Valeo REVO 400 eCBC User manual

Rev.00/July 2022
Code: 036-00364-002
Owner’s Manual
Warranty Certificate
REVO 400 eCBC
AIR CONDITIONER COACHBUS / CITY BUS

INDEX REVO 400 eCBC
INTRODUCTION_____________________________________________________________
3
WARRANTY TERMS
Warrant Terms__________________________________________
4
PREVENTIVE MAINTENANCE
Preventive Maintenance Frequency Check List_____________________________
5
Dry Filter___________________________________________________________
6
Ducts____________________________________________________
6
Items of Responsibility of the Bus Bodybuilder__________________________________________________________________________
6
Conductor evaporator________________________________________
6
Tubes, hoses, drains and wiring harness___________________________
6
Gas Charge Process____________________________________________________
6
Operation Module___________________________________________________
6
Hermetic compressor_________________________________________
6
EQUIPMENT IDENTIFICATION (ID)
Identification Tag___________________________________________
7
OPERATING THE AIR CONDITIONER
1- Main Components Air Conditioner Module_____________________
8
Technical Specifications of the Device_________________________________
10
EQUIPMENT DESCRIPTION
3.1- Central Condenser Module__________________________________________
11
3.2- Evaporators Modules________________________________________
12
3.3- Covering and Fixation Components_______________________________________
13
3.3- Air Conditioning Tubing Components_________________________________
14
3.5- Air Renewall Set__________________________________________________
15
ELECTRICAL DIAGRAM OF THE EQUIPMENT
4- REVO 400 C2 Step 3 - Overview____________________________________
16
4.1- Terminal Plate Connection______________________________________
17
SAFETY PRECAUTION
5- Personal Precaution____________________________________________________
18
SUSTAINABILITY
6- Product Disposal___________________________________________________
19

INTRODUCTION
During operation these equipments have energized parts,
so any irregularity in the system, please contact a Valeo
authorized dealer.
OBSERVATION: to get the best air conditioner performance we
recommend that you read this manual carefully before starting
operation. Keep this manual with your vehicle for reference.
REVO 400 eCBC
VALEO Climatização do Brasil - Veículos Comerciais S/A develops its products,
oncerned with offering passengers a comfortable environment, always seeking
the best HVAC conditions.
The equipment has a design that allows perfect integration with vehicles,
facilitating operation and maintenance.
With optimized sizing, they ensure a high cooling capacity and low noise level.
This manual was developed with the purpose of presenting important aspects of
functioning, operation and maintenance, in order to obtain the best
performance of the air conditioning equipment.
In order to ensure that the equipment has a long and trouble-free service life, it
is essential that the operating and maintenance instructions described in this
manual are followed and executed periodically.
The controls installed by VALEO Climatização do Brasil - Veículos Comerciais S/A
that are used by the user are properly illustrated and explained in this manual.
It is important that the user carefully read the instructions in this manual before
operating the air conditioning equipment.
VALEO Climatização do Brasil - Veículos Comerciais S/A maintains an authorized
service network with tools, equipment and a team trained to perform any type
of maintenance within quality standards.
Thank you for choosing VALEO Climatização do Brasil - Veículos Comerciais S/A
products. In case of doubts, contact the VALEO Climatização do Brasil - Veículos
Comerciais S/A authorized service network or contact the technical assistance
department.
3

