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TechPlus ComfortAire Service Supplement Manual

School bus air conditioning systems
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Summary of Contents for TechPlus ComfortAire

  • Page 1 Comfort Aire Comfort Aire AIR CONDITIONING SYSTEMS TechPlus TechPlus...
  • Page 2 Technical Communications TechPlus Supplement Comfort Aire School Bus Air Conditioning Systems BLue BIrd All American Forward Engine Blue Bird All American Rear Engine Blue Bird Vision Blue Bird MicroBird...
  • Page 3 TechPlus s e r v i c e s u p p l e m e n t © 2006, 2007 Blue Bird Corporation. All rights reserved. In the event of any conflict between the requirements of this publication and any applicable legal requirement, the legal require- ment prevails.
  • Page 4 Technical Publishers; or may be provided by Blue Bird’s manufacturing partners; or may be comprised of both Blue-Bird authored and vendor-authored material. The bulk of this TechPlus Supplement is prepared by Blue Bird’s vendor, Mobile Climate Controls, which builds the Comfort Aire air conditioner units to Blue Bird specifications.
  • Page 5 TechPlus s e r v i c e s u p p l e m e n t...
  • Page 6 c o m f o r t A I r e A / c S y S t e m S Blue Bird Comfort Aire Maintenance Manual All American (A3FE/RE), Conventional Vision (BBCV) & Micro Bird Body Types (REVISION.003) Comfort AIrE APPENDIX...
  • Page 7 TechPlus s e r v i c e s u p p l e m e n t Important Information about Using This Manual Please note that this manual is included with all Blue Bird buses equipped with the Blue Bird factory installed and supported Comfort Aire, air conditioning system.

  • Page 8: Table Of Contents

    c O m F O r t A i r e A / c s Y s t e m s Safety Precautions / 10 General Practices / 10 Refrigerant / 11 First Aid / 11 Refrigeration Oil / 11 First Aid / 11 electrical Hazards / 12 High Voltage / 12...
  • Page 9 TechPlus s e r v i c e s u p p l e m e n t technician Instructions and Information / 28 Charging the Air Conditioning System / 28 Checking the Refrigerant Charge / 29 Checking the Compressor Oil Charge / 29...
  • Page 10 c O m F O r t A i r e A / c s Y s t e m s General trouble Shooting By technician / 53 Blower Motor Does Not Operate / 53 Blower Motor Operates Normally, Bur Air Flow is Insufficient / 53 Insufficient cooling, does not operate at all, or operates improperly / 53 The compressor does not operate at all, or operates improperly / 53 Gauge Pressure Related Troubleshooting / 54...

  • Page 11: Safety Precautions

    TechPlus s e r v i c e s u p p l e m e n t Safety Precautions General Practices 1. ALWAYS WEAR GOGGLES OR SAFETY GLASSES, refrigerant liquid, refrigeration oil, and battery acids can permanently damage the eyes.

  • Page 12: Refrigerant

    c O m F O r t A i r e A / c s Y s t e m s Refrigerant Although fluorocarbon refrigerants are classified as safe refrigerants, certain precautions must be observed when handling them or servicing a unit in which they are used.

  • Page 13: Electrical Hazards

    TechPlus s e r v i c e s u p p l e m e n t Electrical Hazards High Voltage When servicing or repairing an air conditioning unit, the possibility of serious or even fatal injury from electrical shocks exists. Extreme care must be used when working with an operating air conditioning system.

  • Page 14: Low Voltage

    c O m F O r t A i r e A / c s Y s t e m s separating the victim from the power source, check immediately for presence of pulse and respiration. If pulse is not present, START CPR and call for emergency medical assistance.

  • Page 15: Comfort Aire Specifications

    TechPlus s e r v i c e s u p p l e m e n t Comfort Aire Specifications General Compressor ICE TM-21 for A3 and BBCV ICE TM-16 for Micro Bird Both belt driven by the engine Compressor Oil Charge 5 oz.

