Transport Air Conditioning

OPERATION & SERVICE

for
SPLIT SYSTEMS

Generation 4 & 5

T--299 Rev C Change 06/10

OPERATION AND
SERVICE MANUAL

BUS
AIR CONDITIONING
EQUIPMENT

SPLIT--SYSTEMS
Generation 4 & 5
 SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this
manual. They are recommended precautions that must be understood and applied during operation, service, and
maintenance of the equipment covered herein. The general safety notices are presented in the following three
sections labeled: First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and
cautions appearing elsewhere in the manual follows the general safety notices.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.
OPERATING PRECAUTIONS
Always wear protective eye wear (safety glasses or goggles).
Keep hands, clothing and tools clear of the evaporator and condenser fans.
No work should be performed on the system unless battery power is disconnected.
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the system and investigate.
MAINTENANCE PRECAUTIONS
Familiarize yourself with the proper operation of any service equipment you will be using (voltmeter, amp probe,
manifold gauges, etc.). Always read the owner’s manual that is enclosed with the equipment
Always follow the manufacturers instructions for your recovery/recycling equipment. Failure to do so could cause
personal injury or damage to your equipment. Never perform any maintenance or service on your equipment before
consulting with authorized service personnel. Always unplug unit before attempting any maintenance. Removing
internal fittings and filters can release pressurized refrigerant. Slowly release pressure and always wear appropriate
safety wear.
Avoid breathing any refrigerant vapor, lubricant vapor, or mist. Exposure to these, particularly PAG oil mist, may irritate
your eyes, nose, or throat.
Always use a DOT (Department of Transportation) approved cylinder for storing used and recycled refrigerant.
Approved cylinders will be stamped DOT 4BW or DOT 4BA. Carrier recommends a MACS (Mobile Air Conditioning
Society) certification in Recovery/Recycling to gain more information on handling and using refrigerants.
Never attempt to apply heat or open flame to a refrigerant cylinder. High temperatures can raise the cylinder pressure
to dangerous levels. Carrier recommends using a heat blanket to increase the internal temperature of the refrigerant
cylinder, greatly increasing the transfer of refrigerant to the bus air conditioning system.
Never use compressed air (shop--air) to leak--test or pressure test a R134a system. Under certain conditions,
pressurized mixtures of R134a and air can be combustible. In addition, shop air will inject moisture into the system.
Always use mineral oil to lubricate “O” Rings, hoses, and fittings on R134a systems. PAG oils will absorb moisture and
become very acidic and corrosive. Mineral oil will not absorb moisture and thus prevent corrosion. Always wear gloves
when working with PAG and Ester lubricants to prevent irritation to your skin. R134a lubricants can also damage
vehicles paint, plastic parts, engine drive belts and coolant hoses.
Beware of unannounced starting of the evaporator and condenser fans. Do not remove the evaporator cover or
condenser fan guards without disconnecting the vehicle battery cable.
Be sure power is turned off before working on motors, controllers, and electrical control switches. Tag system controls
and vehicle battery to prevent accidental energizing of the system.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with
the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.
When performing any arc welding on the vehicle, disconnect the vehicle battery.
In case of electrical fire, extinguish with CO2 (never use water). Disconnect vehicle battery power if possible.

01/08 Safety - 1 T-299

 SPECIFIC WARNINGS

WARNING
Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans
and compressor unexpectedly as control requirements dictate.

WARNING
Be sure to observe warnings listed in the safety summary in the front of this manual before perform-
ing maintenance on the air conditioning system

WARNING
Never use air for leak testing. It has been determined that pressurized, air-rich mixtures of refriger-
ants and air can undergo combustion when exposed to an ignition source.

WARNING
Do not use a nitrogen cylinder without a pressure regulator. Do not use oxygen in or near a
refrigeration system or as an explosion may occur.

WARNING
To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction
pressure before disconnecting.

WARNING
There may be liquid refrigerant trapped behind the block valve. Slowly loosen the fitting
and avoid contact with exposed skin or eyes.

WARNING
The filter-drier may contain liquid refrigerant. Slowly open the fitting nuts and avoid contact
with exposed skin or eyes.

CAUTION
Unless there was a catastrophic failure, such as a blown or ruptured refrigerant hose, additional oil
may not be needed.

CAUTION
Use only the exact oil specified by the compressor manufacturer. Use of oil other than that specified
will void the compressor warranty.

T-299 Safety - 2 01/08

 TABLE OF CONTENTS
PARAGRAPH NUMBER Page
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety --i
SPECIFIC WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety --ii
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 WHAT IS AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 MODEL AND SERIAL NUMBER TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3.1 PID Data Tag (Decal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 SYSTEM REQUIREMENTS LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 SYSTEM DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7 REFRIGERATION SYSTEM COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.8 COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.9 HEATING CYCLE (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 MANUAL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.1 Driver’s Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.2 Fan Speed Switch (three speed or variable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.3 Thermostat Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.4 Electrical Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 FLORIDA CONTROL (TEMPCON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.1 ON/OFF Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.2 Fan Speed Switch -- 3 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.3 Adjusting Set Point (Interior Temperature Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 IN--LINE FUSE (FLORIDA CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.5 TOTAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.1 Total Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.6 GEN 4 -- WITH TOTAL CONTROL, UNIT OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 2-4
2.7 PRE--TRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.8 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.8.1 Three Position Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.8.2 Variable Speed Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.8.3 Total Control -- Gen 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.8.4 Total Control -- Gen 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.8.5 Heat Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 INSUFFICIENT OR NO COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Checking System Air Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.3 Check The Sight Glass For Bubbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.4 Compressor Amp Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 SYSTEM WILL NOT COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 SYSTEM RUNS BUT HAS INSUFFICIENT COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

01/08 i T--299
 TABLE OF CONTENTS -- Continued:
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 PREVENTATIVE MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 INSTALLING MANIFOLD GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5 REFRIGERANT LEAK CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6 EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6.3 Procedure For Evacuation and Dehydrating System (Triple Evacuation) . . . . . . . . . . . . . . . . . . 4-5
4.7 PROCEDURE FOR EVACUATION AND DEHYDRATING SYSTEM (ONE TIME EVACUATION) 4-5
4.8 ADDING REFRIGERANT TO A SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.8.1 Checking Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.8.2 Adding Full Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.8.3 Adding Partial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.9 COMPRESSOR(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.9.1 . Evaporator Tie-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.10 TORQUE SPECIFICATIONS -- REFRIGERANT FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.11 TORQUE SPECIFICATIONS -- BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.11.1 Electrical Control Panel - Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.12 DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.12.2 Belt Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.12.3 Pulley Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.12.4 Drive Belt Tension Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.12.5 Measuring Methods for Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13 RETURN AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13.1 GEN 4 (EXCEL) Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13.2 GEN 5 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.14 EVAPORATOR BLOWER AND/OR MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.14.1 GEN 4 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.14.2 GEN 5 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.15 RESISTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.15.1 GEN 4 Series (Excel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.15.2 GEN 5 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.16 CONDENSER FAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.17 REPLACING THERMOSTATIC BLOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.18 CHECKING AND REPLACING HIGH PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.18.1 Replacing High or Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.18.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.19 MOISTURE INDICATOR (SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.20 FILTER-DRIER & RECEIVER--DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
ELECTRICAL SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

T--299 ii 01/08
 LIST OF ILLUSTRATIONS
Figure Page

Figure 1-1 Condenser Model CM2/3 - Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Figure 1-2 GEN 4 Evaporator Model - Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1-3 GEN 5 Evaporator Model (All) - Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1-4 GEN 4, IW-2 & IW-7 - Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-5 GEN 4, IW-1 - Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-6 CM-7/11 Rooftop Condensers (No Longer Offered) - Serial Number Location . . . . . . . . . . . . . . . 1-3
Figure 1-7 KR-2/KR-3 Rooftop Condensers - Serial Number/PID Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-8 System Requirements Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-9 Component Location Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-10 Air Conditioning Refrigerant Flow Diagram -- Small Split System . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-11 Heating System Flow Diagram (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Figure 2-1 Drivers Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-2 Electrical Panel (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-3 Switch Assembly (TEMPCON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-4 In--Line Fuse & Holder (3 Amp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-5 Total Control Key Pad/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-6 Null Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-7 Total Control Electrical Control Panel (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 4-1 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-2 Refrigerant Service Connections (Split Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 4-1 Micro-Channel Style Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-3 Metric Bolt Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-4 U.S. Bolt Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-5 Belt Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-6 Belt Misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-7 Straight--Edge Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 4-8 GEN 4 Series Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Figure 4-9. Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Figure 4-10 Filter Drier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Figure 5-1 Electrical Schematic Diagram -- Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-2 Legend -- Electrical Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-3 GEN 4 System Schematic -- EM--1 With CM--2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Figure 5-4 GEN 4 System Schematic -- EM--1 With CM--2/3 -- Tie--In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-5 GEN 4 System Schematic -- EM--3 With (2) CM--3 Condensers & (2) Compressors . . . . . . . . . . 5-5
Figure 5-6 GEN 5 Evaporator (With Variable Speed Control) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Figure 5-7 GEN 5 System Schematic With Total Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Figure 5-8 GEN 4 EM--3 With (2) CM--3 With Total Control -- System Schematic . . . . . . . . . . . . . . . . . . . . . . 5-8
Figure 5-9 GEN 4 Series With Total Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

01/08 iii T--299

 LIST OF TABLES
Table 1-1 Additional Support Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Table 3-1 Evaporator Current Draw (GEN 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-2 Evaporator Current Draw (GEN 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Table 3-3 Condenser Current Draw (GEN 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Table 3-4 GENERAL SYSTEM TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table 3-4 GENERAL SYSTEM TROUBLESHOOTING PROCEDURES -- Continued . . . . . . . . . . . . . . . . . . . 3-4
Table 4-1 Split System Refrigerant And Oil Charging Table -- Thru GEN 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Table 4-2 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (GEN--5) . . . . . . . . . . . . . . . . . . . . 4-6
Table 4-3 SPLIT--SYSTEM GEN--5 WITH MICRO--CHANNEL CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Table 4-4 Compressor Oil Type & Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Table 4-5 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHART . . . . . . . . . . . 4-8
Table 4-6 STANDARD TORQUE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Table 4-7 Metric Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Table 4-8 U.S. Torque Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Table 4-9 Belt Tension Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Table 4-10 R-134a Temperature - Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

T--299 iv 01/08
 SECTION 1
DESCRIPTION
1.1 INTRODUCTION
This manual contains Operating, Service, and
Maintenance Instructions for Gen 4 and Gen 5 Split
System Air Conditioning and Heating equipment
furnished by Carrier Transport Air Conditioning.
Additional support manuals are listed in Table 1-1.
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 evaporator and condenser
models, along with specific data for each, is provided in
the component data that follows.
Specific systems may vary, this manual does not cover
all combinations, variations, and applications, it does
set up standards from which processes can be
measured. Contact Carrier Transport Air Conditioning
Technical Service Hot--Line for additional assistance
(800--450--2211).
condenser data tag locations, Figure 1-2 for GEN 4
evaporator data tag location, Figure 1-3 for GEN 5
evaporator data tag locations, Figure 1-4 & Figure 1-5
for In--Wall data tag locations, Figure 1-7 for KR--2 &
KR--3 PID locations and Figure 1-6 for the CM--7 &
CM--11 rooftop condensers data tag location. The
CM--7 and CM--11 rooftop condensers are no longer
available from Carrier TAC.
NOTE
The EM--9 evaporator data tag is located on the
side of the evaporator assembly, not between
the blower assemblies (See Figure 1-2).
Knowing these locations and the information on the data
tags will aid you in identifying the correct service
procedures.
1.3.1 PID Data Tag (Decal)

1.2 WHAT IS AIR CONDITIONING All KR2, KR3 & KR4 Rooftop Condensers have PID
Decals instead of the standard Model/Serail tag. These
Air Conditioning is the cooling, heating, tags will list the following:
dehumidification, and filtration of the air located within a. System Model No. (Example -- 68KR4--101--2)
the passenger compartment of a vehicle.
b. Serial No.
1.3 MODEL AND SERIAL NUMBER TAGS c. P.I.D. (Example -- KR4C00032)
In order to identify the air conditioning components you d. Refrigerant (Example -- R134a)
have, you will need to know the model number and serial
number. All Carrier Transport Air Conditioning e. Voltage (Example -- 13.5 VDC)
evaporators, condensers and compressors have a f. Amps (Example -- 25A)
model/serial number tag or PID decal located on the
assembly. See Figure 1-1 for all skirt mounted g. Unit Weight (Example -- 186 lbs.)

Table 1-1 Additional Support Manuals

MANUAL NUMBER EQUIPMENT COVERED TYPE OF MANUAL

T--299PL Split Systems Parts List
T--311 Split Systems Installation Procedures
62--50455 Basic Refrigeration Service Training
62--50468 Transport Refrigeration Service Training
62--03213 Service Tools Service Tools

01/08 1--1 T-299

 Figure 1-1 Condenser Model CM2/3 - Serial Number Location

EM-9 Location

Figure 1-2 GEN 4 Evaporator Model - Serial Number Location

Figure 1-3 GEN 5 Evaporator Model (All) - Serial Number Location

T-299 1--2 01/08

 2

Figure 1-4 GEN 4, IW-2 & IW-7 - Serial Number Location

Figure 1-5 GEN 4, IW-1 - Serial Number Location

Obsolete Tag

Figure 1-6 CM-7/11 Rooftop Condensers (No Longer Offered) - Serial Number Location

01/08 1--3 T-299

 Figure 1-7 KR-2/KR-3 Rooftop Condensers - Serial Number/PID Location

Figure 1-8 System Requirements Label
1.4 SYSTEM REQUIREMENTS LABEL
The system requirements label 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 (See Figure 1-8).
01- 22- 07
NOTE
You may encounter installations where the
OEM radiator style condenser is used as the
Tie--In condenser. Call Carrier Transport Air
Conditioning Technical Service Hot--Line
(800--450--2211) for assistance, as this is not a
recommended Carrier Transport Air Cond--
itioning application.

1.5 SYSTEM DESIGNATIONS
Tie--In System -- Is a Carrier evaporator and condenser
connected to an existing OEM compressor and dash
evaporator. The OEM radiator 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.

T-299 1--4 01/08

IW (In--Wall) System -- A Carrier evaporator installed in
the front and/or rear of the vehicle. This type evaporator
is installed between the inside & outside walls of the
vehicle.
1.6 SYSTEM COMPONENTS
Return Air Thermostat/Sensor -- The system may be
supplied with a thermostat or thermistor Both of these
devices are temperature sensitive components which
8
9
7
12 10
3 5
2 11
1 Compressor
2 Electro--Magnetic Clutch
3 Discharge Line
4 Condenser
5 Filter--Dryer or Receiver--Drier
6 Liquid Line
Figure 1-9 Component Location Diagram
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.
01/08 1--5
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 thermister is normally located in 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 (See Figure 1-9).
6
4
7 Evaporator
8 Block Valve (TXV)
9 Freezestat--(Coil freeze--up thermostat)
10 Suction Line
11 Suction Access Valve
12 Discharge Access Valve
Filter--Dryer -- The filter--dryer removes moisture and
particulate matter from the refrigerant.
Receiver--Dryer -- The receiver--dryer removes
moisture and particulate matter from the refrigerant.
The receiver--drier also stores a small amount of liquid
refrigerant.
T-299
Expansion/Block Valve -- Meters the refrigerant flow c. FREEZE--UP THERMOSTAT:
into the evaporator coil. The majority of the Gen 4
(Excel) and all Gen 5 systems use a nonadjustable GEN 4 Series Freeze--Up Thermostat: Cut--out at 26 F,
block valve with an 8 F superheat setting, which is 1.5 F. Cut--in at 34 F, 1.5 F. Pre--set at factory
preset at the factory. If you feel there is a problem with (Adjustable). Turn counterclockwise to end -- then 1/4
the block valve, do not attempt to adjust the valve, turn clockwise for original factory setting.
replace it. GEN 5 Series Freeze--Up Thermostat: Cut--out at 30.5
F, 1.5 F. Cut--in at 45 F, 1.5 F. Pre--set at the
NOTE factory (Non--adjustable).
In the event you encounter a Gen 1, Gen 2, or d. RETURN AIR THERMOSTAT/SENSOR
Gen 3 system with an externally equalized
expansion valve and/or a system with Return Air Thermostat: Adjustable range from 55 F to
85 F. Normal remote (drivers location) setting is 55 F
refrigerant R12, contact Carrier’s Technical with a 5 F differential.
Service Hot Line (800--450--2211) for
assistance. Return Air Sensor (Total Control): Temperature range
60 F to 80 F.
Evaporator -- The evaporator is located in the interior of e. EVAPORATOR MOTORS
the vehicle. Its primary function is to transfer heat Gen 4 Series: Double shafted 12 VDC (13.5 VDC
contained in the passenger compartment air, into the Nominal), permanent magnet, motor/blower
refrigerant, which is circulated by the compressor, assemblies.
through the evaporator coil. During this process the air is
also filtered and dehumidified. Full Load Amps: Refer to Table 3-1
Volts DC Maximum: 15.1 VDC
Resistor -- Resistors are used to control the speeds of Volts DC Minimum: 10.8 VDC
the permanent magnet evaporator blower motors. RPM: 2600 @ zero static
Pressure Switches -- The systems use high and low Gen 5 Series: Single shafted 12 VDC continuous duty
pressure switches wired in series to control the power motors.
circuit of the compressor clutch relay. If either pressure
switch opens, interrupting the circuit to the clutch relay, Full Load Amps: 30 Amps @ 2900 RPM @ 12.5 VDC
the operation of the compressor will stop. When Locked Rotor Amps: 80 Amps
conditions return to normal the switch will automatically Volts DC Maximum: 16 VDC
reset and the compressor will resume operating. The Volts DC Minimum: 4 VDC
switches are non--adjustable.
f. CONDENSER MOTORS
Freeze--Up Thermostat -- Carrier Transport Air
Conditioning systems use a freeze thermostat Rooftop:
(freezestat) wired in series with the system pressure CM--7 and CM--11: Single shafted 12 VDC (12.5
switches to control the operation of the compressor Nominal) continuous duty motors (barrel type) to be
clutch. Freeze--up thermostats are used to prevent ice used with Rooftop Condensers.
from forming on the evaporator coil, which is an
indication that liquid refrigerat is getting back to the Full Load Amps: 30 Amps @ 2900 RPM @ 12.5 VDC
compressor. Locked Rotor Amps: 80 Amps
Volts DC Maximum: 16 VDC
Refrigerant -- A refrigerant is a material that is used to Volts DC Minimum: 4 VDC
move heat from the passenger compartment to the
outside air. It is a substance that gives up heat by KR--2 and KR--3: Fan--Motor Assembly. Single shafted
condensing at high temperature and pressures and 12 VDC (12.5 Nominal) continuous duty motors.
absorbs heat by evaporating at low temperatures and
pressures. The heat transfer properties exhibited when Full Load Amps: 7 Amps @ 2100 RPM @ 12.5 VDC
refrigerant changes state is the foundation of the Locked Rotor Amps: 40 Amps
refrigerant cycle. Most Carrier TAC systems use R134a. Volts DC Maximum: 13.5 VDC
Volts DC Minimum: 5 VDC
1.7 REFRIGERATION SYSTEM COMPONENT KR--4: Single shafted, permanent magnet, 12 VDC
SPECIFICATIONS (12.5 Nominal) continuous duty, single speed motors.

a. EXPANSION/BLOCK VALVE: Full Load Amps: 7 Amps @ 1900 RPM @ 12.5 VDC
Locked Rotor Amps: 30 Amps
Superheat Setting: 8 F Volts DC Maximum: 16 VDC
Volts DC Minimum: 4 VDC
b. PRESSURE SWITCHES:
Skirt Mounted: Permanent magnetic, single speed
High Pressure Switch: Normally closed, open on motor (12VDC nominal) and fan combination
pressure rise. (pancake style) 5 blades.
Cut--out at 400 psig -- Cut--in at 300 psig.( 5%)
Full Load Amps: 7 Amps @ 2100 RPM @ 12.5 VDC
Low Pressure Switch: Normally closed, open on Locked Rotor Amps: 40 Amps @ 13.5VDC
pressure drop. Volts DC Maximum: 13.5 VDC
Cut--in at 25 psig. -- Cut--out at 10 psig ( 5%) Volts DC Minimum: 5 VDC

T-299 1--6 01/08

Skirt Mounted (”Vector” Fan): Permanent magnetic,
single speed motor (12VDC nominal) and fan
combination (pancake style) 10 blades.
Full Load Amps: 6.8 Amps @ 2350 RPM @ 12.5 VDC
Locked Rotor Amps: 25.4 Amps @ 13.5VDC
Volts DC Maximum: 13.5 VDC
Volts DC Minimum: 5 VDC
g. COMPRESSORS
Carrier Transport Air Conditioning uses a variety of
compressors properly sized and suited for split
system applications. Their cubic inch displacement
(c.i.d.) ranges from a 10 cubic inch TM--16 to the 19.1
cubic inch TM--31. Applications include rear and front
engine mounted. Compressor Clutch coils typically
draw 2 to 3 Amps. A compressor must always be
replaced with a compressor of the same style and
capacity.
1.8 COOLING CYCLE
The unit operates as a vapor compression system using
R-134a as the refrigerant (see Figure 1-10 ). The
compressor raises the pressure and the temperature of
the refrigerant vapor 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 liquefy, thus liquid refrigerant leaves the
01/08
condenser and flows to the filter--drier. The filter--drier
contains an absorbent that keeps the refrigerant clean
and dry.
NOTE
The new style micro--channel condensers are
fitted with receiver--driers instead of
filter--driers. The receiver--drier performs the
same function as a filter--drier and it also stores
liquid refrigerant.
From the filter-drier/receiver--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;
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 to
vaporize. This low temperature, low pressure vapor
refrigerant then continues through the suction line and
returns to the compressor where the cycle repeats.
1--7 T-299
 EVAPORATOR COIL
TXV

LPS
(GEN 5 Location)

EVAPORATOR ASSEMBLY

SUCTION LINE

LIQUID LINE

SUCTION ACCESS PORT

SIGHT GLASS

(GEN 5 FILTER DRYER

Location) OR
DISCHARGE
HPS RECEIVER DRIER
ACCESS PORT
CONDENSER COIL
(GEN 4
Location)
DISCHARGE LINE LPS

CONDENSER ASSEMBLY
COMPRESSOR

NOTE:
MICRO--CHANNEL
CONDENSER HPS IS
LOCATED ON RECEIV-
ER--DRIER
DISCHARGE LINE

LIQUID LINE
SUCTION LINE

Figure 1-10 Air Conditioning Refrigerant Flow Diagram -- Small Split System

T-299 1--8 01/08

1.9 HEATING CYCLE (If Applicable)
The optional heating circuit component furnished by
Carrier Transport Air Conditioning is the side or rear
mounted evaporator heater core. Components
furnished by the vehicle manufacturer include coolant
(glycol solution), pumps, and a hot water shut--off valve
(See Figure 1-11).
Engine coolant is circulated through the heating circuit
by the engine and/or auxiliary water pump. When the
heat valve is opened, engine coolant flows through the
heater coil. Heat is transferred from the glycol flowing in
the tubes to the air flowing over the tubes. The heater
tubes have aluminum fins to increase heat transfer from
the glycol to the air.

