Carrier NEOS 100S Guide

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
1
INSTALLATION AND
COMMISSIONING MANUAL
for
Neos 100S
Integra 20X, 30S, 35X, 40X,
50X
Direct Drive Refrigeration Units
Truck Refrigeration
62-11165 Rev D
© 2017 Carrier Corporation • Printed in U. S. A. 0217

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
2
Safety Precautions
Electrical Power
Beware of HIGH VOLTAGE supplied by the main power as
the unit may start automatically.
Before working on any unit, make sure that the main
Run/Stop switch is in STOP position and the negative
battery terminal is disconnected.
Fan Blades
All refrigeration units are equipped with Automatic Start/Stop
and may start at any time without warning. Beware all fan
blade, belts, and other moving parts.
Vehicle Battery
Vehicles are equipped with a lead-acid type battery. The
battery normally vents small amounts of flammable
hydrogen gas. Keep any flame, lighted object, or source of
spark away. A battery explosion can cause serious physical
harm and/or blindness

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
3
Safety Precautions
Electrical Connection
DISCONNECT the battery ground (-) on the vehicle battery.
Engine Coolant
All engines have a pressurized coolant system. Under
normal operating conditions, the coolant in the engine and
radiator is under high pressure and very hot. Do not remove
the cap from a hot radiator. If the cap has to be removed, do
so very slowly in order to release pressure without spray.
Refrigerants
The refrigerant contained in the refrigeration system of the
units can cause frostbite, severe burns, or blindness when in
direct contact with the skin or eyes.
Personal Protective Equipment
Always use personal protective equipment while doing
anything on this refrigeration unit.

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
4
Evaporator Clearances
Do not obstruct the evaporator fan
inlet(s) or outlet
For any movable bulkheads, there
must be a MINIMUM distance “A”
between the evaporator outlet and
any obstruction.
When mounting X Series
evaporators, it is recommended to
leave a MINIMUM distance “B” for
installation and service access.
MODEL “A” Minimum Distance
Inches (millimeters) “B” Minimum Distance Inches (millimeters)
NEOS 100S, 20X
30S
35X,40X, 50X
20.0” (500)
32.0” (800)
40.0” (1,000)
6.0” (150)
Not Applicable
6.0” (150)
A
B

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
5
Condenser Installation – Roof Top Application
30S 28.35” (720)
4 x Ø 0.56”
(4 x Ø 15)
12.20”
(310)
Note: For 30S, use the black marking on the
bottom cover of the unit as a template for drilling
the large refrigerant and electrical pass-thru hole.
Roof Top Applications
Mark and drill the four condenser
mounting holes, as well as the
larger refrigerant and electrical
pass-thru hole, as indicated
above (depending on unit model)
21.65” (550)
14.57” (370)
8.86”
(225)
4 x Ø 0.56”
(4 x Ø 15)
Ø 3.50”
(Ø 90)
3.54”
(90)
1.25” to 9.25”
(30 to 235)
NEOS 100S
20X
35X

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
6
Condenser Installation – Roof Top Application
Install the four condenser mounting pads
by first applying waterproof silicone caulk
to the bottom cups in each pad.
Apply waterproof silicone caulk to each of the
four condenser mounting screws to prevent
water entry around the screw.
Remove the condenser cover. On the bottom cover of the
unit, drill the four 0.56” (15mm) mounting holes and the
larger electrical/hose hole as per the diagram on page 5.
Mount the condenser on the mounting pads in fasten in
place using the hardware supplied in the kit.
Apply waterproof silicone caulk to both sides of the center pad, which is used for
hoses and wiring, and install the center pad.

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
7
Condenser Installation – Front Mount Application
NEOS 100S, 20X
24.41” (620)
5.12”
(130)
2.36”
(60)
2.36” (60)
Ø 3.50”
(Ø 90)
4 x Ø 0.56”
(4 x Ø 15) Ø 4.0”
(Ø 100) 4 x Ø 0.56” (4 x Ø 15)
33.66” (855)
12.75”
(324)
4.33”
(110) 2.17” (55)
Front Mount Applications: Mark and drill the four condenser mounting holes, as well as the
larger refrigerant and electrical pass-thru hole, as indicated above (depending on unit model)
Bolt the condensing unit in place using the hardware supplied in the mounting kit.
30S
40X
50X
44.1” (1,120)
12.6”
(320)
4 x Ø 0.63”
(4 x Ø 16)
Ø 4.0”
(Ø 100)
1.18”
(30)
21.26”
(540)
22.05” (560)
5.31” (135)
6” MIN to
cab roof
35X

