1 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
INSTALLATION MODULE
XARIOS RANGE
2 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
GENERAL INSTALLATION RECOMMENDATION
CONDENSOR INSTALLATION 3CONDENSOR: PREPARATION 4REFRIGERATION HOSES PREPARATION 5HOSES: MOUNTING 6BOX: HARNESS & HOSE 7OIL RETURN FITTING 9
COMPRESSOR INSTALLATION
COMPRESSOR: PREPARATION 10COMPRESSOR: KLIXON INSTALLATION 11
CHECKS & SETTINGS
PRESSURE CHECK: MANIFOLD GAUGES LOCATION 12PRESSURE CHECK: MANIFOLD GAUGES CLEANING 13PRE-LEAK CHECKING 14UNIT VACUUM 15REFRIGERANT CHARGE 16COMMISSIONNING: CPR ADJUSTMENT 17COMMISSIONNING: SUPERHEAT 19COMMISSIONNING: OIL CHARGE 20
TABLE OF CONTENT
3 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
The installation of the deflector on the vehicle cab should not interfere with the functioning of the refrigeration equipment
The deflector must not be installed within a radius of less than 250 mm to 300mm from the unit
The length between the box and the spoiler must be at least 480 mm for a Xarios 150 to 515 mm for a Xarios 600
The installation of the deflector must not hinder accessibility to to the refrigeration unit for mainenance visits
Access to the power and control boxes must comply with standard safety conditions
CONDENSOR INSTALLATION
GENERAL INSTALLATION RECOMMENDATION
4 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
Condenser inlet and outlet
1. Oil separator inlet (« Road » H.P compressor)
2. « Road » compressor oil return
3. Liquid line
4. Hot gas line
5. Hot gas line N°2 (only for MT° unit)
6. Remove the blanks
7. Warning ! Don’t forget to lubricate the ORS joints with
Carrier POE 68 oil and to put them in their respective groove
CONDENSER: PREPARATION1
2
3
4
5
6
7
GENERAL INSTALLATION RECOMMENDATION
5 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
1. Connect the refrigeration hoses Low and high pressure lines
Liquid line Hot gas line
Pass the electrical harnesses and the hoses inside or outside of the body. (Chose one option depending on the vehicle configuration)
2. Important :
Don’t forget to mark the liquid line and the hot gas line
REFRIGERATION HOSES PREPARATION
1
2
GENERAL INSTALLATION RECOMMENDATION
6 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
1. Do not twist or curve the hoses.
2. Keep enough length for movement when the pipes are under pressure.
3. Pipes length can vary between -2% to +4%.
4. Using elbows and fittings make the installation easier and increase hose life.
5. Always insure that minimum radius are respected. Provide a radius as large as possible to avoid a restriction in the hose.
HOSES: MOUNTING
OK
NOT OK
1
5
GENERAL INSTALLATION RECOMMENDATION
7 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
1. Anti thermal bridge methodBy migration and fixing of the refrigeration lines, please avoid when it’s possible the contact between both H.P and L.P lines (to reduce heat transfer phenomenom)
2. Fixing and protecting the lines and harnesses from the inside and the outside of the partition
To protect the refrigeration lines and the electrical harnesses, use trunking
Secure the lines with clamps (RSGU) Secure the trunking with rivnuts, protect the
trunking termination with conduit
BOX: HARNESS & HOSE
1
2
GENERAL INSTALLATION RECOMMENDATION
8 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
Pipes under the vehicle :
Refrigeration lines have to be : Fixed at regular intervals with rubber clamps Kept away as far as possible from each
other to prevent heat transfer
Kept away from any heat source
Protected by grommets (Insulation) were they pass through the vehicle bodywork
BOX: HARNESS & HOSE
GENERAL INSTALLATION RECOMMENDATION
9 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
1. Warning !
After the installation of the service valve connections, please fit service valve caps to avoid any contamination.
The service valve connections have to be as near as possible to the road compressor.
