installation module - carrier dealer · pdf file1 utc climate, controls & security...
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1 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th maI 2013
INSTALLATION MODULE
XARIOS RANGE
2 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th maI 2013
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
TABLE OF CONTENT
3 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th 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
6
7
GENERAL INSTALLATION RECOMMENDATION
5 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th maI 2013
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
BOX: HARNESS & HOSE
1
2
GENERAL INSTALLATION RECOMMENDATION
8 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 your
installation 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 connexion
2. Schrader valve for LP manifold
3. Not yet used, put a cap + Oring
GENERAL INSTALLATION RECOMMENDATION
10 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th 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.P L.P
Refrigerant load
bottle closed
Activated vacuum
pump
Opened valve
Closed valve
CHECKS & SETTINGS
14 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 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
Refrigerant charge R404a
17 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 & Security
PROPRIETARY
62-61661-00 Rev B 29th maI 2013
COMMISSIONING: CPR ADJUSTMENT
Example :
Adjust evaporator N° 1
whilstN° 2 is not functioning
Adjust evaporator N° 2
whilst 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
19 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th 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: SUPERHEAT
A 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 the
adjusting screw
Note for MT units do each compartment
individually
CHECKS & SETTINGS
20 UTC Climate, Controls & Security
PROPRIETARY
62-61661-00 Rev B 29th 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 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
Liquid receiver inlet
Draw in by delta p
Exp= 200ml
Additionnal
oil quantity
When using extension kit
Add 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