Hyster B214 H22 00xm 12ec Europe Forklift repair Manual

This document contains: 912-100-0148

Compressors - Applications, Conditions of Use and Liability

912-100-0007

Water Valve

912-100-0215

Electronic valve and flap controller EVKS

912-100-0258

Condenser unit, 24V

454-500-123 423-100-0005 411-512-0011 381-000-0321

Technical Drawing Technical Drawing Technical Drawing Technical Drawing

Compressors - Applications, Conditions of Use and Liability In principle, AURORA’s General Conditions of Sale and/or Terms of Guarantee apply. In the case of compressors, the points outlined in this Technical Information sheet must also be observed.

This Technical Information applies to all compressors supplied by AURORA. Any special features of specific compressors are mentioned in the text.

1. Guarantee A guarantee is only given on compressors if purpose of application and end-use are agreed with AURORA. If the points mentioned in this Technical Information are not observed, the guarantee is invalid. If in doubt, the conditions of use of compressors must be agreed with AURORA. No guarantee is accepted in the event of non-functioning of a compressor §

If the overall system is not sufficiently lubricated

§

If there is any deviation from the recommended amount of lubricant or refrigerant

§

If foreign bodies are found in the system

§

If the compressor is altered or disassembled without the manufacturer’s permission

§

If the service schedule for the unit is not observed. Parts normally replaced as part of a service, e.g. filters, collector driers, V belts, etc. are not covered by the guarantee.

No guarantee is accepted if the refrigerant circuit is dirty or for normal noises occurring during operation which do not affect the functioning of the compressor.

Under the General Terms of Sale and Delivery, AURORA supplies replacements for faulty parts from its Mudau works. AURORA does not pay the labour costs for fitting these parts.

estabilished: 15.03.00 KH date/name a) 8022 28.01.02 KH b) 8386 10.10.02 KH

checked: 01.04.05 W.Le

approved: 01.04.05 W.Le

date/name

date/name

c) 10408 29.03.05 KH d

e f

g h

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Should any damage occur to the compressor during the guarantee period, customers must contact their ASN partner company or AURORA. For EOS rooftop air-conditioners the guarantee card/service record must be produced. This must show that all prescribed maintenance and service operations have been performed.

If the customer service centre does not have a compressor in stock, a replacement will be dispatched without delay from our Mudau works.

The faulty compressor must be made available to AURORA with the guarantee documents without delay. Where appropriate it should be packaged carefully.

AURORA will not bear any costs if customers have such units repaired at their expense without following the procedure outlined above through the customer service centre.

Replacements are supplied free of charge with the proviso that AURORA is entitled to invoice the customer for the costs incurred if examination of the faulty compressor reveals that the damage is due to incorrect handling or negligence.

2. Notes on application, servicing and repairs Installation, servicing and repairs may only be undertaken by specialist staff who observe the safety regulations.

The following points must be observed: §

The instructions issued by the vehicle/engine manufacturer must be observed.

§

Refrigerant R134a in according to DIN 8960 must be used for all compressors.

§

The EC Safety Data Sheet for R134a must be observed.

§

No fluorescent additives may be added to the refrigerant.

§

All refrigerant must be drained from the system by suction before opening the refrigerant circuit.

§

There must be no possibility for dirt or moisture to enter the refrigerant circuit. The refrigerant circuit must not be opened outdoors in rainy or damp weather. Once the circuit has been opened, all remaining openings must be hermetically sealed to prevent moisture entering the unit.

§

If there are impurities in the refrigerant circuit, the unit must be cleaned and then rinsed with dry nitrogen. The unit is under no circumstances to be rinsed with compressed air!

§

All components must be kept clean.

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§

When filling the unit, the connections must be sealed correctly. New seals must always be used.

§

Compressors must not be lacquered or oiled.

§

The rated voltage of the vehicle and the rated voltage of the compressor coupling must match.

§

The direction of rotation (clockwise or anticlockwise) must be set according to the type of compressor.

§

The maximum rpm of the compressor must be observed.

