Carrier GEN IV Manuale di Installazione

T--311 Rev B Change 06/10INSTALLATION PROCEDURESforSPLIT SYSTEMSGeneration 4 & 5Transport Air Conditioning

ivT-31 1TABLE OF CONTENTS -- Continued:Section Page...LEAK CHECKING 9-1..

T- -311 11-- 4SYSTEM OPERATION - Continued:____ ____Has refrigerant and oil charge been noted on the charging label? Correct type oil?____ ____ Is cha

T--31111-- 511.1 SYSTEM REQUIREMENTS L ABELThe system requirements label must be convenientlylocated within the vehicle’s engine compartment. Thislabe

Index--1 T--311INDEXAAdding Refrigerant to System (Full Charge), 8-2Aesthetics, 2-1AUXILIARY HEATER HOSE ROUTING, 4-10BBarrier Type Hose & Fitting

Index--2T--311INDEXNNitrogen, 9-1OObstructions, 3-1Oil Charge, 6-5Oil Charge , 8-1OPERATING INSTRUCTIONS , 5-6ORQUE SPECIFICATIONS, 4-10PPAGAndPOEOils

©2008 Carrier Corporation D Printed in U. S. A. 0208Carrier Transport Air Conditioning50 Grumbacher RoadYork PA 17406 USATel: 1--800--673--2431Fax: 1-

vT-31 1LIST OF ILLUSTRATIONSFigure Page...Figure 2-14 Installed GEN 4 Ev

viT-31 1LIST OF ILLUSTRATIONSFigure Page...Figure 2-57 In-Wall Cut-Out (

viiT-31 1LIST OF ILLUSTRATIONSFigure Page...Figure 4--23 Hose Routing (C

viiiT-31 1LIST OF TABLESTable Page...Table 1-1 ADDITIONAL SUPPORT MANUA

T--3111-- 1Change 07/09SECTION 1DESCRIPTION1.1 INTRODUCTIONThis manual contains instructions for the properpreparation of and installation of Carrier

T--3111-- 2Table 1-2 CARRIER TRANSPORT AIR CONDITIONING SYSTEMS (GEN 4/5)SYSTEMTYPE BTU EVAP (S) COND (S) COMP (S)AC-3140 FB 26,000 (1) EM-14 OEM OEMA

T--3111-- 3Figure 1-3 GEN 5 Evaporator Model (All) - Serial Number Location52Figure 1-4 GEN 4, IW-2 & IW-7 - Serial Number LocationFigure 1-5 GEN

T--3111-- 4Obsolete TagFigure 1-6 CM-7/11 Rooftop Condensers (No Longer Offered) - Serial Number LocationFigure 1-7 KR-2/KR-3 Rooftop Condensers - Ser

T--3111-- 51.4 SYSTEM COMPONENTS1. Thermostat - A thermostat is a temperaturesensitive device, which when activated, signals theelectro-magnetic clutc

MANUALINSTALLATIONSPLIT--SYSTEMSGEN4&5POLICY AND PROCEDURES

T--3111-- 61.5 COOLING CYCLEThe unit operates as a vapor compression system usingR-134a as the refrigerant (See Figure 1-10). Thecompressor raises the

T--3111-- 71.6 EVAPORATORSEvaporators are located in the interior of the vehicle.Their primary function is to transfer heat contained in thepassenger

T--3111-- 8Table 1-5 GEN 5 EVAPORATORS -- VARIABLE SPEEDEVAP. CFM Amps (High Speed) V ariable Speed WeightEM-1 150029.5 @ 12.5 V olts30.1 @ 13.5 V olt

T--3111-- 91.8 PRE-INSTALLATION INSPECTIONImmediately upon receipt of your Carrier Transport AirConditioning system:Check the number/amount of cartons

T--3112-- 1SECTION 2EVAPORATORS2.1 INTRODUCTION2.1.1 DescriptionEvaporators are located in the interior of the bus. Theirprimary function is to transf

T--3112-- 2Change 07/092.2 REAR MOUNTED EVAPORATORS2.2.1 GEN 4/5 Series EM-1, EM- 2, EM-3, EM-7,EM-6, & EM-14To install the evaporator assembly in

T--3112-- 3Table 2-3 DISTANCE TO BACK WALL (GEN 4)GEN 4 EvaporatorDistance to back wallEM-1 7 InchesEM-2 7 InchesEM-3 4.5 InchesEM-6 7 InchesEM-14 8.7

T--3112-- 4Figure 2-7 Carriage Bolt SealingFigure 2-8 Locking Pliers Clamped to CarriageBoltsInstallation HintIn order to keep carriage bolts from bei

