Easysphere
Contents
1. br 2 5mm Ms 1 5mm 2 gr 2 5mm Coupling gn2 5mm 2 nen ee oM EE m EG p iF3 t a AN wv mot o o Sw ws m rot2 5mm rot2 5mm 2 ee Oo o 2 3L Os ds pe re UNIS ST D s i E E 1 0 iE E 15A 2 Duuu E do bese F 188 85 1 i 2 v i ePlus pin Plus pin B B both sides 4 both M10 dia sides M8 dia Nomenclature Pos 24V Cable size vehicle side Fuse F1 F2 15A 15A Ground Compressor Fuse socket 4 fold FA 81676 24 V version 16 mm 16 mm 2 5 mm LP HP HD ND switch S3 66553 Anti icing switch S4 65345 Lx 12 meters x 70 amps A 15mm Relay K1 34098 Kappa x U 56 x 1 0 volt Rocker switch 1 S2 66596 66595 2 selected standard cross section min 16 mm Axial fan M1 M2 64506 Radial fan M3 80866 Lxi 20 meters x 70 amps A 25mm Prot against reversed F3 75A Kappa x U 56 x 1 0 volt polarity selected standard cross section min 25 mm A cable cross section L cable length in meters max current Kappa specific conductivity of copper cables U 7 max permissible voltage drop Fig 3 1 Page 15 30 Roof top air conditioning system Easysphere 3 5 sw 2 5mm br 2 5mm 2 Circuit diagram for deluxe version sw 2 5mm br 2 5mm 2 w t TER Co o co a co N co N o ge2. 4 7 Make electrical connections The system must be adequately protected by fuses on the vehicle side The cable cross section must be determined by the customer in accordance with the cable length Refer also to Copper cables for use in motor vehicles DIN VDE 0298 Part 4 a Disconnect vehicle battery IMPORTANT Note the vehicle manufacturer s instructions when connecting the power supply for the air conditioning system Only adequately dimensioned cables approved for use in motor vehicles may be used see Fig 3 1 or 3 2 Work on the electrical system may only be performed by authorized personnel Rubber grommets must be used when routing cables through metal sheets b Make and connect the cables as shown in Fig 3 1 or 3 2 Route cables through protective sleeves and secure them appropriately with cable ties The power supply for the system must be connected to the bulkhead Fig 2 2 with the cable bolts provided for this purpose IMPORTANT Correct polarity must be ensured without fail pole M8 cable bolt pole M10 cable bolt The electronic control will be destroyed if the polarity is reversed Use strain relief material NOTE If the operating elements are not installed in the air distribution panel the optionally available cable set for external installation of the operating elements can be used to extend the connecting cables Page 22 30 5 2 5 3 Roof top air condit
3. 1 or 3 2 Fastening elements for routing the connecting cables Reinforcing elements hoops inside the roof to ensure sufficient roof stability Transfer stiffness gt 640 N mm 4 4 Required equipment special tools and accessories a The system is already prefilled R134a Sheet metal cutter for breakthroughs in vehicle cabin roof Mechanics tool kit b For service evacuation filling and testing the refrigerant circuit Servicing recycling station for refrigerant R134a Vacuum pump suction rate min 5 m h final pressure 1 mbar Filler hoses with quick disconnect couplings for R134a Leakage tester Digital thermometer Refrigerant R134a PAG oil for A C compressors Test fittings with intake pressure and high pressure gauges Page 17 30 Roof top air conditioning system Easysphere 4 5 Preparations on vehicle cabin roof Installation depends on the type of vehicle The vehicle manufacturer s instructions must therefore be observed Fig 4 1 shows the installation dimensions and the mounting hole pattern of the roof top unit The breakthroughs for the air intake and discharge openings are located off centre in the baseplate IMPORTANT During preparation of air intake and exhaust openings structural parts e g roof bows stiffeners must not be cut through B 1094 4 8 42
4. 17 18 19 22 23 23 23 23 23 24 24 Roof top air conditioning system Easysphere 6 MAINTENANCE 25 6 1 Safety precautions 25 6 2 General 25 6 3 Maintenance and care 25 6 4 Maintenance and service checklist 26 6 5 Inspections before repair 26 6 6 Troubleshooting 27 6 7 Repairs 28 6 8 Post repair procedures and testing 29 6 9 Visual inspection 29 7 WARRANTY CLAIMS PROCESSING 30 Page 3 30 Roof top air conditioning system Easysphere 1 INTRODUCTION 1 1 Scope and purpose This installation and service manual contains important information to assist trained personnel in the installation operation and maintenance of the roof top air conditioning system CC8 1 2 Meanings of warnings cautions and notes WARNINGS CAUTIONS and NOTES in this manual have the following meaning WARNING This heading is used to highlight that non compliance with instructions or procedures may cause injuries or fatal accidents IMPORTANT This heading is used to highlight that non compliance with instructions or procedures may cause damage to equipment NOTE This heading is used to highlight and draw specific attention to information 1 3 Additional documentation required a Operating manual roof top air conditioning system CC4E 1 4 Safety information and regulations The roof top air conditioning system CC4E has been designed and built in accordance with EC Directives The system can be operated safely when installed and
