YILKAR YK 120 S Additional User manual

YK 120 S Additional
YILKAR
Installation Instruction
EN
SSH.MT.01.08 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023

00
15.02.2023
H.Kübra Şahin
İlk yayın / First Publication
REVISION NO
PUBLISH DATE
REVISING PERSON
REASON FOR REVISION
SSH.MT.01.08 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023

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Contents
1. Introduction .........................................................................................................
4.Installation of Yılkar YK 120 S Additional ...............................................................
3.1 YK 120 S Additional Overview ....................................................................
4.3 YK 120 S Additional Unit Mounting ..........................................................
4.3.1 Additional Unit Dimensions ...........................................................
4.3.2 Additional Unit Roof Mounting .......................................................
1.2.1 ECE R-10 .......................................................................................
2.1 What is the YK 120 S Additional .......................................................
2.2 How does it work? .............................................................................
2.3 YK 120 S Additional Technical Data...................................................
4.2 YK 120 S Additional U Connection Profiles Mounting ..............................
3.1.1 YILKAR Split Unit ............................................................................
1 Warranty and Liability ...............................................................................1.
1.2 Security and Legal Regulations ...............................................................
2. Definition and Technical Information ..................................................................
3.Overview................................................................................................................
3.2 General Description.....................................................................................
4.1 General Assembly Diagram ......................................................................
4.4 Hoses and Fitting .....................................................................................
4.4.1 Air Conditioner Hoses and Fitting Connections..............................
4.4.1.1. Air Conditioner Hoses .......................................................
4.4.1.2. Fitting Sets ........................................................................
4.4.1.3. Clamp and Plastic Adapters ..............................................
4.4.1.4. Hose and Fitting Mounting ..............................................
4.5 Electrical Connections ..............................................................................
4.5.2 Wiring and Circuit Diagram ...........................................................
4.5.1 Control Unit Mounting ..................................................................
4.5.3 Control Unit Owerview ...................................................................
4.5.4 Control Unit Operation ...................................................................
4.5.4.2 Heating (Optional) ...............................................................
4.5.4.3 Ventilating ...........................................................................
4.5.4.1 Cooling ...............................................................................
SSH.MT.01.08 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023

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5. Commissioning the Air Conditioner ......................................................................
6. Spare Parts ...........................................................................................................
7. Usage and Maintenance Recommendations ........................................................
6.1. Evaporator Spare Parts ............................................................................
6.2. Other Spare Parts .....................................................................................
SSH.MT.01.08 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023

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1. Introduction
This instruction is part of the YK 120 S Additional air conditioner. All necessary
information for installation is explained and includes information on safe use of the
device. Please read this installation instruction carefully in order to fully install Yılkar air
conditioner.
It is recommended to be stored in a safe and clean place.
For questions, please contact the service and/or customer service.
You can scan the QR code for Yılkar Klima communication.
EN

