Installation and Operation Manual Man… · Installation and Operation Manual ... Lay the batteryless dynamo capacitor box close to the dynamo where dry and ... before nitrogen gas

1235 201821 86-21-59166868 86-21-59165013

Headquarter: No.1235 Ye Cheng Rd. Jiading District, Shanghai, 201821, China Tel: 86-21-59166868 Fax: 86-21-59165013

60 200434 86-21-65285295 86-21-65923827

Service Centre: No.60 Guang Yue Rd. Shanghai, 200434, China Tel: 86-21-65285295 Fax: 86-21-65923827

77-66883-00 Rev. -

Carrier Transicold China

Installation and Operation Manual

AC112 & CN268/328 Bus Air-Conditioning Units

Content

Rooftop Installation

Compressor and Dynamo Installation

Electric Parts

Refrigeration System Piping

Air Channels and Air Openings

Unit Test

Operation Of An Air Conditioning

2

5

7

8

9

10

12

English Version

Attachment

P2 ~ P13

P14 ~ P21

14

16

17

18

19

20

21

P22 ~ P28

AC112 & CN268/328

VII Attachment VII

128

Drivers Control Panel

1 Run Pilot Lamp

2 Failure Pilot Lamp

3 Air Conditioning Switch

4 Fan Switch

5 Temperature Knob

6 Fresh Air Switch

CN268/368

AC112 & CN268/328

AC112

AC112 & CN268/328 AC112 & CN268/328

I II III CN328 268, 112

2 4500cm

2450cm

2650cm

2220cm

60 120

VI

IV

IV

,

2 3

AC112 & CN268/328

20mm

56 - 69111-00

/

(534 120 )

4 5

AC112 & CN268/328

AC112 & CN268/328

800 - 3500 r/min

( 2200 - 8000 r/min )

355

445 80 100

V

250mm

100A 150A CN328&268/AC112

6 7

AC112 & CN268/328

AC112 & CN268/328

50mm 55mm

O

SE55

200mm

120

5mm

8 9

AC112 & CN268/328

15 24

2 2 /

720mm Hg

AC112 & CN268/328

1/4 1/2

:

CN328 10kg

CN268 8.5kg

AC112 4.5kg

10 11

AC112 & CN268/328

AC112 & CN268/328

R134a R22

1

2

350 - 370 psig

270 - 300 psig

3 - 9 psig

22 - 28 psig

VII

A/C

26

15

AC 112

12 13

AC112 & CN268/328

Installation and Operation Manual Installation and Operation Manual

Rooftop Installation Rooftop Installation

1. Definition

2. Roof-top Preparation Before Lay and Installation

Front The heading direction while bus running.

Rear The opposite direction while bus running.

Right The right-hand side when steering.

Left The left-hand side when steering.

Put connecting pipes and compressor in the same side of bus. Lay out air

inlet/outlet of evaporator in vertical center to make the air flow uniform. Make

sketch and choose a suitable position to uniform the weight.

Consider the weight ratio of emergency exits and air channels. The thickness of

seal rubber and sponge must meet the requirement of the match between unit

and roof.

Construct according to the drawings strictly to make the installation precise (See

Attachment I/II/III).

Fix body shell after finishing the framework. Shadow area should be preserved.

Put stainless steel bolts through fix holes and weld them to the framework; fix

holes can be drilled in field.

Suggest using PVC Foam to do adiabatic process. The insulating material should

have adequate thickness and good insulating performance.

The design of air openings and channels is critical, which decides the unit work

performance.

Return inlet design according to the dimension of framework. Use metal grill with

hinges and bolts to make the maintenance easy. The nylon filter with metal edge

inside the grill can reduce dust, and it should be easy to remove and clean.

Attention: The area of return inlet affects the flux of evaporator fan directly; make 2

sure there is no less than 4500cm .

Place main air channels on the both sides inside the bus body, each area should 2

not less than 450cm .Set static opening on the both sides which face the middle 2

porch and windows, and the total area should not less than 650 cm . Set

adjustable air outlets above every seat, and the total area should not less than 220 2

cm .

3. Roof-top Fixation

Paste seal sponge on the roof and cover it by seal pastern (See Attachment VI).

Make the fix holes on evaporator and condenser aim at the fix bolts, put the unit

on the roof (See Attachment IV) and ensure the seal sponge working well.

Fix the U washer to the bolts vertically which extend from the seats of evaporator

and condenser, then the nut. Make sure the seat of evaporator and the roof is

sealed

Cover the seat with seal pastern carefully. Paste seal pastern round each junction

of evaporator, condenser, U washer and base.

