Académique Documents
Professionnel Documents
Culture Documents
Service.
Fundamentals
1,6
1,4
1,2
MPa
1,0
0,8
Pressure
0,6
0,4
0,2
0
-30 -20 -10 0 10 20 30 40 50 60 70
Temperature o
C
air dition
con
Air conditioning systems have long ceased to be The design of the refrigerant circuit of an
regarded as luxury equipment. air conditioner is identical in all vehicles.
Air conditioners have become a factor in active Air conditioner refrigerant circuits only vary in
safety, and today can almost be considered as respect of how they are adapted to meet
an integral part of a vehicle's safety refrigeration requirements.
specification.
In this Self-Study Programme, you will familiarise
10 years ago, only about 10 percent of yourself with the basic purpose and design of an
all newly registered vehicles were fitted with an air conditioner.
air conditioning system. By 1996, air conditioners You will learn the functions of the component
were being installed as standard in more than parts in the refrigeration process, the special
one in four newly registered vehicles. characteristics of the refrigerant and why air
conditioners require special service
Customer demand for air conditioning is rising specifications.
continually.
The component parts shown in the following SSP
are common to most air conditioners.
New Important
Note
The Self-Study Programme Please always refer to the relevant Service Literature
is not a Workshop Manual! for all inspection, adjustment and repair instructions.
Service literature.
2
Table of Contents
MPa
Applied physics
o
C
The refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
R
The cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 134a
The principle of the refrigerant circuit
Refrigerant circuit with expansion valve
The compressor
The mode of operation of the compressor
Magnetic clutch
The condenser
The fluid container and drier
Expansion valve
Expansion valve – new generation
The evaporator
Refrigerant circuit with restrictor
The restrictor
The collecting tank
System control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Components of the safety system
t" p
Cooling fan circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fan circuit for engine/condenser cooling
Radiator fan control unit J293
Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Manual control
Automatic control
System overview
Control unit with operating and display unit
The main temperature sensors
Auxiliary signals for temperature control
Positioning motor
Air ducting
Air distribution
Air recirculation mode
Technical service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Safety precautions
General information on function influencing factors
Fault diagnosis through pressure testing
Fault diagnosis through self-diagnosis
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Key cooling system terminology
3
The in-car climate
People feel comfortable at a certain ambient – In strong sunlight in particular, the heated
temperature and atmospheric humidity. cabin air can only be exchanged for air with
ambient temperature.
As a component part of active safety, the driver's – In addition, the air temperature usually rises
well-being is a key factor in driving ability. en route from the intake point to the air outlet.
– Opening a window or sliding roof or setting a
The “in-car climate“ has a direct bearing on the higher fan speed for greater comfort will
driver, fatigue-free driving and driving safety. usually result in a draught and expose the
occupants to other nuisances such as noise,
A comfortable interior temperature is dependent exhaust gases and pollen.
upon the prevailing ambient temperature and
upon sufficient air flow:
Why?
High levels of atmospheric humidity put the body
under considerably greater physical strain.
Chest
24 "C 40 "C
5
Physics of the cooling system
Applied physics
Laws
MPa
Ice – solid
o
Many substances are known to exist in three
C
aggregate states.
6
Pressure and boiling point
If the pressure is changed using a liquid, the The evaporation process is also used in vehicle
MPa
boiling point changes. air conditioners.
All liquids behave similarly. A substance with a low boiling point is used for
this purpose. o
C
1,7 17 4,0 40
1,5 15 3,5 35
1,3 13 3,0 30
MPa
MPa
bar
bar
1,1 11 2,5 25
Liquid Liquid
0,9 9 2,0 20
Pressure
Pressure
0,7 7 1,5 15
0,5 5 1,0 10
Gaseous Gaseous
0,3 3 0,5 5
0,1 1 0 0
100 110 120 130 140 150 160 170 180 190 200 -40 -20 0 20 40 60 80 100
Temperature "C Temperature "C
208_006 208_005
– At a constant pressure, the vapours become a liquid – The refrigerant goes from a liquid state to a vapour
through temperature reduction (in the air conditioner state through pressure reduction (in the air conditioner
circuit, this process takes place in the condenser = circuit, this process takes place in the evaporator).
liquefier),
7
The refrigerant
Liquid
12
Expansion
The systems converted in this way are no lon-
10
ger able to match their original refrigeration
8
capacity.
Pressure
6
Evaporation
4
8
State of refrigerant R134a The energy content is a key factor in the design
in the cycle in an air conditioner of an air conditioner.