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Warranty conditions
YILKAR assures its customers that the products they buy are manufactured in
accordance with today's technology and without any errors. All YILKAR Authorized
Dealers are obliged to carry out warranty transactions regardless of which authorized
dealer the vehicle is sold by.
All parts on the product are under warranty for 2 (two) years from the date of delivery in
case of fabrication defects.
If the relevant warranty form indicating that the product was installed at the approved
service points is not found in the business records, the date when the product was
decommissioned is taken as a reference. As of the date of exit from the business, the
warranty is processed for 2 years (two years).
Consumables (belt, bearing, refrigerant, workmanship, filter, dryer and compressor) are
covered by warranty for 1 year or 50,000 km (whichever comes first) from the date of
installation of the product.
In case the product fails during the warranty period, the time spent in repair is added to
the warranty period. This period starts with the delivery of the product to the authorized
service. The repair period of the product is maximum 30 days.
The warranty does not apply in the following cases:
Defects arising from the use or assembly of the product contrary to the points in the user
manuals
Faulty electrical wiring
Damages and malfunctions caused by using a voltage different from the voltage written
on the label of the product
If the product maintenance and repairs are not carried out on time, regularly, by the
services with the necessary technical knowledge and competence and in accordance
with the periodic maintenance and repair procedures (Every 50,000 km and annual
maintenance is obligatory).
The ownership of the parts changed within the warranty belongs to YILKAR.
The warranty period of products replaced by spare parts is 1 (one) year from the date of
installation.
1.1 Warranty and Liability
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1.2 Security and Legal Regulations
Read this service manual carefully before operating your YK 120 S Additional model roof type
air conditioner.
In case of problems that may occur as a result of improper use conditions, the warranty is
canceled and compensation claims are not taken into account.
Have repair and maintenance operations performed only by qualified personnel
who have received the necessary training and authorization. You can find
information about YILKAR authorized service centers on YILKAR's official website,
www.yilkarklima.com.
Do not reach into the unit and do not hold any foreign objects to the condenser and
evaporator fan when the device is in operation.
Please do not touch the condenser, evaporator or its connections with your hands.
The same is true for the resistor on the fan if it will run on the unit and it has not
cooled down completely.
Replace faulty parts immediately and have any detected faults corrected.
It is mandatory to use the necessary safety equipment in maintenance and repair
operations.
Carry out maintenance work only when the engines are turned off.
Before turning on the air conditioning unit, disconnect the battery.
Please pay attention to the following rules for your own safety:
ECE R10 – Electromagnetic compatibility regulation is the type approval test for European
automotive electronics. It has been successfully passed various tests including RF immunity
and emissions, transient immunity and emissions.
Electrically it has met the requirements for waste, explosion, fluctuating harmonics and
vibration.
As a result of the tests, it was certified with the document number E13 R10 - 05 13505.
You can reach Yılkar Klima ECE-R 10 test certificate via the QR code below.
1.2.1 ECE-R 10
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YK 120 S additional is an innovative designed air conditioning device developed for air
conditioning minibuses up to 15 seats.
The easy-to-install unit includes an evaporator. These units must be mounted on the roof
of the vehicle and connected to the compressor via hoses circulating R134a refrigerant.
It can operate in outdoor conditions at 45°. The air conditioner, which has a cooling
capacity of 9-12 kW, can have a heating function with the heat exchanger device. Your
air conditioner makes the waste heat generated in your vehicle's engine usable and can
provide heating power to your air conditioner with its current design. In this way, the
cooling of your engine is more effective, while your vehicle warms up.
YK 120 S is universal, compact and economical with all its features.
2. Definition and Technical Information
2.1 What is YK 120 S Additional?
2.2 How does it work?
Vehicle roof air conditioners are heat machines that provide passenger thermal comfort
by taking the heat inside the vehicle.
Vehicle roof air conditioners work with a vapor compression refrigeration cycle in
thermodynamics. There are 4 main parts in this cycle. These are the compressor,
condenser, evaporator and expander valve.
The refrigerant put into the heat machine is first pressurized in the compressor, and the
fluid pressure is increased from approximately 1 bar to 16 bar. Afterwards, the
temperature of the supercompressed and superheated gas in the condenser is taken and
the fluid is liquefied under extreme pressure. The high pressure liquefied fluid coming to
the expansion valve from here passes through the valve to the low pressure region and
evaporates. It needs heat during evaporation. While the ambient air passed over the
evaporator heats the fluid in the evaporator and causes it to evaporate, it cools the
environment and provides thermal comfort to the passenger cabin.
EN

Roof Type Air Conditioning Unit
YK 120 S Additional
Cooling Power
9-12 kW
(30709 - 40945 BTU/h)
(7738 - 10318 kcal/h)
Oil Type
PAG 100 oil
Oil Amount
250 ccm
Refrigerant / Amount
* R 134 a / 1500 ± 150 gr
Evaporator Fan Flow Rate
3000 m³/h (for 3 Blower Motors)
Dimensions
(Length x Width x Height)
1300 x 420 x 226 mm
Weight (Without Mounting Kit)
23 kg
Maximum Total Electricity Intake
54 A @12 VDC
27 A @24 VDC
2.3 YK 120 S Additional Technical Data
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Table.1 Air Conditioner Technical Data
*It is the value that should be added to the gas amount of the original air conditioner.
*Depends on the features of the additionally connected master air conditioning system.
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EVAPARATOR UNIT - YK 120 S
1 PCS
311.02.YK120.01 (12V)
311.02.YK120.21 (24V)
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EVAPARATOR GROUP - YK 120 S - 2007
1 PCS
501.21.YK120.01 (12V)
501.21.YK120.21 (24V)
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U - DOUBLE - RAIL-EAR 70 CM COMPLETE
1 SET
502.51.UC005.01
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AIR SUCTION GRILL COMPLETE - 4 - BLACK
1 PCS
501.24.HEIPL.11
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HOSE - STEEL WIRE - SPIRAL 12 MM
5 MT
108.02.HC00M.12
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3.1.1. YILKAR Splt Unt
3. Overview
3.1 YK 120 S Additional Overview
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3.2 General Description
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Evaporator
Evaporator is an air conditioning system element
that evaporates the R134a refrigerant coming from
the condenser with the help of a valve and thus
cools the ambient air.
It is an air conditioning system element that
provides the phase change by reducing the
refrigerant pressure.
Valve
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The relay switches on and off the current path with
the help of current and voltage values in the air
conditioning system. In this way, it ensures the
regular operation of the air conditioner. There are
12V and 24V options for the air conditioning system.
Relay Board
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Air Conditioner Hoses
There are 5/8'' 5/16'' and 13/32'' hoses in
compliance with SAE-J 2064 type-E standards in
the air conditioning system. Thanks to these hoses,
R134a refrigerant circulates between the air
conditioner elements.
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Selenoid Valve (Optional)
It is the electromagnetic element that allows it to
separate the air conditioning system from the
original system.
EN