5. 392 437 5 657 1042 15 Kontur Haube lee S 4 i d vl hes ee K9 al Ep 2 oN i 1D ao 255 3 lt o Z A 1 300 340 55 340 250 774 j25 mA ott 1 I 1 800 i 175 300 340 ove 340 f tn LA i a i Y SC A m i N 15 F 1110 gt Direction of travel Contour of baseplate Drilling pattern viewed from above onto the roof of the vehicle Fig 4 1 NOTE The breakthroughs for the air intake and discharge opening are located off centre Cut template out of packaging material Remove intermediate roof insulating material around the air ducts Markthe air duct openings shaded areas Fig 4 1 on the roof and cut them out Page 18 30 Roof top air conditioning system Easysphere Align the template or roof top air conditioning unit without hood with the marked point and drill nine holes with dia 9 mm Attention In the area of the attachment holes the roof must have a transfer stiffness of more than 640 N mm This can be verified by applying the Impact Ham mer Testing method For reasons of noise transmission the attachment ho les are to be placed into roof bows or welded reinforcements An attachment of the system only through the roof cladding is not permitted Remove template or roof top unit as applicable Deburr smooth the cut edges of the openings and drilled holes and coat with corrosion proofing paint Prepare inner r
6. Fig 2 2 is a temperature switch It measures the temperature between the evaporator fins and switches off the power supply to the electric motor if there is any risk of ice forming approx 0 C and back on again at approx 3 C Axial fan The two axial fans 4 Fig 2 2 comprise a DC motor fan wheel housing and protective grille When the air conditioning system is switched on they draw a constant supply of power from the on board system via relay K1 Fig 3 1 and supply the condenser with the required outside air Radial fan The radial fan 5 Fig 2 2 is of the multi speed type It draws the cabin air through the evaporator and blows the air back into the cabin via the nozzles in the air distribution panel Fig 2 3 Compressor The compressor 27 Fig 2 3 comprises a swashplate compressor and a magnetic coupling with belt pulley It is driven at constant speed by an electric motor 28 Fig 2 2 When in operation it compresses the refrigerant to the required condensation pressure Electronic room thermostat optional An electronic room thermostat and temperature sensor are integrated in the deluxe version The intake air temperature is measured The electric motor is switched off when the temperature set on the setpoint potentiometer is reached Electric motor The electric motor 28 Fig 2 2 drives the compressor via a poly V belt The electronic system in the motor includes a soft start function to prevent current pea
7. Page 28 30 6 8 Roof top air conditioning system Easysphere Post repair procedures and testing Check refrigerant pressures and pressure switches function tests a General As a rule every air conditioning system filled with refrigerant is a pressurized system The pressure is the same throughout the system circuit and depends on ambient temperature During operation of the system the working pressure on the intake side differs from that on the delivery side of the compressor The pressures differ and are influenced by the compressor operating speed the temperature inside the vehicle the outside air temperature and relative humidity Abnormal working pressures indicate that there is a fault in the system The working pressure should be tested with an on board power supply of 24 26 V and at air temperatures between 20 C and max 40 C The fan must be operated at full power stage 3 The hood must be fitted for the pressure test since the air pressure of the heat exchangers has a decisive influence on whether or not the operating pressure is reached The following values must be obtained Outside air Low pressure gauge High pressure gauge temperature 27 C 3 0 bar abs 0 2 bar 10 bar abs 2 bar 30 C 3 2 bar abs 0 2 bar 11 bar abs 2 bar 35 C 3 5 bar abs 0 2 bar 13 bar abs 2 bar 40 C 3 9 bar abs 0 2 bar 15 bar abs 2 bar If different pressure values are obtained an authorized
8. etc should be checked for continuity The following possibilities must always be checked and excluded as a possible cause of the malfunction Defective fuses Corrosion of plug contacts Loose contact in plug connectors Wrong crimping on connector Corrosion on wiring and fuses Corrosion on battery poles Cause of faults in the air conditioning system Defective evaporator or condenser fan Contaminated or clogged air filters evaporator or condenser fins Shortage of refrigerant in the system If the system is deactivated continuously we recommend that it be checked by an authorized workshop Dealing with problems in the refrigerant circuit If faults arise in the refrigerant circuit the system must be inspected and repaired by an authorized specialist repairshop Refrigerant must never be discharged into the atmosphere refer to Section 8 of the regulation dated 6 May 1991 banning the use of CFCs and halones Cause of faults making it impossible to reach the required states during pressure tests Divergences from the required state during pressure tests chapter 6 8 may be due to the following causes These causes must be checked the trouble located and defective components repaired or replaced High pressure gauge reading too high Condenser air flow restricted Too much refrigerant High pressure gauge reading too low Not enough refrigerant check sight glass compre
