TaiChang Bus Air Conditioner Co., Ltd User Handbook

Transcription

1 TaiChang Bus Air Conditioner Co., Ltd User Handbook Address: No. 20 Shunxiang Road, Fengxiang Industrial Area, Daliang Town, Shunde, Guangdong, China Tel: Fax:

2 Preface Ltd. Welcome to use the bus air-conditioner that produced by China TaiChang Bus Air Conditioner Co., TaiChang Bus Air Conditioner Co., Ltd.. is a joint-venture company and specialized in the research, development, installation and maintenance of passenger Vehicle air-conditioner. Since 1987, based on the effort of all the staff, company set up a lot of divisions in different cities of China, and now it is a big multiple group company. TaiChang offer you a strict quality control system and a wide and far service system. We are one of the passenger Vehicle air-conditioner companies that took the lead in passing ISO9001 quality system certification and we also have the certification of automobile refrigerating unit of China from Center of Automobile Products of China (CCAP). This handbook is an operation guide for installing and maintaining the passenger Vehicle air-condition. In order to ensure your passenger Vehicle air condition is always working in good state, please read it carefully and performs seriously. Hope your correct installation and the good performance of TaiChang air-conditioner can bring you comfort and satisfaction. 1 2

3 DIRECTORY Preface 1. Summary 4 2. Installation and Debugging 7 3. Operation Manual Maintenance Troubleshooting Service 22 Appendix Drawings: Appendix 1: Drawing of Air Condition Outlook and Holes opening: Appendix 2: Circuit diagram of Non-Freestanding Air Condition (Including the generator) Appendix 3: Circuit diagram of Freestanding Air Condition (Including the generator) 3

4 One. The Product Introduction 1.0 Summary 1) The Vehicle temperature is controlled by the transducer and electric system of air-conditioner. 2) This product is outside roof-mounted. The main parts are come up of evaporator assembly,condenser assembly, controller assembly, high-low pressure refrigeration tubes and compressor. * The position of the main parts: 1) Evaporator assembly and condenser assembly are installed on the roof of the vehicle. 2) Controller is installed in the convenient place for the driver. 3) Electric control part is installed inside air-condition. 4) Compressor is installed beside the engine. (Passive type) condenser assembly 2.evaporator assembly 3.wire coils 4.high pressure refrigeration tube 5.low pressure refrigeration tube 6.compressor 1.1 Character: The two series of all roof-mounted and fission structure has over twenty various specifications, all of them are applicable to all kinds of passenger vehicle. For the usage of refrigeration and dehumidification, our products have a good capability and lower the temperature quickly. The roof-mounted structures are easy to install and maintain. The good-looking outside shell that has high intensity is built by clipper-built glass fiber. Air-conditions have the function of automatically temperature control, malfunction protection, and automatic digital display. (* This function can only available in some of products) 4

5 1.2 The Working Theory Air-condition is a recycling refrigeration equipment that equipped with compressor, condenser, liquor storage, desiccators, Expansion valve, and evaporator that connected with the pipeline. (Please refer to the following drawing) 1.condenser 2.discharge pipe 3.compressor 4.suction pipe 5.evapoator 6.sight glass 7.expansion valve 8.desiccators 9.inspection valve 10.receiver Gaseous Refrigerant is inhaled and compressed by compressor, the gas with the high temperature and pressure goes into the condenser, being cooled and liquefied, at the same time. It emanates heat to the surroundings. Fluidity Refrigerant goes to desiccators to get rid of the moisture and impurity, after going through the Expansion valve, it turns into mixed air with low temperature and low pressure. Then it goes into the evaporator, inhaling the heat to vaporize and low down the temperature of air that went through the evaporator and refrigerate. After vaporized, the Refrigerant steam is inhaled by compressor again and begins the next refrigeration circulation and sent out the heat again and again. At the same time, because the evaporator surface temperature is lower than the air temperature of vehicle, it can condensate the moisture which is close to the evaporator to dew, drain and evacuate out of vehicle and reach to the propose of dehumidification. 1.4 Notes If you found there are any abnormal noises, smell, rotation of air-condition, you should do the inspection in time. And only turn on air-condition after the problems are eliminated, After turning on air-condition, there should be kept 7-8 air intakes available. 5