COMPRESSOR
EVAPORATOR
CONDENSER
VALVE
YK 120 S
EVAPORATOR
ADDITIONAL
SELENOID VALVE
(OPTIONAL)
4.1 General Assembly Diagram
4. Yılkar YK 120 S Additional Installation
In the assembly diagram, the flow direction of the R134a refrigerant and low-high
pressure zones are shown on the components connected to each other by hoses in the
air conditioner system.
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SLAVEMASTER
5/16
5/8
UNIVERSAL
315.01.MNL04.10
MERCEDES
315.01.MNL04.11
VW CRAFTER
315.01.MNL04.12
UNIVERSAL
315.01.MNL01.08
: High Pressure Line
: Low Pressure Line
Slave : Additional Product
Master : Main Product
: Point of connection
At the assembly point, 5/8 and 5/16 attachments are used for the connection of the
additional product to the main product. The original air conditioner hose of the vehicle is cut
and mounted. The attachments used are shown below.
EN

4.2 YK 90 S Additional U Connection Profiles
Mounting
Connection plates are the first mounting parts used to fix the evaporator to the vehicle
roof.
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Assembly Step 1:
First of all, cut the U-connection profiles to the dimensions suitable for the roof of your
vehicle.
Assembly Step 2:
Assemble the U profiles by interlocking the
rail-ear parts.
Assembly Step 3:
Spray the SIMSON ISR 70-03 white sealant
included in the mounting kit on the
evaporator and condenser U-profiles facing
the vehicle body.
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VEHICLE ROOF
FOR EVAPORATOR
CONNECTION
U DOUBLE PROFILE
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930
Assembly Step 4:
The position of the U connection profiles to be used for the evaporator should be marked
on the roof in the vehicle as shown below and mounted to the roof with a drill-tipped
trapezoidal M5x25 screw. 8 connection screws are used for this connection.
DRIVE
DIRECTION
EN

TR
4.3.2 Addtonal Unt Roof Mountng
4.3.1 Addtonal Unt Dmensons
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4.3 YK 120 S Additional Unit Installation
Assembly Step 5:
Assemble the evaporator unit to the U-profiles previously mounted on the vehicle with
drill-tipped trapezoidal hexagon head M5x25 screws.
1300
420
226
Ar Flow Drecton
It is
recommended to
use insulation in
the part where
the evaporator is
located.
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ADDITIONAL UNIT
VIEW
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DRIVE
DIRECTION
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The air conditioning system is sent by the factory
with a pressure of 20 bar inside. While removing the
existing plugs at the connection points, it should be
checked whether there is Nitrogen gas in it.
Ø12 WATER HOSE
5/16 HOSE AND FITTING
CONNECTION
5/8 HOSE AND FITTING
CONNECTION
Ø12 WATER HOSE
Stage
4.4 Hoses and Fitting
For the water discharge hose connection, the
clamps must be tightened behind the stage in the
evaporator water discharge section as shown in the
figure. Water discharge hoses should be inclined at
least 2° so as not to interfere with the water flow.
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4.4.1 Ar Condtoner Hose and Fttng Connectons
HOSE INSIDE
DIAMETER (inc)
HOSE OUTSİDE
DIAMETER (mm)
MINIMUM BENDING RADIUS (mm)
5/16"
12,9
40 mm
13/32"
16,2
50 mm
5/8"
24,0
80 mm
The hose types in compliance with SAE-J 2064 type-E standards available in Yılkar air
conditioning system, the minimum bending radius of these hoses and the unions used with
these hoses are given in the table below.
Fitting sets used in Yılkar air conditioning system are shown in the table below.
4.4.1.2. Fttng Sets
Table.2 Air Conditioner Hose Table
Table.3 Air Conditioner Fitting Set Table
5/16"
13/32''
5/8"
STRAIGHT FITTING
STRAIGHT FITTING
WITH PORT
90° FITTING
90° FITTING WITH
PORT
45° FITTING
45° FITTING WITH
PORT
(5/8'' - 7/8'' x14 UNF)
(5/16'' - 5/8'' x18 UNF) (13/32'' - 3/4'' x16 UNF)
HOSE DIAMETER
FITTING SET TYPE
4.4.1.1. Ar Condtoner Hoses
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HOSE INSIDE DIAMETER
CLAMP
PLASTIC ADAPTERS
5/16"-13,8
13/32''-17
5/8"-25,6
5/8"-25,6
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4
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YILKAR CODE:
212.01.P0000.05
4.4.1.3. Clamp and Plastc Adapters
1-First of all, cut the hoses straight. (one)
2-Lubricate the inner part of the hose where the union will pass.
3-Put the unions on the hoses properly. (2)(3)
4-Tighten the clamps with the help of pliers. (4)(5)
4.4.1.4. Hoses and Fttng Mountng
HOSE
Table.4 Clamp and Plastic Adapters Table
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Assemble 13/32 , 5/8 and 5/16 hoses to
protect them from internal and external
factors. Keep away from the moving
elements and hot parts of the vehicle,
make the assembly by isolating it from all
sharp edges and corners where the line
will pass. Bend the hoses to the minimum
bending radius.
After all connections are made, fix the hoses to the vehicle with cable ties.
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