Carrier Em1 Manual

							7-1
T--311
SECTION 7
EVACUATION
7.1 INTRODUCTION
The process of evacuation is an important step in the
servicing and maintenance of any air conditioning
system. The purpose of evacuation is to remove all air
and moisture from the system in preparation for adding
refrigerant and oil during the charging process. It is
imperative that all air and moisture be removed from the
system, as their presence is detrimental and will
negatively affect performance and longevity of the
systems components. Air remaining in the air
conditioning system will degrade the systems cooling
performance, while any moisture remaining in the
system is both non-condensable and a basis for acid
formation. Moisture is the deadly enemy of refrigeration
systems.
7.2 REFRIGERANT SERVICE TOOLS
The following equipment is essential when performing
an installation of or servicing of any Carrier Transport Air
Conditioning system. Refer to Figure 7-2 for service
component connections.
1Manifold Gauge Set -Provides access to and
monitors pressures within the system. Manifold Gauge
Sets are available in different configurations and styles.
3-way or 4-way, Liquid filled, with or without a sight
glass, 3 hoses or 4 hoses, 1/4 inch or 3/8 inch manifold
connections, etc. All are acceptable for servicing a
Carrier Transport Air Conditioning system. Familiarize
yourself with the proper operation of your Manifold
Gauge Set before attempting any service.
2R134a Low Side (Suction) Coupler -Connects
the air conditioning system Suction Access Port to the
Manifold Gauge Set.
3Ri34a High Side (Discharge) Coupler -Connects
the air conditioning system Discharge Access Port to
the Manifold Gauge Set.
4Vacuum Pump - 2 Stage (5 CFM Minimum) -
Removes moisture and air from the air conditioning
system in order to obtain required micron level.
5Micron Gauge -Monitors the evacuation process
in units of microns. Micron gauges can be either digital
(electronic) or analog. When the Micron Gauge is used
as specified by the manufacturer you can be assured all
contaminants have been removed from the air
conditioning system. Proper use of the Micron Gauge
will also serve as a first indication of a leak tight system.
6Recovery/Recycle Machine (R134a) -Recovers
and Recycles R134a refrigerant that is present within
the air conditioning system.
7Refrigerant Scale -Accurately weighs the transfer
of refrigerant into the air conditioning system.
8Refrigerant Cylinder -Storage tank for R134a.
9Heat Blanket -Used to increase internal
temperature of the refrigerant cylinder, greatly
increasing the transfer of refrigerant to the air
conditioning system.
10Oil Injector -Used to add additional amounts of oil
to a closed system.11Vacuum Pump -Air and moisture are removed
from the system by inducing a vacuum through the use
of a vacuum pump. Carrier Transport Air Conditioning
recommends a 5 CFM or larger vacuum pump for
optimum evacuation in the shortest time. A vacuum,
which is measured in microns, results when pressure is
reduced within the system. Functionally, reducing the
pressure results in reducing the boiling point of water
(moisture) that may be in the system. Through the
process of vaporization, the water (moisture) changes
state from a liquid to a vapor and is drawn off by the
vacuum pump and removed from the system. If properly
completed, the system is now ready for charging.
NOTE
Using a compound gauge (Low Side Gauge) for
determination of vacum level is not recom-
mended because of its inherent inaccuracy. A
micron gauge must always be used to insure a
proper evacuation.
7.2.1 Preparation
a. Evacuate and dehydrate only after pressure leak test.
(Refer to paragraph 9.2 .)
b. Essential tools to properly evacuate and dehydrate
any system include a vacuum pump (5 cfm=8 m
3/hr)
volume displacement) and an electronic vacuum (mi-
cron) gauge. (The pump is available from Carrier
Transicold, P/N 07-00176-11.)
c. If possible, 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 might form before moisture removal is
complete. Heat lamps or alternate sources of heat
may be used to raise the system temperature.
