TechPlus ComfortAire Service Supplement Manual Download Page 1

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For GENUINE BLUE BIRD replacements parts, contact your

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10004175

TechPlus

Comfort Aire

AIR CONDITIONING SYSTEMS

Summary of Contents for ComfortAire

Page 1: ...TechPlus TechPlus S E R V I C E S U P P L E M E N T ComfortAire ComfortAire AIR CONDITIONING SYSTEMS...

Page 2: ...L TechnicalCommunications TechPlusSupplement for ComfortAire SchoolBusAirConditioningSystems on BLueBIrdAllAmericanForwardEngine BlueBirdAllAmericanRearEngine BlueBirdVision BlueBirdMicroBird...

Page 3: ...blication and any applicable legal requirement the legal require ment prevails Technical requirements that exceed the legal requirements are not considered to conflict The material presented in this m...

Page 4: ...where its Tech Publishers have full access to Blue Bird s assembly lines and Engineering department Blue Bird incorporates into its buses top quality components from leading manu facturers in the hea...

Page 5: ...lTechPlus 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 For All American A3FE RE Conventional Vision BBCV Micro Bird Body Types REVISION 003 1 APPENDIX c c 8 0 Comfort Aire...

Page 7: ...checks for both the driver and technician The manual body shows detailed three dimensional models of only the large 55 000 BTU hr evaporators and the dual core large bus condenser All other evaporator...

Page 8: ...ion 18 Cooling 18 Evaporator Coil Defrost 18 Unit Features 18 Protection Features 18 General System Component Details 19 Stacked Skirt Mounted Condenser Configuration 19 Stacked Skirt Mounted Condense...

Page 9: ...spection 38 Evaporator Coil 38 Condenser Coil 38 Mounting Bolts 38 TM 21 TM 16 Compressor and Clutch Maintenance 39 Operation 39 Inspection 39 Clutch Removal 40 Clutch Installation 42 Electrical Conne...

Page 10: ...Compressor Trouble Shooting 57 Refrigeration Diagnosis Chart 58 System Service and Maintenance Notes 59 Service Guidelines 59 Compressor Oil Charge 59 Refrigeration Chart 61 Wiring Schematics 62 Micro...

Page 11: ...hort produce toxic gases that are severe respitory irritants capable of causing death 7 Make sure that all mounting bolts are tight and the correct length for their particular application 8 Use extrem...

Page 12: ...x SKIN Flush area with a large amount of lukewarm water Do not apply heat Remove contaminated clothing and shoes Wrap burns with dry sterile bulky dressing to protect from infection injury Seek medica...

Page 13: ...ing unit and to aid a victim 5 Have electrically insulated gloves cable cutters and safety glasses available in the immediate vicinity in the event of an accident First Aid IMMEDIATE First Aid must be...

Page 14: ...itation but call for emergency medical assistance Low Voltage Control circuits used in air conditioning systems are low 12 24 volts dc This voltage potential is not considered dangerous but the large...

Page 15: ...sion 120 lbs for non auto tensioned arrangements R 134a Refrigeration System Charges and Set points A3FE Blue System Curb Side 4 75 lbs Black System Road Side 4 3 lbs A3RE with TM 21 s Blue System Cur...

Page 16: ...th TM 21 s Electrical System With Roof Top Condenser Pair Evaporator 1 Circuit Breaker 50 amps Evaporator 2 Circuit Breaker 50 amps Roof Top Condenser 1 Circuit Breaker 25 amps Roof Top Condenser 2 Ci...

Page 17: ...ken parts Clean defrost drains Inspect belts for proper tension Clean entire condenser and evaporator coils Check all mounting bolts Note Use only PAG Poly Alkylene Glycol compressor oil in R 134a sys...

Page 18: ...are two evaporators one mounted on the curbside of the bus Rear 1 Evaporator the other mounted on the road side of the bus Rear 2 Evaporator There is a third non MCCII evaporator incorporated into the...

Page 19: ...essor clutch will engage through a drive belt connected to the engine The engine will then turn the compressor During engine operation the engine compressor evaporator fans and condenser fans operate...

Page 20: ...General System Component Details Stacked Skirt Mounted Condenser Configuration Power Stud 12 V Relay H P Binary Switch Drier Cond 2 Cond 1 19 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8 0...

Page 21: ...lus s e r v i c e s u p p l e m e n t Stacked Skirt Mounted Condenser Exploded View Components 1 2 Coils 4 Condenser Grill 6 H P Binary Switch 11 12 V Relays and Base 15 Receiver Drier 20 1 APPENDIX c...

Page 22: ...000 Bth hr Free Blow Evaporator Configuration Thermostat Module Power Studs Expansion Valve 12 V Relays Air Filter Directional Louvers Blower Assy 21 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8...

Page 23: ...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 1 Blower Assembly 2 Coil 5 12 V Relays and base 6 Power Stud 9 Expansion Valve 10 Defrost Drain Tube 22 1 APP...

Page 24: ...Typical TM 21 Compressor Manual Control Panel 23 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8 0...

