YILKAR YK 120 S User manual

YK 120 S
YILKAR
Installation Instruction
EN
SSH.MT.01.02 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023

SSH.MT.01.02 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
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27.12.2022
H.Kübra Şahin
First Publication
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SSH.MT.01.02 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
Contents
1. Introduction ........................................................................................................
4.Installation of Yılkar YK 120 S ..............................................................................
4.4 YK 120 S Indoor Unit Installation .............................................................
3.1 YK 120 S Overview ..................................................................................
4.3 YK 120 S Outdoor Unit Installation ..........................................................
4.3.1 Outdoor Unit Dimensions ..............................................................
4.3.2 Outdoor Unit Positioning and Roof Mounting ................................
4.4.1 Indoor Unit Dimensions ................................................................
4.4.2 Outdoor Unit Positioning and Roof Mounting ..................................
1.2.1 ECE R-10 ....................................................................................
2.1 What is the YK 120 S
.........................................................................
2.2 How does it work? .............................................................................
2.3 YK 120 S Technical Data ..................................................................
4.2 YK 120 S U Connection Profiles Mounting ...............................................
3.1.1 YILKAR Condenser Unit .................................................................
3.1.2 YILKAR Evaporator Unit ................................................................
3.1.3 YILKAR Fiber Cover .......................................................................
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 ......................................................................
4.5 Hoses and Fitting .....................................................................................
4.5.1 Air Conditioner Hoses and Fitting Connections..............................
4.5.1.1. Air Conditioner Hoses .......................................................
4.5.1.2. Fitting Sets ........................................................................
4.5.1.3. Clamp and Plastic Adapters ..............................................
4.5.1.4. Hose and Fitting Mounting ..............................................
4.6 Electrical Connections .............................................................................
4.6.2 Wiring and Circuit Diagram ...........................................................
4.6.1 Control Unit Mounting ..................................................................
4.6.3 Control Unit Owerview ...................................................................

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SSH.MT.01.02 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
4.6.4 Control Unit Operation ...................................................................
4.6.4.2 Heating (Optional) ...............................................................
4.6.4.3 Ventilating ...........................................................................
4.6.4.1 Cooling ...............................................................................
4.7 Fiber Cover Mounting ...............................................................................
5. Commissioning the Air Conditioner ....................................................................
6. Spare Parts .........................................................................................................
7. Usage and Maintenance Recommendations .....................................................
6.1. Condenser Spare Parts ..........................................................................
6.2. Evaporator Spare Parts ...........................................................................
6.3. Other Spare Parts ....................................................................................