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
8
Evaporator Mounting Preparation
35X
40X
18.5”
(470)
33.66”
(855)
17.72”
(450)
30.71”
(780)
17.72”
(450)
40.55” (1,030)
Remove evaporator access panels. If the box has mounting studs, fasten the evaporator using supplied
hardware; otherwise, mark the mounting holes as indicated above (depending on unit model). Leave a
minimum of 6” (150mm) between the box wall and the rear of the evaporator.
50X
21.85”
(555)
58.27” (1,480) 29.13” (740)
53.54” (1,360) 26.77” (680)
20X
30S
15.95”
(405)
20.86”
(530)
Neos
100S

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
9
Evaporator Mounting Preparation – Mushroom Drilling
From the inside of the box, drill 4 holes completely through
the roof of the vehicle using a 7/32” (5mm) drill bit.
From the inside of the box, step drill only through the inside
skin of the vehicle using a ½” (12.5mm) drill bit.
From the outside of the box, use a 7/8” (22mm) hole saw to
drill the outer roof of the box and the insulating foam.
Make certain NOT to drill all the way through
the roof. The ½” (12.5mm) hole in the inside
skin of the vehicle must remain intact.
0.50” (12.5)

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
10
Evaporator Mounting Preparation – Mushroom Installation
Measure the roof depth from the outside of the roof to the inside
of the inner box skin (distance “L”).
L
L
Measure mushrooms from the bottom of the head
to end of the mushroom. Mark and cut them to the
same length “L”. Apply waterproof silicone caulk to
the underside of the mushroom head and tap into
the vehicle roof to slightly crush the caulk. Bolt the
evaporator in place using the hardware supplied.
1 23
4
5
6
7 8
The correct bolting arrangement is show with the mushrooms
and evaporator in place. Note that the evaporator should not
press directly against the mushrooms due to the step drilling.
1) Mushroom (34-01262-00)
2) Silicone caulk
3) Vehicle roof
4) Box insulation
5) Inner box skin
6) Evaporator housing
7) Washer
8) Mounting screw

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
11
Evaporator Mounting – Drain Line Installation
4.0” (100)
Install the evaporator drain lines.
A MINIMUM drop of 4.0” (100mm) is
recommended between the drain pan outlet
and where the drain lines exit the vehicle.
Note the difference in drain line recommendations
for perishable versus frozen applications
For perishable applications, connect the water drain hoses
together and route outside the vehicle. Note the diagram
showing recommended ways of routing the lines.
For frozen applications, do NOT tee drain lines together. It is
important for each line to directly exit the vehicle in as short a
distance as possible to prevent condensate from freezing.
Make certain there are no low spots that can
trap water in any of the drain line routings.
Secure drain lines in place using ty-wraps or clamps.

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
12
Refrigerant Hose Installation – Handling Recommendations
For proper functioning of the refrigeration unit,
the hoses must be kept clean and dry
It is recommended to leave the caps installed on
the ends of the hoses while routing them to
prevent internal damage or moisture entry.
Make sure to use the clamps provided in the installation kit to
secure the hoses and keep them from vibrating or rubbing.
Use the rubber grommets provided in the installation kit when
passing through holes and bulkheads to prevent the hoses and
electrical wires from rubbing on any sharp edges.
As shown in the diagram, do not twist, curve or
route the hoses in any manner which will stress
the hose. Use as large a bend radius as possible.
Use elbows and fitting as necessary to ease
installation and increase hose life.
When securing hoses, note the hoses will slightly change length
under pressure. When securing and clamping the hoses, make
sure to account for the slight variations in length that will occur.
Minimum Bend Radius
#6 hose (3/8”) 3.5” (90mm)
#8 hose (1/2”) 4.0” (100mm)
#10 hose (5/8”) 4.5” (115mm)
#12 hose (3/4”) 5.25” (135mm)

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
13
Refrigerant Hose Installation – Installation Preparation
Always use the required tools as follows:
Hose Cutting / Crimping Kit: 07-60117-00
Fitting Insertion Tool: 07-60177-00
Cut the hose to the required length using
the Carrier hose cutting tool.
Lubricate the inside of the hose end with
POE oil.
Widen the internal hose clearance using
the expanding tool before sliding the
double zinc clamp over the hose.