WARRANTY TERMS
Warrant Terms
VALEO Climatização do Brasil - Veículos Comerciais S/A warrants its products for
two-years period in accordance with the terms listed below:
1 - The warranty will be valid for the period above specified, counting from the
date when the equipment is installed in keeping with the warrant certificate,
even after the property there of has ben transfered.
2 – Should the equipment be installed by a third part, VALEO Climatização do
Brasil - Veículos Comerciais S/A warrant only the product and not its instalations.
3 - During the stipulated period, the warranty completely covers the workman-
ship and spare parts used to repair defects duly identified as being:
premature failure of material and components defects used on its manufacture.
4 - Only a techinician from the VALEO Climatização do Brasil - Veículos Comerciais
S/A authorized network of services is qualified to repair the defects coverd
under the warranty.
5 - The warranty approval is subject to the technical analysis of the defects
shown in the components and operational conditions to which the equipment
has been subjected.
6 - No claims will be accepted if the vehicle is still in use after the defect is
found, even if there is lack of pieces, delay in transportation or any other such
incident.
7 - The Warrant Loses its Validity
a) If the installation or use of the product is not in accordance with the VALEO
Climatização do Brasil - Veículos Comerciais S/A technical recommendations.
b) If the product suffers any damage caused by improper use, neglect, accident,
failures caused by external agents and even lack of maintenance (see owner's
manual) or services performed by unqualified person.
c) If the warranty certificate and/or the serial number of the product are
adulterated, overwritten or damaged.
d) If defects or unsatisfactory performance are caused by the use of non original
spare parts and in disagreement with the technical specifications from VALEO
Climatização do Brasil - Veículos Comerciais S/A.
8 - The Warranty Does Not Cover
a) Displacement of the bus for repairing of the equipment. In case the customer
requests to be attended in the same place where products is operating, the
collection or not of the visitation charge will be the criterion of the authorized
service provider.
b) The attending to the consumer, free or paid, in cities that do not have
authorized services providers. So the expenses with displacement are the sole
responsibility of the owner.
c) Lack of proper preventive maintenance, as described in the preventive
maintenance item in this manual.
d) Loss or loss of profits caused by the stoppage of the vehicle due to
non-operation of the equipment.
REVO 400 eCBC
4

PREVENTIVE MAINTENANCE
Preventive Maintenance
REVO 400 eCBC
Preventive Maintenance Frequency Check List
WEEKLY 1 - Clean or change the return air filter.
1 - Accomplish the weekly check list.
2 - Clean the condenser capillary tube coil (Apply only water and neutral non-aggressive soup to cooper and aluminum). See note (*)
3 - Check if the evaporator hatches are closed to avoid air intake into the equipment.
4 - Test the equipment operation functions: cool / fan (high and low speed) / heat / dry (air renewing) modes.
1 -Accomplish the monthly check list.
2 - Activate the heating system, if any.
3 - Measure the exhaust suction pressure, temperature and suction line condition.
4 -Measure the condenser and evaporator fan flow consumption (check their air outflow).
1 - Accomplish the quaterly check list.
2 - Clean the evaporator capillary tube coil (Apply only water and neutral non-aggressive soup to cooper and aluminum). See note (*)
3 - Clean heating system heaters, if any. (Apply only water and neutral non-aggressive soup to cooper and aluminum). See note (*)
4 - Clean the evaporator drain.
5 - Look carefully, if there is any leakage at coupling spots: oil leakage, refrigerant leakage.
6 - Check if there are any loose, free, damaged, broken, worn parts, rusty, melting, cracked or bad fractioning to the bus body.
1 - Accomplish the semester check list.
2 - Check the opening and closing pressures of high and low pressure switches.
3 - Clean the air conditioning body getting rid of any dust/scrap at components. See note (*)
NOTE (*): when cleaning using water, protect electrical and electronic components to prevent damage.
MONTHLY
QUARTERLY
SEMESTER
YEARLY
IMPORTANT: you do not accomplish the preventive maintenance check list as above, it implies to total or partial loss of warranty coverage.
The actions of preventive maintenance written in this manual have been based on normal conditions. Just in case of environment contaminated and bad weather
conditions, then you must do the maintenance more frequent.
5