1
1. Introduction
This instruction is part of the YK 90 S 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 90 S 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 13503.
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 is an innovative designed air conditioning device developed for air conditioning
minibuses up to 17 seats.
The easy-to-install unit includes a condenser and an evaporator. These units must be
mounted on the roof of the vehicle and connected to the compressor via hoses circulating
R134a refrigerant.
With its aerodynamic design, this unit only increases the height of the vehicle by 19 cm.
Thus, thanks to its design, resistance in air and fuel consumption is minimized.
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 ?
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
Compressor
SD5-SD7-TM16
Cooling Power
9 - 12 kW
(30709 - 40945 BTU/sa)
(7738 - 10318 kcal/sa))
Oil Type
PAG 100 oil
Oil Amount
250 ccm
Refrigerant / Amount
R 134 a / 1750 ± 150 gr
Evaporator Fan Flow Rate
3000 m³/h (for 3 Blower Motors)
Condenser Fan Flow Rate
3400 m³/h (for 2 Axial Fans)
Pressure Switch
Low pressure / 2 bar
Fan Control / 15 bar
High pressure / 25 bar
Dimensions
(Length x Width x Height)
Outdoor Unit: 1200 x 1680 x 190 mm
Indoor Unit: 1300 x 420 x 226 mm
Weight (Without Mounting Kit)
44,5 kg
Maximum Total Electricity Intake
65 A @12 VDC
32,5 A @24 VDC
2.3 YK 120 S Technical Data
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Table.1 Technical Data
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3. Overview
3.1 YK 120 S Overview
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3.1.1. YILKAR Condenser Unt
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CONDENSER UNIT- 1301
1 Piece
312.02.01301.01 (12V)
312.02.01301.21 (24V)
1
CONDENSER GROUP - 1301
1 Piece
502.11.01301.01 (12V)
502.11.01301.21 (24V)
2
AIR CONDITIONING - HOSE CONNECTION
GROMET
1 Piece
504.01.YKMON.33
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AIR CONDITIONING - WEDGE CONNECTION
ASSEMBLY - 20 MM
1 SET
504.01.YKMON.01
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U - DOUBLE - RAIL-EAR 70 CM COMPLETE
2 SET
502.51.UC005.01
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EVAPARATOR UNIT - YK 120 S
1 Piece
311.02.YK120.01 (12V)
311.02.YK120.21 (24V)
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EVAPARATOR GROUP - YK 120 S - 2007
1 Piece
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 Piece
501.24.HEIPL.11
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HOSE - STEEL WIRE - SPIRAL 12 MM
5 m
108.02.HC00M.12
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3.1.2. YILKAR Evaporator Unt
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FIBER - COVER - 1301 - MEDIUM
1 ADT
321.01.01301.02
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FIBER - RAW - COVER - 1301 - MEDIUM
1 ADT
504.11.01301.02
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WICK - LUGGAGE RUBBER
1ADT
103.02.FT001.01
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3.1.3. YILKAR Fber Cover
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3.2 General Description
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Fiber Cover
Condenser
The cover made of fiber material is mounted on the
condenser unit on the vehicle roof and acts as a
condenser protection.
It is the air conditioning system element in which
the high pressure R134a refrigerant gas taken from
the compressor in the condenser air conditioning
system becomes liquid by giving heat to the
environment.
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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
Compact filter is a filter system that keeps the
impurities and moisture in the system positioned at
the condenser outlet.
Compact Filter
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Compressor
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
Air Conditioner Hoses
It is the pump of the system that compresses the
R134a air conditioner gas in the compressor air
conditioning system and increases its pressure.
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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COMPRESSOR
EVAPORATOR
CONDENSER
VALVE
4.1 General Assembly Diagram
4. Yılkar YK 120 S Installation
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Hgh Pressure Lne
Low Pressure Lne
In the above assembly diagram, the flow direction of the R134a refrigerant and the low-
high pressure zones are shown on the components connected to each other by hoses in
the air conditioner system.
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4.2 YK 120 S U Connection Profiles Mounting
Connection plates are the first mounting parts used to fix the condenser and evaporator
to the vehicle roof and to each other. Remove the fiber cover and evaporator plastic
covers just before this procedure.
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..
EN

FOR EVAPORATOR
CONNECTION
U DOUBLE PROFILE
FOR CONDENSER
CONNECTION U
DOUBLE PROFILE
930
470
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Assembly Step 4:
The position of the U connection profiles to be used for the condenser and evaporator
should be marked on the ceiling in the vehicle as shown below and mounted to the ceiling
with a drill-tipped trapezoidal M5x25 screw. 16 connection screws are used for this
connection.
VEHICLE ROOF
DRIVE
DIRECTION
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4.3.1 YK 120 S Outdoor Unt Dmensons
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4.3 YK 120 S Outdoor Unit Installation
950
558
175
To fix the air conditioner, it is necessary to drill 5 holes in the roof of the vehicle.
(4 for connecting wedges, 1 for hose passage)
4.3.2 Outdoor Unt Postonng and Roof Mountng
Before making any cuts on the vehicle, remove the vehicle's battery; Make
sure that there is no electrical cable in the part where you will drill the ceiling
holes.
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. .
.
Ø68
1680 815
235
1200
Ø10*4
15
235
160
275
Assembly Step 5:
Determine the location of the condenser to be mounted on the vehicle with the central line
on the vehicle in accordance with the mounting criteria.
Assembly Step 6:
For YK 120 S, mark the places to be drilled, the details of which are given in the technical
drawing, on the vehicle by referring to the fiber cover dimensions. Drill the marked places
with suitable tools and equipment.
ROOF TOP VIEW
DRIVE
DIRECTION
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Assembly Step 7:
Mount the mounting wedges used for vibration
damping on the vehicle roof to the drilled holes and
insulate with SIMSON ISR 70-03 white mastic.
Assembly Step 8:
Assemble the hose grommet to the hole drilled for the
grommet on the vehicle roof and insulate it with SIMSON
ISR 70-03 white mastic.
Assembly Step 9:
Place the condenser unit of your air conditioner on the roof of the vehicle so that it
coincides with the connection wedges that you insulate. To mount the unit on the vehicle
roof, fasten it to the wedges with M10 nut in accordance with it.
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