Carrier GEN IV Service Manual

T--299 Rev C Change 06/10OPERATION & SERVICEforSPLIT SYSTEMSGeneration 4 & 5Transport Air Conditioning

1-- 2T -299 01/08Figure 1-1 Condenser Model CM2/3 - Serial Number LocationEM-9 LocationFigure 1-2 GEN 4 Evaporator Model - Serial Number LocationFigur

1-- 3T -29901/0852Figure 1-4 GEN 4, IW-2 & IW-7 - Serial Number LocationFigure 1-5 GEN 4, IW-1 - Serial Number LocationObsolete TagFigure 1-6 CM-7

1-- 4T -299 01/08Figure 1-7 KR-2/KR-3 Rooftop Condensers - Serial Number/PID Location01- 22- 07Figure 1-8 System Requirements Label1.4 SYSTEM REQUIREM

1-- 5T -29901/08IW (In--Wall) System -- A Carrier evaporator installed inthe front and/or rear of the vehicle. This type evaporatoris installed betwee

1-- 6T -299 01/08Expansion/Block Valve -- Meters the refrigerant flowinto the evaporator coil. The majority of the Gen 4(Excel) and all Gen 5 systems

1-- 7T -29901/08Skirt Mounted (”Vector” Fan): Permanent magnetic,single speed motor (12VDC nominal) and fancombination (pancake style) 10 blades.Full

1-- 8T -299 01/08TXVEVAPORATOR COILCONDENSER COILFILTER DRYERORRECEIVER DRIERSIGHT GLASSSUCTION ACCESS PORT(GEN 5Location)HPSLPSDISCHARGEACCESS PORTCO

1-- 9T -29901/081.9 HEATING CYCLE (If Applicable)The optional heating circuit component furnished byCarrier Transport Air Conditioning is the side or

2-- 1T -29901/08SECTION 2OPERATION2.1 OPERATING INSTRUCTIONSBefore attempting to operate the system, power mustbe available from the vehicle battery.

2-- 2T -299 01/082.3 FLORIDA CONTROL (TEMPCON)This controller is normally used in school buses locatedwithin the state of Florida, but not limited to

OPERATION ANDSERVICE MANUALSPLIT--SYSTEMSGeneration 4 & 5BUSAIR CONDITIONINGEQUIPMENT

2-- 3T -29901/082.5 TOTAL CONTROLThe Total Control system consists of a Key Pad Display(See Figure 2-5) wired to an Electrical Control Panel(See Figur

2-- 4T -299 01/08CoolingHeatingNull BandSet Point +1/2 Null BandSet Point --1/2 Null BandSet PointFigure 2-6 Null Band2.6 GEN 4 -- WITH TOTAL CONTROL,

2-- 5T -29901/08b. Fan Speed SelectionPress the Fan Speed button.Press the + or -- button to toggle between HIGH,MEDIUM, and LOW speeds.NOTE: Other op

2-- 6T -299 01/08If at any time during operation the circuit frommicroprocessor terminal BPT+ back to terminal BPT-- isopened by the freeze--up thermo

3-- 1T -29901/08SECTION 3TROUBLESHOOTING3.1 INSUFFICIENT OR NO COOLING3.1.1 Preliminary ChecksMake certain that the evaporator filters are not clogged

3-- 2T -299 01/08Table 3-2 Evaporator Current Draw (GEN 5)MODEL VOLTAGESPEED SETTING (3) AND AMP DRAWLOW -- AMP MEDIUM -- AMP HIGH -- AMPEM--113.5 VDC

3-- 3T -29901/08Table 3-4 GENERAL SYSTEM TROUBLESHOOTING PROCEDURESINDICATION/TROUBLEPOSSIBLE CAUSES3.2 SYSTEM WILL NOT COOLCompressor will not run Dr

3-- 4T -299 01/08Table 3-4 GENERAL SYSTEM TROUBLESHOOTING PROCEDURES -- Continued3.6 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOWAir flow through coi

3-- 5T -29901/08Table 3-5 TROUBLESHOOTING ALARM CODES (TOTAL CONTROL)ALARMCODETITLE CAUSE REMEDYAL 13 Return air sensor . Open circuit or short circui

3-- 6T -299 01/08Table 3-5 TROUBLESHOOTING ALARM CODES (TOTAL CONTROL) Cont::AL 47 Not UsedAL 48 Heating ValvemalfunctionMalfunction is detected onthe

Safety - 1T -29901/08SAFETY SUMMARYGENERAL SAFETY NOTICESThe following general safety notices supplement the specific warnings and cautions appearing

4-- 1T -29901/08SECTION 4SERVICEWARNINGBeware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fansand compressor

4-- 2T -299 01/084.2 MAINTENANCE PROCEDURESThe following air conditioning service equipment isrequired in order to properly perform the maintenancepro

4-- 3T -29901/08TXVEVAPORATOR COILCONDENSER COILFILTER DRYERSIGHT GLASSRECEIVER/DRIERSUCTION ACCESSHPSLPSDISCHARGEACCESSCOMPRESSORLPS(New Location GEN

4-- 4T -299 01/081.. Connect the high side field service coupling (seeFigure 4-1) to the discharge line service valve port.2.. Turn the high side fiel

4-- 5T -29901/084.6.3 Procedure For Evacuation and DehydratingSystem (Triple Evacuation)a. Remove all refrigerant using a refrigerant recoverysystem (

4-- 6T -299 01/08Table 4-1 Split System Refrigerant And Oil Charging Table -- Thru GEN 4EvaporatorUp to GEN VCondenserAll SeriesRecommendedR134a Charg

4-- 7T -299Change 06/10CLOSE- UP VIEWCOIL FINSFigure 4-1 Micro -Channel Style Condenser AssemblyThe data listed in Table 4-1 trough Table 4-3 is based

4-- 8T -299 01/08Table 4-5 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHARTDetermine the approximate refrigerant charge using Table 4-1, Ta

4-- 9T -29901/08Table 4-6 STANDARD TORQUE REQUIREMENTSSIZETUBE O.D. * FLAREO--RINGTHREAD **STEEL T UBING ALUM. TUBING4 1/4 inch (.250) 11--13 ft./lbs.

