Carrier Em1 Manual
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7-1 T--311 SECTION 7 EVACUATION 7.1 INTRODUCTION The process of evacuation is an important step in the servicing and maintenance of any air conditioning system. The purpose of evacuation is to remove all air and moisture from the system in preparation for adding refrigerant and oil during the charging process. It is imperative that all air and moisture be removed from the system, as their presence is detrimental and will negatively affect performance and longevity of the systems components. Air remaining in the air conditioning system will degrade the systems cooling performance, while any moisture remaining in the system is both non-condensable and a basis for acid formation. Moisture is the deadly enemy of refrigeration systems. 7.2 REFRIGERANT SERVICE TOOLS The following equipment is essential when performing an installation of or servicing of any Carrier Transport Air Conditioning system. Refer to Figure 7-2 for service component connections. 1Manifold Gauge Set -Provides access to and monitors pressures within the system. Manifold Gauge Sets are available in different configurations and styles. 3-way or 4-way, Liquid filled, with or without a sight glass, 3 hoses or 4 hoses, 1/4 inch or 3/8 inch manifold connections, etc. All are acceptable for servicing a Carrier Transport Air Conditioning system. Familiarize yourself with the proper operation of your Manifold Gauge Set before attempting any service. 2R134a Low Side (Suction) Coupler -Connects the air conditioning system Suction Access Port to the Manifold Gauge Set. 3Ri34a High Side (Discharge) Coupler -Connects the air conditioning system Discharge Access Port to the Manifold Gauge Set. 4Vacuum Pump - 2 Stage (5 CFM Minimum) - Removes moisture and air from the air conditioning system in order to obtain required micron level. 5Micron Gauge -Monitors the evacuation process in units of microns. Micron gauges can be either digital (electronic) or analog. When the Micron Gauge is used as specified by the manufacturer you can be assured all contaminants have been removed from the air conditioning system. Proper use of the Micron Gauge will also serve as a first indication of a leak tight system. 6Recovery/Recycle Machine (R134a) -Recovers and Recycles R134a refrigerant that is present within the air conditioning system. 7Refrigerant Scale -Accurately weighs the transfer of refrigerant into the air conditioning system. 8Refrigerant Cylinder -Storage tank for R134a. 9Heat Blanket -Used to increase internal temperature of the refrigerant cylinder, greatly increasing the transfer of refrigerant to the air conditioning system. 10Oil Injector -Used to add additional amounts of oil to a closed system.11Vacuum 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 measured in microns, results when pressure is reduced within the system. Functionally, reducing the pressure results in reducing the boiling point of water (moisture) that may be in the system. Through the process of vaporization, the water (moisture) changes state from a liquid to a vapor and is drawn off by the vacuum pump and removed from the system. If properly completed, the system is now ready for charging. NOTE Using a compound gauge (Low Side Gauge) for determination of vacum level is not recom- mended because of its inherent inaccuracy. A micron gauge must always be used to insure a proper evacuation. 7.2.1 Preparation a. Evacuate and dehydrate only after pressure leak test. (Refer to paragraph 9.2 .) b. Essential tools to properly evacuate and dehydrate any system include a vacuum pump (5 cfm=8 m 3/hr) volume displacement) and an electronic vacuum (mi- cron) gauge. (The pump is available from Carrier Transicold, P/N 07-00176-11.) c. If possible, keep the ambient temperature above 60_F (15.6_C) to speed evaporation of moisture. If the ambient temperature is lower than 60_F (15.6_C), ice might form before moisture removal is complete. Heat lamps or alternate sources of heat may be used to raise the system temperature. 7.2.2 Procedure - Complete system a. Remove all refrigerant using an approved refrigerant recovery system, following manufacturers recom- mendations. b. The recommended method to evacuate and dehy- drate the system is to connect two evacuation hoses (see Figure 7-2) to the vacuum pump and refrigera- tion system. Be sure the service hoses are suited for evacuation purposes. c. Test the evacuation setup for leaks by drawing a deep vacuum through the manifold gauge set, hoses, and service couplers with the vacuum pump. Shut off the pump and check to see if the vacuum holds. Repair leaks if necessary. d. Open the vacuum pump and electronic vacuum (mi- cron) gauge valves, if they are not already open. Start the vacuum pump. Evacuate unit until the electronic vacuum gauge indicates 2000 microns. Close the electronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure the vacuum holds. e. Break the vacuum with clean dry refrigerant 134a gas. Raise system pressure to approximately 2 psig (0.2 kg/cm@), monitoring it with the compound gauge. f. Remove refrigerant using a refrigerant recovery sys- tem.
