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Operation & Service Manual

Carrier Transicold Europe

31/03/07

Viento - Installation/Rev- #22/54

1. Remove the two side panels.

2. Using the adapted tool, put the evaporator facing the fixing

holes previously drilled.

3. Check the minimum distance between the rear of the

evaporator and the box is correct (refer to the chart p6)

4. Tighten the screws.

Installation Evaporator

installation

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Summary of Contents for 300

Page 1: ...Operation Service Manual Carrier Transicold Europe 31 03 07 Viento Installation Rev 1 54 INSTALLATION ...

Page 2: ...oof top and cut mounting 8 Nosemount 11 Evaporator 12 Harness and hoses hole 14 Drain water hose hole 15 Mushrooms 16 Preparation 16 Set up 18 Unit installation 19 Evaporator installation 22 Hoses 23 Mounting recommendations 24 Preparation 25 Unit connection 27 Refrigeration hoses 29 Evaporator connection 33 Refrigeration hoses 33 RAT sensor 35 Drain pan 36 INSTALLATION Table of content ...

Page 3: ...stallation Rev 3 54 Driver cab preparation 37 Cab command harness fitting 38 Compressor connection 40 Injection thermostat 42 Commissioning 47 Leak checking 47 Unit vacuum 48 Refrigerant charge 49 Settings 51 CPR adjustment 51 TXV setting 53 INSTALLATION Table of content ...

Page 4: ...ATTERY First remove the battery ground then remove the positive battery PERSONAL PROTECTIVE EQUIPMENT Always use adequate personal protective equipment before doing anything on this refrigerant unit BODYBUILDER RECOMMENDATIONS Drain hose from the evaporator to the outside must have an angle to insure water to be drained out A descent of 10 cm minimum must be applied between evaporator drain water ...

Page 5: ...THE DOCUMENT DELIVERED WITH THE UNIT 2 Unpack the box 3 Check if the box content corresponds to the bill of material on the packaging Condenser Evaporator Mounting kit Cab command In the event of any abnormality missing damaged part or part number etc fill in the form Advance Warning DOA Claim Installation Preparation before installation ...

Page 6: ... evaporator section and the ventilation ducts For any mobile partition installation contact our Technical Department or refer to the following chart MODELS Evaporator X Y MXS 600 Viento 200 MXS 850 MXS 850 Viento 300 MXL 850 500 mm MXS 1100 Viento 350 MXL 1100 1000 mm 150 mm Installation Preparation before installation Vehicle partition ...

Page 7: ...ation Rev 7 54 RECOMMENDATIONS Before box preparation and unit installation commences protect the vehicle roof and the refrigeration box floor cover cardboard There are 3 possibilities to fit the unit Roof top Nosemount Roof cut mounting Installation Box preparation Drilling ...

Page 8: ...rilling template not supplied refer to the bodybuilder drawing 2 Mark out the 4 fixing holes and the electrical harness and hoses hole 3 Drill the fixing holes drill 10 mm 4 For roof top mounting drill a hole 80 mm to pass hoses and harnesses Installation Box preparation Drilling Roof top and cut mounting ...

Page 9: ...pe 31 03 07 Viento Installation Rev 9 54 5 Install the 4 silent blocks put silicone to waterproof on the bottom put silicone to waterproof on the 4 screws before to install the host unit Installation Box preparation Drilling Roof top and cut mounting ...

Page 10: ...6 To pass harnesses and hoses between condenser and evaporator drill the electrical harness and hoses hole Roof cut mounting on vertical face of the vehicle Roof top mounting on the roof of the body refer to bodybuilder drawing Installation Box preparation Drilling Roof top and cut mounting ...

Page 11: ...on Rev 11 54 1 Present the drilling template not supplied refer to the bodybuilder drawing 2 Mark out fixing and electrical harness and hoses holes 3 Drill the fixing holes drill 10 mm 4 Drill the electrical harness and hoses hole Installation Box preparation Drilling Nosemount ...

Page 12: ...pace of 15 cm between the box wall and the rear of the evaporator 1 Mark the fixing holes for the evaporator refer to the bodybuilder drawing If needed use the fixing material adapted to reinforcement done by the bodybuilder If you don t have reinforcement you will have to use mushrooms refer to section Mushrooms page 16 Installation Box preparation Drilling Evaporator ...

Page 13: ... Service Manual Carrier Transicold Europe 31 03 07 Viento Installation Rev 13 54 If body reinforced install the insert using the adapted tool manual or pneumatic Installation Box preparation Drilling Evaporator ...

