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DC-19922
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Manuals and User Guides for Carrier DC-19922. We have
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Carrier DC-19922 manual available for free PDF download: Installation Procedures Manual
Carrier DC-19922 Installation Procedures Manual (104 pages)
Transport Air Conditioning, SPLIT SYSTEMS Generation 4 & 5
Brand:
Carrier
| Category:
Air Conditioner
| Size: 5.37 MB
Table of Contents
Installation Procedures
1
Safety Summary
3
Table of Contents
8
Section
15
Condensers
15
Introduction
15
Description
15
System Requirements Label
15
Table 1-1 ADDITIONAL SUPPORT MANUALS
15
Figure
16
Figure 1-1 Condenser Model CM2/3 - Serial Number Location
16
Figure 1-2 GEN 4 Evaporator Model - Serial Number Location
16
Table 1-2 CARRIER TRANSPORT AIR CONDITIONING SYSTEMS (GEN 4/5)
16
Figure 1-3 GEN 5 Evaporator Model (All) - Serial Number Location
17
Figure 1-4 GEN 4, IW-2 & IW-7 - Serial Number Location
17
Figure 1-5 GEN 4, IW-1 - Serial Number Location
17
Figure 1-6 CM-7/11 Rooftop Condensers (no Longer Offered) - Serial Number Location
18
Figure 1-7 KR-2/KR-3 Rooftop Condensers - Serial Number/Pid Location
18
Figure 1-8 KR-4 Rooftop Condenser - Serial Number/Pid Location
18
Figure 1-9 Typical Component Locations
19
System Components
19
Cooling Cycle
20
Figure 1-10 Refrigerant Flow Diagram
20
Table 1-3 GEN 4 EVAPORATORS
21
Table 1-4 GEN 5 EVAPORATORS
21
Table 1-5 GEN 5 EVAPORATORS -- VARIABLE SPEED
22
Table 1-6 IN--WALL EVAPORATORS
22
Pre-Installation Inspection
23
Cap Plugs
24
Evaporators
24
Location
24
Figure 2-1 Template for EM-1 and EM-2 (GEN 4)
25
Rear Mounted Evaporators
25
Table 2-1 GEN 4 EVAPORATORS
25
Table 2-2 GEN 5 EVAPORATORS
25
Figure 2-2 Measurement to Wall (GEN 4)
26
Figure 2-3 Measurement to Wall (GEN 5)
26
Figure 2-4 7/16 Inch Holes in Bus Roof
26
Figure 2-5 Carriage Bolts & Sealant
26
Figure 2-6 Sealant Pattern on Mounting Channel
26
Table 2-3 DISTANCE to BACK WALL (GEN 4)
26
Table 2-4 DISTANCE to BACK WALL (GEN 5)
26
Figure 2-10 Evaporator Mounted to Flat Ceiling
27
Figure 2-11 Mounting Channel Sealing
27
Figure 2-7 Carriage Bolt Sealing
27
Figure 2-8 Locking Pliers Clamped to Carriage Bolts
27
Figure 2-9 Locking Pliers & GEN 4 Evaporator
27
Figure 2-12 Block Valve Insulation
28
Figure 2-13 Drain Line & Condensate Valve
28
Figure 2-14 Installed GEN 4 Evaporator
28
Figure 2-15 Return Air Grill
28
Figure 2-16 Painted Mounting Channel
28
Figure 2-17 GEN-4/5 Front/Rear (EM-1, 2, 6, & 14) Evaporator & Installation Hardware
29
Figure 2-18 Rear Mount Evaporator (GEN 4) - Installed
29
Figure 2-19 Rear Mount Evaporator (GEN-5) - Installed
30
Figure 2-20 EM-6 (GEN 4) Rear Mounted in an Extended Roof Van
30
Luggage Compartment Evaporator
30
Em-3 Evaporator Gen 4 or Gen 5
31
Figure 2-21 EM-3 Installation Diagram
31
Figure 2-22 Side-Mount Template
32
Figure 2-23 Drain Line Elbows