7-2 T--311 g. Repeat steps d.and e. one time. h. Evacuate unit to 500 microns. Close the electronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait five minutes to see if vacuum holds. This procedure checks for residual moisture and/or leaks. i. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant con- tainer on weight scales. 7.3 INSTALLING MANIFOLD GAUGES The manifold gauge set is used to determine system operating pressures, add refrigerant charge, and to equalize or evacuate the system. When the suction pressure hand valve is frontseated (turned all the way in), the suction (low) pressure can be checked. When the discharge pressure hand valve is frontseated, the discharge (high) pressure can be checked. When both valves are open (turned counter-clockwise all the way out), high pressure vapor will flow into the low side. When the suction pressure valve is open and the discharge pressure valve shut, the system can be charged. Oil can also be added to the system. A R-134a manifold gauge/hose set with self-sealing hoses is required for service of the models covered within this manual. The manifold gauge/hose set is available from Carrier Transicold. (Carrier Transicold P/N 07-00294-00, which includes items 1 through 6. To perform service using the manifold gage/hose set, do the following: a.Preparing Manifold Gauge/Hose Set For Use 1. If the manifold gauge/hose set is new or was exposed to the atmosphere it will need to be eva- cuated to remove contaminants and air as follows: 2. Back seat (turn counterclockwise ) both field service couplings (see Figure 7-1) and midseat both hand valves. 3. Connect the yellow hose to a vacuum pump. 4. Evacuate to 10 inches of vacuum. 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 is brought to the tool being used. To connect the manifold gauge/hose set, do the following. 1. Connect the high side field service coupling to the discharge line service valve port.2. Turn the high side field service coupling knob (red) clockwise, which will open the high side of the sys- tem to the gauge set. 3. Connect the low side field service coupling to the suction service valve port. 4. Turn the low side field service coupling knob (blue) clockwise, which will open the low side of the system to the gauge set. CAUTION To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting. OPENED (Backseated ) HAND VALVECLOSED (Frontseated) HAND VALVE SUCTION PRESSURE GAUGEDISCHARGE PRESSURE GAUGE To Low Side Access ValveTo High Side Access Valve Red Knob Blue Knob 1 43 YELLOW2 4 5 63 RED 3 BLUE 2 1. Manifold Gauge Set 2. Hose Fitting (0.5-16 Acme) 3. Refrigeration and/or Evacuation Hose . (SAE J2196/R-134a) 4. Hose Fitting w/O-ring (M14 x 1.5) 5. High Side Field Service Coupling 6. Low Side Field Service Coupling Figure 7-1 Manifold Gauge Set c.Removing the Manifold Gauge Set 1. Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be drawn down to suction pressure. This returns any liquid that may be in the high side hose to the system. 2. Backseat both field service couplings and frontseat both manifold set valves. Remove the couplings from the service ports. 3. Install both service port caps (finger-tight only).