6 The change of pressure switch or insurance switch is forbidden. The specification of insurance system safeguard cannot be changed freely. In winter time, (For the long time suspension of air condition) you should turn it on several times in a month, every time must turn on at least half an hour in order to maintain air conditioner. You cannot turn on the air condition when the compressor discharge pipe valve is shut down, For the non-independent air condition, before the engine stopped, you must turn off the air conditioner. To the independent air condition, only after stopped the engine then you can you turn off the air condition. When the air condition is working, do not touch the running parts (Fan motor, belt, belt wheel, high pressure refrigeration tube and so on.) Do not put the water close to the electric parts, in order to avoid any trouble caused by the swashed water. Two. Installation and Debugging 1. Installation step: Refer to the packing list and check the offer list. (If you have any questions, please contact China TaiChang Bus Air Conditioner Co., Ltd). Record the serial number of evaporator assembly and condenser assembly, prepare for the assemble material and technical equipment. Install compressor. Install the parts of evaporator assembly and condenser assembly. Set up the pipeline. Install the electric wires. System debugging, air purging and refrigerant Adding. 2. Technical demand: 2.1 All the components of air condition should be installed steadily and safely. 2.2 The control facility and the control parts work actively and freely. 2.3 The belt wheel and bearing wheel of compressor must be in the same plane with the transfer wheel, the bevel can not over The upper surface of the air-condition must sticky well on the vehicle roof. All parts must be steady and easy to install. 2.5 Air filter facility which is washable and easy to knocked-down, must install in the suction intakes position of vehicle. 2.6 The condensate water of air-conditions can drain smoothly, no flooding phenomenon. The joint of Drainpipe and general pipe must be tightly coupled with caliper. All the Drainpipes must fix on the wall of vehicle stably. 2.7 The surface of Refrigeration pipe must be sealed with adiabatic layer. The condensate water can never be allowed to flood from the intake of air-condition. 2.8 The exterior section of the low-pressure tube outside the vehicle must be sealed with the adiabatic layers to keep warm and avoid the cutting by the pointedness. 2.9 Use the caliper tightly clip the Refrigeration pipe, the distance between two section can not over 0.5m, 6

7 the distance between the joints and clipper must be less than 100mm.when you lay the pipe, keep them away from the heating parts at least 150mm,and also keep them away from the other parts at least 15mm If the air-condition is installed on the middle of the vehicle roof, the transverse section of vent door of evaporator is around 0.04 square meter. If the air-condition is installed at the end of the vehicle roof, the transverse of section will be around 0.05 square meter Ensure the fission models air-conditioner is easy to fill with oil, water, and Refrigerant. and it is also easy to maintain Keep the fission model air-condition installation cabinet draughty and the heat easy to drop away. Take some necessary security measure to avoid the possible penetrability to the radiator from the slingshot The vehicle structure must take some effective adiabatic and heat preservation measures to reach below demand: Detection of project capability Basic Prescriptive Technology demand ( ) condition time (min) Heat preservation Operating 4 32 Speed 40km/h Notes: listed demand is seted up from below situation, ambient temperature is 36 vehicle temperature is 28,established. we suggest the thickness of adiabatic material on the roof and side of the vehicle must 40mm,the thickness of adiabatic material under the vehicle shall be 20mm;The doors and windows of the vehicle must be thermally protected to guarantee the good performance of air-condition. Three. Installation Content 3.1 upper assembly installations Checking the following details The size of holes opening the vehicle roof (Please refer to appendix drawing1) The outlook of air-condition The discharge air grille The condenser motor fan blade has the distance of 15-20mm with discharge air grille The end of drainpipe (Two ends of the vent entrance) NOTE Record any visible damage situation and contact the sales department of TaiChang Bus Air Conditioner Co., Ltd. Do not disassemble hermetic baffle in the pipe joint,only disassemble it when you start the pipe installation. Make sure the system is hermetic and the pressure is keep 0.1Mpa. Be care when you disassemble flange hermetic board of the pipes, remember release the inner nitrogen Inspect the vehicle upper roof parts Check whether the roof and the installation hole position of air-conditioner is correct; inspect the holes and inter bolts are same as the drawings; then lay down the steel plate, which is 70mm wide and 10mm thick, then drill the holes and threaded the M10 bolts or others. Inspect the hermetic inner heat preservation layer is accord with the installation technology Install the upper parts to the roof of the vehicle 7

