Beruflich Dokumente
Kultur Dokumente
AND REPAIR
TRANSPORT A/C
UNIT
Air conditioning
Controlling the properties of the air so that the air will be
suitable for its intended use.
The air conditioning controls the temperature of the
vehicle interior. It functions as a dehumidifier, in addition
to its heating and cooling temperature control functions.
The A/C also helps to remove obstructions such as frost,
ice, and condensation from the interior surfaces of the
windows.
Temperature Control
HEATER
Heater
To heat the air, a heater core is adopted as
a heat exchanger. The heater core takes in
the engine coolant heated by the engine
and uses the heat to heat the air from the
blower fan, so the temperature of the
heater core is low until the coolant
temperature becomes high. For this reason,
immediately after the engine starts, the
heater core doesnt function as a heater.
Dehumidifier
The amount of water in the air increases as the air
temperature gets higher, and decreases as the air
temperature gets lower.
The air is cooled as it passes the evaporator. Water
in the air will be condensed and adheres to the
evaporator fins. As a result, the humidity in the
vehicle interior is eliminated.
The water adhered to the fins becomes dew and is
stored in the drain pan.
Finally, it is drained from the vehicle by the drain
hose.
( + ): Positive
pressure
( - ) : Negative
pressure
Control panel
There are many selectors on
the control panel for the car
A/C. These selectors are
categorized as follows; air
inlet selector, temperature
selector, airflow selector, and
blower speed selector.
The shape of the selector
varies depending on the
models or grades, but the
functions are the same.
Airflow
selector
TEMPERATURE
SELECTOR
Air inlet
selector
BLOOWER
SPEED
SELECTOR
A/C SWITCH
Evaporator
Defroster
Fresh
air
Airflow dampers
Blower
(motor, fan)
Side vent
Side vent
Air mix damper
Foot outlet
Heater
core
Center vent
Switching dampers
The air inlet control, temperature control, and
switching of outlets can be done by operating
the selectors on the control panel. The air inlet
damper switches the air inlet, the air mix damper
performs temperature control, and the airflow
dampers switch the outlet. These dampers are
operated either by wire cable or by motor.
Switching Dampers
FACE
FACE
Airflow dampers
Side vent
Side vent
Center vent
Moving the dampers switches the outlet. There are five modes.
FACE: Blow to the upper half of the body.
Switching Dampers
BI-LEVEL
BI-LEVEL
Airflow dampers
Side vent
Side vent
Foot outlet
Center vent
2. BI-LEVEL: Blow to the upper half of the body and to the feet.
Switching Dampers
FOOT
FOOT
Airflow dampers
Side vent
Side vent
Foot outlet
Switching Dampers
DEF
DEF
Defroster
Airflow dampers
Switching Dampers
FOOT-DEF
FOOT-DEF
Defroster
Airflow dampers
Foot outlet
5. FOOT-DEF: Blow to the feet and remove the mist on the front window.
Switching Dampers
Types of damper
operation
Wire cable
Motor type
Damper motor
(1) Wire cable type
This type is constructed so that the movement of a selector directly activates the dampers. The construction is simple;
however, selector operation may become hard when the sliding condition of the wire cable becomes faulty and the routing
of the wires is bad.
(2) Motor type
In this type, since a motor operates the dampers to the proper position, the construction is complicated. However, this can
reduce the force required in operation and makes operation easier.
Resistor type
Heater relay
Blower
motor
Transistor type
Blower
resistor
Selector
(1/1)
Refrigeration Cycle
Basic theory of cooling
Evaporation
Thermometer
Tap
Gas
Warm
Cold
Heat
Insulated box
A container provided with a tap is placed in a wellinsulated box. A liquid that will vaporize readily at
atmospheric temperature is placed in the container.
When the tap is opened, the liquid in the container will
take away the heat necessary for vaporization from the
air inside the box, turn into a gas and escapes outside.
At this time, the temperature of the air inside the box
will become lower than that before the tap was opened.
Refrigeration Cycle
Refrigerant
Refrigerant temperature
What is refrigerant?
Refrigerant is a heat exchanging substance that circulates in
the refrigerant cycle. It removes the heat when it evaporates
and releases its heat when it liquidizes.
