(GB) Installation Manual AC 353 G4

APPLICATION AC353 G4
INSTALLATION INSTRUCTION
TITLE: INSTALLATION PROCESS ROOF TOP UNIT AC353 G4

APPLICATION NO. REVISION DATE PAGE
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Notes
REV. RELEASE
DESCRIPTION OF CHANGE
LETTER DATE
Details added regarding:
• Roof radius adaptor
3 February
5 • Reduced number of mounting screws for all units
2009
• Refrigerant charge quantity
• Rrefrigerant charging process
Details added/amended:
Fitting of AC353 I G4 condenser
Pipe size for AC353 III G4
Electrical installation
9 November
6 Removal of lifting parts after installation
2009
Revise torque of unit mounting screws
Add torque for refrigerant connections
Details for cleaning tubes
Refrigerant hose installation
Adjusted to Eberspächer
17 January
7 Layout changes
2011
Deleted pages with internal information (distribution list, approvals)
Added details of new aluminium spacer for 6,5m installations
Revised tightening torque for unit mounting bolts
8 Added tightening torque for electrical connections 04 July 2012
Added lb weights for refrigerant charge
Added °F temperatures to charging process for type I
2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

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TABLE OF CONTENTS
Index
1. Description………………………………………………………………………………….4
1.1. Technical data…………………………………………………………..………….4
1.2. Scope…………………………………………………………………..………….....5
1.3. Safety…………………………………………………………………..……...……..6
1.4. System Cleanliness……………………………………………………………….10
1.5. Installation process……………………..………………………….……………..13
1st step: Roof preparation……………………………………………..…….14
2nd step: Evaporator mounting………………………………………..…….18
3rd step: Condenser mounting…………………………………….………..30
4th step: Refrigerant and Heating connection………………….………..34
5th step: Condensed water drainage……….……………………………...43
6th step: Electrical installation……………………..……………………….44
7th step: Commissioning the air-cooling system………………………..46
Notes: Guide to refrigerant charge………………………………………47

Refrigerant charging process……………………………………48

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1. Description
This instruction consists of general information about the installation process of the HVAC
roof top unit AC353 G4 for large bus (cooling capacity).
AC353 G4
1.1 Technical data
AC353 G4 is a product family comprising 4 units of different cooling capacity, but with common
installation and many common components.
1.1.1 AC353 I G4
Cooling capacity 24.7 kW 21257 kcal/hr 84355 BTU/hr
Heating capacity 38 kW 32700 kcal/hr 130000 BTU/hr
Evaporator air capacity (free blowing) 4070 m³/hr 2400 CFM
Condenser air capacity 6900 m³/hr 4060 CFM
Power supply 26.5 VDC
Power Input (free blowing) 72.4 Amp
Weight 155 kg 340 lbs
Length 3016 mm 119”
Width 1850 mm 73”
Height (installed) 215 mm 8.5”
Fresh Air 0 – 40%
Refrigerant* 5.0 kg (11.0 lbs) R134a
Recommended pipe size (outside diameter) Discharge 22mm (7/8”), Suction 28mm (1 1/8”)
1.1.2 AC353 II G4

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Power Input (free blowing) 94 Amp
Width 1850 mm 73”
Fresh Air 0 – 40%
Recommended pipe size (outside diameter) Discharge 22mm (7/8”) Suction 28mm (1 1/8”)
1.1.3 AC353 III G4

Width 1850 mm 73”
Fresh Air 0 – 40%
Recommended pipe size (outside diameter) Discharge 22mm (7/8”) Suction 28mm (1 1/8”)
1.1.4 AC353 IV G4
Cooling capacity (650cm³ compressor) 42.5 kW 36576 kcal/hr 145145 BTU/hr
Width 1850 mm 73”
Fresh Air 0 – 40%
Recommended pipe size (outside diameter) Discharge 28mm (1 1/8”) Suction 35mm (1 3/8”)
Note *: The refrigerant charge stated above is without driver front box and with a nominal distance
between compressor and unit of 8m (26.3 ft). The addition of a driver front box and different distance
between compressor and unit may change the amount of refrigerant.
1.2 Scope

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Installation of following AC353 G4-components:
Evaporator assembly: with two covers for service access – Blowers – Electric board –
Electric Harness - Refrigerant and heating1 connections – condense water Drain outlets –
Flaps and flap’s motor – integral transfer ducts.
Condenser assembly: with two covers for service access - low noise fans – electric
harness – Refrigerant connections.
1.3 Safety
1
When required

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These safety instructions are intended for the protection of the operator & the system
itself. They must be observed & followed at all times. It is the installer’s responsibility
to make sure that a Safe System of work is in place before starting the installation.
Certificates
Quality assurance has been carried out in accordance with DIN ISO 9001.
Safety
Your Eberspächer Sütrak air-conditioning system has been designed with the optimum safety
of the operating personnel in mind. During normal operation, all moving parts are protected in
order to prevent accidents. During checking prior to commissioning, daily inspection and
maintenance work, moving parts may be accessible to the operator. The operator must
therefore maintain a safe distance from such parts when the air-conditioning system is
working and the switch is in the “ON” position.
The evaporator coil is equipped with thin fins, which can cause cuts to the hands. We
therefore recommend that protective gloves always are worn when working on the air-
conditioning system.
Work on cooling and air-conditioning systems must only be carried out by experienced
persons with the relevant training. Only such persons with the relevant qualifications
may be allowed to work on air-conditioning systems.
Caution:
Protective covers must not be removed when the system is in operation. It is
strictly forbidden to deactivate any safety devices.
Safety when handling refrigerants
The refrigerant contained in the air-conditioning system can cause frostbite and severe cold
burns if it comes into contact with the skin. If refrigerant comes into direct contact with the
eyes, this can result in blindness. If liquid refrigerant gets into the eyes, rinse the eyes
immediately with copious amounts of water, and seek medical aid immediately.
The refrigerant used by Eberspächer Sütrak AC353 G4 unit is R134a.
Refrigerant vapors must not be inhaled. Refrigerant vapors are heavier than air, and may
collect at low points. In larger volumes, refrigerant vapors will displace the air completely.
Protective gloves and goggles must always be worn when working on air-conditioning
systems.

