Econ Installation Manual.cdr
Contents
1. GON ER ria 20 WATERTANK aiar 2 1 WATER TANK SUPPORT OPTIONAL 2 8 WATER PUMP por zi UOI M 210 WATER PUMP COVER P CONNEC TIO N Scanato tari ONE Ris Rc vq capi 4 UNITSWITH TILT CABINS tasas 5 RECOMMENDATIONSTO THE INSTALLER 6 GENERAL MAIN TEN AN CE 7 REPLACEMENT OF THE MAIN COMPONENTS 8 FAILURE LOCATION GUIDE 26 VIESRA 1 ECOLOGICAL COOLER Function VIESA Econ is a roof mounted cab cooler that delivers cool air to the truck s cabin using evaporative cooling and without running the truck s engine Operation Cooling is generated by vaporized cool water delivered by a self contained electrical motor During operation it only consumes water and it makes no use of internal combustion engines nor does it use chemical coolants or emit gases into the atmosphere The unit is equipped with a water pump located in an auxiliary tank which takes water to the evaporator A biturbo blower pushes the exterior air to the interior of the truck forcing the air through the evaporator and therefore cooling the warm air The exceeding water backs to the water tank Application Applied to any vehicle withan operating voltage of 12 V VIESA 1 1 LOCATION OF PARTSAND COMPON2. ECOLOGICAL COOLERS 3 ECON Installation Manual www viesa ca 1 888 438 8444 IMPORTANT Installation requires an experienced mechanic with specific knowledge in the installation of the VIESA Ecological Cooler Installation disassembly repairs and maintenance must be performed by an Authorized Installer Authorized Installer must use proper protective equipment when installing the system Improper installation or use of unauthorized parts can cause malfunctions loss of battery life or other consequences which may result in serious injury Manufacturer or Distributor will not be responsible for injuries or damages resulting from misuse of equipment use contrary to operating instructions or installation by any person other than an Authorized Installer Information contained in this manual is subject to change Manufacturer reserves the right without notice to make changes in equipment design or components as progress in engineering manufacturing or technology may warrant World wide Patents VIGIA is a trademark of Col Ven S A Index INSTALLATION MANUAL l ECOLO GICAL COOLER 1 1 LOCATION OF PARTSAND COMPONENTS od 12 lO CHARACTERISTIC S emer tt oe 2 MAIN COMPONENTS ss 2 Ie BI siii nidi eri ri 2 2 UPHOLSTERY COVER AND ACCESSO RIES ene 2 3 POWER AND CONTROL MODULE mmn ZO REMO CI
3. VIESA VERY IMPORTANT NEVER APPLY TANK TO CABINS WITHOUT REIFORCEMENTS INSIDE REINFORCEMENTS TRUCK CABIN 1 WATER TANK SUPPORT PLATE THREADED RIVET PUT IT IN THE LINE OF WELDING REINFORCEMENT CHANNEL GROWER WASHER ALUMINUM SPACER SCREW WASHER 23 M VIESA Identify the place on the rear part of the cabin where the tank will be installed Use the support plate to mark the points of attachment to the cabin ALLWAYSOVER THE WELDING LINES prove with a 5 mm diameter drill bit and then perforate with a 9 mm drill bit If using neoprene rivets use a 12 mm drill bit eoprene rivets are used in units with fibreglass cabins Important V hen using the 5 or 9 mm drills bits use a depth stop to prevent damaging the inside upholstery Introduce and affix the threaded rivets provided For neoprene rivets insert them manually up to the brim Then adjust the screws Install the water tank support plate to the cabin taking into account that there must be a separation of 10 mm between the plate and the cabin Use the spacers provided Place the polyester foam washers in order to avoid water or humidity filtrations 24 Important Use adequate separators to compensate uneven surfaces Before attaching the support plate to the cabin set the tank s fixing screws and washers provided Attach the support plate firmly W hen using the water tank on vertical positi
