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Carrier DC-12175 Installation Procedures Manual Download Page 13

vii

T-311

LIST OF ILLUSTRATIONS

Figure

Page

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Figure 4--23 Hose Routing (Chassis)

4-9

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Figure 4--24 Hose Routing (Chassis)

4-9

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Figure 4--25 Hose Routing (Chassis)

4-9

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Figure 4--26 Hose Routing (Chassis)

4-9

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Figure 4--27 Hose Routing (Chassis & Condenser)

4-9

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Figure 4--28 Engine Routing (With High & Low In-Line Access Fittings)

4-10

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Figure 4--29 Hose Routing - OEM (To & From Engine)

4-10

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Figure 4-22 Rear Evaporator, OEM Tie-in

4--12

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Figure 4-23 Evaporator, Skirt Monuted Condenser and Compressor

4--13

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Figure 4-24 Evaporator, Skirt Monuted Condenser and Compressor (AC-322, -332, -442)

4--14

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Figure 4-25 Evaporator, Skirt Monuted Condenser Compressor and Aftermarket InDash (AC-4431)

4--15

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Figure 4-26 EM-3 Evaporator, (2) Skirt Monuted Condensers and TM-31 Compressor (AC-882, -883)

4--16

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Figure 4-27 (1)EM-3 Evap, (1)EM-7 Evap, (2) Skirt Condensers and a TM-31 Compressor (AC-9632)

4--17

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Figure 5-1 Harness & Pig-Tail Connections

5-1

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Figure 5-2 Grounded to Clamp

5-2

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Figure 5-3 Grounded to Chassis Rail

5-2

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Figure 5-4 Drivers Control Panel

5-2

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Figure 5-5 Controls Mounted Without Panel

5-2

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Figure 5-6 Drivers Control Panel (Dual Systems)

5-3

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Figure 5-7 Electrical Control Panel (Typical)

5-3

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Figure 5-8 Electrical Control Cables Thru Fire Wall To Electrical Control Panel

5-3

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Figure 5-9 Relay Boards Installed Inside Bus (Dual System)

5-4

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Figure 5-10 Wired Relay Boards (Dual System)

5-4

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Figure 5-11 Relay Boards Inside Dash Panel

5-4

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Figure 5-12 Total Control Key Pad/Display

5-5

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Figure 5-13 Total Control Electrical Panel (Typical)

5-5

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Figure 5-14 Gen 5 Total Control (Dual System)

5-6

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Figure 6-1 Metric Torque Specs

6-2

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Figure 6-2 Metric Bolt Markings

6-2

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Figure 6-3 U.S.S. Torque Specs

6-2

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Figure 6-4 U.S.S. Bolt Markings

6-2

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Figure 6-5 Belt Clearance Requirements

6-3

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Figure 6-6 Belt Misalignment

6-3

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Figure 6-7 Straight-Edge Application

6-3

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Figure 6-8 Belt Tension Guide

6-4

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Figure 6-9 Compressor Mounting Angles

6-5

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Figure 7-1 Manifold Gauge Set

7-2

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Figure 7-2 Refrigerant Service Connections (Split Systems)

7-3

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Figure 1-11 Micro-Channel Style Condenser Assembly

8-2

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Figure 9-1 Refrigerant Service Connections (Split Systems)

9-2

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Figure 10-1 Warranty Registration Card (Obsolete)

10-1

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Figure 11-1 System Requirements Label

11-5

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Summary of Contents for DC-12175

Page 1: ...T 311 Rev B Change 06 10 INSTALLATION PROCEDURES for SPLIT SYSTEMS Generation 4 5 Transport Air Conditioning ...

Page 2: ...MANUAL INSTALLATION SPLIT SYSTEMS GEN 4 5 POLICY AND PROCEDURES ...

Page 3: ...ier recommends a MACS Mobile Air Conditioning Society certification in Recovery Recycling to gain more information on handling and using refrigerants Never attempt to apply heat or open flame to a refrigerant cylinder High temperatures can raise the cylinder pressure to dangerous levels Carrier recommends using a heat blanket to increase the internal temperature of the refrigerant cylinder greatly...

Page 4: ...sily be knocked out of balance Hold unit up to the ceiling with the evaporator framing not the blower wheel CAUTION Failure to seal these noise abatement headliners perforated will allow dissipation of the air and marginal cooling CAUTION Use of substitute hardware or failure to follow the installation instructions may result in structural fatigue and or breakage CAUTION When installing any GEN 5 ...

Page 5: ...UTION 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 tie wrap or secure in any way refrigerant hose or electrical cable to any part that may move during the normal operation of the vehicle Always use in...

Page 6: ...llow the piping diagram provided with the system CAUTION No matter what type of lubricant oil used in the system always use mineral oil to lubricate the O Rings and fittings PAG oils will absorb moisture and become very acidic and corrosive Mineral oil will not absorb moisture and thus prevent corrosion CAUTION Always use existing holes in the chassis frame Never drill holes in the chassis frame C...