8 At the beginning, use the compressed air to clear the installation position. Sticky the heat preservation bar and glued with silica gel all around and then glue the bar with the silica gel (Notice: condenser part bars need to sticky in regular distance, do not sticky at two sides so as to drain the seeper.) Put up rubber spacer at installation holes, between the installation holes and air-conditioner base, lay the suspension rubber spacer and then seal with the glue. Tear the covers of the evaporator and condenser, use the inner suspender hang the upper parts on the roof and then sticky well. And make alignment adjustment between the vent door and suction inlet of the evaporator with sealed bar. Inspect the distance of evaporator base and hermetic bar. Make sure only the base installation surface touch the heat preservation layer and sticky well. If it does not work well, use the silica gel to seal the base interface. When you sure that the base installation surface touch the heat preservation layer and sticky well, then lock up the holddown bolts tightly. Air filter grille assembly provided by the vehicle or the TaiChang Bus Air Conditioner Co., Ltd, which can be pensile and knockdown type. When you finish the installation and do the full cleaning on the spot (including the inner and outer of upper parts.) Evaporator Installation sketch map Condenser Installation sketch map 4. COMPRESSOR INSTALLATION System pipe installation Compressor belt wheel vertical balance adjustment Belt tension adjustment System pipe installation 8

9 Refrigeration tube cannot be over bended or twisted Normal demand is as below: The semi-diameter of discharge pipe cannot be bent over180mm The semi diameter of suction pipe cannot be twisted over230mm discharge pipe and suction pipe cannot intervene each other and they also cannot intervene with the motor and carriage System pipe installation position cannot lower than the compressor Compressor belt wheel vertical balance adjustment (Only for the non-independent model) Below drawing which using the B type belt may rise several vertical balance improper phenomenon. After readjusting, turn on the air-conditioner for 24 hours and recheck the position of belt wheel. Centre Adjustment Bearing belt wheel Compressor belt wheel Angel Adjustment Bearing belt wheel Compressor belt wheel Rotary Degree Adjustment Bearing belt wheel Compressor belt wheel 3. Belt tension adjustment Measuring the belt tension need suitable apparatus. The test demand is as below: Using the 30N outside force to produce the disorder degree by 16mm/m (as the below drawing arrowhead direction. Chop distance 16mm/m Disorder degree 5. Refrigerant tube and cable wires installation demand 9