7.2.2 Procedure - Complete system
a. Remove all refrigerant using an approved refrigerant
recovery system, following manufacturers recom-
mendations.
b. The recommended method to evacuate and dehy-
drate the system is to connect two evacuation hoses
(see Figure 7-2) to the vacuum pump and refrigera-
tion system. Be sure the service hoses are suited for
evacuation purposes.
c. Test the evacuation setup for leaks by drawing a deep
vacuum through the manifold gauge set, hoses, and
service couplers with the vacuum pump. Shut off the
pump and check to see if the vacuum holds. Repair
leaks if necessary.
d. Open the vacuum pump and electronic vacuum (mi-
cron) gauge valves, if they are not already open. Start
the vacuum pump. Evacuate unit until the electronic
vacuum gauge indicates 2000 microns. Close the
electronic vacuum gauge and vacuum pump valves.
Shut off the vacuum pump. Wait a few minutes to be
sure the vacuum holds.
e. Break the vacuum with clean dry refrigerant 134a
gas. Raise system pressure to approximately 2 psig
(0.2 kg/cm@), monitoring it with the compound gauge.
f. Remove refrigerant using a refrigerant recovery sys-
tem. 
						

							7-2
T--311 g. Repeat steps d.and e. one time.
h. Evacuate unit to 500 microns. Close the electronic
vacuum gauge and vacuum pump valves. Shut off the
vacuum pump. Wait five minutes to see if vacuum
holds. This procedure checks for residual moisture
and/or leaks.
i. With a vacuum still in the unit, the refrigerant charge
may be drawn into the system from a refrigerant con-
tainer on weight scales.
7.3 INSTALLING MANIFOLD GAUGES
The manifold gauge set is used to determine system
operating pressures, add refrigerant charge, and to
equalize or evacuate the system.
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
checked. When both valves are open (turned
counter-clockwise all the way out), high pressure vapor
will flow into the low side. When the suction pressure
valve is open and the discharge pressure valve shut, the
system can be charged. Oil can also be added to the
system.
A R-134a manifold gauge/hose set with self-sealing
hoses is required for service of the models covered
within this manual. The manifold gauge/hose set is
available from Carrier Transicold. (Carrier Transicold
P/N 07-00294-00, which includes items 1 through 6. To
perform service using the manifold gage/hose set, do
the following:
a.Preparing Manifold Gauge/Hose Set For Use
1. If the manifold gauge/hose set is new or was
exposed to the atmosphere it will need to be eva-
cuated to remove contaminants and air as follows:
2. Back seat (turn counterclockwise ) both field service
couplings (see Figure 7-1) and midseat both hand
valves.
3. Connect the yellow hose to a vacuum pump.
4. Evacuate to 10 inches of vacuum.
5 Connect yellow line to R134a cylinder, purge line,
then charge with to a slightly positive pressure of 0.1
kg/cm@(1.0 psig).
6. Front seat both manifold gauge set valves and dis-
connect from cylinder. The gauge set is now ready
for use.
b.Connecting Manifold Gauge/Hose Set
Connection of the manifold gauge/hose set (see
Figure 7-2) is dependent on the type system being
serviced. The center hose connection is brought to the
tool being used. To connect the manifold gauge/hose
set, do the following.
1. Connect the high side field service coupling 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 sys-
tem 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.
CAUTION
To prevent trapping liquid refrigerant in the
manifold gauge set be sure set is brought to
suction pressure before disconnecting.
OPENED
(Backseated )
HAND VALVECLOSED
(Frontseated)
HAND VALVE SUCTION
PRESSURE
GAUGEDISCHARGE
PRESSURE
GAUGE
To Low Side
Access ValveTo High Side
Access Valve
Red Knob Blue Knob
1
43
YELLOW2
4
5 63
RED 3
BLUE
2
1. Manifold Gauge Set
2. Hose Fitting (0.5-16 Acme)
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
Figure 7-1 Manifold Gauge Set
c.Removing the Manifold Gauge Set
1. 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.
2. Backseat both field service couplings and frontseat
both manifold set valves. Remove the couplings
from the service ports.