EVAPORATOR

AIR BLEED
VALVE

EVAPORATOR HEATER CORE

*AUXILIARY
HEATER

*HAND VALVE *ENGINE

*AUXILIARY WATER PUMP
HEATER PUMP *ENGINE

* INDICATES COMPONENTS FURNISHED

BY THE VEHICLE MANUFACTURER

Figure 1-11 Heating System Flow Diagram (Typical)

01/08 1--9 T-299

 SECTION 2

OPERATION

2.1 OPERATING INSTRUCTIONS 2.2.3 Thermostat Control

The thermostat controls the temperature within the
Before attempting to operate the system, power must passenger compartment by switching system
be available from the vehicle battery. If the engine is not components on and off.
running, start the engine.
4 3 2
The system may be supplied with Manual Controls (see
Figure 2-1 & Figure 2-3 ) or the Carrier Transport Air
Conditioning Total Control (see Figure 2-5).

Refer to the Sections 2.2 & 2.3 for manual control

operating instructions or Section 2.5 for Total Control
operating instructions.

2.2 MANUAL CONTROLS

Carrier Transport Air Conditioning systems are 1

manually operated by a Drivers Control Panel (See 5
Figure 2-1) wired into an Electrical Control Panel (See
Figure 2-2). 1 Control Panel Housing
2 Nameplate (Switch Mounting)
3 Thermostat Control Switch
2.2.1 Driver’s Control Panel 4 Fan Speed Switch (3 Speed or Variable)
5 Ambient Air Sensor (Thermostat)
The Drivers Control Panel (See Figure 2-1), consists of
an evaporator fan speed switch (three speed or Figure 2-1 Drivers Control Panel
variable) and an adjustable thermostat. The drivers 2.2.4 Electrical Control Panel
control panel is normally located within easy reach of the
driver. On larger bus applications there could be two (2) The electrical control panel contains relays and circuit
separate air conditioning system driver control panels. breakers used for system control.
One for each system.
1 2 3 4 5
There will be some applications where the switch
mounting plate, thermostat and fan speed switch are
mounted in the drivers area without the control panel
housing.

On some applications the vehicle manufacturer (OEM)

will supply different type controls for the air conditioning
system. Refer to OEM technical manual for operating
instructions. 6

2.2.2 Fan Speed Switch (three speed or variable)

Three Speed -- The standard fan speed switch has four

settings, Off (0), Low (1), Medium (2), and High (3)
speed operation. This switch controls the operation of
the system and the evaporator blower(s) by energizing
the appropriate circuits and relays located on the
electrical control panel. See Figure 2-2. 1 High Speed Relay
2 Condenser Relay
3 Compressor Clutch Relay
Variable Speed -- Certain applications may be fitted 4 Circuit Breaker (HSR)
with a variable speed control switch instead of the 5 Circuit Breaker (CR)
standard three speed switch. This switch controls the 6 Circuit Breaker (Ignition)
speed of the evaporator motors by varying the supply
voltage. Figure 2-2 Electrical Panel (Typical)

01/08 2--1 T-299

2.3 FLORIDA CONTROL (TEMPCON)
1
This controller is normally used in school buses located
within the state of Florida, but not limited to that area
(See Figure 2-3). This controller is wired to an electrical
control board. 2
The controller consists of:
a. ON/OFF Switch 3
b. Fan Speed Switch
c. Potentiometer
d. In--Line Fuse (Behind Controller)
5 4
2.3.1 ON/OFF Function
Power is supplied to the controller, through an in--line 1 Face Plate
fuse (see Figure 2-4) from a 12 VDC ignition source 2 Green Light)
originating from the vehicle. The controller will not 3 Rocker Switch, 2 Position, ON/OFF
operate until the ignition switch is activated. 4 Rocker Switch, 3 Position, LOW--MED--HIGH
Move the ON/OFF switch to the ON position. A green 5 Temperature Switch (Potentiometer)
light will illuminate indicating that the controller has Figure 2-3 Switch Assembly (TEMPCON)
power. At the same time the evaporator fans will operate
in either Low, Medium or High speed, depending on the 2.4 IN--LINE FUSE (FLORIDA CONTROL)
Fan Speed switch position.
The controller is protected by a 3 Amp ATO in--line fuse
2.3.2 Fan Speed Switch -- 3 Speed (Figure 2-4). To replace the fuse do the following:
The evaporator fan speeds can be adjusted by pushing a. Make sure ignition power is off.
the rocker switch to the desired position:
b. Grasp fuse cover at finger grips and lift off cover.
a. H = High Speed
c. Remove fuse and check if fuse is defective.
b. M = Medium Speed d. Replace if needed.
c. L = Low Speed e. Push fuse cover back on to in--line holder.
When the evaporator fan speed switch is positioned at f. Restore ignition power and place ON/OFF switch to
the desired speed, a signal is sent to the corresponding ON.
fan speed relay located on the electrical circuit board.

2.3.3 Adjusting Set Point (Interior Temperature Fuse

Adjustment) 3 Amp
The potentiometer switch has an operating range
between 60 and 85 degrees F. (+/-- 1 degree F.).
Rotate the potentiometer switch knob to the right Fuse
(clockwise) for maximum cooling. In--Line Fuse Cover
& Holder
Rotate the potentiometer switch knob to the left
(counterclockwise) for less cooling. Figure 2-4 In--Line Fuse & Holder (3 Amp)

T-299 2--2 01/08

2.5 TOTAL CONTROL 4 Adjusting Fan Speed
The Total Control system consists of a Key Pad Display Press the FAN SPEED button. The present setting (1 to
(See Figure 2-5) wired to an Electrical Control Panel 10) will show in the display.
(See Figure 2-7). Refer to Figure 2-5 for the following
operating functions. Press the + or -- button to adjust the fan speed. The
number 10 represents the highest speed and the
number 1 represents the lowest speed.
12 1 5 Alarms
With the alarm led flashing, the alarm code may be
2 displayed by pressing the SET button. Refer Table 3-5
for system alarm code descriptions.

11 3 2.5.1 Total Control Operation

1 Control Stages
10 4
Temperature control will be regulated using 3 stages
based on the return air temperature.
5 Cool
Null
9 8 7 6 Heat
1 Display When started, if the return air temperature sensor
2 Green LED, Cool Mode senses the temperature higher than the set point, the
3 Red LED, Heat Mode system will run cooling. When the return air temperature
Red LED, Flash, Alarm decreases to lower than the set point, cooling stage will
4 ON Button stop and system will be in the null mode.
5 OFF Button
6 Increase Selection When started, if the return air temperature is lower than
7 SET Button the set point, the system will run heating (refer to
8 Decrease Selection paragraph 2.8.5). When the return air temperature
9 Fan Speed Button increases to higher than the set point, heating stage will
10 Green LED, Inside Temperature stop and system will be in null mode.
11 Green LED, Set Point In the null mode, if return air temperature increases to
12 Total Control Mounting Assembly be out of the null band, system will run heating. If return
Figure 2-5 Total Control Key Pad/Display air temperature decreases to be out of the null mode,
system will run heating. The center of the null band is the
1 ON/OFF Button set point and the width of the null band is controlled by
microprocessor parameter P01.
Press the ON or OFF button to turn the system on or off.
The display will show the temperature set point. For example, if the null band is 4 F and set point is 72 F,
2 Return Air Temperature system will run cooling if temperature is higher than 72 +
2 = 74. System will run heating if temperature is lower
If SET key is pressed the display will show return air than 72 -- 2 = 70.
(inside) temperature. With the inside temperature
displayed, the green led on the left side of the display When in parameter, if no key is pressed for 5 seconds,
(which has the symbol of a bus with a thermal sensor) the display will go back to default mode showing
will be illuminated. If no key is pressed the display will go temperature set point.
back to show set point after 30 seconds. 2 Modification Of Null Band Parameter P01
3 Adjusting Set Point Press and hold + and -- key simultaneously for 5
To adjust the set point, press the SET button. seconds to access parameters programming mode.
The green SET led will illuminate on the left side of the P01 shows up on the display screen for 1 second and
display. the current value of P01 will be shown. While viewing the
current value, press + or -- key to change the value of the
Press the + or -- keys to bring the desired set point into parameter.
the display.
3 Null Band
If the set point is below the inside temperature, the
cooling will come on. This will be characterized by a The null differential can take the values of 2, 4, or 6 F,
green led on the right side at the top of the display. default to 2 F. See Figure 2-6
If the set point is above the inside temperature, heat will 4 Set Point Range
come on.This will be characterized by a red led on the
right side at the top of the display. The valid set point is from 60 F to 80 F.

01/08 2--3 T-299

 2.6 GEN 4 -- WITH TOTAL CONTROL, UNIT OP-
ERATING INSTRUCTIONS

Cooling The controller is configured to operate with the

GEN 5 unit by default. To operate as a GEN 4 unit
Set Point + controller, the following changes need to be made
1/2 Null Band thru the controller. The operation of the controller
is similar between the GEN 4 unit and the GEN 5
unit except the GEN 4 unit has only three speeds.
Set Point Null Band
a. Modification Of Parameter P01
Press and hold + or -- keys simultaneously for 5
Set Point -- seconds to access parameters programing mode.
1/2 Null Band
P01 shows up on the display screen for 1 second
Heating and the current value of P01 will be shown. While
viewing the current value, press + to change the
value of the parameter P01 =1.
When in parameter, if no key is pressed for 5
seconds, the display will go back to default mode
Figure 2-6 Null Band showing temperature set point.

5 6 7 8
1

4 3 2

1 Logic Module (Speed Control) 5 Clutch relay

2 Fuse (5 Amp 6 Relay Filter -- PWM (Pulse Width Modulation)
3 Circuit Breaker (Condenser) 7 Condenser Relay
4 Circuit Breaker (High Speed) 8 High Speed Relay
Figure 2-7 Total Control Electrical Control Panel (Typical)

T-299 2--4 01/08

b. Fan Speed Selection
Press the Fan Speed button.
Press the + or -- button to toggle between HIGH,
MEDIUM, and LOW speeds.
NOTE: Other operating functions like setting the
temperature, checking inside temperature, and
alarm codes are similar between both Generation
(GEN 4/ GEN 5) of units.
2.7 PRE--TRIP INSPECTION
After starting system operation, allow system to
stabilize for ten to fifteen minutes and check for the
following:
1 Listen for abnormal noises from the vehicle engine,
evaporator and condenser areas.
2 Ensure evaporator and condenser fans are operat-
ing.
3 Water dripping from the evaporator or air ducts.
4 Reduced airflow. This is normally caused by dirty or
clogged evaporator filters.
2.8 SEQUENCE OF OPERATION
Three types of control circuit are provided for split
system equipment. They consist of the three position
switch type, adjustable fan speed type and the Total
Control type. Typical operating sequence descriptions
for the various types are provided in the following
subparagraphs.
2.8.1 Three Position Switch Operation
With Power to the ignition circuit breaker (see
Figure 5-3) and battery circuit breaker the fan speed
switch is placed in the LOW, MEDIUM or HIGH position
to start the system. In the LOW and MEDIUM positions,
power flows from the ignition circuit breaker through the
fan speed switch and terminal board (TB) terminal 8 or 7
and the evaporator fan resistor to start the evaporator
fans.
In the HIGH position, power flows through TB--1 to
energize the high speed relay (HSR). HSR closes it’s
normally open contacts to provide power from the high
speed fan circuit breaker through TB--2 and the
evaporator fan resistor to start the evaporator fans.
Power also flows from the fan speed switch common
terminal through the thermostat to TB--3. From TB--3
power flows to energize the condenser relay (CR) which
closes it’s normally open contacts to provide power from
the battery circuit breaker through TB--4 to start the
condenser fans (CM).
Power also flows from TB--3 through the low pressure
switch (LP), high pressure switch (HP) and TB--5 to
energize the clutch relay (CLR). Energizing CLR closes
it’s normally open contacts to provide power from the
battery circuit breaker through TB--6 and energize the
clutch. Energizing the clutch starts the compressor.
The operating sequence of a Tie--In system or a system
with multiple evaporators, condensers or compressors
is similar to the preceding description. Refer to
Figure 5-4 for a typical Tie--In system schematic or
Figure 5-5 for a multiple component schematic.
01/08
2.8.2 Variable Speed Control Operation
With Power to the ignition circuit breaker and battery
circuit breakers (see Figure 5-6) the fan speed switch is
brought to the desired speed position to start the
system. Bringing the fan speed switch to the desired
speed position closes the fan speed switch contacts to
supply power to the input terminal of the thermostat and
through the terminal board terminal TB--1 to energize
the high speed relay (HSR) and optional hour meter.
Energizing HSR closes a set of normally open contacts
to supply power to the electronic speed control.
Power also flows through the fan speed switch
potentiometer to provide a signal through TB--9 to the
electronic speed control ADJ terminal. With this signal
present, the electronic speed control will provide power
to energize the evaporator blower at the desired speed.
With the thermostat calling for cooling, power flows from
the thermostat output terminal, through TB--10, the
Freeze--up thermostat and low pressure switch
(optional location) to TB--3.
From TB--3, power flows to energize the condenser
relay (CR). Energizing CR closes it’s normally open
contacts to provide power from the battery circuit
breaker through TB--4 to start the condenser fans (CM).
Power also flows from TB--4 through the low pressure
switch (LP -- optional location), high pressure switch
(HP) and TB--5 to energize the clutch relay (CLR).
Energizing CLR closes it’s normally open contacts to
provide power from the battery circuit breaker through
TB--6 and energize the clutch. Energizing the clutch
starts the compressor.
2.8.3 Total Control -- Gen 5 Operation
With Power to the battery circuit breakers (see
Figure 5-7) the Total Control Key Pad ON button is
pressed to start the system. The microprocessor will
perform a voltage check (10 seconds) and then proceed
to the start--up sequence. With voltage within the
specified range, the microprocessor will provide power
from the CFM+ terminal to energize the condenser relay
(CR). Energizing CR closes it’s normally open contacts
to supply power from the battery circuit breaker through
terminal board terminal TB--1 to start the condenser fan
motors.
Two seconds after starting the condenser fans, the
microprocessor will provide power from the CL terminal
through TB--3, the low pressure switch (LP -- optional
location) and high pressure switch (HP) to energize the
clutch. Energizing the clutch starts the compressor.
Two seconds after starting the compressor, the
microprocessor will provide power from terminal EFM+
to energize the high speed relay (HSR). Energizing HSR
closes a set of normally open contacts to supply power
through TB--4 to the electronic speed control. At the
same time, the microprocessor will provide power from
terminal BPV+ to energize the pulse width modulation
relay (PWM). Energizing PWM closes a set of normally
open contacts to allow regulated voltage from
microprocessor terminal BPV-- , through TB--5 to the
electronic speed control adjustment (ADJ) terminal. The
voltage output will begin at the lowest setting and then
ramp up to the voltage required in accordance with the
speed selection made at the Total Control Key Pad.
2--5 T-299
If at any time during operation the circuit from If high speed is selected, the microprocessor will
microprocessor terminal BPT+ back to terminal BPT-- is provide power from terminal EFM+ and BPV to energize
opened by the freeze--up thermostat or low pressure the low speed relay (LSR), medium speed relay (MSR
switch (LP -- optional location) the compressor clutch and high speed relay (HSR). Energizing all three relays
will be de--energized. Once the circuit is re--established, closes contacts to provide the required path from the
the clutch will be re--energized after a one minute delay. battery circuit breaker through MSR, TB--5, HSR and
When the system is installed as a tie--in system, power TB--4 to the high speed resistor connection. Although all
is supplied by the vehicle controls to the microprocessor of the resistor connections are actually powered,
ignition terminal (NEIM) when operation of the powering of the high speed connection will bring the
compressor is required by the in--dash defroster. With motors to high speed operation.
power to the NEIM terminal, the compressor clutch is If at any time during operation the circuit from
energized. microprocessor terminal BPT+ back to terminal BPT-- is
2.8.4 Total Control -- Gen 4 Operation opened by the freeze--up thermostat or low pressure
With Power to the battery circuit breakers (see switch (LP -- optional location) the compressor clutch
Figure 5-9) the Total Control Key Pad ON button is will be de--energized. Once the circuit is re--established,
pressed to start the system. The microprocessor will the clutch will be re--energized after a one minute delay.
perform a voltage check (10 seconds) and then proceed When the system is installed as a tie--in system, power
to the start--up sequence. With voltage within the is supplied by the vehicle controls to the microprocessor
specified range, the microprocessor will provide power ignition terminal (NEIM) when operation of the
from the CFM+ terminal to energize the condenser relay compressor is required by the in--dash defroster. With
(CR). Energizing CR closes it’s normally open contacts power to the NEIM terminal, the compressor clutch is
to supply power from the battery circuit breaker through energized.
terminal board terminal TB--1 to start the condenser fan
motors. On multiple compressor or multiple condenser systems,
operation is similar to the preceding description except
Two seconds after starting the condenser fans, the the second compressor is controlled from
microprocessor will provide power from the CL terminal
through TB--3, the low pressure switch (LP -- optional microprocessor terminal HP2+. Refer to Figure 5-8 for
location) high pressure switch (HP) and TB--2 to typical schematic diagram.
energize the clutch. Energizing the clutch starts the 2.8.5 Heat Option
compressor.
When heat option is incorporated with the Total Control
Two seconds after starting the compressor, the system, the heater valve will be controlled by the HGS2
microprocessor will start the evaporator fans in terminal on the microprocessor.
accordance with the speed selection made at the Total
Control Key Pad.
If low speed is selected, the microprocessor will provide
power from terminal EFM+ to energize the low speed
relay (LSR). Energizing LSR closes it’s normally open
contacts to provide power from the battery circuit
breaker through TB--8 to the low speed resistor
connection. It may be noted that the high speed relay
(HSR) is also energized at this time. However, power is
not available to the contacts of this relay so no action will
result.
If medium speed is selected, the microprocessor will
provide power from terminal BPV to energize the
medium speed relay (MSR). Energizing MSR closes it’s
normally open contacts to provide power from the
battery circuit breaker through TB--5 to the medium
speed resistor connection. It may be noted that power is
also supplied to the high speed relay (HSR) at this time.
However, the relay coil is not energized so no action will
result.