T--3112-- 5Figure 2-12 Block Valve Insulationr Connect two drain lines to the EM-1 evaporatordrain pan assembly. Secure both drain lines with theclamp

T--3112-- 6abcdefghiklmnj7/6 inch holesa. Snap Capb. Pan Head Screwc. Snap Cap washerd. Trim Stripe. Flexible Trimf. Evaporator Coverg. Evaporatorh. M

Safety --iT--311SAFETY SUMMARYGENERAL SAFETY NOTICESThe following general safety notices supplement the specific warnings and cautions appearing elsew

T--3112-- 7Change 07/09Figure 2-19 Rear Mount Evaporator (GEN-5) - InstalledFigure 2-20 EM -6 (GEN 4) Rear Mounted In An Extended Roof VanNOTEIf at al

T--3112-- 82.2.3 EM -3 EVAPORATOR GEN 4 OR GEN 5To install the EM-3 utilize the installation proceduresoutlined in Paragraph 2.2 except as noted below

T--3112-- 92.3 SIDE MOUNTED EVAPORATOR - EM-1, EM -2,EM-6, EM-7, & EM-14To install a side mounted evaporator assembly utilizethe following install

T--3112-- 10Top PanelTop PanelRear Hanger AssemblyFront Hanger AssemblyGEN 4/5 Evaporator CoverFront Hanger Detail123456677789810614131211Figure 2-24

T--3112-- 11Side Trim StripRear T rim StripT ransitionT ransitionT rim LockHose CoversFigure 2-26 EM-2 (Gen V) Side-Mount - Free Blow, Installed (Comp

T--3112-- 12Change 07/092.4 EM-9 DUCTED EVAPORATORThe EM-9 evaporator is normally located slightlyforward of the bus center on the drivers side and sl

T--3112-- 13Figure 2-28 Punching out Louver Holes Figure 2-29 End Cap With LouverFigure 2-30 EM-9 Ducted Evaporator - Location - Completed AssemblyFig

T--3112-- 14Figure 2-33 Side Mounted Hose Routing(Using 45° Angles)Figure 2-34 Side Mounted Hose Routing (Straight)

T--3112-- 152.5 EM-17 EVAPORATORThe EM-17 is available in single and dual loopapplications. Due to the weight and size of theevaporator assembly it is

T--3112-- 16Change 07/092.6 IW-1, IW-2, & IW-14 EVAPORATORSThe IW (In-W all) evaporator assemblies are designed tobe installed in the rear and/or

Safety --iiT--311SPECIFIC WARNINGS AND CAUTIONSWARNINGDo not attempt to modify the EM-3 evaporator top panel. Modifications to the top panel could str

T--3112-- 17Figure 2-37 In-Wall Cut-Out (Panel Removed)CAUTIONWhen installing any IW unit, be careful not to cut the bus structure rails or wiring har

T--3112-- 18Move Ground To AreaAbove In -Wall Evap.Figure 2-40 Bus Electrical Harness Groundf Remove bus grounding screw and relocate to anarea that d

T--3112-- 19Drain LineSuction LineEvap. HarnessLiquid LineFigure 2-44 Hose/Harnes/Drain Routed To IWj Attach the IW Evaporator Assembly to the busstru

T--3112-- 20Figure 2-47 Hose Cover Installed (Left-Side)Figure 2-48 In-Wall With Trimmed Cover (Rear)

T--3112-- 212.6.2 Front Mounted In-Wall EvaporatorInstallation of an In-Wall in the front wall of a busrequires a little more thought and planing than

T--3112-- 22CAUTIONNever route refrigerant hose, electricalcable or drain lines in any location wheredriver’s visibality would be impaired.r Follow st

T--3112-- 23Mounting ScrewLocking TabLocking TabMounting ScrewCut-Out Too HighFigure 2-55 In-Wall With Trimmed Cover (Front)u To install the metal cov

T--3112-- 24Change 07/092.6.3 In-Wall Evaporator - TBBFigure 2-57 shows the back wall (cut-out) of a TBBremoved. Figure 2-58 shows an IW-1 installed i

T--3113-- 1SECTION 3CONDENSERS3.1 INTRODUCTION3.1.1 DescriptionCondensers are normally located in the bus skirt or onthe bus roof. Their primary funct

T--3113-- 23.2 CONDENSERSCondensers are normally located on the outside of thevehicle. Their primary function is to reject heat absorbedby the refrige

Safety --iiiT--311CAUTIONBecause of the limited access to the block valve, start the fittings by hand (finger tightening) makingsure that there is no