It shows what energy is required (evaporator
In addition to the vapour pressure curve, the heat, condenser heat) to achieve the intended
cycle shows the change of state of the refrigerant refrigeration capacity.
under pressure and temperature in addition to
the energy balance at which the refrigerant Physical data of R134a:
returns to its original state. R
The diagram is an excerpt from the state
diagram of refrigerant R134a for a vehicle air
Boiling point:
Freezing point:
–26.5
–101.6
°C
°C
134a
conditioner. Critical temperature: 100.6 °C
Different absolute values are possible in Critical pressure: 4.056 MPa
dependence upon the demand of a vehicle type (40.56 bar)
for refrigeration capacity.
4,0 40
90 90
85
MPa
80 80
bar
70 70
2,0 20
C 60
1,6 60 16
B
50 50
40
1,0 40 10
Pressure
Pressure
0,8 30 8
30
0,6 20 20 6
10 10
0,4 4
0,3 0 C 0 C 3
D A
0,2 2
200 240 280 320 360 400 440
9
The refrigerant
10
Refrigerant oil
Compressor
A special oil – the refrigerant oil – free of
impurities such as sulphur, wax and moisture is
required to lubricate all the movable parts in the
air conditioner.
50%
The refrigerant oil must be compatible with the
10% 10%
R
refrigerant itself, because some of the refrigerant
oil mixes with the refrigerant in the refrigerant 10% 20%
134a
circuit. In addition, the refrigerant oil must not
attack the seals used in the system. Condenser Suction hose
11
The cooling system
We know that:
Too cool down an object, heat must be given off.
A compression refrigeration system is used in
motor vehicles for this purpose. A refrigerant
circulates in the closed circuit, continually
alternating changing from a liquid to a gas and
vice versa. The refrigerant is:
High-pressure side
208_071
The c o m p r e s s o r induces cold, gaseous
refrigerant at a low pressure.
12
208_073
The compressed liquid refrigerant continues to
flow up to a narrowing. This narrowing can be in
the form of a restrictor or an expansion valve.
Once the refrigerant reaches the narrowing, it is
Valve injected into the evaporator causing its pressure
Cooled fresh air to drop (low-pressure side).
208_072 208_074
The refrigerant follows the short path to the Now in the gaseous state again, the refrigerant
c o n d e n s e r (liquefier). emerges from the evaporator.
Heat is now extracted from the compressed, hot The refrigerant is again drawn in by the compressor
gas in the condenser by the air flowing through and passes through the cycle once again.
(headwind and fresh air blower). Thus, the circuit is closed.
The refrigerant condenses and becomes a liquid
when it reaches its melting point (pressure-
dependent).
13
The cooling system
A B C D E F 208_032
H
I
1
E D
B
The refrigerant circuit is activated
when the vehicle engine is
running. For this purpose, the
compressor has a magnetic
2
clutch.
1 MPa = 10 bar
The absolute values are
always vehiclespecific.
C
Please observe the
Workshop Manual.
1 2
Pressures and
Compression ratio Condensation
temperature in
at approx. 1.4 MPa (14 bar) Pressure approx. 1.4 MPa (14 bar)
the circuit
Temperature approx. 65 oC Temperature reduction: 10 oC
14 (example)
Legend The components:
208_031
The refrigeration capacity of a vehicle air The pressures and temperatures in the circuit are
conditioner is dependent upon the car-specific always dependent on momentary operating
installation conditions and the vehicle category state. The specified values are intended as a
(passenger cars, vans). rough guideline only. They are reached after
20 min. at an ambient temperature of 20 oC and
The components A to H exist in every circuit. at engine speeds of between 1500 and 2000
Additional connections can be provided for rpm.
service work, temperature sensors, pressure
switches in the high- and low-pressure circuit and At 20 oC and when the engine is at a standstill, a
oil drain screws depending on the circuit design pressure of 0.47 MPa (4.7 bar) will build up
and requirements. The layout of components inside the refrigerant circuit.
within the circuit also differs from one vehicle
type to another. The components of the refrigerant circuit with
Some systems have a damper before the expansion valve will now be examined more
compressor in order to dampen refrigerant closely (for details of the refrigerant circuit with
vibrations. restrictor refer to page 28).