Page 14: ...tion Service Manual Carrier Transicold Europe 31 03 07 Viento Installation Rev 14 54 2 Drill the electrical harness and hoses hole inside the box Installation Box preparation Drilling Harness and hoses hole ...

Page 15: ... not prepared to pass harnesses refrigerant and water drain hoses drill the hose inside body RECOMMENDATIONS A descent of MINIMUM 10 cm must be applied between the drain water hoses pipe and the hoses inside the body to help to drain water out Installation Box preparation Drilling Drain water hose hole ...

Page 16: ...140mm 2 Countersink with a drill 12 5 mm the 4 tapping drill holes realized at the previous step RECOMMENDATIONS Take care not to damage the 5 mm drilling of the box external skin 3 From box outside countersink with a circular slitting saw 22 mm RECOMMENDATIONS Take care not to damage the 12 5 mm drilling of the box internal skin Installation Box preparation Mushrooms Preparation ...

Page 17: ...om length L to the roof thickness minus the internal skin thickness E E L mushroom length E roof thickness E internal skin thickness Mushroom in place 1 mushroom 2 silicon gasket 3 skin of external box 4 polyurethane foam 5 skin of internal box 6 evaporator upper side 7 washer 8 screw M12 Installation Box preparation Mushrooms Preparation ...

Page 18: ...on the internal side of the mushroom head 2 Put mushrooms in holes previously realized in box roof 3 With a mallet slightly crush the silicon gasket 4 Follow silent block installation Take care to clean silent block surface for a better sticking water proof ness Installation Box preparation Mushrooms Set up ...

Page 19: ...Operation Service Manual Carrier Transicold Europe 31 03 07 Viento Installation Rev 19 54 1 Remove the grill remove the 4 fixing screws remove the grill Installation Unit installation ...

Page 20: ...3 07 Viento Installation Rev 20 54 2 Remove the top cover remove the 3 rear fixing screws push the cover and remove it RECOMMENDATIONS Do not try to un tight the 2 front screws of top cover They are part of the caplocks system Installation Unit installation ...

Page 21: ...nt installation Use the 4 fixing holes at the rear of the frame refer to Box preparation Drilling Nosemount page11 5 Using the lifting device P N 07 60110 00 put the unit in place on the 4 silent blocks 6 Roof top and roof cut mounting installation Fix the unit with the 4 silent blocks and bolts delivered in the packaging 7 Nosemount installation Fix the unit with the 4 bolts Installation Unit ins...

Page 22: ...2 54 1 Remove the two side panels 2 Using the adapted tool put the evaporator facing the fixing holes previously drilled 3 Check the minimum distance between the rear of the evaporator and the box is correct refer to the chart p6 4 Tighten the screws Installation Evaporator installation ...

Page 23: ...ess variation in temperature as possible and sheltered from moisture The two ends MUST ABSOLUTELY been blocked with tight caps to avoid any internal damages or condensation until their connection into the circuit To fit hoses and electrical harnesses use as much as possible RSGU clamps To protect hoses and electrical harnesses use adequate rubber funnels to avoid cutting with metallic corners Inst...

Page 24: ...n the pipes are under pressure Pipes length can vary between 2 to 4 Using elbows and fittings make easier installations assist accessibility and increase hoses pipes life Always insure that minimum radius is respected Provide a radius as big as possible to avoid constriction Minimum curve radius Module 6 80 mm Module 8 95 mm Module 10 110 mm Module 12 130 mm Installation Unit hoses Mounting recomm...

Page 25: ...on Rev 25 54 Tools requested 1 Cut the hose at the right length with appropriate tool 2 Put POE oil on the connector on fitting 3 Widen hose clearance with adapted tool before to insert double clic clamp 4 Insert double clic clamp on the hose Installation Unit hoses Preparation ...

Page 26: ...cold Europe 31 03 07 Viento Installation Rev 26 54 5 Lubricate the fitting 6 Don t forget to remove the hose cap 7 Insert connector in the hose 8 Crimp the double click clamp with appropriate crimping tool Installation Unit hoses Preparation ...

Page 27: ...Operation Service Manual Carrier Transicold Europe 31 03 07 Viento Installation Rev 27 54 1 Run the electrical harnesses and ignition cable inside the vehicle body Installation Unit connection ...

Page 28: ...he vehicle body 3 Run the drain water hose inside the vehicle body RECOMMENDATIONS Always mark off the hot gas line both sides of the hose in order to avoid the confusion with the liquid line hose Remove caps from the hoses JUST before connecting in order to avoid too much moisture in the circuit Installation Unit connection ...

