SuperSnow KX-450K Installation Manual
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SuperSnow KX-450K Installation Manual

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Installation Manual
KX-450K
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  • Page 1 Installation Manual KX-450K 1 / 39...

  • Page 2: Table Of Contents

    Table of contents Installation Instruction 1、 .........................................3 Check fitting kit to make sure all parts and drawing are present 2、 ......................5 Preparation before condenser and evaporator installation 3、 ...........................6 Condenser installation ......................................10 Evaporator installation ......................................11 Hose and clamp installation 4、 ....................................12 Refrigeration line, defrost drain hoses and electrical cables installation 5、...

  • Page 3: 1、Installation Instruction

    1、Installation Instruction Protective Equipment ■ Always use adequate personal protective equipment before doing anything on this unit. ■Technicians must wear the proper PPE in right way, including full body harness with two hooks in the waist, safety cap, safety glasses and safety shoes. ■Disconnect the vehicle battery:--Remove the battery ground(-);Then disconnect the positive battery(+).
  • Page 4 1、 Installation Instruction Installation steps ■Technicians must wear the proper PPE in right way, including full body harness with two hooks in the waist, safety cap, safety glasses and safety shoes. ■ Check the grip brake of truck to ensure it being launched in safe.

  • Page 5: 2、Check Fitting Kit To Make Sure All Parts And Drawing Are Present

    2、Check fitting kit to make sure all parts and drawing are present Before installation Unpack the box contents in your warehouse. KEEP THE DOCUMENT DELIVERED WITH THE UNIT 2. Unpack the box Check the box content corresponds to the bill of material on the packaging.

  • Page 6: 3、Preparation Before Condenser And Evaporator Installation

    □ Take care not to obstruct the air intakes on the evaporator section and the ventilation ducts. □ For any mobile partition installation, contact our Technical Department or refer to the attached chart. Model KX-450K 1300mm 150mm 6 / 39...
  • Page 7 3、Preparation before condenser and evaporator installation Recommendations Before box preparation and unit installation start, protect the vehicle roof and the refrigeration box floor (cover, cardboard…). And there should be the embedded bracket inside the box. Evaporator installation 1.Present the drilling template – not supplied - (refer to the Condenser installation bodybuilder drawing).
  • Page 8 3、Preparation before condenser and evaporator installation KX-450K condenser installation drawing 8 / 39...
  • Page 9 3、Preparation before condenser and evaporator installation KX-450K evaporator installation drawing 9 / 39...

  • Page 10: Condenser Installation

    3.1 Condenser installation Condenser installation: 1.Remove the cover: ■ Remove the fixing nuts ■ Remove the cover 2.Fix the condenser in the middle of front wall panel, tie the nuts when make sure it won’t be inclined. 10 / 39...

  • Page 11: Evaporator Installation

    3.2 Evaporator installation Evaporator installation: 1.Remove the evaporator cover: ■ Remove the fixing screws ■ Remove the cover 2.Fix the evaporator in the middle of front wall panel, tie the nuts when make sure it won’t be inclined. 3.Tighten the screws. 11 / 39...

  • Page 12: 4、Hose And Clamp Installation

    4、Hose and clamp installation Hose: Stocking Recommendations ■ For a good functioning of refrigeration circuit, refrigeration hoses must be clean and dry. ■ Hoses must be stocked in a dry area, with less variation in temperature as possible and sheltered from moisture.
  • Page 13 4、Hose and clamp installation Hose: Preparation 1.Tools required. 2.Cut the hose at the right length with appropriate tool. 3.Remove the hose cover. 4.Put POE oil on the connector on fitting. 5.Widen hose clearance with adapted tool before to insert. double-click clamp. 6.Insert double-click clamp on the hose.
  • Page 14 4、Hose and clamp installation Hose: Preparation 1.Lubricate the fitting. 2.Insert connector in the hose. 3.Crimp the double-click clamp with appropriate crimping tool. 4.Example of a good preparation ■ The clamp gauge (arrow) is set between the hose and the fitting stop. The clamp bands are perpendicular with the fitting and hose.

