Lombardini ECOWIND 350 ECC 350 "C" - 12/24 V User manual
Instructions manual, Operation and Maintenance
AIR-CONDITIONING / GEN-SET SYSTEM
AUS version
TYPE: ECOWIND 350 ECC
MODEL: 350 “C” - 12/24 V
vers. 05 July - MY 2011
LOMBARDINI S.r.l.
Via Cav. Del Lavoro,
A. Lombardini, 2 .
42100 - Reggio Emilia
Tel. + 39 - 0522 3891
Telefax + 39 - 0522 389503
AIR-CONDITIONING / GEN-SET SYSTEM
TYPE: ECOWIND 350 ECC
MODEL: 350 C - AUS 12/24 V
Instructions manual, Operation and Maintenance
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ECOWIND WARRANTY CLAUSE
Products manufactured by Lombardini S.r.l., are guaranteed against conformity faults for a period
of 12 months from the date of delivery to the rst end user.
The warranty for stationary units, working at constant speed and/or slightly variable speeds with
the regulation limits, is limited to a maximum of 1000 operating hours within the above period (12
months).
The warranty for parts that are subject to wear and deterioration (injection/power supply units,
electrical system, cooling system, sealing, non-metal piping, belts) is limited to a maximum of 1000
operating hours within the above period (12 months).
Please refer the manuals supplied with each product for the procedures for correct maintenance
and regular replacement of these parts.
For the purposes of the warranty and given their technical nature, products must be installed by
qualied personnel.
The list of authorised Lombardini S.r.l. service centres can be found in the “Service” booklet
supplied with each product.
Special warranties must be agreed to in writing for important modications to the product.
Within the above stated periods Lombardini or one of its authorised service centres will replace and/
or repair any of its products which, upon examination by Lombardini or an authorised Lombardini
agent, are found to be defective in workmanship or materials.
Any other responsibility/obligation regarding expenses, damages and direct/indirect losses deriving
from use of the motors or from the total or partial impossibility of using them, is excluded.
Repair or replacement of any component will not extend or renew the warranty period.
Lombardini’s warranty obligations as per the previous paragraphs are not valid if:
- Products are not installed correctly and hence the correct operating parameters are compromised
or altered;
- Use and maintenance of the products does not comply with the instructions provided by Lombardini
S.r.l. in the operation and maintenance booklet supplied with each product;
- The seals afxed to the motor by Lombardini have been tampered with;
- Spare parts are not Lombardini originals;
- The fuel supply and injection systems are damaged due to the use of unsuitable or poor quality
fuels;
- There are electrical failures caused by components connected to the electrical systems and which
have not been supplied or installed by Lombardini S.r.l.;
- Products have been repaired, disassembled, or altered by any party other than an authorised
Lombardini agent.
With the expiry of the above warranty period(s) and/or the specied operating hour limitations,
Lombardini will have no further responsibility or obligations as per the previous paragraphs of the
clause.
Any warranty request regarding the non-conformity of a product must be addressed to the
Lombardini S.r.l. service centres.
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SERVICE LOMBARDINI - TEL. 0039 - 0522 / 389550
- TEL. 0039 - 0522 / 389547
- TEL. 0039 - 0522 / 389568
MANUFACTURER: LOMBARDINI S.r.l.