10 Refrigerant tubes leak because of wrong installation; If package poorly, cable tube easy to be worn, cause short circuit or even fire. Here is installation demand: 5.1 Refrigerant tube and cable wire need to fix one time with the tube belt clip and stator belt every 0.3 ~0.5 m. exposed low pressure tube and the high, low pressure refrigeration tube will keep heat by the heat preservation tube. All the wire holes need to protect by the plastic protection loop or jacket. Tube need to be fixed at the swerve turn. 5.2 All the cable wires need to be fixed to ensure it do not swing and touch the metal. All the wire holes need to protect by the loop or jacket. 5. Cables and wires need to be isolated from the heat resources, the motor discharge pipe is forbidden to wrap wit the power line. And need to keep definite distance. Or you can use the isolation facility prevent from fire. 6. Air-conditioner system debugging, evacuating air and adding the refrigerant. 6.1 System debugging: after installation, we fill in 1.8Mpa dry nitrogen for suction parts of compressor. Then test the leakage in all linkage parts by using the soap water. and maintain the pressure for 24 hours, and confirm there are no any degressive phenomenon (when temperature low down 3,the pressure can not descend over 0.02Mpa each time ). pothook low-pressure watch(blue) low-pressure manual valve high-pressure watch(red) pressure watch(out) high-pressure manual valve pressure watch(in) nitrogen watch valve switch nitrogen bottle divergent tube watch 6.2 evacuating air At first, use the low-pressure hose (blue) to plug in the joint of the suction hose in divergent hose watch and the high-pressure hose (red) plug in the joint of the vent tube in the divergent hose watch. Connect the middle punch hose to the vacuum pump, open the low-pressure manual valve and high-pressure manual valve of the divergent tube watch, and then start to use the vacuum pump to deflate. When the low-pressure watch show it is below Mpa, close the two manual valves of the divergent hose watch and close the vacuum pump. Suggest to fill I 0.1Mpa pressure gaseous Refrigerant after evacuating, evacuate it again, this step can guarantee the quality of vacuum, so as to prevent from any affection factor to refrigeration result of air-condition. After evacuating, observe the pressure of divergent hose watch, If the indicatory data rise, it indicate that the circuit system have the leakage. After repeating the steps of (6.1) and repeat evacuating again until 10

11 there are no change in the divergent hose watch pothook low-pressure watch(blue) low-pressure manual valve divergent tube watch low-pressure tube vent system of compressor high-pressure watch (red) high-pressure manual valve high-pressure tube middle punch tube suction system of compressor vacuum-pump compressor 6.3 Adding the Refrigerant: plug the middle punch hose of divergent hose watch in the Refrigerant bottle and then upside-down the refrigeration bottle. Open the valve of bottle, loose the screw of tie-in of punch tube, evacuate air in the tube and then tighten the screw. Open the high-pressure manual valve of the divergent tube watch; fill in the Refrigerant from the high-pressure tube. (Don t startup the motor at this moment) pothook low-pressure watch(blue) low-pressure manual valve high-pressure watch(red) high-pressure manual valve divergent tube watch container of refrigerant high-pressure hose connectto the system of air-conditioner middle punch hose When high-pressure parts is not filled with necessary Refrigerant, it need to add compensatory Refrigerant at the low-pressure tube when debugging the air-conditioner; Close high-pressure manual valve, put Refrigerant bottle straight stand, start the motor, turn the wind switch and air-conditioner switch to the maximum, speed up the motor, then open the low-pressure manual valve of divergent tube watch slowly, the Refrigerant will fill in the system from the suction joint parts of compressor, At the same time, monitor the liquid situation through the oil sight glass. Once the bubbles inside have disappeared, It indicate that Refrigerant is adequacy. Close the low-pressure manual valve and then close the refrigeration bottle. 11

12 Warning: Never add liquid Refrigerant from the low-pressure tube, It will do harm to the parts inside compressor. Do not add too much Refrigerant, it will damage the parts inside compressor and cause the malfunction of air-conditioner. When you started air-condition and fill with the Refrigerant, do not open the high-pressure manual valve, or Refrigerant will reverse flow from air-conditioner, It will cause the serious crack of the bottle and drain the lubricating oil, spoil air-conditioner. When adding the frozen oil, check the brand of the oil because the mixture of different refrigeration oil will engender the deposit, it will affect lubrication oil. 7. Air-condition system debugging 71. At first,turn on the switch of wind volume; inspect the operation of Evaporator blower. Check the Evaporator blower turning and different speed; inspect the condenser Fan turning and operation. Change the temperature control knob; inspect the monitor, so as to check the Thermostat. 7.2 turn the switch of refrigeration to open,so as to check the compressor. After startup air-conditioner for some time, check the refrigeration capability, inspect the different data of divergent tube watch is normal or not. (Please refer to the relation list between the temperature and pressure). 7.3 After assure the system debugging is successful, tear down the divergent tube watch. Tighten the plastic baffles of the suction system of compressor and vent system of compressor. If you found there are any abnormal noises, smell, vibration etc, you should stop the machine and check the reasons immediately, and after the problems are eliminated, then you can turn on air-conditioner. Pressure reference data under the normal operation of system in Normal state Relation list between the temperature and pressure AMBIENT TEM. HIGH PRESSURE Mpa/(psi) LOW PRESSURE Mpa/(psi) /(120~170) /(14.3~21.4) /(150~250) /(14.3~21.4) /(180~ /(21.4~25.7) /(200~328.6) /(25.7~31.4) /(230~328.6) /(28.6~35.7) /(270~361.4) /(31.4~42.9) 8. Regular inspection When you installed and debugged the system, check the whole system carefully; make sure there are no abnormal noises, smell, vibration etc. 8.1 Installation Inspection After the installation, all parts are flexible and sealed well. 12