3. Install both service port caps (finger-tight only). 
						

							7-3
T--311
TXV
EVAPORATOR COIL
CONDENSER COILFILTER DRYERSIGHT GLASS SUCTION ACCESS
HPS
LPS DISCHARGE
ACCESS
COMPRESSOR
LPS (New Location GEN 5)
(GEN 4
Location)
DS
12 3
4 5 6
7
1. Vacuum Pump
2. Micron Gauge
3. Manifold Gauge Set
4. Refrigerant Cylinder5. Recovery/Recycle Machine
6. R134a High (Discharge) Side Coupler
7. R134a Low (Suction) Side Coupler
Figure 7-2 Refrigerant Service Connections (Split Systems) 
						

							8-1T--311
SECTION 8
CHARGING PROCEDURES
8.1 INTRODUCTION
Charging is the process of calculating and then
introducing the correct amounts of refrigerant and oil
into the air conditioning system. Accurate charge levels
will result in optimum system performance and insure
the longevity of the system components.
8.1.1 Proper R134a Charge.
A system overcharged with refrigerant operates under
high head pressure which can damage components. A
system undercharged with refrigerant will result in poor
system performance.
NOTE
An overcharged or undercharged system may
contribute to system compressor failure.
Calculations for determining the proper refrigerant
charge are based on component capabilities and liquid
line lengths as indicated on Carrier Transport Air
Conditioning charging tables. Refer to Table 8-1 or
Table 8-2 for the approximate refrigerant charge. Refer
to Table 8-4 to determine the exact refrigerant charge.8.1.2 Proper Oil Charge.
Accurate charge levels of oil with the refrigerant are also
critical to proper performance and component longevity.
A system undercharged with oil will result in reduced
compressor life due to lack of lubrication. A system
overcharged with oil will experience poor system
performance due to reduced thermal transfer
capabilities. Refer to Table 8-1 or Table 8-2 for the
approximate oil amounts. Refer to Table 8-3 for the
correct compressor oil type.
8.1.3 Liquid Charging.
The practice of charging liquid refrigerant into the
suction side with the compressor running will damage or
destroy the compressor, as the liquid is not
compressible.
8.1.4 PAG And POE Oils.
It is very important to use the lubricant type specified by
the compressor manufacturer. (Refer to Table 8-3).
Using oil other than the specified oil can result in
reduced performance and a reduction in compressor
life.
NOTE
Using oil other than that specified in Table 8-3
will void the compressor warranty.
Table 8-1 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (THROUGH GEN 4)
Evaporator
Up to GEN 5
Condenser
All SeriesRecommended
R134a ChargeRecommended
Oil Charge*
EM-1, EM-2, or EM-9CM-25.00 Pounds10.0 Ounces
EM-1, EM-2, or EM-9CM-115.25 Pounds10.5 Ounces
EM-6CM-24.00 Pounds8.0 Ounces
EM-6CM-114.25 Pounds8.5 Ounces
EM-1, EM-2, or EM-9CM-35.50 Pounds11.0 Ounces
EM-1, EM-2, or EM-9CM-76.50 Pounds13.0 Ounces
EM-3(2) CM-24.25 Pounds Each8.5 Ounces Each
EM-3(2) CM-76.25 Pounds Each12.5 Ounces Each
EM-3(2) CM-35.50 Pounds Each11.0 Ounces Each
EM-3(2) CM-76.25 Pounds Each12.5 Ounces Each
EM-14CM-23.50 Pounds7.0 Ounces
EM-14CM-113.75 Pounds7.5 Ounces
EM-17CM-519.0 PoundsConsult Factory
EM-17KR-413.0 PoundsConsult Factory
EM-17 Split System(2) CM-36.00 Pounds Each12.0 Ounces Each 
						

							8-2 T--311Table 8-2 SPLIT SYSTEM REFRIGERANT AND OIL CHARGING TABLE (GEN 5)
Evaporator
GEN 5
Condenser
All SeriesRecommended
R134a ChargeRecommended
Oil Charge*
GEN 5 - EM-1CM-2 or CM-44.75 Pounds9.5 Ounces
GEN 5 - EM-1CM-115.00 Pounds10.0 Ounces
GEN 5 - EM-1CM-35.25 Pounds10.5 Ounces
GEN 5 - EM-1CM-76.25 Pounds12.5 Ounces
GEN 5 - EM-7CM-2 or CM-44.00 Pounds8.0 Ounces
GEN 5 - EM-7CM-114.25 Pounds8.5 Ounces
GEN 5 - EM-2CM-2 or CM-44.50 Pounds9.0 Ounces
GEN 5 - EM-2CM-114.75 Pounds9.5 Ounces
GEN 5 - EM-2CM-35.00 Pounds10.0 Ounces
GEN 5 - EM-2CM-76.00 Pounds12.0 Ounces
The data listed in Table 8-1 and Table 8-2 is based on a
20 foot liquid line. Increase the charge by 0.5 pound for
each additional 10 feet of liquid line.