2. Road compressor refrigeration connections
Install the connections on the HP and LP compressor valves and oil return
OIL RETURN FITTING3 ways suction fitting
1
2
3
Oil return recommended location (position 1)
Use the 3 ways fitting corresponding to yourinstallation instead of the usual LP connection fitting:
•40-60291-50 : IDN 16.1•40-60291-60 : IDN 12.7
There are 3 ways on this fitting:1. Oil return connexion2. Schrader valve for LP manifold3. Not yet used, put a cap + Oring
GENERAL INSTALLATION RECOMMENDATION
10 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
1
2
COMPRESSOR: PREPARATION
COMPRESSOR INSTALLATION
Refrigeration oil is very hygroscopic !
The compressor is under a nitrogen pressure
• Before the compressor mounting, make sure that the compressor has an adhesive label fitted, proof that it is charged with Carrier oil type (no oil change to do)
• Never leave a compressor crankcase opened
If one of these two points is not respected, it is imperative to do a compressor oil change and to restore the right level (see the table ) with Carrier POE 68 oil from a brand new tank.
11 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
Liquid injection thermostat :
Thread the clutch wire and injection thermostat wires with the hoses
Secure with tie-wraps
Install the injection thermostat on the HP compressor connection and secure.
Take the cables, cut to length, crimp to the clutch and injection thermostat wires
Finish and protect the edges
Add the thermal insulation on the injection thermostat
COMPRESSOR: KLIXON INSTALLATION
COMPRESSOR INSTALLATION
12 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
1. Installing Manifold Gauges on a mono-temperature unit
Connect the manifold gauges and vacuum pump on to the road compressor
Connect the manifold gauges and vacuum pump on to the standby compressor
Connect vacuum gauge to the evaporator with a manual valve
2. Installing Manifold Gauges on a multi-temperature unit
Connect the manifold gauges and vacuum pump on to the road compressor
Connect the manifold gauges and vacuum pump on to the standby compressor
Connect the manifold gauges and vacuum pump to the furthest evaporator from the unit
Connect vacuum gauge to the evaporator with a manual valve
PRESSURE CHECK: MANIFOLD GAUGES LOCATION
Vacuum gauge
2
1
CHECKS & SETTINGS
13 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
Cleaning method for gauge hoses
To allow accurate reading and to reduce pollution in the refrigeration circuit, it’s necessary to clean the gauge hoses before commissioning:
Refrigerant bottle is closed Manifold gauge valves are closed except the
refrigerant bottle and the vacuum pump which are opened.
Start the vacuum pump, wait 2 to 3 seconds and close the pump
The connections are cleaned and ready for the commissioning
This operation can’t be done on 3 way service gauges
Warning !
The evacuation has to be done with a vacuum pump (see page 15) and not by purging with the refigerant bottle.
PRESSURE CHECK: MANIFOLD GAUGES CLEANING
H.PL.P
Refrigerant loadbottle closed
Activated vacuumpump
Opened valveClosed valve
CHECKS & SETTINGS
14 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
Quick evacuation Perform evacuation (duration ½ hour)
Nitrogen check Put nitrogen into system (15 bars)
Leak check out procedure Leak check unit with soapy water
around all connections Check that no soap bubbles get
created. This means the refrigeration circuit is tight
PRE-LEAK CHECKING
CHECKS & SETTINGS
15 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
1. Remove nitrogen from unit before connecting the vacuum pump
2. Check oil in vacuum pump and replace if necessary
3. Switch on the vacuum pump
4. Vacuum unit down to 500 microns
UNIT VACUUM
4
CHECKS & SETTINGS
16 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
Charging with refrigerant See attached chart for weight
Add refrigerant to correct level
REFRIGERANT CHARGE
Unit charge must be done monitoring the weight of the refrigerant bottle : Install the manifold gauges on “free Schrader” fitting
located inside the condenser on the high pressure line.
Place refrigerant bottle on scale and connect charging line from bottle to manifold
Purge charging line for inlet manifold and fittings using a vacuum pump
Note the weight of refrigerant bottle. Be sure that he unit is stopped during this operation
Open liquid valve on refrigerant bottle and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by the weight scale.
When refrigerant bottle weight (scale) indicates that the correct charge has been added, close the manifold valves.