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Air-conditioning systems and bottles should never be over-filled. If the temperature

increases, the increased pressure can cause the bottles to burst.
The system must be completely emptied before starting any soldering work. Flush the
system out during such work with dry nitrogen.
First aid for accidents involving refrigerants
Frostbite:
Warm the affected areas up to body temperature.
Eyes:
If liquid refrigerant gets into the eyes, rinse the eyes immediately with copious amounts
of water, and seek medical aid immediately.
Disposal of refrigerants
Observe the applicable legal requirements when disposing of refrigerants.
Installation of replacement and consumable parts
Replacement parts and accessories not supplied by Eberspächer Sütrak are not tested or
approved.
Other replacement parts and accessories may be used after approval by Eberspächer Sütrak.
The installation or use of non-approved products may under certain circumstances have an
adverse effect on the specified performance of the system.
Eberspächer Sütrak accepts no liability for damage caused by the use of non-approved
replacement parts and accessories.
Inert gas brazing procedure
Always relieve all pressure from assemblies, coils or units before attempting to repair or
dissemble a braze joint. Make sure the system is vented and open. If you heat a braze joint
with pressure in it, the pressure can blow the molten filler metal into your face causing severe
burns. If the tube you are attempting to dissemble or repair is pressurized and also contains
oil or refrigerant, you could be severely burned by them. Also burning refrigerant can give off
deadly gasses.
Flux can be applied to the joint to be dissembled, to act as a temperature indicator and to
prevent oxidation.
Heat uniformly until the joint is free. Wear gloves and use pliers to avoid being burned.

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Thoroughly clean the parts after cooling. Use flux, if called for before reassembling the
parts. Inert gas purging with nitrogen or argon must be used where called for to ensure
internal cleanliness. Nitrogen or argon flowing through tubing during brazing displaces oxygen
preventing the formation of oxides on the inside of the tube assemblies. Ideally the purge gas
supply will be attached to the fixture in such a way that simply placing the parts in the fixture
makes the connection to the assembly.
Suction valves, liquid valves, TXV, solenoids and check valves must be protected during
brazing in a “chill block” fixture or with a heat sink. The most common heat sink is a wet rag. A
wet rag wrapped on a valve during brazing will absorb much of the heat preventing damage
to the valve.
Be sure the filler metal you are using to make the repair is compatible with the original
alloy on the joint. As a general rule you should use the same filler metal, but there can be
exceptions. If you use the same class of filler metal alloy (one with or without phosphorus, be
sure to use paste flux with a filler metal containing no phosphorus), you should get an
acceptable joint. The 40% silver filler metal alloy we use, works well in a variety of
applications. You must use paste flux with the 40% silver filler metal.
After making the repair, remove all flux residues.
Never repair a burn through. If you overheat a part to the point of burning a hole through
the metal, discard that part or assembly and start over. Do not fix a hole.
There are two reasons for not fixing a hole:
Material heated to this extreme has been weakened, not just at the hole, but the rest of
the part as well.
There is the risk of a build-up of filler metal inside the tube, plugging the tube or partially
restricting the flow of refrigerant.

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1.4 System cleanliness
General Instructions on commissioning the air-conditioning system:

When installing or repairing an air conditioning system, great care must be taken to ensure
absolute cleanliness, since almost all operating problems are eventually found to be due to
dirt and impurities in the system. Since the cooling circuit is a closed system, foreign matter
will remain in the system until it causes problems, or even severe damage, which can then
frequently only be corrected by time-consuming and costly repairs. The system may
nevertheless be able to be started and operated in apparently perfect condition. Damage due
foreign matter and impurities may not actually occur until many months later. The long-term,
proper functioning of the air-conditioning system depends on proper and thorough working
practices, which must be applied from the very beginning. This includes proper sealing of all
components, correct assembly and installation, including during repairs, through to
conscientious integrity testing, cleaning, filling and commissioning of the air conditioning
system.
The air conditioning unit type AC353 G4 uses the MCHX type heat exchanger for the
condenser coil. This type of heat exchanger is an all aluminium heat exchanger utilising
multiple small channels in parallel to maximise heat transfer surface contact.
This type of heat exchanger is more efficient giving benefits in length and weight reduction,
refrigerant charge reduction and improved corrosion resistance.
Each of the small channels includes multiple small holes. These holes are smaller than a
conventional fin and tube heat exchanger (typically by a factor of 20:1)
Use of copper tube (see also section 1.3 Safety)

Copper tubes are always supplied from the manufacturer with caps over the ends, in order to
prevent the ingress of dust and moisture. The same applies for the complete installation
process. When any stage of the process has been completed, the tube must be sealed again.

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Tube Brazing (or soldering)

a) All soldered or brazed joints shall be made with an inert (or reducing) gas present on
the refrigerant side of the joint. (Typically dry nitrogen or argon is used). The inert gas
flowing though the tubing during brazing displaces oxygen preventing the formation of
oxides on the inside of the tube assemblies. In service, these oxides will loosen from
the pipe and enter the system causing problems of even severe damage.
b) Flux-less brazing shall be used whenever practical for making joints, and where fluxes
must be used, the brazing technique and cleaning method used shall be such to
prevent residual flux on the refrigerant side of the joint
After soldering, tubes must be blown out with dry nitrogen. (See fig 1)
NB; use pressure regulator!
DO NOT use cleaning cloths as these will leave more dirt in the tubes than is cleaned out!
Figure 1: Blow out tubes after soldering
Assembly of Refrigerant hoses and fittings

Important: when making flexible hose assemblies from loose fittings, sockets and hose it is
very important that the assembly instructions from the hose supplier are strictly adhered to:
a) Cut the hose using a proper sharpened cutting machine. Do not use a cutting machine
equipped with an abrasive disc. The hose must be cut clean and square. Avoid
causing damage to the wire braid. Clean the hose carefully of any cutting residue.
b) Secure the socket in position (eg; using a bench vice). Screw the hose counter-
clockwise into the socket until it reaches the bottom. Unscrew ¼ turn.
c) Mark the socket and the hose using an indelible felt-tip pen, to verify the hose does not
rotate inside the socket during the installation of the fitting
d) Lubricate (with a generous amount of refrigerant oil) the thread and taper of the fitting
and the inside of the hose. Insert the fitting into the hose. Press lightly and screw by
hand turning clockwise for the first threads. Then by using an appropriate spanner on
the hexagon, screw the fitting into the socket with a continuous and constant motion.
e) Continue to screw the fitting until it reaches the socket. Do not over-tighten

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Installation of Refrigerant tubes and flexible hoses

Important: whether using flexible hoses or metal tubes, whether you make them yourself or
assemble them from individual parts, all parts must remain sealed at both ends until they are
installed in the vehicle, in order to prevent the ingress of dirt and damp. Finished hoses and
tubes supplied by Eberspächer Sütrak are tightly sealed at both ends with plastic screw
fittings. Hoses without screw fittings are supplied with plastic plugs in the hoses. Care must
be taken here to ensure that the plastic plugs are removed from the hoses before the fittings
are screwed onto the hoses.
Proper practice – general.

