Carrier Em1 Manual

							vi T-311
LIST OF ILLUSTRATIONS -- Continued
FigurePage .................................................................................
Figure 5-4 Drivers Control Panel 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 Total Control Key Pad/Display 5-3.....................................................
Figure 5-9 Total Control Electrical Panel (Typical) 5-4..............................................
Figure 5-10 Gen 5 Total Control (Dual System) 5-4................................................
Figure 6-1 Metric Torque Specs 6-2.............................................................
Figure 6-2 Metric Bolt Markings 6-2.............................................................
Figure 6-3 U.S.S. Torque Specs 6-2.............................................................
Figure 6-4 U.S.S. Bolt Markings 6-2.............................................................
Figure 6-5 Belt Clearance Requirements 6-3.....................................................
Figure 6-6 Belt Misalignment6-3 ................................................................
Figure 6-7 Straight-- Edge Application 6-3.........................................................
Figure 6-8 Belt Tension Guide6-4 ...............................................................
Figure 6-9 Compressor Mounting Angles 6-5.....................................................
Figure 7-1 Manifold Gauge Set 7-2..............................................................
Figure 7-2 Refrigerant Service Connections (Split Systems) 7-3.....................................
Figure 9-1 Refrigerant Service Connections (Split Systems) 9-2.....................................
Figure 10-1 Warranty Registration Card 10-1.....................................................
Figure 11-1 System Requirements Label 11-5....................................................
LIST OF TABLES
Ta b l ePage ..................................................................................
Table 1-1 ADDITIONAL SUPPORT MANUALS 1-1................................................
Table 1-2 CARRIER TRANSPORT AIR CONDITIONING SYSTEMS (GEN 4/5) 1-2....................
Table 1-3 GEN 4 EVAPORATORS 1-6............................................................
Table 1-4 GEN 5 EVAPORATORS 1-6............................................................
Table 1-5 CONDENSERS (Used With GEN 4 And GEN 5 Series) 1-7.................................
Table 2-1 GEN 4 EVAPORATORS 2-2............................................................
Table 2-2 GEN 5 EVAPORATORS 2-2............................................................
Table 2-3 DISTANCE TO BACK WALL (GEN 4) 2-3................................................
Table 2-4 DISTANCE TO BACK WALL (GEN 5) 2-3................................................
Table 3-1 CONDENSERS (Used With GEN 4 And GEN 5 Series) 3-2.................................
Table 3-2 SKIRT MOUNTED CONDENSERS 3-2..................................................
Table 8-1 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (THROUGH GEN 4) 8-1.......
Table 8-2 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (GEN 5) 8-2.................
Table 8-3 COMP. OIL TYPE & PART NUMBERS 8-2...............................................
Table 8-4 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHART 8-3........ 
						

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1-1
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
This manual contains instructions for the proper
preparation of and installation of Carrier Transport Air
Conditioning split systems. This manual does not
replace proper training and/or certification required by
the EPA or other local agencies.
The purpose of this manual is to assist you in completing
a quality, trouble-free installation which will compliment
a quality product, and ensure optimum system
performance for the life of the vehicle.
While this manual does not cover all combinations,
variations, and details, it does set up standards from
which installation processes can be measured.
Common sense and care for quality will result in
superior installations and customer satisfaction.
A Split System normally includes an evaporator(s), a
condenser(s) a compressor(s) and interconnecting
refrigerant hoses, fittings, and electrical harnesses and
controls. Refer to Table 1-3 & Table 1-4 for evaporator
models and Table 1-5 for condenser models. Table 1-2
shows popular system designations. Additional support
manuals are listed in Table 1-1.
When in doubt about a particular installation or if you
require additional information, do not hesitate to call
Carrier Transport Air Conditioning technical service Hot
Line for assistance (800-450-2211).
1.2 WHAT IS AIR CONDITIONING
Air Conditioning is the cooling, dehumidification, and
filtration of the air located within the passenger
compartment of your vehicle.
1.3 SYSTEM NOMENCLATURE DESIGNATIONS
All Carrier Transport Air Conditioning split system
applications will have system numbers consisting of 2
letters followed by 3 or more numbers (ie. AC-512),
identifying them as a free blow or ducted system,
approximate BTU rating, type of evaporator assembly
and type of condenser assembly.
The letter “A” from the letters “AC” means this systems
evaporator(s) are free blow units.The letter “D” from the letters “DC” means this systems
evaporator(s) are corner ducted.
The first number after the letters “AC” or “DC” is the
capacity of the system in BTU”s to the nearest 10
thousand. (Example - 26,000 BTU’s would be rounded
off to 30,000 BTU’s, or the number 3.)
The second and third numbers designate the
evaporator(s) assembly.
The fourth and fifth numbers designate the
condenser(s) assembly.
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).
1.3.1 Model And Serial Number Tags
In order to identify the air conditioning system you are
installing, you will need to know the model number and
serial number. All Carrier Transport Air Conditioning
system components have a model and serial number
data tag located on each evaporator and condenser
assembly. See Figure 1-1 for skirt mounted condenser
data tag location, Figure 1-2 for GEN 4 evaporator data
tag location, Figure 1-3 for GEN 5 evaporator data tag
location and Figure 1-4 for the CM-7 & CM-11 rooftop
condensers data tag location. Knowing these locations
and the information on the data tags will aid you in
completing the Warranty Registration Card (refer to
Section 10), and if needed, ordering the correct
replacement parts.
NOTE
The EM-9 evaporator data tag is located on the
side of the evaporator assembly, not between
the blower assemblies.
1.3.2 System Requirements Label
The system requirements label (See Figure 11-1) is
filled out after the installation and is affixed as close to
the vehicle compressor as possible. Refer to paragraph
11.1 for instruction on completing the system
requirements label.
Table 1-1 ADDITIONAL SUPPORT MANUALS
MANUAL NUMBER
EQUIPMENT COVEREDTYPE OF MANUAL
T-299Split SystemsOperation & Service
T-299PLSplit SystemsParts List
62-10686Split SystemsInstallation Video
62-50455Basic RefrigerationService Training
62-50468Transport RefrigerationService Training
62-03213Service ToolsService Tools
62-02737Transport Air ConditioningWarranty Policy & Procedures 
						