§

Avoid sudden thrusts and vibrations by the shaft and permanent phased operation.

§

The pulley type in the drive and compressor and the type of V belt must be identical.

§

The performance of all components in the refrigerant circuit must be matched, especially as regards the performance of the evaporator and expansion valve, to prevent reflux of the refrigerant.

Correct installation and operation of compressors §

Damaged compressors must not be installed.

§

When installing compressors, the manufacturer’s instructions on installation position must be observed.

Sanden SD: based on the normal axis, the compressor axis can be turned 90° to the right and left of its axis.

Unicla UX310: 0-45° Bock FKX 40: max. 15°

§

When fitting screws, seals, etc., the compressor must never be allowed to stand upright.

Take care not to damage the magnetic coupling and cables during assembly.

§

To prevent damage to sealing surfaces and sealing rings, all new seals must be wetted with clean refrigerant oil of the type used to lubricate the compressor.

§

The compressor caps must only be removed immediately before attaching the refrigerant hoses.

§

When mounting the compressor, make sure that the mount points on the unit are not pushed in or out as this can crack the casing, resulting in leakage of the refrigerant.

§

Make sure that the compressor is the last component in the refrigerant circuit to be attached. The refrigerant circuit must not be open when the refrigerant is attached because the lubricating properties of the refrigerant oil could be lost as a result of exposure to moisture. Prolonged exposure to moisture produces acids that damage the bearings in the compressor and the hoses.

§

The pulley must be aligned properly. This is particularly important for the service life of the V belt and the compressor. If necessary, the mount must be adjusted or reworked.

The compressor must be positioned correctly on the mounted and secured properly.

§

The compressor mount must be attached to the engine block at a suitable point. The mount points provided by the engine manufacturer must be used.

§

Torque must be taken into account when tightening screws and connections.

§

The V belt must be tensioned as instructed. It is advisable to use a tensiometer to measure this.

§

After repair work, the system must be evacuated for at least 45 minutes to remove foreign gases and moisture that have been absorbed by the oil in the compressor.

§

Before evacuating make sure that the vacuum pump can create an absolute pressure of a maximum of 5 mbar. (Checking of the vacuum pump by means of an suitable and calibrated high-vacuum manometer.

§

The following schedule must be used for start-up, i.e. to check seals, evacuate the unit and fill it with refrigerant:

Service intervals: Function checks to be carried out once a year: · Leak test of the unit · Checking the running noise of the compressor (see also chapter 4) · Checking pressures and temperatures of the unit · Checking the tensioner for orderly seating · Checking the V-belts for tension and condition · Checking the fixing screws for tightening · Checking the function of the ancillary units · Checking the electrical connections for clean, firmly fixed contacts and the leads for chafing points · A contaminated compressor has to be cleaned. Is the compressor wet and oily change the axial face seal · Oil level check Refrigerant oil: Compressors are filled with the correct amount of refrigerant oil when they are supplied. For specific applications, it may be necessary to adjust the amount of refrigerant oil to meet system requirements or system specifications. It is essential to agree this with AURORA. The oil level in the compressor must be checked through the glass oil level indicator, if existing, every time the unit is serviced. When filling/refilling compressors, make sure that the type of refrigerant oil required for that compressor is used. If there are questions about the oil type, please contact AURORA or an ASN. Vitiations from the unit´s components or use apart from normal range of application can cause deposits on the lubricant and darken it. In this case the oil should be changed. In no case water shall arrive into the oil.

Oil change: In case of orderly manufactured and operated units an oil change is in principle not absolutely necessary.

Based on experiences we recommend to carry out the following oil change and servicing.

First oil change at the first maintenance of the vehicle.

After that, changing the oil every 5000 operating hours or every two years during regular serving while changing the collector dryer of the AC unit. Albeit the manufacturer´s instruction are valid. AURORA won´t be liable due to information given.

The oil change is carried out according to the instruction manual of the manufacturere of the compressor. The oil change must be carried out by authorized personal only.

Attention: Dispose of waste oil according to valid regulations; mind national law.

