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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
800 - 3500 r/min
( 2200 - 8000 r/min )
355
445 80 100
V
250mm
100A 150A CN328&268/AC112
6 7
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