7-3 T--311 TXV EVAPORATOR COIL CONDENSER COILFILTER DRYERSIGHT GLASS SUCTION ACCESS HPS LPS DISCHARGE ACCESS COMPRESSOR LPS (New Location GEN 5) (GEN 4 Location) DS 12 3 4 5 6 7 1. Vacuum Pump 2. Micron Gauge 3. Manifold Gauge Set 4. Refrigerant Cylinder5. Recovery/Recycle Machine 6. R134a High (Discharge) Side Coupler 7. R134a Low (Suction) Side Coupler Figure 7-2 Refrigerant Service Connections (Split Systems)
8-1T--311 SECTION 8 CHARGING PROCEDURES 8.1 INTRODUCTION Charging is the process of calculating and then introducing the correct amounts of refrigerant and oil into the air conditioning system. Accurate charge levels will result in optimum system performance and insure the longevity of the system components. 8.1.1 Proper R134a Charge. A system overcharged with refrigerant operates under high head pressure which can damage components. A system undercharged with refrigerant will result in poor system performance. NOTE An overcharged or undercharged system may contribute to system compressor failure. Calculations for determining the proper refrigerant charge are based on component capabilities and liquid line lengths as indicated on Carrier Transport Air Conditioning charging tables. Refer to Table 8-1 or Table 8-2 for the approximate refrigerant charge. Refer to Table 8-4 to determine the exact refrigerant charge.8.1.2 Proper Oil Charge. Accurate charge levels of oil with the refrigerant are also critical to proper performance and component longevity. A system undercharged with oil will result in reduced compressor life due to lack of lubrication. A system overcharged with oil will experience poor system performance due to reduced thermal transfer capabilities. Refer to Table 8-1 or Table 8-2 for the approximate oil amounts. Refer to Table 8-3 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 8-3). Using oil other than the specified oil can result in reduced performance and a reduction in compressor life. NOTE Using oil other than that specified in Table 8-3 will void the compressor warranty. Table 8-1 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (THROUGH GEN 4) Evaporator Up to GEN 5 Condenser All SeriesRecommended R134a ChargeRecommended Oil Charge* EM-1, EM-2, or EM-9CM-25.00 Pounds10.0 Ounces EM-1, EM-2, or EM-9CM-115.25 Pounds10.5 Ounces EM-6CM-24.00 Pounds8.0 Ounces EM-6CM-114.25 Pounds8.5 Ounces EM-1, EM-2, or EM-9CM-35.50 Pounds11.0 Ounces EM-1, EM-2, or EM-9CM-76.50 Pounds13.0 Ounces EM-3(2) CM-24.25 Pounds Each8.5 Ounces Each EM-3(2) CM-76.25 Pounds Each12.5 Ounces Each EM-3(2) CM-35.50 Pounds Each11.0 Ounces Each EM-3(2) CM-76.25 Pounds Each12.5 Ounces Each EM-14CM-23.50 Pounds7.0 Ounces EM-14CM-113.75 Pounds7.5 Ounces EM-17CM-519.0 PoundsConsult Factory EM-17KR-413.0 PoundsConsult Factory EM-17 Split System(2) CM-36.00 Pounds Each12.0 Ounces Each
8-2 T--311Table 8-2 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (GEN 5) Evaporator GEN 5 Condenser All SeriesRecommended R134a ChargeRecommended Oil Charge* GEN 5 - EM-1CM-2 or CM-44.75 Pounds9.5 Ounces GEN 5 - EM-1CM-115.00 Pounds10.0 Ounces GEN 5 - EM-1CM-35.25 Pounds10.5 Ounces GEN 5 - EM-1CM-76.25 Pounds12.5 Ounces GEN 5 - EM-7CM-2 or CM-44.00 Pounds8.0 Ounces GEN 5 - EM-7CM-114.25 Pounds8.5 Ounces GEN 5 - EM-2CM-2 or CM-44.50 Pounds9.0 Ounces GEN 5 - EM-2CM-114.75 Pounds9.5 Ounces GEN 5 - EM-2CM-35.00 Pounds10.0 Ounces GEN 5 - EM-2CM-76.00 Pounds12.0 Ounces The data listed in Table 8-1 and Table 8-2 is based on a 20 foot liquid line. Increase the charge by 0.5 pound for each additional 10 feet of liquid line. 8.1.5 Evaporator Tie-In. When an after market in-dash evaporator is added to a standard system the refrigerant charge will increase by approximately 1 pound. If attempting to use a CM-2 condenser with a tie-in call Carrier Transport Air conditioning technical support for an application review. Table 8-3 COMP. OIL TYPE & PART NUMBERS Manufacturer Oil TypePart Number Tama/Zexel/IcePA G07-00336-00 SandenPA G07-00335-00 General MotorsPA G46-50003-00 DodgePA G07-00332-00 FordPA G07-00334-00 Climate ControlPOE07-00317-00 For questions regarding charging procedures, call Carrier Transport Air Conditioning technical support at 1-800- 450-2211.8.1.6 Adding Refrigerant to System (Full Charge). a. Evacuate unit and leave in deep vacuum. b. Place cylinder of R-134a 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 correct weight of refrigerant has been added as indicated by scales. NOTE It may be necessary to finish charging unit through suction service port in gas form, due to pressure rise in high side of the system. d. Close suction line service port coupler. Close liquid valve on cylinder. e. Start unit in cooling mode. Run approximately 10 min- utes and check the refrigerant charge. (Refer to Table 8-4).
