Air conditioning unit, description

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EC220D L Volvo

The advanced integrated air conditioning system, with the heating and the cooling system installed in a single
unit is designed to provide a comfortable indoor environment in all seasons.
The integrated system is ergonomically designed for the most efficient air flow distribution.
According to the indoor and outdoor air condition, indoor or outdoor air circulation can be selected. All fresh air
is drawn through the air filter installed between the duct and the cab vent.
Air cooling type
The air cooling type is used only for cooling. If heating is required, use the integrated system with heating and
cooling systems.
Air conditioning (AC), basic principles
The AC unit conducts heat away from the cab air to the surrounding atmosphere. At the same time as the
temperature is lowered, the air is also dehumidified as the moisture in the air condenses on the cold fins while it
passes through the evaporator.
In order to conduct heat away from the cab air, a medium with a lower temperature than the air is required,
since heat always moves from a warmer object to a colder one.
If water is heated to 100 °C (212 °F), it begins to boil since the water has reached its limit for storing heat. If you
continue to heat the water, it must release an amount of heat equal to the heat that is added. This is
accomplished by boiling which means that some of the water is converted to steam. The steam carries excess
heat with it as it leaves the water.
However, the boiling point of water is too high to be used in an AC unit. A liquid that is converted into gas at a
considerably lower temperature is required. This liquid, so called refrigerant, must also fulfill other requirements
in addition to converting to a gas at a low temperature. Refrigerant R134a fulfills these requirements.
NOTE!
Use only refrigerant R134a.
R134a has a constant pressure-temperature ratio. This means that when the temperature is increased or
decreased, the pressure also either increases or decreases. Likewise, if the pressure is increased or
decreased, then the temperature is either increased or decreased. At normal atmospheric pressure, R134a
boils at -26.1 °C (-14.9 °F). Somewhat simplified, the AC unit can be said to consist of two heat exchangers,
one (evaporator) being located in the cab and the other (condenser) located next to the engine radiator or
separately. Both heat exchangers are connected with hoses to a system. The system is charged with
refrigerant, R134a, which is pumped through the system by the compressor.
The cab fan circulates the cab air through the evaporator where the heat from the air is transferred to the
refrigerant. The compressor pumps refrigerant to the condenser, where the heat is dissipated to the outdoor air
which is blown through the condenser by the engine radiator fan or a separate fan.
Figure 1
Diagram, air conditioning system

1 Engine 7 Heater core A Indoor air

2 Compressor 7-1 Cooling position B Outdoor air
3 Condenser 7-2 Heating position C Face
4 Filter 8 Door D Foot
5 Blower motor 9 Diesel heater (option) E Defrost
6 Evaporator

Air conditioning unit, related components

Figure 2
Location of components

A Ambient temperature sensor E Ambient Filter I Compressor

B Recirculation air sensor F Condenser J Inlet hose
C Air conditioning unit G Heater hose (to air conditioning K Charging hose
unit)
D Keypad H Heater hose (to engine block) L Intake hose

NOTE!
The above illustration explains as an example. Regarding the ports for heater supply and return, please see
Section 2 Engine.
Components of the air conditioning unit
The air conditioning unit components, with their hose connections, make up a closed system where the
refrigerant is circulated by a compressor. The cooling process operates continuously, with the refrigerant
alternating between gaseous and liquid states, depending on the temperature and the pressure changes.
Figure 3
Refrigerant flow

1 Air conditioning unit 9 Evaporator 17 Receiver drier

2 Blower motor 10 Air mix driver 18 Compressor
3 Relay 11 Heater core 19 Electromagnetic clutch
4 Water temperature sensor 12 Battery 20 Service valve
5 Duct temperature sensor 13 Electronic climate controller 21 I-ECU
6 Expansion valve 14 Engine 22 Keypad
7 Recirculation air sensor 15 Condenser
8 Ambient temperature sensor 16 Dual switch

NOTE!
The above illustration explains as an example. Regarding the ports for heater supply and return, please see
Section 2 Engine.
The air conditioning unit is of the compressor type, that is, the refrigerant is circulated by a compressor.
The air conditioning unit consists of the following main components:

1. Air conditioning unit

Air conditioning unit consists of a evaporator, a heater core, an expansion valve, a blower motor,
actuators, relays and sensors.
 2. Blower motor
The blower motor circulates the air in the cab where indoor and outdoor air is transferred to the cab.
Outlet air flow regulated by the motor speed.
3. Relay
The relay is located outside the air conditioning unit and is driven the blower motor and electromagnetic
clutch.
4. Coolant temperature sensor
When coolant temperature is over 25 °C (77 °F), air conditioner is activated automatically if cab auxiliary
heater is equipped.
5. Duct temperature sensor
The duct temperature sensor is installed in the evaporator core at intervals of 5 mm.
NOTE!
If the sensor is out of order, the air conditioning switch turns off the compressor clutch.
6. Thermostatic expansion valve
Controls the quantity of refrigerant supplied to the evaporator. The valve is directly connected to the
inlet pipe on the evaporator.
7. Recirculation air temperature sensor
Recirculation air temperature sensor is installed at the left sides of the driver's seat.
The sensor controls the open and shut angle of the mixing door, the speed of blowing motor, and setting
temperature of compressor with sensing the setting temperature on gauge, inner and outer temperature
of cab.
8. Ambient temperature sensor
The ambient temperature sensor is located in front of the condensor. This sensor has compressor on/off
by sensing the difference between inner and outer temperature of cab.
9. Evaporator
Transfers the heat, from the cab air and the outdoor air supplied to the cab, to the refrigerant. The
evaporator is located in the air conditioning unit in front of or in parallel with the heater core, and
consists of a coiled pipe with fins for heat absorption. To prevent ice formation in the evaporator, there is
a switch which interrupts the power supply to the compressor's magnetic clutch when the temperature
becomes too low.
10. Air mix door driver (actuator)
The air mix door (actuator) is located at the air conditioning unit and regulates the opening/closing angle
of the mix door according to the system conditions (ambient, indoor and setting temperature).
11. Heater core
Always hot coolant flows through the heater core and gives off heat before returning to the engine.
12. Battery
The battery supplies the power to the air conditioning system.
13. Electronic climate control unit
14. Engine
The air compressor is installed to the engine. The engine also provides hot coolant to the heater core.
The engine cooling fan draws air through the condenser core which cools the refrigerant.
15. Condenser
Transfers heat to the outdoor air. Located next to the engine radiator, using the radiator fan for air flow.
16. Dual switch
A dual switch is fitted to the high pressure line of receiver drier top side. Its function is to protect the
system by interrupting the power to the compressor's magnetic clutch if the pressure should become too
high or too low.
17. Receiver drier
Contains a filter and a desiccant which absorbs any moisture in the system. Also serves as a reservoir
for the refrigerant and is located on the front side of condenser.
18. Compressor
Circulates the refrigerant in the system. Located beside the engine and is driven by V belt from the
engine crankshaft pulley. An electromagnetic clutch on the compressor pulley connects or disconnects
the compressor drive.
19. Electromagnetic clutch
An electromagnetic clutch on the compressor pulley connects or disconnects the compressor drive.
20. Service valve
The service valve is installed into the hose, which is mounted to the compressor. This valve provides a
way to check the pressure and supply refrigerant.
21. I-ECU
22. Keypad