9. sight glass 14 Fig 2 2 to ensure that there is sufficient refrigerant in the circuit Thermostatic block valve The thermostatic block valve 11 Fig 2 2 regulates the flow of refrigerant to the evaporator as required and in accordance with the temperature in the evaporator The thermostatic expansion valve represents the control element between high and low pressure part of the refrigerant circuit Evaporator The evaporator 6 Fig 2 2 is basically of the same design as the condenser The refrigerant flowing through the pipe from the expansion valve changes from the liquid to the gaseous state and superheats in the evaporator The required evaporation heat is extracted from the cabin air flowing through the fins and is transmitted through the pipe to the refrigerant The air dries as it cools and condensation water is drained overboard The mist separator 7 Fig 2 2 prevents droplets of condensation being drawn in by the radial fan and entering the interior of the vehicle Page 11 30 Roof top air conditioning system Easysphere Pressure switch The pressure switch 15 Fig 2 2 includes a high pressure and a low pressure switch It monitors the pressure in the high pressure part of the refrigerant circuit and switches off both the electric motor and the compressor if the pressure is too low e g due to loss of refrigerant or too high e g due to overheating in the condenser Anti icing switch The anti icing switch 12
10. 2 5mm d ge 2 5mm 2 sw 2 5mm ES sw 2 5mm vio 2 5mm 2 vio bl 0 5mm or 0 75mm 2 or 0 75mm 2 Wwio bl_ 0 5mm ge 2 5 mm gn 2 5 mm sw ws 2 5mm 1 1 A 0 Mot rot 2 5m rot2 5mm 16mm Plus pin B both sides M10 dia L cable length in meters Page 16 30 max current Nomenclature Pos 24 V Cable size vehicle side Temp selector B3 83051 Ground Compressor Thermostat module B2 66784 24V version 16mm 16mm 2 5mm Temperature sensor B1 Philips KTY 81 110 Fuse F1 F2 15A 15A Fuse socket 4 fold FA 81676 LxI 12 meters x 70 amps A 15mm LP HP HD ND switch S3 66553 Kappa x U 56 x 1 0 volt Anti icing switch S4 65345 selected standard cross section min 16 mm Relay K1 34098 Rocker switch 1 S2 66596 66595 Lx 20 Meter x 70 Ampere A _ _ 225mm Axial fan M1 M2 64506 Kappa x U 56 x 1 0 Volt Radial fan M3 80866 selected standard cross section min 25 mm Prot against reversed F3 75A polarity A cable cross section Kappa s
11. EV SPHEROS Roof top air conditioning system Installation and service instructions Easysphere prefilled Stand 09 2010 Ident Nr 1103757B Roof top air conditioning system Easysphere CONTENTS 1 INTRODUCTION 1 1 Scope and purpose 1 2 Meanings of warnings cautions and notes 1 3 Additional documentation required 1 4 Safety information and regulations 1 5 Certification 1 6 Corrections and improvements GENERAL DESCRIPTION 2 1 Roof top air conditioner unit 2 2 Electrical components 2 3 Principle of operation of the air conditioning system 2 4 Design purpose and principle of operation of the assemblies TECHNICAL DATA 3 1 Air conditioning system 3 2 Electrical fuses 3 3 Compressor 3 4 Circuit diagram for basic version 3 5 Circuit diagram for deluxe version INSTALLATION INSTRUCTIONS 4 1 Safety precautions 4 2 Installation kit 4 3 The following are not included in the installation kit and must be produced on site 4 4 Required equipment special tools and accessories 4 5 Preparations on vehicle cabin roof 4 6 Preparation of sealing frame 4 7 Make electrical connections STARTUP 5 1 Safety precautions 5 2 Operator instructions 5 3 Controls and indicators 5 4 Putting into service for the first time 5 5 Operation 5 6 Operation of the air conditioning system deluxe version Page 2 30 aa fF A LH HR A 11 13 13 13 14 15 16 17 17 17 17
12. W 550 m3 h 1 C 1 3 5 C Max 900g 50g Fuse Ratings Designation F2 15A F3 15A 75A Page 13 30 Roof top air conditioning system Easysphere 3 3 Compressor Designation Dimensions length x width x height Sense of rotation Stroke volume per revolution Lubricating oil for refrigerating compressors type quantity Refrigerant connections Delivery side standard Intake side standard Installation position range of tilt About longitudinal axis About lateral axis Magnetic clutch Power supply Power consumption Connector type Page 14 30 Type Sanden 5D5 H09 183 mm X 124 mm X 124 mm clockwise 87 cm PAG 150 cm 3 4 O ring 7 8 O ring max 30 max 10 24 Volt DC max 34 Watt DIN 46343 AMP 6 3 3 4 Circuit diagram for basic version Roof top air conditioning system Easysphere Pag Guo v0 oe Pa Ad o 0 7 m DL 0000003 M1 M2 j M3 j M i B Cm Cm 9 co M Hi secedere 5 EE S i Hie Urea ET 2 FONE EVS ea il l U l U URU t LU L1 E T E t t E 2 3n sw 2 5mm 5 5 5 5 5 a vio 2 5mm A a N N a N 8 5 8 5 S 8 e sw 2 5mm
13. e setpoint potentiometer Insert the setpoint potentiometer in the hole in the air distribution panel as shown in Fig 4 4 The wiring harness is prepared for connection to the command value switch potentiometer mechanical Simply pull on connector housing to unplug the connector By pulling on the cable loom the terminal plug is arrested self locking NOTE The light conductor must make contact with the rotary selector Installation of air distribution panel a b Prepare the air duct frame if necessary so that it creates an effective seal on all sides and the top of the intake and delivery area between the vehicle roof and the intermediate roof Secure the air duct frame to the roof Ensure that the fitted roof top air conditioning system is not damaged when drilling holes Connect cables between the air distribution panel S1 and S4 in circuit diagram Fig 3 1 or 3 2 and the baseplate Position the air distribution panel as shown in Fig 4 3 and secure it with ten self tapping screws to the intermediate roof or to suitable self made brackets if necessary If the optional recirculating air filter has also been ordered it must be inserted in the intake area of the air distribution panel Page 21 30 Roof top air conditioning system Easysphere NOTE The air distribution panel must not be aligned with the centre of the air intake opening The air distribution panel must cover the air intake opening in the vehicle roof