32
Figure 2-24 Side Mount Installation Instructions (Typical)
33
Figure 2-25 Side Mounted Evaporator GEN 4
33
Figure 2-26 EM-2 (Gen V) Side-Mount - Free Blow, Installed (Complete)
34
Figure 2-27 EM-9 Ducted Evaporator - Hose & Harness Routing
35
Figure 2-28 Punching out Louver Holes
36
Figure 2-29 End Cap with Louver
36
Figure 2-30 EM-9 Ducted Evaporator - Location - Completed Assembly
36
Figure 2-31 School Style Ducting-Passenger Side
36
Figure 2-32 School Style Ducting-Drivers Side
36
Figure 2-33 Side Mounted Hose Routing (Using 455 Angles)
37
Figure 2-34 Side Mounted Hose Routing (Straight)
37
Em-17 Evaporator
38
Figure 2-35 EM-17 Installed
38
Figure 2-36 In-Wall Marked for Cut-Out
39
Rear Mounted In-Wall Evaporator
39
Table 2-5 IW-1 EVAPORATOR DIMENSIONS
39
Table 2-6 IW-2 EVAPORATOR DIMENSIONS
39
Table 2-7 IW-14 EVAPORATOR DIMENSIONS
39
Figure 2-37 In-Wall Cut-Out (Panel Removed)
40
Figure 2-38 In-Wall Cut-Out (Insulation Removed)
40
Figure 2-39 In-Wall Cut-Out (Wires Supported)
40
Figure 2-40 Bus Electrical Harness Ground
41
Figure 2-41 In-Wall Hose/Drain Line Cut-Out
41
Figure 2-42 In-Wall Hose Cover Back
41
Figure 2-43 Bus Light Removed for Access
41
Figure 2-44 Hose/Harnes/Drain Routed to IW
42
Figure 2-45 IN-Wall Installed (Left-Side)
42
Figure 2-46 In-Wall Installed (Right-Side)
42
Figure 2-47 Hose Cover Installed (Left-Side)
43
Figure 2-48 In-Wall with Trimmed Cover (Rear)
43
Figure 2-49 Front In-Wall Template
44
Figure 2-50 Hose/Harness/Drain Line Routing & Access Cut-Out
44
Figure 2-51 In-Wall Front Installation
44
Front Mounted In-Wall Evaporator
44
Figure 2-52 In-Wall Installed (Front Mount)
45
Figure 2-53 Hose Routed over Door (Closeup)
45
Figure 2-54 Hose Routed over Door
45
Figure 2-55 In-Wall with Trimmed Cover (Front)
46
Figure 2-56 In-Wall Cover - Locking Tabs
46
Figure 2-57 In-Wall Cut-Out (TBB)
47
Figure 2-58 IW-1 Installed in TBB (Rear)
47
Figure 2-59 IW-1 Secured to Structure Rail TBB
47
In-Wall Evaporator - TBB
47
Mounting (Rooftop)
48
Mounting (Skirt)
48
Obstructions
48
Protection
48
Skirt Supports
48
Voltage
48
Figure
28
Figure
47
Condensers
48
CM-2, CM-3, CM-4, CM-5, & CM-14 Skirtmounted Condenser Assemblies
49
Skirt--Mounted Installations
49
Table 3-2 SKIRT MOUNTED COND. DIMENSIONS
49
Figure 3-1 3/8 Inch Carriage Bolts Thru Floor
50
Figure 3-2 Condenser Mounted with Hardware
50
Figure 3-3 Installation Drawing (Typical Skirt Mounted)
51
Figure 3-4 CM-2 with Chassis Mounted Grill on an Extended Roof Van (Custom)
51
CM-5 Condenser
52
Condenser
52
Figure 3-5 CM-3 with Chassis Mounted Grill in a Cut-A-Way Chassis
52
Figure 3-6 CM-5 Installation Drawing
52
Rooftop Condenser Assembly
53
Rooftop Condenser Installations
53
Table 3-3 ROOF--MOUNT COND. DIMENSIONS
53
Figure 3-10 KR4 Condenser Mounted Without Mounting Channels (Side View)
54
Figure 3-7 Mounting Options
54
Figure 3-8 KR4 Condenser Mounted Without Mounting Channels (Front/Back View)