4. CURRENT BREAKER T WATER LEVEL SENSOR POLARITY FREE WATER PUMP A Very Important The fuse must be installed at the end Important In ADR dangerous goods Transportation encase and protect the electrical wiring in approved fire proof material N ote use the provided wire terminals terminal covers and sockets Solder wire terminals and or joints with tin The connection of the pump and level sensor must remain inside the pump cover Important the positive cable is the last element to be connected 31 N viesA ATTACHING THE ELECTRICAL AND HYDRAULIC CONNECTIONS Use the self adhesive tie bases and plastic ties provided to attach the electrical and hydraulic connections from the evaporator down to the water tank N ote Clean the surface where the adhesive will be placed 32 VIESA 4 UNITSWITH TILT CABINS a With Water Tank Applied to the Cabin Note The power supply must be direct from the battery or the main switch SET OF ELECTRICAL AND HYDRAULIC CONNECTIONS ORIGINAL MAIN SWITCH b With Water Tank Applied to the Chassis SET OF ELECTRICAL AND HYDRAULIC CONNECTIONS DUAL RESTRICTION QUICK CONNECTION HOSE ELECTRICAL INSTALLATION W a 33 VIESA Wires to the water tank and battery must be extended See detail below TO THE EVAPORATOR UNIT DUAL i RESTRICTION VALVE QUICK CONNECTION
5. TO THE WATER TO THE WATER PUMP PUMP AND LEVEL SENSOR 34 VIESA 5 RECOMMENDATIONSTO THE INSTALLER Wet the evaporator immediately after installation in order to fast start cooling Clean the working area Provide the owner with the User s Manual and warranty information Explain the user the operation and maintenance of the equipment in detail Explain to the user that BEFORE SWITCHING ON THE UNIT one window must have cm opening and all other vents must be closed This opening will allow hot air to be expelled from the interior 6 GENERAL MAINTENANCE The equipment will delay in cooling until the evaporator 15 totally wet Do not use fuses higher than 15 Amp The equipment will deactivate automatically due to low tension so as to prevent damages to the battery Use only clean water Foresee replenishment of water taking into account that the equipment consumes between 2 and 5 litres per hour depending on the ambient temperature During short stops leave the equipment on so as to keep the cabin fresh System must be turned off when exhaust fumes or toxic particles could enter the cab through the system VIESA SCENTED FLUID EVERY 200 HOURS OF USE A When performing maintenance of the equipment or if the evaporator unit s cover or the upholstery cover are removed the system MUST NOT BE SWITCHED ON and you must not switch it on with any of these elements removed Keep the tank clean Every
6. connector head to lock 3 Locate the switch commanding the water cycle and set it according to the water column height See Water C ycle Setting before 4 Connect the electrical installation to the command and control module Note Tie and stick the electrical installation to the upholstery cover with the provided tie STICK THE AUTOADHESIVE nr 6 Place the upholstery cover with the display oriented to the front of the cabin 7 Affix the upholstery cover with the 4 screws without tightening 8 Introduce the air grilles with their weather strips 9 Fasten the air grillesto the upholstery cover with the screws in the indicated sequence 19 VIESA 10 Tighten without forcing the 4 upholstery screws until covering the original upholstery without gaps 2 6 WATER TANK Placement 20 WATER TANK MODELS There are two models Standard 32 litres Dimensions 64 x 52 x 13 5 cm Small 20 litres Dimensions 64 x 35 x 13 5 cm Made of anon translucent material which assures darkness inside and prevents fungi formation on the interior walls Resistant to vibrations and rapid changes in temperature 21 M VIESA INSTALLATION a at the back of the cabin b In the chassis note Do not place it near the exhaust pipe Placing the tank horizontally a is preferred Use vertical placement b only if not possible to place it horizontally 22
7. 200 hours of use Drain all the water from the tank by removing the drain plug Rinse with clean water thoroughly Pour one bottle of Viesa Scented Cleansing Fluid Fill up the tank with clean water Each 6 months change the package of granulated C alfa Bas crystals Do not use chemical products to clean the control panel 35 VIESA Every 2 months or according to working conditions Submerge the evaporator in water with bleach 1 Clean the grids of the air entrances 2 Clean the filter of the collector tray 3 36 7 REPLACEMENT OF THE MAIN COMPONENTS REPLACEMENT OF THE MOTOROF THE BITURBO BLOWER Remove the cover of the evaporator unit fixed with 5 screws Remove the evaporator Remove the two turbines covers taking away the 8 screws Remove the 4 screws of the blower mounting bracket and remove it Replace the motor making the corresponding electrical connection Put back the motor s mounting bracket and adjust Important Before tightening the bracket center the motor correctly so that the turbines do not on rub the sides Put back the two turbine covers Place back and adjust the cover of the evaporator unit 37 E x VIESA REPLACEMENT OF THE POWER MODULE Remove the cover of the evaporator unit Remove the 2 screws holding the power module to the base Change the power module and reconnect Reinstall the cover of the evaporator
