INSTALLATION MODULE

XARIOS RANGE

UTC Climate, Controls & Security 62-61661-00 Rev B

1 PROPRIETARY 29th maI 2013
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

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 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

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 GENERAL INSTALLATION RECOMMENDATION

CONDENSER: PREPARATION Condenser inlet and outlet

1
1. Oil separator inlet ( Road H.P
compressor)
2 5
2. Road compressor oil return
4
3. Liquid line

4. Hot gas line

3
5. Hot gas line N2 (only for MT unit)

6 6. Remove the blanks

7. Warning !
Dont forget to lubricate the ORS joints with
Carrier POE 68 oil and to put them in their
respective groove
7

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 GENERAL INSTALLATION RECOMMENDATION

REFRIGERATION HOSES PREPARATION

1. Connect the refrigeration hoses

1
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 :
2
Dont forget to mark the liquid line and the
hot gas line

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 GENERAL INSTALLATION RECOMMENDATION

HOSES: MOUNTING

1. Do not twist or curve the hoses.

1
2. Keep enough length for movement
when the pipes are under pressure.
OK
3. Pipes length can vary between -2% to
+4%.

4. Using elbows and fittings make the

installation easier and increase hose
NOT OK life.

5. Always insure that minimum radius are

5 respected. Provide a radius as large as
possible to avoid a restriction in the
hose.

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 GENERAL INSTALLATION RECOMMENDATION

BOX: HARNESS & HOSE

1 1. Anti thermal bridge method
By migration and fixing of the refrigeration lines,
please avoid when its 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
2 electrical harnesses, use trunking
Secure the lines with clamps (RSGU)
Secure the trunking with rivnuts, protect the
trunking termination with conduit

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 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

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 GENERAL INSTALLATION RECOMMENDATION

OIL RETURN FITTING

3 ways suction fitting 1. Warning !

After the installation of the service valve

1
connections, please fit service valve caps to avoid
any contamination.
3
The service valve connections have to be as near
as possible to the road compressor.
2
2. Road compressor refrigeration
Oil return recommended location (position 1) connections

Install the connections on the HP and LP

Use the 3 ways fitting corresponding to your compressor valves and oil return
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

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 COMPRESSOR INSTALLATION

COMPRESSOR: PREPARATION

Refrigeration oil is very hygroscopic !

1
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)
2 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.

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 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

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 CHECKS & SETTINGS

PRESSURE CHECK: MANIFOLD GAUGES LOCATION

1 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
Vacuum gauge
Connect vacuum gauge to the evaporator with
a manual valve

2. Installing Manifold Gauges on a multi-

temperature unit
2 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

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 CHECKS & SETTINGS

PRESSURE CHECK: MANIFOLD GAUGES CLEANING

Cleaning method for gauge hoses

To allow accurate reading and to reduce pollution in

the refrigeration circuit, its necessary to clean the
gauge hoses before commissioning:
Refrigerant bottle is closed
Opened valve Manifold gauge valves are closed except the
Closed valve refrigerant bottle and the vacuum pump which
are opened.
Start the vacuum pump, wait 2 to 3 seconds
and close the pump
L.P H.P The connections are cleaned and ready for the
commissioning
Activated vacuum Refrigerant load
pump bottle closed This operation cant 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.
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 CHECKS & SETTINGS

PRE-LEAK CHECKING Quick evacuation

Perform evacuation (duration 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

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 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

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 CHECKS & SETTINGS
Charging with refrigerant
REFRIGERANT CHARGE See attached chart for weight

Add refrigerant 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
Refrigerant charge R404a using a vacuum pump
Note the weight of refrigerant bottle. Be sure that he
XARIOS 150 1,2 kg unit is stopped during this operation
Open liquid valve on refrigerant bottle and allow the
XARIOS 200 1,4 kg liquid refrigerant to flow into the unit until the correct
XARIOS 300-07 1,4 kg weight of refrigerant has been added as indicated by
the weight scale.
XARIOS 300 RY 1,3 kg When refrigerant bottle weight (scale) indicates that
the correct charge has been added, close the
XARIOS 350 1,4 kg manifold valves.
XARIOS 350 MT 1,7 kg
NOTE : it is possible that all the liquid may, to be pulled
XARIOS 500 3 kg in: Complete the charge liquid vaporization through the
XARIOS 600 3,2 kg compressor (LP side).to the circuit

XARIOS 600 MT 3,6 kg UTC Climate, Controls & Security 62-61661-00 Rev B
16 PROPRIETARY 29th maI 2013
 CHECKS & SETTINGS

COMMISSIONING: CPR ADJUSTMENT Mono temperature unit setting

Fitting for manifold gauges
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

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 CHECKS & SETTINGS

COMMISSIONING: CPR ADJUSTMENT

Multi temperature unit setting

Example : To set CPR it is necessary to:

Adjust evaporator N 1 Compartment 1 ON & 2 OFF

whilstN 2 is not functioning

Connect a low pressure gauge on to the evaporator

N 1 N 2
ON OFF 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)
Adjust evaporator N 2
whilst N 1 is not functioning
Keep the pressure between 0,2 to 6 bar to adjust the
CPR to correct setting (see table)
N 1 N 2 Clockwise direction to increase the value
OFF ON
Anti clockwise direction to reduce the value

Repeat procedure for Compartment 2

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 CHECKS & SETTINGS

COMMISSIONING: SUPERHEAT Definition :

A correct superheat is:
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
Connect the low pressure gauge Increase compressor life time

Practice :
Connect the low pressure gauge to the
Access to the evaporator
adjusting screw
Place a thermocouple at the expansion valve
bulb
Start the unit to reduce the box temp to (0C or -
20C)
Check superheat setting
If this value is not correct, adjust the expansion
Bulb : valve
Place the thermocouple Tighten the screw to increase the
superheat value
Loosen the screw th reduce the superheat
value
S/H = Bulb T - Evaporating T Note for MT units do each compartment
(thermometer) (BP manometer)
Example : (thermo.) - 31C - (mano.) - 35C - = S/H 4C individually
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 CHECKS & SETTINGS

COMMISSIONING: OIL CHARGE

Unit Xarios 150 Xarios 200 Xarios 300 Xarios 350 Carrier compressors are delivered with 180ml of oil
Oil (ml) 280 300 300 300 and pressurized with nitrogen.
Unit Xarios 350 MT Xarios 500 Xarios 600 Xarios 600MT
Oil (ml) 350 600 600 680 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
Liquid receiver inlet options:

Draw in by delta p 1 - After vacuum process, using the vacuum pump on LP

Exp= 200ml 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.
For special evaporators configurations
Mandatory: Road mode not standby
Additionnal When using extension kit
oil quantity Add 20 ml/m of additionnal hose
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