Page 29: ...tallation Rev 29 54 RECOMMENDATIONS Always check that O ring is still in place If O ring is missing put a new one in place 4 hoses have to be connected on the unit Oil return line High pressure line Liquid line Hot gas line Installation Unit connection Refrigeration hoses ...

Page 30: ...ope 31 03 07 Viento Installation Rev 30 54 4 Connect the OIL RETURN HOSE to the oil separator lower fitting to the compressor 5 Connect the HIGH PRESSURE LINE to the oil separator upper fitting to the Installation Unit connection Refrigeration hoses ...

Page 31: ...T GAS LINE hose easily 7 Connect the HOT GAS LINE fitting to the Hot Gas valve 8 Re install the Hot Gas valve solenoid 9 Connect the LIQUID LINE HOSE to the filter drier RECOMMENDATIONS 45 fitting recommended if lateral outlet needed GENERALY use the appropriate fitting depending on the installation Installation Unit connection Refrigeration hoses ...

Page 32: ...Operation Service Manual Carrier Transicold Europe 31 03 07 Viento Installation Rev 32 54 10 Attach regularly all hoses harnesses with plastic tie wraps Installation Unit connection Refrigeration hoses ...

Page 33: ...id line hose from the expansion valve through the heat exchanger 8 module 6 to the host unit Hot gas line from the defrost element inlet 8 module 6 to the host unit 1 Run hoses and harness through the hole Suction line Liquid line Hot gas line Fan motor wires RAT cable Injection valve if so equipped 2 Prepare hoses as described in section Unit hoses Preparation p25 Installation Evaporator connecti...

Page 34: ...12 to outlet of the CPR valve 4 Install fitting and connect the HOT GAS LINE hose with red label 8 module 6 to the drain pan serpentin inlet 5 Install fitting and connect the LIQUID LINE 8 module 6 to the Thermostatic Expansion Valve inlet through the heat exchanger 6 Attach all hoses with plastic tie wraps Installation Evaporator connection Refrigeration hoses ...

Page 35: ...arrier Transicold Europe 31 03 07 Viento Installation Rev 35 54 7 With the 6 clamp install the RAT sensor 8 Connect together evaporator fan connectors 9 Put the bottom skin in place Installation Evaporator connection RAT sensor ...

Page 36: ...e applied between the drain water hoses pipe and the hoses inside the body to help to drain water out 11 Connect the drain water hoses between drain water pipes and evaporator water tubes 12 Fix tie wrap sockets to maintain drain tubes in the right position 13 Insulate the two holes with silicone 14 Instal the two evaporator sides Installation Evaporator connection Drain pan ...

Page 37: ...b floor behind driver or passenger seat depends on battery location RECOMMENDATIONS Protect the hole ex armoured hose to avoid harness damage 2 Run water drain hose through the floor 3 Run battery cable through the floor 4 Run the cab command and ignition cable to the dashboard 5 Install a capping not supplied to cover the hoses and harness 6 Insulate the water drain hose Installation Driver cab p...

Page 38: ...icle mounting kit instructions 1 Route the cab command harness to the vehicle dashboard RECOMMENDATIONS Protect or move the harness away from metallic corners of the chassis Avoid connecting the harness to or in contact with heating source Avoid connecting the harness to parts that may cause vibrations Installation Cab command harness fitting ...

Page 39: ...TIONS Take care not to pierce any harness or hoses within the dashboard If the cab command is built into the dashboard fit it as far as possible from the heating ducts Maximum temperature of exposure 70 C 158 F The cab command MUST NOT be located behind the screen T too high and obstruction of windscreen Installation Cab command harness fitting ...

Page 40: ...vehicle battery 2 Attach regularly the harness with plastic tie wraps and base tie wraps onto the chassis 3 Insulate the hole with silicon RECOMMENDATIONS Protect or move the harness away from metallic corners of the chassis Avoid connecting the harness to or in contact with heating source Avoid connecting the harness to parts that may cause vibrations Do not secure the unit harness to the vehicle...

Page 41: ...rier Transicold Europe 31 03 07 Viento Installation Rev 41 54 4 Connect the HIGH PRESSURE HOSE 5 Connect the SUCTION PRESSURE HOSE 6 Connect the OIL RETURN HOSE if available under the compressor Installation Compressor connection ...