8. rubber gasket 28 2 9 LEVEL SENSOR Controls the water pump operation Introduce the level sensor according to the figure Keep the marked arrow UP Use the provided rubber gasket 2 10 WATER PUMP COVER To place the water pump cover insert first one of the holes in the Water tank pin an then manually insert the second hole N ote Make sure not to obstruct the water pump cover draining hole If necessary make an additional hole DRAINAGE Important Don t use tools to remove the water pump cover 29 VIESA 3 CONNECTIONS 3 1 HYDRAULIC THIS VALVE MUST BE INSTALLED BELOW THE THE UPPER EDGE OF THE WATER TANK IN TILT CABINS OR WATER TANKS INSTALLED ON THE TRUCK CHASSIS THE VALVE MUST BE INSTALLED AT MORE THAN 1 BELOW THE EVAPORATOR S LOWER EDGE N ote cut the tubes accordingly The grey cord wrap must cover all the hoses and wires until it reaches the pump cover Important to install the elbow for ventilation in the tank make a 22 mm diameter hole in the center of the top the tank remove shavings Use the elbow provided 30 VIESA 3 2 ELECTRICAL POWER MODULE 5 WAY SOCKET YELLOW BLACK BLACK BROWN BROWN POWER AND CONTROL MODULE RED BLACK Q 4 m BITURBO BLOWER IYELLOWR or LIGHT BLU ANTIPARASITIC FILTER FUSE 15A IMPORTANT THE FUSE HOLDER ii MUST REMAIN OUTSIDE THE BATTERY COMPARTMENT EE E BATTERY
9. ENTS ied EVAPORATOR UNIT UPHOLSTERY COVER WITH DISPLAY CONSOLE ELECTRICAL AND md HYDRAULIC CONNECTIONS WATER TANK 1 2 TECHNICAL CHARACTERISTICS Aerodynamic external design Evaporator unit cover with UV protection Adjustable upholstery cover 8 speed turbo blower Distribution air ducts with airtight closure Turbo blower with sealed motor mounted on bearings D esigned and manufactured according to EMC electromagnetic compatibility norm 32 litre water tank with pump cover Anti spill water system W ater level sensor Low water lever pump disconnection and alarm Protection system for short circuit in the pump and its connections Automatic system disconnection under low battery voltage Protection for high voltage Fused main feed cable Protection for polarity reversal 8 A per hour average consumption with turbine at maximum speed 2 to 5 liter average consumption of water per hour depending on ambient humidity VIESRA 2 MAIN COMPONENTS The equipment consists of an evaporating unit electrical and hydraulic connections an upholstery cover and a water tank with pump Important Vehicle with equipment installed must not exceed maximum allowed height 2 1 EVAPORATOR UNIT VIESA EVAPORATOR 12 UNIT COVER EVAPORATOR R 4 EVAPORATOR TRAY TANK J ssi lt BITURBO BLOWER i T 1 4 COVER OF THE E
10. SSIBLE CAUSES SOLUTIONS HYDRAULIC HYDRAULIC The indicators are ok but the equipment has low efficiency W hen the equipment 15 on water enters by the air grilles and or it spills through the ceiling 1 Inverted electrical connections of water pump s 2 Evaporator 9 x 15 cm hose blocked 3 Evaporator placed upside down 4 Blocked holes at the water distributor of the evaporator 5 Dirty evaporator 6 Water pump damage 7 Faulty power and control module 8 Water Cycle Switch with wrong setting 9 Air grilles without weather strips 10 Blocked air entrances of the base of the unit 11 Faulty blower 1 Incorrectly oriented holes of the water distributor of the evaporator 2 Blocked dual restriction valve 3 Blocked return hoses 4 Blocked PVC filters in the evaporator s tray 5 Water column less than 40 cm 6 Water Cycle Switch with wrong setting 44 1 Connect correctly Red and black 2 Modify 3 Place the evaporator with the hose connector upwards 4 Replace the evaporator 5 Clean and or replace the evaporator 6 Replace the water pump 7 Replace the power and control module 8 Reset Water Cycle Switch according to water column height VENTILATION VENTILATION 9 Put strips to the air grilles 10 Clean the air entrances 11 Replace the motor of the blower 1 Replace the evaporator 2 Clean or replace the valve 3 Clean hoses or cha