  • Page 16: A3Re/Fe & Bbcv With Tm-21'S Electrical System

    c O m F O r t A i r e A / c s Y s t e m s A3RE/FE & BBCV with TM-21’s Electrical System With Stacked Skirt Mounted Condenser Evaporator # 1 Circuit Breaker 50 amps Evaporator # 2 Circuit Breaker 50 amps Stacked Condenser Circuit Breaker...

  • Page 17: Maintenance Inspection Schedule

    TechPlus s e r v i c e s u p p l e m e n t Maintenance Inspection Schedule Weekly Monthly Semi Annual Inspect/Service These Items Annual Electrical • • Check Compressor clutch operation • • Inspect D.C. fan motors •...

  • Page 18: General Unit Description

    c O m F O r t A i r e A / c s Y s t e m s General Unit Description The Blue Bird air conditioning unit is designed to provide comfort, at temperatures between 70 - 80 ºF. The typical A3RE/FE and BBCV system consists of three separate assemblies;...

  • Page 19: General Unit Operation

    TechPlus s e r v i c e s u p p l e m e n t General Unit Operation The unit will start operating as the driver turns on the blower switch for each side of the bus; this sends electrical power to the compressor clutch. The compressor clutch will engage as it is turned by the bus engine, through a compressor drive belt.

  • Page 20: General System Component Details

    c O m F O r t A i r e A / c s Y s t e m s General System Component Details Stacked Skirt Mounted Condenser Configuration Cond. 2 Cond. 1 Power Stud 12 V Relay H.P.Binary Switch Drier APPENDIX...

  • Page 21: Stacked Skirt Mounted Condenser Exploded View

    TechPlus s e r v i c e s u p p l e m e n t Stacked Skirt Mounted Condenser Exploded View Components Coils Condenser Grill H.P. Binary Switch 11 12 V Relays and Base Receiver Drier APPENDIX...

  • Page 22: 55,000 Bth/Hr Free Blow Evaporator Configuration

    c O m F O r t A i r e A / c s Y s t e m s 55,000 Bth/hr Free Blow Evaporator Configuration Directional Louvers Air Filter 12 V Relays Blower Assy. Thermostat Module Power Studs Expansion Valve APPENDIX...

  • Page 23: 55,000 Btu/Hr Free Blow Evaporator Exploded View

    TechPlus s e r v i c e s u p p l e m e n t 55,000 Btu/hr Free Blow Evaporator Exploded View Components Blower Assembly Coil 12 V Relays and base Power Stud Expansion Valve 10 Defrost Drain Tube...

  • Page 24: Typical Tm-21 Compressor

    c O m F O r t A i r e A / c s Y s t e m s Typical TM-21 Compressor Manual Control Panel APPENDIX...

  • Page 25: High Pressure Binary Switch

    TechPlus s e r v i c e s u p p l e m e n t High Pressure Binary Switch Typically located on or near the receiver drier, when the pressure in the high side of the system reaches 385 psi, the switch will open, disrupting the voltage to the compressor clutch.

  • Page 26: Driver Instructions And Information

    c O m F O r t A i r e A / c s Y s t e m s Driver Instructions and Information Evaporator 1 Evaporator 2 Thermostat Control Thermostat Control Evaporator 1 Blower Evaporator 2 Speed Blower Speed Starting the Unit 1.Start the vehicle, and select both blowers switches to #3 high speed, select the thermostat control switches to full cool (clockwise) towards H.

  • Page 27: Bi Monthly Post Trip Checks

    TechPlus s e r v i c e s u p p l e m e n t 4. Driver can also direct the air from the evaporators, by positioning the louvers at the evaporator outlets. Bi Monthly Post Trip Checks 1.
  • Page 28 c O m F O r t A i r e A / c s Y s t e m s Visually check the center of the compressor clutch to make sure it is spinning with the pulley. If not call for service, bring it to a qualified repair facility. Is there any noise from a loose compressor drive belt, or compressor? Listen for abnormal noises, if suspected;...