a) The protective and sealing caps of refrigeration connections must be kept in place until
immediately before joining the connections
b) Always use refrigerant oil for lubrication when fitting screw connections to pipe or hose
connections.
c) The refrigerant coil must be stored clean and properly sealed in order to prevent the
absorption of humidity or moisture.
d) Check the condition of connections and pipes prior to assembly and installation. At the
high pressures occurring in the system, event the slightest dirt or minor damage can
lead to leaks.
e) Dirty connections should only be cleaned with a clean cloth soaked in alcohol.
f) Before the screw connections are tightened, a check must be carried out to ensure that
the hoses are not dirty, kinked or trapped, since subsequent rectification is usually
impossible.
g) Components and hoses must be sealed immediately following dismantling, in order to
prevent the ingress of dirt or moisture.
Cleanliness specification
All Eberspächer Sütrak air conditioning units are manufactured in accordance with the
following cleanliness standards:
SAE J2064: special instructions: Eberspächer Sütrak specification: 38 mg/m²
Eberspächer Sütrak Engineering Requirements:
• Z-293 Contamination Limits for Refrigeration Containing Systems & Components
• 57-60079-00 Refrigerant hoses
All specifications quote a maximum contaminant level of 38mg/m² internal surface area

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Checking prior to dispatch
Every system is checked prior to delivery for:
Condition
Setting of the safety devices and control equipment
Integrity of the refrigerant circuit (and water circuits if applicable)
Function
1.5 Installation process
The installation process is to be proceeding according to the sequenced steps below:
1st step: Roof preparation
2nd step: Evaporator mounting
3rd step: Condenser mounting
4th step: Refrigerant and heating connections
5th step: Condensed water drainage
6th step: Electrical Installation
7th step: Commissioning the air-cooling system

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1st step: Roof preparation.
The installation dimensions and the cut-outs in the vehicle roof for the supply air, exhaust air and
the electrical & refrigerant lines must be taken from the installation drawing and marked on the
roof of the vehicle. (See drawing number 36,06,01,094-00/01/02 & figures 2a, 2b and 2c)
• The unit must be positioned on the roof so that it does not damage the roof ribs.
• The roof construction may have to be reinforced, depending on the type of bus structure.
• It is important that the sealing gasket is fully supported for its entire length.
• The cut-outs for the return air suction and the air inlet openings should preferably not be
obstructed or blocked by the roof rib construction. This can lead to a loss of performance
and the creation of noise.
Evaporator
unit
Condenser
unit
Note A: The return air “Opening in the roof panel”:

350 x 1494 mm (13.78” x 58.82”).
Figure 2a: Installation drawing and roof opening dimension AC353 I G4

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Evaporator
unit
Condenser
unit

350 x 1494 mm (13.78” x 58.82”).
Figure 2b: Installation drawing and roof opening dimension AC353 II, III G4

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Evaporator
unit
Condenser
unit

350 x 1494 mm (13.78” x 58.82”).
Figure 2c: Installation drawing and roof opening dimension AC353 IV G4

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After determining and marking the cut-outs in the roof, the opening should be cut carefully to fit
the drawing requirements. Figure 3 shows as an example of cutting the roof opening for return
and supply air section.
Air supply opening Air supply opening
Air return opening
Figure 3: Roof openings for return and supply air
The installation of the unit must be carried out in accordance with the above dimensioned
installation drawings (figures 2a, 2b, 2c), which specify the relevant mounting points for the
evaporator and for the condenser. If supporting or sealing surfaces are required, these must be
constructed by installing suitable tubes, L-profiles or brackets. Depending on the vehicle, this
material can be welded or screwed to the roof construction (figure 3.1)
Reinforcing interior
Figure 3.1: Example of roof structure that was reinforced to take AC353 G4 with channels that were filled on
the inside with steel of section 6mm x 50mm (¼” X 2”) x length of each channel. (Painted to avoid corrosion)

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2nd step: Evaporator mounting
• The evaporator assembly of AC353 G4 is fitted with a self adhesive EPDM sealing gasket;
this forms the first watertight seal. In addition, a silicon sealing compound, such as
Sikaflex, is applied between the gasket and the roof; this forms the second watertight seal.
These 2 sealing methods (when correctly followed) form a perfect watertight installation.
• It is important when moving the evaporator during the installation that the gasket is not
damaged or deformed. This may affect the water tightness of the installation. (See fig 4)
Gasket damage caused by

laying evaporator on block of
wood
Fig 4: Gasket damage
• AC353 G4 is suitable for 10m (32.8 ft) to 8m (26.2 ft) roof radii. Different roof radii are
managed with additional gaskets (supplied loose with the unit).
• If installing the unit on a roof radius other than 8m (26.2 ft) – 10m (32.8 ft) adaptor gaskets
must be fitted before installing the evaporator.
• There are 3 types of gasket:

42-67045-00 Adaptor gasket for radii 6m (19.7 ft) – 7.5m (24.6 ft)
42-67045-01 Adaptor gasket for roof radii 5m (16.4 ft)
42-67045-02 Adaptor gasket for roof radii 12m (39.4 ft) and above
NB: Each unit requires 2 gaskets. These gaskets are supplied loose with the unit as part
of the accessory kit.
• The adaptor gasket must be fitted to the evaporator before placing the evaporator on the
roof of the bus.

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• To fit the gasket (see also figs 5a and 5b):

o Lift evaporator to a good working height
o Offer up adaptor gasket to main gasket and mark end of adaptor gasket on main
gasket
o Carefully remove the adhesive gasket paper from the main gasket up to the mark.
o Remove the adhesive gasket paper from the top of the adaptor gasket
o Carefully glue the adaptor gasket to the main gasket
Main gasket
Mark here on main gasket
Adaptor gasket
Adaptor gaskets will

exactly match the main
gasket when correctly
fixed in place Adaptor gasket
Fig 5a: Fitting of adaptor gaskets for roof radii less than 8m (26.3 ft)
Main gasket
Mark here on main gasket
Adaptor gasket Adaptor gasket
Fig 5b: Fitting of adaptor gaskets for roof radii greater than 12m (39.4 ft)

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• When using AC353 G4 on a bus with roof radii other than 10m (32.8 ft) spacers are
required between the evaporator housing and the roof to provide a rigid unit fixing to the
bus. (See fig 6a and 6b)
• The following spacers are available from Eberspächer Sütrak:
Roof radius Thickness

Spacer part no. Qty Material Usage
Metre Feet mm inch
5 10,6 58-67106-02 4 15 0,59 Hard Rubber Standard
58-67106-01 4 10 0,39 Hard Rubber Standard
58-67106-00 4 4 0,16 Hard Rubber
68-67542-00 2 6 0,24 Aluminium (Evaporator) Option (AC353 I G4)
6,0 - 6,8 12,7 - 14,4 88-50-47-00007-00 2 6 0,24 Aluminium (Condenser)
58-67106-00 4 4 0,16 Hard Rubber
68-67542-00 2 6 0,24 Aluminium (Evaporator) Option (AC353 II/III/IV G4)
88-50-47-00006-00 2 6 0,24 Aluminium (Condenser)
10 32,8 Not required
NB: Spacers are supplied as part of the unit BOM: they do not need to be ordered
separately.