8.1.5 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.
Table 8-3 COMP. OIL TYPE & PART NUMBERS
Manufacturer
Oil TypePart Number
Tama/Zexel/IcePA G07-00336-00
SandenPA G07-00335-00
General MotorsPA G46-50003-00
DodgePA G07-00332-00
FordPA G07-00334-00
Climate ControlPOE07-00317-00
For questions regarding charging procedures, call
Carrier Transport Air Conditioning technical support at
1-800- 450-2211.8.1.6 Adding Refrigerant to System (Full Charge).
a. Evacuate unit and leave in deep vacuum.
b. Place cylinder of R-134a on scale and connect charg-
ing line from cylinder to liquid line valve. Purge charg-
ing line at liquid line valve and then note weight of cyl-
inder and refrigerant.
c. Calculate the approximate refrigerant charge using
either Table 8-1 or Table 8-2. Open liquid valve on re-
frigerant cylinder. Open suction line service port cou-
pler and allow the liquid refrigerant to flow into the unit
until the correct weight of refrigerant has been added
as indicated by scales.
NOTE
It may be necessary to finish charging unit
through suction service port in gas form, due to
pressure rise in high side of the system.
d. Close suction line service port coupler. Close liquid
valve on cylinder.
e. Start unit in cooling mode. Run approximately 10 min-
utes and check the refrigerant charge. (Refer to
Table 8-4). 
						

							8-3T--311 Table 8-4 CARRIER TRANSPORT AIR CONDITIONING SYSTEM PERFORMANCE CHART
Determine the approximate refrigerant charge using Table 8-1 or Table 8-2 .
Follow the procedures listed below to determine if the correct charge has been obtained.
Ta b l e
ProcedureYour EntryExample
Pres-
sureRefrigerant Temp.1.Connect Manifold Gauge Set To
Air ConditioningSystemNONENONEPSIGR-12R134a
AirConditioningSystem
Certified Air Conditioning MechanicNONENONE
(A)(B)(C)
CertifiedAirConditioningMechanic
Only
958785
10090882.Measure outside(ambient)air
1059390
2.Measureoutside(ambient)air
temperature.DegreesF100DegreesF11 09693Enter here ------------ -->______DegreesF100DegreesF
11 59996
12010298
125104100
40DF40DF1301071033.Add 40 degrees F to the outside
(bit)itt
40 Degrees F
DegreesF
40 Degrees F
140DegreesF135109105(ambient) air temperature --->______DegreesF140DegreesF
14011 2107
14511 4109
15011 711 2
15511 911 44.Find closest refrigerant
temperatureinTableDegreesF139DegreesF16012111 6temperatureinTable
(B or C) and enter here --- -->______DegreesF139DegreesF
16512311 8
(BorC)andenterhere>
170126120
175128122
1801301235. Going across the Table, find the
di(A)(D)=PSI225PSI185132125corresponding pressure (A) -->(D)=______PSI225PSI
190134127
195136129
2001381316.If the Discharge Pressure
(HighSide)ongaugers205140132(HighSide)on gaugers
(With compressor engaged,
210142134
(Withcompressorengaged,
engine speed 1200 RPM, and
215143136
enginespeed1200RPM,and
system operating) is :
220145137
Gtth(D)Rdfit
******
225147139Greater than (D) - Reduce refrigerant
by4ounceincrements235150142by 4 ounce increments.