  • Page 29: Technician Instructions And Information

    TechPlus s e r v i c e s u p p l e m e n t Technician Instructions and Information Note: The following procedures involve servicing the air conditioning system. Some of these service procedures are regulated by federal, and in some cases, State and Local laws.

  • Page 30: Checking The Refrigerant Charge

    c O m F O r t A i r e A / c s Y s t e m s 10. Allow the correct charge (refer to spec’s) to enter the system. Then close the valve on the refrigerant drum and the high side valve on the gauge manifold.
  • Page 31 TechPlus s e r v i c e s u p p l e m e n t Pressure Relief Valve 400 psi O Ring Fitting 1. Connect the gauge manifold to the compressor discharge service valve. 2. Set the thermostat control to the coldest setting.

  • Page 32: Clean Up Procedures

    c O m F O r t A i r e A / c s Y s t e m s Clean Up Procedures Remove internal parts of expansion valve Remove drier and install Install straight Suction pipe Line Drier Compressor Evaporator Condenser...
  • Page 33 TechPlus s e r v i c e s u p p l e m e n t 7. Run unit for 2 hours. 8. Stop unit and check oil sample with acid test kit. If the test kit shows there is no acid in the system, you can proceed to reclaim the charge and reassemble unit.

  • Page 34: Part Replacement Procedures

    c O m F O r t A i r e A / c s Y s t e m s Part Replacement Procedures Note: Is it generally good practice to change the receiver drier whenever the high side or when the low side is opened for an extended period of time.

  • Page 35: Condenser Coil

    TechPlus s e r v i c e s u p p l e m e n t Condenser Coil Removal 1. Remove the refrigerant from the system. 2. Remove lines that are connected to the condenser and receiver driers.

  • Page 36: High Pressure Binary Switch

    c O m F O r t A i r e A / c s Y s t e m s 5. Check for leaks. 6. Evacuate and recharge with refrigerant. High Pressure Binary Switch Removal 1. Disconnect wires from the HP Binary switch. 2.

  • Page 37: Expansion Valve Assembly

    TechPlus s e r v i c e s u p p l e m e n t 3. Install lines and fittings to expansion valve and evaporator outlet. 4. Position and install electronic thermostat with mounting screws. 5. Install lines and fittings to the expansion valve and the evaporator outlet.
  • Page 38 c O m F O r t A i r e A / c s Y s t e m s 7. Check for leaks. 8. Evacuate and recharge with refrigerant. End View Feeler Bulb Suction Line Completely wrap bulb and sensor with tape. Ensure that line and bulb has good clean contact.

  • Page 39: Structural Maintenance

    TechPlus s e r v i c e s u p p l e m e n t Structural Maintenance Unit Inspection Inspect the unit on pre trip and regular scheduled maintenance for loose or broken wires and hardware, compressor oil leaks, or other physical damage which might affect the unit performance and require the repair or replacement of parts.

  • Page 40: Tm-21 & Tm-16 Compressor And Clutch Maintenance

    c O m F O r t A i r e A / c s Y s t e m s TM-21 & TM-16 Compressor and Clutch Maintenance Operation A stationary field coil is mounted on the compressor body eccentric with the shaft.

  • Page 41: Clutch Removal

    TechPlus s e r v i c e s u p p l e m e n t both the pulley and the drive plate must be replaced. There should also be no foreign matter, such as oil or grit, lodged between the drive plate and pulley.
  • Page 42 c O m F O r t A i r e A / c s Y s t e m s 4. Remove the cover. 5. Remove the pulley assembly by using the clutch remover and the spacer positioned on the cylinder hub. Note: To avoid damage to the pulley groove, the pulley claws should be hooked (under) the pulley groove.