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For standard Usage:

Each unit will use 4 spacers; 2 per evaporator, 2 per condenser.
(The spacer has a combination of holes for both evaporator and condenser; once the
spacer has been fitted under the condenser, it will need to be cut to length. Use the
condenser chassis as a jig)
Mounting screw
Fibre-glass
Evaporator housing M8 (5/16”)
Roof Spacer
Fig 6a: Use of spacer for rigid fixing
For optional Usage:

Each unit will use 4 rubber spacers; 2 aluminium spacers under evaporator, 2 aluminium
spacers under the condenser.
(The rubber spacer has a combination of holes for both evaporator and condenser; once
the spacer has been fitted under the condenser, it will need to be cut to length. Use the
aluminium spacers as a template)
It is important that the rubber spacer is placed onto the roof first; the aluminium spacer
must be directly under the unit.
Mounting screw
M8 (5/16”)
Fibre-glass
Evaporator housing Aluminium
Spacer
Roof Rubber
Spacer
Fig 6b: Use of optional rubber/aluminium spacers for rigid fixing

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1. Lift evaporator assembly onto roof of bus using suitable lifting frame/device. (see fig. 7)
2. Lower evaporator assembly into correct position on roof (taking care not to damage / trap
condensate hoses and electrical cables; see fig 7) and check:
a) Correct alignment of holes for supply and return air
b) Evaporator assembly is parallel with bus roof (see fig. 8).
Lifting straps attached
Fig 8: Correct position of evaporator
Check evaporator is
parallel to roof and in
centre
Check condensate drain hose and electrical cables

are not trapped or damaged
Fig 7: Lifting straps & care to prevent damage to hoses
3. Open evaporator covers and secure using support stay. (Make sure support stay is
properly clipped in place; see fig 9).
Correct position of support

stay for covers (important
for safety)
Fig 9: Correct opening of evaporator covers

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4. Mark through the mounting holes (AC353 I, qty 6, 3 per side, AC353 II/III qty 8, 4 per side,
AC353 IV qty 10, 5 per side) in the evaporator housing onto the bus roof with pen/pencil
or drill. (See figs 10 and 11)
5. Mark around outside edge of sealing gasket. (See figs 10 and 11)
Mark around gasket Mark mounting holes and

around gasket
Fig 10: Marking of gasket and holes Fig 11: Marking of gasket and holes
6. Lift evaporator assembly and move to another part of bus roof.
7. Using the marks made in (4) drill through roof and cut threads. (Use either M8 or 5/16”
UNF threads, quantity 6 for AC353 I, 8 for AC353 II/III and 10 for AC353 IV)
8. Wipe clean roof under evaporator assembly.
9. De-grease roof under sealing gasket using Sikaflex Cleaner 205 or similar, using marks
from step 4 as guide. NB: Gasket is 25mm (1”) wide
10. Prime roof under sealing gasket using Sikaflex Primer 215 or similar.
11. Screw 4 long studs in holes tapped in roof. Use 4pcs (30cm / 12” long; thread to suit)
placed in each corner for location. (These are used to guide the evaporator assembly into
the correct position; see fig 12)
Lift evaporator
~60cm (24”) above
Locating studs screwed roof
into position
Fig 12: Position of locating studs and unit lifted above roof

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12. Lift the evaporator assembly ~60cm (24”) above the roof and remove the backing paper
from the bottom surface of the gasket. (See fig. 12)
13. Move the evaporator assembly into correct position and lower onto location studs.
NB: IMPORTANT. Once the gasket has made contact with the roof it must not be
separated. Separating the gasket will damage the adhesive.
14. As the evaporator assembly approaches the roof, look down through mounting holes in
evaporator housing to confirm alignment with holes in roof. (See fig 13)
Evaporator located using

studs
Fig 13: Location of evaporator onto studs
15. Fit mounting screws, spring washers and plain washers. Specification:
• Mounting screws: M8 / 5/16” UNF, grade 8.8, zinc plated, correct length to suit roof
structure
• Spring washer: 8mm / 5/16”, rectangular section, zinc plated (supplied with unit)
• Plain washer: 8mm / 5/16”, 24mm (0.94”) outside diameter, 2mm (0.80”) thick, zinc plated
(supplied with unit)
16. Fit screws until finger tight.
17. Remove location studs and fit screws.
18. As first stage, tighten mounting screws in an even manner to a torque of 15 Nm (11 lb-ft);
then finally tighten the mounting screws to a torque of 20-25 Nm (15-18 lb-ft) (See fig 14).
19. This procedure mentions the use of Sikaflex products. Many different flexible sealing
compounds can be used. Most products typically used by the bus builder will be suitable.
Eberspächer Sütrak part numbers for sealant:

• 02-62004-00 Sikaflex 252 (white)
• 02-62001-00 Bostik FS1100 (white)
NB: If products other than Sikaflex are used it is important that the cleaner and primer
matches the sealant, i.e. Sikaflex cleaner, primer, sealant or Bostik cleaner, primer,
sealant, etc.

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Fig 14: Tightening sequence (evaporator mounting screws)
Evaporator mounting screws:

AC353 I use 1, 2, 3, 4, 5, 6 Condenser
position
AC353 II use 1, 2, 3, 4, 7, 8, 9, 10
AC353 IV use 1-10
20. Apply beads of Sikaflex 252 (white) or similar around edge of gasket.
• Bead size ~ 15mm (5/8”)
• The beads should cover the gasket.
• It is estimated you need ~ 4 tubes (315 ml) to seal around evaporator ass’y. (see fig 15)
Beads of sealant
Fig 15: Beads of Sikaflex or similar around evaporator
21. Using spatula or similar tool, smooth beads of Sikaflex or similar to achieve a continuous
fillet around the complete perimeter of the evaporator assembly. (See figs 16 and 17)
Spatula
Fig 16: Using spatula to smooth beads of Sikaflex or similar

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Fig 17: Pictures showing finished Sikaflex or similar application
22. Remove lifting frame/device

23. Remove 2 screws and remove rear evaporator lifting plate. (This will allow evaporator
covers to fully open)
24. Refit screws into fresh air cover.
25. Remove front evaporator lifting plates (2).
26. Close the evaporator covers.
27. Evaporator installation is now complete.