Page 7: ...1 5 Aesthetics 2 1 2 1 6 Mounting Front Rear 2 1 2 1 7 Mounting Side 2 1 2 1 8 In Wall Evaporators 2 1 2 1 9 Drain Lines 2 1 2 1 10 Ducted Systems 2 1 2 1 11 Bus Headliners 2 1 2 1 12 Mounting Hardware 2 1 2 2 REAR MOUNTED EVAPORATORS 2 2 2 2 1 GEN 4 5 Series EM 1 EM 2 EM 3 EM 7 EM 6 EM 14 2 2 2 2 2 Luggage Compartment Evaporator 2 7 2 2 3 EM 3 EVAPORATOR GEN 4 OR GEN 5 2 8 2 3 SIDE MOUNTED EVAPOR...

Page 8: ...CM 2 AND CM 3 STACKED CONDENSER ASSEMBLIES 3 10 HOSE ROUTING 4 1 4 1 INTRODUCTION 4 1 4 1 1 Planning 4 1 4 1 2 Service Loop 4 1 4 1 3 Dual Systems 4 1 4 1 4 Connection Lubrication Mineral Oil 4 1 4 2 QUICK CLICK RESUABLE HOSE FITTINGS 4 1 4 2 1 Assembly Instructions For Quick Click Resuable Hose Fitting Connections 4 1 4 2 2 Barrier Type Hose Fittings 4 2 4 3 EVAPORATOR HOSE ROUTING INSIDE THE BUS...

Page 9: ...6 2 INSTALLATION 6 1 6 2 1 Torque Specifications Bolts 6 2 6 2 2 Torque Specifications Split System ELectrical Panels 6 2 6 3 DRIVE BELT INSTALLATION 6 2 6 3 2 Belt Clearance 6 2 6 3 3 Pulley Alignment 6 3 6 3 5 Measuring Methods for Belt Tension 6 4 6 4 COMPRESSOR INSTALLATION 6 4 6 4 1 Installation Position 6 4 6 4 2 Installation Precautions 6 4 6 4 3 Mounting Compressors 6 4 6 4 4 Oil Charge 6 ...

Page 10: ...n 1 3 Figure 1 4 GEN 4 IW 2 IW 7 Serial Number Location 1 3 Figure 1 5 GEN 4 IW 1 Serial Number Location 1 3 Figure 1 6 CM 7 11 Rooftop Condensers No Longer Offered Serial Number Location 1 4 Figure 1 7 KR 2 KR 3 Rooftop Condensers Serial Number PID Location 1 4 Figure 1 8 KR 4 Rooftop Condenser Serial Number PID Location 1 4 Figure 1 9 Typical Component Locations 1 5 Figure 1 10 Refrigerant Flow ...

Page 11: ...32 School Style Ducting Drivers Side 2 13 Figure 2 33 Side Mounted Hose Routing Using 455 Angles 2 14 Figure 2 34 Side Mounted Hose Routing Straight 2 14 Figure 2 35 EM 17 Installed 2 15 Figure 2 36 In Wall Marked For Cut Out 2 16 Figure 2 37 In Wall Cut Out Panel Removed 2 17 Figure 2 38 In Wall Cut Out Insulation Removed 2 17 Figure 2 39 In Wall Cut Out Wires Supported 2 17 Figure 2 40 Bus Elect...

Page 12: ...R4 Dual Loop 3 8 Figure 3 14 Condenser Feed Thru Plate KR2 3 3 9 Figure 3 15 Condenser Feed Thru Plate KR2 3 3 9 Figure 3 16 Stacked Condenser Assembly Side View 3 11 Figure 3 17 Stacked Condenser Assembly Bus Skirt View 3 11 Figure 4 1 Quick Click 1 4 1 Figure 4 2 Quick Click 2 4 1 Figure 4 3 Quick Click 3 4 1 Figure 4 4 Quick Click 4 4 2 Figure 4 5 Quick Click Hose Capped 4 2 Figure 4 6 Bus With...

Page 13: ...l 5 2 Figure 5 5 Controls Mounted Without Panel 5 2 Figure 5 6 Drivers Control Panel Dual Systems 5 3 Figure 5 7 Electrical Control Panel Typical 5 3 Figure 5 8 Electrical Control Cables Thru Fire Wall To Electrical Control Panel 5 3 Figure 5 9 Relay Boards Installed Inside Bus Dual System 5 4 Figure 5 10 Wired Relay Boards Dual System 5 4 Figure 5 11 Relay Boards Inside Dash Panel 5 4 Figure 5 12...

Page 14: ... WALL GEN 4 2 3 Table 2 4 DISTANCE TO BACK WALL GEN 5 2 3 Table 2 5 IW 1 EVAPORATOR DIMENSIONS 2 16 Table 2 6 IW 2 EVAPORATOR DIMENSIONS 2 16 Table 2 7 IW 14 EVAPORATOR DIMENSIONS 2 16 Table 3 1 CONDENSERS Used With GEN 4 And GEN 5 Series 3 2 Table 3 2 SKIRT MOUNTED COND DIMENSIONS 3 2 Table 3 3 ROOF MOUNT COND DIMENSIONS 3 6 Table 8 1 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE THROUGH GEN 4 ...

Page 15: ...000 BTU s would be rounded off to 30 000 BTU s or the number 3 When only three numbers are in the designation the second number is the evaporator and the third number is the condenser Example AC 512 AC designates a free blow system 5 means approximately 50 000 BTU 1 is an EM 1 evaporator assembly while the 2 designates a CM 2 condenser assembly When more than three digits are in the model number t...

