Waeco SP-900 User manual

DE 11 LKW-Splitklimaanlage
Einbauanleitung
EN 30 HGV split air conditioner
Installation manual
FR 49 Climatiseur split pour poids lourds
Notice de montage
ES 68 Equipo de aire acondicionado Split para
camiones
Instrucciones de instalación
IT 87 Impianto di climatizzazione split per
autocarri
Istruzioni di montaggio
NL 107 Split airconditioning voor vrachtwagens
Montagehandleiding
DA 126 Splitklimaanlæg til lastbiler
Installationsvejledning
SV 145 Split-klimatanläggning för lastbilar
Monteringsanvisning
NO 164 Delt klimaanlegg for lastebiler
Montasjeveiledning
FIN 182 Kuorma-auton ilmastointilaite
Asennusohje
SP-900
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CoolAir
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CoolAir
C
+
T
F
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C
+
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w
br
gr
gl
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w
br
gl
gr
4441300108
4441300108
4441300097
4441300097
4441300096
4441300096
sw
ro
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sw ro
ro
gl
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ro
br
br
ro +-
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bl br gl gr ro sw w
DE Blau Braun Gelb Grün Rot Schwarz Weiss
EN Blue Brown Yellow Green Red Black White
ES Azul Marrón Amarillo Verde Rojo Negro Blanco
FR Bleu Marron Jaune Vert Rouge Noir Blanc
IT Blu Marrone Giallo Verde Rosso Nero Bianco
NL Blauw Bruin Geel Groen Rood Zwart Wit
DA Blå Brun Gul Grøn Rød Sort Hvid
SV Blå Brun Gul Grön Röd Svart Vit
NO Blå Brun Gul Grønn Rød Svart Hvit
FI Sininen Ruskea Keltainen Vihreä Punainen Musta Valkoinen
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Safety instructions
CoolAir
30
Contents
1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
1.1 Using the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
1.1.1 Handling electrical cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 Conventions in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2.1 General information on the installation manual . . . . . . . . . . . . . . . . . . . . . . . . .32
2.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
2.3 Symbols and formats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.1 Prescribed installation method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.2 Notes on installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.3 Installation steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
5.3.1 Determining the installation position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.3.2 Installing the condenser unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.3 Installing the evaporator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.4 Connecting the condenser unit to the evaporator unit . . . . . . . . . . . . . . . . . . . . . . 39
5.3.5 Installing and connecting the power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.6 Sealing and attaching the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6.1 Starting and ending configuration mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.2 Menu level 1: Set temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3 Menu level 2: Low voltage cut-off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4 Menu level 3: Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.5 Menu level 4: Default setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
7.1 Condenser unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2 Evaporator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.3 Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
1 Safety instructions
You must read the entire manual thoroughly and carefully. We can only
guarantee the reliability of the air conditioner if the instructions are adhered
to. The same applies to the prevention of injury and damage to property.
a
The manufacturer will not be held liable for claims for damage resulting
from the following:
Installation errors
Damage to the system resulting from mechanical influences
or overvoltage,
Changes to the air conditioner that are made without explicit permission
by the manufacturer,
Use for purposes other than those described in the installation manual.
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31
Safety instructions
CoolAir
1.1 Using the device
Only use the air conditioner for the purpose specified by the manufacturer
and do not make any alterations or structural changes to the device.
Only operate the air conditioner if you are certain that the housing and
the cables are not damaged.
Installation, maintenance and repair work may only be carried out by
qualified personnel from a specialist company who are familiar with the
risks involved and the relevant regulations.
Do not use the air conditioner near flammable fluids or in closed rooms.
Do not reach into air grilles or ventilation nozzles or insert any foreign
objects in the system.
Do not open the system in the event of a fire. Use approved
extinguishing agents instead. Do not use water to extinguish fires.
Switch off the air conditioner before using automatic washing equipment
(automatic car washes etc.) to clean the vehicle.
Disconnect all connections to the power supply when carrying out work
on the device.
The system must be switched off before you tilt the cab.
1.1.1 Handling electrical cables
The electrical cables might be laid over sharp edges. Use ducts or
tubes to prevent damage.