  • Page 43: Clutch Installation

    TechPlus s e r v i c e s u p p l e m e n t 6. Remove the coils lead wire from the holder on the compressor. 7. Remove the three screws that attach the coil to the compressor and remove the coil.
  • Page 44 c O m F O r t A i r e A / c s Y s t e m s 4. Install the pulley assembly and using the compressor holder and press. 5. Install the cover and the snap ring using external snap ring pliers. Make sure the chamfered inner edge of the snap ring must face upward.
  • Page 45 TechPlus s e r v i c e s u p p l e m e n t 6. Install the driver plate on the drive shaft, together with the original shim(s). Press the drive plate down by hand. 7. Tighten the bolt to the required torque specifications using the puller arbor to prevent drive plate rotation.

  • Page 46: Electrical Connection

    c O m F O r t A i r e A / c s Y s t e m s 8. Ensure that clutch clearance is as specified. If necessary, adjust the clearance using shims. Specified clearance is 0.01 to 0.02 in. (0.3 to 0.6mm) Electrical Connection 1.
  • Page 47 TechPlus s e r v i c e s u p p l e m e n t 4. Use the seal remover to remove the shaft seal. Turn the seal remover to engage the hook on the seal remover with the hook on the shaft seal, and then slowly pull the seal out of the cylinder head.
  • Page 48 c O m F O r t A i r e A / c s Y s t e m s Inspection The shaft seal must never be reused. Always use a new shaft seal when reassembling a compressor. Be extremely careful to make sure the lip of the shaft seal that is being installed is not scratched or damaged in any way.
  • Page 49 TechPlus s e r v i c e s u p p l e m e n t 4. Use the seal installer to press the shaft seal into the cylinder head as far as possible. 5. Remove the seal guide from the shaft.
  • Page 50 c O m F O r t A i r e A / c s Y s t e m s APPENDIX...

  • Page 51: System Compressor And Oil Handling

    TechPlus s e r v i c e s u p p l e m e n t System Compressor and Oil Handling Installation of the Compressor The compressor(s) is mounted on the under side of the engine. The side to side mounting of the compressor must remain 45 degrees from the horizontal.

  • Page 52: Oil Contamination

    c O m F O r t A i r e A / c s Y s t e m s Oil Contamination 1. Dirt in the oil. 2. Color changed to a varnish color. 3. Presence of foreign substances, metal shavings, etc. in the oil. When a system becomes contaminated A Severely contaminated system may be indicated by black oil in the compressor.

  • Page 53: Belt Tensions

    TechPlus s e r v i c e s u p p l e m e n t Belt Tensions Engine Compressor Belts and Pulleys Correct pulley alignment and proper belt tension are very important when installing a compressor. The compressor clutch must line exactly with the engine pulley and other auxiliary idler or belt adjustment components.

  • Page 54: General Trouble Shooting By Technician

    c O m F O r t A i r e A / c s Y s t e m s General Trouble Shooting by Technician Blower Motor Does Not Operate Possible Cause Inspection Solution 1. Blown Fuse Inspect fuse/wiring Replace fuse/wiring 2.

  • Page 55: Gauge Pressure Related Troubleshooting

    TechPlus s e r v i c e s u p p l e m e n t Gauge Pressure Related Troubleshooting Normal compressor suction (low side) and discharge (high side) pressures at ambient temperature of 86 – 95 degrees F (30 – 38 degrees C) and compressor speed of approximately 3300 rpm are: High Pressure: 210 –...

  • Page 56: Operation To Return Oil To The Compressor

    c O m F O r t A i r e A / c s Y s t e m s 5. Restriction in drier, High pressure side will be Evacuate and flush system condenser, or high pressure high, and low pressure side replacing defective parts line will be low.

  • Page 57: Electrical System Trouble Shooting

    TechPlus s e r v i c e s u p p l e m e n t Electrical System Trouble Shooting Clutch Not Engaging: Power is supplied to the clutch from the blower switch, to the electronic thermostat and through the H.P. Binary Switch to the compressor.