ADDRESS: Via Cav. Del Lavoro,
A. Lombardini, 2 . 42100 - Reggio Emilia (Italia)
Tel. + 39 - 0522 3891
Telefax + 39 - 0522 389503
E-mail [email protected]
DOCUMENT TYPE: Instructions manual, Operation and Maintenance
PRODUCT: AIR-CONDITIONING / GEN SET SYSTEM
TYPE : ECOWIND 350 ECC
MODEL: 350 “C” - AUS 12/24 V
CONFORMITY:
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CONTENTS
1 WARNINGS AND GENERAL INFORMATION .............................................................................................8-9
1.1 INTRODUCTION .............................................................................................................................. 8
1.2 Preliminary information regarding how the system works ................................................................ 8
1.3 OPERATING PRINCIPLE ............................................................................................................... 8
1.4 GENERAL AND SAFETY WARNINGS ........................................................................................... 8
1.5 IDENTIFICATION PLATE ........................................................................................................9
1.6 DIRECTIVE AND STANDARD REFERENCES APPLIED .................................................................9
2 GENERAL DESCRIPTION AND TECHNICAL DATA ..............................................................................10-14
2.1 GENERAL DESCRIPTION OF THE AIR-CONDITIONING SYSTEM ............................................ 10
2.2 Description and arrangement of the components of the air-conditioning system ........................... 10
2.3 TECHNICAL CHARACTERISTICS – Table of technical data ......................................................... 11
2.4 Characteristics of coolant - Tab. and diagram ............................................................................ 11-13
2.5 Operating limit conditions ................................................................................................................14
3 OPERATION AND USE ............................................................................................................................15-32
3.1 Residual risk of contact with coolant ..............................................................................................15
3.2 SAFETY DEVICES .........................................................................................................................15
3.3 Summary diagram of the air-conditioning system for model 350 STD:
CONVENTIONAL COOLING CYCLE ............................................................................................16
3.4 DESCRIPTION OF OPERATING MODES ...................................................................................... 16
3.5 OPERATING INSTRUCTIONS – Control equipment and commands ........................................... 17
3.6 KEYPAD: Instructions and Use ECO 350 “C” ECC ..................................................................18-32
4 TROUBLESHOOTING ..............................................................................................................................33-43
4.1 TABLES OF PROBLEMS, CAUSES AND SOLUTIONS ...........................................................34-39
5 MAINTENANCE CARRIED OUT BY LOMBARDINI SERVICE ...............................................................44-58
5.1 GENERAL SAFETY REGULATIONS FOR MAINTENANCE .........................................................44
5.2 MAINTENANCE OF MECHANICAL PARTS - INSTRUCTIONS
Checking and relling lubricating oil ..........................................................................................44-47
5.3 Oil and lter replacement ..........................................................................................................48-50
5.4 Diesel lter replacement ................................................................................................................. 51
5.5 Air lter cleaning or replacement ................................................................................................52-53
5.6 Control operations following maintenance ..................................................................................... 53
5.7 MAINTENANCE OF THERMODYNAMIC PARTS – OPERATING INSTRUCTIONS
Warnings and general information ..................................................................................................54
5.8 REPLACING THE DEWATERING FILTER ................................................................................54-55
5.9 Replacing the cab lter (inside split) - only model AUS ..............................................................57-58
6 SCHEDULED PREVENTIVE MAINTENANCE ..............................................................................................60
6.1 SCHEDULED PREVENTIVE MAINTENANCE ............................................................................... 59
6.2 SUMMARY TABLE OF SCHEDULED MAINTENANCE ..................................................................59
7 DIAGRAMS AND WIRING ........................................................................................................................60-66
7.1 ELECTRICAL WIRING 12V SYSTEM ........................................................................................60-66
7.2 ELECTRICAL WIRING 24V SYSTEM ........................................................................................62-66
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1.1 INTRODUCTION
Important warnings
To safeguard both professional and non-professional users, as well as authorised installation and maintenance technicians, and
to prevent the possibility of damage to the equipment, make sure that you are familiar with the entire contents of the instruction
manual before performing any operation on the system.
Restrictions
Users (professional and non-professional) must in no way follow the instructions destined for specialised and
authorised installation and maintenance technicians.
ECOWIND by Lombardini declines all responsibility for damage caused to things, persons, animals or the equipment
itself as a result of non-observance of this regulation.
Limited liability
ECOWIND by Lombardini declines all responsibility for damage caused to persons or things resulting from improper use of the system.
1.2 Preliminary information regarding how the system works
The air-conditioning system has been designed to carry out the following functions:
• Conditioning of the area in which it is installed (vehicle cabs or other areas to be air-conditioned), according to the specications
shown inside this documentation;
• Recharging the battery of the vehicle on which the system is installed, as described in paragraph 3.7 “Battery charging function”.
1.3 OPERATING PRINCIPLE
General description
The air-conditioning system is able to regulate the temperature inside the vehicle cab, or in the area in which the
split unit is installed. The desired temperature may be set using the controls on the control pad (depending on the model) located
on the split .
1.4 GENERAL AND SAFETY WARNINGS
Symbols used inside the manual
The following symbols will be used throughout the manual to highlight particularly important information and warnings:
ATTENTION: This symbol highlights accident prevention rules for the operators and/or other persons at risk.
