INSTALLATION MODULE XARIOS RANGE 1
TABLE OF CONTENT GENERAL INSTALLATION RECOMMENDATION CONDENSOR INSTALLATION 3 CONDENSOR: PREPARATION 4 REFRIGERATION HOSES PREPARATION 5 HOSES: MOUNTING 6 BOX: HARNESS & HOSE 7 OIL RETURN FITTING 9 COMPRESSOR INSTALLATION COMPRESSOR: PREPARATION 10 COMPRESSOR: KLIXON INSTALLATION 11 CHECKS & SETTINGS PRESSURE CHECK: MANIFOLD GAUGES LOCATION 12 PRESSURE CHECK: MANIFOLD GAUGES CLEANING 13 PRE-LEAK CHECKING 14 UNIT VACUUM 15 REFRIGERANT CHARGE 16 COMMISSIONNING: CPR ADJUSTMENT 17 COMMISSIONNING: SUPERHEAT 19 COMMISSIONNING: OIL CHARGE 20 2
GENERAL INSTALLATION RECOMMENDATION CONDENSOR INSTALLATION 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 3
GENERAL INSTALLATION RECOMMENDATION CONDENSER: PREPARATION 1 2 5 4 3 6 7 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 4
GENERAL INSTALLATION RECOMMENDATION REFRIGERATION HOSES PREPARATION 1 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 2. Important : Don t forget to mark the liquid line and the hot gas line 5
GENERAL INSTALLATION RECOMMENDATION HOSES: MOUNTING 1 OK NOT OK 5 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. 6
GENERAL INSTALLATION RECOMMENDATION BOX: HARNESS & HOSE 1 2 1. Anti thermal bridge method By 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 7
GENERAL INSTALLATION RECOMMENDATION BOX: HARNESS & HOSE 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 8
GENERAL INSTALLATION RECOMMENDATION OIL RETURN FITTING 3 ways suction fitting 1 2 Oil return recommended location (position 1) Use the 3 ways fitting corresponding to your installation instead of the usual LP connection fitting: 40-60291-50 : IDN 16.1 40-60291-60 : IDN 12.7 3 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 There are 3 ways on this fitting: 1. Oil return connexion 2. Schrader valve for LP manifold 3. Not yet used, put a cap + Oring 9
COMPRESSOR INSTALLATION COMPRESSOR: PREPARATION 1 2 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. 10
COMPRESSOR INSTALLATION COMPRESSOR: KLIXON INSTALLATION 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 11
CHECKS & SETTINGS PRESSURE CHECK: MANIFOLD GAUGES LOCATION 1 2 Vacuum gauge 1. Installing Manifold Gauges on a monotemperature 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 multitemperature 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 12
CHECKS & SETTINGS PRESSURE CHECK: MANIFOLD GAUGES CLEANING Cleaning method for gauge hoses L.P H.P Opened valve Closed valve 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 Activated vacuum pump Refrigerant load bottle closed 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. 13
CHECKS & SETTINGS PRE-LEAK CHECKING 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 14
CHECKS & SETTINGS UNIT VACUUM 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 4 15
CHECKS & SETTINGS REFRIGERANT CHARGE Charging with refrigerant See attached chart for weight Add refrigerant to correct level Refrigerant charge R404a XARIOS 150 1,2 kg XARIOS 200 1,4 kg XARIOS 300-07 1,4 kg XARIOS 300 RY 1,3 kg XARIOS 350 1,4 kg XARIOS 350 MT 1,7 kg XARIOS 500 3 kg XARIOS 600 3,2 kg XARIOS 600 MT 3,6 kg 16 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 COMMISSIONING: CPR ADJUSTMENT Fitting for manifold gauges Mono temperature unit setting To set CPR it is necessary to: : Pressures: 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 Max test pressure = 25 bar Operating pressure range: 0.2 to 6 bar 17
CHECKS & SETTINGS COMMISSIONING: CPR ADJUSTMENT Multi temperature unit setting Example : Adjust evaporator N 1 whilstn 2 is not functioning To set CPR it is necessary to: Compartment 1 «ON» & 2 «OFF» N 1 ON N 2 OFF Connect a low pressure gauge on to the evaporator Start the unit in «Heat» and Road» mode Adjust evaporator N 2 whilst N 1 is not functioning N 1 OFF N 2 ON 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 18
CHECKS & SETTINGS COMMISSIONING: SUPERHEAT A correct superheat is: Connect the low pressure gauge Access to the adjusting screw Bulb : Place the «thermocouple» S/H = Bulb T - Evaporating T (thermometer) (BP manometer) Example : (thermo.) - 31 C - (mano.) - 35 C - = S/H 4 C 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 Practice : Optimise the unit performance Increase compressor «life time» 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 Note for MT units do each compartment individually 19
CHECKS & SETTINGS COMMISSIONING: OIL CHARGE 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 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: Liquid receiver inlet Draw in by delta p Additionnal oil quantity Exp= 200ml For special evaporators configurations When using extension kit Add 20 ml/m of additionnal hose 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 600ml 2 - 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 20