3. Notes on safe handling of the refrigerant circuit Compressors in air-conditioning units operate under high pressure. To prevent injury, the notes in this Technical Information must be followed closely.

Refrigerant R 134a according DIN 8960 is a fluorinated hydrocarbon, i.e. it does not contain chlorine and does not damage the ozone layer. It is known as a safety refrigerant. In other words, it is not combustible and has no taste or odour. A mixture of R134a and air is in case of raised pressure inflammable and therfore is to be avoided under any circumstances.

The following points must be observed: · ·

Do not exceed the maximum operating pressure of the compressor. (see type label) Compressors are machines under pressure and as such require special care in handling.

For maintenace work the compressor has to be set to a pressure-free state. · Only qualified personnel are allowed to perform any work on refrigeration compressors. · The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely. · Never put the safety switch out of action. · Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor. · Prior to starting the compressor open discharge shut-off valve and suction shut-off valve. · Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged. · Caution! Danger of burning because of high surface temperatures. · Never grab rotating parts during operation. Danger of injury! · Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather gloves to protect hands.

Do not inhale refrigerant vapour. · Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed.

Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside.

Refrigerant must not be drained into the environment. Only authorised equipment may be used to suction of refrigerants. · No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion. · Full bottles of refrigerant must not be thrown or exposed to sunlight or other sources of heat for prolonged periods. The maximum permissible temperature of a full refrigerant bottle is 45°C. · It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only.

4. Troubleshooting ·

·

·

·

·

Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit.

By wrong refrigerant level there is a danger of compressor malfunction.

The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.

With undercharged refrigerant the compressor will become hotwhich caused a failure.

The sealing will be damaged.

Faulty shaft seals: On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result of lack of lubrication when it is not in use. When the seals are damaged, the refrigerant leaks out of air-conditioner very quickly. It is therefore advisable to run the air-conditioner for 10-15 minutes at least once a month to ensure regular lubrication of seals.

Noises Mechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with the drive or the fixation of the compressor or related components. Noises can often be halted by altering the tension of the V belt.

Electrical faults A 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click.

If the magnetic coupling does not start up, the fuse, magnetic relay or all power components such as the thermostat, switch, pressure switch, relay, etc. should be tested and replaced if necessary.

Further fault diagnosis Plaese pay attention to the maintence instructions of the compressor manufacturers for a possible continuative fault diagnosis.

- We reserve the right to make technical changes -

Water Valve Brief description: The water valve serves to adjust the rate of water flow on AURORA heating units and thus to control the heating performance.

Features: -

Ideal characteristic curve

-

Minimum pressure drop

-

Flexible connection diameter

-

Flexible actuation method (knob, bowden control, motor)

-

Universal fixing facilities

-

Low weight

-

All-plastic design

further applicable documents: Technical Information 912-100-0322 "water valve with servo motor and HCC" Technical Information 912-100-0305 "HCC"

Technical modifications reserved edited: 23.01.95

verified: 29.09.04 CK

approved: 29.09.04 CK

date/name

date/name

date/Name

a) 6623 21.12.98 b) 7621 02.05.01 KH

c) 8221 04.06.02 KH d) 8260 04.07.02 KH

e) 9548 23.08.04 KH f

g h

The Function: The water valve is employed to adjust and/or control the water flow-through quantity at the inlet or the return flow point of a heating unit in order to be able to match the heating performance with the demand.

The Design: The valve is made completely of plastic materials. The chamber consists of PA66, the rotary piston of POM. The connecting pieces are direct-injected onto the valve chamber.

Water valves with the following connction-diameter can be deliverd: Æ16/16, Æ18/18, Æ22,22, Æ28/22, Æ28/28.

The valve top is welded to the chamber in such a way that it is water-tight. It is not possible to open it.

Flexible fixing facilities make customised assembly possible.

Actuation is by: -

direct slip-on actuation knob, or Bowden pulcable in conjunction with the Bowden pull panel that can be slipped on at an angle of 90°, or actuating motor.