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1-2 Table 1-2 CARRIER TRANSPORT AIR CONDITIONING SYSTEMS (GEN 4/5)
SYSTEM
TYPEBTUEVAP (S)COND (S)COMP (S)
AC-3140FB26,000(1) EM-14OEMOEM
AC-360FB30,000(1) EM-6OEMOEM
AC-3142FB26,000(1) EM-14(1) CM-2(1) 10 CID
AC-362FB30,000(1) EM-6(1) CM-2(1) 10 CID
AC-422FB40,000(1) EM-2(1) CM-2(1) 10 CID
AC-512FB48,000(1) EM-1(1) CM-2(1) 10 CID
AC-513FB52,000(1) EM-1(1) CM-3(1) 10 CID
AC-633FB60,000(1) EM-3(1) CM-3(1) 12.6 CID
AC-8322FB78,000(1) EM-3(2) CM-2(2) 10 CID
AC-82222FB80,000(2) EM-2(2) CM-2(2) 10 CID
AC-91223FB92,000(1) EM-1, (1) EM-2(1) CM-2, (1) CM-3(2) 10 CID
AC-11122FB96,000(2) EM-1(2) CM-2(2) 10 CID
DC-19922CD96,000(2) EM-9(2) CM-2(2) 10 CID
AC-11133FB104,000(2) EM-1(2) CM-3(2) 10 CID
DC-19933CD104,000(2) EM-9(2) CM-3(2) 10 CID
AC-16333FB108,000(1) EM-3, (1) EM-6(2) CM-3(2) 10 CID
DC-12175CD120.000(1) EM-3(1) CM-5(1) 05K or 05G
LEGEND:
FB = Free Blow
CD = Corner DuctedEM = Evaporator Module
CM = Condenser Module
CID = Cubic Inch Displacemrnt
Figure 1-1 Condenser Model - Serial Number Location
EM-9 Location
Figure 1-2 GEN 4 Evaporator Model - Serial Number Location 
						

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1-3
Figure 1-3 GEN 5 Evaporator Model - Serial Number Location
Figure 1-4 CM-7/11 Rooftop Condensers - Serial Number Location
1.4 SYSTEM COMPONENTS
1. Thermostat - A thermostat is a temperature
sensitive device, which when activated, signals the
electro-magnetic clutch to engage.
2. Electro-Magnetic Clutch - The electro-magnetic
clutch controls the operation of the compressor. When
engaged, the compressor circulates refrigerant and
provides cooling (See Figure 1-5).
3. Compressor - The compressor is a belt driven,
high-pressure pump, which circulates the refrigerant
through the evaporator and condenser (See
Figure 1-5). The operation of the compressor is
controlled by the electro-magnetic clutch, which in turn
is controlled by the thermostat.
4. Condenser - The condenser is normally located in
the skirt or on the roof of the bus (vehicle), (See
Figure 1-5). Its primary function is to reject heat, whichwas transferred to the refrigerant by the evaporator from
the passenger compartment of the bus (vehicle).
5. Filter/Dryer - The filter/dryer removes moisture and
particulate matter from the refrigerant (See Figure 1-5).
6. Expansion Valve/Block Valve - Meters the
refrigerant flow into the evaporator coil.
7. Evaporator - The evaporator is located in the interior
of the bus (vehicle) (See Figure 1-5). 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 also filtered and dehumidified
8. Refrigerant - A refrigerant is any material that
possesses high heat transfer capabilities. Its primary
function is to act as the medium for heat transfer, which
facilitates the movement of heat from the passenger
compartment to the outside air. Refrigerant under
varying pressures exists in different states, and 
						

