1 UTC Climate, Controls & Security PROPRIETARY 62-61661-00 Rev B 29th maI 2013 INSTALLATION MODULE XARIOS RANGE

1 UTC Climate, Controls & SecurityPROPRIETARY

62-61661-00 Rev B29th maI 2013

INSTALLATION MODULE

XARIOS RANGE


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


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



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: PREPARATION

1

2

3

4

5

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77



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

11

22



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

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55



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

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22



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



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 FITTING

3 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



62-61661-00 Rev B29th maI 2013

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22

COMPRESSOR: PREPARATION


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.


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



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

22

11

CHECKS & SETTINGS


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 valve

Closed valve

CHECKS & SETTINGS


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


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

44

CHECKS & SETTINGS


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


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


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° 2

ON 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


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


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 600MT

Oil (ml) 350 600 600 680

CHECKS & SETTINGS

Documents

1 UTC Climate, Controls & Security PROPRIETARY 62-61661-00 Rev B 29th maI 2013 INSTALLATION MODULE XARIOS RANGE