SuperSnow KX-600K Installation Manual
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SuperSnow KX-600K Installation Manual

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Installation Manual
KX-600K
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Summary of Contents for SuperSnow KX-600K

  • Page 1 Installation Manual KX-600K 1 / 48...

  • Page 2: Table Of Contents

    Table of contents 1、 Installation Instruction.................................3 2、Check fitting kit to make sure all parts and drawing are present..................5 3、Preparation before condenser and evaporator installation....................6 ..............................9 Condenser installation ..............................14 Evaporator installation 3.2.1 Drilling.................................15 3.2. Fix evaporator................................17 4、Hose and clamp installation.............................18 5、Refrigeration line, defrost drain hoses and electrical cables installation.................21 6、Charge compressor oil..............................29 7、Mount compressormounting kit &...
  • Page 3 10、Install cab control and connect electricals........................37 11、Check and adjust CPR(only suitable for unit with R404A)...................42 12、Check and adjust expansion valve superheat.........................44 13、Installation overview..............................46 3 / 48...

  • Page 4: 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 5 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 6: 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 7: 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 Model Technical Department or refer to the attached chart. KX-600K 1500mm 150mm 7 / 48...
  • Page 8 The left figure shows the holes location for condenser and evaporator installation, A is the distance from the hole to the outside of front body, B is the distance from the hole to the outside of top body. Model KX-600K 350~540mm 140~260mm 8 / 48...
  • Page 9 3、Preparation before condenser and evaporator installation Box: preparation 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. RECOMMENDATIONS Install condenser on the top of the cab, and in front of the box. Install evaporator on the top of the box.
  • Page 10 3、Preparation before condenser and evaporator installation KX-600K condenser installation drawing 10 / 48...
  • Page 11 3、Preparation before condenser and evaporator installation KX-600K evaporator installation drawing 11 / 48...

  • Page 12: Condenser Installation

    3.1、Condenser installation Box：drilling-nosemount 1. Unpack condenser, route harness, remove the two side panels and covers. 2. Adjust solenoid valve in the vertical tube direction to facilitate installation. 12 / 48...
  • Page 13 3.1、Condenser installation Box：drilling-nosemount Insure holes location of the box, make the top of condenser as the same height as box as possible, allow enough space for lifting cab and not contact with condenser. 13 / 48...
  • Page 14 3.1、Condenser installation Box：drilling-nosemount 1. Condenser mounting dimensions are as shown. 2. Condenser fixing holes is Ø 15 mm, and note that gaskets are used both in and out of the box. 3. Reserve location of hole Ø 90 mm for hoses and harness, as figure 2 shown.
  • Page 15 3.1 Condenser installation Box: drilling 1. Drilling holes inside the box, which can be used to connect wires, refrigerant hoses, drain hoses. 2. Drain hoses can use the above holes to the outside of the RECOMMENDATIONS  A descent of MINIMUM 10 cm must be applied between the drain water hoses and the hoses inside the body to help to drain water out.
  • Page 16 3.1 Condenser installation Box: drilling-nosemount 1. Lift condenser, fix it on the front of the box by the location of holes. 2. Tighten the screws with nuts, install the skins, and complete installation. 16 / 48...

  • Page 17: Evaporator Installation

    3.2、Evaporator installation Box: drilling-evaporator installation 1. Unpack the evaporator; remove the cover on both sides of the evaporator. 2. Find the installing holes on the rear of the evaporator. 17 / 48...

  • Page 18: Drilling

    5. If needed, use the fixing material adapted to reinforcement done by the bodybuilder. ■ Reinforcement must be used, if any other requirements, please contact Kaixue(SuperSnow) agency. NOTE  Let a minimum space of 150 mm between the box wall and the rear of the evaporator.
  • Page 19 3.2.1、Drilling Box: drilling-evaporator installation  If body reinforced, install the insert using the adapted tool (manual or pneumatic) 19 / 48...

  • Page 20: Fix Evaporator

    3.2.2、Fix evaporator Box: drilling-evaporator installation 1. Using the adapted tool, put the evaporator fixed to the holes previously drilled. 2. Check the minimum distance between the rear of the evaporator and the box. 3. Install evaporator side plates. NOTE：When installed, a shield should be installed in the fan blade side in the inlet, to avoid the harm 20 / 48...