WARNING: This symbol indicates that there is a risk of damage to the line and/or its components.
NOTE: This symbol highlights important information.
WARNINGS AND GENERAL INFORMATION - 1
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Fig. 1
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Legal provisions
Reference Title
P. D. no. 459 of 24.7.96 Implementation of EEC Directive no. 89/392 known as the Machinery Directive
L. D. no. 476 of 4.12.92 Implementation of EEC Directive no. 89/336 regarding Electromagnetic Compatibility (EMC)
Table 1-1
EU Directives
Reference Title
EU Directive no. 98/37 Machinery Directive 89/392/EEC codied 98/37
EU Directive no. 89/336 Electromagnetic Compatibility (EMC)
Directive 2000/2/EC Directive regarding electromagnetic compatibility (EMC) for agricultural and forestry tractors.
Directive 2004/104/EC Directive regarding electromagnetic compatibility (EMC) for motor vehicles and their trailers.
Directive 95/54/EC Directive regarding electromagnetic compatibility (EMC) for motor vehicles.
ECE R10 ECE/UN regulation regarding electromagnetic compatibility for motor vehicles.
Table 1-2
Legal provisions
Reference Title
P. D. no. 459 of 24.7.96 Implementation of EEC Directive no. 89/392 known as the Machinery Directive
L. D. no. 476 of 4.12.92 Implementation of EEC Directive no. 89/336 regarding Electromagnetic Compatibility (EMC)
Table 1-1
EU Directives
Reference Title
EU Directive no. 98/37 Machinery Directive 89/392/EEC codied 98/37
EU Directive no. 89/336 Electromagnetic Compatibility (EMC)
Directive 2000/2/EC Directive regarding electromagnetic compatibility (EMC) for agricultural and forestry tractors.
Directive 2004/104/EC Directive regarding electromagnetic compatibility (EMC) for motor vehicles and their trailers.
Directive 95/54/EC Directive regarding electromagnetic compatibility (EMC) for motor vehicles.
ECE R10 ECE/UN regulation regarding electromagnetic compatibility for motor vehicles.
Table 1-2
1 - WARNINGS AND GENERAL INFORMATION
1.5 IDENTIFICATION PLATE
The air-conditioning system is manufactured in a European Union state, and therefore complies with the safety
requisites of Machinery Directive 98/37/EC, in force since 23 July 1998.
This conformity is certied by the “CE” mark located on the body of the power unit, inside the front protective casing.
NOTE!
Do not damage or remove the CE identication plate (below engine), even when the system is resold.
1.6 DIRECTIVE AND STANDARD REFERENCES APPLIED
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10
7
1
3
2
6
5
4
8
Fig. 3 Fig. 5
Fig. 2 Fig. 4
2.1 GENERAL DESCRIPTION OF THE AIR-CONDITIONING SYSTEM
The air-conditioning system consists of the following main units/elements:
• Power unit;
• Condenser;
• Split (diffuser);
• Cooling circuit pipes and electrical cables;
• Accessories.
2.2 Description and arrangement of the components of the air-conditioning system
Description of the main functional components
Figures 2-3-4-5 show the main components of the air-conditioning Genset system:
1 Support structure of the power unit;
2 Power unit: its function is to supply energy at the right power to the entire system, by the action of a diesel motor;
3 ECU Power Unit.
4 Compressor: the function of the compressor is to increase the pressure of the coolant by compressing it and sending it to the
condenser by transforming it from gas to liquid form;
5 Alternator: the function of the alternator is to keep the vehicle battery and the system charged;
6 Exhaust gas mufer;
7 Condenser: the function of the condenser is to transform the coolant from gas to liquid form;
8 Split (evaporator): its function is to cool or regulate ambient temperature in which it is installed;
9 Split control panel: allows manual access to all the system functions
10 Adjustable nozzles for the distribution/direction of the airow.
GENERAL DESCRIPTION AND TECHNICAL DATA - 2
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2.4 CHARACTERISTICS OF COOLANT
Recommended products:
Non-recommended Products:
ATTENTION–Allcoolantsnotmentionedinthe“recommendedproducts”sectionarenottobeconsideredforuse,
areinappropriateandhenceprohibited.
