Carrier GEN IV User manual

OPERATOR’S MANUAL

for

SPLIT SYSTEM

Bus Air Conditioning Units

T--326 Rev --

Transport Air Conditioning

TRANSPORT AIR CONDITIONING

OPERATOR’S

MANUAL

BUS AIR CONDITIONING

UNITS

GEN IV & GEN V

CONTENTS

Page

Introduction 1............................

Safety 3..................................

Unit/System Information 4.................

1.1 WHAT IS AIR CONDITIONING 4.............

1.2 SPLIT SYSTEM 4..........................

1.3 SYSTEM DESIGNATIONS 4................

1.4 SYSTEM COMPONENTS 4.................

1.5 MODEL AND SERIAL NUMBER TAGS 6......

1.6 SYSTEM REQUIREMENTS LABEL 8........

Unit Operation 9..........................

2.1 OPERATING INSTRUCTIONS 9.............

2.2 DRIVER’S CONTROL PANEL -- STANDARD 9.

2.3 DRIVER’S CONTROL PANEL -- FLORIDA 10...

2.4 PRE--TRIP INSPECTION 12..................

System Maintenance 13....................

3.1 Maintenance Schedule 13....................

3.2 Warranty/Service 14.........................

Index Index 1...............................

INTRODUCTION

SPLIT SYSTEM OPERATOR’S MANUAL

This guide has been prepared for the operator of Carrier Transport

Air Conditioning systems. It contains basic instructions for the daily

operation of the air conditioning system as well as safety

information, and other information that will help you to maintain a

comfort level for your self and your passengers. Please take the

time to read the information contained in this booklet and refer to

it whenever you have a question about the operation of your Carrier

Transport Air Conditioning system.

More comprehensive information can be found in the Split System

Operation and Service Manual (T--299). This manual can be

obtained from your Carrier Transport A/C dealer.

Your air conditioning system has been engineered to provide long,

trouble-free performance when it is properly operated and

maintained. A comprehensive maintenance program will help to

insure that the unit continues to operate reliably. Such a

maintenance program will also help to control operating costs,

increase the unit’s working life, and improve performance.

Some Vehicles may require information from manuals supplied by

the vehicle manufacturer or other special equipment suppliers. We

urge you to review all these publications carefully. This will help you

enjoy safe and trouble--free operation of your vehicle.

When having your unit serviced, be sure to specify genuine Carrier

Transicold replacement parts for the highest quality and best

reliability.

Carrier Transport Air Conditioning Dealers know your vehicle air

conditioning system best and will ensure your complete

satisfaction. To find the Dealer nearest you, go to

www.transportaircon.carrier.com and click on “Dealer Locator”, or

refer to the Carrier Bus Stop Dealer Directory (62--10810) or

contact the Carrier Transport Air Conditioning Technical Service

Hot--Line 1 (800) 450--2211.

At Carrier Transport Air Conditioning, we are continually working to

improve the products that we build for our customers. As a result,

specifications may change without notice.

3T--326

SAFETY

Your Carrier Transport Air Conditioning system has been designed

with the safety of the operator in mind. During normal operation, all

moving parts are fully enclosed to help prevent injury. During all

pre-trip inspections, daily inspections, and problem

troubleshooting, you may be exposed to moving parts; please stay

clear of all moving parts when the unit is in operation.

WARNING

Beware of unannounced starting of the unit. The unit

may cycle the fans and operating compressor unex-

pectedly as control requirements dictate. Turn system

off and disconnect battery power.

REFRIGERANT

The refrigerant contained in the air conditioning system can cause

frostbite, severe burns, or blindness when in direct contact with the

skin or eyes. For this reason, and because of legislation regarding

the handling of refrigerants during system service, we recommend

that, whenever your unit requires service of the refrigeration

system, you contact your nearest Carrier Transport Air

Conditioning authorized dealer for service.

T--326

UNIT/SYSTEM INFORMATION

1.1 WHAT IS AIR CONDITIONING

Air Conditioning is the cooling, heating, dehumidification, and

filtration of the air within the passenger compartment of a vehicle.

1.2 SPLIT SYSTEM

A Split System normally includes an Evaporator(s), a Condenser(s)

a Compressor(s) and interconnecting refrigerant hoses, fittings,

and electrical harnesses and controls. A listing of the system

components, along with specific data for each, is provided in

Paragraph 1.4.

1.3 SYSTEM DESIGNATIONS

Tie--In System -- Is a Carrier evaporator and condenser connected

to an existing OEM compressor and dash evaporator. The OEM

radiator type condenser is normally removed.

Max System -- A Carrier system installed along with an existing

OEM system. The systems operate independent of each other.