245154145Lessthan(D)-Addrefrigerant255157148Lessthan(D)-Addrefrigerant
265160151Wait 10 minutesfor system to
275163153
Wait10minutesforsystemto
stabilize before taking new readings 
						

							9-1 T-- 311
SECTION 9
LEAK CHECKING
9.1 INTRODUCTION
The purpose of leak checking is to verify the integrity of
the hose/fitting connections and components. A
refrigerant leak check should always be performed after
installing a new system or the system has been opened
to replace or repair a component. It is imperative that the
inspection for refrigerant leaks be conducted in a
through and meticulous manner. Even the smallest leak
can result in poor system performance and premature
compressor failure. When a leak occurs, the refrigerant
is replaced by air and moisture from outside the system.
Without a complete charge of refrigerant in the system,
insufficient oil is returned to the compressor. The
compressor will overheat and eventually fail. Following
established leak checking procedures will result in long
term performance and assure longevity of the system
components.
9.1.1 Micron (Vacuum) Gauge
Carrier Transport Air Conditioning recommends a
Micron (Vacuum) Gauge to assure that the proper
vacuum level is attained. When isolated according to
instructions the Micron Gauge will show a loss of
evacuation vacuum, making it an excellent first leak
check.
9.1.2 Nitrogen
A common method in use for leak detection, is
pressurizing the system with dry nitrogen and checking
with a soap bubble solution at suspected leak sites.
While this method will find large leaks, it is limited in
detection of the smaller leaks found with R134a.
WARNING
DO NOT USE A NITROGEN CYLINDER
WITHOUT A PRESSURE REGULATOR
NOTE
If the system is to be pressurized with refriger-
ant gas it must be emphasized that only the cor-
rect refrigerant cylinder be connected to pres-
surize the system. Any other gas or vapor will
contaminate the system, which will require
additional evacuations (Refer to Figure 9-1 for
service connections).9.2 REFRIGERANT LEAK CHECKING
WARNING
Never use air for leak testing. It has been de-
termined that pressurized, air-rich mixtures
of refrigerants and air canundergo com-
bustion when exposed to an ignition
source.
a. Charge the system with refrigerant 134a to build up
pressure between 30 to 50 psig.
b. Add sufficient nitrogen to raise system pressure
to150/200 psig. (10.21/13.61 bar).
Note
Larger split systems may be equipped with ser-
vice valves and a liquid line solenoid. Ensure
these service valves are open and power the
liquid line service valve from an external
source.
c. The recommended procedure for finding leaks in a
system is with a R-134a electronic leak detector (CTD
Part Number 07-00295-00). Testing joints with soap-
suds is satisfactory only for locating large leaks.
d. Remove refrigerant using a refrigerant recovery sys-
tem and repair any leaks.
e. Evacuate and dehydrate the unit (Refer to Section 7).
f. Charge the unit. (Refer to Section 8). 
						

							9-2 T--311
TXV
EVAPORATOR COIL
CONDENSER COILFILTER DRYERSIGHT GLASS SUCTION ACCESS
HPS
LPS DISCHARGE
ACCESS
COMPRESSOR
LPS
(New Location GEN 5)
(GEN 4
Location)
DS
1 7
6
5
43
2
1. Vacuum Pump
2. Micron Gauge
3. Manifold Gauge Set
4. Refrigerant Cylinder5. Recovery/Recycle Machine
6. R134a High (Discharge) Side Coupler
7. R134a Low (Suction) Side Coupler
Figure 9-1 Refrigerant Service Connections (Split Systems) 
						

							T--311
10-1
SECTION 10
WARRANTY REGISTRATION
10.1 INTRODUCTION
The warranty registration process is an important part of
the installation of any air conditioning system. In order to
experience the full benefits of Carrier Transport Air
Conditioning’s warranty, it is imperative that your
system is registered completely and accurately. Failure
to properly register the system will adversly affect the
availability of warranty coverage. A properly registered
system will enable Carrier Transport Air Conditioning to
respond immediately in the event of a warrantable
failure.