Water around to check the leak after silica gel got dried. Eliminate any wrong.

Finally fix the transition duct.

4. Condense Tubes

Cut drain tubes (i.d.20mm) as need, connect the front and the rear joints that in

the same side of evaporator to the T-joint hoop and seal them. Connect the last

end of T-joint to the drain tube and hoop it, lead the tube outside the bus bottom,

seal the joint.

Attention: All the drain tubes should incline down and as short as possible.

Exclude any bend or shrinkage to let the condensate flow out. The tubes must not

touch any sharp thing, or it may break and leak.

14 15

If the dynamo is provided by Shanghai Carrier Transicold, we suggest following

steps:

Put the dynamo beside compressor. It is drived by belt wheel, so the speed can

be satisfied (800-3500r/min) if only the speed of compressor is correct (2200-

8000r/min).

Lay the batteryless dynamo capacitor box close to the dynamo where dry and

convenient for maintenance.

Confirm the upsides and undersides of both compressor and dynamo belt wheels

in a same linearity, make sure the bolts are firm and the belts get suitable tension.

Ensure the two belts are new and replacing together.

Check the other parts.

If the dynamo requires a ventilation hoop, the duct sleeve should be connected to

somewhere dry and clean and get low temperature.

Installation and Operation Manual Installation and Operation Manual

Compressor and Dynamo Installation Electric Parts

1. Compressor Lay and Installation

1. Driver Control BoardWhen design the unit, the lay of compressor and dynamo should be considered

and preserve enough space. It's also need to consider anti-vibration, operating

space in connection, convenience of maintenance.

It should give some maintenance space or doors; air grill make for the airflow and

cooling; attend to keep compressor and dynamo from water.

Compressor usually lay in rear of the bus.

Put the compressor in a suitable position.

Make compressor belt wheel and dynamo crankshaft belt wheel (or intergraded

wheel) in line.

Fix the drive belt (provided by user) into belt wheel; adjust the tension till it reach

534N/120pound.

Keep the upside and underside of compressor belt wheel in a same linearity,

make sure the bolts are firm, and the belts get suitable tension.

Finally, check the whole installation, obviate conflicts; Ensure both two belts are

new.

2. Dynamo Lay and Installation

Driver control board consists of control panel, fan speed control switch,

temperature setting switch, the size of switch showed in control panel dimension

(See Attachment V).

2. Power Cable2

50mm insulated cable.

If the power is provided by bus dynamo, put the main fuse somewhere dry and

convenient for maintenance. Connect wires according to the drawing of unit

connection.

If the power is provided by batterryless dynamo, put the capacitor, fuse control

box somewhere dry and convenient for maintenance. Wiring according to the unit-

wiring sketch.

3. Control Cable

The unit provides two control wire harnesses:

One from driver operating panel to roof-top control panel;

One from rooftop control panel to compressor.

Wire harnesses must be kept far from running and hot parts; Use protect rings

where there are sharp things; Keep suitable tension.

All the connection must be firm. Bolts should have loose taken.

16 17

Installation and Operation Manual Installation and Operation Manual

Refrigeration System Piping Air Channels and Air Openings

Refrigeration system piping (high pressure tube 50mm, low pressure tube

55mm,both with insulated skin) start from the connection of evaporator and

condenser. First, loosen the cap slowly, exhaust nitrogen gas; Remove the cap of

inlet and outlet, then do the connection. (Attention: Must not remove any part

before nitrogen gas exhausted)

Use new seal paper washer instead of old seal parts around the suction and

discharge flange. Connect the flange to the joints on high and low-pressure tubes

All the joints should be covered by insulating material.

Cover the discharge pipes inside bus with insulating material that can endure

120 high temperature.

Check refrigeration system; condense tubes, wire harnesses again.

All channels ought to be insulated, and the material thickness must more than

5mm, and it should adhere to the outside of the channel to reduce resistance.

Check if there is leak at the junction. Check the air speed and temperature

uniformity inside the bus, use guide valve to correct deviations.

18 19

Installation and Operation Manual Installation and Operation Manual

Unit Test Operation Of AC System

Let the feeding solenoid valve on; connect compressor suction and discharge line

to the high and low pressure tubes, screw the suction and discharge valve to the

middle position, open the valve on pressure gauge slowly to exhaust nitrogen gas.

(Or connect the pressure gauge to the condenser tank shut-off valve to let the gas

out.)

Connect vacuum pump to the middle joint of pressure gauge, evacuate the

system to 720mmHg (keep the solenoid valve on), then close high and low

pressure hand valves, remove vacuum pump.