At present, HCF-134a (R134a) is used as a refrigerant.
Gas
Boiling point
Liquid
Gauge pressure
Refrigeration Cycle
Refrigerant (Reference)
Sun
40km
Ultraviolet rays
Ozone layer
Destruction of
ozone layer
20km
CFC discharge
(1/1)
1. CFC-12
. A refrigerant called CFC-12 (R12) had been used for car A/C until 1995. However,
CFC-12 (R12) was found to destroy the ozone layer when it is released in the air. The
depletion of the ozone layer increases the amount of ultraviolet from the sun to the
earth and causes skin cancer and environment destruction, so this has become a
global problem.
. Therefore, when the parts for A/C need replacing and repairing, it is necessary to
recover the refrigerant. However, if the gas is correctly recovered with a refrigerant
recovery machine, the refrigerant will not reduce performance when reused. At
present, refrigerant HFC-134a (R134a) that does not include the substances that
destroy the ozone layer is being used. The A/C system designed for using HFC-134a
(R134a) is not compatible with that designed for using HFC-12 (R12), so be careful not
to mistake the type of refrigerant and compressor oil or to mix them up.
2. Retrofit
. Replacing the hose for air conditioning system, O-ring and compressor oil on the
vehicle for CFC-12 (R12) with those for HFC-134a (R134a) makes it possible to use
HFC-134a (R134a).
Refrigeration Cycle
Refrigeration Cycle
1. Flow of refrigerant
Evaporator
Expansion
valve
Cabin
Engine
room
Compressor
Condenser
Receiver / Dryer
Refrigeration System
Outline
1. Description
The basic components of an
automobile refrigeration system
Blower
consist of the compressor,
condenser, receiver/dryer,
expansion valve, and
evaporator.
Besides the basic components,
there is a blower, which sends
wind, and clean air filter, which
purifies the air that the blower
Receiver /
sucks in.
dryer
In addition, there are other
(Sight-glass)
devices and functions which
Condenser
help bring out the systems full
potential, such as anti-frosting,
engine stall prevention, engine
idle-up, etc.
Cooling unit
(Expansion valve,
Clean air filter
evaporator)
Compresso
r
Refrigeration System
1. Functions 2. Swash plate type compressor
Construction
Compressor
(1)
Pressure relief
valve
Shaft seal
Piston
Magnetic clutch
Discharge valve
Swash plate
Cylinde
r
Suction valve
1. Functions
After being converted into low-temperature, low-pressure gas, the refrigerant is compressed by the
compressor, and changed into high-temperature, high-pressure gas. It is then sent to the condenser.
2. Swash plate type compressor
(1) Construction
A number of paired pistons are set on the swash plate at intervals of 72 for a 10-cylinder compressor or
at intervals of 120 for a 6-cyiinder compressor.
When one side of a piston is in a compression stroke, the other is in a suction stroke.
Refrigeration System
Compressor
(2) Operation
(2) Operation
The piston moves right and left synchronized with the rotation of the
swash plate, which is combined with a shaft to make a unit, and
compresses the refrigerant. As the piston moves inside, the suction valve
opens due to the pressure difference and sucks the refrigerant into the
cylinder. Inversely, as the piston moves outside, the suction valve closes
to compress the refrigerant. Due to the refrigerant pressure, the discharge
valve opens and the refrigerant is sent out. The suction valve and
discharge valve also prevent the refrigerant from flowing back.
Refrigeration System
3. Scroll type compressor
Compressor
(1) Construction
Fixed scroll
Discharge port
Suction port
Rotating scroll
Shaft
Shaft seal
Dischar
Fixed scroll
ge
port
Discharge
valve
Rotating scroll
Refrigeration System
Compressor
(2) Operation
(2) Operation
Following the circular movement of the rotating scroll, three
spaces between the rotating scroll and the fixed scroll are moving
to make their volume smaller gradually. That is, the refrigerant
sucked in through the suction port becomes compressed due to
the circular movement of the moving scroll, and every time the
rotating scroll completes 3 turns, it is discharged from the
discharge port. In fact, it is discharged once every turn.