Page 16: ... 78 000 1 EM 3 2 CM 2 2 10 CID AC 82222 FB 80 000 2 EM 2 2 CM 2 2 10 CID AC 91223 FB 92 000 1 EM 1 1 EM 2 1 CM 2 1 CM 3 2 10 CID AC 11122 FB 96 000 2 EM 1 2 CM 2 2 10 CID DC 19922 CD 96 000 2 EM 9 2 CM 2 2 10 CID AC 11133 FB 104 000 2 EM 1 2 CM 3 2 10 CID DC 19933 CD 104 000 2 EM 9 2 CM 3 2 10 CID AC 16333 FB 108 000 1 EM 3 1 EM 6 2 CM 3 2 10 CID DC 12175 CD 120 000 1 EM 17 1 CM 5 1 05K or 05G LEG...

Page 17: ...T 311 1 3 Figure 1 3 GEN 5 Evaporator Model All Serial Number Location 5 2 Figure 1 4 GEN 4 IW 2 IW 7 Serial Number Location Figure 1 5 GEN 4 IW 1 Serial Number Location ...

Page 18: ... 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 PID Serial Model Number Plate Figure 1 8 KR 4 Rooftop Condenser Serial Number PID Location ...

Page 19: ...rigerant See Figure 1 9 6 Expansion Valve Block Valve Meters the refrigerant flow into the evaporator coil 7 Evaporator The evaporator is located in theinterior of the bus vehicle See Figure 1 9 Its primary function is to transfer heat contained in the passenger compartment air into the refrigerant which is circulated by the compressor through the evaporator coil During this process the air is als...

Page 20: ...perature of the liquid and meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface The low pressure low temperature liquid that flows into the evaporator tubes is colder than the air that is circulated over the evaporator tubes by the evaporator fans Heat transfer is established from the evaporator air flowing over the tubes to the refr...

Page 21: ...M 9 1330 32 0 12 5V 33 2 13 5V N A 24 5 15 0 12 5V 18 0 13 5V N A 24 5 8 1 12 5V 10 3 13 5V N A 24 5 85 Lbs EM 10 2060 57 25V 57 25V 57 25V 150 Lbs EM 14 525 21 12 5V 23 13 5V 10 24 5V 10 0 12 5V 11 0 13 5V 6 0 24 5V 7 0 12 5V 8 0 13 5V 4 0 24 5V 35 Lbs EM 17 2060 57 25V 196 Lbs EM 20 425 12 12 5V 12 25V 30 Lbs EM 21 425 12 12 5V 32 Lbs EM 22 525 20 12 5V 12 25V 40 Lbs EM 23 525 20 12 5V 12 25V 40...

Page 22: ... located on the vehicle skirt or on the roof If space in the vehicle skirt is a problem two 2 CM 2 s or two 2 CM 3 s can be stacked on each other with a kit available from Carrier Transport Air Conditioning Carrier Transport Air Conditioning condensers are listed in Table 1 7 Table 1 7 CONDENSERS Used With GEN 4 Or GEN 5 Series Evaporators Component Type CFM Approx Amps Weight CM 2 SKIRT MOUNTED 1...

Page 23: ...nents for hidden damage If hidden damage exists initiate a claim directly with the transporting company All instances of hidden damage are also the responsibility of the transporting company Check contents of cartons against the enclosed packing lists If any parts are missing incomplete or defective call Carrier Transport Air Conditioning customer service for assistance Before installing any evapo...

Page 24: ...ies When and if the bus roof is drilled through to mount the evaporator care must be taken to ensure that the bus roof is properly sealed to prevent leaks 2 1 7 Mounting Side Mounting brackets front rear must always be attached to the bus roof bows Installing the mounting brackets to the bus ceiling skin will not provide sufficient support for the evaporator 2 1 8 In Wall Evaporators In Wall Evapo...

Page 25: ...tor Refer to Section 4 for detailed instructions regarding hose harness and drain line routing d Locate and review installation instructions supplied with the evaporator assembly Review piping and wiring diagrams for proper hose and fitting size and the correct wiring harness Refer to Section 4 for detailed instructions regarding hose and harness routing e For ease of installation trace evaporator...

Page 26: ...bit drill 4 holes through the bus ceiling The smaller bit will allow you to check the angle of the hole and where you have exited the bus roof If the angle is incorrect the 3 16th hole is easily repaired with a pop rivet k After determining the pilot hole is correct enlarge the 4 holes to 7 16 inch See Figure 2 4 Figure 2 4 7 16 Inch Holes in Bus Roof l Matching holes in reinforcing rails to holes...

Page 27: ...us ceiling and or roof 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 9 Locking Pliers GEN 4 Evaporator Figure 2 10 Evaporator Mounted to Flat Ceiling Figure 2 11 Mounting Channel Sealing o Seal outer edge of reinforcing rails Improper sealing of the reinfo...

Page 28: ...te Valve Figure 2 13 Drain line Condensate Valve t Fit evaporator cover over unit If evaporator cover needs no trimming mount cover with the hardware provided Figure 2 14 Installed GEN 4 Evaporator u 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...

Page 29: ...or Cover g Evaporator h Mounting Channel i Carriage Head Bolt 3 8 16 x 4 j Optional Spacers k Drain Line l Drain Line Clamp m Condensate Valve Kazoo n Locking Nut 3 8 16 Figure 2 17 GEN 4 5 Front Rear EM 1 2 6 14 Evaporator Installation Hardware X Hose Cover Partially Blocking Rear Window Figure 2 18 Rear Mount Evaporator GEN 4 Installed ...