54
Figure 3-9 KR4 Condenser Mounted with Mounting Channels (Front/Back View)
54
Figure 3-11 KR4 Condenser Mounted with Mounting Channels (Side View)
55
Figure 3-12 Condenser Feed-Thru Plate KR4 (Single Loop)
55
Figure 3-13 Condenser Feed-Thru Plate KR4 (Dual Loop)
55
Figure 3-14 Condenser Feed-Thru Plate KR2/3
56
Figure 3-15 Condenser Feed-Thru Plate KR2/3
56
Connecting to Side-Mounted Evaporators
57
Kr2 & Kr3
56
And CM-3 Stacked Condenser Assemblies
57
Figure 3-16 Stacked Condenser Assembly (Side View)
58
Figure 3-17 Stacked Condenser Assembly (Bus Skirt View)
58
Hose Routing
59
Introduction
59
Planning
59
Service Loop
59
Dual Systems
59
Connection Lubrication (Mineral Oil)
59
Quick-Click Resuable Hose & Fittings
59
Assembly Instructions for Quick--Click
59
Resuable Hose & Fitting Connections
59
Figure 4--1 Quick--Click #1
59
Barrier Type Hose & Fittings
60
Evaporator Hose Routing-Inside the Bus Wall
60
Figure 4--4 Quick--Click #4
60
Figure 4--5 Quick-Click Hose (Capped)
60
Figure 4--6 Bus with Rear Seat Removed
60
Figure 4--10 Rear Wall Access
61
Figure 4--7 Hose Back Positioning
61
Figure 4--8 Hole-Saw Cuts in Floor
61
Figure 4--9 Hole-Saw Cuts Joined
61
Figure 4--11 Hose Cover Back
62
Figure 4--12 Hose Cover Backs on Rear Wall
62
Figure 4--13 Access Hole with Trim-Lock
62
Figure 4--14 Hoses Routed through Access
62
Figure 4--15 Hoses Routed through Floor
63
Figure 4--16 Incorrect Hose/Harness Routing
63
Evaporator Hose Routing, Outside the Bus Wall
64
Figure 4--17 Correct Hose/Harness Corner Routing (Window Not Blocked)
64
Figure 4--18 Side-Mounted Routing (Top)
64
Figure 4--19 Hose/Harness/Drain Line Tie-Wraped to Hose Cover Backs
64
Figure 4--20 Hose/Harness Clamped to Wall
64
Evaporator Hose Routing, Side-Mounted
65
Chassis Hose Routing
66
Figure 4--21 Metal Hose Cover Backs W/Tie-Wraps
66
Figure 4--22 Side-Mounted Hose/Harness Routing
66
Condenser Hose Routing
67
Figure
67
Figure 4--23 Hose Routing (Chassis)
67
Figure 4--24 Hose Routing (Chassis)
67
Figure 4--25 Hose Routing (Chassis)
67
Figure 4--26 Hose Routing (Chassis)
67
Figure 4--27 Hose Routing (Chassis & Condenser)
67
Figure 4--28 Engine Routing (with High & Low In-Line Access Fittings)
68
Figure 4--29 Hose Routing - OEM (to & from Engine)
68
Vehicle Compressor Hose Routing
68
(Generic)
69
Auxiliary Heater Hose Routing
69
Piping Diagrams
69
Rooftop Condenser Hose Routing
69
Torque Specifications - Refrigerant Fittings
69
Figure 4-22 Rear Evaporator, OEM Tie-In
70
Figure 4-23 Evaporator, Skirt Monuted Condenser and Compressor
71
Figure 4-24 Evaporator, Skirt Monuted Condenser and Compressor (AC-322, -332, -442)
72
Figure 4-25 Evaporator, Skirt Monuted Condenser Compressor and Aftermarket Indash (AC-4431)
73
Figure 4-26 EM-3 Evaporator, (2) Skirt Monuted Condensers and TM-31 Compressor (AC-882, -883)
74
Figure 4-27 (1)EM-3 Evap, (1)EM-7 Evap, (2) Skirt Condensers and a TM-31 Compressor (AC-9632)
75
Section