LombardiniS.r.ldeclinesallresponsibilityfordamagetopersonsorthingscausedbynon-observanceofthisregulation.
Safety warnings: It is important to observe the following safety regulations when carrying out maintenance on the system:
ATTENTION–uorocarboncoolantsevaporaterapidly,freezinganythingwithwhichtheycomeintocontact,if
accidentallyreleasedinliquidformintotheatmosphere.Furthermore,inthepresenceofamesorelectricalshortcircuits,
theymayproducetoxicgasescapableofcausingseriousirritationtotherespiratorytract.
Moreover,thiskindofcoolanttendstodisplaceair,causingareductioninthelevelofoxygenandtheriskofsuffocation.
Alwaystakeprecautionswhenworkingwithcoolantsoronair-conditioningsystemsthatcontaincoolants,particularly
inclosedorconnedspaces.
2 - GENERAL DESCRIPTION AND TECHNICAL DATA
2.3 TECHNICAL CHARACTERISTICS
Table of technical data
Air-conditioning system
Model 350 “C” - AUS
Dimensions and weight Power unit Condenser Split (diffuser)
Length 710 mm 560 mm 560 mm
Height 560 mm 360 mm 360 mm
Depth 290 mm 120 mm 140 mm
Weight 110 kg * 6 kg 10 kg
* Without support structure
350 C - AUS Technical data
Fuel Diesel for automotive use
(taken from the vehicle’s own tank for
models installed directly in vehicles)
Maximum fuel consumption 0,7 litre/ h
Cooling capacity 13.000 btu/h (3.800 W)
Coolant R-134a
Quantity of coolant min 1000 ÷ max 1200 gr. *
The amount of gas may vary according to pipe length
see chart 1 - pag. 12
Optimum operating pressure: Delivery pressure HP = 13 ÷ 17 bar - @ 30°C ext temp.
Intake pressure LP = 1 ÷ 3 bar - @ 30°C ext temp.
ATTENTION !!!
It is important to comply with the above quantities.
Non-observance of this recommendation could compromise the performance of the system
Onboard electrical power supply 12 V 24 V
Battery recharge capacity (alternator) 70 A - MAX 40 A - MAX
Evaporator airow 600 m3/h - MAX 600 m3/h - MAX
Control system power supply 12 Vdc 24 Vdc
Fluorocarbon coolant R-134a TETRAFLUORETHANE
Compressor oil PAG SP 20 or equivalent
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TAB 1
TAB 2
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R134a
LP
(kg/cm2)
HP
(kg/cm2)
15,5
21,0
26,5
32,0
38,8
43,0
min..............max
0,5...............3,0
0,5...............3,0
0,5...............3,0
0,5...............3,5
0,5...............3,5
0,5...............3,5
min..............max
9,5...............13,0
12,5...............17,5
14,0...............20,5
16,0...............24,0
18,5...............25,5
22,0...............28,0
A/C pressures according to ambient temperature for R134a
REFERENCE PRESSURE TABLE
Fixed displacement compressor (F)
(es. SD5H09, SDH15)
Outside
Temperature
(°C)
TEST QTY R134a HOSE LENGHT TEMPERATURE
EXT
SUC LOW
PRESS DISC HIGH PRESS.
GENERAL DESCRIPTION AND TECHNICAL DATA - 2
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TAB 3
TAB 4
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LUBRICANT SP20
SPECIAL GRAVITY 15°C 1.044
COLOUR (ASTM) L 0.5
KINEMATIC
VISCOSITY (cst)
40°C
100°C
104.5
21.15
VISCOSITY INDEX 235
FLASH POINT 230
POUR POINT < -50
FALEX LOAD
TEST (LBS/IN2)
1350
CRITICAL UPPER
SOLUBILITY POINT LOWER (°C)
+52 (3%)
< -40
TYPE PAG
OIL FOR R-134 A PHYSICAL PROPERTY
p = absolute pressure (in bars)
t = temperature (in °C)
Pressure/temperature diagram for the R134a refrigerant
2 - GENERAL DESCRIPTION AND TECHNICAL DATA
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2.5 Operating limit conditions
WARNING
Alternator operating limits
The system uses an alternator that is able to supply enough energy to guarantee the functions mentioned
under “general operating features”.
