Carrier Em1 Manual
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T-311 Rev- Carrier Tr a n s i c o l d Tr a n s p o r t Air Conditioning Installation Procedures SPLIT-SYSTEMS
MANUAL INSTALLATION Split -- Systems POLICY AND PROCEDURES Carrier Transport Refrigeration and Air Conditioning, A member of the United Technologies Corporation family. Stock symbol UTX. Carrier Transicold, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221 U. S. A. 2003 CarrierCorporationDPrintedinU.S.A.1103
Safety--i T--311 SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during installation, operation, service, and maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Installation Precautions. A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices. FIRST AID An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately. OPERATING PRECAUTIONS Always wear protective eye wear (safety glasses or goggles). Keep hands, clothing and tools clear of the evaporator and condenser fans. No work should be performed on the system unless battery power is disconnected. Always work in pairs. Never work on the equipment alone. In case of severe vibration or unusual noise, stop the system and investigate. When vehicle engine is running, keep your hands, clothing and tools clear of the engine fan blade and drive belts. INSTALLATION PRECAUTIONS Familiarize yourself with the proper operation of any service equipment you will be using (voltmeter, amp probe, manifold gauges, etc.). Always read the owner ’s manual that is enclosed with the equipment Always follow the manufacturers instructions for your recovery/recycling equipment. Failure to do so could cause personal injury or damage to your equipment. Never perform any maintenance or service on your equipment before consulting with authorized service personnel. Always unplug unit before attempting any maintenance. Removing internal fittings and filters can release pressurized refrigerant. Slowly release pressure and always wear appropriate safety wear. Avoid breathing any refrigerant vapor, lubricant vapor, or mist. Exposure to these, particularly PAG oil mist, may irritate your eyes, nose, or throat. Always use a DOT (Department of Transportation) approved cylinder for storing used and recycled refrigerant. Approved cylinders will be stamped DOT 4BW or DOT 4BA. Carrier recommends a MACS (Mobile Air Conditioning Society) certification in Recovery/Recycling to gain more information on handling and using refrigerants. 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 increasing the rate of transfer of refrigerant to the bus air conditioning system. Never use compressed air (shop-air) to leak-test or pressure test a R134a system. Under certain conditions, pressurized mixtures of R134a and air can be combustible. In addition, shop air will inject moisture into the system. Always use mineral oil to lubricate “O” Rings, hoses, and fittings on R134a systems.PAG oils will absorb moisture and become very acidic and corrosive. Mineral oil will not absorb moisture and thus prevent corrosion. Always wear gloves when working with PAG and Ester lubricants to prevent irritation to your skin. R134a lubricants can also damage vehicles paint, plastic parts, engine drive belts and coolant hoses. Beware of unannounced starting of the evaporator and condenser fans. Do not remove the evaporator cover or condenser fan guards without disconnecting the vehicle battery cable. Always wear gloves when handling evaporators and condensers. Be sure power is turned off before working on motors, controllers, and electrical control switches. Tag system controls and vehicle battery to prevent accidental energizing of the system. Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel. When performing any arc welding on the vehicle, disconnect the vehicle battery. In case of electrical fire, extinguish with CO 2(never use water). Disconnect vehicle battery power if possible. Never route hoses or electrical harnesses down the front of the bus on the driver ’s side when installing a front mounted evaporator assembly. Driver visibility could be impaired. Before drilling holes for routing hoses and harnesses through the bus floor or wall, make sure there are no electrical harnesses, floor braces, tubing, etc. in the path of the holes to be drilled. Drilling into an electrical harness or fuel line could cause a fire or explosion.
Safety--ii T--311 SPECIFIC WARNINGS AND CAUTIONS WARNING Beware of unannounced starting of theevaporator and condenser fans. the unit maycycle the fans and compressor unexceptedly as control requirements dictate. WARNING Do not attempt to modify the EM-3 evaporator top panel. Modifications to the top panel could struc- turally weaken the evaporator assembly, causing system failures and/or injuries to passengers. WARNING Do not use a nitrogen cylinder without a pressure regulator WARNING Do not use oxygen in or near a refrigeration system as an explosion may occur. WARNING Be sure to observe warnings listed in the safety summary in the front of this manual before perform- ing maintenance on the air conditioningsystem WARNING Never use air for leak testing. it has been determined that pressurized, air-rich mixtures of refriger- ants and air can undergo combustion when exposed to an ignition source. CAUTION When selecting a location for installing theevaporator it is highly recommended that two roof bows are used to secure the mounting rails. CAUTION Make sure there is nothing installed where you are going to drill through the bus floor. CAUTION This condenserassembly must contact the bus roof in the center. If not, damage will occur. Consult factory as optional mounting may be required. CAUTION All 3/16 and 1/4 In. rivet engagement thickness (grip range) must be between 0.080 and 0.625. Using rivets other than those specified may allow the condenserassembly to come loose from the bus roof. CAUTION It must be emphasized that only the correct refrigerant cylinder should be connected to pressurize the system. Any other gas or vapor will contaminate the system, which will require additional evacu- ations. CAUTION When drilling into the vehicle wall, always use a drill stop to help protect against damaging any wir- ing that might be located behind the wall. CAUTION Never substitute fittings or hose. Follow the piping diagram provided with the system.