  • Page 15: 5、Refrigeration Line, Defrost Drain Hoses And Electrical Cables Installation

    5、Refrigeration line, defrost drain hoses and electrical cables installation Hose: Mounting 1.Do not twist or curve the hose. 2.Keep enough length to avoid length variation when the pipes are under pressure. 3.Pipes length can vary between -2% to +4%. 4.Using elbows and fittings make easier installations, assist accessibility and increase hoses/pipes life.
  • Page 16 5、Refrigeration line, defrost drain hoses and electrical cables installation Unit: Condenser connection refrigeration hoses Recommendation Check O-ring if good, if not please replace with new one ■ Five ports in condenser, 2 connected to compressor, 3 connected to evaporator 1.Suction line-LP return gas (evaporator 2) 2.Road suction line-LP (compressor LP) 3.Road discharge line-HP (compressor HP) 4.Liquid line (evaporator 3)
  • Page 17 5、Refrigeration line, defrost drain hoses and electrical cables installation Unit: Evaporator connection refrigeration hoses 3 Pipes to condenser 1.Hot gas defrost 2.Suction(LP return gas) 3.Liquid Recommendation ■ Marks shall be made on the hot gas pipe line (at both ends of the pipe) to avoid confusion with the liquid pipe ■...
  • Page 18 5、Refrigeration line, defrost drain hoses and electrical cables installation 1.Connect the condenser, evaporator, compressor and Unit: refrigeration hoses stand-by compressor to the corresponding ports as the drawing. 2.The pipeline can’t be twined, use the strapping tape to fix it tightly. 3.Use hose clamps to fix the pipes on the front wall to avoid shaking.
  • Page 19 5、Refrigeration line, defrost drain hoses and electrical cables installation Unit: battery cable connection 1. Run the cab cable and hoses through the box. 2. Connect motors of evaporator. 3. Maintain all cables with plastic tie-wraps. 19 / 39...
  • Page 20 5、Refrigeration line, defrost drain hoses and electrical cables installation Evaporator: drain water pipe RECOMMENDATIONS A descent of MINIMUM 100mm must be applied between the drain water hoses and the hoses inside the body to help to drain water out. 1. Install drain hoses. 2.

  • Page 21: 6、Charge Compressor Oil

    2.If there is no cover or the no nitrogen pressure protection, must use brand new POE oil instead of the oil come together with compressor. Model KX-450K □ Charging Refrigerant R404A □ Choose one way to charge the excess oil into system:...

  • Page 22: 7、 Mount Compressormounting Kit & Compressor(Optional)

    7、Mount compressor mounting kit & compressor(optional) MANDATORY BEFORE ANY ELECTRICAL Compressor: connection OPERATION: ■ DISCONNECT THE VEHICLE BATTERY: Remove the battery ground (-), the positive battery (+) and lock-out. Compressor is separate from evaporator and condenser, need connect it use a hose 1.Move along hoses and battery harness to the compressor and vehicle battery.
  • Page 23 7、Mount compressor mounting kit & compressor(optional) Compressor: connection Compressor is separate from evaporator and condenser, connect to the vehicle engine with belt, connect the evaporator and condenser with hose 1.Connect the EXHAUST HOSE. 2.Connect the SUCTION PRESSURE HOSE. 23 / 39...
  • Page 24 7、Mount compressor mounting kit & compressor(optional) Compressor: connection RECOMMENDATIONS ■ Make sure right thermo switch to good connection with the exhaust pipe, and wrap it well with insulated materials. 1.Fix the thermo switch on the compressor exhaust pipe with clamp 2.Wrap with insulated material and fix with tie-wraps 24 / 39...
  • Page 25 7、Mount compressor mounting kit & compressor(optional) Compressor: connection Fix all hoses and harness with plastic tie-wraps. 2.Ensure the suction pipe go smooth to prevent oil bay. 25 / 39...