Page 25: ...urring to the system The HP Binary switch will then close once the pressure has reduced As well when the pressure on the low side reaches 28 psi the switch will open disrupting voltage to the compress...

Page 26: ...ed into the dash 2 Leave the unit running if allowed not legal in some municipalities with all windows and doors closed for a period of 10 20 minutes to stabilize the temperature of the bus 3 Driver c...

Page 27: ...year to keep internal parts lubricated It is generally a good rule to inspect the compressor and drive belt wear weekly The condenser should be kept clean and should be checked frequently Basic Troub...

Page 28: ...f suspected take it to a qualified repair facility Is there any compressor oil on hoses fittings or around the compressor If so do not operate A C system and take it to a qualified repair facility Is...

Page 29: ...valve on the drum is closed 4 Open the valves on the gauge manifold and the evacuation station 5 Start the vacuum pump and evacuate the system to 500 microns After the system reaches 500 microns evac...

Page 30: ...With these systems being larger an additional an additional 5 oz of oil should be added to each system during a charge The compressor is filled with PAG oil Poly Alkylene Glycol Oil must be added at...

Page 31: ...charge pressure of the compressor by blocking the air flow through the condenser coil or flipping the condenser breaker in the main electrical panel 4 Failure of the high pressure cut out system to st...

Page 32: ...ts of the expansion valve and re assemble valve body 2 Remove receiver drier and install straight copper pipe or hose to bridge the system 3 Install suction line clean up drier between the evaporator...

Page 33: ...he test kit shows there is no acid in the system you can proceed to reclaim the charge and reassemble unit If the acid test check fails change the suction line drier and repeat the steps above 9 Only...

Page 34: ...revent contamination 5 Remove the compressor mounting screws Remove the compressor Installation 1 Place the compressor in position and attach all mounting screws and belt 2 Use belt tension tool and a...

Page 35: ...2 Install grill set condenser unit in place and install mounting screws 3 Install all lines and tighten fittings 4 Replace receiver drier 5 Pressurize system and check for leaks 6 Evacuate and rechar...

Page 36: ...nstallation 1 Install O Ring 2 Install HP Binary switch 3 Install wires to HP Binary switch 4 Check for leaks Evaporator Coil Removal 1 Remove refrigerant from the system 2 Remove the evaporator cover...

Page 37: ...Assembly Removal 1 Remove refrigerant from system 2 Remove evaporator cover 3 Remove drain pan assembly 4 Remove line and fitting from expansion valve inlet 5 Remove equalizer line 6 Peel back tape an...

Page 38: ...Evacuate and recharge with refrigerant Completely wrap bulb and sensor with tape Ensure that line and bulb has good clean contact Suction Line Feeler Bulb End View 37 1 APPENDIX C O M F O RT A IRE A...

Page 39: ...out opposite the normal air flow Inspect the coil and fins for physical damage and repair if necessary Note Air pressure should not be high enough to damage coil and fins Safety Note When blowing dow...

Page 40: ...lley web friction Surface When an electric current flows through the field coil a magnetic field is created The magnetic field pulls the disc against the pulley web and compresses the flat springs Thi...

Page 41: ...ked insulation If the insulation is cracked replace the coil Repair or replace the wire or connector if either is loose or damaged Clutch Removal Note Make sure the proper tools are available before p...

Page 42: ...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 41 1 APPENDIX C...

Page 43: ...Installation 1 Confirm the felt is installed on the front of the cylinder head 2 Install the coil on the compressor with the lead wire on top At this time confirm the coil s concave portion is aligne...

Page 44: ...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 43 1 APPENDIX C O M F...

Page 45: ...ether 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 Torque bolts to 8 7 10...

Page 46: ...ap firmly against the pulley Compressor Front seal Removal and Installation Removal 1 Remove the clutch as outlined in Clutch Removal 2 Remove the felt pad 3 Use the seal remover to remove the shaft s...

Page 47: ...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 cylin...

Page 48: ...dirt that could damage the shaft seal surface Installation of Shaft Seal 1 Clean the front section of the cylinder head that holds the front seal 2 Apply clean PAG compressor oil to the shaft seal and...

Page 49: ...l into the cylinder head as far as possible 5 Remove the seal guide from the shaft 6 Place the seal guide on the end of the shaft 7 Place the shaft seal cover on the seal guide and slide the shaft sea...

Page 50: ...49 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8 0...

Page 51: ...e proper amount of oil be added to the system During normal operation of the system there is always oil traveling throughout the system The oil lubricates all the components in the systems and returns...

Page 52: ...onnection 1 Connect the lead wire to the electrical circuit 2 Engage and disengage the clutch several times to check the clutch engagement The disc should snap firmly against the pulley Clutch Test 1...

Page 53: ...h manual there are step by step photo illustrated instructions for install of the compressor mount kit Of particular importance to the technician is proper alignment of the six groove belts on eight g...

Page 54: ...tes improperly Possible Cause Inspection Solution 1 System low on refrigerant The high side pressure will be low Repair any leaks evacuate and charge 2 Excessive Refrigerant The high side pressure wil...