11. VAPORATOR UNIT EVAPO RATO R Composed of two even distributed layers of special wood shavinos EVAPO RATOR TRAY TANK This element works as a water deposit and it collects the excess water that the evaporator receives It allows the return of excess water to the water tank LEVEL SENSOR Its function is to monitor permanently the presence of water in the tank activating the water pump when the level is low BITURBO BLOWER It has two turbines which absorbs the air that comes from outside forcing it to the interior Maximum consumption is 7 5 12 volt units POWERMODULE It controls the biturbo blower speed 26 VIESA INSTALLATION PROCDURE Units Without Hatch EVAPORATOR UNIT ee e es UNIT S ROOF lt STEEL FRAME FOR ROOF WITHOUT HATCH PLASTIC NUT FOR UPHOLSTERY COVER THE EVAPORATOR UNIT k ADJ USTING SCREWS FOR WASHER aa be UPHOLSTERY COVER ADJ USTING UPHOLSTERY COVER SCREWS AIR GRILLE ADJ USTING GRILLE SCREWS ADO NOT CUT ROOF OVER REINFORCING CHANNELS 10 VIESA a UseViesa 5 Interior and Exterior Templates to cut the roof openings a l Determine the suitable place where the evaporator unit will be placed a 2 Mark the openings to be cut a 3 Check from the inside that no reinforcement channels or electrical wires will be cut a 4 Cut the roof and shave any roughness Neer Note W hen cut
12. e base of the evaporator Make sure weather strip will sit on the roof not over the opening c Apply silicone glue on the underside of weather strip so as to avoid water filtration d Place and affix the evaporator unit to the truck s roof 12 VIESA e Place the adjustable roof supports in the interior against the celling f Use the 4 screws changeable length in accordance with the thickness of the ceiling and tighten until the weather strip is compressed to 10 mm approximately N ote If there is enough space use a nut and locking nut between the underside of the roof and the base of the evaporator unit N ote If the adjustable supports are to long cut them at their ends Important In roofs without reinforcements some support must provided in order to maintain rigidity to the cab WEATHER STRIP i 1 BASE OF THE EVAPORATOR UNIT REN ADJUSTING SUPPORT b UP TO THE INDENT OR REINFORCEMENT eee NUTS MINIMUM 20 MM WEATHER STRIP NUT AND LOCKING NUT TIGHTEN di 4 SCREWS IN ROTATING SEQUENCE 13 VIESA 2 2 UPHOLSTERY COVER AN D ACCESSORIES lt lt vara WEATHER STRIP FOR AIR DUCT AND GRILLE lt __ AIR DUCT REDUCING SUPPORT EE lt WEATHER STRIP WEATHER STRIP 5 p 4 T ADJUSTABLE ROOF SUPPORT POWER AND CONTROL MODULE UPHOLSTERY COVER 2 3 POWER AND CONTROL MODULE It allows the follow ing operations To change the speed o
13. f the biturbo blower up to 8 speeds To control the water pump cycles TECHNICAL CHARACTERISTICS a Protection for polarity reversal 0 Protection for high voltage VIESRA Short circuit protection in the water pump the biturbo fan and or in its corresponding electrical connections d Automatic disconnection due to lack of water the tank e Working tension 12 volts f Auto switch off for low battery tension N ote voltage is monitored at the battery terminals CONTROL OF THE WATER The module controls the operation of the pump cycle It is showed in the following chart WATER PUMP OFF OPERATING WATER PUMP BETWEEN 14 AND 30 SECONDS 35 SECONDS 7 MINUTES IGNITION 4 d SELECTABLE SEE WATER CYCLE SETTING LOW WATER LEVEL SENSOR OPERATING WATER PUMP It monitorsthe presence of water in the tank if there is alack of water it informs the operator with a red LED indication and it stops the operation of the water pump automatically N ote After replenishing the water tank the alarm will stop after approximately 3 minutes VIESA Water Cycle Setting Very important It is necessary to select one of the settings for the water cycle and according to the height of the water column W ithout this setting the power and control module will not work Water column 35 Sec Do not use 40 Sec Do not use Important to change the setting after installation