14. ed into the air distribution panel e 9 amp w D D D C26 Q ozo 200000000000000000000 N 9 e S Fig 2 3 1 Air conditioning system ON OFF 2 3 position rocker switch 3 Setpoint potentiometer optional Page 8 30 Roof top air conditioning system Easysphere 22 Electrical components Electrical connections for the equipment are made as shown in the circuit diagrams Figs 3 1 and 3 2 The roof top air conditioning system is equipped with a protective circuit to prevent total exhaustion of the battery The system is switched off automatically if the power supply drops below 20 V for more than 10 seconds It is restarted by repeatedly switching on If the system is only to be operated when the engine is running a working contact relay must be installed and connected via terminal D 61 from the alternator see circuit diagram on page 16 The electronic system for the motor includes a soft start function to prevent current peaks being transmitted to the on board supply In add
15. eight fastening points and insert the nine M8 bolts with washers into the holes Fig 4 3 Condensation water Armaflex Sealing frame Vehicle roof LI a Luftkanalrahmen Intermediate roof 00 Air distribution panel Self tapping screw 00000 9 Oo O oO O sI CY Bottom view Fig 4 3 b Check that the baseplate has been positioned correctly and screw it tightly into place with the washers serrated washers and nuts included in the installation kit tightening torque 9 Nm IMPORTANT Ensure that moisture can escape between the vehicle roof and the baseplate When sealing the sealing frame care must be taken to ensure that the drains for condensation and rainwater remain free Others seals in addition to those described here using Sikaflex 221 and the Armaflex sealing frame are therefore not permitted Page 20 30 Roof top air conditioning system Easysphere Pre assembly of air distribution panel The rocker switches and the setpoint potentiometer if applicable must be installed in the air distribution panel depending on the individual version and scope of supply Installation of the operating Setpoint element Rocker switch potentiometer optional Right Wrong Fig 4 4 Installation of the rocker switches Locate rocker switches in rectangular cut outs of air distributor panel so that they engage Fig 4 4 Installation of th
16. erior of the vehicle is cooled in recirculation mode in keeping with the set fan speed 1 2 or 3 C The temperature of the air conditioning system CC4E without electronic room thermostat is controlled via the anti icing thermostat in the system which switches off the electric motor when the temperature at which ice forms on the evaporator is reached The evaporator and condenser fans continue to run The electric motor is switched on again when the threshold temperature of the anti icing thermostat is exceeded d Manual control of the cooling performance may be achieved by means of fan power stage selection Stage 1 low cooling performance at low air outlet temperature and low fan power Stage 2 mid cooling performance at mid air outlet temperature and mid fan power Stage 3 high cooling performance at somewhat higher air outlet temperature and maximum fan power NOTE In order to cool and dehumidify the interior of the vehicle after standing for a long time in high outside temperatures and direct sunlight it is advisable to switch the fan to speed 3 at first It can then be turned down to speed 2 or 1 depending on the outside temperature when a pleasant temperature has been achieved inside the vehicle 5 6 Operation of the air conditioning system deluxe version Operation is as described in 5 5 for the basic version In addition the temperature can be selected via a setpoint potentiometer optional with knob The electric motor is switched
17. gulations Non compliance with the installation manual and its procedures will void the Webasto warranty The same applies to unskilled repairs or repairs not using original spare parts Electrical wiring and operating elements of the air conditioning system must be arranged in the vehicle in such a way that their correct functioning cannot be impaired under normal operating conditions Page 4 30 Roof top air conditioning system Easysphere Safety instructions for maintenance If faults develop in the refrigerant circuit the system must be tested and repaired by an authorized specialist repairshop Under no circumstances may refrigerant be discharged into the atmosphere refer to Section 8 of the regulation dated 6 May 1991 banning CFCs and halones Never heat refrigerant cylinders with a naked flame Liquid refrigerant must never be allowed to come into contact with the skin Always wear protective clothing and goggles when handling refrigerant 1 6 WARNING Do not perform soldering or welding directly on components of the closed refrigerant circuit or in its vicinity The heating will cause a rise in the circuit pressure There is a danger of explosion Before performing any work allow the system to cool down completely Risk of injury due to burns on the condenser compressor and hoses Installation maintenance and repair work must be carried out by duly qualified personnel Such work may only be undertaken with the engine