Optionaly the water valve can be equipped with an end switch.

In case of the version of the servo motor optionally the heating and cooling controller HCC can be integrated.

For these versions the technical information 912-100-0322 is valid.

More information about the HCC can be find in technical information 912-100-0355.

Note: When the rotary barrel is rotated the valve opens counter-clockwise, when looking at the square head from the top.

Installation: During the mounting of the device make sure that the flow direction of the water accords with the arrow indicating the flow direction on the housing as well as with the slant of the rotary piston's square.

Attention: In order to ensure a safe installation and impermeability and to avoid deformations of the connecting branch band clamp fittings have to be installed, which in case of mounting with hot-water hoses have to be tightened at a tightening torque of 4,5±0,5 Nm. For the assembly of Bowden wires see TI 912-100-0025.

For the assembly of an actuation knob drawing 381-000-0101 is to be considered (see enclosure).

Installation advice for motoric water valve with HCC: The mounting space must be protected against contamination and splash water.

Pressure Drop At a water flow volume of 1,000 l/h the pressure drop of the valve amounts to approcimately 4,200 Pa. In conjunction with a heat exchanger and piping the influence of the valve's pressure drop on the overall pressure drop declines continuously with the increasing number of in-series components in the system. Since the piping arrangement in the vehicle means that high system losses are to be expected the valve's own pressure drop has no - or only a small - effect on the water volume flow and thus on the heating performance. In this context reference needs to be made to the characteristic curve of the pump: The steeper the pump's characteristic curve the smaller the decline of the water volume flow.

Pump`s charakteristik curve with system resistance curve (qualitatively)

AKL 1 AKL 2 AKL 3 AKL 4 K

-System resistance: piping, heat exchanger, fine tune valve - System resistance: piping, heat exchanger, stop cock - System resistance: piping, heat exchanger - System resistance. heat exchanger - Pump`s charakteristic curve

& water kv = V

1bar Dp v Opening angle of the valve

6 5 4 3 2 1 0 90° = Zu

~75°

~60°

~45°

~30°

~15°

0° = Auf

The valve can be used as a control unit. The design of the valve's rotary piston ist such that it ensures fine tuning between "closed" and 30° "opening" There will be 22% of the maximum volume flow.

The following drawing shows the water flow of the combination of a round tube heater core with the new water valve.

The characteristic heater performance is linear to the opening of the water valve:

heater performance in reference of the cock position 12 Q80 10 h e a 8 t e r p 6 e r f 4 o r m a 2 n c e 0 kW 90°=closed

~75°

~60°

~45°

~30°

~15°

postion of the cock

Cooling water circuit: When refilling the cooling water quality has to be considered. When using AURORA water valves the warranty expires when defects occur due to contaminations in the water circuit. (see TI 971-190-0003 anticorrosion/antifreeze solution)

Advantages compared to previous AURORA valves: -

better control behaviour more flexible connecting diameters more flexible actuation modes lower weight more flexible fixing facilities lower actuating forces no corrosion (all-plastic design) low leakage risk linear characteristic of heater performance

0°= open

Electronic valve and flap controller EVKS AURORA- part no.: 423-100-0005

Content: 1.

Application and function

2.

2.1 2.2 2.3

Electrical connection / Electric data Electrical data Control voltage Electrical connection

3.

Installation instruction

4.

4.1 4.2 4.3

Mechanical and thermical data Dimensions Weight Thermical data

5

Safety measures

Appendix: Drawing EVKS Drawing wiring / additional circuit for 12 V

423-100-0005 912-200-0001

Technical modifications reserved etablished: 27.09.01 KH/He

examined: 22.5.03 He

approved: 27.5.03 W.Le

Date/Name

Date/Name

Date/Name

a) 07.10.02 He b) 8743 21.05.03 KH

c d

e f

g h

1.

Application and function

The EVKS (electrical valve and flap controller) is used to permit infinitely variable adjustment of the opening angles of the valves and flaps with dependence only on a control voltage. Actuation takes place in connection with a servomotor.

