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INSTALLATION MODULE

INSTALLATION MODULE. XARIOS RANGE. 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

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INSTALLATION MODULE

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  1. INSTALLATION MODULE XARIOS RANGE

  2. 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

  3. 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

  4. GENERAL INSTALLATION RECOMMENDATION CONDENSER: PREPARATION 1 Condenser inlet and outlet • Oil separator inlet (« Road » H.P compressor) • « Road » compressor oil return • Liquid line • Hot gas line • Hot gas line N°2 (only for MT° unit) • Remove the blanks • Warning ! • Don’t forget to lubricate the ORS joints with Carrier POE 68 oil and to put them in their respective groove 2 5 4 3 6 7

  5. GENERAL INSTALLATION RECOMMENDATION REFRIGERATION HOSES PREPARATION 1 • Connect the refrigerationhoses • Low and high pressure lines • Liquid line • Hot gas line • Pass the electricalharnesses and the hosesinside or outside of the body. (Chose one option depending on the vehicle configuration) • Important : • Don’tforget to mark the liquid line and the hot gas line 2

  6. GENERAL INSTALLATION RECOMMENDATION HOSES: MOUNTING 1 • Do not twist or curve the hoses. • Keep enough length for movement when the pipes are under pressure. • Pipes length can vary between -2% to +4%. • Using elbows and fittings make the installation easier and increase hose life. • Always insure that minimum radius are respected. Provide a radius as large as possible to avoid a restriction in the hose. OK NOT OK 5

  7. GENERAL INSTALLATION RECOMMENDATION BOX: HARNESS & HOSE 1 • Anti thermal bridge method By migration and fixing of the refrigerationlines, pleaseavoidwhenit’s possible the contact betweenboth H.P and L.P lines (to reduceheattransferphenomenom) 2. Fixing and protecting the lines and harnessesfrom the inside and the outside of the partition • To protect the refrigerationlines and the electricalharnesses, use trunking • Secure the lineswith clamps (RSGU) • Secure the trunkingwithrivnuts, protect the trunkingterminationwith conduit 2

  8. 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

  9. GENERAL INSTALLATION RECOMMENDATION OIL RETURN FITTING 3 ways suction fitting • 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. • Road compressor refrigeration connections • Install the connections on the HP and LP compressor valves and oil return 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: • Oil return connexion • Schrader valve for LP manifold • Not yet used, put a cap + Oring

  10. COMPRESSOR INSTALLATION COMPRESSOR: PREPARATION • Refrigerationoilisveryhygroscopic ! • The compressorisunder a nitrogen pressure • Beforethe compressormounting, make sure thatthe compressor has an adhesive label fitted, proof thatitischargedwith Carrier oil type (no oil change to do) • Never leave a compressorcrankcaseopened If one of thesetwo points is not respected, itisimperative to do a compressoroil change and to restore the right level (see the table ) with Carrier POE 68 oilfrom a brand new tank. 1 2

  11. 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

  12. CHECKS & SETTINGS PRESSURE CHECK: MANIFOLD GAUGES LOCATION 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 • 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 Vacuum gauge 2

  13. CHECKS & SETTINGS PRESSURE CHECK: MANIFOLD GAUGES CLEANING Cleaningmethod for gauge hoses To allowaccuratereading and to reduce pollution in the refrigeration circuit, it’snecessary to clean the gauge hosesbeforecommissioning: • Refrigerantbottleisclosed • Manifold gauge valves are closedexcept the refrigerantbottle and the vacuum pumpwhich 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 operationcan’tbedone on 3 way service gauges Warning ! The evacuation has to bedonewith a vacuum pump (see page 15) and not by purgingwith the refigerantbottle. Opened valve Closed valve L.P H.P Activated vacuum pump Refrigerant load bottle closed

  14. 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

  15. CHECKS & SETTINGS UNIT VACUUM • Remove nitrogen from unit before connecting the vacuum pump • Check oil in vacuum pump and replace if necessary • Switch on the vacuum pump • Vacuum unit down to 500 microns 4

  16. CHECKS & SETTINGS REFRIGERANT CHARGE Chargingwithrefrigerant • Seeattachedchart for weight Addrefrigerant to correct level 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

  17. CHECKS & SETTINGS COMMISSIONING: CPR ADJUSTMENT Fitting for manifold gauges Mono temperature unit setting To set CPR itisnecessary to: : • Connect a low pressure gauge on to the evaporator • Start the unit in « Heat » and Road » mode • Keep the « road » compressor rotation speed at2400 tr/mn (ratio engine/compressordefined in the CMK instructions) • Keep the pressure between 0,2 to 6 bar to adjustthe 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

  18. CHECKS & SETTINGS COMMISSIONING: CPR ADJUSTMENT Example : Adjust evaporatorN° 1 whilstN° 2is not functioning Adjust evaporator N° 2 whilst N° 1 is not functioning Multi temperature unit setting To set CPR itisnecessary 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 at2400 tr/mn (ratio engine/compressordefined in the mountinginstructions) • 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 N° 1 N° 2 OFF ON N° 1 N° 2 OFF ON

  19. CHECKS & SETTINGS COMMISSIONING: SUPERHEAT A correct superheat is: Definition : The superheatis a T° differencebetween: The T° indicated on the expansion valve bulb and the evaporatingtemperature It isimperative to set correctly the superheat to • Optimise the unit performance • Increasecompressor « 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 Connect the low pressure gauge Access to the adjusting screw Bulb : Place the « thermocouple » Note for MT units do each compartment individually S/H = Bulb T° - Evaporating T° (thermometer) (BP manometer) Example : (thermo.) - 31°C - (mano.) - 35°C - = S/H 4°C

  20. CHECKS & SETTINGS 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 pressurethrough 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

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