18. inspection a Outer condition of roof top unit Hood without cracks and no damage to paint finish Air inlets and outlets clean and undamaged Attachment points secure and without corrosion Hose and wiring connections serviceable Openings in metal undamaged Condition of air distribution panel Attachment points screws secure Ventilation switches serviceable Circulating air inlet outlet screen undamaged and clean Condition of compressor Hose connections undamaged and secure Attachment parts screws secure Poly V belt correctly tensioned Poly V belt and V belt pulleys undamaged Electrical connection undamaged Page 26 30 Roof top air conditioning system Easysphere 6 6 Troubleshooting General a A systematic approach is advisable for troubleshooting Appropriate action must be undertaken as described below for faults of a general nature or when normal conditions are not obtained during the pressure test b Certain faults can only be located and remedied by skilled personnel using special tools C If the compressor is damaged e g defective valve plates it is absolutely essential to replace the expansion valve as a possible cause of the malfunction Cause of faults in the electrical system The individual circuits must be systematically checked with the aid of the circuit diagram see Fig 3 1 and the fault localized Above all plug connections switches relays
19. ioning system Easysphere STARTUP Safety precautions The safety instructions in chapter 1 4 must be observed IMPORTANT The system may only be started when the hood has been fitted Risk of injury due to motor fans belts and the compressor coupling Operator instructions IMPORTANT The air conditioning system can only be put into operation with the vehicle engine running Controls and indicators The roof top air conditioning system is operated via the two rocker switches Fig 5 1 Air conditioning system ON OFF 1 3 position rocker switch 2 1 N N P 2 R Ol S 2 1 Fig 5 1 Putting into service for the first time Start the vehicle engine as described in the owner s manual Switch on system using ON OFF switch Operate system at maximum fan power 3 position rocker switch in position stage 3 Cold air must emerge from the air distribution panel after at least 2 minutes Reduce fan speed and check airstream Page 23 30 Roof top air conditioning system Easysphere 5 5 Operation NOTE Note the instructions in chapter 5 2 Prior to operation ensure that air conditioning system is in serviceable condition air inlets and outlets are unobstructed no leaves etc condensation water drain holes are unobstructed Operation of the system a The system is controlled by means of the rocker switches ON OFF and the fan switch b The int
20. ition the electric motor is switched off automatically in the event of overloads i e current consumption gt 80 A for more than 1 second due to possible system damage Restarting is effected by repeatedly switching on the system The electric motor is switched off automatically to prevent damage to the electronics at temperatures of less than 5 C or more than 96 C 2 3 Principle of operation of the air conditioning system When the air conditioning system is switched on via the ON OFF rocker switch the electric motor starts up and drives the compressor via a poly V belt The compressor compresses the refrigerant gas and delivers it to the condenser 3 where it condenses and gives off heat The resultant condensation heat is transferred to the outside air flowing through the condenser 19 and 20 Figs 2 4 and 2 5 Two axial fans 4 maintain a sufficient air flow even when the vehicle is stationary The liquid refrigerant flows through the receiver drier 13 to the expansion valve 11 where it expands as a result of the controlled pressure drop and then reverts to the gaseous state in the evaporator 6 absorbing heat at the same time The hot air 21 circulating in the driver s cab is drawn in by the radial fan 5 cooled in the evaporator dried and returned to the cab via the air distribution panel 22 The resultant condensation water is collected and discharged into the atmosphere via the drain outlet 25 During o
21. ks being transmitted to the on board supply In addition the electric motor is switched off automatically in the event of undervoltage 20 V for more than 10 seconds or overload current consumption gt 80 Amp for more than 1 second It is restarted by repeatedly Switching on the system The electric motor is switched off automatically at temperatures of less than 5 C or more than 96 C Page 12 30 3 TECHNICAL DATA 3 1 Air conditioning system Designation Dimensions roof top unit Length x width x height Weight Operating voltages depending on vehicle s electr System Current consumption Total current consumption Electric motor Condenser fan Compressor fan Switching points low pressure switch Off On Switching points high pressure switch Off On Refrigerant max ambient temperature 45 C Power rating at 46 rel humidity inside temperature 27 C outside temperature 35 C Evaporator air flow rate air flow unobstructed Switching point anti icing thermostat Off On Refrigerant capacity R134a prefilled 3 Electrical fuses Protected components 24V Radial fans compressor 2axial fans Electric motor Roof top air conditioning system Easysphere Type Easysphere 1 110 mm X 774 mm X 215 mm approx 55 kg 24 Volt DC max 68 A 53A 10A 5A 2 0 0 2 bar 2 1 0 3 bar 26 5 2 bar 20 2 bar R134a 3 5 k
