Installation and Use Manual for Vehicle Electric Air Conditioner

1、Overview
This unit is used for heavy truck, mobile engineering machine.It is driven by dc powered electricity, save the fuel, low
power consumption, low noise, no waste gas discharging, high efficiency, good cooling.Small volume, compact design,
light weight, nice style.Monoblock design, save pipe connection, low refrigerant‘s leak, easy to install and repair.

This unit is powered by Battery. When work, not need turn on the engine, more safeness.
Use R134a refrigerant, save energy and safeguard environment.

2、Principle
Open the switch and connect the power supply, electric compressor start, sucked hot gas by compressor is discharged
into condenser through pipe. Inside the condenser, after hot gas is heat exchanged with air, and then condensed into cold
liquid. Through expansion valve, low pressure and throttle into evaporator, suck hotness in the cab. Then, enter into
sucking room in the compressor, is compressed and reach the next time’s working circulation .repeat this, evaporator
constantly suck hotness in the cab and reach the cooling.
 3. Data sheet

1 Cooling capacity 4KW(13600Btu/h)

2 Air flow 650 m3/h
3 Voltage Dc24V
4 Rated power consumption ≤1500W
6 Refrigerant R134a
7 Gas charge 0.7kgs
8 Electric compressor PS
9 Battery unit 100AH×2
10 Set temperature 18℃－35℃
11 Pressure protection 0.02－3.14MPa
12 Size 1055mm*800mm*206mm

4、Operation
4.1、Control button :
A, Temperature control switch: adjust temperature when cooling
B, Air flow switch: control rotating speed of radial blowers to choose suitable air flow
C, Indicating light:
Green light : compressor’s start, cooling system is on work
Yellow light : power supply connection, radial blowers is on work.
Red light: fault of cooling system which stops working.

4.2、Use

4.2.1 When use cooling system for first time, after compressor start, turn air flow switch into high level, running for 5
minutes, then turn temperature control switch to cool. This time the temperature in the cab start to become low , when
reach the required temperature , turn slowly temperature control switch in anticlockwise till indicating light go out ,
compressor stop working . This time temperature in the cab is the set temperature. When temperature in the cab is higher
then this temperature, indicating light is on, compressor start working automatically, system starts cooling. When the
temperature in the cab is lower than this temperature, indicating light goes out, system stop working.

4.2.2 Adjust the angle of air outlet, can change cooling air’s angle and direction; adjust air flow switch, there are three
levels of air flow which is high, middle and low.
4.2.3 Use the a/c ,please do not turn temperature control switch to cool , air flow switch is turn to low level , this will cause
freezing in evaporator, impact cooling .

5、Attention
5.1、Do not dismantle the a/c to prevent refrigerant’s leakage .
5.2、Periodically clean the surface of condenser to improve cooling .
5.3、Please do not dismantle and repair the a/c if he is not specialist .

Note: You had better add two sets of 24V dc powered power supply and directly parallel connection in battery. This
could add the time of using the a/c. (charge once and using time reach 8hours)

6、Trouble Shooting
Radial Axial fans not rotate Compressor Check if fan’s connection
blowers work drop, if ground connection good ,
Not rotate if fan damage
Cooling Compressor Check if temperature switch damage ,
not work if relay actuation , if relay’s connection loose
Axial fans rotate Compressor Check if clutch damage , if connection drop, if
not work belt loose and slip
Radial Axial fans rotate , Check if adjusting speed switch not work , blower’s electric wire
blowers compressor work disconnect ,
not work if ground wire good
Axial fans Check if fuse melting , check if relay work ,if wire loose
Not rotate ,
Compressor not work
Compressor Both radial blower Check if R134a is overcharged. use high/low pressure gage to
work and axial fan work check
if meet specified the value of gage
Long time not use , R134a has leaked , Use the gage to check
if there is R134a
Both radial blower Receiver’s inlet and outlet are connected inversely.
Not and axial fan work Check if expansion valve exist ice blocking or dirty blocking ,
Enough Compressor Evaporator And Replace receiver.
Cooling work Condenser is Replace R134a
on work
Both blowers and Check if the surface of condenser is blocked by dirty
fans also work , other
also is good
7、Other fault solve