13 Wind intakes and back wind entrance sticky well. 8.2 Condenser parts Inspection Pressure release valve is in good working condition and baffle is inside. Ball valve is open Electromagnetism valve is in good working condition Condenser Fan motor is working well and in correct rotating direction. Liquid in Oil sight glass is clear and green. 8.3 Evaporator parts Inspection Evaporator Fan motor is working well and in correct rotating direction. Expansion valve s outer balance tube is fixed well and condensation water drains well. 8.4 Compressor Inspection Compressor is fixed well and in good working condition. Refrigeration oil brand is correct and volume is correct. Refrigerant identifier is correct Concerned cables and plugs and grounded wires are connect and fixed well with safety. All transportation belts have suitable size and the intension is measure up the demand. Clutch is in good working condition Belt wheel is in good working condition Pressure switch is in good working condition 8.5 System Refrigeration pipe Inspection All the tube sizes are correct. All the cupreous tubes have the safeguard. All the pipes are fixed well. All the pipes did not across and touch each other and intervene All the bracket flanges are linking well. 8.6 Refrigeration tube Inspection All the Refrigeration tubes is not over bent and shrinked All the tubes do not intervene All the joint parts of tube are sealed well. High-pressure and low-pressure tubes is not connected in reverse 8.7 electronic control parts Inspection All the plugs are fixed well and in right position Power supply and grounded wires are working well. All the cables connections are protected with safeguard. 8.8 Air-conditioner draining Inspection All the interfaces of drain are sealed well. Drain tubes do not twist. Current is unblocked after pipe installation. 8.9 Motor parts Inspection (only for the non-independent model) Inspect the fixing screw is tighten or not. Motor base footstool layer is damage or not Belt transportation position is straight Belts have suitable elasticity. Water tank wing is block? Water tank tube is damage or not 13

14 Refrigeration water in the Water tank is enough or not Lubricating oil volume is suitable or not. Any leakage phenomenon in the engine Any abnormal sound after starting the engine three. Operation manual (1) Non- independent type Vehicle air-conditioner (digital control panel display) A. Function Temperature indicator-led 1. Indicator light for automatic controlled function 2. Cooling startup indicator light 3. Cooling working light 4. Evaporator at high running controlled indicator light 5. Evaporator at middle running controlled indicator light 6. Evaporator at low running controlled indicator light 7. Evaporator blower speed controlled button 8. Automatic controlled selective button 9. Cooling mode choosing button by hands 10. Carriage temperature increased setting button 11. Carriage temperature decreased setting button 12. System controlled switch button B How to use the control panel First, for assuring the engine works in a normal condition, press No. 13 button, the carriage temperature will appear, at the same time, No. 7 indicator light turns on. It means the evaporator blower starts to work.. If you want the carriage temperature lower, it needs to set the required temperature fist. Such as : carriage temperature is 30, and 14