22. n in Fig 2 2 It comprises Hood 1 as external contour element with openings and protective grilles for air inlet and outlet Baseplate 8 as the load bearing structural element The following are integrated into the baseplate Radial fan 5 Receiver drier 13 with sight glass 14 and pressure switch 15 Condenser 3 Evaporator 6 with mist separator 7 Expansion valve 11 Anti icing switch 12 Screw connections 9 10 Relay 16 and holder 17 for blade type fuses Cable harness with grommet 26 Axial fan 4 Electric motor 28 Compressor 27 Refrigerant hoses 29 30 Connecting pins 31 Page 6 30 Roof top air conditioning system Easysphere e Direction of travel T L 28 10 31 31 27 16 1 15 14 13 12 26 11 30 29 Fig 2 2 Page 7 30 Roof top air conditioning system Easysphere The air distribution panel Fig 2 3 is not included in the scope of supply The following operating elements ON OFF rocker switch 1 and fan rocker switch 2 can be integrated into the air distribution panel An electronic room thermostat is additionally integrated into the roof top unit in the deluxe version A set point potentiometer 3 Fig 2 3 is supplied for setting the temperature and can be integrat
23. off and the power supply switched off The battery must be disconnected before opening the roof top air conditioner removing the compressor or starting any work on the electrical wiring Do not wear metal jewellery bracelets watches necklaces rings when working on the air conditioning system Certification The electro magnetic compatibility EMC has been checked to meet the EN 45014 standard requirements The CE mark has been affixed to the roof top air conditioning system Corrections and improvements Complaints improvements and suggestions for correcting this manual should be addressed to Spheros GmbH Friedrichshafener Stra e 9 11 D 82205 Gilching Tel 49 0 8105 7721 887 Fax 49 0 8105 7721 889 www spheros de service spheros de Page 5 30 Roof top air conditioning system Easysphere 2 GENERAL DESCRIPTION The roof top air conditioning system CC4E 1 contains all the documents required for installation and operation Electric power is supplied by the on board vehicle supply via cables 2 The system is designed for operation with 24 V The roof top air conditioning system is designed for the cooling air conditioning of buses as well as the air conditioning of the driver s area in buses The system is prefilled with refrigerant R134a and need only be connected to the on board power supply when installed Easysphere Fig 2 1 2 1 Roof top air conditioner unit The roof top unit is show
24. off when the set temperature is reached The electric motor is switched on again when the temperature increases again by approx 2 C Page 24 30 Roof top air conditioning system Easysphere 6 MAINTENANCE 6 1 Safety precautions The safety instructions and regulations in chapter 1 4 must be observed 6 2 General a Work on the refrigerant circuit may only be carried out by qualified personnel from duly authorized specialist repairshops b The special equipment tools and accessories listed in chapter 4 5 are required and must be used for maintenance work on the refrigerant circuit C Like all parts of the vehicle the air conditioning system is subject to constant stresses The specified maintenance work must be carried out regularly in order to ensure troublefree operation of the system and avoid damage to the components d Proper handling of the system and a complete record of all the required scheduled maintenance are essential for acceptance of possible warranty claims concerning damaged components subject to maintenance e To prevent not only the shaft seals of the refrigerant compressor drying out but also moving parts in the refrigerant circuit from seizing up due to resinification of the oil the air conditioning system must be switched on for approx 15 minutes at least once per month when it is not in regular use Requirement Minimum outside temperature gt 5 C or heated hall 6 3 Maintenance and care a Rega
25. on 8 of the regulation dated 6 May 1991 banning the use of CFCs and halones Page 25 30 Roof top air conditioning system Easysphere 6 4 Maintenance and service checklist System component Maintenance task Frequency m 6m a Refrigerant circuit Hoses Check for chafing and general condition X Connections Test for leaks with leak tester X Refrigerant quantity Check refrigerant level in sight glass X Condenser Check condition of fins must be cleaned if soiled X Receiver drier Replace X Condensation water Check that opening is clear and clean if necessary X drain X Roof top air Check overall condition and secure attachment of conditioner unit connections Compressor Magnetic clutch Check engagement without slip compressor start up X Compressor Check noiseless operation X Poly V belt Check serviceability and tension X Mounting bracket Check condition and secure attachment X Electrical connections Wiring Check undamaged condition X Connections Check undamaged condition and secure attachment X Motor connections Check for signs of oxidation Abbreviations m monthly a yearly a every six months if operated throughout the year 6 5 Inspections before repair In order to avoid unnecessary disassembly or duplication of work the overall condition of the air conditioning system must be checked before starting any repairs Visual