In the event of alternator overload, caused by the addition of other equipment, Lombardini S.r.l. declines all responsibility
regarding possible faults in the system or other vehicle equipment and facilities
GENERAL DESCRIPTION AND TECHNICAL DATA - 2
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IE
R
CR
FS
200 A - 12 V
100 A - 24 V
Fig. 8 Fig. 9
Fig. 6 Fig. 7
3 - OPERATION AND USE
3.1 RESIDUAL RISK OF CONTACT WITH COOLANT
Origin of the residual risk: This risk exists in the event of accidental contact with the coolant. The characteristics and the
safety warnings of the coolant are described in section “Characteristics of coolant”.
ATTENTION: First aid treatment in the event of contact with the coolant.
Contact with EYES: • if there is contact with the liquid, rinse thoroughly with water and seek immediate medical attention.
Contact with SKIN: • rinse the area with plenty of lukewarm water and stay calm;
• wrap the burns in thick, dry, sterile bandages to protect the area from further infections or wounding;
• seek medical attention.
INHALATION: • immediately remove the patient to the open air and, if necessary, help him/her to breathe again;
• seek medical attention and remain with the patient until the arrival of professional help.
3.2 SAFETY DEVICES
Introduction : The ECOWIND air-conditioning system is equipped with safety devices illustrated below, which protect users,
specialised technicians and the system itself:
• Automatic reset fuses - to protection of all systems electrical/electronic
• Main electric power supply fuse FS (Fig. 6); • Motor oil temperature sensor;
• Split Strat/Stop button for IE (Fig. 7) and stop emergency; • Coolant gas safety pressure switch;
• Fixed protection cases (CR) (Fig. 9); • Diesel on/off cock (R) (Fig. 8).
• Motor oil safety pressure switch; • Waterprof connectors IP68
• Polarity reversal protection
ATTENTION: Safetydevicesmustbynomeansbetamperedwithorremoved.
Lombardinideclinesallresponsibilityfordamagecausedtothings,persons,animalsortheequipment
itselfasaresultofnon-observanceofthisregulation.
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OPERATION AND USE - 3
3.3 SUMMARY DIAGRAM OF THE AIR-CONDITIONING SYSTEM FOR MODEL :
350 C
CONVENTIONAL COOLING CYCLE
The diagram in gure 7 shows the ow chart of the conditioning process:
HP) High pressure - Compression (min 10 - max 27 bars _coolant R 134 a);
LP) Low pressure - Intake (min 1 - max 5 – bars_coolant R 134 a);
N.B.: Optimal values for a correct functioning of the system are: suc 1.5 ÷ 2.0 (bar) - dics 13÷17 (bar)
LEGEND:
1 COMPRESSOR AC;
2 AC CONDENSER;
3 DEWATERING FILTER;
4 EXPANSION VALVE;
5 EVAPORATOR AC;
GAS R134a LOW PRESSURE (LP)
GAS R134a HIGH PRESSURE (HP)
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3.4 DESCRIPTION OF OPERATING MODES
Operating mode types for the user (professional and non-professional)
The air-conditioning system can be operated by means of the controls located on the evaporator unit (split), according
to the settings and procedures described in the paragraphs under “Operating instructions”.
3.5 OPERATING INSTRUCTIONS
Control equipment and commands
General description of control devices
The control apparatus on the system has been designed to handle the air-conditioning of special vehicle where the
cooling power is supplied by the diesel motor. In addition to its normal air-conditioning functions it also supervises and controls
correct function of the diesel motor. It can also monitor battery voltage , and, if necessary, recharges it automatically.
3 - OPERATION AND USE
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Fig. 10
OPERATION AND USE - 3
3.6 KEYPAD: Instructions and Use ECO 350 “C” ECC
This keypad located on the internal unit (Split) allows the user to programme all the system functions.
Control panel (touchpad, Fig.10).