The EVKS made a self calibration by applying operating voltage on Ubatt.

For this reason the entire range of adjustment of the connected servo motor will be driven up and the end positions will be declared.

After this procedure the servo motor takes the from the potentiometer adjusted position.

The calibration last about 20 seconds and is set at each apply of operating voltage on Ubatt.

Attention: For 12 V a additional circuit is necessary.

2.

Electrical connection / Electrical data

2.1

Electrical data

Nominal voltage: Maximum continous current: Maximum short-circuit current: 2.2

12V/24 V 150 mA 2,5 A

Control voltage

The control voltage can be varied with a potentiometer (10 kOhm). The control voltage (0V5V) can also be fed by a suitable electronic control system. In specific cases control is possible with a change-over switch. This however means that the valves or flaps can only be set to „OPEN“ or „CLOSED“ positions and intermediate settings are not possible.

2.3

Electrical connection

All EVKS connectors are safe against short-circuit and incorrect polarity. If there should be a continuous current consumption greater than 150 mA the EVKS switches off thermally and it switches itself on again automatically after cooling.

The electrical connections have been wired according to drawing 912-200-0001 (see appendix) It is possible to operate up to 3 EVKS units with one potentiometer.

6,3 x 0,8 mm flat plugs are provided for the electrical connection.

In the case of distances above 2 m between the servomotor and the EVKS screened cables must be installed, e.g. LIYCY 5x0,5² If the EVKS shall be used for 12 V a additional circuit is necessary.

See drawing 912-200-0001 (appendix).

3.

Installation instruction

The mounting space must be protected against contamination and splash water.

For the installation of the EVKS it is important to pay attention to chapter 2.3 electrical connection.

The unit can be attached with standard screws according to the installation conditions.

4.

Mechanical and thermical data

4.1.

Mechanical dimensions

See drawing no. 423-100-0005 (Appendix) For protection against moisture the housing is complete casted.

4.2

Weight

Weight approx. 96 g 4.3

Thermical data

Storage temperature: Operating temperature: 5.

-40 - + 120°C -40 - +85°C

Safety measures for electronic control units in vehicles:

The following listed safety measures must be unconditionally observed, in order to avoid and prevent damage to components as well as to the cable set: · · · · · · · · · · · · · ·

No external voltage should be connected to the control outputs.

If, for testing purposes, the bord voltage is directly fed at the motor, the circuit has to be seperated from the motor beforehand.

Only start the engine if the batteries are firmly connected.

Don´t disconnect the batteries when the engine is running.

Don´t use a boost charging device to start the engine.

Only use separate batteries for help in starting.

Don´t start the vehicle with an external charging unit.

For fast charging the batteries the battery terminals must be removed. Follow the fast charging device instructions.

The control unit connections may only be withdrawn or plugged on again with the electrical system switched off.

Incorrect connection of the control unit supply voltage (e.g. wrong battery terminal connections) can lead to destruction of the control unit.

Always withdraw the device plug when testing the connected components.

Always use the test software provided for testing the outputs.

Only use appropriate test leads for measurements on the plugged connections.

Telephones and radio devices, which are not connected to an outside aerial can lead to functional faults on the vehicle electronics and thus endanger the operating safety.

· · · · ·

Fixed radio aerials without sufficient ground surfaces (plastic roof) will cause considerable interference through mismatching in the vehicle.

If sufficient ground surfaces cannot be found then window aerials (adhesive aerials) should be used.

When carrying out welding work the earth cable from the electrical welding unit must be connected directly onto the vehicle part to be welded.

When carrying out electrical welding work the battery terminals must be removed and the two cables (+ and -) firmly fixed to one another.

When carrying out work, which could lead to electrostatic charging of vehicle parts (e.g. spraying on the plastic underseal) any electronic components attached to the control electronics in the vicinity (e.g. external sensors) must be unplugged.

Temperature compatibility of electronic components: · The indicated max. permitted temperatures of control units must not be exceeded. · If temperatures over the max. permitted temperatures are anticipated control units must be removed.