Page 30: ...n an enclosure such as a rear luggage compartment you must insure there is sufficient passenger compartment air returned to the evaporator assembly The normal ratio of return air in to evaporator air out is 2 to 1 The return air vents must be high enough so there is no interference with the return air flow Example If there is 60 square inches of cooling vents you must have at least 120 square inch...

Page 31: ...of and the evaporator assembly See Detail A Figure 2 21 These spacers will help keep the bus roof and or evaporator from distorting when tightening the lock nuts WARNING Do not attempt to modify the EM 3 evapora tor top panel Modifications to the top panel could structurally weaken the evaporator assembly causing system failures and or injuries to passengers NOTE Any refrigerant hose and or electr...

Page 32: ...ting hardware m Level evaporator assembly front to rear using a small level and the 3 8 16 jam nuts See Figure 2 23 n Tighten all jam nuts and lock nuts on front and rear mounting brackets and evaporator assembly o Connect refrigerant hoses Liquid and Suction and electrical harnesses at this time Refer to Section 4 for proper routing of hoses and harnesses p After the liquid and suction lines have...

Page 33: ...ide Mount Installation Instructions Typical 1 Trim Strip Front 2 Trim Strip Rear 3 Rear Hanger Bracket 4 3 8 16X1 Carriage Head Bolt 5 Spacer 1 8 Inch 6 Flat Washer 7 3 8 16 Hex Nut Lock 8 3 8 16 Hex Nut 9 Front Hanger Bracket 10 Lock washer 11 3 8 16 X 6 Carriage Head Bolt 12 3 8 16 X 2 Hex Head Bolt 13 Front Hanger 14 Spacer 1 inch Figure 2 25 Side Mounted Evaporator GEN 4 ...

Page 34: ...T 311 2 11 Side Trim Strip Rear Trim Strip Transition Transition Trim Lock Hose Covers Figure 2 26 EM 2 Gen V Side Mount Free Blow Installed Complete ...

Page 35: ...s the duct section to butt against the evaporator cover e Mark and cut the duct section when routing hose harness out of the ducting Insure the hose cover will completely cover the hole cut into the duct See Figure 2 29 and Figure 2 34 f Snap a chalk line to insure duct sections are installed straight on the ceiling and the wall g Starting at the evaporator temporarily position a duct section in p...

Page 36: ...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 ...

Page 37: ...T 311 2 14 Figure 2 33 Side Mounted Hose Routing Using 45 Angles Figure 2 34 Side Mounted Hose Routing Straight ...

Page 38: ...rols be installed only by OEM s Original Equipment Manufacturers Reinforced mounting channels must be welded to the bus roof bows in order to support the evaporator assembly An example of this application can be seen in Figure 2 35 Before attempting to install this type system it is strongly advised that you contact Carrier Transport Air Conditioning Technical Service Hot Line for assistance 1 800...

Page 39: ...evaporator make sure you have the cor rect evaporator and cooresponding mounting brackets cover necessary to complete the in wall installation All bus manufacturers OEM s construct their buses vehicles differently and it stands to reason that there will be different mounting brackets cover arrangements for most OEM s If in doubt contact the Carrier Transport Air Conditioning Technical Service Hot ...

Page 40: ...sses 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 e Carefully remove the insulation from between the walls Nothing should interfear with the In Wall evaporator Move the wiring to the top of the cut out and support in place See Figure 2 39 ...

Page 41: ...rea thus allowing any water to drain away quickly See Figure 2 41 Notch out for Drain Line Access Figure 2 41 In Wall Hose Drain Line Cut Out Figure 2 42 In Wall Hose Cover Back i 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 INSTALLATION HINT Remove the red light immedi...

Page 42: ...re in the butt connectors Refer to Section 5 Electrical n Securely ground the evaporator using the green wire in the harness to the structure rail Normally this ground wire would be secured to a chassis rail under the bus o Connect the drain lines to the In Wall evaporator Make sure the drain lines run down hill Always clamp the drain hose to the evaporator assembly See Figure 2 45 NOTE Drain line...

Page 43: ...T 311 2 20 Figure 2 47 Hose Cover Installed Left Side Figure 2 48 In Wall With Trimmed Cover Rear ...

Page 44: ...t would not be limited to 1 The safest and least intrusive way to route refrigerant hose and electrical cable 2 How and where to route drain lines 3 Drivers visibality not impaired Figure 2 49 Front In Wall Template Ground Location Moved Access Cut Out Figure 2 50 Hose Harness Drain Line Routing Access Cut Out Cut Out Too High Fitting Access Hole Serial Model Data Tag Figure 2 51 In Wall Front Ins...

Page 45: ...kets it is recom mended that you mark both sides of the plug socket arrangement This way you will not have to guess what goes where when re connecting t In this example the hose was routed from the passenger side over the top of the entrance door over the top of the IW evaporator and connected to the block valve Removal of the indicator light assembly allowed access for fitting hose assembly and c...

Page 46: ...ttle resistance Making sure the top holes are lined up properly secure the cover with two screws supplied with the installation kit Tug on the bottom of the cover to make sure it is firmly secured to the IW 1 NOTE If the metal cover mounting tabs do not slide into the drain pan easily you will have to space out the IW 1 assembly with thin washers placed between the bus structure rails and the IW 1...