T--3113--3NoteThe condenser assembly should contact asmany of the floor supports (stringers) as pos-sible, while hitting the least amount of skirt sup

T--3113--4BUS FL OORSTRINGERALTERNATE MOUNTINGBLOCK SPACER REQUIREDIF NO STRINGER ATMOUNTING LOCATIONNot Required WhenUsing Chassis GrillCONDENSERFigu

T--3113--5Chassis Mounted GrillFigure 3-5 CM- 3 With Chassis Mounted Grill In A Cut-A-Way Chassis3.4 CM-5 CONDENSERThe Carrier Transport Air Condition

T--3113--63.5 KR-4 ROOFTOP CONDENSER ASSEMBLYThe Carrier Transport Air Conditioning KR4 condensersare designed to be installed on the roof of the bus.

T--3113--7Without Mounting ChannelWith Mounting ChannelBus roof outer skinRoof bowSealant1/4 In. steelmonobolt.Bolt, 3/8-16 X 1-1/4 In.4 per side.3/8

T--3113--8Apply sealant to unit mounting surfaceand rivet heads to prevent water leaksRoof BowBus RoofMountingChannelRoof BowFigure 3-11 KR4 Condenser

T--3113--93.6 KR2 & KR3The Carrier T ransport Air Conditioning KR2/3condensers are designed to be installed on the roof ofthe bus.To install the K

T--3113--103.6.1 Connecting To Side-Mounted EvaporatorsThe preceding steps are for connecting a rooftopcondenser assembly to a rear mounted evaporator

T--3113--11FLOOR MEMBER (STRINGER)BUS FLOORCHASSISRAILTop CondenserBottom CondenserBus SkirtAir Outlet BracketAir Inlet StiffenAir Inlet BracketFigure

T--3114--1SECTION 4HOSE ROUTING4.1 INTRODUCTIONAll bus air conditioning systems use a network ofrefrigerant hose and fittings to connect the majorcomp

Safety --ivT--311CAUTIONCondenser assemblies must be properly installed using graded hardware. The CM- 2 condenser as-sembly requires at least 4 bolts

T--3114--24. Lubricate the fitting O--Rings with mineral oil. Pushthe fitting into the hose until it contacts the fittingclamp stop angle (See Figure

T--3114--3Figure 4--7 Hose Back PositioningBefore drilling holes for the hoses in the wall or throughthe floor, make sure there are no electrical harn

T--3114--4fumes, dust and other foreign material fromentering the passenger compartment.Figure 4--11 Hose Cover BackFigure 4--12 Hose Cover Backs On R

T--3114--5ProtectionInstall Condensate Valve(Kazoo) on Drain Line EndFigure 4--15 Hoses Routed Through FloorA piece of scrap drain hose or heater hose

T--3114--6Figure 4--17 Correct Hose/Harness CornerRouting (Window Not Blocked)T rim-LockFigure 4--18 Side-Mounted Routing (Top)Figure 4--19 Hose/Harne

T--3114--7Always keep hose capped until ready to connect to asystem component (See Figure 4--5).1. Determine which side of the vehicle the hosesshould

T--3114--8Installation TipTo help keep hoses, harness, and drain linessecure and in the center of the hose covers,3/16 inch holes can be drilled in th

T--3114--9Figure 4--23 Hose Routing (Chassis)Figure 4--24 Hose Routing (Chassis)Figure 4--25 Hose Routing (Chassis)Figure 4--26 Hose Routing (Chassis)

T--3114--10Always try to leave a service loop in the hose to relievestress from the condenser fitting and for ease ofserviceability.When making conden

T--3114--11Change 07/09willabsorbmoistureandbecomeveryacid-ic and corrosive. Mineral oil will notabsorbmoisture and thus prevent corrosion.CAUTIONAlwa

iT-31 1TABLE OF CONTENTSSection Page...SAFETY SUMMARY i...

4--12T--311Figure 4-22 Rear Evaporator, OEM Tie-inFILTER DRIER

4--13 T--311Figure 4-23 Evaporator, Skirt Monuted Condenser and CompressorFILTER DRIER

4--14T--311Figure 4-24 Evaporator, Skirt Monuted Condenser and Compressor (AC-322, -332, -442)FILTER DRIER

4--15 T--311Figure 4-25 Evaporator, Skirt Monuted Condenser Compressor and Aftermarket InDash (AC-4431)FILTERDRIER

4--16T--311Figure 4-26 EM-3 Evaporator, (2) Skirt Monuted Condensers and TM -31 Compressor (AC-882, -883)FILTERDRIERFILTERDRIER

