Rear Hanger Assembly GEN 4/5 Evaporator Cover Figure 2-24 Side Mount Installation Instructions (Typical) Trim Strip - Front Trim Strip - Rear Rear Hanger Bracket 3/8-16X1 Carriage Head Bolt Spacer, 1/8 Inch Flat Washer 3/8-16 Hex Nut, Lock 3/8-16 Hex Nut... -
Page 34: Figure 2-26 Em-2 (Gen V) Side-Mount - Free Blow, Installed (Complete)
Trim Lock Side Trim Strip Transition Rear Trim Strip Hose Covers Transition Figure 2-26 EM-2 (Gen V) Side-Mount - Free Blow, Installed (Complete) T--311 2--11... -
Page 35: Figure 2-27 Em-9 Ducted Evaporator - Hose & Harness Routing
NOTE wiring channel to the hose cover. Optional “school style ducting” is available from Carrier Transport AC (See Figure 2-31 & Figure 2-32). Contact the Carrier Transport Air Trim cover to the contour of bus ceiling. Trim around the hose/harness cover if routed from rear of evaporator Conditioning Technical Service Hot Line cover. -
Page 36: Figure 2-28 Punching Out Louver Holes
Figure 2-28 Punching out Louver Holes Figure 2-29 End Cap With Louver Figure 2-30 EM-9 Ducted Evaporator - Location - Completed Assembly Figure 2-31 School Style Ducting-Passenger Side Figure 2-32 School Style Ducting-Drivers Side T--311 2--13... -
Page 37: Figure 2-33 Side Mounted Hose Routing (Using 455 Angles)
Figure 2-34 Side Mounted Hose Routing (Straight) Figure 2-33 Side Mounted Hose Routing (Using 45° Angles) T--311 2--14... -
Page 38: Figure 2-35 Em-17 Installed
Due to the weight and size of the Before attempting to install this type system, it is evaporator assembly it is recommended that this type strongly advised that you contact Carrier Transport Air evaporator and accompanying condenser and electrical Conditioning Technical Service Hot Line for assistance controls be installed only by OEM’s (Original Equipment... -
Page 39: Figure 2-36 In-Wall Marked For Cut-Out
& cover arrangements for NOTE most OEM’s. If in doubt, contact the Carrier Steps a through q cover the installation of an Transport Air Conditioning Technical Service IW-1 in the Rear of an IC bus. Additional steps Hot Line (1--800-450-2211). -
Page 40: Figure 2-37 In-Wall Cut-Out (Panel Removed)
Figure 2-37 In-Wall Cut-Out (Panel Removed) CAUTION When installing any IW unit, be careful not to cut the bus structure rails or wiring harnesses. Figure 2-38 In-Wall Cut-Out (Insulation Removed) Bracket To Hold Wiring Up Left Structure Rail Right Structure Rail Figure 2-39 In-Wall Cut-Out (Wires Supported) Carefully remove the insulation from between the evaporator. -
Page 41: Figure 2-40 Bus Electrical Harness Ground
Move Ground To Area Above In-Wall Evap. Figure 2-42 In-Wall Hose Cover Back Secure hose backs to bus wall. Route refrigerant hose, electrical cable and drain lines to the IW evaporator. Refer to Section 4, Hose Routing Procedures and Section 5, Electrical Figure 2-40 Bus Electrical Harness Ground Remove bus grounding screw and relocate to an area that doesn’t interfear with the In-Wall evaporator... -
Page 42: Figure 2-44 Hose/Harnes/Drain Routed To Iw
Evap. Harness Mounting Bolt Suction Line Electrical Connections Liquid Line Drain Line Ground Screw Structure Rail No-Drip Tape Figure 2-44 Hose/Harnes/Drain Routed To IW Attach the IW Evaporator Assembly to the bus structure using the appropriate hardware. See Figure 2-45 and Figure 2-46. Mounting Bolt Remove plugs or tape from the hose ends and attach the appropriate fittings to the hose assemblies. -
Page 43: Figure 2-47 Hose Cover Installed (Left-Side)
Figure 2-47 Hose Cover Installed (Left-Side) Figure 2-48 In-Wall With Trimmed Cover (Rear) T--311 2--20... -
Page 44: Figure 2-49 Front In-Wall Template
2.6.2 Front Mounted In-Wall Evaporator 1 The safest and least intrusive way to route refrigerant hose and electrical cable Installation of an In-Wall in the front wall of a bus requires a little more thought and planing than when 2 How and where to route drain lines. installing a rear mounted IW. -
Page 45: Figure 2-52 In-Wall Installed (Front Mount)