4-- 10T -299 01/08Clearance Zone IdentificationClearance at Mid SpanFigure 4-5 Belt Clearance Requirements4.12 DRIVE BELT INSTALLATION4.12.1 Introduct

Safety - 2T -29901/0801/08SPECIFIC WARNINGSWARNINGBeware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fansand

4-- 11T -29901/08Angular misalignment is often caused by tolerances inseveral pieces, such as hardware to mounting holes andplates to components. Angu

4-- 12T -299 01/084.13.2 GEN 5 SeriesReplace the GEN 5 series return air filter(s) as follows:a. Insert a 3mm Allen wrench into the 1/4 turn receptacl

4-- 13T -29901/08e. Reassemble by reversing steps a. thru c.f. Check condenser fan assembly operation.4.17 REPLACING THERMOSTATIC BLOCK VALVEThe Therm

4-- 14T -299 01/084.19 MOISTURE INDICATOR (SYSTEM)There are two types of moisture indicatorspresently in use with Carrier Transport A/Csystems.1.Green

4-- 15T -29901/08Table 4-10 R-134a Temperature - Pressure ChartTemperatureVacuum°F °CPSIG Kg/cm@ Bar-- 4 0 -- 4 0 14.6 37.08 0.49-- 3 5 -- 3 7 12.3 31

T -2995-- 101/08SECTION 5ELECTRICAL SCHEMATIC DIAGRAMS5.1 INTRODUCTIONThis section contains Electrical Schemat ics covering the GEN 4 and GEN 5 system

T -2995-- 201/08LEGENDADJ Adjusting GRDGroundALT Alternator HGS1Compressor #2 RelayAMP Ampere HGS2Heat ValveAUX Load HPHigh Pressure SwitchBAT Battery

5-- 3T -29901/08FREEZESTATFigure 5-3 GEN 4 System Schematic -- EM--1 With CM--2/3

5-- 4T -299 01/08BLOWERRESISTORFAN SPEEDSWITCHHPCMCMCONDENSERMOTORSPRESSURESWITCHBLK--10BLU--14RED--14RED--14YEL--12ORG--10GRN--1020 AMP40 AMP40 AMPBL

5-- 5T -29901/083Figure 5-5 GEN 4 System Schematic -- EM--3 With (2) CM--3 Condensers & (2) Compressors

iT--29901/08TABLE OF CONTENTSPARAGRAPH NUMBER PageSAFETY SUMMARY Safety --i...SPECIFIC

5-- 6T -299 01/08-- +HOURMETERDIODEFAN SPEEDSWITCHBLK--14GRNYELHIGHCMBLK--1418BLUYEL--10RED--12THERMOSTAT18ORG10ORGBLK--1018ORG8ORGRED--14RED--148BLK8

5-- 7T -29901/08123101845 678ORGBLKBLU1886BLU188785BLK30CR10ORG1018ORG87858618REDBLU1830HSRORG1018ORGAUX40 AMPBATBATTERYAUX50 AMPBAT1818BLURED910BLUBL

5-- 8T -299 01/08123101845678ORGBLKRED1886GRN188785BLK30CR10BLK1018ORG87858618REDBLU1830CRORG10AUX40 AMPBATBATTERYAUX40 AMPBAT1818BLURED910ORG1818ORGR

5-- 9T -29901/081231045678ORGBLK86188785BLK30CR10ORG1018ORG878586BLU1830HSRYEL10AUX40 AMPBATBATTERYAUX50 AMPBAT1818BLURED910ORG1818ORGRED1818REDRASCOM

INDEXIndex--1T -29901/08AAdding Refrigerant, 4-5AIR CONDITIONING, 1-1CCHECKING AND REPLACING HIGH PRESSURESWITCH, 4-13COMPONENT SPECIFICATIONS, 1-6COM

INDEXIndex--2T -299 01/08SSafety Summary, General, Safety --iSEQUENCE OF OPERATION, 2-5SERIAL TAG, 1-1SERVI CE, 4-1SYSTEM COMPONENTS , 1-5SYSTEM DESIG

©2008 Carrier Corporation D Printed in U. S. A 01/08Carrier Transport Air Conditioning50 Grumbacher RoadYork P A 17406 USATel: 1--800--673--2431Fax: 1

iiT--299 01/0801/08TABLE OF CONTENTS -- Continued:SERVICE 4-1...4.1 P

iiiT--29901/08LIST OF ILLUSTRATIONSFigure PageFigure 1-1 Condenser Model CM2/3 - Serial Number Location 1-2...Figur

ivT--299 01/0801/08LIST OF TABLESTable 1-1 Additional Support Manuals 1-1.....Table 3-1 Evapora

1-- 1T -29901/08SECTION 1DESCRIPTION1.1 INTRODUCTIONThis manual contains Operating, Service, andMaintenance Instructions for Gen 4 and Gen 5 SplitSyst