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1-4 performs different heat transfer functions. Under low
pressure, refrigerant exists as a gas that can absorb
heat. under high pressure, refrigerant exists as a liquid
that can reject heat. The heat transfer propertiesexhibited when refrigerant changes state is the
foundation of the refrigerant cycle.
1
234
56
7Ambient Air InCool Air Out
1. Compressor
2. Discharge Line (hot gas)
3. Condenser
4. Liquid Line5. Filter Dryer
6. Evaporator
7. Suction Line
Figure 1-5 Refrigerant Flow and Typical Component Locations
1.5 COOLING CYCLE
The unit operates as a vapor compression system using
R-134a as the refrigerant (See Figure 1-6). The
compressor raises the pressure and the temperature of
the refrigerant and forces it thru the discharge lines into
the condenser tubes. The condenser fan circulates
surrounding air (which is at a temperature lower than the
refrigerant) over the outside of the condenser tubes.
Heat transfer is established from the refrigerant (inside
the tubes) to the condenser air (flowing over the tubes).
The condenser tubes have fins designed to improve the
transfer of heat from the refrigerant gas to the air; this
removal of heat causes the refrigerant to liquify. Liquid
refrigerant leaves the condenser and flows to the filterdrier. The filter drier contains a medium (absorbent) that
keeps the refrigerant clean and dry.
From the filter-drier, the liquid refrigerant then flows to
the block type expansion valve. The expansion valve
reduces pressure and temperature 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 refrigerant (flowing
inside the tubes). The evaporator tubes have fins to
increase heat transfer from the air to the refrigerant; 
						

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1-5 therefore the cooler air is circulated to the interior of the
vehicle.
The transfer of heat from the air to the low temperature
liquid refrigerant in the evaporator causes the liquid tovaporize. This low temperature, low pressure vapor
refrigerant then continues through the suction line and
returns to the compressor where the cycle repeats.
1 234
5 6 78
9
10
1. Compressor
2. Electro-Magnetic Clutch
3. Discharge Line
4. Condenser
5. Filter Dryer6. Liquid Line
7. Evaporator
8. Block Valve
9. Thermostat-(Freeze-Up)
10. Suction Line
Figure 1-6 Refrigerant Flow Diagram 
						

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1-6 1.6 EVAPORATORS
Evaporators are located in the interior of the vehicle.
Their primary function is to transfer heat contained in the
passenger compartment into the refrigerant. The
evaporators may be free blow mounted in the front, side
or rear of the vehicle (bus) to blow directly into theinterior or ducted to distribute the air in a planned
pattern, (the EM-20 is designed to sit on the vehicle’s
floor).
Refer to Table 1-3 (Gen 4) and Table 1-4 (Gen 5) for
Carrier Transport Air Conditioning evaporator
assemblies, their approximate CFM, Amp draw, weight,
and cooling/heating BTU’s.
Table 1-3 GEN 4 EVAPORATORS
Component
Ty p eCFM
(Approx)Amps
(High Speed)WeightBTU Cooling
(Approx)BTU Heating
(Optional)
EM-1 GEN 4FB - F/R/[email protected] Lbs.52,00060,000
EM-2 GEN 4FB - F/R/[email protected]
10@25V55 Lbs.39,00040,000
EM-3 GEN 4FB - [email protected]
26@25V96 Lbs.86,00070,000
EM-6 GEN 4FB - F/R/[email protected]
10@25V56 Lbs.30,00030,000
EM-9DT - [email protected] Lbs.52,00060,000
EM-10DT - RM206057@25V150 Lbs86,00090,000
EM-14FB or [email protected]
12@25V35 Lbs.26,00035,000
EM-17RM - DT206057@25V196 Lbs.125,00090.000
EM-20FL - MT - [email protected]
12@25V30 Lbs.27,00035,000
EM-21AMB - FB - [email protected] Lbs.27,00035,000
EM-22FB - [email protected]
12@25V40 Lbs.25,00030,000
IW-1FB - [email protected] Lbs.43,000Not Available
IW-2FB - [email protected] Lbs.28,000Not Available
IW-7FB - [email protected] Lbs.20,000Not Available
IW-14FB - [email protected] Lbs.30,000Not Available
Table 1-4 GEN 5 EVAPORATORS
Component
Ty p eCFM
(Approx)Amps
(High Speed)WeightBTU Cooling
(Approx)BTU Heating
(Optional)
EM-1FB - F/R/[email protected]
16@25V60 Lbs.53,000Not Available
EM-2FB - F/R/[email protected]
12@25V49 Lbs.43,000Not Available
EM-3FB - [email protected]
24@25V90 Lbs.90,000Not Available
EM-7FB - F/R/[email protected]
10@25V41 Lbs.35,000Not Available
LEGEND:
AMB Ambulance Unit
DT Ducted Unit
FM Front Mount
FW Front Wall Mounted
IW In-Wall UnitEM Evaporator Module FB - Free Blow Unit
FL Floor Mounted
RW Rear Wall Mounted
RM Rear Mount 
						