NOTE : it is possible that all the liquid may, to be pulled in: Complete the charge liquid vaporization through the compressor (LP side).to the circuit
CHECKS & SETTINGS
XARIOS 150 1,2 kgXARIOS 200 1,4 kgXARIOS 300-07 1,4 kgXARIOS 300 RY 1,3 kgXARIOS 350 1,4 kgXARIOS 350 MT 1,7 kgXARIOS 500 3 kgXARIOS 600 3,2 kgXARIOS 600 MT 3,6 kg
Refrigerant charge R404a
17 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
Mono temperature unit setting
To set CPR it is necessary to: :
Connect a low pressure gauge on to the evaporator
Start the unit in « Heat » and Road » mode
Keep the « road » compressor rotation speed at 2400 tr/mn (ratio engine/compressor defined in the CMK instructions)
Keep the pressure between 0,2 to 6 bar to adjust the CPR to correct setting (see table)
Clockwise direction to increase the value
Anti clockwise direction to reduce the value
Pressures:
Max test pressure = 25 bar
Operating pressure range: 0.2 to 6 bar
COMMISSIONING: CPR ADJUSTMENT
Fitting for manifold gauges
CHECKS & SETTINGS
18 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
COMMISSIONING: CPR ADJUSTMENT
Example :
Adjust evaporator N° 1whilstN° 2 is not functioning
Adjust evaporator N° 2whilst N° 1 is not functioning
N° 1
N° 1
N° 2
N° 2ON OFF
OFF ON
Multi temperature unit setting
To set CPR it is necessary to:
Compartment 1 « ON » & 2 « OFF »
Connect a low pressure gauge on to the evaporator
Start the unit in « Heat » and Road » mode
Keep the « road » compressor rotation speed at 2400 tr/mn (ratio engine/compressor defined in the mounting instructions)
Keep the pressure between 0,2 to 6 bar to adjust the CPR to correct setting (see table) Clockwise direction to increase the value Anti clockwise direction to reduce the value
Repeat procedure for Compartment 2
CHECKS & SETTINGS
19 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
Definition :
The superheat is a T° difference between:The T° indicated on the expansion valve bulb and the evaporating temperature
It is imperative to set correctly the superheat to Optimise the unit performance Increase compressor « life time »
Practice : Connect the low pressure gauge to the
evaporator Place a « thermocouple »at the expansion valve
bulb Start the unit to reduce the box temp to (0°C or -
20°C) Check superheat setting If this value is not correct, adjust the expansion
valve Tighten the screw to increase the
superheat value Loosen the screw th reduce the superheat
value
COMMISSIONING: SUPERHEATA correct superheat is:
S/H = Bulb T° - Evaporating T° (thermometer) (BP manometer)Example : (thermo.) - 31°C - (mano.) - 35°C - = S/H 4°C
Bulb :Place the « thermocouple »
Connect the low pressure gauge
Access to theadjusting screw
Note for MT units do each compartmentindividually
CHECKS & SETTINGS
20 UTC Climate, Controls & SecurityPROPRIETARY
62-61661-00 Rev B29th maI 2013
COMMISSIONING: OIL CHARGE
Carrier compressors are delivered with 180ml of oil and pressurized with nitrogen.
Oil charge must be completed (see table), with the oil delivered with the unit.Those oil quantities include the 180ml of oil already inside the road compressor.
Example: Xarios 600MT = 680 ml. The compressor is provided with 180ml
=> add 500ml in the circuit.
Adjustment:
Fill the extra oil in the unit using one of the following 2 options: 1 - After vacuum process, using the vacuum pump on LP side. Oil will be drawn in by differential pressure through the liquid receiver for oil quantity up to 600ml2 - Into the oil separator (200 ml max).
At commissioning let the unit run 10 min at idle speed to allow a good lubrication. Mandatory: Road mode not standby
Liquid receiver inlet
Draw in by delta p
Exp= 200ml
Additionnal oil quantity
When using extension kitAdd 20 ml/m of additionnal hose
For special evaporators configurations
Unit Xarios 150 Xarios 200 Xarios 300 Xarios 350 Oil (ml) 280 300 300 300
Unit Xarios 350 MT Xarios 500 Xarios 600 Xarios 600MTOil (ml) 350 600 600 680
CHECKS & SETTINGS