ing the fittings, make sure that the Block CAUTION Valve does not move. Never route refrigerant hose, electrical cable or drain lines in any location where driver’s visibality would be impaired. Follow steps a through c above. The additional 2 inches of cut-out may not be required if there is access from another source (See Figure 2-50 &... -
Page 46: Figure 2-55 In-Wall With Trimmed Cover (Front)
Cut-Out Too High Mounting Screw Mounting Screw Locking Tab Locking Tab Figure 2-55 In-Wall With Trimmed Cover (Front) To install the metal cover to the front mounted IW-1 assembly, carefully line-up and place the two slotted mounting tabs above the IW-1 drain pan and push down (See Figure 2-56). -
Page 47: Figure 2-57 In-Wall Cut-Out (Tbb)
The EM-23 is an after-market heating/cooling unit normally installed in the vehicle dash. For installation instructions and or information on these type systems contact the Carrier Transport Air Conditioning Technical Figure 2-59 IW-1 Secured To Structure Rail TBB Service Hot Line (1--800-450-2211). -
Page 48: Protection
3.1.7 Mounting (Skirt) NOTE All Carrier Transport Air Conditioning condensers are To minimize air recirculation, install condenser supplied with the proper mounting hardware. Never as close to skirt as possible. If distance is 3 substitute mounting hardware. -
Page 49: Cm-2, Cm-3, Cm-4, Cm-5, & Cm-14 Skirtmounted Condenser Assemblies
Condensers are normally located on the outside of the available from Carrier Transport Air Conditioning (Refer vehicle. Their primary function is to reject heat absorbed to paragraph 3.7) Carrier Transport Air Conditioning by the refrigerant from the passenger compartment to condenser assemblies are listed in Table 1-7 &... -
Page 50: Figure 3-1 3/8 Inch Carriage Bolts Thru Floor
Note The condenser assembly should contact as many of the floor supports (stringers) as pos- Bus Floor sible, while hitting the least amount of skirt sup- ports. Bus Stringer Note Always attempt to use at least one of the ve- hicles floor supports (stringers) to mount the condenser assembly. -
Page 51: Figure 3-3 Installation Drawing (Typical Skirt Mounted)
BLOCK SPACER REQUIRED ALTERNATE MOUNTING IF NO STRINGER AT MOUNTING LOCATION BUS FLOOR STRINGER CONDENSER Not Required When Using Chassis Grill Figure 3-3 Installation Drawing (Typical Skirt Mounted) Condenser Mounted Grill Figure 3-4 CM-2 With Chassis Mounted Grill On An Extended Roof Van (Custom) T--311 3--4... -
Page 52: Condenser
Chassis Mounted Grill Figure 3-5 CM-3 With Chassis Mounted Grill In A Cut-A-Way Chassis 3.4 CM-5 CONDENSER Refer to the installation drawing enclosed with the condenser or see Figure 3-6. Carrier Transport Conditioning CM-5 Note Condenser is designed to be installed in the skirt of the Because of the size and weight of the CM-5 bus. -
Page 53: Rooftop Condenser Assembly
3.5 KR-4 ROOFTOP CONDENSER ASSEMBLY CAUTION The Carrier Transport Air Conditioning KR4 condensers are designed to be installed on the roof of the bus. They The Rooftop Condenser assembly must are available in single and dual loop configurations. contact the bus roof in the center. If not, Refer to Table 3-3 for Rooftop Condensers dimensions. -
Page 54: Figure 3-7 Mounting Options
Bolt, 3/8-16 X 1-1/4 In. 4 per side. 1/4 In. steel monobolt. 3/8 In. flat washer 3/8 In. flat washer Mounting channel Sealant Bus roof outer skin Bus roof outer skin Roof bow Roof bow Without Mounting Channel With Mounting Channel Figure 3-7 Mounting Options Roof Bow Center of condenser assembly must contact bus roof... -
Page 55: Figure 3-11 Kr4 Condenser Mounted With Mounting Channels (Side View)
Bus Roof Mounting Apply sealant to unit mounting surface Channel Roof Bow Roof Bow and rivet heads to prevent water leaks Figure 3-11 KR4 Condenser Mounted With Mounting Channels (Side View) j. After deciding where the feed-thru plate(s) will be lo- NOTE cated, trace around the outside edges of the plate Two single plates installed on both sides of the... -
Page 56: Kr2 & Kr3