3 4 1
Expansion Evaporation 208_033
from approx. 1.4 MPa (14 bar) to approx. 0.12 MPa Pressure: approx. 0.12 MPa (1.2 bar)
(1.2 bar), Temperature: from approx. 55 oC to –7 oC Temperature: approx. –7 oC
15
The cooling system
The compressor
The compressors used in vehicle air conditioners
are oil-lubricated displacement compressors.
They operate only when the air conditioner is
switched on, and this is controlled by means of a
magnetic clutch.
16
Mode of operation of compressor
– Reciprocating compressors
– Coiled tube compressors
– Vane-cell compressors
– Wobbleplate compressors
17
The cooling system
Input shaft
High pressure
Low pressure
208_047
Upper side Lower side Springs
18
High delivery rate for high cooling capacity - low chamber pressure
Chamber pressure
Chamber pressure
Restrictor bore
208_048
Spring 1 Spring 2
The high and low pressures are relatively high. – The combined force resulting from the low
pressure acting upon the upper sides of the
– Bellows 2 is compressed by the high pressure . piston and the force of spring 1 is greater than
the combined force resulting from the cham-
– Bellows 1 is also compressed by the relatively ber pressure acting upon the lower sides of
high low pressure. the piston and the force of spring 2.
19
The cooling system
Low delivery rate and low cooling capacity - high chamber pressure
Chamber pressure
Chamber pressure
Restrictor bore
The high and low pressures are relatively low. – The combined force resulting from the low
pressure acting upon the upper side of the
– Bellows 2 opens out. piston and the force of spring is greater than
the combined force resulting from the cham-
– Bellows 1 also opens out as a result of the ber pressure acting upon the lower sides of
relatively low pressure. the piston plus the force of spring 2.
20
Magnetic clutch Schematic diagram of clutch switched off
Design
Compressor
Input shaft
The clutch comprises
21
The cooling system
The condenser
Design of condenser
22
The fluid container and drier
Function
Drier
23
The cooling system
Expansion valve
Membranes
Pressure-equalising
hole To evaporator
(low pressure)
From condenser
(high pressure)
208_017
The expansion valve is heat-controlled. It has a The expansion valve is always fitted with thermal
control unit with a thermal head and a globe insulation.
valve.
The thermal head on one side of the membrane
has a special gas filling. The other side is
connected to the evaporator outlet (low pressure)
via pressure-equalising holes.
The globe valve is push rod actuated. Fitting the valve without thermal
The pressure of the special gas, and therefore insulation will alter the set control
also the amount of refrigerant injected, is characteristic.
dependent upon the temperature on the low-
pressure side.
25
The cooling system
enlarged
via diaphragms and the push rod.
208_020
208_021
26
The evaporator
Tubular evaporator
208_030
Function
The refrigerant released by the expansion valve Moisture in the cooled air collects at the
expands in the evaporator, cooling the evaporator in the places where the air
evaporator down considerably. temperature drops below the dewpoint
temperature, i.e. it condenses. Condensation
The refrigerant becomes a gas (boiling point). water is produced.
The air is “dried“.
When the refrigerant in the evaporator boils, the This improves the climate and air quality inside
temperatures are well below the freezing point the vehicle noticeably.
of water. Deposits of matter suspended in the air build up
at the evaporator in addition to moisture.
The refrigerant extracts the heat required for The evaporator also "purifies" the air.
evaporation from its surroundings – which is the
air flowing through the evaporator in this case.
This air is channeled into the passenger cabin in Pools of water below a stationary
a “cooled" state. vehicle (condensation) are therefore not
an indication of a fault.
27
The cooling system
ND E
HD
H
208_034 I
A B C D
D
A
B
2 C
1 MPa = 10 bar
Pressures and
temperatures
in the circuit
1 2
Compression ratio Condensation
Max. pressure 2 MPa (20 bar) Max. pressure 2 MPa (20 bar)
28 Max. temperature 70 oC Temperature reduction: approx. 10 oC
Legend The component parts:
3
4
E
F
208_007
In contrast to the circuit with expansion valve, the All other components are identical to those used
liquid refrigerant is injected into the evaporator in the circuit with expansion valve.
through a restrictor.
Additional connections for service work or
In restrictor-regulated air conditioners, a sensors for monitoring functions can be
collecting tank is fitted at the low-pressure side in integrated in the circuit, depending on circuit
place of the fluid container on the high-pressure design and necessity.
side.
The pressures and temperatures are dependent
This collecting tank serves as a reservoir and upon the momentary operating state of the
protects the compressor (fluid shock). Also refer refrigerant circuit. The specified values are
to page 31. achieved after a specific period depending on
the ambient temperature (refer to Workshop
Manual).