PREVENTIVE MAINTENANCE
ATTENTION: Just in case a problem happens in the refrigeration system, then it
must be repaired in an authorized shop or qualified professional.
If a third party installs the equipment, VALEO Climatização do Brasil - Veículos
Comerciais S/A, guarantees only the product, not the installation of it.
• Driver´s evaporator:
Problems with any driver´s air conditioning component, leakage, bad working or
operation.
IMPORTANT: lclean the return filter of the driver´s air conditioning, at least, once
a week.
• Tubes, hoses, drains and wiring harness:
Bad attachment. Leakage at connections and welding points. Damages due to
frictioning / chassis and components frictioning or bad installed.
• Gas Charge Process:
Leakage test procedure. Vacuum process and refrigerant gas charge.
• Operation module:
Control and commissioning of the air conditioning are also of responsibility of
the bus bodybuilder.
• Hermetic compressor:
Mounted close to the ceiling unit.
IMPORTANT: the vehicle owner must do preventive maintenance actions.
If you do not do the preventive maintenance as described in this chapter, it
implies you lose partially or full warranty coverage.
Items of Responsibility of the Bus Bodybuilder
REVO 400 eCBC
Dry Filter
We recommend that you shall preventively change the drier filter every 3 years.
Just in case, you need to refill in the equipment with gas, we recommend you
replace to a new filter to extinguish any dirt out of the system.
Ducts
The cleaning of the air ducts must be done every tree months, it can be earlier,
depending on: the frequency of operation of the air conditioning system,
quantity of passengers and resistivity of the environment where it is driven. This
cleaning is the responsibility of the vehicle owner´s only, he is in charge of this
cleaning in order to offer good air quality to his passengers.
NOTE: ducts are components of the bus body.
SAY NO TO RECONDITIONED PARTS
The application of reconditioned parts will diminish the air conditioning
efficiency, will overcharge the electric system causing early brake of
the compressor and set a fire!
6

EQUIPMENT IDENTIFICATION (ID)
Identification Tag
It is very important, when you need to ask for spare parts or after sales parts,
and similar ones, customer must identify the model of the air conditioning,
telling the series number, model and manufacturing date.
This information can be found in the Air Conditioning Warranty Certificate and ID
tag. The ID tag also contains the type of refrigerant gas used and the amount
required for the model.
Application information regarding to: series and bus body model, series and
chassis model are very important to identify which parts the equipment carries.
In order to identify the bus body and chassis, you need to check the bus body
builder manual.
REVO 400 eCBC
The refrigerant gas amount can vary
according to application.
7

AIR CONDITIONING OPERATION
1- Main Components Air Conditioner Module
8
14
15
2
Note: illustrative drawing.
6
7
9
12
4
13
13
12
5
10
1
1
11
11
3
5
REVO 400 eCBC
8

Drain
It is a way to get the condensed moisture from
evaporator tubes from the condensed tray to putting
out.
15
Air circulation
Air being cooled by the evaporator, then it follows
to the bus interior through fans.
14
Air filter
Air return filter retains impurities from air avoiding
any block of dirt at evaporator capillary tubes and
coil.
13
Evaporators
Now at evaporators, the refrigerant fluid, at low
pressure, turns from liquid to gaseous state,
absorbing the interior heat of the vehicle in this
process.
12
Valve hinders the refrigerant inlet that comes from
de condenser at high pressure and its goal is adjust
the refrigerant gas flow that passed by the
evaporator looking for making the pressure steady
and temperature at the capillary tubes output.
11 Expansion Thermostatic Valve
Drier filter
Tiene la finalidad de retener impurezas y/o
humedad que pueda haber en el sistema
impidiendo que lleguen en la válvula de expansión.
10
Compressor
When it is working, the compressor sucks the refrigerant
fluid from evaporator at gaseous state and under low
pressure, compressing it, so temperature and pressure
8
Its main goal is dissipate the heat out, which was
absorbed by the refrigerant fluid along the
refrigeration system.
At the condenser, the overheat refrigerant fluid is
sent to outside losing its force, changing from
gaseous state to liquid state.
Condenser
9
Refrigerant Fluid
7
It is inside the air conditioning equipment, inside the
system. It works absorbing the heat from the interior
/ room of the vehicle, at the evaporator, and then it
goes to the condenser where the heat is thrown to
the outside. VALEO Climatização do Brasil - Veículos
Comerciais S/A, products apply refrigerant R134a,
according to the Protection Environmental Law.
Ice Sensor
The interior temperature is measured by the
temperature sensor placed at the air return spot.
5
Evaporator Fan
Evaporator fans are working at cool and fan modes,
fans can be set in two speeds.
Sped control can be manual or automatic.
4
Condenser Fan
Condenser fan and the compressor will only work at
“Cool Mode”.
3
Controller
It is installed in the instrument panel, it offers to the
driver to set-point of temperature, to see by display the
interior temperature, offering full climatic control inside
de bus.
Set-point: it is the temperature the driver wishes to set
inside the vehicle for passengers.
2
Air renewall
This permits the entry of the exernal in order to expel
unwanted odors and impurities from the vehicle.
1
Pressure Sensor
Pressure sensors are devices that read pressure
and convert it into electrical signals.
6
REVO 400 eCBCAIR CONDITIONING OPERATION
ELECTRIC SYSTEM
MECHANIC SYSTEM MECHANIC SYSTEM
9