10.2 PROCEDURES
Locate the warranty registration card that is inclosed
with the installation kit. (See Figure 10-1).
The warranty registration card consists of three (3)
copies.
1. Yellow copy:Installer copy:
a. Completely fill out all Installer and Product informa-
tion. Date of Installation, Installer Name, Address,
City, State, Zip code and Phone number.
b. When Purchaser information is known, the installer
can complete this part of the form also.c. If the Warranty Registration Card is complete, the
white (pre-addressed) copy can be mailed to Carrier
Transport Air Conditioning at this time.
d. Installer to keep yellow copy for file.
e. Installer to forward (with bus) green and white copy
to purchaser (end-used).
2. Green copy:Purchaser (End User) copy:
a. Complete Purchaser copy, sign, then mail white
(pre-addressed) copy to Carrier Transport Air Condi-
tioning.
b. Purchaser (end user) to keep green copy for file.
NOTE
The Carrier Transport Air Conditioning limited
warranty is printed on the back of the purchaser
(green) copy.
3. White Copy:Carrier Transport Air Conditioning
copy:
a. Must be mailed to Carrier Transport Air Conditioning
in order to validate the system warranty.
Figure 10-1 Warranty Registration Card
10.3 WARRANTY POLICY
10.3.1 In-Line Failures - OEM/Installer Repair
Refer to Warranty Policy, Procedures & LaborAllowance Manual (62-02737) for instructions on
returning, replacing or repairing any parts that were
defective at time of installation. Or call Carrier Transport
Air Conditioning Technical Support Hot-Line (800)
450-2211) for assistance. 
						

							T--311
11 - 1
SECTION 11
FINAL (CHECK-OUT SHEET)
INSTALLATION CHECK-OUT
The installation checkout procedure is an important step in the installation of any air conditioning system. The reason
for the installation checkout procedure is to insure that all Carrier Transport Air Conditioning standards of installation
quality have been met. An itemized checkout form will help you in the checkout process and will provide a device for
permanently recording your findings. The form that follows this introduction represents a guideline, that can be used as
is, or as a starting point for the development of your own custom installation checkout sheet. A correctly completed
final checkout will guarantee a quality installation that will last the life of the bus.
GENERAL INFORMATION
BUS MODEL/BODY_______________________BUS VIN#__________________________________
CARRIER TAC SYSTEM___________________EVAP’S_______COND’S_______COMP’S_______
ENGINE AREA:
YES NO
____ ____
Is compressor and compressor mount secure?
____ ____Were bolts torqued to proper specifications when noted on mount kit drawing?
____ ____Is there good alignment between the compressor, idler and crank pulley? Always use a
straight edge to determine alignment. Eye sighting is not good enough!
____ ____Were belts tightened per manufacturers recommendations?
____ ____Are refrigerant hoses routed through the engine compartment to the compressor
correctly? Refrigerant hose must be protected from heat sources and sharp objects!
Refrigerant hose should be supported with insulated clamps wherever possible.
____ ____Was mineral oilused to lubricate the fittings, hose and O Rings?
____ ____Was excess oil wiped from fittings and hose?
____ ____Is 12.5 Volts available at the compressor clutch?
____ ____Are the Quick-Click fittings clamped to the Quick-Click refrigerant hose correctly?
CONDENSER AREA:
YES NO
____ ____
Is the condenser(s) mounted securely to the bus floor?
____ ____ Is condenser(s) mounted as close as possible to bus skirt? If condenser cannot be
mounted close to the skirt, a shroud must be installed to prevent re-circulation of heat.
____ ____ Is bus skirt cut out to allow maximum airflow across the coil? Cut out must beat
least as large as the condenser coil to allow for maximum heat rejection.