3 4 1
Expansion Evaporation 208_033
from 2 MPa (20 bar) to > 0.15 MPa (1.5 bar) Max. pressure > 0.15 MPa (1.5 bar)
Temperature: from 60 oC to > –4 oC Temperature: > –4 oC 29
The cooling system
The restrictor
30
The collecting tank
Plastic cap
As a result, the compressor draws in gaseous
refrigerant only, and no liquid droplets.
Protection of the compressor against damage is
thereby ensured.
Drier
31
System control
10 9 7
6
8
2
4
5
3 208_054
t" p An air conditioner will only function if all system The air conditioner does not necessarily
components are working properly. Failure of one have to have all the components shown
of these components could cause the working in the diagram. Neither do these
pressures to change. In this case, it is not possible components have to be connected in
to rule out consequential damage to the system this way.
and the engine. To avoid this, there are The diagram shows the system control of a
monitoring devices in the refrigerant circuit. simple manual air conditioner.
A control unit processes the signals from the 1 Air conditioner switch
monitoring devices and controls the periodic 2 Pressure relief valve at compressor
switch-off and switch-on of the compressor and 3 Radiator fan
the speed of the fan. This ensures that the 4 Air conditioner pressure switch
pressure level in the refrigerant circuit always 5 Coolant temperature sender
adapts itself to the normal values. 6 Radiator fan thermo switch
In systems equipped with an open-loop 7 Evaporator temperature sender
compressor, the signals from the monitoring 8 Fresh air blower
device are also used for adaptation to demand 9 Engine control unit
for cooling. 10 Magnetic clutch
(switch-on and switch-off the air conditioner in
accordance with demand for refrigeration. Air conditioner control unit
Icing of the evaporator is avoided at the same (and/or radiator fan
time.) control unit,
The diagram shows the basic layout of the air depending on system type)
conditioner.
32
30 30
15 15
X X
31 31
J 257 J 257
E 35
J 301
J 32 t1 t2
F 18
A -t" G 153 G 62
N 25
p2 p1
F 129
M
V7
J 101
31 31 208_055
t" p
A Battery Simple functional example showing how the
E35 Air conditioner switch compressor (via magnetic clutch N25) and radiator
F18 Radiator fan thermo switch fan are switched on and off.
t1 = 95 oC
t2 = 103 oC
F129 Pressure switch for air conditioner Colour codes:
P1 = 0.2 MPa (2 bar)/3.2 MPa (32 bar) Positive
P2 = 1.6 MPa (16 bar) Negative
G62 Coolant temperature sender Input signal
G153 Evaporator temperature sender Output signal
J32 Air conditioner relay Bidirectional signal
J101 Radiator fan 2nd speed relay
J257 Mono-Motronic control unit
J301 Air conditioner control unit
N25 Air conditioner magnetic clutch
V7 Radiator fan
S Fuse
In the new-generation air conditioners,
there is a high pressure sender in place
of the pressure switch for air conditioner
(refer to page 36).
33
System control
Components of the safety systems Switch for switching on the air conditioner – the
magnetic clutch makes the connection to the
compressor.
Air conditioner switch E35
In automatically controlled systems, the radiator
fan and the fresh air blower start simultaneously.
In manual air conditioners, the fresh air blower
must be switched to the 1st speed.
A signal indicating that the air conditioner has
been switched on is transmitted to the engine
control unit, and engine idling speed is increased
(to compensate for load resulting from
compressor work).
208_068 The switch may be located downstream of an
ambient temperature switch.
This ensures that the air conditioner cannot start
when the temperature is below 5 °C.
34
Pressure switch F129 To monitor and/or limit the pressure conditions in
the closed refrigerant circuit, high-pressure and
low-pressure switches are installed on the high
pressure side.
p > 1,6 MPa = – it switches the fan one speed higher at 1.6
MPa (16 bar) excess pressure. As a result,
condenser performance is optimised.
208_060
35
System control
Self-diagnosis “fault message“ The fault in the high pressure sender is stored to
the fault memory of the e n g i n e e l e c t r o n i c s .
36
Function of high pressure sender The refrigerant pressure is applied to a silicon
crystal. Depending on the pressure level, the
2V/Div 5ms/D
crystal will be more or less “deformed“.
A
The silicon crystal, together with a
microprocessor, is integrated in the sensor and
supplied with voltage.
Test voltage
Silicon crystal
(resistance)
208_063
37