3.6 KR2 & KR3 c. Remove rooftop cover from unit and place condens- er on the center (side to side) of the bus roof at the Carrier Transport Conditioning KR2/3 predetermined location. condensers are designed to be installed on the roof of the bus. -
Page 57: Connecting To Side-Mounted Evaporators
Install air inlet brackets to both sides of the condenser and the block-off plate to the bottom. The Carrier Transport Air Conditioning stacked condensers are designed to be installed in the skirt of j. Install condenser screens (2) to the bus skirt. -
Page 58: Figure 3-16 Stacked Condenser Assembly (Side View)
BUS FLOOR FLOOR MEMBER (STRINGER) Top Condenser CHASSIS Air Inlet Stiffen RAIL Air Outlet Bracket Air Inlet Bracket Bottom Condenser Bus Skirt Figure 3-16 Stacked Condenser Assembly (Side View) Air Inlet Bracket Front Bracket Air Inlet Bracket Block-Off Plate Figure 3-17 Stacked Condenser Assembly (Bus Skirt View) T--311 3--11... -
Page 59: Hose Routing
4.2 QUICK-CLICK RESUABLE HOSE & FITTINGS It is highly recommended that all installations be performed using Carrier Transportation Air Conditioning “Quick-Click” hose and fittings. Mineral Oil 4.2.1 Assembly Instructions For Quick- -Click Resuable Hose &... -
Page 60: Barrier Type Hose & Fittings
(CTAC P/N 07--00417--00) available to aid in the installation. 4.2.2 Barrier Type Hose & Fittings (Not Recommended By Carrier TAC) The setup, operation and equipment maintenance are all critical when using this type hose & fittings. Failure to crimp properly will result in immediate leaks or leaks that become evident due to heat and vibration. -
Page 61: Figure 4--7 Hose Back Positioning
Figure 4- -9 Hole-Saw Cuts Joined Repeat steps 1. through 6. to obtain access to the wall or floor, depending which one you start with. Figure 4- -7 Hose Back Positioning Before drilling holes for the hoses in the wall or through the floor, make sure there are no electrical harnesses, braces, etc. -
Page 62: Figure 4--11 Hose Cover Back
fumes, dust and other foreign material from CAUTION entering the passenger compartment. When drilling into the vehicle wall, always use a drill stop to help protect against dam- aging any wiring that might be located be- hind the wall. Installation Hint To help keep hoses, harness, and drain lines secure and in the center of the hose covers, 3/16 inch holes can be drilled in the hose cover... -
Page 63: Figure 4--15 Hoses Routed Through Floor
Protection Install Condensate Valve (Kazoo) on Drain Line End Figure 4- -15 Hoses Routed Through Floor A piece of scrap drain hose or heater hose, split down the middle, can be used for protection. 11. After hoses and harness are protected, secure them to the hose cover backs with the Tie-Wraps (See Figure 4- -16 Incorrect Hose/Harness Routing Figure 4--19). -
Page 64: Evaporator Hose Routing, Outside The Bus Wall
Proper hose to fitting clamping is critical. Do not attempt to attach any hose or fitting until you have familiarized yourself with Carrier Transport Air Conditioning Quick-Click hose/fitting crimping procedures. 4.4 EVAPORATOR HOSE ROUTING, OUTSIDE THE BUS WALL The evaporator has been previously installed. -
Page 65: Evaporator Hose Routing, Side-Mounted
1. Determine which side of the vehicle the hoses to attach any hose or fitting until you have familiarized should be routed; the drivers side or passenger side. yourself with Carrier Transport AC’s Quick-Click 2. Determine what route the hoses will take. Take into hose/fitting crimping procedures. -
Page 66: Chassis Hose Routing
Do not attempt to attach any hose or fitting “P-Clamps”. Clamps should be spaced no more than 24 until you have familiarized yourself with Carrier inches apart. Secure the hoses and harness to the Transport Air Conditioning Quick-Click hose/fitting vehicles floor supports and/or chassis frame (see clamping procedures. -
Page 67: Condenser Hose Routing
