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

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Presentation on theme: "1 UTC Climate, Controls & Security PROPRIETARY 62-61661-00 Rev B 29th maI 2013 INSTALLATION MODULE XARIOS RANGE."— Presentation transcript:

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

2 2 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 2013 GENERAL INSTALLATION RECOMMENDATION CONDENSOR INSTALLATION3 CONDENSOR: PREPARATION4 REFRIGERATION HOSES PREPARATION5 HOSES: MOUNTING6 BOX: HARNESS & HOSE7 OIL RETURN FITTING9 COMPRESSOR INSTALLATION COMPRESSOR: PREPARATION10 COMPRESSOR: KLIXON INSTALLATION11 CHECKS & SETTINGS PRESSURE CHECK: MANIFOLD GAUGES LOCATION12 PRESSURE CHECK: MANIFOLD GAUGES CLEANING13 PRE-LEAK CHECKING 14 UNIT VACUUM 15 REFRIGERANT CHARGE16 COMMISSIONNING: CPR ADJUSTMENT17 COMMISSIONNING: SUPERHEAT19 COMMISSIONNING: OIL CHARGE20 TABLE OF CONTENT

3 3 UTC Climate, Controls & Security PROPRIETARY 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 4 UTC Climate, Controls & Security PROPRIETARY 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 GENERAL INSTALLATION RECOMMENDATION

5 5 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 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 GENERAL INSTALLATION RECOMMENDATION

6 6 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 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 GENERAL INSTALLATION RECOMMENDATION

7 7 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 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 GENERAL INSTALLATION RECOMMENDATION

8 8 UTC Climate, Controls & Security PROPRIETARY 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 9 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 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 Oil return recommended location (position 1) Use the 3 ways fitting corresponding to your installation instead of the usual LP connection fitting: : IDN : 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 10 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 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 11 UTC Climate, Controls & Security PROPRIETARY 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 12 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 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 CHECKS & SETTINGS

13 13 UTC Climate, Controls & Security PROPRIETARY 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 14 UTC Climate, Controls & Security PROPRIETARY 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 15 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 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 4 CHECKS & SETTINGS

16 16 UTC Climate, Controls & Security PROPRIETARY 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

17 17 UTC Climate, Controls & Security PROPRIETARY 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 18 UTC Climate, Controls & Security PROPRIETARY Rev B 29th maI 2013 COMMISSIONING: CPR ADJUSTMENT 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 19 UTC Climate, Controls & Security PROPRIETARY 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 20 UTC Climate, Controls & Security PROPRIETARY 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 CHECKS & SETTINGS


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