  • Page 58: Compressor Trouble Shooting

    c O m F O r t A i r e A / c s Y s t e m s Compressor Trouble Shooting 1. Excessive Heat Load such as running the compressor with the doors and windows open will increase incidence of compressor failure. Poor door and window seals or loose parts, can also contribute to premature failure.

  • Page 59: Refrigeration Diagnosis Chart

    TechPlus s e r v i c e s u p p l e m e n t Refrigeration Diagnosis Chart POSSIBLE CAUSES • • Over charge of refrigerant • • • • • • Sortage of refrigerant • •...

  • Page 60: System Service And Maintenance Notes

    c O m F O r t A i r e A / c s Y s t e m s System Service and Maintenance Notes Service Guidelines Routine maintenance such as cleaning filters and checking the compressor belt tension are procedures that should be included in the driver pre-use inspection.
  • Page 61 TechPlus s e r v i c e s u p p l e m e n t Once the leak is found, replace and correct the leak or part. Also, whenever the system is opened to the atmosphere or there has been a leak in the system, the receiver drier must be changed.

  • Page 62: Refrigeration Chart

    c O m F O r t A i r e A / c s Y s t e m s Refrigeration Chart Normal Evaporator Range Normal Condenser Range Off Coil Air Temp Outside Air Temp 15.69 110.20 17.04 112.10 18.43 114.10 19.87...

  • Page 63: Wiring Schematics

    TechPlus s e r v i c e s u p p l e m e n t 1g. WIRING SCHEMATIC-MICROBIRD MICRO BIRD – MANUAL - TM 16 (Dwg.-P1- 14839) APPENDIX...

  • Page 64: Micro Bird Ecc

    c O m F O r t A i r e A / c s Y s t e m s 1h. WIRING SCHEMATIC- MICROBIRD MICROBIRD - ECC - TM16 (Dwg. P1-14852) APPENDIX...

  • Page 65: Bbcv, A3Re, A3Fe Manual

    TechPlus s e r v i c e s u p p l e m e n t 2u. WIRING SCHEMATIC- (P1-14838) BBCV,A3RE ,A3FE – MANUAL-2TM21-SPLIT–SKIRT MOUNT COND. APPENDIX...

  • Page 66: Bbcv, A3Re, A3Fe Ecc

    c O m F O r t A i r e A / c s Y s t e m s 2v. WIRING SCHEMATIC ( P1-14851) BBCV,A3RE ,A3FE – ECC-2TM21-SPLIT–SKIRT MOUNTED COND. APPENDIX...

  • Page 67: Slimline System Manual

    TechPlus s e r v i c e s u p p l e m e n t 4c. WIRING SCHEMATIC- (P1-14853) SLIM LINE SYSTEM (06/07) – MANUAL - 2TM21-SPLIT–SKIRT MOUNT. APPENDIX...

  • Page 68: Slimline System Ecc

    c O m F O r t A i r e A / c s Y s t e m s 4d. WIRING SCHEMATIC- (P1-14854) SLIM LINE SYSTEM (06/07) – ECC - 2TM21-SPLIT–SKIRT MOUNT APPENDIX...

  • Page 69: Electronic Control User Guide

    TechPlus s e r v i c e s u p p l e m e n t Electronic Climate Control User Guide Front Rear Temp:21°C Temp:68°F Temp:25°C Temp:75°F Fan: Med Fan: Med Fan: Max Fan: High © 2006 Mobile Climate Control Industries Inc. Rev 0...

  • Page 70: Electronic Climate Control (Ecc)

    c O m F O r t A i r e A / c s Y s t e m s Electronic Climate Conrol (ECC) The ECC is a control interface, automatic climate controller, diagnostics and auto protection packed into one module.

  • Page 71: Ecc Control

    TechPlus s e r v i c e s u p p l e m e n t ECC Controls Front Rear Temp:21°C Temp:68°F Temp:25°C Temp:75°F Fan: Med Fan: Med Fan: Max Fan: High 1 & 5. Front and Rear Temperature Set-Point Control These Buttons changes air temperature setting for both front and rear air conditioning units.