1 ON – OFF, Power Unit engine ignition / stop.
2 System operating mode selector.
3 Timer mode selector.
4 Ambient climate mode selector.
5 Ambient climate thermostat selector.
6 Split suction fan speed selector.
7 APU engine status LED.
8 System reset button.
9 IrDA infrared sensor.
10 System information display
DATA-SHEET
• Operating voltage: 12V (6-16V)/ 24 V (18-30 V)
• Maximum absorption in stand-by mode: 20 mA
• BLUE display, negative dot MATRIX STN
• Digital control system
• Automatic battery recharge system
• Tone signal conrmation (beep)
SAFETY
• Polarity reversal protection
• Electric system totally protected using automatic rearming fuses
• Fuse for general supply circuit protection: 200 A (12V) / 100 A (24V)
• Emergency stop button
• Waterproof connectors IP 68
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3 - OPERATION AND USE
GENERAL INFORMATION
The machine operating modes are outlined through the buttons that are on the ECC module control panel.
All system operating and setting parameters in “AIR CONDITIONING” and “HEATING” mode are executed by the ECC unit only
when the Power Unit (diesel engine) is working.
The split suction fan works with stopped Power Unit when the “FAN” ventilation mode is on. This parameter allows the activation of
the control mode for fan self-disabling. When the set batteries’ minimum voltage value is reached – OFF FAN ≤11.7 (12 v) / ≤23.0
(24V) Volts, the system automatically stops.
CONTENTS
1. DESCRIPTION KEY PAD CONTROL
1.1- Selector POWER _ Start / Stop
1.2- Selector MODE
1.3- Selector TIMER
1.4- Selector CLIMA
1.5- Selector TEMP
1.6- Selector FAN
1.7- Led status diesel engine
1.8- Reset
1.9- IrDA infrared sensor
1.10- Display
2. CLIMATE SECTION
2.1- Climate Mode (CLIMA)
2.2- Starting
2.3- Temperature adjust
2.4- Automatic fan
2.5- Ventilation mode (FAN)
2.6- Starting
3. GENSET SECTION
3.1- Starting
4. AUTOMATIC RECHARGE BATTERY SECTION
4.1- Starting
5. TIMER SECTION
5.1- Programming
6. ALARMS SECTION
6.1- General information
6.2- Primary Alarms
6.3- Generic service alarm
6.4- Device alarms
7. REMOTE CONTROL
7.1- Description
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1 – FUNCTIONS KEY PAD DESCRIPTIONS
1.1 - POWER selector “1” ( start / stop engine)
The system is activated by pressing POWER selector “1”. 10 seconds after the last set control, the system will activate the
automatic sequence for PU* engine ignition will be activated after the preheating time (maximum of 5 attempts). If ignition is not
carried out within 5 maximum attempts, the system will send a “start-up failure” alarm by means of the “G” display and will set the
system in OFF mode (see warning section).
For a functioning system, if the POWER selector “1” has again been pressed, the system’s stop sequence will be activated. The
PU diesel engine, as well as the whole electronic apparatus, will stop after about 30 seconds based on the command indicated
above. This time interval is needed to correctly cool down the diesel engine before it stops. During this period of system shut down,
the “WAIT” sign will inherently be seen on the “G” display..
ATTENTION!!
“IMMEDIATE EMERGENCY SHUT DOWN”.
In order to activate the immediate shut down of the system (with relevant PU diesel engine shut down), the POWER selector “1”
will have to be pressed for at least 3 seconds. Upon doing this, the system will be set in OFF mode.
PU* _ Power Unit
1.2 - MODE selector “2”
Pressing in sequence the MODE selector “2” will bring about the following modes:
► AIR-CONDITIONING MODE
► CURRENT GENERATOR (DC) MODE
► AUTOMATIC BATTERY RECHARGE MODE
1.3 - TIMER selector “3”
The system can be set in automatic start or stop mode by pressing TIMER selector “3” depending on the user’s preset time.
1.4 - CLIMATE selector “4”
Allows to choose one of the three preferred climate modes inside the cab: conditioned air AC (cooling) and forced air FAN
(ventilation).
1.5 - TEMP balancer “5”
Allows to increase or decrease the temperature set value (°C or °F) inside the cab.
1.6 - FAN balancer “ 6”
Allows to increase or decrease the ventilation set value (ow) inside the cab.
1.7 - Diesel engine state LED indicator “7”
Monitors the functionality of the power unit diesel engine. “OFF” Led - engine stopped, “GREEN” Led - diesel engine is working,
“RED” Led - warning signal indicating a malfunction in the APU diesel engine.. This LED will also indicate any type of alarm
warning the system encounters.
OPERATION AND USE - 3
Table of contents
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