Page 42: ... High pressure line fitting with the clamp RECOMMENDATIONS Take care to place correctly the thermostat in order to have a good contact with the fitting 8 Fit injection thermostat wires and compressor clutch wires in a retractable sleeve 9 Insert terminals in the injection thermostat Installation Compressor connection Injection thermostat ...

Page 43: ...ervice Manual Carrier Transicold Europe 31 03 07 Viento Installation Rev 43 54 10 Protect the wires with sleeve 11 Maintain all cables with plastic tie wraps Installation Compressor connection Injection thermostat ...

Page 44: ... the mounting kit 1A 3 Refer to the corresponding mounting kit instruction to connect the 12Vdc ignition live 4 Cut the battery harness to the required length 5 Strip the battery 35mm2 red and the fuse holder for the microprocessor positive 6 Using a crimping tool install the 125A fuse supplied with the mounting kit NOTE Soft solder is recommended Installation Battery ignition key harness fitting ...

Page 45: ...to insulate the connector 8 Strip the battery ground 35mm2 black crimp the terminal with the adapted crimping tool NOTE Soft solder is recommended 9 Install the 80 amps fuse holder as closed as possible from the 12 Vdc battery 10 Put grease on the fuse holder connections Installation Battery ignition key harness fitting ...

Page 46: ...1 03 07 Viento Installation Rev 46 54 11 Install the 80 amps fuse in the fuse holder 12 Install protection cap on the fuse 13 Connect unit ground to the vehicle chassis 14 Re connect the ground of the vehicle battery Installation Battery harness fitting ...

Page 47: ... the compressor side 2 Connect the vacuum pump to the manifold gauges 3 Start the vacuum pump and vacuum for 15 mn to remove the air in the circuit 4 After 15mn stop the vacuum pump 5 Connect the nitrogen to the manifold gauges 6 Put 15 bar 219 psi in the circuit 7 Use bubbles water on all refrigeration fittings 8 No bubbles formation means that the circuit is tight Installation Commissioning Leak...

Page 48: ...4 To vacuum the circuit 1 Remove the nitrogen 2 Start the vacuum pump 3 Apply Triple evacuation process refer to refrigeration training module 4 Stop the vacuum pump 5 Check if vacuum is complete with vacuumeter refer to refrigeration training module Installation Commissioning Unit vacuum ...

Page 49: ...e the condenser on the high pressure line 2 Place refrigerant cylinder on scale and connect charging line from cylinder to manifold 3 Purge charging line at inlet manifold 4 Note the weight of refrigerant cylinder Be sure that the unit is stopped during this operation 5 Open liquid valve on refrigerant cylinder and allow the liquid refrigerant to flow into the unit until the correct weight of refr...

Page 50: ...cale indicates that the correct charge has been added close the manifold valves Refrigerant charge Viento 200 0 85 Kg 5 Viento 300 1 Kg 5 Viento 350 1 1 Kg 5 NOTE It is possible that all liquid may not be pulled into the circuit Complete the charge in vapour through the compressor Installation Commissioning Refrigerant charge ...

Page 51: ...he compressor from the evaporator this ensures correct capacity for the unit The Compressor Regulation valve also reduces the load on the compressor during start up whilst in operation which is why it is important it is correctly set up on commissioning Adjustment has to be done Road operation Heat or defrost mode Compressor speed at 2400 rpm Installation Commissioning Settings CPR adjustment ...

Page 52: ...ction pressure turn the setting screw clockwise To lower the suction pressure turn the setting screw counterclockwise CPR adjustment R134a R404A Viento 200 3 bar 2 7 bar Viento 300 2 2 bar LA 1 85 bar HA 1 25 bar Viento 350 2 8 bar LA 3 4 bar HA 1 8 bar 6 When the setting has been adjusted tighten the jam nut securely against the setting screw to prevent any movement of the setting screw due to vi...

Page 53: ...oration of the refrigerant in the evaporator The Thermo Expansion valve can control the refrigerant gas leaving the evaporator at a pre determined superheat The superheat is the temperature difference between T1 Temperature measured at remote bulb location and P2 Evaporation temperature of the last liquid drop T1 Temperature at remote bulb location P2 Evaporator outlet pressure S Superheat Install...

Page 54: ...n valve bulb location 3 Run the unit on COOLING mode 4 Correct superheat Turn anti clockwise to increase flow decrease superheat Turn clockwise to decrease flow and increase superheat TXV adjustment Viento 200 Viento 300 Viento 350 8 C at box temperature 0 C 14 4 F at box T 32 F 4 C at box temperature 20 C 7 2 F at box T 4 F Installation Commissioning Settings TXV setting ...

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