Figure 4- -23 Hose Routing (Chassis) Figure 4- -25 Hose Routing (Chassis) Figure 4- -24 Hose Routing (Chassis) Figure 4- -26 Hose Routing (Chassis) Figure 4- -27 Hose Routing (Chassis & Condenser) When mounting hose in the condenser area, secure the 4.7 CONDENSER HOSE ROUTING hose in a manner so that the weight of the hose is not on Always keep hose capped until ready to connect to a... -
Page 68: Vehicle Compressor Hose Routing
High Side Access Properly clamping a fitting to the refrigerant hose is very important. Do not attempt to attach any hose or fitting until you have familiarized yourself with Carrier Transport Air Conditioning Quick-Click hose/fitting clamping procedures. Refer to paragraph NO TAG. -
Page 69: Torque Specifications - Refrigerant Fittings
Minimize air pockets in the system by adding an air Carrier Transport Air Conditioning does not supply bleed-off device at the systems high point. heater hose for connecting to a Carrier Transport Air The use of a positive shut-off valve in the auxiliary hot Conditioning supplied heater coil. -
Page 70: Figure 4-22 Rear Evaporator, Oem Tie-In
Figure 4-22 Rear Evaporator, OEM Tie-in T--311 4--12... -
Page 71: Figure 4-23 Evaporator, Skirt Monuted Condenser And Compressor
Figure 4-23 Evaporator, Skirt Monuted Condenser and Compressor 4--13 T--311... -
Page 72: Figure 4-24 Evaporator, Skirt Monuted Condenser And Compressor (Ac-322, -332, -442)
Figure 4-24 Evaporator, Skirt Monuted Condenser and Compressor (AC-322, -332, -442) T--311 4--14... -
Page 73: Figure 4-25 Evaporator, Skirt Monuted Condenser Compressor And Aftermarket Indash (Ac-4431)
Figure 4-25 Evaporator, Skirt Monuted Condenser Compressor and Aftermarket InDash (AC-4431) 4--15 T--311... -
Page 74: Figure 4-26 Em-3 Evaporator, (2) Skirt Monuted Condensers And Tm-31 Compressor (Ac-882, -883)
Figure 4-26 EM-3 Evaporator, (2) Skirt Monuted Condensers and TM-31 Compressor (AC-882, -883) T--311 4--16... -
Page 75: Figure 4-27 (1)Em-3 Evap, (1)Em-7 Evap, (2) Skirt Condensers And A Tm-31 Compressor (Ac-9632)
Figure 4-27 (1)EM-3 Evap, (1)EM-7 Evap, (2) Skirt Condensers and a TM-31 Compressor (AC-9632) 4--17 T--311... -
Page 76: Electrical
Carrier Transport Air Conditioning components are 5.2.1 Electrical Kits designed to operate efficiently at 12.5 or 25 volts. For The electrical kits provided with Carrier Transport Air continued proper operation, all components must have Conditioning systems contain the harnesses/cables a proper voltage supply, even during low idle. After at... -
Page 77: Evaporator Chassis Ground, Gen
a. Carefully make an 8 Inch incision in the evaporator 5.4.2 Evaporator Chassis Ground, Gen 5 cable close to where you will attach the ground wire Gen 5 evaporators are supplied with a 12 foot section of terminal. green, 10 or 6 gauge wire, depending on the evaporator assembly. -
Page 78: Electrical Control Panel
Figure 5-6 Drivers Control Panel (Dual Systems) 5.5.2 Electrical Control Panel When wiring is routed through the bus fire-wall the cables muste be protected from the sharp edges of the The manual controls are wired to the electrical control cut-out hole. Use a plastic or rubber grommet and seal panel (See Figure 5-7 - Figure 5-9 - Figure 5-10) The the area around the opening (See Figure 5-8). -
Page 79: Electrical Control Panel - Torque Values
Mounting Screw Mounting Screw Figure 5-9 Relay Boards Installed Inside Bus (Dual System) To aid you in properly mounting the electrical panel hole (See Figure 5-9). After installing the relay board, using the pre-punched mounting holes it will be easier if carefully place the MSR back into its connector. -
Page 80: Total Control
5.6 TOTAL CONTROL located in an area that is protected from heat, moisture and road hazards. The Total Control system consists of a Key Pad Display Care must be taken when routing the return air sensor (Figure 5-12), an Electrical Control Panel, (Figure 5-13) (thermistor) cable and the cab command cable. -
Page 81: Operating Instructions
Figure 5-14 Gen 5 Total Control (Dual System) 5.7 OPERATING INSTRUCTIONS running, start the engine. For complete operating instructions refer to operation and service manual T-299 Before attempting to operate the system, power must Split-Systems. be available from the vehicle battery. If the engine is not 5--6 T--311... -