  • Page 72: Ecc User Display

    c O m F O r t A i r e A / c s Y s t e m s ECC User Display Temp:68°F E Temp:75°F Fan: Med Fan: High 1 & 3. Temperature and Fan Speed Display It displays set-point temperature in Celsius or Fahrenheit and fan speed in Low, Medium, High or Off for both front and rear air- condition units.

  • Page 73: Basic Operation

    TechPlus s e r v i c e s u p p l e m e n t Basic Operation Air Conditioning Front Rear 1. Adjust set-point temperature to desired Temp:21°C Temp:68°F Temp:25°C Temp:75°F setting buy using temperature adjustment Fan: Med...

  • Page 74: System Diagnosis

    c O m F O r t A i r e A / c s Y s t e m s System Diagnostics Diagnostics mode are divided into two sections: Section 1: System run-time Section 2: System and sensor errors Displays system run-time, system cycling times and supply voltage.
  • Page 75 TechPlus s e r v i c e s u p p l e m e n t Fr Evap Time Fr Return Temp. 75°F 12.5 Hrs Open: 0Shrt: 0 Rst System run-time: Temperature sensor status: Indicates run-time in hours that units has been...

  • Page 76: System Schematics

    c O m F O r t A i r e A / c s Y s t e m s 2s. SYSTEM SCHEMATIC-TRANSIT COMP. (Dwg. P1-14849) A3RE – ECC - BITZER – ROOF TOP CONDENSER APPENDIX...

  • Page 77: A3Re Ecc Roof Top Condenser

    TechPlus s e r v i c e s u p p l e m e n t 2t. WIRING SCHEMATIC ( P1-14849) A3RE – ECC - BITZER – ROOF TOP CONDENSER APPENDIX...

  • Page 78: Engine Kit Compressor

    c O m F O r t A i r e A / c s Y s t e m s 5c. BLUE BIRD – ENGINE KIT COMPRESSOR PRODUCT NO. 26-1385 Product View APPENDIX...
  • Page 79 TechPlus s e r v i c e s u p p l e m e n t 5d. BLUE BIRD – ENGINE KIT COMPRESSOR PRODUCT NO. 26-1385 Exploded Product View APPENDIX...
  • Page 80 n O t e s otes...
  • Page 81 TechPlus s e r v i c e s u p p l e m e n t otes...
  • Page 82 n O t e s otes...
  • Page 83 TechPlus s e r v i c e s u p p l e m e n t otes...
  • Page 84 n O t e s otes...
  • Page 85 Customer Name ____________________________________________ Body Number ____________________________________________ In-Service Date ____________________________________________ Inspection Date ____________________________________________ Odometer Reading ____________________________________________ Dealer Name ____________________________________________ Dealer Address ____________________________________________ City | State | Zip ___________________________| ____| ___________ Technician Name ____________________________________________ Technician Phone ____________________________________________ Electrical Checks c Check Compressor Clutch Operation c Record Compressor Clutch Voltage c Record Compressor Amperage c Record Clutch Gap c Check Condenser Fan Motor Operation c Check All Three Blower Speeds c Inspect Wire Harnesses c Clean, Lubricate Condensor Power Studs c Inspect Binary Pressure Switch Connectors Refrigeration Checks c Check Refrigerant Level c Check Moisture Indicator c Compressor Oil Acid Test c Pressure Within Range c Check Refrigeration Lines Structural Checks c No Loose or Broken Parts c Clean Defrost Drains & Check Valves c Inspect Compressor Mount Bracket c Check Mount Bracket Torque c Inspect Belts & Adjust Tension c Inspect, Clean and/or Replace Evaporator Side Filters...
  • Page 86 For GENUINE BLUE BIRD replacements parts, contact your Blue Bird Authorized Dealer...

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