Do not lay loose or bent cables next to electrically conductive materials
(metal).
The electrical power supply may only be connected by a
qualified workshop.
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Conventions in this manual
CoolAir
32
2 Conventions in this manual
2.1 General information on the installation manual
This installation manual contains the essential information and instruc-
tions for installing the air conditioner. The information is intended to be
read by the installation personnel of the air conditioner.
The following instructions are intended to help you use the installation
manual properly:
The installation manual is part of the scope of delivery and should be
stored carefully.
The installation manual provides you with important information on the
installation of the device and can also be used as a reference material
in the event of repairs.
The manufacturer assumes no liability for non-observance of this
installation manual. Any claims are excluded in this case.
I
The operating manual for the CoolAir SP-900 is included in the air condi-
tioner's scope of delivery.
2.2 Target group
The installation and configuration information in this manual is intended for
qualified installation personnel who are familiar with the guidelines and safety
precautions to be applied during the installation of lorry accessory parts.
2.3 Symbols and formats
You will come across certain symbols and formats in this documentation.
This is what they mean:
e
The safety instruction indicates a danger from an electrical current
or voltage.
Failure to observe this instruction can cause injury or damage the device.
Format Meaning Example
Bold Important information in
the text which must not be
misunderstood
Set the switch (3) to the
COOLING symbol.
➤Instruction text ➤Place the air conditioner on
a work surface with the
housing facing down.
✓Results of an action ✓ The system is now ready
for operation.
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33
Proper use
CoolAir
a
The safety instruction indicates potential hazards which could arise during
the installation or operation of the product and cause damage to the de-
vice or environmental or economic damage.
I
Supplementary information on the product.
3 Proper use
The CoolAir SP-900 is for supplying the cab of a lorry with cooled and
dehumidified air. It can be used while driving.
a
Caution
The CoolAir SP-900 is not suitable for installation in agricultural machines
and construction machines or similar equipment. It does not work properly
in the event of strong vibrations and exposure to dust.
a
Caution
Operating the SP-900 air conditioner with voltages other than those speci-
fied can result in damage to the device.
The SP-900 air conditioner is only designed for ambient temperatures of
up to 43 °C in cooling mode.
The CoolAir SP-900 is ready to install on delivery. The manufacturer
strongly recommends the use of a vehicle-specific WAECO fastening
frame for optimally installing the CoolAir SP-900 condenser unit on the
rear panel of the cab.
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Scope of delivery
CoolAir
34
4 Scope of delivery
CoolAir SP-900
5Installation
a
Caution
The air conditioner may only be installed by qualified personnel from a
specialist company. The following information is intended for specialists
who are familiar with the guidelines and safety precautions to be applied.
5.1 Prescribed installation method
The condenser unit (see Fig. 1 on page 3, 2) is attached to the firm and
straight rear panel of the cab or by means of a firm fastening frame. The
evaporator unit (see Fig. 1 on page 3, 1) is fitted on the inside of the rear
panel of the cab.
I
The connection line (see Fig. 1 on page 3, 3) can only be installed after
fitting the evaporator unit and the condenser unit.
The condensation from the evaporator unit is automatically drained off.
This purely physical function is only possible within certain angles of incli-
nation of the cab. Horizontal inclination during operation should not exceed
10°, vertical forward inclination should not exceed 18°.
The lorry's split air conditioner consists of the following components:
Part designation Quantity Item no.
CoolAir SP-900 air conditioning unit
consisting of:
- Condenser unit
- Evaporator unit with connection line
1 9100100002
4442700183
4442700184
Remote control (incl. type CR2025 battery) 1 4441600084
Battery cables 2 x AWG 8 1 4441300097
Operating manual 1 4445100326
Installation manual 1 4445100327
Installation template, evaporator unit 1 see
packaging
Installation template, condenser unit 1 see
packaging
No. in fig. 15 Designation
1Condenser unit
2Evaporator unit
3Connection lines
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35
Installation
CoolAir
5.2 Notes on installation
e
Warning
Make sure that all electrical components are electrically discharged before
carrying out work on them.