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1-7 1.7 CONDENSERS
Condensers are normally located on the outside of the
vehicle. Their primary function is to reject heat absorbed
by the refrigerant from the passenger compartment to
the outside air. Condensers are normally located on thevehicle 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 1-5.
Ta b l e 1 -5CONDENSERS (Used With GEN 4 And GEN 5 Series)
Component
Ty p eCFM
(Approx)AmpsWeightBTU Heat
Rejection
CM-2SKT [email protected]
16@25V66 Lbs.57,000
CM-3SKT [email protected]
24@25V76 Lbs.76,000
CM-4SKT OR RF [email protected] Lbs.43,000
CM-5SKT MT600041@24V202 Lbs.162,000
CM-7RF [email protected]
12@25V87 Lbs.76,000
CM-11RF [email protected] Lbs.57,000
KR-4RF [email protected]
22@25V187 Lbs.130,000
CM-14SKT [email protected]
30@25V92 Lbs.85,000
CM-2 STKD (2 ea)SKT [email protected] Lbs.114,000
CM-3 STKD (2 ea)SKT [email protected] Lbs.152,000
LEGEND:
CM - Condenser Module
KR - 4 Fan Roof Mounted
SKT - Skirt Mounted
RF - Roof Mounted
STKD - Stacked Condenser Assembly
1.8 PRE-INSTALLATION INSPECTION
Immediately upon receipt of your Carrier Transport Air
Conditioning system:
Check the number/amount of cartons and skids/pallets
against the shipping company’s “Bill of Lading” (B.O.L.).
Inspect all shipping cartons for any evidence of damage
in transit. If visible damage exists, indicate on “Bill of
lading” and initiate a claim directly with the transporting
company. All instances of visible damage or missing
cartons are the responsibility of the transporting
company.Unpack and check components 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 evaporator assembly, spin the
blower wheels by hand to insure they turn freely. It is
possible they could have been knocked out of alignment
during transit. This would be easy to correct before
installing.
Note
Before attempting to install any evaporator or
condenser always insure that each component
will fit in the location of choice. 
						

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2-1
SECTION 2
EVAPORATORS
2.1 INTRODUCTION
2.1.1 Description
Evaporators are located in the interior of the bus. Their
primary function is to transfer heat contained in the
passenger compartment into the refrigerant. The
evaporators may be free blow mounted in the front, side
or rear of the bus to blow directly into the interior or
ducted to distribute the air in a planned pattern.
2.1.2 Location
Before attempting to install any evaporator, always
insure that the evaporator will fit in the location of choice.
2.1.3 Cap Plugs
Carrier Transport Air Conditioning evaporators are
leak-checked at the factory then shipped with a small
charge of inert gas which keeps the coil free from
moisture. The evaporator caps/plugs must not be
removed until ready to use.
2.1.4 Blower Wheels
Before installing any evaporator assembly, spin the
blower wheels by hand to insure they turn freely. It is
possible they could have been knocked out of alignment
during transit. This would be easier to correct before
installing.
2.1.5 Aesthetics
When the installation is completed, the evaporator
fittings and trim should be visually examined for
completeness and looks. All trim should be flush and
mounting hardware hidden from sight where possible in
a manner designed to be pleasing to the customer.
2.1.6 Mounting (Front & Rear)
Carrier Transport Air Conditioning recommends
sufficient structure be built into the bus ceiling by the
“OEM” (original equipment manufacturer) so that the
bus roof will not have to be drilled through when
mounting the evaporator assemblies. When and if the
bus roof is drilled through to mount the evaporator, caremust 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. Mounting brackets to the
bus ceiling skin will not provide sufficient support for the
evaporator.
2.1.8 Drain Lines
The drain lines must always run down hill immediately
from the attachment point on the evaporator drain pans.
Both drains should be run independently and in opposite
directions for maximum efficiency. Drain line routing
must be smooth and without kinks. Failure to properly
route the drain lines may result in water back-up into the
passenger compartment.
2.1.9 Ducted Systems
In ducted systems, insure that all refrigerant hoses and
electrical harnesses are firmly attached to the ceiling.
Failure to secure these components may cause noise
and vibration, inadequate air flow, or a blockage that will
degrade the system cooling.
2.1.10 Bus Headliners
Bus ceilings with noise abatement headliners
(perforated) must be sealed with a non-porous material
in the areas that will be covered by ducts prior
to
installation of the ducts to the ceiling. Failure to seal
these areas will cause dissipation of the air and marginal
cooling.
2.1.11 Mounting Hardware
All Carrier Transport Air Conditioning evaporators are
supplied with the proper mounting hardware. Never
substitute mounting hardware without the permission of
Carrier Transport Air Conditioning. Proper mounting
procedures are supplied with every evaporator. Use of
substitute hardware or failure to follow the installation
instructions may result in structural fatigue and/or
breakage. 
						

