INSTALLATION MODULE - dms.hvacpartners.com · Liquid injection thermostat : Thread the clutch wire and injection thermostat wires with the hoses Secure with tie-wraps Install the

1 UTC Climate, Controls & Security

PROPRIETARY

62-61661-00 Rev F 26th July 2017

INSTALLATION MODULE

XARIOS RANGE


PROPRIETARY

62-61661-00 Rev F 26th July 2017

GENERAL INSTALLATION RECOMMENDATION

INSTRUCTIONS FOR REFRIGERANT SELECTION 3

CONDENSOR INSTALLATION 6

CONDENSOR: PREPARATION 7

REFRIGERATION HOSES PREPARATION 8

HOSES: MOUNTING 9

BOX: HARNESS & HOSE 10

OIL RETURN FITTING 12

COMPRESSOR INSTALLATION

COMPRESSOR: PREPARATION 13

COMPRESSOR: KLIXON INSTALLATION 14

CHECKS & SETTINGS

PRESSURE CHECK: MANIFOLD GAUGES LOCATION 15

PRESSURE CHECK: MANIFOLD GAUGES CLEANING 16

PRE-LEAK CHECKING 17

UNIT VACUUM 18

REFRIGERANT CHARGE 19

COMMISSIONNING: CPR ADJUSTMENT 20

COMMISSIONNING: SUPERHEAT 22

COMMISSIONNING: OIL CHARGE 23

TABLE OF CONTENT


PROPRIETARY

62-61661-00 Rev F 26th July 2017


IMPORTANT NOTICE FOR ADMINISTRATIVE DOCUMENTS

For units to be used with R-452A refrigerant

Manufacturing certificates are not provided with the unit. They are only accessible online from

our dedicated eDocuments portal.

https://edocuments.carriertransicold.eu/

For units to be used with R-404A refrigerant

Manufacturing certificates will no longer be supplied in paper format from October 1st

onwards. They will be accessible online from our dedicated eDocuments portal - opening on

June 19th, 2017.


Your Carrier Transicold representative is at your disposal for further information on this new

service.

INSTRUCTIONS FOR REFRIGERANT SELECTION







PROPRIETARY

62-61661-00 Rev F 26th July 2017



Fig.1 safety decal

Do not charge system with a mixture of

R-404A refrigerant and R-452A refrigerant.

In order to be compliant with ATP rules, it is

recommended to check with your local ATP

authorities if any procedures exist to declare

refrigerant type.

Below instructions are to be followed for

following products: Xarios 150 / 200 / 300 /

350 / 500 / 600 / 500MT / 600MT

Depending on the refrigerant to be used for your

mounting, place the appropriate decal as per below

recommendations.

1. On the "safety decal" (fig.1), either place the R-

404A decal or place the R-452A refrigerant

decal on the dedicated location as per beside

drawings.

2. On each evaporator, either place the R-404A

decal or place the R-452A refrigerant decal close

to TXV depending on the refrigerant to be used

1.

2.

62-60063-03

62-60063-04

or

Place

Place

62-60063-00

62-60063-02

or

Place

Place


PROPRIETARY

62-61661-00 Rev F 26th July 2017


3. On the host unit, depending on the refrigerant to

be used, either place the "R-404A GWP" decal

or place the "R-452A GWP" decal the closest

possible to the nameplate as per instruction

beside.

62-70001-01

62-70001-00

or

Xarios 150 / 200

Xarios 300 / 350

Xarios 500 / 600

Nameplate localisation



3.

Fig.2 GWP decals


If the unit is to be installed with R-452A, you

must erase from the nameplate the reference

to R-404A

Make sure to identify in Catena which

refrigerant type is added


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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



PROPRIETARY

62-61661-00 Rev F 26th July 2017

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



PROPRIETARY

62-61661-00 Rev F 26th July 2017

1. Connect the refrigeration hoses

Low and high pressure lines

Liquid line

1a. Integra 35X: reverse outlet of receiver

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


1a


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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



PROPRIETARY

62-61661-00 Rev F 26th July 2017

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



PROPRIETARY

62-61661-00 Rev F 26th July 2017

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



PROPRIETARY

62-61661-00 Rev F 26th July 2017

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



PROPRIETARY

62-61661-00 Rev F 26th July 2017

1

2

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, compressor oil should be change and the right level of oil should be refilled (see the table ) with Carrier POE 68 oil from a brand new tank.


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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



PROPRIETARY

62-61661-00 Rev F 26th July 2017

1. Installing Manifold Gauges on a mono-

temperature unit

Connect the manifold gauges and vacuum

pump on to the road compressor


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


pump on to the road compressor


pump on to the standby compressor


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


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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

NOTE :

Refer to the Material Safety

Data Sheet (MSDS) of the

refrigerant supplier or

Carrier CTE Partners

https://carriertransicold.force.co

m/ctepartners


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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

INTEGRA 35X 2.1 b


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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


PROPRIETARY

62-61661-00 Rev F 26th July 2017

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/6,08.Oz of oil

already inside the road compressor.

Example: Xarios 600MT = 680 ml/22,99Oz. The

compressor is provided with 180ml/6,08.Oz

=> add 500ml/16,9.Oz 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 /6,76.Oz 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

6,76.Oz

CHECKS & SETTINGS

Unit Xarios

150

Xarios 200

Integra 20X

Xarios 300

Xarios 350 Z30s Integra 35X

Oil 280ml

9,46.Oz

300ml

10,14.Oz

300ml

10,14.Oz

350ml

11,83.Oz

260ml

8,79.Oz

Unit Xarios

350MT

Xarios 500

Integra 50X Xarios 500

Xarios

600Mt

Oil 350ml

11,83.Oz

600ml

20,28.Oz

600ml

20,28.Oz

680ml

22,99.Oz

For special evaporators configurations

Additional Oil quantity

When using extension kit Add 20ml/0,676.Oz/m of additional hose