I
The manufacturer strongly recommends the use of a vehicle-specific
WAECO fastening frame for optimally installing the SP-900 condenser unit
on the rear panel of the cab.
This installation manual must be read completely prior to the installation of
the air conditioner.
The following tips and instructions must be observed while installing the
air conditioner:
Please ask your vehicle dealer whether the rear panel of the cab is
suitable for installing the unit.
Check there is sufficient space for installation. Always check whether
any vehicle components could be damaged, deformed or their operation
impaired by the installation before installing the system.
Avoid any unnecessary and frequent mechanical stress to the supply
line between the evaporator unit and the condenser unit. Damage can
result in the loss of refrigerant and impair the performance of the system.
The supplied assembly parts must not be modified during installation.
If a WAECO fastening frame is not used to install the system, make
sure that the installation position of the condenser unit on the rear panel
is not too low. The system could be damaged by high temperatures of
the engine's waste heat.
a
Warning
Improper installation of the air conditioner can result in irreparable damage
to the device and put the safety of the user at risk.
The manufacturer will not be held liable for claims if the air conditioner
is not installed according to this installation manual. That applies to mal-
functions and the safety of the air conditioner, in particular to injuries and
damage to property.
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Installation
CoolAir
36
5.3 Installation steps
a
Caution
The manufacturer only assumes liability for parts included in the scope
of delivery. The validity of the warranty expires if the system is installed
together with third-party parts.
5.3.1 Determining the installation position
The system's installation position must meet the following criteria:
The installation position must be chosen so that maintenance work can
be performed without difficulties and so that there is sufficient space for
the add-on parts (refrigerant line).
The condenser and evaporator unit may not be inclined horizontally or
vertically during installation (see Fig. 5 on page 5).
The condenser unit must not be fitted near direct waste heat
(engine heat etc.).
The length of the refrigerant line (approx. 1.7 m) must be sufficient for
the connection of the condenser and evaporator unit. The line must not
be laid taut (see Fig. 5 on page 5).
The fastening surface should be as flat as possible. Use spacer sleeves
for uneven surfaces. If spacer sleeves are used, longer fastening
screws with sufficient tensile strength (not included in the assembly set)
must be used.
a
Caution
Due to its weight, the condenser unit must have contact with at least two
fastening points of the fastening surface. Do not use spacer sleeves for all
six fastening points.
The freedom of movement of semi-trailers (the outer edges of the trailer
when turning) and other vehicle attachments must not be restricted.
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37
Installation
CoolAir
5.3.2 Installing the condenser unit
I
To install the condenser unit using a vehicle-specific WAECO fastening
frame, please observe the instructions included in the frame's scope of
delivery. The following work steps describe the installation of the con-
denser unit without vehicle-specific fastening frame.
a
Caution
Before drilling any holes, make sure that no electrical cables or other parts
of the vehicle can be damaged.
➤Use the enclosed template (cardboard print) to determine the
position of the condenser unit. Six holes for fastening are marked on
the template.
➤Use a felt pen to mark the positions selected for the holes.
➤Drill fastening holes (Ø 9 mm) at the marked positions.
I
Apply anti-oxidant compound to all drilled through-holes to prevent
rust formation.
➤Remove the eight hex screws from the housing of the condenser unit.
➤Remove the housing and place it to the side (see Fig. 4 on page 4).
➤Fasten the condenser unit using the four M8 x 18 screws, the
AD Ø 40 mm washers (inside) and the M8 retainer nuts
(see Fig. 5 on page 5).
I
The panelling can only be fitted once the refrigerant lines and the cables
(see chapter “Connecting the condenser unit to the evaporator unit” on
page 39) have been connected.
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Installation
CoolAir
38
5.3.3 Installing the evaporator unit
The evaporator unit is fitted on the vertical rear panel, near the bunk, in a
horizontal position:
➤Remove the panelling from the evaporator unit
(see Fig. 6 on page 5).
➤Find a suitable fastening position in the cab that allows sufficient
air circulation.
➤Use the enclosed template (cardboard print) to determine the position of
the evaporator unit. Position the template at the selected point and use
a felt pen to mark the positions of the six holes (Ø 6.5 mm) for fastening.