							T--311
2-2 2.2 REAR MOUNTED EVAPORATORS
2.2.1 GEN 4/5 Series EM-1, EM-2, EM-3, EM-7,
EM-6, & EM-14
To install the evaporator assembly in the rear of a bus
utilize the following installation procedures:
1. Un-pack the evaporator and check for any obvious
damage (Refer to Sec. 1.8).
2. Check the interior of the bus/vehicle to make sure the
evaporator(s) can be safely and properly installed in
the selected area. Refer to Table 2-1 or Table 2-2 for
evaporator dimensions.
Table 2-1 GEN 4 EVAPORATORS
Evaporator
A(width)B(height)C(depth)
EM-141.12inch9.88 inch22.25 inch
EM-241.12 inch9.88 inch22.25 inch
EM-359.44 inch10.75 inch22.75 inch
EM-625.63 inch9.88 inch22.25 inch
EM-1436.13 inch7.00 inch19.91 inch
Table 2-2 GEN 5 EVAPORATORS
Evaporator
A(width)B(height)C(depth)
EM-141.25inch7.62 inch19.13 inch
EM-233.95 inch7.62 inch19.13 inch
EM-359.44 inch7.62 inch19.13 inch
EM-726.64 inch7.62 inch19.13 inch
NOTE
Except for the EM-3, all the evaporators listed in
paragraph 2.2.1 can also be mounted in the
front and/or on either side of the vehicle.NOTE
In some cases it may be necessary to relocate
the ceiling lights and/or speakers.
3. Plan refrigerant hose, drain lines, and electrical har-
ness routing. Some small bus applications will allow
routing inside the walls and back panel. If this is the
case it is better to route your hose, drain lines, and
electrical harnesses before mounting the evaporator.
Refer to Section 4 for detailed instructions regarding
hose, harness, and drain-line routing.
4. Locate and review installation instructions supplied
with the evaporator assembly. Review piping and wir-
ing diagrams for proper hose and fitting size, plus the
proper wiring harness. Refer to Section 4 for detailed
instructions regarding hose and harness routing.
5. For ease of installation, trace evaporator tray unto
cardboard or other thin material. Refer to the installa-
tion drawing for the dimension the evaporator assem-
bly has to be from the back wall. Refer to Table 2-3 or
Table 2-4 for these dimensions if the installation
drawing is not available. Example: For an EM-1 Gen
4, this dimension is 7 Inches. Without this added di-
mension the return air grill will not fit on to the evapo-
rator cover.
NOTE
An optional rear panel is available for all the
Gen 5 evaporator assemblies. This panel is
used when the rear wall is curved and the evap-
orator cover cannot fit flat against the rear wall.
This panel can be trimmed to compensate for
the ceiling curve.
6. Mark and drill all mounting holes and cut out template.
SeeFigure2-1.
7. Mark center of template in order to match center of
bus ceiling. See Figure 2-1.
Cardboard
EM-1/2 Template
Drain Line
LocationDrain Line
Location
Evaporator Mounting HolesEvaporator Mounting Holes
Center of
Te m p l a t e
Center of Bus Ceiling
Back Wall
of Bus
Figure 2-1 Template For EM-1 And EM-2 (GEN 4)