2- Technical Specifications of the Device
OPERATING THE AIR CONDITIONER
Component Characteristics REVO 400 eCBC
Maximum Cooling Capacity 136.500 BTU/h (40kW)
Maximum Heating Capacity 130.000 BTU/h (38kW)
Air Renewal (1) 25%
Evaporator Air flow (free blowing) 9.280 m
³
/h
Radial Blowers 8
Condenser Air flow (free blowing) 11.600 m
³
/h
Axial Fans 4
L x W x H (mm) 3227 x 2076 x 215
Unit Weight (2) 162 Kg
Raio de Teto (mm) 8.000
ELECTRIC Tension / Current 24V - 116 A
COMPRESSOR Refrigerant Gas (3) R134a
(2) Unit without integrated heating system.
(3) Gas charge values vary by application.
DIMENSIONS
(1) Refers to the total flow of the free evaporator.
AIR CONDITIONING
REVO 400 eCBC
10

EQUIPMENT DESCRIPTION
3.1- Central Condenser Module
1
4
7
6
5
2
3
REVO 400 eCBC
ITEM DESCRIPTION QTY.
1 REVO 400 eCBC Condenser Unit 1
2 MPE REVO 400 eCBC Condenser Coil 1
3 REVO 400 eCBC axial Fan Module 4
4 Axial SPAL Fan 24V 4
5 REVO 400 eCBC Condenser Support 16
6 Plastic Strap with Clip 8
7 REVO 400 eCBC (11117934) Condenser Electric Harness 1
11

3.2- Evaporators Modules
11
4
14
15 16
7
8
9
10
11 12
13
12
6
5
2
3
17
REVO 400 eCBC EQUIPMENT DESCRIPTION
ITEM DESCRIPTION QTY.
1 REVO 400 eCBC Right and Left Side Evaporators Unit 1
2 REVO 400 eCBC Right and Left Side Evaporators base 1
3 REVO 400 eCBC Right and Left Side Evaporator Coil - Aluminum 1
4 Viral Filter REVO 8
5 Electronic Radial Blower - 1150 024 BLDC 0 - REVO 400 eCBC 8
6 REVO 400 eCBC Blower Clamp Body 8
7 Clamp for Blower 8
8 Air Directing Guide 360 REVO 400 eCBC 8
9 Cover 400/450 eCBC 2
10 REV0 400 eCBC Right Side Water Drain Connection 2
11 REV0 400 eCBC eft Side Water Drain Connection 2
12 REVO 400 eCBC Deflector Long Plate Renewal Support 8
13 Side Plate REVO 400 - 450 eCBC 2
14 REVO 400 eCBC Evaporator Air Filter Support 8
15 Plastic Quick Nut EJOT EASY BOSS 60 X 2 X 11 20
16 Quick Nut M6 5246C SJ 4
17 REVO 400 eCBC (11115964) Evaporator Electric Harness 1
12

3.3- Covering and Fixation Components
1
1
4
7
8
13
13
15
15
9
9
98
7
10
11
6
6
5
5
2
2
3
12
14
REVO 400 eCBC EQUIPMENT DESCRIPTION
ITEM DESCRIPTION QTY.
1 REVO 400 eCBC Right or Left Side Cover Set 1
2 Urban Bus Coverage REVO 400 eCBC E (11116078) 2
3 Connection Coverage eCBC 1
4 REVO 400 eCBC Central Covering Plate 1
5 Air Duct Adapter I (Evaporator Insufflation) REVO 400 eCBC 2
6 Air Duct Adapter II (Evaporator Insufflation) REVO 400 eCBC 2
7 REVO 400 eCBC Water Deflector Plate 2
8 Expanded Metal Mesh Grid REVO 400 eCBC 450 Left or Right Side 1
9 REVO 400 eCBC Coverage Stick 2
10 REVO 400 eCBC Hood Jamb Support 4
11 Cable Clamp DM8 Form 1 - 11787 4
12 REVO 400 eCBC Front/Side/Rear Base Fixation Support 36
13 Cable Clamp CFCC-3-05A3-RT 16
14 REVO 400 eCBC Electrical Interface Plate 1
15 Sealing Foam REVO 400 eCBC - 2050 X 116 X 10 2
13