Page 47: ...der to install the In Wall Access Panel Removed Structure Rail Figure 2 57 In Wall Cut Out TBB Serial Model Data Tag Figure 2 58 IW 1 Installed In TBB Rear Figure 2 59 IW 1 Secured To Structure Rail TBB 2 7 EM 20 EM 21 EM 22 EVAPORATORS The EM 20 EM 21 and EM 22 are floor mounted heating cooling units normally used on ambulances and or armored vehicles For installation instructions and or informat...

Page 48: ...e free of any obstruction including the bus chassis rail and the bus skirt Failure to have free air flow will restrict the rate of heat rejection causing a pressure rise in the system Excessive pressure may cause cooling inefficiencies and possible compressor failure The bus skirt must always be cut out when installing a skirt mounted condenser 3 1 6 Skirt Supports Whenever a bus skirt support mus...

Page 49: ...KIRT MOUNTED CONDENSER ASSEMBLIES The Carrier Transport Air Conditioning Condensers listed in paragraph 3 3 are designed so they can easily be installed in the skirt of a bus while other condenser assemblies are mounted on the bus roof Check the location selected under the bus for any obstacles that might interfere with the proper installation of the condenser assembly Using the dimensions listed ...

Page 50: ... floor or stringers See Figure 3 1 NOTE To safely attach mount the CM 2 it will require a minimum of 4 bolts while the CM 3 requires 6 bolts NOTE Block spacers or jam nuts may be required if the condenser mounting area is not tight against the bus stringers See Figure 3 3 Bus Stringer Bus Floor Figure 3 1 3 8 Inch Carriage Bolts Thru Floor l Mount the condenser using 3 8 inch diameter hard ware Se...

Page 51: ...K SPACER REQUIRED IF NO STRINGER AT MOUNTING LOCATION Not Required When Using Chassis Grill CONDENSER 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 ...

Page 52: ...stallation drawing enclosed with the condenser or see Figure 3 6 Note Because of the size and weight of the CM 5 condenser assembly ten 10 bolts are re quired to safely install it to the bus floor string ers Five 5 in the front and 5 in the rear ALTERNATE MOUNTING FLOOR SKIRT POP RIVET 3 16 STEEL OR SELF DRILLING SCREWS GRILL 3 MOUNTING HARDWARE SUPPLIED BY INSTALLER MOUNTING HARDWARE SUPPLIED BY ...

Page 53: ...onsult factory as op tional mounting may be required e Trace around both mounting channels or condenser mounting surface See Figure 3 7 f When installing the KR4 also trace around the loca tion where you will be attaching the feed thru plate s See Figure 3 12 or Figure 3 13 g Remove mounting channels if used from condenser assembly Note It is recommended that a drill stop be used when drilling thr...

Page 54: ...of Bow Center of condenser assembly must contact bus roof Figure 3 8 KR4 Condenser Mounted Without Mounting Channels Front Back View Roof Bow Center of condenser assembly must contact bus roof Bus Roof Mounting Channel Figure 3 9 KR4 Condenser Mounted With Mounting Channels Front Back View Roof Bow Roof Bow Apply sealant to unit mounting surface and rivet heads to prevent water leaks Bus Roof Figu...

Page 55: ...can be used for rear mounted evaporators AC301 029 Cut Out Area Figure 3 12 Condenser Feed Thru Plate KR4 Single Loop AC301 082 Cut Out Area Figure 3 13 Condenser Feed Thru Plate KR4 Dual Loop l Drill13 64 inch holes in the bus roof using the holes in the feed thru plate as a guide Drill out all holes m Apply sealant around all the holes and under the plate n Using 3 16 inch rivets attach plate s ...

Page 56: ...er on the center side to side of the bus roof at the predetermined location d Install the KR2 3 Rooftop Condenser assembly fol lowing steps h or i in Section3 5 Someapplications will allow the use of bolts through the bus roof and ceiling e Mark where the feed thru plate will be located and cut out so the feed thru plate fittings will drop through the opening Note If connecting to a rear mounted e...

Page 57: ...3 STACKED CONDENSER AS SEMBLIES The Carrier Transport Air Conditioning stacked condensers are designed to be installed in the skirt of the bus when there is insufficient room for a standard installations To install Stacked Condensers utilize the following installation procedures NOTE The top and bottom condenser assemblies can be assembled as one then installed as a com plete stacked condenser ass...

Page 58: ... Condenser Bottom Condenser Bus Skirt Air Outlet Bracket Air Inlet Stiffen Air Inlet Bracket Figure 3 16 Stacked Condenser Assembly Side View Front Bracket Block Off Plate Air Inlet Bracket Air Inlet Bracket Figure 3 17 Stacked Condenser Assembly Bus Skirt View ...

Page 59: ...g both ends of the hose assembly for identification is recommended 4 1 4 Connection Lubrication Mineral Oil System hose connections fitting threads and O Rings must always be lubricated with mineral oil Never use PAG or POE oils Failure to lubricate the system O Rings and fitting threads or the use of an improper lubricant may lead to torn seals local corrosion and leaks 4 2 QUICK CLICK RESUABLE H...

Page 60: ... fitting tube outside diameter Use of a combination that has clearance between components will result in a much higher probability of leaks 4 3 EVAPORATOR HOSE ROUTING INSIDE THE BUS WALL Always keep hose capped until ready to connect to a system component see Figure 4 5 Figure 4 5 Quick Click Hose Capped Cutaway bus hose routing will normally be routed through the bus floor up the lower wall see ...