T-299 2--6 01/08

 SECTION 3
TROUBLESHOOTING
3.1 INSUFFICIENT OR NO COOLING
3.1.1 Preliminary Checks
Make certain that the evaporator filters are not clogged
with dirt. Check to make certain that all vehicle body
openings are air tight. Check the adjustment and
condition of the compressor drive belt (s); adjust or
replace as necessary. Refer to Section 4, paragraph
4.12 for complete drive belt installation and
maintenance procedures.
3.1.2 Checking System Air Output
If the evaporator air flow appears less than normal,
check the evaporator filter and coil for dirt and
obstructions. Clean where necessary. Check the blower
assembly for proper operation. Current draw will vary as
to evaporator, speed setting and voltage. See Table 3-1,
Table 3-2 or Table 3-3 for approximate evaporator
current draw. If the current drawn by the motor is not to
specifications, replace the motor.
3.1.3 Check The Sight Glass For Bubbles
If the preceding steps do not remedy the problem, check
the sight glass for bubbles. Run the vehicle engine at
high idle (approximately 1200 RPM) while maintaining a
minimum discharge pressure of 150 psig. The
Table 3-1 Evaporator Current Draw (GEN 4)
thermostatic switch should be positioned for maximum
cooling.
Bubbles in the sight glass indicate an undercharge of
refrigerant and/or a restriction in the liquid line. If the
charge is low, check the system for leaks; repair if
necessary and charge the system with the proper
amount of refrigerant.
NOTE
Under certain ambient conditions a few bubbles
may appear in the sight glass. Refer to Section
4, Table 4-5 to determine if system has correct
charge.
No bubbles in the sight glass will indicate either a full
charge or a complete loss of refrigerant. To determine if
there is refrigerant in the system, run the vehicle engine
at high idle (approximately 1200 RPM) with the
thermostatic switch positioned for maximum cooling.
Allow system to stabilize, then shut system down while
observing the sight glass. If bubbles begin to appear, the
system has a refrigerant charge. If no bubbles appear,
system is without refrigerant.
A restriction in the liquid line can be found by feeling the
liquid line. Any portion that is cold to the touch or that
frosts up is restricting the refrigerant flow.

SPEED SETTING AND AMP DRAW (COLOR)

MODEL VOLTAGE
LOW -- (Red) MED. -- (Yellow) HIGH -- (Orange) HIGH PERF. -- (Black)
12.5 VDC 8.6 Amp 14.4 Amp 18.5 Amp 30 Amp
EM--1 13.5 VDC 10 Amp 15 Amp 19.4 Amp 32 Amp
24.5 VDC 7.8 Amp 10.7Amp 12.7 Amp 16 Amp
12.5 VDC 5.0 Amp 8.0 Amp 10 Amp 17 Amp
EM--2 13.5 VDC 6.0 Amp 9.0 Amp 12 Amp 20 Amp
25 VDC 4.5 Amp 6.0 Amp 6.5 Amp 9 Amp
12.5 VDC 11 Amp 22 Amp 28 Amp 47 Amp
EM--3 13.5 VDC 12 Amp 25 Amp 30 Amp 52 Amp
24.5 VDC 6.0 Amp 14 Amp 17 Amp 21 Amp
12.5 VDC 4.6 Amp 7.5Amp 9.4 Amp 16 Amp
EM--6 13.5 VDC 5.1 Amp 8.4 Amp 10.6 Amp 19.3 Amp
24.5 VDC 4.0 Amp 6.0 Amp 7.0 Amp 9.0 Amp
12.5 VDC 8.1 Amp 15 Amp 32 Amp 37.1 Amp
EM--9
13.5 VDC 10.3 Amp 18 Amp 33.2 Amp 37.4 Amp
12.5 VDC 7.0 Amp 10 Amp 21 Amp Not Applicable
EM--14 13.5 VDC 8.0 Amp 11 Amp 23 Amp Not Applicable
24.5 VDC 4.0 Amp 6.0 Amp 10 Amp Not Applicable
IW--1 12.5 VDC 7.7 Amp 11.5 Amp 24 Amp --
IW--2 12.5 VDC -- -- 21 Amp --
IW--7 12.5 VDC -- -- 15 Amp --
IW--14 12.5 VDC 7.0 Amp -- 18 Amp --

01/08 3--1 T-299

 Table 3-2 Evaporator Current Draw (GEN 5)

SPEED SETTING (3) AND AMP DRAW

MODEL VOLTAGE
LOW -- AMP MEDIUM -- AMP HIGH -- AMP
13.5 VDC 9.7 Amp 17.9 Amp 29.5 Amp
EM--1
24.5 VDC
13.5 VDC 8.8 Amp 13.3 Amp 24.3 Amp
EM--2
24.5 VDC
13.5 VDC 16 Amp 32.2 Amp 46 Amp
EM--3
24.5 VDC
13.5 VDC 7 Amp 11.5 Amp 15.9 Amp
EM--7
24.5 VDC

VARIABLE SPEED CONTROL -- AMP DRAW

MODEL VOLTAGE
HIGH SPEED -- MAX
12.5 VDC Fully Loaded 29.5 Amp
EM--1 13.5 VDC Fully Loaded 30.1 Amp
24.5 VDC Fully Loaded 16 Amp
12.5 VDC Fully Loaded 23 Amp
EM--2 13.5 VDC Fully Loaded 24.3 Amp
24.5 VDC Fully Loaded 12 Amp
12.5 VDC Fully Loaded 46 Amp
EM--3 13.5 VDC Fully Loaded 46 Amp
24.5 VDC Fully Loaded 24 Amp
12.5 VDC Fully Loaded 15 Amp
EM--7 13.5 VDC Fully Loaded 15.9 Amp
24.5 VDC Fully Loaded 10 Amp

Table 3-3 Condenser Current Draw (GEN 5)

MODEL VOLTAGE AMP DRAW

CM--2 13.5 VDC 14.5 Amp
CM--2 With
Vector Fans 13.5 VDC 13.5 Amp

CM--3 13.5 VDC 22.5 Amp

CM--3 With
Vector Fans 13.5 VDC 20.5 Amp

CM--14 13.5 VDC 27.8 Amp

13.5 VDC 14.0 Amp
KR--2 25 VDC 10.0 Amp
13.5 VDC 21.0 Amp
KR--3 25 VDC 16.0 AMp
13.5 VDC 44.0 Amps
KR--4 25 VDC 22.0 Amps

Note: Condenser Amp Draw Increases As Static Pressure Increases

3.1.4 Compressor Amp Draw

Split System Compressor clutch coils typically draw 2 to 3 Amps.

T-299 3--2 01/08

 Table 3-4 GENERAL SYSTEM TROUBLESHOOTING PROCEDURES

INDICATION/
POSSIBLE CAUSES
TROUBLE
3.2 SYSTEM WILL NOT COOL
Compressor will not run Drive--Belt loose or defective
Clutch coil defective
Clutch malfunction
Low refrigerant charge
Compressor malfunction
Circuit Breaker Open
Relay Defective
3.3 SYSTEM RUNS BUT HAS INSUFFICIENT COOLING
Compressor Drive--Belt loose or defective
Compressor defective
Refrigeration system Abnormal pressures
No or restricted evaporator air flow
Expansion valve malfunction
Restricted refrigerant flow
Low refrigerant charge
3.4 ABNORMAL PRESSURES
High discharge pressure Refrigerant overcharge
Noncondensables in system
Condenser motor(s) failure
Dirty Condenser coil
Skirt--Mounted Condenser recirculating hot air from under bus.

3.5 ABNORMAL NOISES, VIBRATIONS OR CONDITIONS

Compressor -- Engine area
Evaporator area
Liquid slugging
Insufficient oil
Excessive oil
Clutch loose, rubbing or defective
Dirt or debris on vehicle fan blades
Drive belt cracked, worn or loose
Evaporator blower assembly broken or loose
Blower wheel loose or out of alignment
Blade interference
Broken or missing fan blade
Condenser assembly loose
Fan assembly loose

01/08 3--3 T-299

 Table 3-4 GENERAL SYSTEM TROUBLESHOOTING PROCEDURES -- Continued

3.6 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW

Air flow through coil blocked Coil frosted over
Dirty coil
Dirty filter assembly
No or partial evaporator air flow Motor running in reverse
Motor(s) defective
Evaporator fan loose or defective
Fan damaged
Dirty filter
Icing of coil
Fan speed relay(s) defective
Fan rotation incorrect
3.7 EXPANSION VALVE MALFUNCTION
Low suction pressure Low refrigerant charge
Ice formation or dirt at block valve orifice
3.8 CONTROL SYSTEM MALFUNCTION
Circuit breaker or relay defective
Fan speed switch defective
Thermostat defective
Microprocessor controller malfunction (Total Control)
3.9 NO OR INSUFFICIENT HEATING
Insufficient heating Dirty or plugged heater core
Coolant heat valve(s) malfunctioning or plugged
Low coolant level
Hand valve(s) partially closed
Water pump defective
Auxiliary Heater malfunctioning.
No Heating Hand valve(s) closed
Coolant heat valve(s) malfunctioning or plugged
Pump(s) malfunctioning
Continuous Heating Hand valve(s) defective
Coolant heat valve(s) malfunctioning
Debries under heat valve diaphragm

T-299 3--4 01/08

 Table 3-5 TROUBLESHOOTING ALARM CODES (TOTAL CONTROL)
ALARM TITLE CAUSE REMEDY
CODE
AL 13 Return air sensor. Open circuit or short circuit Check connections on RAS + and RAS -- on the
on the return air sensor con- control board. Make sure the Red terminal is con-
nection. nected to RAS + and Black terminal is connected
to RAS -- on the control board.
AL 15 Set point out of Wrong set point is saved on Controller will correct this problem automatically.
range the controller.
AL 17 Not Used
AL 21 Low Voltage Controller senses battery Check battery voltage.
voltage is less than 10 volts.
AL 27 Compressor 1 Open or short circuit in the Turn off the controller by pressing OFF button.
pressure alarm clutch related circuit (CLHR Measure the resistance between terminal 3 and
on the control board) such terminal 2 on the electrical panel. The reading
as: should be less than 1 OHM. This is to check the
High pressure switch open pressure switch circuit. If the resistance is too
circuit. high, look for open circuit on the high pressure or
Low pressure switch open low pressure switches.
circuit, if the low pressure Measure the resistance between terminal 2 to
switch is in series with the ground. The readings should be about 6 OHM.
high pressure switch in the This is to check the clutch coil. If readings are low,
condenser. look for a open circuit in the clutch coil.
Wire from controller CLHR
to terminal 3 on the electri- Check with power on:
cal panel terminal board is
open. Connect voltmeter to terminal 3 and ground.
Press the ON button on the controller and wait for
Wire from terminal 3 to con- 10 seconds. If you see 12 VDC appear for about
denser is open, short to 1second and disappears, the circuit from CLHR
ground or short to battery. on control board to terminal 3 is good but circuit
Wire from terminal 2 to from terminal 3 to clutch is open.
clutch is open, short to Connect voltmeter to terminal 2 and ground. Turn
ground or short to battery. on controller by pressing the ON button. Wait for
Wire from clutch to ground about 10 seconds. If you see 12 VDC appear for 1
is open. second and disappear, the circuit from CLHR on
Clutch coil open or short cir- control to terminal 2 is good but the circuit from
cuit. terminal 2 to clutch is open.
If the 12 VDC does not appear, then the pressure
switch circuit is open. Follow the procedure men-
tioned above for tracing the pressure switch cir-
cuit.
AL 41 Compressor 2 Open circuit on compressor If the second compressor is used follow the proce-
pressure alarm 2 high pressure circuit. dure for Alarm 27.
If the second compressor is not used, there should
be a jumper wire between HP2 + and HP -- on the
control board inputs.
AL 43 Condenser fan Short circuit between CFM Check condenser fan relay CR and its related cir-
relay malfunction + and CFM -- on the control cuit.
board.
AL 44 Evaporator fan Short circuit between EFM + Check evaporator fan relay HSR and the related
relay malfunction and EFM -- on the control circuits.
board.
AL 45 Clutch Relay Malfunction is detected on
malfunction the CLR output.
AL 46 EFS Control Malfunction is detected on
malfunction the EFS output.

01/08 3--5 T-299

 Table 3-5 TROUBLESHOOTING ALARM CODES (TOTAL CONTROL) Cont::
AL 47 Not Used
AL 48 Heating Valve Malfunction is detected on
malfunction the HV output.

NOTE
If the controller calls for cooling (green led is on), the condenser and evaporator fans are running, but the
compressor is OFF without any alarm code, this indicates one of the following has occured:

1. The freezestat is open. The compressor is disabled when the freezestat is open and will be enabled when the free-
zestat is closed.
2. The low pressure switch, also present in the evaporator (GEN 5 units) which is in series with the freezestat is open.
3. The compressor is disabled by minimum off time. When the compressor is turned OFF by temperature control,
freezestat, low or high pressure switches, it will remain OFF for a minute (60 seconds) before it is re--energized. This
protects the compressor clutch from short cycling.

T-299 3--6 01/08

 SECTION 4
SERVICE

WARNING
Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans
and compressor unexpectedly as control requirements dictate.

WARNING
Be sure to observe warnings listed in the safety summary in the front of this manual before
performing maintenance on the air conditioning system
4.1 PREVENTATIVE MAINTENANCE SCHEDULE
SYSTEM
OPERATION
ON OFF
a. Daily Maintenance
X X Pre--trip inspection -- after starting. (Refer to paragraph 2.7)
X Check tension and condition of drive belts. (Refer to paragraph 4.12)
b. Weekly Maintenance
X Perform daily inspection
X Check condenser, evaporator coils and return air filters for cleanliness
c. Monthly Maintenance
X Perform weekly inspection
X Clean or replace Evaporator return air filters
X Inspect Condenser coil fins -- Clean when necessary
X Inspect refrigerant hoses and fitting connections. (Refer to paragraph 4.10)
X Inspect electrical harness and connections
X Check battery voltage -- System operates efficiently at 13.5 volts
d. Quarterly Inspection
X Inspect Evaporator(s) coil fins (heater coil if installed) Clean if needed.
X Check blower operation.
X Check current draw and voltage of system components including fan motors. (Repair or replace
any component showing more than 0.2 volt drop). (Refer to Table 3-1, Table 3-2, or Table 3-3)
X Check that all compressor mounting brackets and hardware are tight. Tighten and torque to
proper specifications. (Refer to paragraph 4.11)
X X Check hose and harness under vehicle for proper support and protection
X Check Evaporator drain lines.
e. Semi--Annual Inspection and Maintenance
X Check system pressures. (Refer to Table 4-5)
Check refrigerant in sight glass.
X Check element in the the sight glass. (Green is dry -- Yellow is wet)
X Inspect condenser fan blades.
X Open bus heater valves (In winter).
X Close bus heater valves (In spring).
X Remove or install optional condenser winter guard kit.
f. Annual Inspection and Maintenance
X Inspect electrical panel and terminals. Clean if needed with a high-grade cleaner specifically
formulated for this purpose.
X Tighten all electrical connections at terminal boards and at the battery. (Refer to Par. 4.11)
Inspect Evaporator drain pan. (Clean if needed)
X Check pressure switch operation.
X Check evaporator roof mounting and sealing.
X Check condenser mounting, fan guards, and screen/grill.

01/08 4--1 T-299

4.2 MAINTENANCE PROCEDURES a. Preparing Manifold Gauge/Hose Set For Use
The following air conditioning service equipment is 1.. If the manifold gauge/hose set is new or was
required in order to properly perform the maintenance exposed to the atmosphere it will need to be
procedures. evacuated to remove contaminants and air as
1.. Manifold Gauge Set CTD P/N 07--00294--00 follows:
Provides access to and monitors pressures within the
system. Manifold gauge sets are available in different 2.. Backseat (turn counterclockwise )both field service
configurations and styles. 3--way or 4--way, liquid filled couplings (see Figure 4-1) and midseat both hand
gauges, with or without a sight glass, 3 hoses or 4 valves.
hoses, 1/4 inch or 3/8 inch manifold connections, etc.
Familiarize yourself with the proper operation of your 3.. Connect the yellow hose to a recovery machine,
manifold gauge set before attempting any service. vacuum pump or refrigerant 134a cylinder.
Depending on tools available and service to be
2.. R134a Low Side (Suction) Coupler CTD P/N performed.
07--00307--04 -- Connects the air conditioning system
Suction Access Port to the Manifold Gauge Set. 4.. Evacuate to 10 inches of vacuum and then charge
3.. R134a High Side (Discharge) Coupler CTD P/N with R-134a to a slightly positive pressure of 0.1
07--00307--05 -- Connects the air conditioning system kg/cm@ (1.0 psig).
Discharge Access Port to the Manifold Gauge Set.
5.. Front seat both manifold gauge set valves and
4.. Vacuum Pump -- 2 Stage (5 CFM Minimum) CTD disconnect from cylinder. The gauge set is now
P/N 07--00176--11 -- Removes moisture and air from the ready for use.
air conditioning system in order to obtain required
micron level.
5.. Micron Gauge, Digital CTD P/N 07--00414--00 SUCTION DISCHARGE
Monitors the evacuation process in units of microns. 1.
PRESSURE PRESSURE
Micron gauges can be either digital (electronic) or GAUGE GAUGE
analog.
6.. Recovery/Recycle Machine (R134a) CTD P/N
MVS--115--F--L--CT (115VDC), MVS--240--F--L--CT
(240 VDC) -- Recovers and recycles R134a refrigerant
that is present within the air conditioning system.
7.. Refrigerant Scale CTD P/N 07--00315--00 -- OPENED CLOSED
Accurately weighs the transfer of refrigerant into the (Backseated ) (Frontseated)
air--conditioning system. HAND VALVE HAND VALVE
8.. Refrigerant Cylinder -- Storage tank for R134a.
To Low Side 2. To High Side
9.. Heat Blanket -- Used to increase internal Access Valve Access Valve
temperature of the refrigerant cylinder, greatly
increasing the transfer of refrigerant to the air
conditioning system. 3.
BLUE 3.
10.. Oil Injector -- Used to add additional amounts of oil RED
to a closed system.

4.3 INSTALLING MANIFOLD GAUGES

3.
The manifold gauge set (see Figure 4-1) is used to 4. 2. YELLOW 4.
determine system operating pressures, add refrigerant
charge, and to equalize or evacuate the system. 6. 5.
Blue Knob Red Knob
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 1.. Manifold Gauge Set
checked. When both valves are open (turned 2.. Hose Fitting (0.5-16 Acme)
counter-clockwise all the way out), high pressure vapor 3.. Refrigeration and/or Evacuation Hose
will flow into the low side. When the suction pressure . (SAE J2196/R-134a)
valve is open and the discharge pressure valve shut, the 4.. Hose Fitting w/O-ring (M14 x 1.5)
system can be charged. 5.. High Side Field Service Coupling
6.. Low Side Field Service Coupling
A R-134a manifold gauge/hose set with self-sealing
hoses is required for service of the models covered Figure 4-1 Manifold Gauge Set
within this manual. The manifold gauge/hose set is
available from Carrier Transicold. (Carrier Transicold b. Connecting Manifold Gauge/Hose Set
P/N 07-00294-00, which includes items 1 through 6,
Figure 4-1 .) To perform service using the manifold To connect the manifold gauge set, (See Figure 4-2) do
gage/hose set, do the following: the following.

T-299 4--2 01/08

 TXV

LPS
EVAPORATOR COIL (New Location GEN 5)

HPS
NOTE:
MICRO--CHANNEL

Rec/Dri
CONDENSER HPS IS
SUCTION ACCESS LOCATED ON RECEIV-
ER--DRIER SIGHT GLASS
RECEIVER/DRIER
7.
FILTER DRYER

DISCHARGE
ACCESS
6. (GEN 4
Location)
HPS
LPS

CONDENSER COIL

COMPRESSOR S D 3.

5.

2.

4.
1.