Connect pressure gauge and refrigerant bottle to the outlet valve on liquid tank,

open the outlet valve on refrigerant bottle a little and loosen the end of hose near

the tank to let the air out. Tighten the pipe and weigh the bottle at inversion,

charge refrigerant according to the requirement. If it's still not adequate when

pressure reach a balance, close maintain valve and the outlet valve on bottle;

tighten the caps of evaporator and condenser. Connect high and low pressure

tubes to the maintain joints of compressor suction and discharge valves (don't

tighten suction joint at once), close high-pressure hand valve. Connect the middle

joint of pressure gauge to the bottle and weigh it (no inversion), loosen bottle

valve and open low pressure hand valve, exhaust air and tighten the tube joint,

open the maintain joint and outlet valve on bottle.

Start air conditioner; be careful of the weight of refrigerant.

Observe the mass, stop discharge when it reaches requirement.

Observe compressor lubricant level through sight glass; keep it at 1/4 to 1/2

position (lubricant should be recharged by professional when it falls below the

position).

Observe the suction and discharge pressure, open the suction and discharge

valves (maintain valve closed), loosen pressure gauge slowly, let refrigerant out

and remove the gauge.

Ensure there is no leak and restart air conditioner, check every part, then close it

and complete the test.

Attention: When operating the compressor high and low pressure valves, man

should not touch any running part or should stop the main engine first.

Refrigerant

The refrigerant used in Carrier air conditioning systems is R134a.

Cooling capacity

1.The capacities can vary depending upon the length of the refrigerant hoses. The

length of the refrigerant hoses varies depending upon vehicle and location of the

system and the compressor.

2.The capacities can vary depending upon the type of compressor.

Pressure monitors

Switching pressures (pressure gauge readings):

High-pressure

OFF: 350~370 psig

ON: 270~300 psig

Low-pressure

OFF: 3~ 9 psig

ON: 22~28 psig

Run Pilot Lamp

The pilot lamp show green when air conditioning is running (See Attachment VII).

Failure Pilot Lamp

The pilot lamp shows red when the pressure of the system is abnormal.

Air Conditioning Switch

Operating this button to choice different function of the air conditioning.

- Start the air conditioning

- Stop the air conditioning, only start the blower

Fan Switch

Using this switch to control the blower speed. You can adjust the air throughput by

this switch when the air conditioning switch is on A/C or FAN.

- Low Speed

- High Speed

Temperature Knob

Using this switch to control the inside temperature. When the inside temperature

arrived the setting temperature, the air conditioning will stop automatically. And

when the inside temperature is higher than the setting temperature, the air

conditioning will run automatically.

Fresh Air Switch (AC 112 without)

Using this switch to control the fresh air and create a comfortable condition.

20 21

22 23

I Attachment IAC112 & CN268/328

CN328CN328 Unit Inst. Dim (mm)

CN268CN268 Unit Inst. Dim (mm)

A, B, C

Dim A, B, C Depends On Application Engineer's Instruction

A, B, C

Dim A, B, C Depends On Application Engineer's Instruction

II Attachment IIAC112 & CN268/328

TRANSITION DUCT

MOUNTING BOLT

CONNECTING PIPLINE

B

515

C

895

180

A-A

A

A

BASELINE

13 18

M8

GROUND BLOT

A

BASELINE

13 18( M8 )

A

TRANSITION DUCT

MOUNTING BOLT

CONNECTING PIPLINE

B

515

C

895

180

A-A

24 25

III Attachment III IV Attachment IV

AC112AC112 Unit Inst. Dim (mm)

CN268/328CN268/328 Evap Cover Lifting Method

AC112 & CN268/328 AC112 & CN268/328

Hoist Hoist

Hoist

A130

19

98

85

0

17

30

13

15

90

04

15

99 60

320

130

4 3/4

91

0

12

8

18

5

M8 35

91280 min:1260 max:1320)

1700

180

26 27

AC112 & CN268/328

V Attachment V VI Attachment VI

CN268/328CN268/328 Drivers Control Panel Inst.Dim (mm)

AC112AC112 Drivers Control Panel Inst.Dim (mm)

CN268/328CN268/328 Units Sealing

AC112 & CN268/328

Evap Ass Sealing

40 5mm ,

40 5mm Foam Tap (For Air conduct Seal)

Cond Ass Sealing

40 20mm ,

40 20mm Foam Tap For Air Return Ass, etc.

150

141

130 R3

4.5

58

68

59

58

68

R3

6 4

150

118

70.570.5

52