8-3T--311 Table 8-4 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHART Determine the approximate refrigerant charge using Table 8-1 or Table 8-2 . Follow the procedures listed below to determine if the correct charge has been obtained. Ta b l e ProcedureYour EntryExample Pres- sureRefrigerant Temp.1.Connect Manifold Gauge Set To Air ConditioningSystemNONENONEPSIGR-12R134a AirConditioningSystem Certified Air Conditioning MechanicNONENONE (A)(B)(C) CertifiedAirConditioningMechanic Only 958785 10090882.Measure outside(ambient)air 1059390 2.Measureoutside(ambient)air temperature.DegreesF100DegreesF11 09693Enter here ------------ -->______DegreesF100DegreesF 11 59996 12010298 125104100 40DF40DF1301071033.Add 40 degrees F to the outside (bit)itt 40 Degrees F DegreesF 40 Degrees F 140DegreesF135109105(ambient) air temperature --->______DegreesF140DegreesF 14011 2107 14511 4109 15011 711 2 15511 911 44.Find closest refrigerant temperatureinTableDegreesF139DegreesF16012111 6temperatureinTable (B or C) and enter here --- -->______DegreesF139DegreesF 16512311 8 (BorC)andenterhere> 170126120 175128122 1801301235. Going across the Table, find the di(A)(D)=PSI225PSI185132125corresponding pressure (A) -->(D)=______PSI225PSI 190134127 195136129 2001381316.If the Discharge Pressure (HighSide)ongaugers205140132(HighSide)on gaugers (With compressor engaged, 210142134 (Withcompressorengaged, engine speed 1200 RPM, and 215143136 enginespeed1200RPM,and system operating) is : 220145137 Gtth(D)Rdfit ****** 225147139Greater than (D) - Reduce refrigerant by4ounceincrements235150142by 4 ounce increments. 245154145Lessthan(D)-Addrefrigerant255157148Lessthan(D)-Addrefrigerant 265160151Wait 10 minutesfor system to 275163153 Wait10minutesforsystemto stabilize before taking new readings
9-1 T-- 311 SECTION 9 LEAK CHECKING 9.1 INTRODUCTION The purpose of leak checking is to verify the integrity of the hose/fitting connections and components. A refrigerant leak check should always be performed after installing a new system or the system has been opened to replace or repair a component. It is imperative that the inspection for refrigerant leaks be conducted in a through and meticulous manner. Even the smallest leak can result in poor system performance and premature compressor failure. When a leak occurs, the refrigerant is replaced by air and moisture from outside the system. Without a complete charge of refrigerant in the system, insufficient oil is returned to the compressor. The compressor will overheat and eventually fail. Following established leak checking procedures will result in long term performance and assure longevity of the system components. 9.1.1 Micron (Vacuum) Gauge Carrier Transport Air Conditioning recommends a Micron (Vacuum) Gauge to assure that the proper vacuum level is attained. When isolated according to instructions the Micron Gauge will show a loss of evacuation vacuum, making it an excellent first leak check. 9.1.2 Nitrogen A common method in use for leak detection, is pressurizing the system with dry nitrogen and checking 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 other gas or vapor will contaminate the system, which will require additional evacuations (Refer to Figure 9-1 for service connections).9.2 REFRIGERANT LEAK CHECKING WARNING Never use air for leak testing. It has been de- termined that pressurized, air-rich mixtures of refrigerants and air canundergo com- bustion when exposed to an ignition source. a. Charge the system with refrigerant 134a to build up pressure between 30 to 50 psig. b. Add sufficient nitrogen to raise system pressure to150/200 psig. (10.21/13.61 bar). Note Larger split systems may be equipped with ser- vice valves and a liquid line solenoid. Ensure these service valves are open and power the liquid line service valve from an external source. c. The recommended procedure for finding leaks in a system is with a R-134a electronic leak detector (CTD Part Number 07-00295-00). Testing joints with soap- suds is satisfactory only for locating large leaks. d. Remove refrigerant using a refrigerant recovery sys- tem and repair any leaks. e. Evacuate and dehydrate the unit (Refer to Section 7). f. Charge the unit. (Refer to Section 8).