General: Not every malfunction will result in the part or complete breakdown of the unit. In order to test the condition of the relevant unit the following must be carried out: · Switch off the engine and ignition. · Withdraw all plugs from the unit and replace them after approx. 10 seconds. · Wait for the unit to carry out a „self-test“ if present. · Check the functioning of the installation again.

Condenser unit, 24V part no.: 175-FR2-0002

1

Safety advices

2 2.1 2.2 2.3

Design of the condenser unit Condenser Condenser blower Pressure switch

3

Mounting information

4

Connection to the refrigerant circuit

5

Electrical connection

6

Maintenance

7

Spare parts

8

Technical data

9

Fault diagnosis

- we reserve the right to make technical modifications -

author: 16.01.03 KH

checked: 11.11.04 W.Le

approved: 11.11.04 W.Le

date/name

date/name

date/name

a b c

d e f

g h i

j k l

1

Safety advices

Please note the following information for your own safety. · Make sure that maintenance and repair work is only carried out by specialised and authorised personnel. · Do not reach into the unit and never stick objects into the blower. · Only carry out maintenance work when the engine is stationary. · Attention! Danger of burning! Please do not get into contact with the heat exchanger and its connections. Cooling tubes and cooling hoses can be hot and stand under pressure. Be careful by touching them. · At maintenance work and repairs wear necessary protective clothing.

Advice for installation and maintenance work: The rules for the prevention of accidents as well as other recognises technical and labour medical security regulations must be observed.

Maintenance work on the refrigeration circuit: ·

· · · ·

The unit must always be emptied before any work is carried out on the refrigeration circuit. This may only be done by specialist personnel.

Please follow the safety data sheet for refrigerant R134a.

Do not discharge refrigerant to the environment.

Liquid refrigerant must not come into contact with the skin.

Safety glasses must be worn when handling refrigerants.

CAUTION! Risk of explosion! · Never carry out soldering or welding work directly on parts in the closed refrigeration circuit or in its vicinity. Due to the strong heating effect the pressure will increase within the unit giving a risk of explosion. · Refrigerant bottles must never be thrown around or subjected to lengthy periods of sunshine or other heat sources when filled.

The highest permitted temperature of a filled refrigerant bottle must not exceed 45°C. CAUTION! Risk of contamination! · It is essential that the refrigeration system is kept free from chlorine and substances containing chlorine, as well as oils and greases. Consequentially it is necessary to invest in separate evacuation and filling systems which are exclusively used for R134a.

2

Design of the condenser unit

2.2

Condenser blowers

The housing of the condenser unit consists of steel sheet.

In the housing there are the round-tube condenser, 2 axial blowers and a pressure switch.

The condenser consists of jointly soldered round copper tubes and fins. The fins are attached solidly to the round tubes.

The 2 condenser blowers sucks the air through the condenser. The air takes the heat of the refrigerant. The gaseous refrigerant is cooled and condensed. The liquid refrigerant leaves the condenser at its base.

The condenser unit has the outer dimensions 788x259x300 mm and a weight of about 19 kg.

The axial blowers have protective gratings.

For the protection of the compressor there is a pressure switch integrated into the receiver drier.

To protect the air conditioning unit the pressure switch switches off the electromagnetic clutch of the compressor at a critical pressure.

The pressure switch has the following shift points (over-pressure):

2.1

Condenser

The compressed refrigerant is condensed in the condenser which means that the refrigerant passes from the gaseous to the liquid state.

The liquid refrigerant leaves the condenser at its base.

The capacity of the condenser is essentially influenced by the air flow quantity and air temperature. The most favourable air temperature is that of the direct outside air. Ventilation is carried out by a supplementary blower. The condenser consists of a serpent coil and fins to create the greatest possible cooling surface.

The fins are attached solidly to the tubes to achieve good heat transfer.