26. oof so that the air distribution panel can be installed under the roof see Fig 4 3 4 6 Preparation of sealing frame a The height of the sealing frame must be cut adapted to the roof contour beads gutters camber in such a way as to seal the contours as shown in Fig 4 2 The sealing strips should be compressed by approx 2096 4096 in height when fitting the air con ditioning unit b Affix the sealing profile to the roof with the Sikaflex 221 included in the installation kit as shown in Fig 4 3 OE CE es az pcc LC Eccc o Oo Oo l pcr 60 la e lg Installation proposal for CC4E with Armaflex l viewed from above onto the vehicle roof R Il O JENNI 122 190 A us Y Direction of travel 370 frs Y 122 Cut edges and top and bottom surfaces bonded o with SIKAFLEX 221 to ensure they are watertight o o o A Cut edges Contour of baseplate Fig 4 2 C Coat the top of the sealing profile with Sikaflex sealing compound Page 19 30 Roof top air conditioning system Easysphere NOTE The curing time of 3 5 hours must be observed when using Sikaflex 221 for installation of the roof top air conditioning system Mount the baseplate before Sikaflex has cured Do not expose seal to moisture before Sikaflex has cured Mounting the baseplate a Place the baseplate on the roof sealing frame and align it Place silent blocks under the
27. pecific conductivity of copper cables U max permissible voltage drop Fig 3 2 Roof top air conditioning system Easysphere 4 INSTALLATION INSTRUCTIONS 4 1 Safety precautions The safety instructions set out in chapter 1 4 must be read and noted before starting work Installation should be performed by someone well versed in auto mechanics IMPORTANT Transmitter units e g radio antennas that are located in a distance of less than 1m from the roof top unit can under unfavourable circumstances ge nerate an electro magnetic radiation which tops the limits according to the European standard 72 245 EEC and thus can cause damage to the motor The cable routing is to be chosen in such a way that a sufficient distance to the transmitter unit is ensured In addition the electrical wires plus minus shall be routed together as bundle 4 2 Installation kit In addition to the main components i e the roof top air conditioning unit the basic scope of supply also includes the following parts and materials a For mounting the roof top air conditioning unit with air distribution panel 10 self tapping screws Sikaflex sealing compound 3 Armaflex sealing strips 9 silent blocks with bolts and nuts 4 3 The following are not included in the installation kit and must be produced on site Air duct frame between roof and air distribution panel Connecting cables and elements vehicle side see Fig 3
28. peration the refrigerant circuit is monitored by the anti icing switch 12 S4 see circuit diagram Fig 3 1 or 3 2 and the pressure switch 15 S3 see circuit diagram Fig 3 1 or 3 2 The electric motor and consequently also the compressor are monitored via these two switches When the air conditioning system is switched off via the ON OFF rocker switch the electric motor and the fan motors are de energized The refrigerant circuit and recirculating air circuit are switched off Rainwater entering the roof top system is discharged via the drain outlet 24 Fig 2 2 Page 9 30 Roof top air conditioning system Easysphere Page 10 30 Roof top air conditioning system Easysphere 20 EE C 32 00000 22 Fig 2 5 24 Design purpose and principle of operation of the assemblies Condenser The condenser 3 Fig 2 2 consists of a continuous pipe coil and fins interconnected to form a large heat exchanger surface It cools the hot refrigerant gas so that the latter liquefies and undercools At the same time it transfers the condensation heat to the outside air flowing through it via the fins Receiver drier The receiver drier with sight glass 13 Fig 2 2 is an expansion and storage reservoir for refrigerant Its lower part contains a granulated desiccant which extracts and chemically binds small amounts of water from the refrigerant During operation the level can be checked in the