Stand--Alone (Standard) System -- All Carrier components

installed on a vehicle. These can be either single or dual

compressor systems.

1.4 SYSTEM COMPONENTS (Refer To Figure 1-1)

Return Air Thermostat/Sensor -- The system may be supplied

with a thermostat or thermistor. Both of these devices are

temperature sensitive components which when activated, signals

the Electro--Magnetic Clutch to engage/disengage. The return air

thermostat is normally located in the drivers control panel while the

return air thermistor is normally located in the return air flow of the

evaporator assembly.

Electro--Magnetic Clutch -- The Electro--Magnetic clutch controls

the operation of the compressor. When engaged, the compressor

circulates refrigerant and provides cooling.

Compressor -- The compressor is a belt driven, high--pressure

pump, which circulates the refrigerant through the evaporator and

condenser . The operation of the compressor is controlled by the

Electro--Magnetic clutch.

Condenser -- The condenser is normally located in the skirt or on

the roof of the vehicle. Its primary function is to reject heat, which

was transferred to the refrigerant by the evaporator from the

passenger compartment of the vehicle.

5T--326

Air In

Air Out

Air In

Air Out

1. Compressor

2. Electro--Magnetic Clutch

3. Discharge Line

4. Condenser

5. Filter Dryer/Sight Glass

Assembly

6. Liquid Line

7. Evaporator

8. Block Valve (TXV)

9. Freezestat--(Coil

freeze--up thermostat)

10. Suction Line

Figure 1-1 Component Locations

Filter/Dryer -- The filter/dryer removes moisture and particulate

matter from the refrigerant.

Expansion/Block Valve -- Meters the refrigerant flow into the

evaporator coil. The majority of the Gen 4 (Excel) and all Gen 5

systems use a nonadjustable block valve with an 8°F superheat

setting, which is preset at the factory. If you feel there is a problem

with the block valve, do not attempt to adjust the valve, if needed,

it should be replaced by an authorized Carrier Transport A/C

service center.

Evaporator -- The evaporator is located in the interior of the

vehicle. 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.

Resistor -- Resistors are used to control the speeds of the

permanent magnet evaporator blower motors.

T--326

Pressure Switch -- The systems use high and low pressure

switches wired in series to control the power circuit of the

compressor clutch relay. If either pressure switch opens,

interrupting the circuit to the clutch relay, the operation of the

compressor will stop. When conditions return to normal the switch

will automatically reset and the compressor will resume operating.

The switches are non--adjustable.

Freeze--Up Thermostat -- Freeze--up thermostats are used to

prevent ice formation on the evaporator coil, which is an indication

that liquid refrigerat is getting back to the compressor. Carrier

Transport Air Conditioning systems use a freeze thermostat

(freezestat) wired in series with the system pressure switches and

thermostat/thermistor to control the operation of the compressor

clutch.

Refrigerant -- A refrigerant is a material that is used to move heat

from the passenger compartment to the outside air. It is a

substance that gives up heat by condensing at high temperature

and pressures and absorbs heat by evaporating at low

temperatures and pressures. The heat transfer properties

exhibited when refrigerant changes state is the foundation of the

refrigerant cycle.

1.5 MODEL AND SERIAL NUMBER TAGS

In order to identify the air conditioning components you have, you

will need to know the model number and serial number. All Carrier

Transport Air Conditioning evaporators, condensers and

compressors have a model/serial number tag located on the

assembly. See Figure 1-2 for skirt mounted condenser data tag

location, Figure 1-3 for the CM--7/11 rooftop condensers data tag

location, Figure 1-4 for GEN 4 (Excel) evaporator data tag location

and Figure 1-5 for GEN 5 evaporator data tag location. Knowing

these locations and the information on the data tags will aid you in

identifying the correct service procedures.

Figure 1-2 Skirt Mounted Condensers

7T--326

Figure 1-3 Roof Mounted Condensers

EM--9 Location

Figure 1-4 Rear/Side Mounted Gen IV Evaporators

NOTE

The EM--9 evaporator data tag is located on the side of the

evaporator assembly, not between the blower assemblies.

Figure 1-5 Rear/Side Mounted Gen V Evaporators

T--326

1.6 SYSTEM REQUIREMENTS LABEL

The system requirements label (See Figure 1-6) is conveniently

located within the vehicle’s engine compartment. This label, when

properly completed by the installer, will give the servicing technician

the refrigerant and oil charge(s), evaporator(s), condenser(s), and

compressor(s) serial numbers, the drive belt(s) number, mount kit

number, the date of installation and the installer.

Figure 1-6 System Requirement Label

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