Page 61: ...e Figure 4 8 Figure 4 8 Hole Saw Cuts in Floor 6 Saw out any material remaining between the two holes leaving an oblong hole to route the hoses through see Figure 4 9 Figure 4 9 Hole Saw Cuts Joined Repeat steps 1 through 6 to obtain access to the wallor floor depending which one you start with Figure 4 10 Rear Wall Access 7 Remove any sharp edges from around the holes to prevent hose cutting and ...

Page 62: ...s through the holes be fore securing the hose cover backs to the wall See Figure 4 21 8 Drill a 3 inch hole in the vehicle wall in order to rout the hoses and harness to the evaporator area 9 Remove deburr any rough edges from around the cut out Using a small piece of Trim Loc or similar material around the cut out will help protect the hoses and harness from chaffing and or cutting See Figure 4 1...

Page 63: ... 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 19 X Figure 4 16 Incorrect Hose Harness Routing Rear window is partially blocked ...

Page 64: ... procedures for installing a rear mounted evaporator assembly 12 You may now make the appropriate connection to the evaporator 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 evaporato...

Page 65: ...e proper procedures for installing a rear mounted evaporator assembly 16 You may now make the appropriate connection to the evaporator Proper hose to fitting clamping is critical Do not attempt to attach any hose or fitting until you have familiarized yourself with Carrier Transport AC s Quick Click hose fitting crimping procedures 4 5 EVAPORATOR HOSE ROUTING SIDE MOUNTED The side mounted evaporat...

Page 66: ...e familiarized yourself with Carrier Transport Air Conditioning Quick Click hose fitting clamping procedures Figure 4 22 Side Mounted Hose Harness Routing 4 6 CHASSIS HOSE ROUTING Always keep hose capped until ready to connect to a system component Exact routing of hose and harness in the chassis area cannot possibly be covered in detail due to the various manufacturers of vehicles and chassis as ...

Page 67: ...is Figure 4 26 Hose Routing Chassis Figure 4 27 Hose Routing Chassis Condenser 4 7 CONDENSER HOSE ROUTING Always keep hose capped until ready to connect to a system component When mounting hose in the condenser area secure the hose in a manner so that the weight of the hose is not on the condenser fittings ...

Page 68: ... Access High Side Access Figure 4 28 Engine Routing With High Low In Line Access Fittings Heat Shielding Clamps Low Side Access High Side Access Figure 4 29 Hose Routing OEM To From Engine CAUTION Never substitute fittings or hose Follow the piping diagram provided with the system Follow any special instructions on hose routing that may have been supplied with the vehicle compressor mount kit Alwa...

Page 69: ...ting 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 4 11 AUXILIARY HEATER HOSE ROUTING GENERIC Carrier Transport Air Conditioning does not supply heater hose for connecting to a Carrier Transport Air Conditioning supplied heater coil The ...

Page 70: ...4 12 T 311 Figure 4 22 Rear Evaporator OEM Tie in FILTER DRIER ...

Page 71: ...4 13 T 311 Figure 4 23 Evaporator Skirt Monuted Condenser and Compressor FILTER DRIER ...

Page 72: ...4 14 T 311 Figure 4 24 Evaporator Skirt Monuted Condenser and Compressor AC 322 332 442 FILTER DRIER ...

Page 73: ...4 15 T 311 Figure 4 25 Evaporator Skirt Monuted Condenser Compressor and Aftermarket InDash AC 4431 FILTER DRIER ...

Page 74: ...4 16 T 311 Figure 4 26 EM 3 Evaporator 2 Skirt Monuted Condensers and TM 31 Compressor AC 882 883 FILTER DRIER FILTER DRIER ...

Page 75: ...4 17 T 311 Figure 4 27 1 EM 3 Evap 1 EM 7 Evap 2 Skirt Condensers and a TM 31 Compressor AC 9632 FILTER DRIER FILTER DRIER ...

Page 76: ...ttery Failure to follow these precautions could lead to system failure or in extreme conditions an electrical short circuit which could cause a fire All connections must be tight and secure When any electrical connection is exposed to the elements it should be coated with an electrical protectant Ensure a solid electrical ground to the vehicle chassis Failure to ensure tight protected connections ...

Page 77: ... section of green 10 or 6 gauge wire depending on the evaporator assembly One end of the green groundingwire willhave a 10 ring terminal crimped to it Securely attach this end to the evaporator assembly top panel The other end of the wire will have a 1 4 inch ring terminal tie wrapped to it Cut the ground wire to desired length strip off the insulation and crimp the 1 4 inch ring terminal to the w...

Page 78: ...om heat moisture dirt and road hazards 1 2 3 4 5 6 1 High Speed Relay 2 Condenser Relay 3 Compressor Clutch Relay 4 Circuit Breaker HSR 5 Circuit Breaker CR 6 Circuit Breaker Ignition Figure 5 7 Electrical Control Panel Typical When wiring is routed through the bus fire wall the cables muste be protected from the sharp edges of the cut out hole Use a plastic or rubber grommet and seal the area aro...