3.4- Air Conditioning Tubing Components
1
16
15
14
14
15
16
25
26
10 11 928
17
3
19
18 13
12
4
5
8
6
7
21
22
20
24
24
23
23
REVO 400 eCBC EQUIPMENT DESCRIPTION
ITEM DESCRIPTION QTY.
1
Liquid Line Tube with SMA Connection (REVO EDC) 1
2 Condenser Tube - Dryer Filter 2 SMA eCBC Connection (REVO EDC) 1
3 eCBC Connection Pressure Tube 1
4 Suction Tube with eCBC Connection 1
5 Tube 2 Defroster Left Side Connection 1
6 eCBC Defroster Return Tube 1
7 Left Side Defroster Tube 1
8 Expansion Valve Tgen 3,5TR – Danfoss (Static Overheat 5k) 2
9 Drying Filter R134a - Connection SMA - REVO 400 eCBC 1
10 REVO 400 eCBC Filter Dryer Support 1
11 Endless Cable Tie 14mm 70 - 89 Stainless Steel AISI 304 - Super 1
12 Support Adapter Rf Central REVO 400 eCBC 1
13 eCBC Suction and Pressure Tube Support 1
14 eCBC Left or Right Side Cover Support 1
15 REVO 400 eCBC Tube Support 2
16 Support for Tube and Electrical Whip Harness REVO 400 eCBC 2
17 Solenoid + Plug Ref SG 1102620A 1
18 Clamp Body Diameter 28mm – PP 4
19 ICE Temperature Sensor 1
20 REVO 400 eCBC Liquid Tank 3 Liters Aluminum 1
21 Liquid Tank X Condenser Tube Set - REVO 400 eCBC 1
22 Liquid Tank Tube Set - Sub Cooling - REVO 400 eCBC 1
23 Right or Left Side Closure Support REVO 400 eCBC 1
24 REVO 400 eCBC Cover Support Foam Shield 2
25 WABCO REVO 400 eCBC Electronic Module 1
26 REVO 400 eCBC Control Unit Support 1
14

3.5- Air Renewall Set
1
1
"A"
8
"A"
"B"
9
"B"
1
14
12
2
65
11 713
3
4
4
10
16
16
15
15
17
17
REVO 400 eCBC EQUIPMENT DESCRIPTION
ITEM DESCRIPTION QTY.
1 REVO 400 eCBC Air Renewall Set 2
2 REVO 400 eCBC Deflector Long Plate Renewal 2
3 REVO 400 eCBC Engine Damper Base Support 2
4 DAMPER II REVO 400 eCBC Base Support 4
5 BUSCHJOST 24V Electric Engine Air Renewall 2
6 REVO 400 eCBC Gear for Engine Side Air Flap 2
7 REVO 400 eCBC Gear for Engine Side Air Flap 2
8 REVO 400 eCBC Axis for Flap Partition 2
9 REVO 400 eCBC Axis for Flap Partition 2
10 REVO 400 eCBC Axle Pin 2
11 Axis for Position FLAP REVO 400 eCBC 2
12 Axis for Position FLAP REVO 400 eCBC 2
14 Extruded Profile of the REVO 400 eCBC Deflector 2
15 Felt Tape with Adhesive 4
16 Sealing Foam REVO 400 eCBC 4
17 Renewall Trim REVO 400 - 450 eCBC 4
15