1. Vacuum Pump 5. Recovery/Recycle Machine

2. Micron Gauge 6. R134a High (Discharge) Side Coupler
3. Manifold Gauge Set 7. R134a Low (Suction) Side Coupler
4. Refrigerant Cylinder
Figure 4-2 Refrigerant Service Connections (Split Systems)

01/08 4--3 T-299

1.. Connect the high side field service coupling (see
Figure 4-1) 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
system 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.
WARNING
To prevent trapping liquid refrigerant in the
manifold gauge set be sure set is brought to
suction pressure before disconnecting.
c. Removing the Manifold Gauge Set
1. Backseat (turn counterclockwise) the high side
(discharge) field service coupling (red knob).
2.. 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.
3.. Backseat the low side (suction) field service coupling
(red knob) and frontseat (clockwise) both manifold
gauge set valves. Remove the couplings from the
service ports.
4.. Install both service port caps (finger-tight only).
4.4 REFRIGERANT RECOVERY
To remove the entire refrigerant charge, do the
following:
a. Connect a manifold gauge set to the system as
shown in Figure 4-2.
b. Connect a reclaimer to the center manifold gauge set
connection.
c. Recover refrigerant in accordance with reclaimer
manufacturers instructions.
4.5 REFRIGERANT LEAK CHECKING
A refrigerant leak check should always be performed
after the system has been opened to replace or repair a
component.
To check for leaks in the refrigeration system, perform
the following procedure:
WARNING
Never use air for leak testing. It has been
determined that pressurized, air-rich
mixtures of refrigerants and air can
undergo combustion when exposed to an
ignition source.
T-299
Note
Larger split systems may be equipped with
service valves and a liquid line solenoid. Ensure
these service valves are open and power the
liquid line service valve from an external
source.
a. If the system is without refrigerant, charge the system
with refrigerant vapor to build up pressure to
approximately 30 PSIG (R134a).
b. Add sufficient nitrogen to raise system pressure
to150/200 psig. (10.21/13.61 bar).
c. Check for leaks. The recommended procedure for
finding leaks in a system is with a R-134a electronic
leak detector. Testing joints with soapsuds is
satisfactory and may be necessary under conditions
where when an electronic leak detector will not
function properly, such as with large leaks.
d. Remove test gas and replace filter--drier.
e. Evacuate and dehydrate the unit. (Refer to paragraph
4.6.)
f. Charge the unit. (Refer to paragraph 4.8).
4.6 EVACUATION AND DEHYDRATION
4.6.1 General
The presence of moisture in a refrigeration system can
have many undesirable effects. The most common are
copper plating, acid sludge formation, “freezing-up” of
metering devices by free water, and formation of acids,
resulting in metal corrosion. A triple evacuation (Refer to
paragraph 4.6.3) should be performed after a major
system repair (compressor, evaporator, or condenser
replacement). A one time evacuation (Refer to
paragraph ) should take place after a minor system
repair, such as a filter--drier replacement.
4.6.2 Preparation
NOTE
Using a compound gauge for determination of
vacuum level is not recommended because of
its inherent inaccuracy.
a. Evacuate and dehydrate only after pressure leak test.
(Refer to paragraph 4.5 .)
b. Essential tools to properly evacuate and dehydrate
any system include a vacuum pump (6 cfm volume
displacement -- (CTD P/N 07--00176--11) and an
electronic vacuum (micron) gauge (CTD P/N
07--00414--00).
c. 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 may
form before moisture removal is complete. Heat
lamps or alternate sources of heat may be used to
raise the system temperature.
4--4 01/08
4.6.3 Procedure For Evacuation and Dehydrating
System (Triple Evacuation)
a. Remove all refrigerant using a refrigerant recovery
system (Refer to paragraph )
b. The recommended method is connecting lines (3/8“
refrigerant hoses designed for vacuum service) as
shown in Figure 4-2.
c. Make sure vacuum pump valve is open.
d. Start the vacuum pump. Slowly open valves halfway
and then open vacuum gauge valve.
e. Evacuate unit until vacuum gauge indicates 2000
microns (Hg vacuum). Close gauge valve, vacuum
pump valve, and stop vacuum pump.
f. Break the vacuum with nitrogen. Raise system
pressure to approximately 2 psig (0.14 bar).
g. Purge the nitrogen from the system.
h. Repeat steps d. thru f. one time.
i. Start vacuum pumpand open all valves. Dehydrate
system to 500 microns (Hg vacuum).
j. Close off pump valve, and stop pump. Wait 5 minutes
to see if vacuum holds.
k. Charge system. Refer to paragraph 4.8.
4.7 PROCEDURE FOR EVACUATION AND
DEHYDRATING SYSTEM (ONE TIME
EVACUATION)
a. Remove all refrigerant using a refrigerant recovery
(reclaimer) system (Refer to paragraph 4.4)
b. The recommended method is connecting lines (3/8“
refrigerant hoses designed for vacuum service) as
shown in Figure 4-2.
c. Make sure vacuum pump valve is open.
d. Start the vacuum pump. Slowly open valves halfway
and then open vacuum gauge valve.
e. Evacuate unit until vacuum gauge indicates 500
microns (Hg vacuum). Close gauge valve, vacuum
pump valve, and stop vacuum pump.
f. Close off pump valve, and stop pump. Wait 5 minutes
to see if vacuum holds.
g. Charge system. Refer to paragraph 4.8.
4.8 ADDING REFRIGERANT TO A SYSTEM
4.8.1 Checking Refrigerant Charge
The following conditions must be met to accurately
check the refrigerant charge.
a. Bus engine operating at high idle.
b. Air conditioning system operating in high cool 10 to 15
minutes.
c. Compressor discharge (head) pressure a minimum
of 150 psig with R134a. It may be necessary to block
condenser air flow to raise discharge pressure.
d. On the large split systems that are equiped with a
liquid line receiver, the system is properly charged
when the refrigerant level is at 1/2 to 3/4 of the
01/08
receiver sight glass. If it is not at the proper level, add
or remove refrigerant to bring it ro the proper level.
e. On the smaller split systems refer to Table 4-5 to
determine if correct charge has been obtained.
4.8.2 Adding Full Charge
a. Install manifold gauge set at the suction and
discharge service valves. See Figure 4-2.
b. Evacuate and dehydrate system. (Refer to paragraph
4.6 ).
c. Place R134a refrigerant cylinder on scales.
d. Calculate the approximate refrigerant charge using
either Table 4-1 or NO TAG. Open the liquid valve on
refrigerant cylinder. Open the discharge line service
port coupler and allow refrigerant to flow into the unit
until the correct weight of refrigerant has been added
as indicated by scales.
e. Backseat discharge service coupler (to close off
gauge port). Close liquid valve on cylinder.
f. Start unit in cooling mode. Run approximately 10
minutes and check the refrigerant charge. (Refer to
paragraph 4.8.1)
4.8.3 Adding Partial Charge
a. Examine the unit refrigerant system for any evidence
of leaks. Repair as necessary. (Refer to paragraph
4.5.)
b. Maintain the conditions outlined in paragraph 4.8.2.
c. Connect charging line between suction service port
and cylinder of refrigerant R-134a. Open VAPOR
valve.
d. Slowly add charge as required. Refer to Table 4-5.
4.9 COMPRESSOR(S)
If the compressor(s) is inoperative and the system still
has refrigerant pressure, recover the refrigerant with an
approved recovery/recycle machine before attempting
repair and/or replacement of the compressor.
Always ensure the replacement compressor has the
correct amount of oil as specified by the manufacturer.
Approximate oil charges:
A--6 -- -- -- 10 Fluid Ounces
TM--16 -- -- 6.08 Fluid Ounces (180CC)
TM--21 -- -- 8 Fluid Ounces
TM--31 -- 16.9 Fluid Ounces
CAUTION
Unless there was a catastrophic failure,
such as a blown or ruptured refrigerant
hose, additional oil may not be needed.
Refer to the specific compressor manufacturer’s
service manual for proper maintenance and handling
procedures for the compressor installed on your
vehicle.
NOTE
Carrier Transport A/C does not recommend
chemical flushing of the refrigeration system. If
required, flushing is to be performed using the
system refrigerant.
4--5 T-299
 Table 4-1 Split System Refrigerant And Oil Charging Table -- Thru GEN 4
Evaporator Condenser Recommended Recommended
Up to GEN V All Series R134a Charge Oil Charge*
EM--1, EM--2, or EM--9 CM--2 5.00 Pounds 10.0 Ounces
EM--1, EM--2, or EM--9 CM--11 5.25 Pounds 10.5 Ounces
EM--6 CM--2 4.00 Pounds 8.0 Ounces
EM--6 CM--11 4.25 Pounds 8.5 Ounces
EM--1, EM--2, or EM--9 CM--3 5.50 Pounds 11.0 Ounces
EM--1, EM--2, or EM--9 CM--7 6.50 Pounds 13.0 Ounces
EM--3 (2) CM--2 4.25 Pounds Each 8.5 Ounces Each
EM--3 (2) CM--11 4.25 Pounds Each 8.5 Ounces Each
EM--3 (2) CM--3 5.50 Pounds Each 11.0 Ounces Each
EM--3 (2) CM--7 6.25 Pounds Each 12.5 Ounces Each
EM--14 CM--2 3.50 Pounds 7.0 Ounces
EM--14 CM--11 3.75 Pounds 7.5 Ounces
EM--17 CM--5 19.0 Pounds Consult Factory
EM--17 KR--4 13.0 Pounds Consult Factory
Table 4-2 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (GEN--5)
Evaporator Condenser Recommended Recommended
GEN 5 All Series R134a Charge Oil Charge*
GEN 5 - EM-1 CM-2 or CM-4 4.75 Pounds 9.5 Ounces
GEN 5 - EM-1 CM-11 5.00 Pounds 10.0 Ounces
GEN 5 - EM-1 CM-3 5.25 Pounds 10.5 Ounces
GEN 5 - EM-1 CM-7 6.25 Pounds 12.5 Ounces
GEN 5 - EM-7 CM-2 or CM-4 4.00 Pounds 8.0 Ounces
GEN 5 - EM-7 CM-11 4.25 Pounds 8.5 Ounces
GEN 5 - EM-2 CM-2 or CM-4 4.50 Pounds 9.0 Ounces
GEN 5 - EM-2 CM-11 4.75 Pounds 9.5 Ounces
GEN 5 - EM-2 CM-3 5.00 Pounds 10.0 Ounces
GEN 5 - EM-2 CM-7 6.00 Pounds 12.0 Ounces

Table 4-3 SPLIT--SYSTEM GEN--5 WITH MICRO--CHANNEL CONDENSER

Condenser Recommended Recommended
Evaporator Micro--Channel R134a Charge Oil Charge
EM--1, EM--9, IW--1 CM--2 3.25 Pounds 6.5 Ounces
EM--1, EM--9, IW--1 CM--3 3.75 Pounds 7.5 Ounces
EM--2, IW--2 CM--2 3.00 Pounds 6.0 Ounces
EM--2, IW--2 CM--3 3.50 Pounds 7.0 Ounces
EM--7, IW--14 CM--2 2.75 Pounds 5.0 Ounces
EM--7, IW--14 CM--3 3.00 Pounds 6.0 Ounces
EM--3 (dual loop) (2) CM--3 4.50 Pounds (each) 9.0 Ounces (each)

NOTE
Micro--Channel Style Condensers (See Figure 4-1) will require 1--1/2 to 2 lbs less charge than standard
condenser assemblies.

NOTE
The information contained within Table 4-3 may change. Refer to document number 62--11317 for the latest
revisions to the GEN--5 Micro Channel charging chart.

T-299 4--6 01/08

 CLOSE-UP VIEW
COIL FINS

Figure 4-1 Micro-Channel Style Condenser Assembly

The data listed in Table 4-1 trough Table 4-3 is based on a 20 foot liquid line. Increase the charge by 0.5 pound for each
additional 10 feet of liquid line.
After determining the approximate charge using the above tables, refer to “System Performance Chart” (Table 4-5)
to determine if the correct charge has been obtained.

4.9.1 . 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.

NOTE
The above chart is based on a 20 foot liquid line. Increase the charge by 0.5 pound for each additional 10 feet of liquid
line.
When an after market evaporator or 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 4-4 Compressor Oil Type & Part Numbers
Manufacturer Oil Type CTAC Part Number
Seltec -- Valeo -- ICE -- Zexel -- Sanden PAG 46--50006--00
Alma (A--6) PAG 46--50004--00
05G & 05K Bus & 06D POE 46--50008--00

CAUTION
Use only the exact oil specified by Carrier Transicold. Use of oil other than that specified will void the
compressor warranty.

Change 06/10 4--7 T-299

 Table 4-5 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHART
Determine the approximate refrigerant charge using Table 4-1, Table 4-2 or Table 4-3 .
Use the following table to determine if the correct charge has been obtained.
Table Procedure Your Entry Example
Pressure Refrigerant Temp.
PSIG R--12 R134a 1. Connect Manifold Gauge Set To
Air Conditioning System NONE NONE
(A) (B) (C)
95 87 85
100 90 88 2. Measure outside (ambient) air
105 93 90 temperature. _____Degrees F 100 Degrees F
110 96 93 Enter here ---------------------->

115 99 96
120 102 98
125 104 100 3. Add 40 degrees F to the outside
(ambient) air temperature ------> 40 Degrees F 40 Degrees F
130 107 103
_____Degrees F = 140 Degrees F
135 109 105 (SEE NOTE BELOW)
140 112 107
145 114 109
150 117 112
4. Find closest refrigerant
155 119 114 temperature in Table _____Degrees F 139 Degrees F
(B or C) and enter here -------->
160 121 116
165 123 118
170 126 120
175 128 122
5. Going across the Table, find the
180 130 123 (D)=______ PSI 225 PSI
corresponding pressure (A) ---->
185 132 125
190 134 127
195 136 129
200 138 131 6. If the Discharge Pressure
(High Side) on gaugers
205 140 132 (With compressor engaged,
210 142 134 engine speed 1200 RPM, and
system operating) is :
215 143 136
220 145 137
Greater than (D) -- Reduce refrigerant *** ***
225 147 139 by 4 ounce increments.
235 150 142
245 154 145 Less than (D) -- Add refrigerant
255 157 148
Wait 10 minutes for system to
265 160 151 stabilize before taking new readings
275 163 153

NOTE
If using the Micro-Channel type Condenser assembly, add 37 degrees in step 3 instead of 40 degrees.
This is due to the approximately 10 psi lower discharge pressure that will be experienced with this
type application.

T-299 4--8 01/08

 Table 4-6 STANDARD TORQUE REQUIREMENTS

O--RING
SIZE TUBE O.D. * FLARE THREAD **
STEEL TUBING ALUM. TUBING
4 1/4 inch (.250) 11--13 ft./lbs. 30--35 ft./lbs. 5--7 ft./lbs. 7/16
5 3/8 inch (.375) 15--17 ft./lbs. 30--35 ft./lbs. 8--10 ft./lbs 9/16
6 3/8 inch (.375) 18--20 ft./lbs. 30--35 ft./lbs. 11--13 ft./lbs 5/8
8 1/2 inch (.500) 36--39 ft./lbs. 30--35 ft./lbs. 15--20 ft./lbs 3/4
10 5/8 inch (.625) 52--57 ft./lbs. 30--35 ft./lbs. 21--27 ft./lbs 7/8
12 3/4 inch (.750) 71--79 ft./lbs. 30--35 ft./lbs. 28--33 ft./lbs 1--1/16
* The tube O.D. is measured at the point it passes through the nut. ** Thread pitch may vary.

4.10 TORQUE SPECIFICATIONS -- REFRIGERANT Table 4-8 U.S. Torque Specs

FITTINGS
All refrigerant hose fitting connections must be torqued Torque Torque Torque
to the specifications listed in Table 4-6. Bolt Size (Ft--Lb) (Ft--Lb (Ft--Lb
Dia. mm Cast Iron Cast Iron Cast Iron
Grade 2 Grade 5 Grade 8

NOTE 1/4--20 5 7 11
5/16--18 10 15 22
No matter what type of lubricant (oil) used in the 3/8--16 18 30 40
system, always use mineral oil to lubricate the 7/16--14 30 45 65
O--Rings and fittings. PAG oils will absorb 7/16--20 32 50 70
moisture and become very acidic and 1/2--13 45 70 95
corrosive. Mineral oil absorbs moisture at a 1/2--20 50 75 110
5/8--11 82 135 190
much lower rate than PAG oils. 5/8--18 93 155 215

4.11 TORQUE SPECIFICATIONS -- BOLTS

The torque values listed in Table 4-7 and Table 4-8 are
are based on the use of lubricated threads. Commercial Grade Head Markings
U.S. Customary Bolts
Table 4-7 Metric Torque Specs

Torque Torque Torque

Bolt Size (Ft--Lb (Ft--Lb (Ft--Lb
Dia. mm Cast Iron Cast Iron Cast Iron
Grade 8.8 Grade 10.9 Grade 12.9
6 7 9 9 Grade 2 Grade 5 Grade 8
7 10 13 18
8 18 23 27
10 30 45 50
12 55 75 95 Figure 4-4 U.S. Bolt Markings
14 85 120 145
16 130 175 210 4.11.1 Electrical Control Panel - Torque Values

Torque values for all Split-System electrical panels are

as follows.
Commercial Grade Head Markings
Metric Bolts
1. Torque value for wire connections at the plastic circuit
breakers are: 24 In-Lbs max.
8.8 10.9 12.9 2. Plastic Breaker mounting screw torque is:15 In-Lbs.

3. Torque value for wire connections at the plastic

Grade 8.8 Grade 10.9 Grade 12.9 terminal strip are: 25 In-Lbs max.

Figure 4-3 Metric Bolt Markings 4. Terminal Strip mounting screws are: 25 In-Lbs max.

01/08 4--9 T-299

 Clearance Zone Identification Clearance at Mid Span

Figure 4-5 Belt Clearance Requirements

4.12 DRIVE BELT INSTALLATION Alignment methods are illustrated in Figure 4-6 and
Figure 4-7. A high quality straight edge is a necessity,
4.12.1 Introduction your eye is not an acceptable method of determining
There are several factors that have major effects on proper belt alignment. All mounting brackets should
compressor and alternator drive belt(s) life expectancy allow for minor belt centerline adjustments.
and reliability. Belt alignment and proper tension being
the most critical and controllable by the installer and
end--user. Improper alignment and/or tension will cause
premature failure of drive belts, driven components as
well as a possible safety issue. When improperly
installed and/or maintained, drive belts can cause
significant damage to equipment. The following are the
biggest factors that effect belt life and system
dependability.
A. Belt Alignment
B. Belt Tension
1. Over Tensioned
2. Under Tensioned
C. Belt Clearance
D. Temperature--Heat
E. Fluids
F. Maintenance Procedures
4.12.2 Belt Clearance
A certain belt clearance needs to be maintained for belt
span vibration when installing compressors and
alternator belts. Figure 4-5 shows the recommended
guidelines for clearance. Due to the large number of
variables, actual testing is required to determine Parallel Angular
whether the clearances are acceptable. Misalignment Misalignment
4.12.3 Pulley Alignment
Correct belt alignment is essential for alternator and
compressor belt life. The centerline of all pulleys related Figure 4-6 Belt Misalignment
to compressor or alternator drive must be within 1/3
degree of true center. Refer to Figure 4-6 for Parallel adjustment is designed into a mount for final
approximate measurements, and keep in mind, these alignment during the installation process. Parallel
are maximum values. You should try to attain perfect misalignment is corrected by moving the driven pulley
alignment whenever possible to maximize component (alternator or compressor) into alignment with the drive
and belt life. pulley. This can be done using several methods.
Maximum allowable run--out for Poly ”V” belts is 1/8 Spacing the component forward or rearward by adding
inch. or removing spacers is the most popular method used to
achieve proper alignment. Other methods such as
Maximum allowable run--out for Standard ”V” belts is 1/4 sliding the component forward or rearwards using slide
inch. plates and/or slots in the main weldment are also used.