Safety--iii T--311 SPECIFIC WARNINGS AND CAUTIONS; Continued CAUTION Tie-Wraps may be used to bundle hoses and harnesses, but should never be used to secure hoses to the vehicle. CAUTION Use only the exact oil specified by the compressor manufacturer. Use of oil other than that specified will void the compressor warranty. CAUTION Condenserassemblies must be properly installed using graded hardware. The CM-2 condenser as- sembly requires at least 4 bolts and the CM-3 requires at least 6 bolts. CAUTION 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. CAUTION Never secure hoses or harnesses to any part of the vehicle fuel system. CAUTION Always use existing holes in the chassis frame. Never drill holes in the chassis frame. CAUTION Verify that the oil added to the air conditioningsystem is the same oil that is in the compressor. The mixing of incompatible oils will possibly damage your system. CAUTION To prevent trapping liquid refrigerant in the manifold gauge set be sure manifold gauge set is brought to suction pressure before disconnecting.
i T-311 TABLE OF CONTENTS SectionPage ................................................................................ SAFETY SUMMARYi ......................................................................... SPECIFIC WARNINGS AND CAUTIONS ii..................................................... DESCRIPTION1-1 ............................................................................ 1.1 INTRODUCTION1-1 .................................................................. 1.2 WHAT IS AIR CONDITIONING 1-1...................................................... 1.3 SYSTEM NOMENCLATURE DESIGNATIONS 1-1........................................ 1.3.1 Model And Serial Number Tags 1-1.................................................. 1.3.2 System Requirements Label 1-1..................................................... 1.4 SYSTEM COMPONENTS 1-3.......................................................... 1.5 COOLING CYCLE1-4 ................................................................. 1.6 EVAPORATORS1-6 ................................................................... 1.7 CONDENSERS1-7 ................................................................... 1.8 PRE--INSTALLATION INSPECTION 1-7................................................. EVAPORATORS2-1 ........................................................................... 2.1 INTRODUCTION2-1 .................................................................. 2.1.1 Description2-1 .................................................................... 2.1.2 Location2-1 ...................................................................... 2.1.3 Cap Plugs2-1 ..................................................................... 2.1.4 Blower Wheels2-1 ................................................................. 2.1.5 Aesthetics2-1 ..................................................................... 2.1.6 Mounting (Front & Rear) 2-1........................................................ 2.1.7 Mounting (Side)2-1 ................................................................ 2.1.8 Drain Lines2-1 .................................................................... 2.1.9 Ducted Systems2-1 ............................................................... 2.1.10 Bus Headliners2-1 ................................................................ 2.1.11 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 EM--3 EVAPORATOR GEN 4 OR GEN 5 2-7.......................................... 2.3 SIDE MOUNTED EVAPORATOR -- EM--1, EM--2, EM--6, EM--7, & EM--14 2-9................ 2.4 EM-- 9 DUCTED EVAPORATOR 2-12.................................................... 2.5 EM--17 EVAPORATOR 2-15............................................................ 2.6 IW--1, IW--2, IW--7 & IW--14 EVAPORATORS 2-15........................................ 2.7 EM-- 20, EM-- 21 & EM-- 22 EVAPORATORS 2-15.......................................... CONDENSERS3-1 ............................................................................ 3.1 INTRODUCTION3-1 .................................................................. 3.1.1 Description3-1 .................................................................... 3.1.2 Location3-1 ...................................................................... 3.1.3 Cap Plugs3-1 ..................................................................... 3.1.4 Protection3-1 ..................................................................... 3.1.5 Obstructions3-1 ................................................................... 3.1.6 Skirt Supports3-1 ................................................................. 3.1.7 Mounting (Skirt)3-1 ................................................................ 3.1.8 Mounting (Rooftop) 3-1............................................................. 3.1.9 Voltage3-1 .......................................................................