Refrigeration System
Pressure relief
valve
Shaft seal
2. Shaft seal
The shaft seal is at the shaft that turns the compressor.
When the shaft seal is deteriorated or damaged,
refrigerant leaks.
Refrigeration System
Fixed
contact
Thermoswitch
+B
Ro
d
Bimetallic strip
Compressor
High
temperat
ure
Low
temperatu
re
[Temperature of
refrigerant]
1. Function
The through-vane type
compressor has a temperature
switch that detects the
refrigerant temperature on top
of the compressor. If the
refrigerant temperature
becomes excessively high, the
bimetal in the switch deforms
and pushes the rod upward to
open the contact of a switch. As
a result, current doesnt pass
through the magnetic clutch,
which stops the compressor.
Thus the compressor seizure is
prevented.
Refrigeration System
Compressor Oil
Old
New
out a portion
compressorLeave
compressor
of oil equivalent to the
remaining oil in the
refrigeration cycle.
Replacement
part
Condenser
Evaporator
3
Receiver
40mm
Pipes
Compressor oil
replenishment
volume
40mm3
10mm3
10mm3(per pipe)
compressor type
1. Function
Compressor oil is necessary to lubricate the moving parts of the compressor. Compressor oil lubricates the
compressor by dissolving in the refrigerant and circulating throughout the refrigeration circuit. For this
reason, the recommended oil must be used.
NOTICE:
The compressor oil used in the R-134a system is not interchangeable with the one used in the R-12
system. If the wrong type of oil is used, it may lead to compressor seizure.
Refrigeration System
Refrigeration System
Magnetic clutch
relay OFF
Front
housing
Drive belt
Pulley
Stator
Center
piece
Magnetic clutch
Compressor
shaft
Magnetic Clutch
1. Function
A magnetic clutch is driven by engine
through the drive belt. The magnetic clutch
is a device to connect the engine and the
compressor. The magnetic clutch stops and
drives the compressor as necessary.
2. Construction
The magnetic clutch consists of a stator
(electromagnet), pulley, center piece, and
other components. The center piece is
installed together with the compressor
shaft and the stator is held on the front
housing of the compressor.
3. Operation
When the magnetic clutch turns on, current
passes through the stator coil, which
makes the stator a strong electromagnet.
As a result, the stator pulls the center piece
with strong magnetic force so the
compressor turns together with the pulley.
Refrigeration System
Magnetic clutch
Front
housing
Stator
Magnetic
clutch
relay ON
Magnetic Clutch
Drive belt
Pulley
Suction force
Center
piece
Compressor
shaft
Refrigeration System
Condenser
Tube
Fin
1. Function
The condenser cools the gaseous refrigerant that reaches a high temperature and high
pressure by being compressed by the compressor to change it into the high-temperature and
high-pressure (mostly liquid state refrigerant but mixed with some gas) refrigerant.
2. Construction
The condenser consists of tubes and fins, and is installed on the front surface of the radiator.
3. Operation
The high-temperature and high-pressure gaseous refrigerant sent from the compressor
separates out 3 passages of tubes to pass through the condenser to be cooled.
Refrigeration System
Strainer
Desiccant
Gaseous refrigerant
Liquid refrigerant
Sight-glass
Insufficie
Continuous
nt
flow of bubbles
Sufficient
Almost no
bubbles
Overfilled
No bubbles
observed
1. Receiver/dryer
. A receiver is a device to store the refrigerant liquidized by the condenser temporarily, and it supplies the required
amount of refrigerant to the evaporator.
. A dryer has a desiccant and strainer in itself, and eliminates foreign matter or moisture in the refrigeration cycle.
. If moisture is in the refrigeration cycle, parts in it will corrode or freeze inside the expansion valve, which could
cause the clogging.
2. Sight-glass
(1)Function
()A sight-glass is an inspection hole used to observe the refrigerant flowing inside the refrigeration cycle and to
check the level of the refrigerant.
(2) Construction
()There are 2 types: one is installed at the outlet of the receiver and the other at the piping between the receiver
and the expansion valve.
(3) Notes of inspection
()Generally, when many bubbles are seen from the sight-glass, it means the amount of refrigerant is insufficient,
and when no bubbles are seen, the amount is appropriate.