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3rd step: Condenser mounting:
3.1 Condenser mounting AC353 II, III and IV
• AC353 G4 is suitable for 10m (32.8 ft) to 8m (26.2 ft) roof radii.
• When using AC353 G4 on a bus roof with roof radii other than 10m (32.8 ft) spacers are
required between the condenser chassis and the roof to provide a rigid unit fixing to the
bus. (See fig 6)
• NB: The spacers supplied by Eberspächer Sütrak are common for evaporator and
condenser. Once the spacers have been fitted under the condenser they will need to be
cut to length. (Use the condenser chassis as a jig)
1. Lift condenser assembly onto roof of bus using suitable lifting frame/device. There are 3
lifting points: Two ‘eye’ bolts at the rear and a central plate at the front. (see fig 18)
Central lifting plate Lifting ‘eye’ bolts
Fig 18: Lifting of condenser (AC353 II, III, IV: NB Type IV shown)
2. Lower condenser assembly into correct position on roof. Correct position is defined as:
• Parallel / in-line with evaporator assembly
• With a 10mm (3/8”) gap between the condenser and evaporator covers.
3. When in correct position, open condenser covers and secure with support stay. (Make
sure support stay is correctly clipped in place) See fig 19
Support stay in
correct position
Fig 19: Correct position for condenser cover support stay (AC353 II, III, IV)

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4. Mark through the mounting holes (qty 8, 4 per side) in the condenser chassis onto the
bus roof with pen/pencil or drill. (See fig 20)
Mark through holes

onto bus roof
Fig 20: Mark through mounting holes in condenser chassis
5. Lift condenser assembly and move to another part of the bus roof.
UNF threads, quantity 8)
7. Clean area around holes in roof (approx 50mm / 2” diameter).
8. De-grease area around holes in roof using Sikaflex Cleaner 205 or similar.
9. Prime area around holes in roof using Sikaflex Primer 215 or similar.
10. Add ‘dome’ of Sikaflex 252 (white) or similar around holes in roof. Dome to be 50mm
(2”) diameter and 12mm (1/2”) high.
11. Lift the condenser assembly ~60cm (24”) above the roof. Clean, de-grease and prime
underside of condenser chassis around mounting bolt holes.
12. Move the condenser assembly to the correct position and lower into place.
13. Assemble mounting screws, spring washers and plain washers. (see fig 21)
• Specification:
structure
Sikaflex or similar
around screw thread
Fig 21: Screw and washer assembly

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14. Apply bead of Sikaflex 252 (white) or similar around thread of mounting screws and fit in
place. Fit all screws finger tight. (See figs 22)
Sikaflex or similar
around screw thread
and under condenser
chassis
Fig 22: Sikaflex or similar around condenser mounting screw
15. Tighten mounting screws in an even manner (as with the evaporator assembly) to a
torque of 20-25 Nm (15-18 lb-ft)
16. Apply a dome of Sikaflex or similar over the head of the mounting screw and round off.
(Mounting screw/washer should be completely covered)
17. Remove lifting frame/device.
18. The liquid hose assembly (evaporator to condenser) is already fitted to the evaporator
• The condenser and evaporator assemblies are filled with a holding charge of Nitrogen
• Release this pressure by depressing the Shrader valves
• Remove the blanking plugs fitted to the condenser assembly and the liquid hose
assembly.
• Fit the liquid hose assembly to the condenser outlet connection.
• NB; Use refrigerant oil on connection before tightening & make sure backing spanner
is used to prevent strain on copper pipe connection. (See figs 23 and 37)
• Tightening torque (ORFS connection with 1”-14 thread) 62-68Nm (46-50lbft)
Condenser Inlet
Connection
Fig 23: Hose connections to condenser liquid pipe (AC353 II, III, IV)

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19. Fit condenser wiring cables through grommet in front of evaporator housing. NB: there
are 2 holes for grommets (see fig 24), grommets are supplied with unit:
• hole A (diameter 48 mm) is for the wiring cable;
• hole B (diameter 38 mm) is for the liquid hose assembly.
Evaporator liquid
Use hole A (48mm) hose assembly uses
for condenser wiring hole B 38mm (with
cable (with grommet) grommet)
Fig 24: Use of correct holes for wiring cable and hose assembly
20. Important: remove lifting eyes (M8 qty 2) at rear of condenser.

21. Lower lifting plate at front of condenser (loosen 2 screws in centre of chassis) if required.

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3rd step: Condenser mounting:
3.2 Condenser mounting AC353 I

• AC353 G4 is suitable for 10m (32.8 ft) to 8m (26.2 ft) roof radii.
• When using AC353 G4 on a bus roof with roof radii other than 10m (32.8 ft) spacers are
required between the condenser chassis and the roof to provide a rigid unit fixing to the
bus. (See fig 6)
• NB: The spacers supplied by Eberspächer Sütrak are common for evaporator and
condenser. Once the spacers have been fitted under the condenser they will need to be
cut to length. (Use the condenser chassis as a jig)
22. Remove the condenser cover (4 quarter turn screws; see fig 25)
Cover fixing screws, 2

per side
Fig 25: Removal of cover fixing screws
23. Lift condenser assembly onto roof of bus using suitable lifting frame/device.
• There are 3 lifting points: One plate at the front & 2 openings at the rear, one per side.
(see fig 26)
Use lifting hook

Loosen screw and through this opening
pivot plate to upright each side
position; re-tighten
screw
Fig 26: Lifting of condenser (AC353 I, showing bare chassis only)

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24. Lower condenser assembly into correct position on roof. Correct position is defined as:
• Parallel / in-line with evaporator assembly
• With a 10mm (3/8”) gap between the condenser and evaporator covers.
25. Mark through the mounting holes (qty 4, 2 per side) in the condenser chassis onto the
bus roof with pen/pencil or drill. (See fig 27)
Mark through holes

onto bus roof
Fig 27: Mark through mounting holes in condenser chassis
26. Lift condenser assembly and move to another part of the bus roof.
UNF threads, quantity 8)
28. Clean area around holes in roof (approx 50mm / 2” diameter).
29. De-grease area around holes in roof using Sikaflex Cleaner 205 or similar.
30. Prime area around holes in roof using Sikaflex Primer 215 or similar.
31. Add ‘dome’ of Sikaflex 252 (white) or similar around holes in roof. Dome to be 50mm
(2”) diameter and 12mm (1/2”) high.
32. Lift the condenser assembly ~60cm (24”) above the roof. Clean, de-grease and prime
underside of condenser chassis around mounting bolt holes.

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33. Move the condenser assembly to the correct position and lower into place.
34. Remove lifting frame/device.
35. Assemble mounting screws, spring washers and plain washers. (see fig 28)
• Specification:
structure
Sikaflex or similar
around screw thread
Fig 28: Screw and washer assembly
36. Apply bead of Sikaflex 252 (white) or similar around thread of mounting screws and fit in
place. Fit all screws finger tight. (See figs 29)
Sikaflex or similar
around screw thread
and under condenser
chassis
Fig 29: Sikaflex or similar around condenser mounting screw
37. Tighten mounting screws in an even manner (as with the evaporator assembly) to a
torque of 20-25 Nm (15-18 lb-ft)
38. Apply a dome of Sikaflex or similar over the head of the mounting screw and round off.
(Mounting screw/washer should be completely covered)
39. Loosen screw securing front lifting plate and lower plate to downwards position. Re-
tighten screw.