76
Electrical
76
Introduction
76
System Wiring
76
Electrical Kits
76
Protection
76
Dual Systems
76
Voltages
76
Component Connections
76
Evaporator Chassis Ground, Gen 4 (Excel)
76
Figure 5-1 Harness & Pig-Tail Connections
76
Evaporator Chassis Ground, Gen
77
Controls
77
Manual Controls
77
Figure 5-2 Grounded to Clamp
77
Figure 5-3 Grounded to Chassis Rail
77
Figure 5-4 Drivers Control Panel
77
Figure 5-5 Controls Mounted Without Panel
77
Electrical Control Panel
78
Figure 5-6 Drivers Control Panel (Dual Systems)
78
Figure 5-7 Electrical Control Panel (Typical)
78
Figure 5-8 Electrical Control Cables Thru Fire Wall to Electrical Control Panel
78
Electrical Control Panel - Torque Values
79
Figure 5-9 Relay Boards Installed Inside Bus (Dual System)
79
Figure 5-10 Wired Relay Boards (Dual System)
79
Figure 5-11 Relay Boards Inside Dash Panel
79
Total Control
80
Total Control Electrical Control Panel
80
Figure 5-12 Total Control Key Pad/Display
80
Figure 5-13 Total Control Electrical Panel (Typical)
80
Operating Instructions
81
Figure 5-14 Gen 5 Total Control (Dual System)
81
Mount Kits and Compressors
82
Introduction
82
Installation
82
Torque Specifications - Bolts
83
Torque Specifications - Split System Electrical Panels
83
Drive Belt Installation
83
Belt Clearance
83
Figure 6-1 Metric Torque Specs
83
Figure 6-2 Metric Bolt Markings
83
Figure 6-3 U.S.S. Torque Specs
83
Figure 6-4 U.S.S. Bolt Markings
83
Pulley Alignment
84
Figure 6-5 Belt Clearance Requirements
84
Figure 6-6 Belt Misalignment
84
Figure 6-7 Straight-Edge Application
84
Measuring Methods for Belt Tension
85
Compressor Installation
85
Installation Position
85
Installation Precautions
85
Mounting Compressors
85
Figure 6-8 Belt Tension Guide
85
Oil Charge
86
Figure 6-9 Compressor Mounting Angles
86
Evacuation
87
Introduction
87
Refrigerant Service Tools
87
Preparation
87
Procedure - Complete System
87
Figure 7-1 Manifold Gauge Set
87
Installing Manifold Gauges
88
Figure 7-2 Refrigerant Service Connections (Split Systems)
89
Charging Procedures
90
Introduction
90
Proper R134A Charge
90
Proper Oil Charge
90
Liquid Charging
90
PAG and POE Oils
90
Table 8-1 SPLIT SYSTEM REFRIGERANT and OIL CHARGING TABLE (through GEN 4)
90
Evaporator Tie-In
91
Figure 1-11 Micro-Channel Style Condenser Assembly
91
Table 8-3 SPLIT--SYSTEM GEN--5 with MICRO--CHANNEL CONDENSER
91
Adding Refrigerant to System (Full Charge)
92
Table
93
Table 8-5 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHART
93
Section
94
Leak Checking
94
Micron (Vacuum) Gauge
94
Refrigerant Leak Checking
94
Figure 9-1 Refrigerant Service Connections (Split Systems)
95
Authorized Carrier Transport A/C Dealers
96
Paper Registration (Obsolete)
96
Warranty Policy
96
In-Line Failures - Oem/Installer Repair
96
Figure 10-1 Warranty Registration Card (Obsolete)
96
Final (Check-Out Sheet)
97
Installation Check-Out
97
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