ii T-311 TABLE OF CONTENTS -- Continued SectionPage ................................................................................ 3.2 CONDENSERS3-2 ................................................................... 3.3 CM--2, CM--3, CM--4, CM--5, & CM--14 SKIRTMOUNTED CONDENSER ASSEMBLIES 3-2.... 3.4 Cm-- 5 CONDENSER3-5 ............................................................... 3.5 Cm--7, CM--11 ROOFTOP CONDENSER ASSEMBLIES 3-6................................ 3.5.1 Connecting to Side-- Mounted Evaporators 3-8......................................... 3.6 KR--4 ROOFTOP CONDENSER ASSEMBLY 3-10......................................... 3.6.1 Connecting To The Evaporators 3-11................................................. 3.7 CM--2 AND CM--3 STACKED CONDENSER ASSEMBLIES 3-12............................ HOSE ROUTING4-1 ........................................................................... 4.1 INTRODUCTION4-1 .................................................................. 4.1.1 Planning4-1 ...................................................................... 4.1.2 Service Loop4-1 .................................................................. 4.1.3 Dual Systems4-1 .................................................................. 4.1.4 Connection Lubrication (Mineral Oil) 4-1.............................................. 4.1.5 Quick-- Click Hose & Clamps 4-1..................................................... 4.1.6 Barrier Type Hose & Fittings 4-1..................................................... 4.2 EVAPORATOR HOSE ROUTING-- INSIDE THE BUS WALL 4-1............................. 4.3 EVAPORATOR HOSE ROUTING, OUTSIDE THE BUS WALL 4-5........................... 4.4 EVAPORATOR HOSE ROUTING, SIDE-- MOUNTED 4-5................................... 4.5 CHASSIS HOSE ROUTING 4-6......................................................... 4.6 CONDENSER HOSE ROUTING 4-7..................................................... 4.7 VEHICLE COMPRESSOR HOSE ROUTING 4-8.......................................... 4.8 TORQUE SPECIFICATIONS -- REFRIGERANT FITTINGS 4-8............................. 4.9 ROOFTOP CONDENSER HOSE ROUTING (CM-- 7 & CM-- 11) 4-9.......................... 4.10 AUXILIARY HEATER HOSE ROUTING (GENERIC) 4-9................................... 4.11 PIPING DIAGRAMS4-9 ............................................................... ELECTRICAL5-1 ............................................................................. 5.1 INTRODUCTION5-1 .................................................................. 5.2 SYSTEM WIRING5-1 ................................................................ 5.2.1 Electrical Kits5-1 .................................................................. 5.2.2 Protection5-1 ..................................................................... 5.2.3 Dual Systems5-1 .................................................................. 5.3 VOLTAGES5-1 ....................................................................... 5.4 Component Connections 5-1............................................................ 5.4.1 Evaporator Chassis Ground, Gen 4 (Excel) 5-1........................................ 5.4.2 Evaporator Chassis Ground, Gen 5 5-2............................................... 5.5 CONTROLS5-2 ...................................................................... 5.5.1 Manual controls5-2 ................................................................ 5.5.2 Electrical Control Panel 5-3......................................................... 5.6 TOTAL CONTROL5-3 ................................................................. 5.6.1 Total Control Electrical Control Panel 5-3.............................................. 5.7 OPERATING INSTRUCTIONS 5-4......................................................
iii T-311 TABLE OF CONTENTS -- Continued SectionPage ................................................................................ MOUNT KITS AND COMPRESSORS 6-1........................................................ 6.1 INTRODUCTION6-1 .................................................................. 6.2 INSTALLATION6-1 ................................................................... 6.2.1 TORQUE SPECIFICATIONS 6-2.................................................... 6.3 DRIVE BELT INSTALLATION 6-2....................................................... 6.3.2 Belt Clearance6-2 ................................................................. 6.3.3 Pulley Alignment6-3 ............................................................... 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 Charge6-5 .................................................................... EVACUATION7-1 ............................................................................. 7.1 INTRODUCTION7-1 .................................................................. 7.2 REFRIGERANT SERVICE TOOLS 7-1.................................................. 7.2.1 Preparation7-1 .................................................................... 7.2.2 Procedure - Complete system 7-1.................................................... 7.3 INSTALLING MANIFOLD GAUGES 7-2.................................................. CHARGING PROCEDURES8-1 ................................................................. 8.1 INTRODUCTION8-1 . .................................................................. 8.1.1 Proper R134a Charge 8-1. .......................................................... 8.1.2 Proper Oil Charge 8-1. .............................................................. 8.1.3 Liquid Charging8-1 . ................................................................ 8.1.4 PAG And POE Oils 8-1. ............................................................. 8.1.5 Evaporator Tie-- In 8-2. .............................................................. 8.1.6 Adding Refrigerant to System (Full Charge) 8-2. ........................................ LEAK CHECKING9-1 ......................................................................... 9.1 INTRODUCTION9-1 .................................................................. 9.1.1 Micron (Vacuum) Gauge 9-1........................................................ 9.1.2 Nitrogen9-1 ...................................................................... 9.2 REFRIGERANT LEAK CHECKING 9-1.................................................. WARRANTY REGISTRATION 10-1.............................................................. 10.1 INTRODUCTION10-1 ................................................................. 10.2 PROCEDURES10-1 .................................................................. 10.3 WARRANTY POLICY 10-1............................................................. 10.3.1 In-- Line Failures -- OEM/Installer Repair 10-1.......................................... FINAL (CHECK-- OUT SHEET) 11-1.............................................................. INSTALLATION CHECK-- OUT 11-1 11.1 SYSTEM REQUIREMENTS LABEL 11-5................................................. 11.1.1 System Requirement Label Completion 11-5..........................................