15 you want to set to 22, press button 12. And the numbers will change to the one you want to set. After five seconds, indicator turns to the carriage temperature and then you can press the cooling switch button.. If you want to set the carriage temperature by hands, just press No. 10 button. And if you want to set the carriage temperature automatically, just press No. 9 button. But you can not choose automatic mode and manual mode at the same time. When choosing automatic mode, the system is under automatic controlled, when press button 9, automatic controlled indicator light, cooling startup indicator light and evaporator blower speed controlled light are turn on. Cooling working light turns on after three seconds and it also means that it starts cooling. When the carriage temperature is lower 7 than the setting temperature, the evaporator blower will turn to high speed and function indicator light turns on. When the carriage temperature is lower 3 than setting temperature, the evaporator blower will turn to middle speed and function indicator light turns on. When carriage temperature is lower 1 than setting temperature, the evaporator blower will turn to low speed and function indicator light turns on. When the system is in automatic mode running, press cooling startup indicator button or evaporator blower speed controlled button, automatic mode will be cancelled and automatic mode will change to manual mode. If you want to change the evaporator blower speed, you just can adjust it by button because the evaporator speed is out of carriage temperature controlled. When the carriage temperature is lower 1 than setting temperature, whole cooling system will stop except evaporator blower working. When the carriage temperature is higher 1 than setting temperature, the system keeps working. four.maintaince 1. Daily inspection and maintenance (1) Check the V shape belt the character of tensity and status. The tensity shall be always controlled within the prescriptive field. If the belt is too limp, it will cause the skid or forepart damage. If the belt is too tight, the bearing of the compressor will also be damaged. So it is important to check the tensity of V shape belt. If there are any breakage happen, you need to replace it as soon as possible. (2) Check the Refrigerant. a. During the high speed of motor process, check through the oil sight glass, if there is no bubble appears, it indicates that the system is in normal state and Refrigerant is also enough. b. If there are a lot of bubbles, it shows deficient Refrigerant. Also check the different joint parts, if you found any oil stain, it indicates that leakage of Refrigerant. c. If you inspect from oil sight glass, inside water turned the color from green to yellow, and you need to replace the filter drier. (3) Clean the air filter meshwork. a. Open the evaporator assembly discharge grille, take out the air filter meshwork, inspect the cleanness, and remove particles. b. If necessary, clean by the compressed air or warm water, which some mild household detergent being added, then use the clean water clean again. 2. Maintenance schedule 15

16 Period Maintenance Summary Project Method Interval (Per) Refrigeration Cycling Refrigeration volume Inspect from oil sight glass Week hours Week week week week week 10000hours week week week week one month one month three month 5000~10000 hours every year week 5000 hours Pipe Check Tube damage Check joint leakage Check Clip fall off Check Drainpipe clog Compressor Abnormal noise Check the belt wheel of electromagnet clutch in Compressor Triangle belt Check tensility Oil position Check position Oil envelop Check any stain on bearing cover Condenser Condenser fin Use compressed air Clean (or water) Condenser Fan motor Check the cycling Evaporator Evaporator fin Use compressed air or water Clean assembly Evaporator Fan motor Check the operation situation month week week day day month month week week three months Three months Filter drier Wind reversing filter Electric switch Replacing Use compressed air or water Clean Check the operation situation Cable Check worn or not Circuitry Check connection Fission model Water tank Check volume 16

17 Motor Oil volume Check by the oil ruler Lubricating oil Replacing Lubricating oil filter Replacing Transportation belt Check the belt tensility Air filter Cleaning Air filter Replacing Diesel segregator Notice: indicate inspection repair or replace when necessary indicate heavy repair or replace Five. TROUBLE-SHOOTNG 1) Abnormal pressure data malfunction analysis and remedy. TROUBLE/ SYMPTON Pressure Situation Other phenomenon Probable cause Remedy Refrigerant High& low Pressure Inside bubble Low Leakage Inspection Low charge lower than normal appear Refrigeration and find the holes, Standard Carriage is not cold charge repair High-pressure tube Or system Charge Lubricating is warm; leakage oil, Low-pressure tube Charge Refrigerant cold Thermostat differential too narrow. No High& low Pressure No liquid flow, Serious Leakage Inspection Refrigerant far lower than normal No Refrigeration Leakage in and find the holes, Inside system Standard Temperature same system repair for high low tubes Charge Lubricating Compressor stop oil, Condenser motor Charge Refrigerant stop Expansion Low-pressure close to No Refrigeration, Expansion valve Replacing Expansion valve defective zero even negative, two tube ends of defective valve, repack its High-pressure Expansion valve clogged; Inductive parts Lower than normal have frost or Inductive parts Standard condensation water. damage, defective installation 17