HINT:
In the case of no refrigerant or excessive refrigerant, no bubbles are seen, so it is necessary to pay attention.
In addition, depending on the conditions such as engine speed or refrigerant pressure, even if the level is
appropriate, bubbles can be seen.
For sub-cool type condenser, since more refrigerant is filled at the point at which the bubbles disappear, the
refrigerant may be insufficient even if it seems normal in the inspection from the sight-glass.
Refrigeration System
MPa
NOTICE:
Add100g
Proper range
High-pressure
Shelf
Point where
bubbles
disappear
Amount of refrigerant
Overcharged
Sub-cool cycle
NOTICE:
In the sub-cool cycle, the point where bubbles disappear is before the cooling
capability stabilizing range, which requires 100 g more refrigerant to reach the
appropriate filling amount. If filling of refrigerant stops at the point where
bubbles disappear, cooling capability is not enough. Further, overcharging
decreases fuel economy and cooling capability, so be sure to fill the
appropriate amount of refrigerant.
Refrigeration System
1.
Function
An expansion valve injects the high-temperature and high-pressure
liquid refrigerant, which has passed through the receiver, from
the small hole to cause the refrigerant to expand suddenly and
to change it into the low-temperature and low-pressure mist
refrigerant.
Needle valve
.
According to the cooling load, the expansion valve adjusts the
Diaphragm
refrigerant amount to supply to the evaporator.
2. Construction
.
The valve directly detects the refrigerant temperature (cooling
load) around the outlet of the evaporator by the heat-sensing
rod and transmits it to the gas inside the diaphragm. The
change of the pressure of the gas due to the temperature
change and the balance between the pressure of the outlet of
the evaporator and that of the pressure spring moves the
needle valve to adjust the amount of the refrigerant flow.
3. Operation
.
The temperature around the outlet of the evaporator changes
according to the cooling load.
Heat-sensing rod
Refrigeration System
Equalizer line
Capillary tube
Heat sensing
tube
Diaphragm
Capillary tube
Equalizer line
Heat
sensing
tube
Needle
valve
Evaporator
Expansion Valve
1. Construction
The temperature sensing part of the
expansion valve is attached to the
outside of the outlet of the evaporator. At
the top of the diaphragm that leads to the
heat sensing tube, refrigerant gas is
contained and the pressure of the gas
changes depending on the temperature
at the outlet of the evaporator.
The refrigerant pressure at the outlet of
the evaporator is applied at the bottom of
the diaphragm.
The balance between the force to press
the diaphragm up (refrigerant pressure at
the outlet of the evaporator + spring
force) and the refrigerant pressure of the
heat sensing tube moves the needle
valve to adjust the refrigerant flow.
2. Function, Operation
The function and operation of this type
are same as that of the box type.
Refrigeration System
Evaporator
1. Function
An evaporator evaporates the mist
refrigerant, which is made low-temperature
and low-pressure at the expansion valve,
and cools the air around the evaporator.
Tank
2. Construction
This consists of a tank, tubes and cooling
fins. The tubes penetrate through a number
of cooling fins and form minute passages for
good conductivity.
Drain hose
Cooling fin
Tube
3. Operation
A blower motor fan forces air to the
evaporator. The refrigerant removes the heat
of evaporation from the air and is heated into
a gas.
When the air that has passed the evaporator
is cooled, the moisture in the air condenses
and attaches to the cooling fin. The moisture
becomes droplets and is stored in the drain
pan to be drained out of the vehicle through
the drain hose.
1. Description
To operate the A/C normally or to reduce the damage to the components when a
malfunction occurs, the signals from each sensor or switch are sent to the A/C
amplifier in order to control the A/C.
(1) Pressure switch control:
This detects the abnormal rise of refrigerant pressure and turns off the magnetic
clutch to protect the components in the refrigeration cycle and stops the compressor
from operating.
(2) Evaporator temperature control:
This detects the surface temperature of the evaporator, and turns the magnetic clutch
on and off to control the operation of the compressor so that the evaporator does not
frost.
(3) Drive belt protection system:
This detects the lock of the compressor, prevents the drive belt from being damaged
by turning off the magnetic clutch, and causes the A/C switch indicator light to blink.