14. h commanding the water cycle is properly set See Water C ycle Setting before 40 The restriction valve is not clogged and that water flows freely trough the outlet The water pump supply voltage is correct 9 8 V minimum Important M easure at the pump s connector with the pump working and the turbo blower at maximum speed The water pump consumption Amp is between the specified values between 2 0A and 4 0A with water running through Important Remove the fuse and measure at the fuse box while the pump is running and the biturbo blower is off The water pump electrical connections are correct 41 VIESA If the water collected is above the maximum check that NO RESTRICTION CLOGGED The restriction valve is not clogged and that water returns freely trough the outlet The switch commanding the water cycle is properly set See Water Cycle Setting before EVAPO ASSESSMENT Manually pull up the evaporator and with the water pump working check that water is distributed evenly around the evaporator VENTILATION Check that the air grilles have their weather strips Check that the air intakes are not obstructed 42 Verify that the evaporator is not dirty or lacking wooden chips Verify the biturbo blower input voltage 9 5 V minimum Important M easure at the biturbo blower pins and when it is working and the water pump is working 43 VIESA PROBLEM PO
15. nge path 4 Clean PVC filters 5 Place the tank lower 6 Reset Water Cycle Switch according to water column height VIESRA PROBLEM POSSIBLE CAUSES SOLUTIONS The equipment works well but 1 Short circuit in the blower or 1 Replace the blower or repair the fuse burns out continuously in its connections 2 Short circuit in the water 2 Replace the water pump or pump or its connections repair 3 Damaged power wire 3 Locate repair and seal correctly W ater pump operation not 1 Inverted electrical connections 1 Connect red wire to showing on display to battery black to blower works at one speed only 2 Faulty power and control 2 Replace the command and module control module Power module burns out 1 Seized biturbo blower 1 Replace biturbo blower motor Pump cycles are not right ones 1 Water Cycle Switch with 1 Reset Water Cycle Switch wrong setting according to water column height Blower at its maximum speed 1 Faulty power module 1 Replace the power module cannot be turned off Check the free spinning of the blower Blower works display shows 1 False contact and or 1 Repair and or connect normal operation but the disconnection of the ribbon cable pump doesn t work control and command module 2 False contact and or 2 Repair and or connect disconnection of the water pump Tinterminals of the water pump 3 Faulty control and command 3 Replace the control and mod
16. on you have to make 3 holes of 22 mm in diameter Plug original holes with provided plugs For venting On the upper part of the tank and at its center For the level sensor On one of the ends of the marked line where the water pump will be placed 25 VIESA For draining at the bottom of the water tank and on the same side of the water tank cap Important Remove shavings INSERT DRAIN PLUG Place the water tank on the support plate and affix with the provided screws and washers O nce the tank has been installed cut the cord from the evaporator containing hoses and wires See electrical and hydraulic diagrams in order to assess their length 2 7 WATER TANK SUPPORT OPTIONAL Depending on the vehicle the water tank support can be placed parallel or perpendicular to the chassis frame Never drill the frame s flange 26 Additional U channel pieces may be necessary gt ADDITIONAL Add U SHAPED SUPPORT Important distances A and B must be equal p fi Lai ole V 4 SMALL TANK POINTS OF REMOVE ATTACHMENT POINTS OF ATTACHMENT STANDARD TANK POINTS OF ATTACHMENT REMOVE POINTS OF ATTACHMENT 27 VIESA 2 8 WATER PUMP Technical Characteristics a Centrifugal b Consumption 12 volts 3 1 A Installation Place the water pump in vertical postilion Insert the pump s nipple into the water tank cap with hole Use the