18 Air in the Refrigerant Moisture In the Refrigerant Defective condenser Defective Compressor (Cont) High- Low pressure Higher than normal Standard High-pressure higher Than normal Standard Low-Pressure lower than normal Standard High- Low pressure Higher than normal Standard, clock pointer obviously swing High- pressure Higher than normal Standard; Low-pressure close to zero even negative; pressure clock swing heavily W/O regulation Low-pressure far Higher than normal, High-pressure higher Than normal Standard High Low pressure lower than normal Standard Compressor suction tube surface temperature lower than normal, have frost or water. Compressor suction tube has frost or condensation water. Low Refrigeration charge, bubble sometimes appears. Wind Charged intermittently, the colour of oil sight glass is yellow No Refrigeration Low-pressure tube Glow Low Refrigeration charge Expansion valve Open too much Expansion valve damage Vacuum quality is not good after charging Refrigeration Too much Moisture, frozen Moisture Block valve Fan motor Break down Radiator block Compressor intestine Malfunction Replacing Expansion valve, readjust its tolerance Replacing Expansion valve. Drain the Refrigerant, replacing filter drier, recharge Refrigerant Replace filter drier, repeat evacuating air and recharge Refrigerant Check the electric system or clean condenser if defective Replace Compressor Refrigerant or Refrigerant oil Over charge Defective Evaporator High Low pressure higher than normal High Low pressure lower than normal Low Refrigeration charge Evaporator sufficient airflow Fan motor break down or Radiator clogged Drain some Refrigerant or Refrigerant oil in Low- pressure sections Check the electric system or rinse Evaporator Radiator 18

19 (two) Air-condition system abnormal noise analysis and remedy (1) There are several kind malfunction Probable cause Probable cause Remedy Belt loose, twisted, worn Tighten or replace the belt Compressor installation parts bolts loose Tighten the bolts No enough Refrigerant oil Charge Refrigerant oil Refrigerant over filled Drain Refrigerant in Low pressure parts Clutch skid or clog Replace Clutch Compressor inside parts worn Replace Compressor Pleas check above items one by one when you found the abnormal noise, If you are not sure of it, Please do not repair optionally, Please contact our company. (2) Fan motor abnormal Probable cause and Remedy Probable cause Remedy Fan motor bolts loose Tighten the bolts Fan blade touch the other parts Correct or replace fan blade Fan blade separate from the motor Fix or replace fan blade Obstruction came into the pipe Remove the obstruction Fan motor worn Replace Fan motor Abnormal current or voltage in Check the electrical system system (three) Electrical system troubleshooting According to the electrical theory, analysis and remedy (1)Manipulator indicator cannot light Probable cause Remedy D+ power off (4) Replace or repair the generator D+ wire or retrofire switch connect Reconnect the D+ wire or retrofire badly switch Wire connection is not reliable Reconnect the wire Manipulator malfunction Replace Manipulator (2)Manipulator malfunction indicator light on Probable cause Remedy System pressure abnormal (3) Test by the divergent tube watch, replace or repair the motor Pressure switch malfunction Replace or repair the Pressure switch Pressure switch extended wires Reconnect the Pressure switch connect badly extended wires Wires connection not reliable Reconnect the wires Manipulator malfunction Replace Manipulator 19