ELECTRICAL DIAGRAM OF THE EQUIPMENT
4- REVO 400 C2 Step 3 - Overview
REVO 400 eCBC
16

4.1- Terminal Plate Connections
TERMINAL PLATE CONNECTIONS
REVO 400 eCBCELECTRICAL DIAGRAM OF THE EQUIPMENT
Pin Description Imput Output
1
N/C - -
2 Blower floor stage 1 - x
3 Cylinder compressor cutoff - x
4
Relais mixed circulation pump - x
5
water valve floor (rear section) - x
6
N/C - -
7 Reserve Output 300mA - -
8 Air outlet temperatur sensor Tair roof rear x -
9
Reference temp. Sensors x -
10
N/C - -
11 N/C - -
12 N/C - -
13
Water valve floor x -
14
Return pot. water valve roof heating x -
15
water valve floor (rear section) - x
16 N/C - -
17 Stadtbus: outlet floor
Reisebus: room roof front - x
18 Low pressure switch x -
19 N/C - -
20
N/C - -
21
N/C - -
22
Water valve floor (rear section) - x
23 Water valve roof heating (+) - x
24 PWM sensor blower diag. temp. sens. roof rear x -
25
N/C - -
26
Room temp. sensor roof rear x -
27 High pressure switch x -
28 N/C - -
29
N/C - -
30
N/C - -
31 Water valve floor (rear section) - x
32 Water valve roof heating (-) - x
33
N/C - -
34
N/C - -
35
N/C - -
36 N/C - -
36 PIN MCP CONNECTOR
AMP N
O
1-1718492-1 (X57M)
Pin
Description Imput Output
1
N/C - -
2
N/C - -
3 N/C - -
4
Code 2 x -
5
N/C - -
6
Blower floor stage 2 - x
7 CAN L x x
8 CAN GND x x
9
LIN x x
10
N/C - -
11 N/C - -
12 N/C - -
13
Code 1 x -
14
N/C - -
15
CL15 x -
16 CAN H x x
17 HVAC LIN/CAN (GND) x x
18
LIN 12V x x
19
N/C - -
20 compressor - x
21 CL 31 x -
22
CL 30 x -
23
N/C - -
24
N/C - -
25 Terminating resistor 120 ohm x x
25 PIN MCP CONNECTOR
AMP N
O
1-171849-1 (X58M)
17

SAFETY PRECAUTION
5- Personal Protection
Air conditioning systems offers chemic, mechanic and
electric risks.
It is mandatory to wear IPE (Individual Protection
Equipment), picture 1 to protect yourself from refrigerant
gas, refrigerant oil, battery acid, waste launched, engine
high temperature and noise.
Other Care:
• Ladders and platforms: they can slip or break;
• Whenever working at a height greater than 1.5m use
proper PPE for working at height (belt, helmet, etc.;
• Cooling oil can cause skin and eye irritation, use the
appropriate PPE (gloves and goggles);
• Check that all screws are adequate and torqued correct.
High Pressure:
The refrigerant in liquid state and
high pressure causes a potential
risk. When the refrigerant is
sprayed to natural air, it can
cause serious injuries to eyes and
skin.
Hoses:
Check if manometer hoses
are in good conditions,
when holding them; stay far
from belts, pulleys and hot
surfaces.
Hot Surface:
The compressor discharges,
exhaust pipes and other engine
components can be extremely
hot.
Rotation Components:
The fans, pulleys and belts are not
visible under certain conditions.
Special care must be taken when
putting your hands near them.
Welding:
Welding must be done
carefully; it causes burns and
spray toxic gases out. Provide
ventilated places to do it.
Toxic Gases:
The refrigerant gas along with
flame becomes into toxic gases
and can cause very serious
breathing illness. Take special
care in closed places, if gases
scape somehow (leakage) and
then it can cause no toxygen in
the air.
REVO 400 eCBC
18

SUSTAINABILITY
6- Product Discard
Concerned about sustainability at Valeo Climatização do Brasil - Veículos
Comerciais S/A guides its customers and its authorized service network to
discard products in an environmentally sound and safe manner.
Proper disposal of the product or components at the end of their useful life will
contribute with the preservation and pollutinon reduction of the environment,
creating economic growth through the Reverse Logistics Program.
According to Law 12,305 / 2010, the environmentally adequate destination of
components (parts, oil, refrigerant) is required.
It is the responsibility of all to ensure that products and components are sent to
appropriate treatment to companies approved by the environmental agencies.
For more information about our Reverse Logistics Program, please see our
website: http://www.valeo-thermalbus.com/br
REVO 400 eCBC
19

Valeo Climatização do Brasil - Veículos Comerciais S/A
Av. Rio Branco, 4688 - Bairro São Cristóvão - CEP 95060-145 | Caxias do Sul - RS - Brasil | Tel. [phone]
www.valeo-thermalbus.com/br