17. proceed as follows Remove the fuse or disconnect the main positive wire Activate the corresponding key Place the fuse or connect the main positive cable VIESA 2 4 BOARD INDICATIONS Important before switching on the equipment With parked vehicle Open one of the windows 2 to 3 cms With the vehicle in motion Open one of the windows 2 to 3 cms and close all other air entrances to the cabin so that hot air does not enter from exterior BOARD O REMOTE SYSTEM ON OFF TURBO FAN SPEED WATER PUMP SWITCH CONTROL TO HIGHER ON OFF SWITCH TURBO FAN SPEED WATER TANK INDICATOR INDICATOR EMPTY WATER SLOW FLASHING Hid gaa 1 2AND3 TANK ALARM CONNECTED VERE FAST FLASHING TURNS OFF G97 AND 8 AUTOMATICALLY OPERATING N ote Keys must be held pressed for 1 second 17 VIESA 2 5 UPHOLSTERY COVER INSTALLATION PROCEDURE 1 Insert the weather strips into the evaporator s base openings and push the air ducts burr up through the weather strips making pressure until they are firmly placed Important Cut the air ducts if needed Air ducts 240 mm high can be ordered for very thick ceilings 2 Attach the command and control module to the upholstery cover inserting the 3 locking pegs into their holes Insert the ribbon cable as indicated the figure raise the connector head first introduce the ribbon cable and then push down the
18. ting be carefull not to make right angles on the the corners Corners must be round see detail in order to avoid future roof fissures Important If the roof surface is a thin metal sheet a 1cm fold upwards has to be made all around the perimeter b Glue the weather strip to the base of the evaporator c Apply silicone glue on the underside of weather strip so as to avoid water filtration d Place and affix the evaporator unit to the roof e Place the steel frame in the interior against the ceiling f U se the 4 screws changeable length in accordance with the thickness of the ceiling and tighten until the weather strip is compressed to 10 mm approximately DIRECT PLASTIC WASHERS INWARDS N ote If there is enough space use a nut and locking nut between the underside of the roof and the base of the evaporator unit Important In roofs without reinforcements some support must be provided in order to maintain rigidity to the cab VIESA U nits with Hatch EVAPORATOR UNIT er m WEATHER 27 STRIP _ UNIT S ROOF p ADJ USTABLE ROOF SUPPORT pe n PLASTIC NUT FOR UPHOLSTERY COVER ML di PRI P THE EVAPORATOR UNIT WASHER UPHOLSTERY COVER A ADJ USTING UPHOLSTERY DO me 7 GRILLE COVER SCREWS _ ADJ USTING GRILLE SCREWS 26 1 a Remove the original hatch b Glue the weather strip to th
19. ule command module 4 Faulty water pump 4 Replace the water pump The speeds do not match the 1 Faulty blower 1 Replace the motor of the display indications or they do not blower change 2 Humidity or water in the 2 Clean and seal Check conditio power module s terminals of evaporator 3 Faulty power module 3 Replace the command and control module 45 INSTALLATION MANUAL VIESA ECON REVISION 003 1 2012 RCR Systems P O Box 1352 1500 Avenue Road Toronto Ontario M5M 0A1 CANADA COLVEN Ruta 11 Km 814 Guadalupe Norte Prov de Santa Fe S3574XAB ARGENTINA ORDER ON LINE 1 888 438 8444
20. unit REPLACEMENT OF THE EVAPORATOR Remove the upper cover after removal of the 5 screws Remove and replace the evaporator disconnect reconnect the 9 x 15 cm hose Place back the upper cover fixing it with the 5 screws 38 REPLACEMENT OF THE POWERAND CONTROL MODULE Remove the air grilles and upholstery cover Disconnect the electrical installation and the ribbon cable from the module Remove the module unlocking the 3 locking pegs Locate the switch commanding the water cycle in the new module and set it See Water Cycle Setting before Put the new command and control module to the upholstery cover inserting the 3 locking pegs into their holes Insert the 43 ribbon cable as indicated the figure raise the connector head first introduce the ribbon cable and then push down the connector head to lock Reconnect the electrical installation to the module Put back air grilles and upholstery cover 39 X VIESR 8 FAILURE LOCATION GUIDE EQUIPMENT WITH LOW EFFICIENCY Check WATER PUMP PERFORMANCE AND ELECTRICAL CONNECTIONS a Remove the upper cover 0 Remove the water hose from the evaporator Using a container with a cm scale on it turn on the pump and collect the water for one cycle which should be between 800 cm minimum and 1500 cm3 maximum If the water collected is below the minimum check that The evaporator hoseis not obstructed bent or kinked The switc
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