T-299 4--10 01/08

Angular misalignment is often caused by tolerances in
several pieces, such as hardware to mounting holes and
plates to components. Angular misalignment is
corrected by loosening the mounting hardware,
adjusting the compressor/alternator to the proper angle
and retightening the mounting hardware.
Incorrect
Correct
Figure 4-7 Straight--Edge Application
Proper use of a straight edge is illustrated in Figure 4-7 .
Never use a straight edge on the wide/flat side, as they
are not accurate. The thin edge is a straight surface and
the only accurate surface. The straight edge must be
flush across the face of the pulley. Then, to measure
the alignment, lower the other end down to the driven
pulley(s). Adjustments are made based on results of the
aforementioned. Note that the pulley rim width must be
considered when making the aforementioned
measurements.
The next step is to lay the straight edge flush across the
face of the driven pulley. This is the best way to
determine angular misalignment. Again, adjust as
required. You should repeat this step for all pulleys until
acceptable alignment is achieved. Note the drive pulley
is the primary guide for alignment. Do not use idlers as a
guide for proper component belt alignment as bearing
play could give you false readings.
4.12.4 Drive Belt Tension Guidelines
Proper belt tension is essential for not only belt life, but
also the alternator and compressor life as well. Heat is a
major enemy of compressors and alternators that can
cause unnecessary stress and greatly reduce
component life.
Listed in Table 4-9 are the examples specific to belt
tension concerns:
Table 4-9 Belt Tension Guide
New Belt
Drive Belt Top Width Lbs. Tension
Alternator All 110
Compressor All 130
Poly--Rib Belt
& Serpentine Drive 6 or More Ribs 145
4.13.1 GEN 4 (EXCEL) Series
Replace the GEN 4 series return air filter(s) as follows:
a. Remove the evaporator return air grill.
b. Remove the return air filter from behind the coil
assembly.
01/08 4--11
A. Under tension would promote belt slippage causing
excessive heat. Heat equals premature alternator
and/or compressor failure.
B. Over tension could cause premature bearing failure
and excessive wear on drive and driven components.
Proper belt tension is obtained by referring to Table 4-9.
Find the belt used and where applied (compressor or
alternator drive, Single ”V” or Ploy ”V” 4--8 ribs).
Notice that new belt tension is higher than in--service or
re--tension amount. All new belts require a run--in
period. During this period, a new belt will stretch more in
a 10 hour run time than the entire life of the belt. So it is
important to recheck belt tension after run--in or
re--tension new belts if less than re--tension amount
prescribed above. You should check belt tension with
the belt ”hot.” However, the belt must be allowed to cool
before re--tensioning. Drives which incorporate
automatic tensioners do not require a run--in period or
re--tensioning.
4.12.5 Measuring Methods for Belt Tension
There are several methods and tools available for
determining belt tension. The industry’s acceptable
method would be to use a belt tension gauge as
manufactured by Burroughs or approved equal. There
are also several models available than can be used.
Please follow manufacturer guidelines regarding gauge
selection operation and calibration requirements. You
must get the correct tension gauge for your specific belt
type(s).
4.13 RETURN AIR FILTER
NOTE
Never operate the evaporator without the
return--air filter properly installed.
The evaporator return air filter(s) should be checked for
cleanliness periodically(refer to table 4.1) and always
with regard to operating conditions. A system operating
on unpaved dusty roads will need a stricter maintenance
schedule than a bus operating consistently on paved
roads. A dirty air filter will restrict the air flow over the
evaporator coil. This could cause insufficient cooling or
heating and possible frost build-up on the coil. The GEN
4 series return air filters are secured to the rear of the
evaporator coil assembly, while the GEN 5 series return
air filters are located under the evaporator cover
assembly.
Re--Tension Re--Tension
Lbs. Tension Threshold
90 70
105 80
105 90
c. With the return air filter(s) and return air grill
removed, it is advisable to check the evaporator coil. If
the coil is dirty proceed with cleaning the coil.
d. Clean or replace the return air filter(s).
e. Replace evaporator return air grill.
T-299
4.13.2 GEN 5 Series
Replace the GEN 5 series return air filter(s) as follows:
a. Insert a 3mm Allen wrench into the 1/4 turn receptacle
stud.
b. Turn counterclockwise opening the filter channel.
c. Slide filter out of the evaporator grill. (In some
applications, needle--nosed pliers may be needed in
order to grip the filter assembly).
d. Clean or replace the return air filter(s) as required.
e. Close the filter channel and lock the 1/4 turn stud into
place by turning clockwise with 3mm Allen wrench.
4.14 EVAPORATOR BLOWER AND/OR MOTOR
ASSEMBLY
4.14.1 GEN 4 Series
Replace the blower motor assembly as follows:
a. Disconnect bus battery.
b. Pop--off the snap cap covers and remove all screws
holding the cover to the unit assembly. Remove the
evaporator cover.
c. Remove drain hoses from drain pan assembly.
d. Remove hardware securing drain pan to the
evaporator assembly (4 places).
e. Supporting the blower motor assembly, remove the
hardware that secures the blower motor assembly to
the evaporator. (4 places).
f. Unplug the motor from the evaporator wiring harness.
g. Replace as necessary.
h. Reinstall blower motor assembly reversing steps a.
thru f.
i. Check blower motor assembly operation.
4.14.2 GEN 5 Series
Replace the blower wheel and/or motor as follows:
a. Disconnect bus battery.
b. Pop--off the snap cap covers and remove all screws
holding the cover to the unit assembly. Remove the
evaporator cover
c. Disconnect the red and black wire from the terminal
block.
d. Using a 1/8 inch (EM--1 only) or 3/32 inch (EM--2/3/7)
Allen handle loosen the set screw securing the motor
shaft to the blower wheel. The set screw can be
accessed through a notched fin in the blower wheel.
e. Remove hardware (4 places) securing the motor
strap to the top panel.
f. Remove motor strap and motor gasket from motor
assembly.
g. Slide motor assembly shaft out of blower wheel.
h. Pull blower wheel assembly from bearing cup.
i. Replace motor and/or blower wheel if necessary.
j. Carefully place blower wheel assembly into the
bearing cup.
k. Insert motor shaft into the blower wheel hub.
T-299
l. Align blower wheel set screw to flat spot on motor
shaft and tighten.
m.Continue to reassemble by reversing steps a. thru f.
n. Check motor and blower wheel operation.
4.15 RESISTORS
4.15.1 GEN 4 Series (Excel)
Low, Medium, High, and High Performance speeds (for
ducted systems) on the GEN 4 series of evaporators are
controlled by the speed selection switch located on the
drivers control panel. High (orange wire) or High
Performance ducted (black wire) speed is determined at
time of installation. See Figure 2-2 for wire connections
and Section 5 Electrical for appropriate wiring diagram.
Every GEN 4 series evaporator blower motor assembly
has a speed control resistor. See Figure 4-8 for wire
color connections (speed control) and Ohm’s between
prongs.
Total resistance rating of the 4--prong resistor is 1.8
Ohm with a 5% tolerance rating. Total wattage is 115.
Yellow Orange Black Red
1.8
Medium High High Performance Low
Figure 4-8 GEN 4 Series Resistor Assembly
4.15.2 GEN 5 Series
GEN 5 evaporator motor speeds can be controlled by
the driver three ways:
1. Standard GEN 4 type operation using the 3 speed
switch and resistors.
2. Variable speed switch control.
3. Electronic Total Control.
Refer to Section 2, paragraph NO TAG GEN 5
Operating Instructions and Section 5, Electrical, for the
appropriate GEN 4/5 wiring diagram.
NOTE
If evaporator fan motor is only functioning in 1 or
2 of the 3 speeds, the resistor is bad, not the fan
motor.
4.16 CONDENSER FAN ASSEMBLY
Condenser fan assemblies for GEN 4 and GEN 5 are
identical in function and fit. Replace a condenser fan
assembly as follows:
a. Disconnect bus battery.
b. While supporting both parts, remove hardware (4
places) securing the fan guard and condenser fan
assembly to the condenser venturi.
c. Un--plug fan assembly from condenser harness.
d. Repair or replace as necessary.
4--12 01/08
e. Reassemble by reversing steps a. thru c. 4.18.2 Checking High Pressure Switch
f. Check condenser fan assembly operation.

4.17 REPLACING THERMOSTATIC BLOCK VALVE WARNING

The Thermostatic Block Valve is an automatic device Do not use a nitrogen cylinder without a
which regulates the flow of refrigerant into the
evaporator coil. Properly operating it will also prevent pressure regulator. Do not use oxygen in or
liquid refrigerant from returning to the compressor. If the near a refrigeration system or as an
valve is defective, it must be replaced. explosion may occur.

a. Disconnect bus battery. a. Remove switch from unit. All units are
b. Recover refrigerant from air conditioning system.
equipped with schrader valves at the high and
low pressure switch connections.
c. Pop--off the snap cap covers and remove all screws
holding the cover to the unit assembly. Remove the b. Connect an ohmmeter across switch
evaporator cover . terminals. If the switch is good, the ohmmeter
d. Remove no--drip insulating tape from block valve and will indicate no resistance, indicating that the
fitting connections. contacts are closed.
e. Carefully loosen fittings connected to the block valve.
c. Connect switch to a cylinder of dry nitrogen.
(See
Figure 4-9.
WARNING
1
There may be liquid refrigerant trapped 4 1. Cylinder Valve
behind the block valve. Slowly loosen and Gauge
the fitting and avoid contact with 2 5 2. Pressure
exposed skin or eyes. Regulator
3. Nitrogen Cylinder
f. Remove and replace block valve, lubricating the 4. Pressure Gauge
fittings with mineral oil before torquing to required
specifications (Refer to paragraph 4.10). (0 to 400 psig =
3 6 0 to 36 kg/cm@)
5. Bleed-Off Valve
NOTE 6. 1/4 inch
Do not attempt to adjust the replacement block Connection
valve. Valves are preset at the factory.

g. Insulate block valve with no--drip insulating tape.

h. Leak check and evacuate per paragraphs 4.5 & 4.6.
i. Charge system with the recovered refrigerant.
j. Check operation of the system. Adjust refrigerant
charge as needed.
4.18 CHECKING AND REPLACING HIGH
PRESSURE SWITCH
4.18.1 Replacing High or Low Pressure Switch
a. The high and low pressure switches are
See next
equipped withpage
schrader valve to allow removal
and installation without pumping the unit
down.
b. Disconnect wiring from defective switch.
c. Install new cutout switch after verifying switch
settings. (Refer to paragraph 4.18.2)
Figure 4-9. Checking High Pressure Switch
d. Set nitrogen pressure regulator higher than
cutout point on switch being tested.(Refer to
paragraph 1.7)
e. Open cylinder valve. Slowly open the regulator
valve to increase the pressure until it reaches
cutout point. The switch should open, which is
indicated by an infinite reading on an
ohmmeter (no continuity).
f. Close cylinder valve and release pressure
through the bleed-off valve. As pressure drops
to cut-in point, the switch contacts should
close, indicating no resistance (continuity) on
the ohmmeter.
g. Replace switch if it does not function as
outlined above.

01/08 4--13 T-299

4.19 MOISTURE INDICATOR (SYSTEM)
There are two types of moisture indicators
presently in use with Carrier Transport A/C
systems.
1. Green/Yellow (Previous Configuration)
Green = Dry System Yellow = Wet System
2. Blue/Pink (Current Configuration)
Blue = Dry Pink = Wet
4.20 FILTER-DRIER OR RECEIVER--DRIER
Carrier Transport A/C condensers are supplier with
either a filter--drier or a receiver--drier.
NOTE
All microchannel condenser assemblies are
equiped with a receiver--drier with an integral
high pressure switch. All other condensers are
equiped with filter driers.
h. Assemble the new filter-drier or receiver--drier
to the liquid lines ensuring that the arrow on
the body of the filter-drier or receiver--drier
points in the direction of the refrigerant flow
(liquid refrigerant flows from the condenser to
the evaporator). Finger tighten the liquid line
fittings.
i. Tighten filter-drier or receiver--drier O--ring
fittings using two open end wrenches. Refer to
paragraph 4.10 for torque specifications.
j. Evacuate system to 500 microns by
connecting a vacuum pump as shown in
Figure 4-2.
k. Charge system according to paragraph 4.8.2.
To Evaporator

If a pressure drop across the Filter-Drier (see O--Ring

Figure 4-10) or Receiver--Drier (see Figure 4-11)
is indicated or the moisture-indicator shows an Filter Drier--Sight
abnormal (wet) condition, the Filter-Drier or Glass
Assembly
Receiver--Drier must be changed.
a. Check for a restricted filter by touching the filter
Clamp
drier or receiver--drier on inlet and outlet
connections. If there is a noticeable
temperature difference the filter is probably
restricted and should be replaced.
O--Ring
b. Recover refrigerant, refer to paragraph 4.4.
c. Place a new filter-drier or receiver--drier near To Condenser
the unit for immediate installation.
d. Using two open end wrenches, slowly crack Figure 4-10 Filter Drier
open and remove the liquid line O--ring fittings
on each side of the filter-drier. Refrigerant “OUT” Sight Glass
Connection
Moisture Indicator
WARNING
The filter-drier or receiver--drier may
contain liquid refrigerant. Slowly open
the fitting nuts and avoid contact with Flow Label
exposed skin or eyes.
e. Loosen the hose clamp(s) securing the filter
drier or receiver--drier to the condenser
assembly.
f. Remove the filter-drier or receiver drier. HPS Connection
Transfer high pressure switch if required.
Refrigerant “IN”
g. Remove seal caps from the new filter-drier or Connection
receiver--drier. Apply a light coat of mineral oil
to the fittings and O’rings. Figure 4-11 Receiver--Drier

T-299 4--14 01/08

 Table 4-10 R-134a Temperature - Pressure Chart
Temperature Vacuum Temperature Pressure
F C PSIG Kg/cm@ Bar F C Psig Kg/cm@ Bar
--40 --40 14.6 37.08 0.49 28 --2 24.5 1.72 1.69
--35 --37 12.3 31.25 0.42 30 --1 26.1 1.84 1.80
32 0 27.8 1.95 1.92
--30 --34 9.7 24.64 0.33
34 1 29.6 2.08 2.04
--25 --32 6.7 17.00 0.23
36 2 31.3 2.20 2.16
--20 --29 3.5 8.89 0.12
38 3 33.2 2.33 2.29
--18 --28 2.1 5.33 0.07 40 4 35.1 2.47 2.42
--16 --27 0.6 1.52 0.02 45 7 40.1 2.82 2.76
--14 --26 0.4 0.03 0.03 50 10 45.5 3.20 3.14
--12 --24 1.2 0.08 0.08 55 13 51.2 3.60 3.53
--10 --23 2.0 0.14 0.14 60 16 57.4 4.04 3.96
--8 --22 2.9 0.20 0.20 65 18 64.1 4.51 4.42
--6 --21 3.7 0.26 0.26 70 21 71.1 5.00 4.90
--4 --20 4.6 0.32 0.32 75 24 78.7 5.53 5.43
--2 --19 5.6 0.39 0.39 80 27 86.7 6.10 5.98

0 --18 6.5 0.46 0.45 85 29 95.3 6.70 6.57

90 32 104.3 7.33 7.19
2 --17 7.6 0.53 0.52
95 35 114.0 8.01 7.86
4 --16 8.6 0.60 0.59
100 38 124.2 8.73 8.56
6 --14 9.7 0.68 0.67
105 41 135.0 9.49 9.31
8 --13 10.8 0.76 0.74
110 43 146.4 10.29 10.09
10 --12 12.0 0.84 0.83
115 46 158.4 11.14 10.92
12 --11 13.2 0.93 0.91
120 49 171.2 12.04 11.80
14 --10 14.5 1.02 1.00 125 52 184.6 12.98 12.73
16 --9 15.8 1.11 1.09 130 54 198.7 13.97 13.70
18 --8 17.1 1.20 1.18 135 57 213.6 15.02 14.73
20 --7 18.5 1.30 1.28 140 60 229.2 16.11 15.80
22 --6 19.9 1.40 1.37 145 63 245.6 17.27 16.93
24 --4 21.4 1.50 1.48 150 66 262.9 18.48 18.13
26 --3 22.9 1.61 1.58 155 68 281.1 19.76 19.37

01/08 4--15 T-299

 SECTION 5
ELECTRICAL SCHEMATIC DIAGRAMS
5.1 INTRODUCTION
This section contains Electrical Schematics covering the GEN 4 and GEN 5 systems. Figure 5-3 shows a GEN 4
EM--1 Evaporator with a CM--2/3 Condenser, Figure 5-4 shows a GEN 4 Series EM--1 Evaporator with a CM--2/3
Condenser tied into an OEM compressor, Figure 5-5 shows a GEN 4 EM--3 evaporator with (2) CM--3 condensers,
Figure 5-6 shows a (typical) GEN V evaporator with variable speed controls, Figure 5-7 shows a (typical) GEN 5 sys-
tem with Total Control, Figure 5-8 shows a GEN 4 EM--3 with Total Control, and Figure 5-9 shows a (typical) GEN 4
evaporator (s) with Total Control. Contact your Carrier Transport Air Conditioning Field Service representative or call
Carrier’s technical hot line at 800--450--2211 for a copy of the schematic for your specific model and/or series.

Ohm
Indicates Wire Ground
Indicates Relay Coil
Indicates Diode
Indicates Optional Wiring

Indicates Fuse
CIRCUIT BREAKER IDENTIFICATION

Indicates Motor TYPE III MANUAL RESET--RESETS WHEN

EXTERNAL BUTTON IS PUSHED.

Indicates Resistor TYPE II RESETS WHEN POWER

IS REMOVED AND REAPPLIED

Indicates Wire Connection

CIRCUIT BREAKER COLOR CODE
Indicates Manual Reset Breaker 20 AMP -- -- -- -- Yellow Dot
30 AMP -- -- -- -- Green Dot
Indicates Reset Breaker
40 AMP -- -- -- -- Red Dot

Figure 5-1 Electrical Schematic Diagram -- Symbols

01/08 5--1 T-299

 LEGEND
ADJ Adjusting GRD Ground
ALT Alternator HGS1 Compressor #2 Relay
AMP Ampere HGS2 Heat Valve
AUX Load HP High Pressure Switch
BAT Battery HP1 For Grounding of Low Pressure & Frozen
Coil Switch For Comp. #1
BP Low Pressure & Frozen Coil HP2 For Grounding of Low Pressure & Frozen
Switch For Compressor #2 Coil Switch For Comp. #2
BPT Low pressure & Frozen Coil HSR High Speed Relay
Switch For Compressor #2
BPV Fan Speed PWM Signal Output IGN Ignition Circuit
CFM Condenser Fan Motor LP Low Pressure Switch
CL Clutch LSR Low Speed Relay
CLR Clutch Relay M Motor
CLR2 Clutch Relay #2 MSR Medium Speed Relay
CM Condenser Motor NEIM (IGN) Tie--In (OEM)
CR Condenser Relay OEM Original Equipment Manufacturer
EFM Evaporator Fan Motor PWM Pulse Width Modulation
EM Evaporator Module RAS Return Air Sensor
G4 Generation 4 (Excel) Series
G5 Generation 5 Series

Figure 5-2 Legend -- Electrical Schematic Diagrams

T-299 5--2 01/08

01/08
FREEZESTAT

5--3
T-299
Figure 5-3 GEN 4 System Schematic -- EM--1 With CM--2/3
T-299
FAN SPEED
SWITCH
YEL--12
THERMOSTAT
RED--14

M FREEZESTAT

L H
B C EVAPORATOR, EM--1
20 AMP
BLU
IGN. BLK--12 BLK--12 BLK--12
14
BLU
14 BLOWER BLOWER
40 AMP YEL
12
ORG
10
40 AMP RED RESISTOR RESISTOR
BAT. ORG
14
BLK 8 10 14 HARNESS
BLU--14 BLU--14
BLK--10 9 BLU--14
BLK--14 RED--14 RED--14
8
YEL--12 YEL--12
30 87 7
RED--14 BLU ORG--10
CLR
6 14 GRN--10
RED--14
ORG BLK--10
5 10
ORG BLK--10
4
10 ORG

5--4
30 BLU--14 14
CR 3
87
2
ORG
10 1

30 87
HSR CONDENSER
DIODE HIGH PRESSURE HP
ORG--14 MOTORS
6 AMP RED SWITCH
14
BLK CM CM CM
OEM 10
RED LOW PRESSURE LP
OEM PRESS SWITCH 14 SWITCH
BLU
14

BLK CONDENSER, CM--2,3

BLU--14
RED--14
BLK--10

OEM CLUTCH HARNESS

01/08
Figure 5-4 GEN 4 System Schematic -- EM--1 With CM--2/3 -- Tie--In
01/08
3

5--5
T-299
Figure 5-5 GEN 4 System Schematic -- EM--3 With (2) CM--3 Condensers & (2) Compressors
T-299
FAN SPEED
SWITCH
FREEZESTAT
THERMOSTAT
BLK--14
ORG LOW PRESSURE
18
SWITCH
BLU
18
15 AMP EVAPORATOR, EM--1,2,7 G5

IGN. BLK--14 BLK--14

BLU BLOWER
ORG 18
50 AMP
GRN 18
YEL 18 BLU
ORG RED BLK
10 18 18 12 12
LP ELECTRONIC
40 AMP ORG SPEED
BAT.
18 HARNESS CONTROL
BLK 8 10
BLU--18 BLU--18 BLU--18 BLK--12 M--
BLK--10 9 BLU/RED--18 BLU--18
BLK--14 RED--12 M+
DIODE 8 RED--12
YEL--10 YEL--10
85
30 7
RED--14 BLU/RED YEL--12 ADJ
CLR 18
87 6 ORG--8 ORG--12 BAT
86 RED--14
5 GRN--10 GRN--12 GRD
ORG
ORG BLK--10 8
10 4
85
30 BLU--14
3 ORG

5--6
CR
87 18
86 2
ORG
10 1 CONDENSER, CM--2,3
85
30
HSR
87 HIGH PRESSURE
RED
86 ORG--14 14 SWITCH HP
-- +
RED
HOURMETER 18 CM CM CM
LOW PRESSURE
BLK
8 SWITCH LP
BLU
OPTIONAL WIRING OPTIONS 18 HARNESS

BLU--18 BLU--18
RED--18 RED--18 CONDENSER
BLK--8 BLK--8 MOTORS

CLUTCH

01/08
Figure 5-6 GEN 5 Evaporator (With Variable Speed Control) Schematic
01/08
CAB
COMMAND

RED TERMINAL

RAS+
BPV+
RAS
RAS-- BPV--
GRN
12

OV
BLK
BLACK TERMINAL 18
BP+ ORG
EFM+
18
FREEZESTAT
BP-- ORG
EFM-- 18
HP1+ BLU LOW PRESSURE
CFM+
18 SWITCH
BLU
HP1-- CFM--
18
EVAPORATOR, EM--1,2,7 G5
HGS2+ BLK