9-2 T--311 TXV EVAPORATOR COIL CONDENSER COILFILTER DRYERSIGHT GLASS SUCTION ACCESS HPS LPS DISCHARGE ACCESS COMPRESSOR LPS (New Location GEN 5) (GEN 4 Location) DS 1 7 6 5 43 2 1. Vacuum Pump 2. Micron Gauge 3. Manifold Gauge Set 4. Refrigerant Cylinder5. Recovery/Recycle Machine 6. R134a High (Discharge) Side Coupler 7. R134a Low (Suction) Side Coupler Figure 9-1 Refrigerant Service Connections (Split Systems)
T--311 10-1 SECTION 10 WARRANTY REGISTRATION 10.1 INTRODUCTION The warranty registration process is an important part of the installation of any air conditioning system. In order to experience the full benefits of Carrier Transport Air Conditioning’s warranty, it is imperative that your system is registered completely and accurately. Failure to properly register the system will adversly affect the availability of warranty coverage. A properly registered system will enable Carrier Transport Air Conditioning to respond immediately in the event of a warrantable failure. 10.2 PROCEDURES 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, Installer Name, Address, City, State, Zip code and Phone number. b. When Purchaser information is known, the installer can complete this part of the form also.c. If the Warranty Registration Card is complete, the white (pre-addressed) copy can be mailed to Carrier Transport Air Conditioning at this time. d. Installer to keep yellow copy for file. e. Installer to forward (with bus) green and white copy to purchaser (end-used). 2. Green copy:Purchaser (End User) copy: a. Complete Purchaser copy, sign, then mail white (pre-addressed) copy to Carrier Transport Air Condi- tioning. b. Purchaser (end user) to keep green copy for file. NOTE The Carrier Transport Air Conditioning limited warranty is printed on the back of the purchaser (green) copy. 3. White Copy:Carrier Transport Air Conditioning copy: a. Must be mailed to Carrier Transport Air Conditioning in order to validate the system warranty. Figure 10-1 Warranty Registration Card 10.3 WARRANTY POLICY 10.3.1 In-Line Failures - OEM/Installer Repair Refer to Warranty Policy, Procedures & LaborAllowance Manual (62-02737) for instructions on returning, replacing or repairing any parts that were defective at time of installation. Or call Carrier Transport Air Conditioning Technical Support Hot-Line (800) 450-2211) for assistance.
T--311 11 - 1 SECTION 11 FINAL (CHECK-OUT SHEET) INSTALLATION CHECK-OUT The installation checkout procedure is an important step in the installation of any air conditioning system. The reason for the installation checkout procedure is to insure that all Carrier Transport Air Conditioning standards of installation quality have been met. An itemized checkout form will help you in the checkout process and will provide a device for permanently recording your findings. The form that follows this introduction represents a guideline, that can be used as is, or as a starting point for the development of your own custom installation checkout sheet. A correctly completed final checkout will guarantee a quality installation that will last the life of the bus. GENERAL INFORMATION BUS MODEL/BODY_______________________BUS VIN#__________________________________ CARRIER TAC SYSTEM___________________EVAP’S_______COND’S_______COMP’S_______ ENGINE AREA: YES NO ____ ____ Is compressor and compressor mount secure? ____ ____Were 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! ____ ____Were belts tightened per manufacturers recommendations? ____ ____Are refrigerant hoses routed through the engine compartment to the compressor correctly? Refrigerant hose must be protected from heat sources and sharp objects! Refrigerant hose should be supported with insulated clamps wherever possible. ____ ____Was mineral oilused to lubricate the fittings, hose and O Rings? ____ ____Was excess oil wiped from fittings and hose? ____ ____Is 12.5 Volts available at the compressor clutch? ____ ____Are the Quick-Click fittings clamped to the Quick-Click refrigerant hose correctly? CONDENSER AREA: YES NO ____ ____ Is the condenser(s) mounted securely to the bus floor? ____ ____ Is condenser(s) mounted as close as possible to bus skirt? If condenser cannot be mounted close to the skirt, a shroud must be installed to prevent re-circulation of heat. ____ ____ Is bus skirt cut out to allow maximum airflow across the coil? Cut out must beat least as large as the condenser coil to allow for maximum heat rejection.