Page 79: ...refully place the MSR back into its connector Figure 5 10 Wired Relay Boards Dual System Figure 5 11 Relay Boards Inside Dash Panel 5 5 3 Electrical Control Panel Torque Values Torque values for all Split System electrical panels are as follows 1 Torque value for wire connections at the plastic circuit breakers are 24 In Lbs max 2 Plastic Breaker mounting screw torque is 15 In Lbs 3 Torque value f...

Page 80: ...tains relays circuit breakers and the microprocessor used for system control It must be located in an area that is protected from heat moisture and road hazards Care must be taken when routing the return air sensor thermistor cable and the cab command cable Both these cables can be damaged easily if pulled across rough or sharp areas of the bus chassis or A C system 1 2 3 4 5 6 7 8 Figure 5 13 Tot...

Page 81: ...5 7 OPERATING INSTRUCTIONS Before attempting to operate the system power must be available from the vehicle battery If the engine is not running start the engine For complete operating instructions refer to operation and service manual T 299 Split Systems ...

Page 82: ...e mount kit use where and how speci fied per the mount kit installation instructions Some installations may require a slight modification or rearrangement of the radiator mounting turbo tubes fuel lines reservoirs water lines harnesses or the oil fill tube for proper clearance On some applications it may be necessary to install the refrigerant hose and fittings to the auxiliary compressor before m...

Page 83: ...ignment and proper tension being the most critical and controllable by the installer and end user Improper alignment and or tension will cause premature failure of drive belts driven components as well as a possible safety issue When improperly installed and or maintained drive belts can cause significant damage to equipment as well as service personnel This document will act as a guideline for pr...

Page 84: ...cturing and engine tolerances as well as multiple applications and different engine options available Parallel misalignment is corrected by moving the driven pulley alternator or compressor into alignment with the drive pulley This can be done using several methods Spacing the component forward or rearward by adding or removing spacers is the most popular method used to achieve proper alignment Ot...

Page 85: ... operation and calibration requirements You must get the correct tension gauge for your specific belt type s Drive Belt Top Width New Belt Lbs Tension Re Tension Lbs Tension Re Tension Threshold Alternator All 110 90 70 Compressor All 130 105 80 Poly Rib Belt Serpentine Drive 6 or More Ribs 145 105 90 Figure 6 8 Belt Tension Guide 6 4 COMPRESSOR INSTALLATION 6 4 1 Installation Position The compres...

Page 86: ...mited ability to reject heat that kind of extra heat simply means less cooling inside the bus where it is needed 6 4 4 Oil Charge Each compressor comes with a standard charge of oil inside This quantity of oil is enough to supply the com pressor lubrication when installed into an already oil wet system New systems require an extra quantity of oil be added to wet all interior surfaces of the system...

Page 87: ...y increasing the transfer of refrigerant to the air conditioning system 10 Oil Injector Used to add additional amounts of oil to a closed system 11 Vacuum Pump Air and moisture are removed from the system by inducing a vacuum through the use of a vacuum pump Carrier Transport Air Conditioning recommends a 5 CFM or larger vacuum pump for optimum evacuation in the shortest time A vacuum which is mea...

Page 88: ...m 5 Connect yellow line to R134a cylinder purge line then charge with to a slightly positive pressure of 0 1 kg cm 1 0 psig 6 Front seat both manifold gauge set valves and dis connect from cylinder The gauge set is now ready for use b Connecting Manifold Gauge Hose Set Connection of the manifold gauge hose set see Figure 7 2 is dependent on the type system being serviced The center hose connection...

Page 89: ... ACCESS COMPRESSOR LPS New Location GEN 5 GEN 4 Location D S 1 2 3 4 5 6 7 HPS MICRO CHANNEL 1 Vacuum Pump 2 Micron Gauge 3 Manifold Gauge Set 4 Refrigerant Cylinder 5 Recovery Recycle Machine 6 R134a High Discharge Side Coupler 7 R134a Low Suction Side Coupler Figure 7 2 Refrigerant Service Connections Split Systems ...

Page 90: ...oximate oil amounts Refer to Table 8 4 for the correct compressor oil type 8 1 3 Liquid Charging The practice of charging liquid refrigerant into the suction side with the compressor running will damage or destroy the compressor as the liquid is not compressible 8 1 4 PAG And POE Oils It is very important to use the lubricant type specified by the compressor manufacturer Refer to Table 8 4 Using o...

Page 91: ...Recommended R134a Charge Recommended Oil Charge EM 1 EM 9 IW 1 CM 2 3 25 Pounds 6 5 Ounces EM 1 EM 9 IW 1 CM 3 3 75 Pounds 7 5 Ounces EM 2 IW 2 CM 2 3 00 Pounds 6 0 Ounces EM 2 IW 2 CM 3 3 50 Pounds 7 0 Ounces EM 7 IW 14 CM 2 2 75 Pounds 5 0 Ounces EM 7 IW 14 CM 3 3 00 Pounds 6 0 Ounces EM 3 dual loop 2 CM 3 4 50 Pounds each 9 0 Ounces each After determining the approximate charge using the above ...

Page 92: ...34a on scale and connect charg ing line from cylinder to liquid line valve Purge charg ing line at liquid line valve and then note weight of cyl inder and refrigerant c Calculate the approximate refrigerant charge using either Table 8 1 or Table 8 2 Open liquid valve on re frigerant cylinder Open suction line service port cou pler and allow the liquid refrigerant to flow into the unit until the co...