4--17 T--311Figure 4-27 (1)EM-3 Evap, (1)EM-7 Evap, (2) Skirt Condensers and a TM-31 Compressor (AC-9632)FILTERDRIERFILTERDRIER

5--1T--311Change 07/09SECTION 5ELECTRICAL5.1 INTRODUCTIONElectrical harness routing is a critical process in theinstallation of any transportation air

5--2T--311a. Carefully make an 8 Inch incision in the evaporatorcable close to where you will attach the ground wireterminal.b. Locate the green #10 w

5--3T--311Figure 5-6 Drivers Control Panel (Dual Systems)5.5.2 Electrical Control PanelThe manual controls are wired to the electrical controlpanel (S

5--4T--311Mounting ScrewMounting ScrewFigure 5-9 Relay Boards Installed Inside Bus (Dual System)To aid you in properly mounting the electrical panelus

iiT-31 1TABLE OF CONTENTS -- Continued:Section Page...CONDENSERS 3-1...

5--5T--3115.6 TOTAL CONTROLThe Total Control system consists of a Key Pad Display(Figure 5-12), an Electrical Control Panel, (Figure 5-13)and inter co

5--6T--311Figure 5-14 Gen 5 Total Control (Dual System)5.7 OPERATING INSTRUCTIONSBefore attempting to operate the system, power mustbe available from

6--1 T--311SECTION 6MOUNT KITS AND COMPRESSORS6.1 INTRODUCTIONCarrier transport Air Conditioning offers a wide range ofcompressors and corresponding m

6--2T--311 Change 07/096.2.1 Torque Specifications - BoltsAlways torque to the specifications noted on eachmount kit installation instructions. The to

6--3T--311Change 07/09Clearance Zone IdentificationClearance at Mid SpanFigure 6-5 Belt Clearance Requirements6.3.3 Pulley AlignmentCorrect belt align

6--4T--311considered when making the aforementionedmeasurements.The next step is to lay the straight edge flush across theface of the driven pulley. T

6--5 T--311NoteThe side to side mounting angle of the A-6 com-pressor must remain ±15° from the horizontal(See Figure 6-9).Access to the air condition

7--1T--311SECTION 7EVACUATION7.1 INTRODUCTIONThe process of evacuation is an important step in theservicing and maintenance of any air conditioningsys

7--2T--311g. Repeat steps d.and e. one time.h. Evacuate unit to 500 microns. Close the electronicvacuum gauge and vacuum pump valves. Shut off thevacu

7--3T--311TXVEVAPORATOR COILCONDENSER COILFILTER DRYERRECEIVER DRIERSIGHT GLASSSUCTION ACCESSHPSLPSDISCHARGEACCESSCOMPRESSORLPS (New Location GEN 5)(G

iiiT-31 1TABLE OF CONTENTS -- Continued:Section Page...ELECTRICAL 5-1...

8--1T--311SECTION 8CHARGING PROCEDURES8.1 INTRODUCTIONCharging is the process of calculating and thenintroducing the correct amounts of refrigerant an

8--2T--311CLOSE- UP VIEWCOIL FINSFigure 1-11 Micro-Channel Style Condenser AssemblyTable 8-2 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (GEN--5)E

8--3T--311Change 06/10Table 8-4 COMPRESSOR OIL TYPE & PART NUMBERSManufacturerOil Type CTAC Part NumberSeltec -- Valeo -- ICE -- Zexel -- Sanden P

8--4T--311Table 8-5 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHARTDetermine the approximate refrigerant charge using Table 8-1 or Table 8

9--1 T--311SECTION 9LEAK CHECKING9.1 INTRODUCTIONThe purpose of leak checking is to verify the integrity ofthe hose/fitting connections and components

9--2T--311TXVEVAPORATOR COILCONDENSER COILFILTER DRYERRECEIVER DRIERSIGHT GLASSSUCTION ACCESSHPSLPSDISCHARGEACCESSCOMPRESSORLPS(New Location GEN 5)(GE

T--31110--1Change 07/09SECTION 10WARRANTY REGISTRATION10.1 INTRODUCTIONThe warranty registration process is a very importantpart of the installation o

T--31111-- 1SECTION 11FINAL (CHECK-OUT SHEET)INSTALLATION CHECK- OUTThe installation checkout procedure is an important step in the installation of an

T- -311 11-- 2INSTALLATION CHECK-OUT, CONDENSER - Continued:____ ____Are exposed terminals/connections protected with an anti-corrosive coating?____ _

T--31111-- 3REFRIGERATION HOSE AND ELECTRICAL HARNESS ROUTING - Continued:YES NO____ ____Is “Mineral Oil” used to lubricate the fittings, hose and “O”