Page 82: Mount Kits And Compressors
MOUNT KITS AND COMPRESSORS 6.1 INTRODUCTION If system is a “Tie-In” to factory dash air, the refrigerant Carrier transport Air Conditioning offers a wide range of must be removed with an EPA approved recovery ma- compressors and corresponding mount kits for most chine. -
Page 83: Torque Specifications - Bolts
Figure 6-3 U.S.S. Torque Specs For questions or concerns not covered here, please feel free to contact the Carrier Transport Air Conditioning Commercial Grade Head Markings Technical Service Hot Line (1--800-450-2211). U.S. Customary Bolts 6.3.2 Belt Clearance... -
Page 84: Pulley Alignment
Minimizing tolerances must be alignment purposes. Other alternatives are available considered during the design process to minimize this please contact the Carrier Transport Air Conditioning problem. Angular misalignment is corrected by Technical Service Hot Line (1--800-450-2211) with any loosening the mounting hardware, adjusting the questions or comments. -
Page 85: Measuring Methods For Belt Tension
considered when making aforementioned Proper belt tension is obtained by referring to Figure 6-8 measurements. . Find the belt used and where applied (compressor or alternator drive, Single ”V” or Poly ”V” 4-8 ribs). The next step is to lay the straight edge flush across the face of the driven pulley. -
Page 86: Oil Charge
Note 6.4.4 Oil Charge Each compressor comes with a standard charge of oil The side to side mounting angle of the A-6 com- inside. This quantity of oil is enough to supply the com- pressor must remain ±15° from the horizontal pressor lubrication when installed into an already “oil (See Figure 6-9). -
Page 87: Evacuation
The following equipment is essential when performing proper evacuation. an installation of or servicing of any Carrier Transport Air Conditioning system. Refer to Figure 7-2 for service 7.2.1 Preparation component connections. -
Page 88: Installing Manifold Gauges
HAND VALVE within this manual. The manifold gauge/hose set is available from Carrier Transicold. (Carrier Transicold To Low Side To High Side P/N 07-00294-00, which includes items 1 through 6. To... -
Page 89: Figure 7-2 Refrigerant Service Connections (Split Systems)
(New Location GEN 5) EVAPORATOR COIL SUCTION ACCESS SIGHT GLASS FILTER DRYER MICRO CHANNEL RECEIVER DRIER DISCHARGE ACCESS (GEN 4 Location) CONDENSER COIL COMPRESSOR Vacuum Pump Recovery/Recycle Machine Micron Gauge R134a High (Discharge) Side Coupler Manifold Gauge Set R134a Low (Suction) Side Coupler Refrigerant Cylinder Figure 7-2 Refrigerant Service Connections (Split Systems) 7--3... -
Page 90: Charging Procedures
Calculations for determining the proper refrigerant charge are based on component capabilities and liquid line lengths as indicated on Carrier Transport Air NOTE Conditioning charging tables. Refer to Table 8-1 or Using oil other than that specified in Table 8-4 Table 8-2 for the approximate refrigerant charge. -
Page 91: Evaporator Tie-In
When an after market in-dash evaporator is added to a standard system the refrigerant charge will increase by approximately 1 pound. If attempting to use a CM-2 condenser with a tie-in call Carrier Transport Air conditioning technical support for an application review. -
Page 92: Adding Refrigerant To System (Full Charge)
For questions regarding charging procedures, contact the Carrier Transport Air Conditioning Technical Service Hot Line (1--800-450-2211). CAUTION Use only the exact oil specified by Carrier Transicold. Use of oil other than that specified will void the compressor warranty. 8.1.6 Adding Refrigerant to System (Full Charge) -
Page 93: Table
Table 8-5 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHART Determine the approximate refrigerant charge using Table 8-1 or Table 8-2 . Follow the procedures listed below to determine if the correct charge has been obtained. Procedure Table Your Entry Example Pres- Refrigerant Temp. -