Phenomenon Reason Solve

System cooling is good at the beginning , Often driving on the bad Use the leak detector to find the
for some time , cooling is not enough , find road , vibration cause point of leakage , carefully screw
the gas bubble from level glass in the connection loose and leak down the loosen position, supply
1 receiver ; “ reading “ is small in the the R134a
high/low pressure gage
System is not cooling , air outlet comes out Use improperly. Replace expansion valve , supply
hot air ,feel there is not temperature temperature wrap in the、 R134a
2 difference in the inlet and outlet of expansion valve is wear
expansion valve , low pressure gage and leak , valve port close
‘readings” is very low
Air in the outlet is not cooling, temperature There is impurity in the Interval to start cooling system, if
raise in the compressor. low pressure system, filter screen of block is not serious, may clear the
3 gage’s hand swiftly decline , reach “0” , expansion valve is blocked, instant block. Dismantle
high pressure gage’s readings is high expansion valve sweat. expansion valve, use alcohol
clear, discharge the system, and
supply R134a.
Not enough cooling , evaporator frosting ; Inside orifice of Discharge the system , replace
4 high/low pressure gage ‘s reading are too expansion valve is bad expansion valve, Supply R134a
low
After running for some time , cooling Desiccant in the receiver Discharge the system ,
5 becomes to decrease , high pressure gage saturation , orifice is blocked replace the receiver ,
‘s reading is high ,low pressure gage’s by ice supply R134a
reading is lower than 0.4MPa
Cooling system start , only there is wind Temperature control switch Use AVO meter to check if
6 not cooling air , high/low pressure gage’s poor contact , or clutch coil temperature control switch
reading doesn’t change of compressor damage damage , replace clutch
Compressor’s clutch move frequently , Turn temperature control Check if temperature control
7 short time in integration , not cooling in switch too small , switch turn to cool
the cab , gage’s reading is right Automatically force
compressor stop running ,
cause cooling is not enough

8、Installation

8.1 Before installation. Firstly confirm if a/c’s voltage is the same as that of vehicle .otherwise don’t install.
8.2 Drill the hole in the top of cab as per the position of installation hole , air outlet , air return (see the illustration 1)
8.3 Put a/c to install at open hole, use M10 screw to fix the a/c into the top of cab.
8.4 Use glue to seal the gap between bottom cover and top of cab
8.5 Water drain hose is connected into blow off pipe , fix the water drain hose into side wall and droop it , from high to
low ,prevent water is saved .
8.6 Connect wire harness’s one end with 100A fuse box (this is positive pole), the other end is connected with positive
pole of battery; a/c’s negative pole is not needed to connect, itself is bonding. Then fix the wire harness into side wall of
vehicle.
8.7 Fix the mechanic controller into square hole inside the air diffuser , then fix the control panel inside the
cab(underface of a/c), air outlet , return air
8.8 Connect pressure gage, vacuumize, time is within 0.5hours to 1hours .depending on different vacuum pump. after
vacuum, pressure gage ‘s valve must be closed ,keep the pressure till above 2hours , if pressure doesn’t increase , that
means installation and pipe connection both are good , now refrigerant can be charged .
8.9 Refrigerant charge: Take the middle yellow manifold of pressure gage off vacuum pump; connect the port of R134a
vessel. Open the valve of vessel, discharge the yellow manifold and exhaust the air in the yellow manifold. Then open
high pressure manifold in the high pressure gage, Upside down the vessel of R134a, start to charge the refrigerant.
Observe the sight glass in the upper end of receiver, when there is a bubble occasionally for a few seconds in the sight
glass, this means refrigerant charged is enough. If gas charge in upside down the vessel is not fulfill and also can’t be
charged again , this needs put vessel upside , close the valve of high pressure manifold , turn on the a/c , then open the
valve of low pressure manifold , continue to gas charge till it is enough .
8.10 Finish the gas charge, take off the vessel and manifold. Put the cover fix into the a/c.
8.11 Trial for running
Figure 1：