  • Page 21: 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 22 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 23 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 24: 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 25 5、Refrigeration line, defrost drain hoses and electrical cables installation Unit: refrigeration hoses connection 1. Run refrigeration hoses inside the vehicle body. 2. Run the drain water hoses inside the vehicle body. RECOMMENDATIONS  Always mark the hot gas line (both sides of the hose) in order to avoid the confusion with the liquid line hose.
  • Page 26 5、Refrigeration line, defrost drain hoses and electrical cables installation RECOMMENDATIONS Unit: Condenser connection refrigeration hoses  Always check O-ring is still in place. If O-ring is missing, put a new one in place. Condenser has 5 outlets, 2 outlets to compressor, 3 outlets to evaporator, connection is as shown: 1.
  • Page 27 5、Refrigeration line, defrost drain hoses and electrical cables installation Unit: Evaporator connection refrigeration hoses RECOMMENDATIONS ■ Always check O-ring is still in place. If O-ring is missing, put a new one in place. 3 lines to condenser: 1. Hot gas defrost line 2.
  • Page 28 5、Refrigeration line, defrost drain hoses and electrical cables installation Unit: refrigeration hoses 1. Refer to the above connection, connect condenser, evaporator and compressor accordingly. 2. Clamp all hoses properly. 28 / 48...
  • Page 29 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. 29 / 48...
  • Page 30 5、Refrigeration line, defrost drain hoses and electrical cables installation Evaporator: drain water hoses 1. Install drain hoses. RECOMMENDATIONS  A descent of MINIMUM 10 cm must be applied between the drain water hoses and the hoses inside the body to help to drain water out. 2.

  • Page 31: 6、Charge Compressor Oil

    □ Charging □ Choose one way to charge the excess oil into system: 1.Suck the oil into low pressure side during vacuum Unit model KX-600K 2.Charge the high pressure pipe before the oil Road compressor model QP16 Refrigerant...

  • Page 32: 7、Mount Compressormounting Kit & Compressor(Optional)

    7、Mount compressor mounting kit & compressor(optional) Compressor: connection MANDATORY BEFORE ANY ELECTRICAL 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 33 7、Mount compressor mounting kit & compressor(optional) Compressor: connection The compressor is away from evaporator and condenser, installed in the side of vehicle engine, connected with engine by belts, and connected with evaporator, condenser by hoses. 1. Connect the DISCHARGE HOSE. 2.
  • Page 34 7、Mount compressor mounting kit & compressor(optional) Compressor: connection RECOMMENDATIONS ■ Carefully place correctly the thermostat in order to have a good contact with the exhaust pipe, and wrap the thermostat with insulation materials. 1 Install injection thermostat on the compressor High pressure line with the clamp.
  • Page 35 7、Mount compressor mounting kit & compressor(optional) Compressor: connection 1. Maintain all hoses and wires with plastic tie-wraps. 2. Route the suction and discharge hoses smoothly to avoid oil storage. 35 / 48...

  • Page 36: 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 37 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) 37 / 48...

  • Page 38: 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. Model KX-600K 6.When refrigerant cylinder weight (scale) indicates that the R404A 2.8kg...

  • Page 39: 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 40 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 41 10、Install cab control and connect electrical Cab ignition connection □ 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 42 10、Install cab control and connect electrical Battery: connection 1、Clean the battery terminals before installation. 2、Connect the harness as figure 1 shown. 3、After installation, brush butter on terminals to prevent rust. NOTES：Figure 2 shows the incorrect connection, this situation must be avoided. ...
  • Page 43 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 unit ground (-) to the vehicle chassis. Re-connect the ground (-) of the vehicle battery. Remark:All wires must be pressed tightly 43 / 48...

  • Page 44: 11、Check And Adjust Cpr(Only Suitable For Unit With R404A)

    11、Check and adjust CPR(only suitable for unit with CPR) Commissioning: adjusting CPR □ 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 45 ■ counter clockwise. When the setting has been adjusted, tighten the jam nut securely against the setting screw to prevent any CPR Adjust KX-600K movement of the setting screw due to vibrations in the R404A 2.2bar unit. Replace the cap.

  • Page 46: 12、Check And Adjust Expansion Valve Superheat

    ■ Turn anti-clockwise to increase flow & decrease superheat ■ Turn clockwise to decrease flow and increase superheat. KX-600K 8°C at box temp. 0°C (14.4°F at box T° : 32°F) adjustment 4°C at box temp. -20°C (7.2°F at box T° : -4°F)

  • Page 47: 13、Installation Overview

    13、Installation overview a.Evaporator b.Condenser c.Controller d.compressor e.Pipes & hareness 47 / 48...
  • Page 48 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 48 / 48...

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