Page 94: Leak Checking
Charge the system with refrigerant 134a to build up 9.1.1 Micron (Vacuum) Gauge pressure between 30 to 50 psig. Carrier Transport Air Conditioning recommends a Micron (Vacuum) Gauge to assure that the proper b. Add sufficient nitrogen to raise system pressure vacuum level is attained. -
Page 95: Figure 9-1 Refrigerant Service Connections (Split Systems)
(New Location GEN 5) EVAPORATOR COIL SUCTION ACCESS SIGHT GLASS FILTER DRYER RECEIVER DRIER DISCHARGE ACCESS (GEN 4 Location) CONDENSER COIL COMPRESSOR Vacuum Pump Recovery/Recycle Machine Micron Gauge R134a High (Discharge) Side Coupler Manifold Gauge Set R134a Low (Suction) Side Coupler Refrigerant Cylinder Figure 9-1 Refrigerant Service Connections (Split Systems) T--311... -
Page 96: Authorized Carrier Transport A/C Dealers
3. White Copy: Carrier Transport Air Conditioning copy: a. Click on: Warranty a. Must be mailed to Carrier Transport Air Conditioning, b. Click on: Register your unit 50 Grumbacher Road, York, PA. 17406, in order to validate the system warranty. -
Page 97: Installation Check-Out
The installation checkout procedure is an important step in the installation of any air conditioning system. The reason for the installation checkout procedure is to insure that all Carrier Transport Air Conditioning standards of installation quality have been met. An itemized checkout form will help you in the checkout process and will provide a device for permanently recording your findings. - Page 98 EVAPORATOR AREA: ____ ____ Is evaporator(s) mounted securely to the bus roof? Either through the roof using hardware supplied by Carrier Transport Air Conditioning or by Carrier Transport Air Conditioning approved OEM supplied mounting brackets? ____ ____ If evaporator is mounted with carriage bolts through the roof, are the roof rails...
- Page 99 REFRIGERATION HOSE AND ELECTRICAL HARNESS ROUTING - Continued: ____ ____ Is “Mineral Oil” used to lubricate the fittings, hose and “O” Rings? ____ ____ Is there a workable “service loop” at all refrigerant hose connections? ____ ____ Are refrigerant hoses routed to the condenser, evaporator and compressor properly? ____ ____...
- Page 100 SYSTEM OPERATION - Continued: ____ ____ Has refrigerant and oil charge been noted on the charging label? Correct type oil? ____ ____ Is charging label attached as closely as possible to the compressor? ____ ____ Is there an installation check-out sheet in use? FINAL: Record readings after system has been running for at least 10 minutes at high idle.
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Page 101: System Requirement Label Completion
11.1 SYSTEM REQUIREMENTS LABEL ounces. If this is a dual system, designate on tag which system (#1 or #2) is front (F) or rear (R), drivers (D) or The system requirements label must be conveniently passenger (P) side. located within the vehicle’s engine compartment. This 4. - Page 102 INDEX EM-23 COOL/HEAT EVAPORATOR, 2-24 EM-3 EVAPORATOR, 2-8 Adding Refrigerant to System (Full Charge), 8-2 EM-9 DUCTED EVAPORATOR , 2-12 Aesthetics, 2-1 Evaporator Chassis Ground, 5-2 AUXILIARY HEATER HOSE ROUTING, 4-10 Evaporator Chassis Ground, Gen 4 , 5-1 EVAPORATOR HOSE ROUTING, 4-1, 4-5 EVAPORATOR HOSE ROUTING, SIDE-MOUNTED, Barrier Type Hose &...
- Page 103 INDEX Requirements Label, 1-1 ROOFTOP CONDENSER HOSE ROUTING, 4-10 Nitrogen, 9-1 Serial Number Tags , 1-1 Obstructions, 3-1 Service Loop, 4-1 Oil Charge, 6-5 SERVICE TOOLS, 7-1 Oil Charge , 8-1 SIDE MOUNTED EVAPORATOR, 2-9 OPERATING INSTRUCTIONS , 5-6 Skirt Supports, 3-1 ORQUE SPECIFICATIONS, 4-10 SKIRTMOUNTED CONDENSER ASSEMBLIES, 3-2 SYSTEM COMPONENTS, 1-4...
- Page 104 Tel: 1- -800- -673- -2431 Transport Air Conditioning Group Fax: 1- -717- -764- -0401 P.O. Box 4805 Syracuse, N.Y. 13221 U.S A www.carrier.transicold.com A member of the United Technologies Corporation family. Stock symbol UTX ©2008 Carrier Corporation D Printed in U. S. A. 0208...