+BAT.
HP2+
18

85
87
BLOWER
HP2--

18
HGS2-- PWM

RED
30
BLK

86
YEL
BPT+ 12
HGS1+ 10 RED ELECTRONIC
BLK RED LP 12 SPEED
12 18 HARNESS CONTROL

10
BPT-- ORG
HGS1-- BLU--18 BLU--18 BLU--18 M--
18 BLK--12

9
NEIM BLU/RED--18 BLU--18
CL BLU RED--12 RED--12 M+
18

8
BLK BLU/RED YEL--10 YEL--10
BLU BLU 18
14

7
18 18 ORG--8 YEL--12 ADJ
RED RED ORG--12 BAT

6
18 18
ORG GRN--10 GRN--12 GRD

5--7
8

5
ORG
18
50 AMP

85
87
15 ORG ORG
HSR

BAT
4

AUX
AMP 10 10

30
86
CONDENSER, CM--2,3

3
ORG
18
BLU BLU
18 HIGH PRESSURE
18
RED--18 SWITCH HP

85
IGNITION

87
BLK BLK CR BLK CM CM CM
BATTERY

1
LOW PRESSURE

BAT
AUX
8 10 10

30
LP

86
40 AMP SWITCH
BLU
18 HARNESS
100 AMP
ALT. OR BAT
RED BLU--18 BLU--18
BLK--4 BLK--4 14 CONDENSER
RED--18 RED--18 MOTORS
OPTIONAL WIRING BLK--8 BLK--8 BLK--8

CLUTCH

T-299
Figure 5-7 GEN 5 System Schematic With Total Control
T-299
CAB
COMMAND

RED TERMINAL

RAS+ BPV+
BPV--
RAS
RAS--

OV
GRN
BLACK TERMINAL 12
BP+ RED
EFM+ 18
FREEZESTAT
BP-- ORG EVAPORATOR, EM--3
RED EFM-- 18
18
HP1+ ORG
CFM+
18
HP1-- CFM-- ORG
18 BLOWER BLOWER BLOWER
14
HGS2+ BLU
RED--18

+BAT.
HP2+ 14
13

85
87
LSR RED HARNESS RESISTOR RESISTOR RESISTOR
HP2-- HGS2-- 14

30
12 BLU--14

86
BLK
BPT+ 12 BLU--14
HGS1+ 11 RED--12 RED--12
YEL
10 YEL--10 YEL--10
RED 10
BPT-- 18 ORG--8 ORG--8
HGS1-- GRN--8
NEIM RED 9 BLK--8
CL 18
8
BLU BLU
18 18 7
RED RED
18 18 6
BLK BLU
14 14 YEL
18 CONDENSER, CM--2,3
BLU 5 RED BLU
14 RED 14
RED 14 HIGH PRESSURE HP
18

5--8
10 4 SWITCH
BLK CM CM CM

85
87
YEL YEL 10
MSR LOW PRESSURE LP
10 10 3

30
SWITCH

86
BLU
RED 14
YEL 14
2 BLU--14 CONDENSER
15 18 RED MOTORS
14 RED--14
AMP
BLK--10

60 AMP
ORG
ORG 18 RED HARNESS
10 1 14 CONDENSER, CM--2,3
BLU

85
87
ORG 14 BLK
HSR 10 HIGH PRESSURE
10 HP

30
RED

86
BLU SWITCH
10 14 CM CM CM
IGNITION ORG
18 LOW PRESSURE LP
SWITCH
ORG
18
BLU--14

85
CONDENSER

87
CLR2 RED--14 MOTORS

85
40 AMP

87
ORG BLK BLK--10

30
86
BATTERY BLK 8 CR CLUTCH CLUTCH

BAT
AUX
10 10

30
RED

86
HARNESS
RED 14
14
ORG
18 RED
14

GRN
85
87

18
CLR
30

85
87
86

BLK CR BLK

BAT
AUX
10 10

30
86
40 AMP
RED RED
18 14

01/08
Figure 5-8 GEN 4 EM--3 With (2) CM--3 With Total Control -- System Schematic
01/08
EVAPORATOR, EM--14
FREEZESTAT

BLOWER BLOWER
CAB
COMMAND
YEL YEL
RED RED
RED TERMINAL ORG ORG
BLU-- 14
BLU-- 14
RED-- 14
FREEZESTAT
BPV+ YEL
RAS+ 18 YEL-- 12
BPV-- YEL
RAS 18 ORG-- 10
RAS--
GRN-- 10

OV
GRN
BLACK TERMINAL 12
BP+ RED
EFM+ 18
BP-- RED EVAPORATOR, EM--1,2,6,9
RED EFM-- 18
18
HP1+ CFM+ ORG
18
HP1-- CFM-- ORG BLOWER BLOWER
18
HGS2+

+BAT.
HP2+
RESISTOR RESISTOR
HP2-- HGS2--
BLK HARNESS
BPT+ HGS1+ 12
BLU--14 BLU--14
BLU--14
BPT-- 10 RED--14 RED--14
HGS1--
NEIM RED 9
CL 18 YEL--12 YEL--12
ORG--10
BLU BLU
BLK 18 18 GRN--10
14 8
RED BLK--10
18 7
ORG
10

5--9
6
15
AMP

85
87
BLK RED RED 5
10 LSR 10

30
12

86
CONDENSER, CM--2,3
4
IGNITION HIGH PRESSURE
YEL SWITCH
18 HP

85
87
YEL YEL 3 CM CM CM

BAT
LOW PRESSURE

AUX
50 AMP 10 MSR 10

30
86
SWITCH LP
YEL RED
18 14 BLU
ORG 2
10
14
ORG
18
CONDENSER

85
87
ORG BLU--14
HSR 10 RED--14 MOTORS

30
86
BLK--10
1
RED HARNESS
ORG
18 14

ORG
18

85
87
BLK BLK

BAT
AUX
BATTERY BLK 8 10 CR 10 CLUTCH

30
86
40 AMP
ORG
18

Figure 5-9 GEN 4 Series With Total Control

T-299
 A I
Adding Refrigerant, 4-5 IN--LINE FUSE , 2-2
AIR CONDITIONING, 1-1
INSTALLING MANIFOLD GAUGES, 4-2
INSUFFICIENT COOLING, 3-1
C
CHECKING AND REPLACING HIGH PRESSURE
SWITCH, 4-13 L
COMPONENT SPECIFICATIONS, 1-6
LEAK CHECKING, 4-4
COMPRESSORS, 4-5
Low Pressure Switch, 4-13
CONDENSER FAN ASSEMBLY, 4-12
COOLING CYCLE, 1-7

M
D
MAINTENANCE PROCEDURES, 4-2
DESCRIPTION , 1-1
MANUAL CONTROLS, 2-1
DRIVE BELT INSTALLATION, 4-10
MODEL TAG, 1-1
Driver’s Control Panel, 2-1
MOISTURE INDICATOR (SYSTEM), 4-14

E
Electrical Control Panel, 2-1 O
ELECTRICAL SCHEMATIC DIAGRAMS, 5-1
OPERATING INSTRUCTIONS, 2-1
EVACUATION , 4-4
OPERATION , 2-1
EVAPORATOR BLOWER/MOTOR, 4-12
Evaporator Tie--In, 4-7

P
F PID Data Tag, 1-1
Fan Speed Switch, 2-1
PRE--TRIP INSPECTION, 2-5
FILTER--DRIER, 4-14
PREVENTATIVE MAINTENANCE SCHEDULE, 4-1
FLORIDA CONTROL, 2-2

G R
GEN 4 -- WITH TOTAL CONTROL, 2-4 RECEIVER--DRIER, 4-14
REFRIGERANT CHARGE, 4-5
H REFRIGERANT RECOVERY, 4-4

Heat Option, 2-6 REPLACING BLOCK VALVE, 4-13

HEATING CYCLE , 1-9 RESISTORS, 4-12

High Pressure Switch, 4-13 RETURN AIR FILTER, 4-11

01/08 Index--1 T-299

 S T
Safety Summary, General, Safety --i
SEQUENCE OF OPERATION, 2-5
SERIAL TAG, 1-1
SERVICE, 4-1
SYSTEM COMPONENTS , 1-5
SYSTEM DESIGNATIONS, 1-4
SYSTEM REQUIREMENTS LABEL, 1-4
T-299
Thermostat Control, 2-1
Three Position Switch Operation, 2-5
TORQUE SPECIFICATIONS -- BOLTS, 4-9
TORQUE SPECIFICATIONS -- FITTINGS, 4-9
TOTAL CONTROL, 2-3
Total Control -- Gen 4 Operation, 2-6
Total Control -- Gen 5 Operation, 2-5
Total Control Operation, 2-3
TROUBLESHOOTING, 3-1
V
Variable Speed Control Operation, 2-5
Index--2 01/08
 Carrier Transport Air Conditioning
50 Grumbacher Road
York PA 17406 USA
Tel: 1--800--673--2431
Fax: 1--717--764--0401
A member of the United Technologies Corporation family. Stock symbol UTX
2008 Carrier Corporation D Printed in U. S. A 01/08
Carrier Transicold Division,
Carrier Corporation
Transport Air Conditioning Group
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A
www.carrier.transicold.com
 SECTION 3
OPERATION BT324 CONTROLLER
3.1 STARTING, STOPPING AND OPERATING
INSTRUCTIONS
The BT324 Carrier Sutrak Digital Display (CSDD) is
marked with international symbols (See Figure 3--2).
Figure 3--1 Bus Dash With A/C Switch & BT324 CSDD Controller
3.1.1 Starting
a. If the engine is not running, start the engine.
b. When the 12/24VDC power is applied, the driver dis-
play will illuminate and show return air set point.
Press the A/C key (Item 5 Figure 3--2) on the display
to trigger the start up sequence.
c. After the pre--trip inspection is completed, the
switches may be set in accordance with the desired
control modes.
3.1.2 Stopping
04/08 3--1
Before starting, electrical power must be available from
the bus power supply (See Figure 3--1).
A 150 Amp @12 VDC or a125 Amp @ 24 VDC fuse in
the battery compartment passes power for the clutch,
evaporator and condenser assemblies.
A/C
Toggling the A/C key (Item 5 Figure 3--2) on the display
again will stop the system operation.
3.2 PRE--TRIP INSPECTION
After starting system, allow system to stabilize for ten to
fifteen minutes and check for the following:
a. Listen for abnormal noises in compressor or fan mo-
tors.
b. Check compressor oil level (05G Compressor only).
c. Check refrigerant charge. (Refer to section 5.8.1 )
T--304
 1 6

2 3 4 5
7 8 9 10

Figure 3--2 BT324 CSDD Controller

KEYS LEDS
1. Plus Key 6. Display
2. Minus Key 7. Fresh Air Operation (Green)
3. Recirculate/Fresh Air Key 8. Manual Blower Control ’ON’ (Green)
4. Blower Control Key 9. Heating Mode (Green)
5. Automatic Climate Control (A/C) 10. Malfunction Light (Red)

3.3 SEQUENCE OF OPERATION BT324 CSDD NOTE

3.3.1 Function of Keys when “Engine On” and
controller active:
a. Plus Key -- Increases interior temperature setpoint by
1 per stroke or increases manual blower speed, de-
pending on displayed mode.
b. Minus Key -- Decreases interior temperature setpoint
by 1 per stroke or decreases manual blower speed,
depending on displayed mode.
c. Recirculating Air/Fresh Air -- Switches from Recircu-
lating Air to Fresh Air and vice--versa.
d. Blower Control -- Switches on the manual blower con-
trol.
e. Automatic Climate Control -- Switches on the Auto-
matic Temperature Control.
f. Temperature Indicator (Key 2 + Key 3) -- Shows the
inside temperature for 10 seconds. If pressed a sec-
ond time shows the outside temperature for 10 sec-
onds (optional).
g. Reheat (optional) (Key 3 + Key 5) -- Starts Reheat
mode for 3 minutes (duration adjustable).
h. Controller Off (A/C Switch To Off) -- Switches off all
control functions and the display.
The following blower steps are disabled when
the automatic climate control is on:
2--, 3--step blower: Off
Continuously adjustable blower: Off
3.3.2 Illuminating Indications (Display)
With “Engine--On” and Controller active
3.4 Operating Instructions BT324
When the engine is running, toggle the A/C Switch to on
to activate the Air Conditioning Unit.
3.4.1 Display
When the unit is ON, the display shows the interior
setpoint temperature. When selecting individual
functions, the display shows the corresponding
information for a short period of time. The display is dark
when the engine and control unit are OFF.
3.4.2 Interior Temperature Control
Press the Plus (1) or Minus (2) keys to set the desired
interior temperature.
The temperature can be adjusted between 64 F (18 C)
and 82 F (28 C).
When the outside temperatures are below 35 F (2 C)
(adjustable parameter), the cooling function remains
disabled.
3.4.3 Ventilation
When the unit is operating in Automatic Climate Control
mode, the blower speed is controlled based on the room
temperature.

T--304 3--2 04/08

However, the blowers may be switched to manual mode
of operation by pressing the blower key.
Press the Plus or Minus keys to define one of 5 different
blower steps. The blowers can not be switched OFF
when Automatic Climate Control is ON.
When Automatic Climate Control is OFF, the blowers
stop when the manual control is turned to zero.
3.4.4 Reheat (optional)
The Reheat mode is used to remove air humidity and to
help defog the windshield. Press Key 3 (Recirculating
Air/Fresh Air) and Key 5 (Automatic Climate Control) at
the same time to activate Reheat. Heating and cooling
will be energized on for 3 minutes (adjustable
parameter). In addition, the blowers are switched to
maximum speed and the fresh air flap is closed. At the
end of the pre--set duration of time, the functions return
to the previously selected settings.
Reheat mode is disabled with the outside temperature is
below 35 F (2 C) (adjustable parameter), when the
sensor is not installed, or when there is a sensor failure.
3.4.5 Temperature Indication
Press key 2 (minus) and key 3 (Recirculating Air/Fresh
Air) at the same time to display the inside temperature
for 10 seconds.
Optionally, the outside temperature may be displayed
when pressing the keys a second time.
04/08
A sensor malfunction is displayed by “i ----” or “o ----”.
3.5 CHANGING BETWEEN F (FAHRENHEIT)
AND C (CELCIUS )
Procedures for changing the BT324 Controller between
Fahrenheit and Celcius is as follows:
a. Engine “OFF” & Ignition “ON”.
b. Press Key 1 (plus) and Key 2 (minus) at the same
time until the display shows the word “Code”.
NOTE
After the display shows the word “Code” you
have 5 seconds to enter the correct access
code.
c. Press Key 1 (Plus Key) one time and release.
d. Press Key 3 (Recirculating Air/Fresh Air) one time
and release.
e. Press Key 4 (blower control) one time and release.
The display will show the mode “Fah” for temperatures
in F or the mode “Cel” for temperatures in C.
f. Press Key 1 (plus) or Key 2 (minus) to change the
temperature mode.
g. Press Key 5 (automatic climate control) one time to
end the program.
3--3 T--304
 SECTION 4
TROUBLESHOOTING

Table 4--1 General System Troubleshooting Procedures

INDICATION -- REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
4.1 System Will Not Cool
Compressor will not run Drive--Belt loose or defective Check
Clutch coil defective Check/Replace
Clutch malfunction Check/Replace
Compressor malfunction See Table 1--3
Electrical malfunction Coach power source defective Check/Repair
Circuit Breaker/safety device open Check/Reset
4.2 System Runs But Has Insufficient Cooling
Compressor Drive-Belt loose or defective Check
Compressor valves defective See Table 1--3
Refrigeration system Abnormal pressures 4.3
No or restricted evaporator air flow 4.5
Expansion valve malfunction 4.6
Restricted refrigerant flow 5.11
Low refrigerant charge 5.8
Service valves partially closed Open
Safety device open 1.5
Liquid solenoid valve stuck closed 5.13
Restricted air flow No evaporator air flow or restriction 4.5
Heating system Heat valve stuck open 4.7
4.3 Abnormal Pressures
High discharge pressure Refrigerant overcharge 5.8.1
Noncondensable in system Check
Condenser motor failure Check
Condenser coil dirty Clean
Low discharge pressure Compressor valve(s) worn or broken See Table 1--3
Low refrigerant charge 5.8
High suction pressure Compressor valve(s) worn or broken See Table 1--3
Low suction pressure Suction service valve partially closed Open
Filter-drier inlet valve partially closed Check/Open
Filter-drier partially plugged 5.11
Low refrigerant charge 5.8
Expansion valve malfunction 4.6
Restricted air flow 4.5
Suction and discharge pressures Compressor valve defective See Table 1--3
tend to equalize when system is
operating
4.4 Abnormal Noise Or Vibrations
Compressor Loose mounting hardware Check/Tighten
Worn bearings See Table 1--3
Worn or broken valves SeeTable 1--3
Liquid slugging 4.6
Insufficient oil 1.3
Clutch loose, rubbing or is defective Repair/Replace
Drive-Belt cracked, worn or loose Adjust/Replace
Dirt or debris on fan blades Clean

04/08 4--1 T-304

 Table 4--1 General System Troubleshooting Procedures -- Continued

INDICATION -- REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
4.4 Abnormal Noise Or Vibrations -- Continued
Condenser or evaporator fans Loose mounting hardware Check/Tighten
Defective bearings Replace
Blade interference Check
Blade missing or broken Check/Replace
4.5 No Evaporator Air Flow Or Restricted Air Flow
Air flow through coil blocked Coil frosted over Defrost coil
Dirty coil Clean
Dirty filter Clean/Replace
No or partial evaporator air flow Motor(s) defective Repair/Replace
Motor brushes defective Replace
Evaporator fan loose or defective Repair/Replace
Fan damaged Repair/Replace
Return air filter dirty Clean/Replace
Icing of coil Clean/Defrost
Fan relay(s) defective Check/Replace
Safety device open 1.5
Fan rotation incorrect Check
4.6 Expansion Valve Malfunction
Low suction pressure with high Low refrigerant charge 5.8
superheat Wax, oil or dirt plugging valve orifice Check
Ice formation at valve seat 4.6
Power assembly failure Replace
Loss of bulb charge Replace
Broken capillary tube 5.16
Low superheat and liquid slugging Bulb is loose or not installed. 5.16
in the compressor Superheat setting too low 5.16
Ice or other foreign material holding valve open
Side to side temperature differ- Wax, oil or dirt plugging valve orifice Check
ence (Warm Coil) Ice formation at valve seat 5.7
Power assembly failure Replace
Loss of bulb charge Replace
Broken capillary 5.16
4.7 Heating Malfunction
Insufficient heating Dirty or plugged heater core Clean
Coolant solenoid valve(s) malfunctioning or plugged Check/Replace
Low coolant level Check
Strainer(s) plugged Clean
Hand valve(s) closed Open
Water pumps defective Repair/Replace
Auxiliary Heater malfunctioning. Repair/Replace
No Heating Coolant solenoid valve(s) malfunctioning or plugged Check/Replace
Controller malfunction Replace
Pump(s) malfunctioning Repair/Replace
Safety device open 1.5
Continuous Heating Coolant solenoid valve stuck open 5.12

T--304 4--2 04/08

 SECTION 5

SERVICE

WARNING
Be sure to observe warnings listed in the safety summary in the front of this manual before perform-
ing maintenance on the hvac system

WARNING
Read the entire procedure before beginning work. Park the coach on a level surface, with parking
brake applied. Turn main electrical disconnect switch to the off position.

NOTE
To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing refriger-
ant. The refrigerant recovery system is available from Carrier Transicold (Carrier Transicold P/N MVSII--115
or MVSII--240). When working with refrigerants you must comply with all local goverment environmental laws.

5.1 MAINTENANCE SCHEDULE

SYSTEM REFERENCE
SYSTEM SECTION
ON OFF
a. Daily Maintenance
X Pre-trip Inspection -- after starting 2.2
X Check tension and condition of drive belts. None
b. Weekly Inspection
X Perform daily inspection See above
X Check condenser, evaporator coils and air filters for cleanliness None
X Check refrigerant hoses, fittings and component connections for leaks 5.6
X Feel filter-drier for excessive temperature drop across drier 5.11
c. Monthly Inspection and Maintenance
X Perform weekly inspection and maintenance See above
X Clean evaporator drain pans and hoses None
X Check wire harnesses for chafing and loose terminals Replace/Tighten
X Check fan motor bearings None
X Check compressor mounting bolts for tightness None

5.2 REMOVING EVAPORATOR COVER
To remove the evaporator cover do the following:
1. Turn all the 1/4 turn cam locks counterclockwise.
2. Using two people carefully grasp the cover under the
bottom edge and lift up.
3. Place the evaporator cover on top of the condenser
section.
5.3 REMOVING CONDENSER COVER
To remove the condenser cover do the following:
1. Turn all the 1/4 turn cam locks counterclockwise.
2. Using two people carefully grasp the cover under the
bottom edge and lift up.
3. Place the condenser cover on top of the evaporator
section.
5.4 INSTALLING MANIFOLD GAUGE SET
A manifold gauge set can be used to determine system
operating pressures, add charge, equalize or evacuate
system.
When the suction pressure hand valve is frontseated
(turned all the way in), the suction (low) pressure can be
read. When the discharge pressure hand valve is
frontseated, discharge (high) pressure can be read.
When both valves are open (turned counterclockwise),
high pressure vapor will flow into the low side. When
only the low pressure valve is open, the system can be
charged or evacuated.