  • Page 26: 8、Check Leak And Evacuate System

    8、Check leak and evacuate system Leak checking □ Requirements ■ 1 Vacuum pump ■ 1 Manifold gauges (4 connections) ■ 1 Vacuumeter □ Check gas leak 1.Install manifold gauges on the compressor side. 2.Connect the vacuum pump to the manifold gauges. 3.Start the vacuum pump and vacuum for 15 min: to remove the air in the circuit.
  • Page 27 8、Check leak and evacuate system Unit vacuum □ System vacuum Remove the nitrogen. Start the vacuum pump. Apply "Triple evacuation" process (refer to refrigeration training module) Stop the vacuum pump. Check if vacuum is complete with vacuumeter. (refer to refrigeration training module) 27 / 39...

  • Page 28: 9、Check And Charge Refrigerant

    5.Open liquid valve on refrigerant cylinder and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by weight scale. KX-450K Model 6.When refrigerant cylinder weight (scale) indicates that the R404A 1.8kg...

  • Page 29: 10、 Install Cab Control And Connect Electricals

    10、Install cab control and connect electrical Driver cab: preparation RECOMMENDATIONS ■ Before drilling the floor, check the location of fuel tank, harness and/or tubes. 1.Drill a hole in the cab floor (behind driver or passenger seat – depends on battery location). RECOMMENDATIONS ■...
  • Page 30 10、Install cab control and connect electrical Cab ignition connection NOTE: For cab IGNITION KEY harness fitting, refer to the vehicle mounting kit instructions. Connect the ignition switch line to the vehicle □ dashboard □ Connect the white wires to fuse(1A) Refer to the corresponding mounting kit instruction to □...
  • Page 31 10、Install cab control and connect electrical Cab command: harness fitting Fit the cab command (in specified location) □ RECOMMENDATIONS ■ 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.
  • Page 32 10、Install cab control and connect electrical Battery: connection 1.Clean the terminals firstly before main circuit connecting 2、Connect the main circuit as First picture 3、Paint grease on the terminals to prevent corrosion Note: Second picture is wrong(the wires installation is not stable) □...
  • Page 33 10、Install cab control and connect electrical Battery: connection 1.Install right fuse in the fuse holder 2.Install protection cap on the fuse 3.Connect (+) to one end of the fuse holder 4.The shorter battery(50cm) wire connected to one end of fuse, the other to (+) 5.Connect the units (-) wire to battery(-) Remark:All wires must be pressed tightly 33 / 39...

  • Page 34: 11、 Check And Adjust Cpr(Only Suitable For Unit With R404A)

    11、Check and adjust CPR(only suitable for unit with CPR) Commissioning: CPR adjust □ The CPR (Compressor Regulation) valve is a device designed to regulate the flow of refrigerant returning to the compressor from the evaporator, this ensures correct capacity for the unit. □...
  • Page 35 ■ counter clockwise. When the setting has been adjusted, tighten the jam nut securely against the setting screw to prevent any CPR adjust KX-450K movement of the setting screw due to vibrations in the R404A 2.2bar unit. Replace the cap.

  • Page 36: 12、Check And Adjust Expansion Valve Superheat

    ■ Turn anti-clockwise to increase flow & decrease superheat ■ Turn clockwise to decrease flow and increase superheat. KX-450K 8°C at box temp. 0°C (14.4°F at box T° : 32°F) 4°C at box temp. -20°C (7.2°F at box T° : -4°F) 36 / 39...
  • Page 37 13、Pipe connect drawing a.Evaporator b.Condenser c.Controller d.compressor e.Pipes & hareness 37 / 39...

  • Page 38: 13、 Installation Overview

    14、Installation overview 38 / 39...
  • Page 39 Zhengzhou Kaixue Cold Chain Co., Ltd. Address: Zhongmu Auto Industry Park, Zhengzhou 451450, Henan, China. Tel.:0371-56701069 Fax.:0371-60862175 Website: www.supersnowcold.com 39 / 39...

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