iv T-311 LIST OF ILLUSTRATIONS FigurePage ................................................................................. Figure 1-1 Condenser Model -- Serial Number Location 1-2......................................... Figure 1-2 GEN 4 Evaporator Model -- Serial Number Location 1-2.................................. Figure 1-3 GEN 5 Evaporator Model -- Serial Number Location 1-3.................................. Figure 1-4 CM-- 7/11 Rooftop Condensers -- Serial Number Location 1-3.............................. Figure 1-5 Refrigerant Flow and Typical Component Locations 1-4.................................. Figure 1-6 Refrigerant Flow Diagram 1-5......................................................... Figure 2-1 Template For EM-- 1 And EM-- 2 (GEN 4) 2-2............................................ Figure 2-2 Measurement To Wall (GEN 4) 2-3.................................................... Figure 2-3 Measurement To Wall (GEN 5) 2-3.................................................... Figure 2-4 7/16 Inch Holes in Bus Roof 2-3....................................................... Figure 2-5 Carriage Bolts & Sealant 2-3.......................................................... Figure 2-6 Sealant Pattern on Mounting Channel 2-3.............................................. Figure 2-7 Carriage Bolt Sealing 2-4............................................................. Figure 2-8 Locking Pliers Clamped to Carriage Bolts 2-4........................................... Figure 2-9 Locking Pliers & Evaporator 2-4....................................................... Figure 2-10 Evaporator Mounted to Flat Ceiling 2-4................................................ Figure 2-11 Mounting Channel Sealing 2-4....................................................... Figure 2-12 Block Valve Insulation 2-5........................................................... Figure 2-13 Drain line & Condensate Valve 2-5................................................... Figure 2-14 Installed Evaporator 2-5............................................................. Figure 2-15 Return Air Grill2-5 ................................................................. Figure 2-16 Painted Mounting Channel 2-6....................................................... Figure 2-17 GEN-- 4/5 Front/Rear (EM-- 1, 2, 6, & 14) Evaporator & Installation Hardware 2-6............ Figure 2-18 Rear Mount Evaporator -- Installed 2-7................................................ Figure 2-19 EM-- 6 Rear Mounted In An Extended Roof Van 2-7..................................... Figure 2-20 EM-- 3 Installation Diagram 2-8....................................................... Figure 2-21 Side-- Mount Template 2-9........................................................... Figure 2-22 Drain Line Elbows2-9 .............................................................. Figure 2-23 Side Mount Installation Instructions (Typical) 2-10...................................... Figure 2-24 Side Mounted Evaporator GEN 4 2-10................................................ Figure 2-25 EM-- 2 (Gen V) Side-- Mount -- Free Blow, Installed (Complete) 2-11....................... Figure 2-26 EM-- 9 Ducted Evaporator -- Hose & Harness Routing 2-12............................... Figure 2-27 Punching out Louver Holes 2-13..................................................... Figure 2-28 End Cap With Louver 2-13.......................................................... Figure 2-29 EM-- 9 Ducted Evaporator -- Location -- Completed Assembly 2-13........................ Figure 2-30 School Style Ducting-- Passenger Side 2-13............................................ Figure 2-31 School Style Ducting-- Drivers Side 2-13............................................... Figure 2-32 Side Mounted Hose Routing (Using 455 Angles) 2-14................................... Figure 2-33 Side Mounted Hose Routing (Straight) 2-14............................................ Figure2-34EM--17INSTALLED 2-15............................................................ Figure 3-1 3/8 Inch Carriage Bolts Thru Floor 3-3................................................. Figure 3-2 Condenser Mounted With Hardware 3-3................................................ Figure 3-3 Installation Drawing (Typical Skirt Mounted) 3-3......................................... Figure 3-4 CM-- 3 Condenser Mounting (Typical) 3-4............................................... Figure 3-5 CM-- 2 Condenser Mounted on an Extended Roof Van (Custom) 3-4........................