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40. The liquid hose assembly (evaporator to condenser) is already fitted to the evaporator
• The condenser and evaporator assemblies are filled with a holding charge of Nitrogen
• Release this pressure by depressing the Shrader valves
• Remove the blanking plugs fitted to the condenser assembly and the liquid hose
assembly.
• Fit the liquid hose assembly to the condenser outlet connection.
• NB; Use refrigerant oil on connection before tightening & make sure backing spanner
is used to prevent strain on copper pipe connection. (See figs 30, 31 and 37)
• Tightening torque (ORFS connection with 1”-14 thread) 62-68Nm (46-50lbft)
Connection liquid
hose assembly to
here
Fig 30: Hose connections to condenser liquid pipe (AC353 I)
Connection liquid
hose assembly to
here
Fig 31: Hose connections to condenser liquid pipe (AC353 I)
40. Fit condenser wiring cable through grommet in front of evaporator housing. NB: there are
2 holes for grommets (see fig 24):
• hole A (diameter 48 mm) is for the wiring cable;
• hole B (diameter 38 mm) is for the liquid hose assembly.

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4th Step: Refrigeration and Heating connections
4.1 Refrigeration Connections
IMPORTANT:
1. The refrigerant lines (copper pipes and flexible tubes) must be kept clean during the
manufacture of the bus and installation of AC353 G4.
2. It is recommended that copper pipes and flexible tubes are kept closed at all times
until the system is connected (AC353 G4, copper pipes / flexible tubes and
compressor).
3. It is recommended that the copper tubes and flexible hoses are purged or blown
through with Nitrogen just before the system is connected.
There are 2 different types of refrigeration connections used on AC353 G4.
1. Connections inside the unit using refrigerant hose (see fig 32, left side shown)
(NB: Only available with units AC353 I, II, III)
Fig 32: Connections inside unit using refrigerant hose (AC353 I, II, III)
2. Connections at roof level (see fig 33, left side shown)

NB: Option for AC353 I, II, III; standard for AC353 IV)
Fig 33: Roof level connections (AC353 I, II, III option; AC353 IV standard)
AC353 G4 Recommended Sizes for Refrigerant flexible hose and copper tubes
Suction Discharge
Unit type
Hose Tube (OD) Hose Tube (OD)
AC353 I
AC353 II Sz20 (DN28) 28mm (1 1/8") Sz16 (DN22) 22mm (7/8")
AC353 III
AC353 IV Sz24 (DN35) 35mm (1 3/8") Sz20 (DN28) 28mm (1 1/8")

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4.1.1 Connections inside the unit using refrigerant hose (not available with AC353 IV)
Front box liquid hose

Discharge Hose
Suction Hose
Fig 34: Fitting of hoses through grommets
42. Route hoses as follows:
• Suction hose (see fig 35 - shown in blue):

• This is routed through sealing grommet around rear of evaporator, through P clip (1)
and is connected to evaporator coil using a 90º flange connection.
• Discharge hose (see fig 35 - shown in red):

o This is routed through sealing grommet, alongside evaporator, through 3 P clips
(2), 1 P clip (3) and is connected to the condenser using a 90º M36 nipple.
• Front box liquid line (see fig 35 - shown in green) NB: use size 6 or 8 hose:
o This is routed through grommet in side of evaporator housing, past the end of the
evaporator coil and is connected to the liquid line using a 45º ORFS nipple.
Front box Hose

(Green) Use 3 P Clips (2)
Supplied with unit
Suction Hose Discharge hose
(Blue) (Red)
Use 1 P Clip (3)

Supplied with unit
Use P Clip (1)
Supplied with unit
Connect to liquid line Connect to condenser

using 45º ORFS nipple using 90º M36 nipple
Connect to
evaporator using 90º
flange nipple
Fig 35 Routing and clipping of hoses (left side installation shown)
43. To install the suction and discharge hoses through the grommets it is permissible to add
a small amount of refrigerant oil to the outside of the hoses. (see fig 36)

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44. Once the suction and discharge hoses are installed in the correct position, add a cable
tie around the lip at the bottom edge of the grommet (ie inside the bus) See fig 36.
Use small amount of

refrigerant oil (if required) Add cable tie to
to help push hose through suction and
grommet discharge grommets
Fig 36: Addition of cable tie for additional sealing
45. Fit the nipple (90º flange type) to the suction hose and connect to the evaporator coil
suction connection.
• NB; Use refrigerant oil on connection and gasket before tightening.
• Tighten M10 screws of flange connection to 47-51 Nm (35-37 lb-ft)
46. Fit the nipple to the discharge hose and connect to either:
• AC353 I: the condenser coil inlet connection (1 1/6” Pilot O ring connection)
• AC353 II, III: the condenser inlet tube connection (M30 or M36 screwed connection)
• Use refrigerant oil on connection and gasket before tightening
• Make sure 2 spanners are used to prevent strain on copper pipe connection. (See fig 37)
• Tighten connection (1 1/16” Pilot O ring) to 41-48 Nm (30-35 lb-ft)
• Tighten M30 screwed connection to 117-127 Nm (86-94 lb-ft)
• Tighten M36 screwed connection to 152-173 Nm (112-128 lb-ft)
47. Fit the 45º nipple to the front box hose and connect to the liquid line inside the unit (the
tee connector just before the expansion valve)
• Use refrigerant oil on connection before tightening
• Make sure 2 spanners are used to prevent strain on copper pipe connection. (See fig 37)
• Tighten connection (Sz8 ORFS) to 43-47 Nm (32-35 lb-ft)
Fig 37: Use 2 spanners to prevent damage

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• It is also possible to use a mixture of copper tube and flexible hoses with this connection
type. (See fig 38)
• In this case the connections inside the unit are the same.
Suction hose assembly: Evaporator assembly

Flange connections both ends
Flange connections Discharge hose assembly:

Flange connection to copper; various connection to
condenser
Copper tube AC353 I, II , III use 22m discharge, 28mm suction
Tube must be suitable for refrigeration system
(Both tubes should be correctly insulated and supported)
It is also permissible to use flexible hose from compressor to
unit
Flange connections
Compressor
assembly
Flexible hose / tube assembly to compressor.
AC353 I, II, III use size 16 discharge, size 20 suction
Fig 38: Refrigerant schematic diagram for units with internal connections

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4.1.2 Connections at roof level using refrigerant hose or copper pipe (see fig 39)
• This is option for AC353 I, II, III
• This is standard for AC353 IV
Discharge Tube Suction Tube
Front box liquid tube
Fig 39: Picture from top of unit showing roof level connection option (left side AC353 I, II, III shown)
Front box liquid hose
Suction connection
Discharge connection
Fig 40: Picture from inside of bus showing roof level connection option
Discharge connection with 22m copper

tube. Front box connection using
Tighten screws to 47-51Nm (35-37 lbft) size 8 hose.
Tighten to 41-48Nm (30-35 lbft)
Suction connection using 28mm

copper tube.
Tighten screws to 47-51Nm (35-37 lbft)
Insulation omitted for photograph.
(Final installation will use insulation to unit)
Fig 41: Picture from inside of bus showing connections (copper tube)