20 (3)Manipulator indicator COOL cannot light Probable cause Manipulator malfunction indicator light on(5) Defrost transducer malfunction or wires loose Potentiometer malfunction Wires connect badly Manipulator malfunction (4)Condenser Fan motor malfunction Probable cause System pressure abnormal malfunction indicator light on (3) Relay malfunction Fuse blown Wires connect badly Fan motor malfunction Manipulator malfunction (5)Compressor malfunction Probable cause Compressor Clutch extended wires connect badly Clutch malfunction System pressure abnormal malfunction indicator light on (3) Relay malfunction Compressor malfunction (6)Evaporator Fan motor malfunction Probable cause Relay malfunction Wires connect badly Fuse blown Fan motor or speed resistance malfunction Manipulator malfunction Remedy Do the process as above list Replace Defrost transducer or reconnect the wires. Adjust or repair Potentiometer Reconnect the wires Replace or repair Manipulator Remedy Inspect and repair Replace Relay Replace same standard fuse Reconnect the wires Replace Fan motor Replace Manipulator Remedy Reconnect the extended wires Replace Clutch Inspect the pressure and remedy Replace Relay Replace Compressor Remedy Replace Relay Reconnect the wires Replace same standard fuse Replace or repair and machine or speed resistance Replace Manipulator (four)other malfunction Phenomenon Probable cause Remedy Refrigeration Intermittently 1. Electromagnetic Clutch skid or Refrigerant overcharge 2. Expansion valve clog 1.check the Clutch or remove excess Refrigerant 2.replace the filter drier 3. Reconnect the wires. 20

21 3. electrical wires badly connect Refrigeration available Only in high speed Shortage of cold wind Evaporator and low pressure tube frosted 1. Condenser clog 2. Compressor skid 3. Compressor valve Defective 1.Evaporator clog 2.Fan motor Defective 3.Fan motor resistance Defective 1. Clean up the Condenser 2. Adjust the belt tensility 3. Repair the Compressor 1. Clean Evaporator 2. Repair or replace Fan motor 3. Repair or replace fan motor resistance Leakage of dew inside 1. Drain pipe badly 1. Install the pipe again. vehicle installed 2. Take some adiabatic 2. Low pressure tube measures exposure in the vehicle Notice: Because company is keep on improving the products so it may cause the difference between the handbook and existing product, Please note that we reserve the right to modify the specification or facility without forehand inform.. six. Service guide 1) Please fill in the form of Products Warranty list and send it back in twenty days after installation, so that we provide the better service. 2) Failure to observe the installation instructions or use of the unit under conditions other than those indicated in handbook will immediately void the service warranty. The manufacturer declines any liability for damage resulting from modifications or safety reasonability cause by the wrong operation. 3) The maintain service period is 12 months after the day of installation or purchase. During the maintain service period, the user cannot tear down or repair air-conditioner optionally, also factitious damage is not allowed, otherwise the TaiChang company would not take responsibility of maintaining service. 4) The products of TaiChang Company obey the rules of national quality guarantee. If you meet any defects of products, Please contact the TaiChang Bus Air Conditioner Co., Ltd. 21

22 TaiChang Bus Air Conditioner Co., Ltd. Products Warranty List (Keep by the user) Vehicle No. Air-condition No Motor No. Compressor No. Customer company Air-condition Installation day Customer address Zip code Customer telephone no Contact Customer signature Transactor signature 1. Customer hot line: Please contact the service agent of TaiChang Passenger Vehicle Air Conditioner Co., Ltd Products Warranty List (For sending back the Factory) Vehicle No. Motor No. Customer company Customer address Customer telephone no Customer signature Air-condition No Compressor No. Air-condition Installation day Zip code Contact Transactor signature Attention: Please fill in this list and send it back in twenty days after installation, otherwise TaiChang Company will void the warranty 22

23 TC33N CONDENSER INSTALLATION SIZE TC33N EVAPORATOR INSTALLATION SIZE 23

24 TC33N DRAWINGS 24

25 25

26 TC33N ELECTRIC DRAWINGS 26

27 27