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
14
Lubricate the fitting and O-ring with POE oil.
Insert the connector into the hose.
To avoid damaging to the O-ring, do NOT twist
the fitting during or after insertion into the hose
Crimp the double zinc clamp using the required crimping tool.
You will need to prepare up to 5 refrigerant lines, as indicated:
• Oil return line (all units EXCEPT 20X)
• Discharge line
• Liquid line
• Hot gas line
• Suction line
Refrigerant Hose Installation – Installation Preparation

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
15
Refrigerant Connection Lines – Neos 100S / 20X ONLY
Hot Gas
90°ORS 3/8”
Road Suction
90°ORS 5/8”
Liquid
90°ORS 3/8”
Road Suction
O-Ring pilot 5/8”
Road Discharge
O-Ring pilot 1/2”
Low Pressure
Service Valve
5/8”
High Pressure
Service Valve
1/2”
Road Discharge
90°ORS 1/2”
Liquid Line
90°ORS 3/8”
Hot Gas
90°ORS 3/8”
Neos 100S /
20X
ONLY Road Compressor
Evaporator
Condenser

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
16
Refrigerant Connection Lines – 30S ONLY
Hot Gas
90°ORS 3/8”
Road Suction
90°ORS ¾”
Liquid
90°ORS 3/8”
Road Suction
O-Ring pilot 5/8” -> ¾”
Road Discharge
O-Ring pilot ½”
Low Pressure
Service Valve
3/4”
High Pressure
Service Valve
½”
Road Discharge
90°ORS ½”
Liquid Line
90°ORS 3/8”
Hot Gas
90°ORS 3/8”
30S ONLY
Road
Compressor
Evaporator
Condenser
Standby
Suction
90°ORS 5/8”
Standby Units
ONLY
Standby Suction
90°ORS 5/8”
Oil Return
90°ORS ¼” -> 3/8”

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
17
Refrigerant Connection Lines – 35X, 40X, 50X ONLY
Hot Gas
90°ORS 3/8”
Road Suction
90°ORS ¾”
Liquid
90°ORS 3/8”
Road Suction
O-Ring pilot 5/8” -> ¾”
Road Discharge
O-Ring pilot ½”
Low Pressure
Service Valve
3/4”
High Pressure
Service Valve
5/8”
Road Discharge
90°ORS 5/8”
Liquid Line
90°ORS 3/8”
Hot Gas
90°ORS 3/8”
35X, 40X, 50X
ONLY
Road
Compressor
Evaporator
Condenser
Standby
Suction
90°ORS 5/8”
Standby Units
ONLY
Standby Suction
90°ORS 5/8”
Oil Return
90°ORS ¼” -> 3/8”

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
18
Electrical Connections
Make all required electrical connections.
Note that most are connectors that are “plug
and play”. The required electrical
connections are listed as follows:
If required, route the Return Air Sensor
(RAS) and mount to the evaporator fan inlet.
Evaporator Connections:
• Evaporator fan motor(s)
• Return Air Sensor (RAS)
• BPV (quench valve)
• Low Pressure switch
Engine Compartment:
• CLHR (road clutch)
• BBT (quench thermostat)

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
19
Cab Command Installation
Route the cab command harness to the interior of the vehicle
Protect the harness from all sharp sheet metal
Make sure the harness is not in contact with anything hot
Make certain the harness is secured from vibration
Mount the cab command in a accessible location
where it may not be damaged; for example, where
the rear view mirror would otherwise be mounted.
Be careful not to damage any of the vehicle hoses or wires.
If it is mounted in the dashboard, keep as far as possible from heating ducts.
Maximum exposure temperature: 158°F (70°C).
Do not mount it where it can be exposed to constant, direct sunlight

Installation & Commissioning Manual:
Neos 100S, 20X, 30S, 35X, 40X, 50X
62-11165 Rev D
®
20
Compressor Mounting
Install the road compressor on the vehicle following the bracket manufacturer’s
installation instructions.
Connect the high pressure line (HP) and the larger
suction line (LP).
Install the injection thermostat (BPT) on the compressor
high pressure line using the supplied clamp.
HP
LP
BPT
Make sure the injection thermostat is making
good contact with the high pressure line.
After connecting the injection thermostat terminals,
insulate the injection thermostat body with the
insulating material supplied.
Make electrical connections for the injection thermostat and
the compressor clutch. Place wires in protective split loop.