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Copper tubes are routed in the bus and shaped to connect with the unit.
Suction and Discharge tubes:
Supplied with unit are:
• Flange with threads
• Screws and washers
The following parts are also required:
• Solder adaptor suction
• Solder adaptor Discharge
• Gasket
• Flange (holes)
48. Solder the adaptors to the copper tubes in the bus (see fig 42).
49. Apply refrigerant oil to the suction and discharge connections (including gasket).
50. Assemble copper tube with soldered fitting to AC353 G4
51. Loosely fit the screws, check the gasket is correctly positioned and fully tighten M10
screws of flange connection to 47-51 Nm (35-37 lb-ft). NB: The same torque is used for
suction and discharge connections.
Evaporator assembly
Flange with threads

• Gasket
Copper tube: • ODS solder coupling
AC353 I, II, III use 22m discharge, 28mm suction • Flange with holes
AC353 IV use 28mm discharge, 35mm suction • Screws and lockwashers
Tube must be suitable for refrigeration system Not part of unit
(Both tubes should be correctly insulated & supported)
It is also permissible to use flexible hose from compressor to
unit
Flange connections
Compressor
Flexible hose / tube assembly to compressor. assembly
AC353 I, II use size 16 discharge, size 20 suction
AC353 III, IV use size 20 discharge, size 24 suction
Fig 42: Refrigerant schematic diagram for units with roof level connections

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Front box connection:

There are 2 options:
• Connect direct to unit with copper tube
• Connect hose assembly to unit (see fig 43)
52. If connecting direct with copper tube, solder the adaptor to the tube.
53. Apply refrigerant oil to the connection and assemble to the unit
54. Tighten connection (either size 8 or size 6 Pilot O ring) to 41-47 Nm (30-35 lb-ft).
Front box connection to unit
Fig 43: Front box connection (hose) under unit

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Discharge Hose Connections

• The roof level option also requires that a discharge hose assembly be connected between the discharge
tube and condenser.
• The connection to the discharge tube is either M30 or M36 threaded connection.
• There are various connections to the condenser, either 1 1/16” Pilot O ring, M30 or M36 screwed
connections.
• Tightening torques are:
a. 1 1/16” Pilot O ring: 41-48 Nm (30-35 lb-ft)
b. M30 screwed connection: 117-127 Nm (86-94 lb-ft)
c. M36 screwed connection: 152-173 Nm (112-128 lb-ft)
Connection to condenser
AC353 I = 1 1/16” Pilot O ring
Discharge hose assembly AC353 II/III = M30 or M36
AC353 IV = M36
Connection to discharge tube

M30 or M36 screwed connection
Fig 25: Discharge Hose connections (AC353 IV G4 shown)
Connection to discharge tube

M30 screwed connection
Connection to condenser
AC353 I = 1 1/16” Pilot O ring
Fig 25: Discharge Hose connections (AC353 I G4 shown)

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4.2 Heating Connections (NB: Heating is option) See figs 45 and 46 (right side shown)
• Units using heating are only available with the roof level connection option.
• Heating connections are always on the opposite side to suction & discharge connections
• Both connections are made directly under the unit within the air channel.
• EPDM or Silicon hoses (22mm ID) connect direct to the unit (type of hose dependant on
coolant to be used)
• NB Supply/feed connection is outboard; return connection is inboard
• It is recommended that 22mm copper pipe is used for water supply/return. The pipe must
be correctly supported and insulated.
Supply/feed connection Return connection
Outside of bus Inside of bus
EPDM 90º hoses (customer supply)

Clips omitted from photograph
Fig 45: Picture from inside of bus showing roof level heating connections
(right side shown)
Evaporator assembly
EPDM Hose (suitable for heating system)

Copper tube 22mm (suitable for heating system)
Both tubes correctly insulated and supported
Fig 46: Heating connection schematic diagram

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5th step: Condensed water drainage
There are 4 short lengths of drain hose already attached to each drain outlet of the evaporator.
These can be connected directly to the tee connector.
The lay out of the drain hoses should be applied according the drawing No 1,000,53,001,00,00,3
(see fig 26).
Air/water trap
(Quack/Kazoo valve)
Hose already 301-204 or
connected to 75,80,05,001
unit
Drain hose
Clamp 44-00045-28
19mm (3/4”) ID
58-62056-00
Tee- connector
58-62057-00
Fig. 26: lay out of drainage line
The drain hose should be laid out in 4 directions connected to each other by a T-piece and
clamps. To avoid air plugging in the drain system an entrapulator (also known as ‘quack’ valve or
‘kazoo’ valve) should be used.

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6th step: Electrical Installation
6.1 Connections direct to control panel

For details of main fuse rating and battery cable size, see the individual electrical diagram
It is possible to route electrical cables into unit from left or right side.
Battery cables and control cable are routed through 2 rubber grommets are fitted at the front (condenser end) of the
evaporator housing. (See fig 44)
Main battery cables

NB: Both cables must be
covered in conduit (photograph
Control cable shows prototype installation)
Route cables around

evaporator/heater coils and
under metal strip
Fig. 26: Routing of electrical cables into unit
The 24v + battery cable is connected to the insulated power stud in the centre of the unit (access from below)
A rubber sleeve is supplied to cover this connection. (This is clipped to the cables above the power stud)
The 0v – battery cable is connected to the M10 bolt adjacent to the power stud.
It is recommended that both cables are routed away from the filter drier and solenoid valve so service access is not
restricted. (See fig 44)
The condenser wiring cables connect to X13 and X14
The control cable connects to the plug X3 (Each connector is numbered)
24v + battery cable
0v – battery cable
Make condenser cable and

Route cables to this control cable connections
side to give service to these plugs
clearance for filter
drier, etc
NB: Both cables must be Add rubber cover to

covered in conduit (photograph this connection
shows prototype installation)
Fig. 27: Electrical connections under unit

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6.2 Connections at roof level (option)

For details of main fuse rating and battery cable size, see the individual electrical diagram
The battery cables are routed to a plate mounted under the evaporator mounted on the left and right side.
The control cable is connected directly to a cable that hangs below the unit on either the left or right side depending
on unit specification.
Evaporator housing
Positive (24v) connection
Negative (0v) connection
Control cable
Position for
connection of
battery cables
Fig. 26: Remote connections under unit for battery and control cables (option – left side shown)
(View from under unit, looking towards condenser)
6.3 Tightening Torque for Battery cable connections

24 Volt Positive cable must be tightened to 15 Nm (11 lb-ft)
0 Volt Negative cable must be tightened to 35 Nm (26 lb-ft)

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7th step: Commissioning the air cooling system

Great care must be taken to ensure absolute cleanliness, since almost all operating problems
are eventually found to be due to dirt and impurities in the system. Since the cooling circuit is
a closed system, foreign matter will remain in the system until it causes problems, or even
severe damage, which can then frequently only be corrected by time-consuming and costly
repairs. The system may nevertheless be able to be started and operated in an apparently
perfect condition. Damage due to foreign matter and impurities may not actually occur until
many months later. The long-term, proper functioning of the air-conditioning system depends
on proper and thorough working practices, which must be applied from the very beginning.
This includes proper storage and sealing of all components, correct assembly and installation,
including during repairs, through to the conscientious integrity testing, cleaning, filling and
commissioning of the air-conditioning system.
Proper and careful handling of cooling tools, the vacuum pump, manometer battery etc. will
also help to ensure long-term, reliable operation of the system.
The commissioning of the unit must be carried out by people trained in the
installation/operation of air conditioning systems.
For more details regarding commissioning see Eberspächer Sütrak Installation Manual,
section 12.
NB: It may be desired to carry out a rain water test after installation. Please note maximum
water pressure to be used is 3.5 Bar(g). Pressures higher than this are likely to damage the
unit.