Page 93: ...40 112 107 145 114 109 4 Find closest refrigerant temperature in Table B or C and enter here ______Degrees F 139 Degrees F 150 117 112 155 119 114 160 121 116 165 123 118 170 126 120 5 Going across the Table find the corresponding pressure A D ______ PSI 225 PSI 175 128 122 180 130 123 185 132 125 190 134 127 195 136 129 6 If the Discharge Pressure High Side on gaugers With compressor engaged engi...

Page 94: ...with a soap bubble solution at suspected leak sites While this method will find large leaks it is limited in detection of the smaller leaks found with R134a WARNING Do not use a nitrogen cylinder without a pressure regulator NOTE If the system is to be pressurized with refriger ant gas it must be emphasized that only the cor rect refrigerant cylinder be connected to pres surize the system Any othe...

Page 95: ...DISCHARGE ACCESS COMPRESSOR LPS New Location GEN 5 GEN 4 Location D S 1 7 6 5 4 3 2 1 Vacuum Pump 2 Micron Gauge 3 Manifold Gauge Set 4 Refrigerant Cylinder 5 Recovery Recycle Machine 6 R134a High Discharge Side Coupler 7 R134a Low Suction Side Coupler Figure 9 1 Refrigerant Service Connections Split Systems ...

Page 96: ... Unit c Click on Installer Information Only or Installer Own er Information d Follow promps 10 2 3 Paper Registration Obsolete Locate the warranty registration card that is inclosed with the installation kit See Figure 10 1 The warranty registration card consists of three 3 copies 1 Yellow copy Installer copy a Completely fill out all Installer and Product informa tion Date of Installation Install...

Page 97: ...clutch factory set air gap was not compromised Never place the compressor on the clutch assembly ____ ____ Is compressor and compressor mount secure ____ ____ Are bolts torqued to proper specifications when noted on mount kit drawing ____ ____ Is there good alignment between the compressor idler and crank pulley Always use a straight edge to determine alignment Eye sighting is not good enough ____...

Page 98: ... ____ Is suction fitting and block valve TXV wrapped with no drip tape to prevent condensate drip ____ ____ Is suction hose covered with insulation to prevent condensate drip ____ ____ Are blowers fans running in the proper direction Through evaporator filter and pushing air into the passenger compartment ____ ____ Are evaporators properly grounded Evaporator must be grounded on the nearest vehicl...

Page 99: ...re relays circuit breakers and controls located in an area with adequate ventilation ____ ____ Is the electrical panel properly grounded ____ ____ Are controls located within easy reach of the driver ____ ____ Are current latest revision wiring diagrams available to the installer SYSTEM OPERATION YES NO ____ ____ Does the installer clearly understand and consistently apply a method for calculating...

Page 100: ...re _____F Evaporator Air Temperature In _____ F _____ F _____ F Evaporator Air Temperature Out _____ F _____ F _____ F Charges Actual values as recorded on charging sticker in engine compartment Rear or Passenger Side Refrigerant ______Lb ______ Oz Oil ______Oz Front or Drivers Side Refrigerant ______Lb ______ Oz Oil ______Oz Electrical Data Alternator Size _____Amps Alternator current with all ac...

Page 101: ...e designated on the tag 3 Enter the type of refrigerant used and the amount that was placed into each system in pounds and ounces If this is a dual system designate on tag which system 1 or 2 is front F or rear R drivers D or passenger P side 4 Enter print the type oil used and the amount in ounces 5 Enter the compressor s drive belt s part number or length 6 Enter the mount kit if used part numbe...

Page 102: ...cal Control Panel 5 3 5 4 Electrical Kits 5 1 EM 17 EVAPORATOR 2 15 EM 20 EM 21 EM 22 EVAPORATORS 2 24 EM 23 COOL HEAT EVAPORATOR 2 24 EM 3 EVAPORATOR 2 8 EM 9 DUCTED EVAPORATOR 2 12 Evaporator Chassis Ground 5 2 Evaporator Chassis Ground Gen 4 5 1 EVAPORATOR HOSE ROUTING 4 1 4 5 EVAPORATOR HOSE ROUTING SIDE MOUNTED 4 6 Evaporator Tie In 8 2 EVAPORATORS 1 7 F Front Mounted In Wall Evaporator 2 21 ...

Page 103: ...Rear Mounted In Wall Evaporator 2 16 REFRIGERANT SERVICE TOOLS 7 1 Requirements Label 1 1 ROOFTOP CONDENSER HOSE ROUTING 4 10 S Serial Number Tags 1 1 Service Loop 4 1 SERVICE TOOLS 7 1 SIDE MOUNTED EVAPORATOR 2 9 Skirt Supports 3 1 SKIRTMOUNTED CONDENSER ASSEMBLIES 3 2 SYSTEM COMPONENTS 1 4 SYSTEM NOMENCLATURE 1 1 SYSTEM REQUIREMENTS LABEL 11 5 SYSTEM WIRING 5 1 T TORQUE SPECIFICATIONS 6 2 TOTAL ...

Page 104: ...Grumbacher Road York PA 17406 USA Tel 1 800 673 2431 Fax 1 717 764 0401 A member of the United Technologies Corporation family Stock symbol UTX Carrier Transicold Division Carrier Corporation Transport Air Conditioning Group P O Box 4805 Syracuse N Y 13221 U S A www carrier transicold com ...

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