04/08 5--1 T-304

 SUCTION DISCHARGE
CAUTION PRESSURE 1. PRESSURE
GAUGE GAUGE
The AC310 & AC350 Rooftop Systems have
R134a service port couplings installed on
the compressor and 1/4 inch flare (Acme)
fittings installed on the unit piping.

5.4.1 Installing R--134a Manifold Gauge/Hose SET OPENED CLOSED

(Backseated ) (Frontseated)
An R--134a manifold gauge/hose set with self--sealing HAND VALVE HAND VALVE
hoses is pictured in Figure 5--1. The manifold
gauge/hose set is available from Carrier Transicold.
(Carrier Transicold P/N 07--00294--00, which includes To Low Side 2. To High Side
items 1 through 6, Figure 5--1). To perform service using Access Valve Access Valve
the manifold gauge/hose set, do the following:
a. Preparing Manifold Gauge/Hose Set for use. 3.
BLUE 3.
1. If the manifold gauge/hose set is new or was ex-
posed to the atmosphere it will need to be evacuated RED
to remove contaminants and air as follows:
2. Back--seat (turn counterclockwise) both field service 3.
couplers (see Figure 5--1) and mid--seat both hand 4. 2. YELLOW 4.
valves.
3. Connect the yellow hose to a vacuum pump and an 6. To Refrigerant Tank 5.
R--134a cylinder. Blue Knob or Vacuum Pump Red Knob
4. Evacuate to 10 inches of vacuum and then charge Figure 5--1 Manifold Gauge Set (R--134a)
with R134a to slightly positive pressure of 1.0 psig.
5. Front--seat both manifold gauge set hand valves and 1. Manifold Gauge Set
disconnect from cylinder. The gauge set is now 2.. Hose Fitting (0.5-16 Acme)
ready for use. 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

b. Connecting the Manifold Gauge Gauge/Hose Set.

To connect the manifold gauge/hose set for reading
pressures, do the following:
1. Connect the field service couplers (see Figure 5--1)
to the high and low in--line service ports.
2. Turn the field service coupling knobs clockwise,
which will open the system to the gauge set.
3. Read the system pressures.
c. Removing the Manifold Gauge Set.
1. While the compressor is still ON, mid--seat both
hand valves on the manifold gauge set and allow the
pressure in the manifold gauge set to be drawn down
to low side pressure. This returns any liquid that may
be in the high side hose to the system.

CAUTION
To prevent trapping liquid refrigerant in the
manifold gauge set be sure set is brought to
suction pressure before disconnecting.
2. Back--seat both field service couplers and front--seat
both manifold set hand valves. Remove the couplers
from the in--line access valves.
3. Install both in--line access valve caps.

T-304 5--2 04/08

5.5 PUMPING THE SYSTEM DOWN OR REMOV-
ING THE REFRIGERANT CHARGE 3.
1. D S

NOTE
To avoid damage to the earth’s ozone layer, use
a refrigerant recovery system whenever remov- 2.
ing refrigerant.
4.

5.5.1 System Pump Down For Low Side Repair

To service or replace the filter--drier, pump the To Compressor
refrigerant to the condenser and receiver as follows:
a. Remove evaporator and condenser covers.
b. Install manifold gauge/hose set. (Refer to Section
5.4.1). 5.
c. Frontseat the filter--drier inlet service valve by turning 7.
clockwise. It will be necessary to install a jumper 6.
across the low pressure switch (LPS) contacts at the
compressor in order to reach 0 PSIG.
Figure 5--2 In--Line Service Connections
d. Start the system and run in cooling. Stop the unit
when suction reaches 10 ”/hg (25.4 cm/hg) vacuum.
1. Discharge Service 4. Vacuum Pump
e. Frontseat filter/drier outlet service valve to trap refrig- Port 5. Reclaimer
erant in the high side of the system between the com- 2. Suction Service 6. Refrigerant Cylinder
pressor and the filter--drier inlet valve. Wait 5 minutes Port 7. Thermistor Vacuum
to verify that system remains in a vacuum.
3. Manifold Gauge Gauge
f. Service or replace filter--drier. Set
g. Leak check connections after replacing filter--drier. 5.6 REFRIGERANT LEAK CHECK
Refer to paragraph 5.6.
A refrigerant leak check should always be performed
h. Using refrigerant hoses designed for vacuum service, after the system has been opened to replace or repair a
evacuate and dehydrate the filter--drier by connecting component.
a vacuum pump to center connection of manifold To check for leaks in the refrigeration system, perform
gauge set. Evacuate system to 500 microns. Close the following procedure:
off pump valve, isolate vacuum gauge and stop
pump. Wait 5 minutes to verify that vacuum holds. NOTE
i. Read Micron Gauge again to verify that the pressure It must be emphasized that only the correct re-
did not rise more than 500 microns within that 5--min- frigerant should be used to pressurize the sys-
ute timeframe. tem. Use of any other refrigerant will contami-
nate the system, and require additional
If the Micron Gauge rises more than 500 microns (to
excede a gauge reading of 500 + 500 = 1000 microns) at evacuation.
the end of 5 minutes, either a leak is present or an
unacceptable level of moisture remains in the circuit. If a. Ensure filter drier service and solenoid valves are
the gauge reads a gain of less than 500 microns during open.
the 5--minute wait, the circuit is acceptably tight and dry. 1. Filter drier service valves should be back seated.
b. If system is without refrigerant, charge system with
j. Once vacuum is maintained, recharge system by ad- refrigerant vapor to build up pressure between 20 to
mitting vapor from the refrigerant cylinder. 30 psig (1.36 to 2.04 bar).
k. Remove manifold gauges. Backseat both filter drier c. Add sufficient nitrogen to raise system pressure to
service valves. 150 to 200 psig (10.21 to 13.61 bar).
5.5.2 Removing Entire System Charge d. Check for leaks. The recommended procedure for
finding leaks in a system is with an electronic leak de-
To remove the entire refrigerant charge, do the tector. Testing joints with soapsuds is satisfactory
following: only for locating large leaks.
a. Connect a manifold gauge set to the system as e. Remove test gas and replace filter--drier.
shown in Figure 5--2 . f. Evacuate and dehydrate the system. (Refer to para-
graph 5.7.)
b. Connect a reclaimer to the center manifold gauge set
connection. g. Charge the unit. (Refer to paragraph 5.8.)

c. Recover refrigerant in accordance with reclaimer 5.7 EVACUATION AND DEHYDRATION

manufacturers instructions. 5.7.1 General

04/08 5--3 T-304

The presence of moisture in a refrigeration system can
have many undesirable effects. The most common are
copper plating, acid sludge formation, “freezing-up” of
metering devices by free water, and formation of acids,
resulting in metal corrosion. An evacuation should take
place after a system repair (replacement of filter drier.
expansion valve, solenoid valve, etc).
5.7.2 Preparation
NOTE
Using a compound gauge (manifold gauge) for
determination of vacuum level is not recom-
mended because of its inherent inaccuracy.
a. Evacuate and dehydrate only after pressure leak test.
(Refer to paragraph 5.6)
b. Essential tools to properly evacuate and dehydrate
any system include a good vacuum pump with a mini-
mum of 5 cfm (8.5 m 3/hr) volume displacement, (CTD
P/N 07-00176-11), and a good vacuum indicator
(CTD P/N 07--00414--00).
c. Keep the ambient temperature above 60 F (15.6 C)
to speed evaporation of moisture. If ambient temper-
ature is lower than 60 F (15.6 C), ice may form be-
fore moisture removal is complete.
5.7.3 Procedure for Evacuation and Dehydrating
System
a. Remove refrigerant using a refrigerant recovery sys-
tem. Refer to paragraph 5.5.2
b. The recommended method is connecting 3/8” OD re-
frigerant hoses designed for vacuum service as
shown in Figure 5--3.
c. Make sure vacuum pump valve is open.
d. Start vacuum pump. Slowly open valves halfway and
then open vacuum gauge valve.
e. Evacuate unit until vacuum gauge indicates 500 mi-
crons Hg vacuum. Close gauge valve, vacuum pump
valve, and stop vacuum pump.
f. Close off pump valve, and stop pump. Wait five min-
utes to see if vacuum holds.
g. Charge system. Refer to paragraph 5.8.2
5.8 ADDING REFRIGERANT TO SYSTEM
5.8.1 Checking Refrigerant Charge
The following conditions must be met to accurately
check the refrigerant charge.
a. Bus engine operating at high idle.
b. Unit operating in cool mode for 15 minutes.
c. Compressor discharge pressure at least 150 psig
(10.21 bar). (It may be necessary to block condenser
air flow to raise discharge pressure.)
NOTE
Ideal charging conditions are with ambient
above 86 F (30 C) and interior vehicle temper-
ature above 77 F (25 C). Charging to a full
sight glass at lower temperatures may lead to
system overcharge.
T-304
d. Under the above conditions, the system is properly
charged when the liquid line sight glase shows full (no
bubbles present).
5.8.2 Adding Full Charge
a. Install manifold gauge set at the in--line suction and
discharge service ports.
b. Evacuate and dehydrate system. (Refer to paragraph
5.7)
c. Place appropriate refrigerant cylinder on scales. Pre-
pare to charge liquid refrigerant by connecting charg-
ing hose from container to center connection on gage
manifold. Purge air from hoses.
d. Note weight of refrigerant and cylinder.
e. Open cylinder valve, backseat discharge valve on
gauge manifold and allow liquid refrigerant to flow into
the high side of the system
f. When correct charge has been added (refer to para-
graph 1.3, refrigerant specifications), close cylinder
valve and frontseat manifold discharge valve.
g. Prepare the cylinder as required to allow vapor charg-
ing. Backseat the manifold suction valve and charge
vapor until the correct charge has been added. Close
cylinder valve and frontseat suction manifold set.
h. Check charge level in accordance with the proce-
dures of paragraph 5.8.1.
5.9 CHECKING FOR NONCONDENSIBLES
To check for noncondensibles, proceed as follows:
a. Stabilize system to equalize pressure between the
suction and discharge side of the system.
b. Check temperature at the condenser and receiver.
c. Check pressure at the discharge (in--line) service
port.
d. Check saturation pressure as it corresponds to the
condenser/receiver temperature. See temperature--
Pressure chart Table Table 5--1. for R134a.
e. If gauge reading is 3 psig or more than the calculated
P/T pressure in step d., noncondensables are pres-
ent.
f. Remove refrigerant using a refrigerant recovery sys-
tem.
g. Evacuate and dehydrate the system. (Refer to para-
graph 5.7.)
h. Charge the unit. (Refer to paragraph 5.8.2.)
5.10 CHECKING AND REPLACING HIGH OR LOW-
PRESSURE CUTOUT SWITCH
5.10.1 Replacing High Or Low Pressure Switches
a. The high and low pressure switches are equipped
with schrader valves to allow removal and installation
without recovering the refrigerant charge.
b. Disconnect wiring from defective switch.
c. Install new cutout switch after verifying switch set-
tings.
5--4 Change 07/09
5.10 CHECKING AND REPLACING HIGH OR LOW PRESSURE CUTOUT SWITCH

5.10.1 Replacing High or Low Pressure Switches

5.10.2 Checking High Or Low Pressure Switch

WARNING

WARNING

Figure 5 --4 Checking High Pressure Switch

5.11 FILTER-DRIER

1 2 3 4 3 26 5

Figure 5- 5 Filter- Drier Removal

5.11.1 To Check Filter- Drier

5.11.2 To Replace Filter- Drier Assembly

WARNING
The filter-drier may contain liquid refriger-
ant. Slowly loosen the connecting nuts and
avoid contact with exposed skin or eyes.
5.12 SERVICING THE HEAT VALVE 1. Coil Retaining Screw 5. Kick-Off Spring
2. Nameplate 6. Plunger
The heat valve (Figure 5--6) requires no maintenance
unless a malfunction to the internal parts or coil occurs. 3. Coil Housing 7. Closing Spring
This may be caused by foreign material such as: dirt, Assembly 8. Diaphragm
scale, or sludge in the coolant system, or improper 4. Enclosing Tube & 9. O-Ring
voltage to the coil. Bonnet Assembly 10. Valve Body

NOTE 5.12.1 Coil Replacement

The OEM supplied heating (hot water) Solenoid a. It is not necessary to drain the coolant from the sys-
Valve is normally located outside of the tem.
AC310/350 rooftop air conditioning system. b. Place main battery disconnect switch in OFF position
and lock.
There are only three possible valve malfunctions: coil c. Disconnect wire leads to coil.
burnout, failure to open, or failure to close.
d. Remove coil retaining screw and nameplate.
Coil burnout may be caused by the following:
e. Lift burned-out coil from enclosing tube and replace.
1. Improper voltage
f. Connect wire leads and test operation.
2. Continuous over-voltage, more than 10% or Under-
voltage of more than 15%. 5.12.2 Internal Part Replacement
3. Incomplete magnetic circuit due to the omission of the a. Disconnect system from bus battery.
coil housing or plunger. b. Open the vent fitting at the top of the outlet header of
4. Mechanical interference with movement of plunger the heater coil.
which may be caused by a deformed enclosing tube. c. Drain coil by opening the drain-cock on the inlet tube.
Failure to open may be caused by the following: d. Disassemble valve and replace defective parts.
1.Coil burned out or an open circuit to coil connections. e. Assemble valve, refill and bleed coolant lines.
2. Improper voltage. 5.12.3 Replace Entire Valve
3. Torn diaphragm. a. Disconnect system from bus battery.
4. Defective plunger or deformed valve body assembly. b. Drain coolant from lines as previously described and
disconnect hoses to valve .
Failure to close may be caused by the following:
c. Disconnect wire leads to coil.
1. Defective plunger or deformed valve body assembly.
d. Remove valve assembly from bracket.
2. Foreign material in the valve.
e. Install new valve and re-connect hoses. It is not ne-
3. Torn diaphragm. cessary to disassemble the valve when installing.
1. f. Refill and bleed coolant lines.
2. g. Connect wire leads and test operation.
5.13 SERVICING THE LIQUID LINE SOLENOID
3. VALVE
The Liquid line solenoid valve (Figure 5--7) is very
4. similar to the heat valve. It requires no maintenance
unless a malfunction to the internal parts or coil occurs.
This may be caused by foreign material such as: dirt,
5. scale, or sludge in the refrigeration system, or improper
6. voltage to the coil.
7. There are only three possible valve malfunctions: coil
8. burnout, failure to open, or failure to close.
9. Coil burnout may be caused by the following:
1. Improper voltage.
2. Continuous over-voltage, more than 10% or under-
voltage of more than 15%.
10. 3. Incomplete magnet circuit due to the omission of the
coil hosing or plunger.
4. Mechanical interface with movement of plunger
Figure 5--6 Heat Valve which may be caused by a deformed enclosing tube.

T-304 5--6 04/08

Failure to open may be caused by the following:
1.
1. Coil burned out or an open circuit to coil connections. 2.

2. Improper voltage.

3. Defective plunger or deformed valve body assembly.

3.
Failure to close may be caused by the following:

1. Defective plunger or deformed valve body assembly. 4.

5.
2. Foreign material in the valve.
6.
5.13.1 Coil Replacement
7.
a. It is not necessary to remove the refrigerant charge 8.
from the system.

b. Disconnect system from bus battery.

Figure 5--7 Liquid Line Solenoid Valve
c. Disconnect wire leads to coil.
1. Snap Cap 5. Gasket
d. Remove coil retaining clip and nameplate. 2. Coil Assembly 6. Piston Assembly
3. Enclosing Tube 7. Body
e. Lift failed coil from enclosing tube and replace. Assembly 8. Bracket Adapter
4. Plunger Assembly
f. Connect wire leads and test operation
5.14 SERVICE VALVES
5.13.2 Internal Part Replacement
The filter/drier (High Side) service valves (Figure 5--8)
are provided with a double seat and a gauge port, which
a. Disconnect system from bus battery. allows servicing of the filter drier assembly.
b. Recover and recycle system refrigerant. Turning the valve stem counterclockwise (all the way
out) will backseat the valve to open the line to the
system and close off the gauge port. In normal
c. Slowly loosen enclosing tube assembly to bleed any operation, the valve is backseated to allow full flow
remaining pressure from the valve. Disassemble through the valve. The valve should always be
valve and replace defective parts. backseated before removing the gauge port cap.

d. Assemble valve and leak check. Turning the valve stem clockwise (all the way forward)
will frontseat the valve to isolate the system and open
the gauge port.
e. Evacuate and recharge system.
TO DISCHARG LINE VALVE CAP
5.13.3 Replace Entire Valve

a. Recover and recycle system refrigerant.

b. Remove valve assembly from bracket.

c. Disconnect wire leads to coil.

Port To SERVICE VALVE
d. Disassemble new valve, to protect internal parts, and Compressor PORT STEM
solder to lines.
Service Valve Service Valve
e. Assemble and leak check valve. Frontseated Backseated
(clockwise) (counterclockwise)
f. Evacuate and recharge.system.

g. Connect wire leads and test operation. Figure 5--8 Service Valve R134a (High Side)

04/08 5--7 T-304

5.15 REPLACING RETURN AIR FILTERS
The return air filters are located behind the return air
grill, inside the vehicle.
The filters should be checked for cleanliness
periodically depending on operating conditions. A dirty
filter will restrict air flow over the evaporator coil which
may cause insufficient cooling or heating and possible
frost buildup on the coil. To remove the filters, do the
following.
a. Insure air conditioning system is in the off position.
b. Remove the return air grille with the filter--diffuser as-
sembly, by turning the six 1/4 turn fasteners counter-
clockwise.
Composit Frame
Return Air Filter
Figure 5--9 Return Air Grill Assembly
With Air Filter Showing
c. Remove diffuser from the bus composit frame.
Diffuser
Return Air Filter
Figure 5--10 Diffuser and Filter Element
d. Remove and replace the filter element.
e. Center diffuser on filter element.
T-304
f. Pull filter element approximately 1/4 inch over ends of
the diffuser.
Diffuser
Air Filter
Composit Frame
Figure 5--11
Filter, Diffuser and Composit Frame
g. Place filter and diffuser into composit frame, with filter
element down (See Figure 5--11).
Captive 1/4 Fastners
Figure 5--12 Return Air Grill Assembly
With Diffuser And Composit Frame Showing
h. Insert filter--diffuser assembly into composit frame on
bus with the six captive 1/4 fasteners. (See
Figure 5--12)
i. Lock the six captive 1/4 turns in place by rotating
clockwise.
5.16 THERMOSTATIC EXPANSION VALVE
The thermostat expansion valve (Figure 5--13) is an
automatic device which maintains constant superheat
of the refrigerant gas leaving the evaporator regardless
of suction pressure. The valve functions are: (a)
automatic control of refrigerant flow to match the
evaporator load and (b) prevention of liquid refrigerant
entering the compressor. Unless the valve is defective,
it seldom requires any maintenance.
5--8 04/08
 1.
2.
3.
3. 4.
4.
2.
5. 5.
1.
4.

6.
Figure 5--14 Thermostatic Expansion Valve Bulb
7. and Thermocouple
1.. Suction Line 4.. Thermocouple
Figure 5--13 Thermostatic Expansion Valve (section view) 5.. TXV Bulb (Shown
1.. Power Head 4.. Gasket 2.. TXV Bulb Clamp in the 4’clock
Assembly 5.. Cage Assembly 3.. Nut & Bolt (clamp) position)
2.. Equalizer Connection 6.. Body Flange
3.. Bulb 7.. Cap screw
a. Open top cover.
5.16.1 Valve Replacement
a. If compressor is operative perform low side pump b. Remove Presstite insulation from expansion valve
down to replace expansion valve. (refer to 5.5.1) If bulb and suction line.
compressor is inoperative recover and recycle refrig-
erant from the system.(refer to 5.5.2) c. Loosen one TXV bulb clamp and make sure area un-
der clamp is clean.
b. Remove insulation from expansion valve bulb. (See
Figure 5--13 and Figure 5--14.)
d. Place temperature thermocouple in contact with the
c. Loosen retaining straps holding bulb to suction line suction tube and parallel to the TXV bulb, and then
and detach bulb from the suction line. secure loosened clamp making sure both bulb and
d. Loosen flare nuts on equalizer line and disconnect thermocouple are firmly secured to suction line. (See
equalizer line from the expansion valve. Figure 5--14). Reinstall insulation around the bulb.
e. Check, clean and remove any foreign material from
the valve body, valve seat and mating surfaces. If re- e. Connect an accurate low pressure gauge to the low
quired, replace valve body. pressure port.