2.3

Pressure switch

low pressure: OFF at <1,2± 0,3 bar, ON at >2,4 bar high pressure: OFF at 25±2 bar, ON at19±1,5 bar To increase the heat dissipation on the condenser the pressure switch has a middle pressure switch for the condenser blower integrated . switch-on pressure: 18±1 bar switch-off pressure: 14±1 bar

3

Mounting information

The housing bottom has to be fixed with 4 screws M8.

Lift and transport the condenser unit only on the housing. Don’t pull at the cable set. Otherwise the plug can tear off.

Wear necessary protecting equipment at installation.

5

Electrical connection

bushing housing Deutsch DT04-6P PIN 1 +24V (fused) red PIN 2 ground black PIN 3 relay signal yellow PIN 4 pressure switch in blue PIN 5 pressure switch out green

4

Connection to the refrigerant circuit

Inlet: 3/4“-16UNF, O-ring sealing, from the compressor Outlet: 5/8“-18UNF, O-ring sealing to the evaporator

6

Maintenance

CAUTION Please pay attention to the safety advice during all maintenance work.

Maintenance work is only carried out by wellinformed and authorised personnel.

Pay attention to chapter 1 - safety advice.

By working on open unit please pay attention to the rules for the prevention of accidents.

When the weather is damp or if it is raining the refrigeration circuit must not be opened outside. Repairs may only be carried out if the air conditioning unit has been emptied.

Remove blower open the service lid pull off the cable remove the blower to the front Remove condenser take off the cover and remove condenser to above.

The condenser and the blower are maintenance-free. Also this components has to be cleaned in regular intervals.

We recommend the following maintenance intervals: every six months â&#x20AC;&#x201C; authorised workshop: The complete unit has to be checked every two years through well-informed personnel of an authorised workshop. refrigerant Check of the cooling circuit on refrigerant filling quantity (renew contaminated refrigerant and oil) State of the refrigerant hoses Check of the fixing, leak control and laying of the hoses and fittings. The hose fixings are to be tightened if necessary.

Electric Check electric connection pipes on correct state and firm position.

State of the condenser A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner).

every month sight checks - Operator The following checks should be carried out every month by the operator: State of the refrigerant hoses Check of the fixing, leak control and laying of the hoses and fittings. The hose fixings are to be tightened if necessary.

State of the condenser Check condenser of contamination by dust, insects or parts of plants.

A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner).

Fins that were pushed down by external influences can be adjusted.

Please note: Attention and acidity are most important by the engagement into the refrigerant circuit.

Sucked off refrigerant may not be used again.

Components of the refrigerant circuit may not be stored open.

7

Spare parts

see spare parts list: 075-FR2-0002 Installation of replacement parts · When installing replacement parts the sealing plugs must only be removed just prior to installation so that no moisture can get into the unit. This is because if moisture gets into the unit the cooling performance is reduced and the compressor can also be damaged. ·

During assembly it is important to ensure that all connections are clean and undamaged.

·

Always use new sealing rings

·

To avoid damage to sealing surfaces and sealing rings it is advisable to wet this parts with refrigerant machine oil.

·

When tightening up the connections a screwdriver should always be used as a counterbrace to avoid damage to the soldered joints.

Please note: The condenser is filled with an inert gas. After removal of the protective cap the inert gas must audibly escape.

8

Technical data

Technical data for every blower: current consumption: 3,5 A ± 0,2 A max. stat. pressure: 245 Pa ±15 Pa max. air flow: 1585 m3/h ± 65 m3/h weight of the condenser unit about 19 kg.

9

Fault diagnosis

Fault

cause

remedy

Insufficient air supply at condenser

Contamination of cooling fins on condenser

Clean cooling fins with water jet Note: Do not use high pressure cleaner

suction opening contaminated

clean suction opening

plug loose

check plug and mount correctly if necessary

Connecting cable damaged or torn out

Replace cable.

interruption of the refrigerant pipe leak within the unit

check all pipes for leaks through external influences or chafing evacuation, filling, leakage check and repair to be made

Blowers will not work

loss of refrigerant

Supplementary technical information: ¡ Technical information 912-100-0078 filling and extraction of air conditioning systems

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