v T-311 LIST OF ILLUSTRATIONS -- Continued FigurePage ................................................................................. Figure 3-6 CM-- 3 Mounted In Cut-- A-- Way Chassis 3-4............................................. Figure 3-7 CM-- 5 Installation Drawing 3-5........................................................ Figure 3-8 Installing Mounting Feet & Mounting Channels 3-6....................................... Figure 3-9 Attaching To Feed-- Thru-- Plate & Remote Filter Drier 3-6................................. Figure 3-10 Attaching Mounting Channels To Bus Roof 3-7......................................... Figure 3-11 Adjusting Mounting Foot Height 3-7................................................... Figure 3-12 Hose Cover Transition Cut-- Outs 3-8.................................................. Figure 3-13 Hose Cover Transition & Refrigerant Hose Connections 3-8.............................. Figure 3-14 Mounting Options 3-10.............................................................. Figure 3-15 Condenser Mounted Without Mounting Channels 3-11.................................. Figure 3-16 Condenser Mounted With Mounting Channels 3-11..................................... Figure 3-17 Condenser Mounted Without Mounting Channels (Side View) 3-11........................ Figure 3-18 Condenser Mounted With Mounting Channels (Side View) 3-11.......................... Figure 3-19 Stacked Condenser Assembly (Side View) 3-12........................................ Figure 3-20 Stacked Condenser Assembly (Bus Skirt View) 3-13.................................... Figure 4-- 1 Quick-- Click Hose (Capped) 4-1...................................................... Figure 4-- 2 Bus With Rear Seat Removed 4-1.................................................... Figure 4-- 3 Hose Back Positioning 4-2........................................................... Figure 4-- 4 Hole-- Saw Cuts in Floor 4-2.......................................................... Figure 4-- 5 Hole-- Saw Cuts Joined 4-2........................................................... Figure 4-- 6 Rear Wall Access4-2 ............................................................... Figure 4-- 7 Hose Cover Back4-3 ............................................................... Figure 4-- 8 Hose Cover Backs On Rear Wall 4-3.................................................. Figure 4--9 Access Hole With Trim--Lock 4-3...................................................... Figure 4-- 10 Hoses Routed Through Access 4-3.................................................. Figure 4-- 11 Hoses Routed Through Floor 4-4.................................................... Figure 4-- 12 Hoses/Harness Secured With Tie-- Wraps To Hose Cover Back 4-4....................... Figure 4-- 13 Hose/Harness Clamped to Wall 4-5.................................................. Figure 4-- 14 Hose Cover Backs W/Tie-- Wraps 4-6................................................. Figure 4-- 15 Hose Routing (Chassis) 4-7......................................................... Figure 4-- 16 Hose Routing (Chassis) 4-7......................................................... Figure 4-- 17 Hose Routing (Chassis) 4-7......................................................... Figure 4-- 18 Hose Routing (Chassis) 4-7......................................................... Figure 4-- 19 Hose Routing (Chassis & Condenser) 4-7............................................. Figure 4-- 20 Engine Routing (With High & Low In-- Line Access Fittings) 4-8........................... Figure 4-- 21 Hose Routing -- OEM (To & From Engine) 4-8......................................... Figure 4-22 Rear Evaporator OEM Tie-- In 4-10.................................................... Figure 4-23 Evaporator, Skirt Mounted Condenser, and Compressor 4-11............................ Figure 4-24 Evaporator, Skirt Mounted Condenser and Compressor (AC-- 322, -- 332, -- 442) 4-12......... Figure 4-25 Evaporator, Skirt Condenser, Compressor, and Aftermarket In-- Dash (AC-- 4431) 4-13....... Figure 4-26 EM-- 3 Evaporator, (2) Skirt Condensers, and TM-- 31 Compressor (AC-- 882, -- 883) 4-14..... Figure 4-27 (1) EM-- 3 Evap., (1) EM-- 7 Evap., (2) Skirt Condensers, & (1) TM-- 31 Comp. (AC-- 9632) 4-15 Figure 5-1 Harness & Pig-- Tail Connections 5-1................................................... Figure 5-2 Grounded to Clamp 5-2.............................................................. Figure 5-3 Grounded to Chassis Rail 5-2.........................................................