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Notes:
Guide to refrigerant charge:
Refrigerant charge Refrigerant charge

Unit type (no front box) (with front box)
kgs lbs kgs lbs
AC353 I G4 5.0 11.0 5.5 – 6.0 12.1 – 13.2
AC353 II G4 6.0 13.2 6.5 - 7.0 14.3 – 15.4
AC353 III G4 7.0 15.4 7.0 - 7.5 15.4 – 16.5
AC353 IV G4 7.5 16.5 8.0 - 8.5 17.6 – 18.7
Refrigerant type: R134a

Tolerance +/- 0.2 kg (+/- 0.4 lb)
Based on 8m long lines between compressor and unit
For reference:
• Using line sizes of 22/28 (units AC353 I, II, III), you need an extra 0.12kg (0,25lb) charge
per 3m (10’)
• Using line sizes of 28/35 (unit AC353 IV), you need an extra 0.19kg (0,41lb) charge per
3m (10’)
Process for checking refrigerant quantity:

The Condenser assembly uses MCHX coil(s) and does not have a sub-cooling circuit.
Due to this, a correctly charged system can, for a short time, show bubbles in the liquid line
sight glass.
Before starting the air condition system for the first time, it is important that the system has
been correctly pressure tested, evacuated and partially filled with refrigerant, ie:
• AC353 I G4 add 5.0 kg (11,0 lbs)
• AC353 II G4 add 6.0 kg (13,2 lbs)
• AC353 III G4 add 7.0 kg (15,4 lbs)
• AC353 IV G4 add 7.5 kg. (16,5 lbs)
The next step is to confirm the correct refrigerant quantity for specific customer applications.
See following processes.

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Process for checking correct refrigerant quantity: AC353 I G4
There is 1 sight glass mounted on the right side of the receiver tank. This is used to
determine correct refrigerant level. (The receiver tank is mounted at the rear of the condenser
section)
The process for checking correct refrigerant quantity is:
1. Remove condenser cover
2. Set minimum evaporator return air temperature of 18ºC (64ºF)
3. Set bus engine speed to 1500 rpm
4. Run system for 10-15 minutes in cool mode
5. Check discharge pressure is minimum of 14 Bar / 200 psig (NB: cover condenser air
intake and/or disable condenser fans if necessary to raise discharge pressure)
6. Check refrigerant level at sight glass in receiver tank (see fig 50).
• Ambient temperatures up to 35ºC (95°F); indicator ball should be at bottom of
sight glass (balls should just be moving)
• Ambient temperature of 45ºC (113°F); indicator bal ls should be in centre of sight
glass (ie half full)
• Ambient temperature of 55ºC (131°F); indicator bal ls should be at top of sight
glass (ball should just be moving)
• Add or remove refrigerant as required to achieve the correct level.
Once check is complete, refit condenser cover
Sight glass
Fig. 50 Refrigerant levels AC353 I

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Process for checking correct refrigerant quantity: AC353 II, III, IV
There are 2 sight glasses mounted in the receiver tank; these are used to determine correct
refrigerant level. (The receiver tank is mounted at the front of the condenser section)
The process for checking correct refrigerant quantity is:
1. Remove 2 grommets from front of left side condenser cover. NB: condenser covers must
be closed during this process
2. Set minimum evaporator return air temperature of 18ºC (64ºF)
3. Set bus engine speed to 1500 rpm
4. Run system for 10-15 minutes in cool mode
5. Check refrigerant level at sight glasses in receiver tank by looking through holes in front of
condenser cover (see fig 51):
• Lower sight glass = full, i.e. indicator balls at top of sight glass
• Upper sight glass = empty, i.e. indicator balls at bottom of sight glass, just moving
• Add or remove refrigerant as required to achieve the correct level.
Once check is complete, re-fit grommets to hole in condenser cover.
Fig. 51 Refrigerant levels AC353 II, III, IV

(GB) Installation Manual AC 353 G4

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APPLICATION AC353 G4

TITLE: INSTALLATION PROCESS ROOF TOP UNIT AC353 G4

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

1.1. Technical data…………………………………………………………..………….4

1.4. System Cleanliness……………………………………………………………….10

1.5. Installation process……………………..………………………….……………..13

1st step: Roof preparation……………………………………………..…….14

2nd step: Evaporator mounting………………………………………..…….18

3rd step: Condenser mounting…………………………………….………..30

4th step: Refrigerant and Heating connection………………….………..34

5th step: Condensed water drainage……….……………………………...43

6th step: Electrical installation……………………..……………………….44

7th step: Commissioning the air-cooling system………………………..46

Notes: Guide to refrigerant charge………………………………………47

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

Heating capacity 38 kW 32700 kcal/hr 130000 BTU/hr

1.1.3 AC353 III G4

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

Installation of following AC353 G4-components:

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

Safety when handling refrigerants

The refrigerant used by Eberspächer Sütrak AC353 G4 unit is R134a.

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

Air-conditioning systems and bottles should never be over-filled. If the temperature

First aid for accidents involving refrigerants

Observe the applicable legal requirements when disposing of refrigerants.

Installation of replacement and consumable parts

Inert gas brazing procedure

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

After making the repair, remove all flux residues.

There are two reasons for not fixing a hole:

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

1.4 System cleanliness

General Instructions on commissioning the air-conditioning system:

Use of copper tube (see also section 1.3 Safety)

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

Tube Brazing (or soldering)

Figure 1: Blow out tubes after soldering

Assembly of Refrigerant hoses and fittings

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

Installation of Refrigerant tubes and flexible hoses

Proper practice – general.

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

Checking prior to dispatch

Every system is checked prior to delivery for:

Setting of the safety devices and control equipment

Integrity of the refrigerant circuit (and water circuits if applicable)

1.5 Installation process

The installation process is to be proceeding according to the sequenced steps below:

1st step: Roof preparation

2nd step: Evaporator mounting

3rd step: Condenser mounting

4th step: Refrigerant and heating connections

5th step: Condensed water drainage

6th step: Electrical Installation

7th step: Commissioning the air-cooling system

2012 Eberspächer Sütrak / Dave Rolls Installation_Manual_AC353_G4.doc

1st step: Roof preparation.