(4)Idle-up control:
This stabilizes the engine idling when the A/C is on.
Expansion valve
Evaporator
Refrigerant
pressure
Receiver
Condenser
Compressor
Pressure switch
A/C ECU
1. Function
A pressure switch is installed on the high-pressure side of
the refrigeration cycle. When the switch detects abnormal
pressure in the refrigeration cycle, it stops the compressor
to prevent the trouble from expanding to protect the
components in the refrigeration cycle.
Thermistor
A/C ECU
Magnetic
clutch
relay
Evaporator
1. Function
To prevent the evaporator from frosting, the surface temperature of the
evaporator controls the compressor operation.
The surface temperature of the evaporator is detected by thermistor and
when the temperature is below a certain degree, the magnetic clutch is
turned off to prevent the evaporator from dropping below 0C (32F).
Idle-up Control
B
A/C
Idle speed
control valve
(ISCV)
A/C ECU
Engine
ECU
Throttle valve
1. Function
In idle state such as in slow traffic or during stop, the engine output is small. In
this state, driving the compressor applies overload to the engine, which results in
overheating or engine stalling. So, an idle-up device is installed to make the idle
speed a little higher to use the A/C.
2. Operation
An engine ECU that receives an A/C switch-on signal opens the idle speed
control valve a little to increase intake air to make the engine revolve at the
appropriate speed.
Inspection / Test
Inspection / Test
Refrigerant recovery
machine
Moisture
Air
Nitrogen
gas
Dust
Plug
Inspection / Test
Compressor oil
Over-tightening
Loose
A/C ON
Inspection / Test
Inspection / Test
1,500rpm(R-134a)
2,000rpm(R-12)
Inspection / Test
1. Normal
Lowpressure
side
Highpressure
side
1. Normal
If the refrigeration cycle is normal,
the gauge pressure values are as
shown.
Low-pressure side 0.15 to 0.25
MPa (1.5 to 2.5 kgf/cm)
High-pressure side 1.37 to 1.57
MPa (14 to 16 kgf/cm)
Inspection / Test
Lowpressure
side
Highpressure
side
Inspection / Test
Lowpressure
side
Highpressure
side
4. Moisture in
refrigeration cycle
Inspection / Test
Lowpressure
side
Highpressure
side
Inspection / Test
5. Compression defect in compressor
Lowpressure
side
Highpressure
side
5. Compression defect in
compressor
When a compression defect occurs
in the compressor, the gauge
pressure at the low-pressure side is
higher than the normal value. The
gauge pressure at the high-pressure
side is lower than the normal value.
(1) Symptom
Low-pressure side is high, highpressure side is low.
Turning off the air conditioner
immediately restores the highpressure side and low-pressure side
to the same pressure.
Compressor unit is not hot to the
touch.
Insufficient cooling.
(2) Cause
Compressor defect.
(3) Remedy
Inspect and repair the compressor.
Inspection / Test
6. Clog in
refrigeration cycle
Lowpressure
side
Highpressure
side
Inspection / Test
Lowpressure
side
Highpressure
side
Inspection / Test
Lowpressure
side
Highpressure
side
Inspection / Test
escription
2. Test condition
Performance Test
Thermometer
Psychrometer
1. Description
For cooling performance of the A/C, measure the
difference of temperature between the inlet port and
outlet port of the air, and judge whether the value is
within the standard range in the standard performance
chart.
2. Test condition
Test the vehicle in the following conditions:
Stopping condition in shade
Engine coolant temperature: After warm-up
All doors: Fully open
Airflow selector: FACE
Air inlet selector: RECIRC
Engine speed: 1,500 rpm (R-134a), 2,000 rpm (R-12)
Blower speed: HI
Temperature selector: MAX.COOL
A/C Switch: ON
Pressure on the high-pressure side: 1.5MPa (15.5
kgf/cm)
3. Measure each temperature
Place a dry and wet bulb thermometer at the air inlet
and a dry bulb thermometer at the center of the outlet
port. When the air temperature at the outlet stabilizes
(after approximately 5 to 6 minutes), measure the
difference between both dry bulb thermometers and
the relative humidity of the air at the air inlet port.