Page 55: ...too low 1 Low refrigerant charge The high side pressure will be low and bubbles may be present in the sight glass on the receiver drier Repair any leaks and recharge the refrigerant to the correct lev...

Page 56: ...high pressure side will be low and bubbles may appear in the sight glass at the receiver drier Repair any leaks and recharge the refrigerant to the correct level 2 Compressor not pumping Equal high a...

Page 57: ...connector wire s 19 and 20 Evaporator Fans not Operating Low Speed Power is supplied to the R4 relay when the blower switch is set to the low first Position The R4 relay energizes and sends voltage t...

Page 58: ...e premature failure on clutch and bearings 4 Shortage of refrigerant check and repair leaks 5 Faulty expansion valve high superheat will cause low suction pressure and low super heat will cause high s...

Page 59: ...evaporator restricted Evaporator needs defrosting iced up Broken compressor belt Too much compressor oil in the system Loose compressor pulley Compressor bearing loose or burnt out Broken valve plate...

Page 60: ...The compressor is filled with PAG oil Poly Alkylene Glycol To retain a valid warranty on the compressor Seltec ZXL 100 PAG oil must be used Add the oil on the suction port on the compressor prior to v...

Page 61: ...minate the possibility of contaminants entering the system Never leave hose fittings compressor fittings or components uncapped Dirt and moisture will harm the system performance very quickly and this...

Page 62: ...141 90 42 27 79 70 146 50 44 29 52 72 151 30 46 31 32 74 156 10 48 33 17 76 161 10 50 35 07 78 166 10 52 37 03 80 171 30 54 39 05 82 176 60 55 40 09 84 182 00 60 45 48 86 187 50 65 51 27 88 193 10 70...

Page 63: ...lTechPlus 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 62 1 APPENDIX c c 8 0...

Page 64: ...1h WIRING SCHEMATIC MICROBIRD MICROBIRD ECC TM16 Dwg P1 14852 63 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8 0...

Page 65: ...lTechPlus 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 64 1 APPENDIX c c 8 0...

Page 66: ...2v WIRING SCHEMATIC P1 14851 BBCV A3RE A3FE ECC 2TM21 SPLIT SKIRT MOUNTED COND 65 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8 0...

Page 67: ...lTechPlus 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 66 1 APPENDIX c c 8 0...

Page 68: ...4d WIRING SCHEMATIC P1 14854 SLIM LINE SYSTEM 06 07 ECC 2TM21 SPLIT SKIRT MOUNT 67 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8 0...

Page 69: ...i c e s u p p l e m e n t 2006 Mobile Climate Control Industries Inc Rev 0 Electronic Climate Control User Guide Temp 21 C Temp 25 C Fan Med Fan Max Front Temp 68 F Temp 75 F Fan Med Fan High Rear 68...

Page 70: ...ace automatic climate controller diagnostics and auto protection packed into one module It allows precise temperature control and yet is simple to use With the built in diagnostic and auto protection...

Page 71: ...n 16 C 62 F and 28 C 82 F 2 6 Front and Rear Fan Speed Control The front and rear fan speed can be set individually with the fan speed keys Fan speeds can be cycled between low medium and high then of...

Page 72: ...peed in Low Medium High or Off for both front and rear air condition units 2 System Error Indicator When the E flashes on the ECC s screen it indicates there is a fault with the air condition system P...

Page 73: ...ront Temperature Up or Down buttons to select between Brightness or Contrast 3 Press Rear Temperature Up or Down to adjust settings 2 Turn on fans and select speed by pressing fan speed button 1 Adjus...

Page 74: ...r 1 Press the Diagnostic Button to system diagnostic mode 2 The user can scroll through by using Front or Rear Temperature Set Point buttons 3 Errors and run time can be cleared by pressing the Rear T...

Page 75: ...ndicates malfunctions of sensor Pressure switch status Indicates the number of low or high pressure trips System run time Indicates run time in hours that units has been running for evaporator condens...

Page 76: ...2s SYSTEM SCHEMATIC TRANSIT COMP Dwg P1 14849 A3RE ECC BITZER ROOF TOP CONDENSER 75 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8 0...

Page 77: ...lTechPlus 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 76 1 APPENDIX c c 8 0...

Page 78: ...5c BLUE BIRD ENGINE KIT COMPRESSOR PRODUCT NO 26 1385 Product View 77 1 APPENDIX C O M F O RT A IRE A C S Y STEMS c c 8 0...

Page 79: ...lTechPlus 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 78 1 APPENDIX c c 8 0...

Page 80: ...79 Notes n o t e s...

Page 81: ...lTechPlus s e r v i c e s u p p l e m e n t 80 Notes...

Page 82: ...81 Notes n o t e s...

Page 83: ...lTechPlus s e r v i c e s u p p l e m e n t 82 Notes...

Page 84: ...83 Notes n o t e s...

Page 85: ..._________________ 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 Chec...

Page 86: ...ForGENUINEBLUEBIRDreplacementsparts contactyour BlueBirdAuthorizedDealer 10004175 T E C H N I C A L C O M M U N I C A T I O N S...

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