NOTE f. Close top cover being careful to route thermocouple

R--134a valves are adjustable. Valves are pre-
set at the factory.
f. Leak check the new valve and evacuate and dehy-
drate the system. (Refer to paragraph 5.7.)
g. The thermal bulb is installed below the center of the
suction line (four or eight o’clock position). This area
must be clean to ensure positive bulb contact. Strap
thermal bulb to suction line. Ensure that retaining
straps are tight and renew insulation.
h. Fasten equalizer line to the expansion valve.
i. Evacuate and recharge the system.
j. Run the coach for approximately 30 minutes on fast
idle.
k.Check refrigerant charge. (Refer to 5.8.1)
5.16.2 Superheat Measurement
sensing wire and gauge hose outside the unit.
g. Start bus and run on fast idle until unit has stabilized,
about 20 to 30 minutes.
NOTE
When conducting this test, the suction pressure
must be at least 6 psig (0.41 bar) below the ex-
pansion valve maximum operating pressure
(MOP). Refer to paragraph 1.3 for MOP.
h. From the temperature/pressure chart, determine the
saturation temperature corresponding to the evapo-
rator outlet pressure.

NOTE i. Note the temperature of the suction gas at the expan-

sion valve bulb. Subtract the saturation temperature
All readings must be taken from the TXV bulb from this temperature. The difference is the super-
location and out of the direct air stream. heat of the suction gas.

04/08 5--9 T-304

j. The superheat may cycle from a low to high reading. readings taken to determine average superheat. The
Monitor the superheat taking readings every 3--5 min- superheat should be 18 3 F.
utes for a total of 5--6 readings. Calculate the super-
heats, add the readings and divide by the number of k. If superheat is not within tolerance, replace the valve.

T-304 5--10 04/08

 Table 5--1. R-134a Temperature - Pressure Chart
Temperature Vacuum Temperature Pressure
F C “/hg cm/hg kg/cm bar F C psig kPa kg/cm bar
--40 --40 14.6 49.4 37.08 0.49 28 --2 24.5 168.9 1.72 1.69
.35 .37 12.3 41.6 31.25 0.42 30 --1 26.1 180.0 1.84 1.80
--30 --34 9.7 32.8 24.64 0.33 32 0 27.8 191.7 1.95 1.92
--25 --32 6.7 22.7 17.00 0.23 34 1 29.6 204.1 2.08 2.04
--20 --29 3.5 11.9 8.89 0.12 36 2 31.3 215.8 2.20 2.16

--18 --28 2.1 7.1 5.33 0.07 38 3 33.2 228.9 2.33 2.29
40 4 35.1 242.0 2.47 2.42
--16 --27 0.6 2.0 1.52 0.02
45 7 40.1 276.5 2.82 2.76
Temperature Pressure 50 10 45.5 313.7 3.20 3.14
F C psig kPa kg/cm bar 55 13 51.2 353.0 3.60 3.53
--14 --26 0.4 1.1 0.03 0.03 60 16 57.4 395.8 4.04 3.96
--12 --24 1.2 8.3 0.08 0.08 65 18 64.1 441.0 4.51 4.42
--10 --23 2.0 13.8 0.14 0.14 70 21 71.1 490.2 5.00 4.90
--8 --22 2.9 20.0 0.20 0.20 75 24 78.7 542.6 5.53 5.43
--6 --21 3.7 25.5 0.26 0.26 80 27 86.7 597.8 6.10 5.98
--4 --20 4.6 31.7 0.32 0.32 85 29 95.3 657.1 6.70 6.57
--2 --19 5.6 36.6 0.39 0.39 90 32 104.3 719.1 7.33 7.19
0 --18 6.5 44.8 0.46 0.45 95 35 114.0 786.0 8.01 7.86
2 --17 7.6 52.4 0.53 0.52 100 38 124.2 856.4 8.73 8.56
4 --16 8.6 59.3 0.60 0.59 105 41 135.0 930.8 9.49 9.31
6 --14 9.7 66.9 0.68 0.67 110 43 146.4 1009 10.29 10.09
8 --13 10.8 74.5 0.76 0.74 115 46 158.4 1092 11.14 10.92
10 --12 12.0 82.7 0.84 0.83 120 49 171.2 1180 12.04 11.80
12 --11 13.2 91.0 0.93 0.91 125 52 184.6 1273 12.98 12.73
14 --10 14.5 100.0 1.02 1.00 130 54 198.7 1370 13.97 13.70
16 --9 15.8 108.9 1.11 1.09 135 57 213.6 1473 15.02 14.73
18 --8 17.1 117.9 1.20 1.18 140 60 229.2 1580 16.11 15.80
20 --7 18.5 127.6 1.30 1.28 145 63 245.6 1693 17.27 16.93
22 --6 19.9 137.2 1.40 1.37 150 66 262.9 1813 18.48 18.13
24 --4 21.4 147.6 1.50 1.48 155 68 281.1 1938 19.76 19.37
26 --3 22.9 157.9 1.61 1.58

04/08 5--11 T-304

 SECTION 6
ELECTRICAL
6.1 INTRODUCTION
This section includes electrical wiring schematics. The
schematics shown in this section provides information
for the AC310 and AC350 model rooftop air conditioning
units which are fitted with eight (8) and twelve (12)
single--shafted or four (4) and six (6) double--shafted
evaporator blower/motor assemblies and four (4) or six
(6) condenser fan motors. Figure 6--1 through
Figure 6--6 shows the Thermostat with manual re--heat.
Figure 6--7 thru Figure 6--13 shows the CSDD BT324
controller used with the AC310 single and dual systems
and the AC350 single loop with transit compressors.
Figure 6--14 thru Figure 6--18 shows Thermostat
control with one or two compressors.

UNIT CONTROLLER FIGURE NUMBERS

AC 310 Thermostat With Manual Reheat Figure 6--1 Thru Figure 6--6
AC 350 BT324 Figure 6--7 Thru Figure 6--13
AC 310/AC350 Thermostat One/Two Compressors Figure 6--14 To Figure 6--18

04/08 6--1 T--304

T--304
CONDENSER EVAPORATOR
CONTROL PANEL

Convection Heating Connection

R2N R1N
S1A
S2A S1A
S3A

6--2
Operation Board Operation Board
VERSION A VERSION B

AC 310 100A @ 24VDC LP Switch

FOM AC 350 125A @ 24VDC
AC310 OPTION 150A @12VDC
M31M
G Y31A

ALTERNATOR HEATING VALVE HP Switch

WATER PUMP HEATING Compressor Clutch
Battery 24 VDC

04/08
Figure 6--1 System Controls (Typical)
 B+ B+

04/08
Battery

RD

Evap. High U5 BKYE

1 810 11 OR
F1A 15A
BKBU ---- 12V 24V UR
Evap. Low U2 REL 1 REL 2 Sensors
Thermostat
Cooling Heating
OGRD Poti. Sensor
Cond. Mtrs. U3
7 1 9162435

WHRD
LL

85 30 87a 87 85
K1A K4A
86 87a 87 30 86
WH BKGY
UH
OGRD
UK
V1
WH
WH

Clutch
V5

BKRD
WH
BN

RDWH
Inside sensor
V2 V3

6--3
V4
B1N

WHYE
WHOG
WHBU

X3 12 34 5 91011
X20
WH

1 2
Vent 1 Vent 2
or
swor

Low High Y1A Y2A

F01A 7
Climate
1
5A R1N
S1A S2A Dash Control
Liquid Line Valve
3
Temperature setting

Operation Board Operation Board

A/C Power
Breaker 10 30 A Relay
87
5A 30 Wire 393
87A
* T---- Splice Into Freightliner Other Signal Indicating
Wire 393 At Hydraulic OR Vehicle Electrical System OEM SUPPLIED
85 86 Brake Module Is Ready To Operate AC
*
System
REF: 98--62--62668--00

T--304
*
Figure 6--2 Manual Controls With Manual Reheat Control (Sheet 1)
 B+

T--304
RD
12VDC * OEM SUPPLIED
Over-- -- Ride Switch

RD

60F 25F F2A 10A

OR

T-- --Stat Note A

86 30

BU
K2A

85 87a 87
NOTE A
60 Switch ---- Closes On Temperature Rise
25 Switch ---- Opens On Temperature Decrease
LL

LL Solenoids
BK
85 86 30
85
K3A
30 CLR2 30 CLR1
85 87a 87
UH 87a 87 86 87a 87 86

UK BKGY

BK

6--4
A/C Low Voltage
OGRD F3A F4A
10A 10A Breaker

BK
85 85
8
15A
30 CR2 30
* CR1
* *
87a 87 86 87a 87 86

B10F B20F
P HP -- -- switch P HP -- -- switch

B11F B21F
P LP -- -- switch P LP -- -- switch

M
= M31M
Y31A
Y7M Y8M

Compressor clutch Heating valve Waterpump heating

Compressor clutch
REF: 98--62668--00

04/08
Figure 6--3 Manual Controls With Manual Reheat Control (Sheet 2)
 B+

04/08
15A 15A 15A 15A
F1M F2M F3M F4M
U2

BK
GN
85 30 85 30
K2M K5M
86 87 86 87
U4

BKBU
GN
BKBU
GN
BKGN

BKYE

BKRD
BKOG

BN
BN
85 87 85 87 85 87 85 87

86 30 86 30 86 30 86 30

K1M K3M K4M K6M

6--5
BKBU
BKWH

F01M
150 AMP

X2
BLACK 1 2 3 4 5 6

SAO
BN

WHRD
WHYE
+
WHOG
BN
WHGN

M M MM
----
(OPTIONAL)
M1M M2M M3M M4M
BATTERY 12 VDC

REF: 98--62668--00

T--304
Figure 6--4 Evaporator Motors 1 -- 4
T--304
B+ B+

F5M 15A F6M 15A 15A 15A

F7M F8M
U2 U2

BU

GY
85 30 85 30
K8M K11M
86 87 86 87
U4

87a 87 85

WHRD
BKBU
GN
WHOG
BKBU
GN K13M

WHYE
30 86
WHGN

U5

BN
BN

85 87 85 87 85 87 85 87

6--6
86 30 86 30 86 30 86 30

K7M K9M K10M K12M

WHBK

WHBU
10 11 12 13 14 15
X2

BKRD
BN
BKYE
BKOG
BN
BKGN

M M M M

M5M M6M M7M M8M

(Optional)
REF: 98--62668--00

04/08
Figure 6--5 Evaporator Motors 5 -- 8
04/08
B+ B+

BKBU
U2 U2

BKYE
U5 U5

OGRD
U3

30 86 30 86
K14M K15M
87 85 87 85

6--7
F13M 15A F14M 15A F15M 15A F16M 15A

X1 10 13 14 15

WHITE

GNOG
GNWH
GNBU
GNYE

M MMM

(Optional)
M21M M22M M23M M24M

REF: 98--62668--00

T--304
Figure 6--6 Condenser Motors
T--304
CONDENSER EVAPORATOR
CONTROL PANEL

BT 324 Convection Heating Connection

6--8
UNLOADER
LP Switch
ALT
UL SWITCHES
M31M
ALTERNATOR WITH Y31A
DASH SWITCH

HEATING VALVE HP Switch

WATER PUMP HEATING
Y7M Compressor Clutch

04/08
Figure 6--7 BT324 Controls With (1) Compressor (AC350)
 REF: 98--62668--00

04/08
CONTROL PANEL

(RAS)
INSIDE SENSOR

6--9
WP

HSV

BT324
CONTROLLER

Compressor
Clutch
05G

5A 5A 5A

05G - 05K OPTION WP -- WATER PUMP

OPTION HSV -- HEATING SOLENOID VALVE
OUTSIDE SENSOR
U2 -- EVAPORATOR RELAY -- COIL
UReg -- SPEED CONTROL POWER
(ATS) U4 -- EVAPORATOR RELAY -- COIL

T--304
Figure 6--8 BT324 Control Circuit (AC350)
 2xRD 16 CONTROL PANEL

T--304
U1
U2

U3
Fma Ureg
BN U3a
3A U4

30 86 30 86 30 86 30 86 30 86 30 86
K1M K2M K3M K4M K5M K6M
87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85

15A 15A 15A 15A 15A 15A

F1M F2M F3M F4M F5M F6M F7M F8M F9M F10M F11M F11M

1 4 7 10 13 14 11 15 12 9 6 3 Ureg

6--10
+ X2

RDBU
+

FOM
125A -- AC350 X10.1 X10.1 X10.1 X10.1 X10.1 X10.1
100A -- AC310 X10 X10 X10 X10 X10 X10

X10.2 X10.2 X10.2 X10.2 X10.2 X10.2

INSTALLED BLOWERS
M M M M M M AC310 M1M -- M4M
AC350 M1M -- M6M
ALT
M1M M2M M3M M4M M5M M6M

EVAPORATOR MOTORS

REF: 98--62668--00

04/08
Figure 6--9 BT324 Evaporator Motors (AC350)
 WHRD
+U4A

04/08
15A X1
U1 U4A
6 BU
U2 UVd

X2
8 RDBU
Ureg Ureg

9
U4 7 WHGN UKo

30 85 30 85 30 85 BUWH
UFri
K7M K8M K9M
87a 87 86 87a 87 86 87a 87 86

CONTROL PANEL

15A 15A 15A 15A 15A 15A

F13M F14M F15M F16M F17M F18M

6--11
1pol. 1pol.
10 13 14 15 12 11
X1

X10.1
1 2 1 2 X10 GY(GN)
X20 X21

LIQUID LINE VALVE FRESH AIR FLAP

(OPTIONAL) GY(OG) GY(BN)
CONDENSER MOTORS
AC310 M21 -- M24M
M M M M M M X10.2
AC350 M21 -- M26M

M21M M22M M23M M24M M25M M26M M

CONDENSER BLOWER MOTORS
SPEED CONTROLLER CONNECTION
REF: 98--62668--00

T--304
Figure 6--10 CSDD BT324 Condenser Motors
T--304
1....K1A = Compressor Clutch -- Liquid Line
+ Solenoid -- Condenser Fans
K1M
-- 2....K2A = Heat Valve -- Boost Pump
F1M 10A 3....K3A = Evaporator Fans
F2M 10A 4....K1M -- K6M = Individual Evaporator Fans
F3M 10A
K2M
(M1M -- M6M)
5....K7M -- K9M = Individual Condenser Fans
K3M
(M21M -- M26M)
F4M 10A
6....Fuse = Boost Pump & Heat Valve
F5M 10A
X2 7....F13M -- F18M = Individual Condenser
F6M 10A
Contact arrangement K4M Fans
Connect X1 -- X2 F7M 10A
8....F1M -- F12M = Individual Evaporator
F8M 10A
Fans
K5M 9....U Reg = Evaporator Speed Regulation
U3 F9M 10A
10...X1 = Condenser Fans
F10M 10A
11...X2 = Evaporator Fans
F11M 10A K6M 12...X3 -- X4 (Not Shown On Drawing) =
K1A
Top View F12M 10A Dash To Unit Interface Plug
U3A
F13M 15A
K7M

6--12
Ureg
K2A
F14M 15A
F15M 15A K8M
X1
F16M 15A
F17M 15A K3A
F18M 15A
K9M

Part Number
26.38.08.001
+ +

GND

SUTRAK SCHMATIC #65, 01, 28, 056--01--3

UNIT RELAYS FOR EVAP. MOTORS RELAYS FOR COND. MOTORS

AC310 K1m -- K4M K7M -- K8M

AC350 K1M -- K6M K7M -- K9M
Relay Board

04/08
Figure 6--11 AC350 With BT324 Control
 X3 PLUG

04/08
(FROM)
1

(FROM)

(FROM)

AC--310/350 ELECTRICAL PANEL 24 V

SUTRAC PT.# 60--01--28--126
SCHEMATIC 65--01--28--056--01--3

X4 PLUG

6--13
100 Amp 24 VDC AC310
125 Amp 24 VDC AC 350

05G -- 05K OPTION

LEGEND

HPS -- HIGH PRESSURE SWITCH

HSV -- HEATING SOLENOID VALVE
LPS -- LOW PRESSURE SWITCH
WP -- WATER PUMP
UPS1 -- UNLOADER PRESSURE SWITCH #1
UPS2 -- UNLOADER PRESSURE SWITCH #2
UPS3 -- UNLOADER PRESSURE SWITCH #3
UV1 -- UNLOADER VALVE #1
UV2 -- UNLOADER VALVE #2

T--304
Figure 6--12 CSDD BT324 Control Circuit
T--304
Input Power 5A
1 BT--324
Ground
2
12 or 24 Night Light 5A
VDC 5
Alternator 5A
9
Compressor Failure Signal (Optional)
13
24 V (15) 6
or 12 V
a) Blower ON
b) Blower Speed 1 4
<P >P 8
Compressor Load
Clutch Pressure Relay Fresh Air
Free Switches Valve 12
Wheeling
Diode 16

20
Blower Motor Blower Speed Signal
M DRM 17
Blower Speed 2 18

Outside Sensor 3

6--14
(Optional) NTC
7
11
Inside Sensor
NTC
15
19

23
RS232 RxD 21
(Optional)
Blower Control Options a) Speed Controller RS232 TxD 22
(Software Selectable) b) Steps
10
Reat
Speed Blower Speed 2 Blower Speed 1 Relay Reserve 14
0 Off Off Not Used 24
1 Off On
2 On Off
3 On All Outputs 0.5 A Max.
On

Digital Controller
CSDD BT324

04/08
Figure 6--13 CSDD BT324
 +

04/08
+
U1
U2

BN6
Ureg
--
U4

86 86 86 86 86 86
30 30 30 30 30 30
K1M K2M K3M K4M K5M K6M
87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85

10A 10A 10A 10A 10A 10A 10A 10A 10A 10A 10A 10A

Ureg

6--15
1 4 7 10 13 14 11 15 12 9 6 3
X2

FOM

M M M M M M M M M M M M
--
BATTERY
24 VDC EVAPORATOR MOTORS INSTALLED BLOWERS
AC310 M1M -- M8M
AC350 M1M -- M12M

T--304
Figure 6--14 Thermostat (One/Two Compressors)
 + +

T--304
6--16
+

Yellow X10.1
X10
Red Grey

X10.2

M Green Brown
M M M M M
Installed Motors M
AC310 M21M -- M24M
AC350 M21M -- M26M
CONDENSER MOTORS

04/08
Figure 6--15 Thermostat (One/Two Compressors)
 RD6
U1 Installed In Units With Heating
+

04/08
F1A 15A

X10
WHBU U2 B1N
U2
TEMP. SENSOR
K6A

Ureg WHYE UR
F2 F1

WHGN U3 D5
U3 U3
BN6 GND
V6
1 11 1 9
3
87 87a 85
A1P 7
K2A
30
280P/282P
85 1 86 COOLING HEATING
1
K1A 4 *
2 THERMOSTAT 3
86 87a 87 2 10 6 4 5
1 2
3

X3.4
1 3 2

6--17
V2 V4 B1
BKRD
V7
V1 4 2
86 30 86 30 86 30
B2N
V3 1 BKYE K3A K4A K5A
V5
B5 A1 85 87a 85 87a 87 85 87a 87

1 2 6 3 4 7 5 8 9 10 11 8 9 6 4 1 2 3
X4 X5

2 3

R1N
YM3
Operation Panels
Fresh Air Flap
D+61 OPTION
Alternator

T--304
Figure 6--16 Thermostat (One/Two Compressors)
 UNIT WITH 1 COMPRESSOR

T--304
UNIT WITH 2 COMPRESSORS

3/B15 3/B15
U3 U3

F3A 10A F2A 10A F3A 10A

F2A 10A

3 1 2 3 1 2
X3.5 X3.5

GN GN

86 30 86 30
K7A K7A
Option 85 87a 87 Option 85 87a 87

1 2
X20
11 10 7 5 11 10 7 5
X5 X5

6--18
B1F 1 B2F 1 B1F 1
LP Switch LP-- Switch LP Switch
+ 4 2 4 2 + - 4 2

1
Y6A Y7A
B11F B21F 1 B11F 1
HP Switch HP-- Switch
Y7A HP Switch
+ 2 4 4 - + 2 4
2
Liquid Line Valve
Liquid Line Valves Compressor Unloader

B11N 1

+ 4 2
OPTION

Y7M Y8M Y7N Y8A

Compressor Clutch Compressor Clutch Compressor Clutch Unloader Valve

04/08
Figure 6--17 Thermostat (One/Two Compressors)
04/08
CONTROL PANEL CONTROL PANEL
(OPTION 1) (OPTION 2)
1

2
V1 V5

2 3 4 7 5 8 9 2 3 4 7 5 8 9
X4 X4

Speed Setting
R1

6--19
Evaporator Blowers S3A 1
Evaporator Blowers S3A 1 Fresh Air Flap
Ventilation: Stepless 7 1
7 1 S2A 1 Fresh Air Flap S1A OPTION
5
Clima Operation:
Ventilation -- 2 Steps S1A Clima 5 Stepless, depending 3
OPTION
3 5 on temperature

VERSION A VERSION B

T--304
Figure 6--18 Thermostat (One/Two Compressors)