➤Mark the positions of the through-holes for the connection line and
the condensation line (interior trim: Ø 32 mm and rear panel of lorry
Ø 25 mm).
I
If the space between the interior trim and the rear panel of the lorry is large,
the hole (Ø 25 mm) for the inclined condensation line must be drilled slightly
lower than specified on the template. That does not apply to the small hole
(Ø 16 mm). If the space between the interior trim and the rear panel of the
lorry is approx. 30 mm, the hole (Ø 25 mm) should be about 5 mm lower.
➤Use a knife to cut out the interior trim around the hole.
➤Use suitable drill bits to drill the marked points and insert the supplied
cable sleeves in the large holes.
➤Remove the six hex screws and the lower hex screw from the housing
of the evaporator unit.
➤Pull the housing back slightly and disconnect the connecting plug from
the connection cable of the control panel (see Fig. 7 on page 5).
➤Pull out the flexible condensation splash guard.
➤Carefully unwind the connection line.
➤To attach the evaporator unit, guide the connection line through
the Ø 32 mm hole and guide the condensation line through the
Ø25mmhole.
➤Insert the M6 x 30 screws from the outside.
➤Use the M6 retainer nuts and the M6 washers to fasten the evaporator
unit from the inside (see Fig. 8 on page 6).
➤Insert the flexible condensation splash guard.
➤Connect the connection cable of the control panel to the connecting
plug in the housing.
➤Use the previously removed hex screws to fasten the housing of the
evaporator unit.
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39
Installation
CoolAir
5.3.4 Connecting the condenser unit to the evaporator unit
a
Caution
Avoid narrow radii during bending. Use a suitable round object as a
bending aid. If the radius is too narrow, the refrigerant line will be kinked
and the air conditioner would not be ready for operation.
a
Caution
Before fastening the connection couplings, make sure that the sealing
and thread faces are absolutely clean. Any contamination will result in a
malfunction of the air conditioner.
➤At the rear panel of the lorry, bend the connection line down vertically
with a radius of approx. 50 mm.
➤Install the connection line for the condenser unit and insert it in the
condenser unit.
a
Caution
To screw and tighten the coupling halves, always use an open-ended
spanner to firmly hold the fixed coupling half in position.
I
Make sure that the coupling half with the thin capillary tube is not twisted
or kinked.
a
Caution
The tube couplings are single couplings! The couplings must not be
removed once they are connected.
➤Join the rear coupling halves (thin refrigerant line) and use an
open-ended spanner to hand-tighten the connection + 1/4 turn
(see Fig. 9 on page 6).
➤Join the front coupling halves (thick refrigerant line) and use an
open-ended spanner to hand-tighten the connection + 1/4 turn
(see Fig. 10 on page 6).
➤Insert the protective sheath in the holder, under the coupling.
➤Use the supplied pipe clip to fasten the refrigerant line to the holder in
the condenser unit (see Fig. 11 on page 7).
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Installation
CoolAir
40
I
The connection lines should be installed at right angles to the rear panel
of the lorry (see Fig. 12 on page 7). For this purpose, use body adhesive
(e.g. Betalink K1) and a self-tapping screw to fasten the holders (see Fig.
13 on page 7).
➤Use the supplied holders to fasten the connection line to the rear panel
of the lorry.
➤Loosen the two screws on the cap of the control electronics and
remove the cap (see Fig. 14 on page 8).
➤Install the electrical cables for the control electronics.
➤Connect the electrical cables according to the following wiring table
(see Fig. 16 on page 10):
➤Use cable ties to protect the electrical cables from rubbing and damage.
No. in fig. 15 Designation
1Compressor with control unit
2Condenser fan
3Control unit
4Room sensor
5Vaporiser fan
6Control unit bus cable
7Condenser fan connection cable
8Power cable
Item no. in
fig. 15 No. in fig. 16 Parameter
4441300096 1Connection cable (condenser fan)
4441300108 2Bus cable (control panel/control electronics)
4441300097 3Main connection cable
SP-900-Install.book Seite 40 Montag, 25. Januar 2010 4:53 16