29. rdless of the following schedule all screw connections securing the roof top air conditioning system must be checked within four weeks of using the system for the first time in order to ensure that they are secure b Even if the air conditioning system is not operated individual components are subject to wear due to normal ageing or stress due to vehicle operation All checks listed in the maintenance and servicing plan must therefore be performed regardless of the system operating hours C Even if hose connections do not leak refrigerant may be lost regardless of operating hours Due to the structure of the material used for the refrigerant hoses their diffusion rate can vary depending on ambient temperature However a leak must be assumed to exist somewhere in the system if relatively large quantities of refrigerant are lost at short intervals d Slight contamination of evaporator and condenser fins is removed with compressed air applied against normal direction of air flow Major contamination or greasy deposits must first be removed with soapy water or a suitable cleaning solvent not aggressive for copper or aluminum before cleaning with compressed air or a water jet e The receiver driver must be replaced at least once per year and whenever work has been performed on the refrigerant circuit f The filter mat must be replaced at regular intervals IMPORTANT Refrigerant must never be discharged into the atmosphere refer to Secti
30. repair shop must be consulted to investigate the reasons When the pressure test is complete disconnect the pressure gauges and refit the sealing caps Testing the high pressure monitor Connect pressure gauges to system Remove fuse F3 condenser fan and fit the hood Switch on the air conditioning system Check whether compressor switches off at a pressure of 26 5 2 bar Remove the hood and refit fuse F3 condenser fan Check that compressor switches on again when pressure drops to 20 2 bar Perform complementary steps IMPORTANT If the high pressure switch is not working properly switch off the air conditioning system immediately to prevent undue refrigerant pressure buildup Replenishing partially filled systems with refrigerant 6 9 A sight glass is integrated into the circuit at the receiver drier to check the refrigerant level When correctly filled refrigerant will flow through the sight glass without air bubbles roughly 5 minutes after starting the air conditioning system Occasional bubbles are meaningless If gas bubbles are visible the refrigerant quantity in the system has fallen below the minimum fill level Visual inspection The system must be inspected visually as described in chapter 6 5 when the repairs are complete Page 29 30 Roof top air conditioning system Easysphere 7 WARRANTY CLAIMS PROCESSING a Parts subject to natural wear or which have been handled incorrec
31. ssor speed too low e g by slippage of V belt Compressor defective Low pressure gauge reading too high Expansion valve defective Compressor speed too low e g by slippage of V belt Compressor defective Page 27 30 Roof top air conditioning system Easysphere Low pressure gauge reading too low 6 7 Intake or delivery line restricted e g by kinks Expansion valve defective Not enough refrigerant check sight glass Evaporator air flow restricted Clogged filter drier Repairs IMPORTANT Refrigerant must never be discharged into the atmosphere refer to Section 8 of the regulation dated 6 May 1991 banning the use of CFCs and halones NOTE The safety precautions and regulations contained in chapter 1 4 and 6 2 must be observed Only genuine spare parts may be used for repairs and the original condition must be restored Always use genuine spare parts or standard parts for repairs The system s original condition must always be restored when performing repairs Before opening disassembling components in the refrigerant circuit the refrigerant must be drained into the recycling station provided and disposed of properly or reused After completing repairs on the refrigerant circuit the system must be evacuated in accordance with the operating instructions of the recycling station filled with refrigerant on the high pressure side with the system at rest tested see chapter 6 8
32. tly are excluded from the warranty The warranty period is not extended by repairs or delivery of replacement parts b In the event that a warranty claim arises contact your local distributor dealer in charge and provide the following part under warranty warranty card warranty claim form Page 30 30
33. used correctly in accordance with the installation and service instructions If the vehicle height specified in the vehicle s licensing documents is exceeded by installation of the roof top air conditioning system this must be legalized by an official acceptance inspection in accordance with Section 19 of the German Road Traffic Licensing Regulations StVZO The following general and operational safety regulations for the prevention of accidents have to be observed at all times Safety regulations for the manufacture and operation of earth moving machinery published by the foundation works association Technischer Aufsichtsdienst Technical Supervisory Services Landsberger Str 309 80687 M nchen DIN ISO 3471 Roll over protective installations DIN ISO 3449 Protective installations against falling objects DIN ISO 3411 Machine operator s body size minimum working space Guidelines safety rules general rules and principles and the data sheets issued by the committees of the Central Health and Safety Office BG7 of the Central Association of Manufacturing Employers Liability Insurance Associations published by Carl Heymanns Verlag KG Luxemburger Strasse 449 D 50939 K ln General safety regulations beyond the scope of these regulations are detailed below The specific safety regulations applicable to this manual are highlighted in the individual chapters by WARNINGS CAUTIONS and NOTES General safety re
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