Valeo CC 336 User manual
Rev.00/ December 2021
Code: 036-00359-002
Owner’s Manual
Warranty Certificate
CC 336 - CC 356
AIR CONDITIONER COACHBUS - CITY BUS
INDEX CC 336 - CC 356
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.
INTRODUCTION ______________________________________________________________________________________________________________________________________________________
3
WARRANTY TERMS
Warrant Terms__________________________________________________
4
PREVENTIVE MAINTENANCE
Preventive Maintenance Frequency Check List_________________________
5
Refrigerant Gas R134a_________________________________________
6
Dry Filter_____________________________________________________
6
Compressor Sealing Part______________________________________________
6
Heating System___________________________________________
6
Oil___________________________________________________________
6
Ducts______________________________________________________________________
6
Pulley Belts_______________________________________________________
6
EQUIPMENT IDENTIFICATION (ID)
Identification Tag______________________________________________
7
OPERATING THE AIR CONDITIONER
1- Operating the Air Conditioner_____________________________________________________
8
2- SBU 400-410 Controllers___________________________________________
10
2.1- Control Panel Description_______________________________________________________
10
2.2- Operation Instructions_______________________________________________________________________________________________
11
2.3- Auto Mode_________________________________________________________________
11
2.4- ON/OFF Air Conditioner Compressor___________________________________________
12
2.5- Heating Mode__________________________________________________________
12
2.6- Desired temperature level SET POINT________________________________
12
2.7- Evaporator fan speed configuration_________________________________________
13
2.8- Enabling / Disabling the ventilation function__________________________________________
13
2.9- Faults (errors)________________________________________________________
14
EQUIPMENT DESCRIPTION
3- Technical Data Sheet________________________________________
15
3.1- Condenser Module____________________________________________________
16
3.2- Evaporator Module_____________________________________________________
17
3.3- BOCK FKX 40 Compressor Components___________________________________________________
18
3.4- TM 65 Compressor Components___________________________________________________
19
3.5- Electric Components________________________________________________
20
ELECTRICAL SYSTEM
4- Electric Diagram_____________________________________________
21
SAFETY PRECAUTION
5- Safety Precaution_____________________________________________
22
SUSTAINABILITY
6- Product Discard_____________________________________________________________________
23
INTRODUCTION
VALEO Climatização do Brasil - Veículos Comerciais S/A offers a full line of
equipment for bus air conditioning systems for vans, micro and midi buses,
commuter, articulated, coaches and double-deckers.
Air conditioning system that is modern and high quality, the products of
VALEO Climatização do Brasil - Veículos Comerciais S/A have been
developed looking for comfort and tranquility to passengers that uses the
public transport.
However, you need to take care to assure a good use and operation of the
air conditioning system, and then you can obtain a better performance of its
technology resources.
It is mandatory to do the preventive and corrective maintenance
procedures, they must be accomplished by experts or dully technicians.
Looking for improving and updating the refrigeration technical teams, this
manual describes the fundamentals of our air conditioning system based on
the most important thermodynamic formulas.
You can find operation instructions of VALEO Climatização do Brasil - Veículos
Comerciais S/A air conditioning too, besides it advises you to follow
technical procedures of adequate preventive maintenance obeying
environmental and safety rules.
Frequent training for technical team make them able to get right diagnosis
from equipment (appliances) to accomplish the servicing.
correctly with quality and responsibility, assuring to the whole fleet a
perfect operation of VALEO Climatização do Brasil - Veículos Comerciais S/A
equipment.
CC 336 - CC 356
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.
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) Replacement of bearings, belts, filters in general and lubricating oil, since
they are considered items of natural wear.
Bearings, belts and alternators have limited warranty as follows:
- Bearings in general = 60,000km or 2 years, whichever occurs sooner.
- Belts in general = 20,000km or 3 months, whichever occurs sooner.
- Alternators = 2 years with no mileage limit, however, respecting the
conditions established in these warranty terms and the manufacturer's technical
specifications.
e) Loss or loss of profits caused by the stoppage of the vehicle due to
non-operation of the equipment.
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.
CC 336 - CC 356
4
- Preventive Maintenance Frequency Check List
PREVENTIVE MAINTENANCE
1 - Clean or change the return air filter.
2 - Check out the belt stretchiness condition and compressor with alternator alignment, observing the wear and tear of them.
3 - Check the water level of the radiator reservoir. See note (*)
1-Accomplishtheweeklychecklist.
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 - Check the refrigerant charge: wait 15 minutes, it has to flow through the liquid display without bulb formation.
5 - Check the compressor oil level: wait 15 minutes, it must be 3/4 up to 1/4 full at oil display.
6 - Test the equipment operation functions: cool / fan (high and low speed) / heat / dry (air renewing) modes.
7 - Lubricate the components of the compressor support. It includes articulation (elbows), axles, bushing and pulleys, if necessary.
8 - Operate the heating system (if any) for at least 30 minutes.
1-Accomplishthemonthlychecklist.
2 - Measure the exhaust suction pressure, temperature and suction line condition.
3 - Check the tightening of alternator potency cables fuses in general, electric board and start motor.
4 - Measure the condenser and evaporator fan flow consumption (check their air outflow).
5 - Measure the electromagnetic clutch coil.
6 - Measure the Voltage and Current from alternator.
1-Accomplishthetrimestralchecklist.
2 - Clean the evaporator capillary tube coil (Apply only water and neutral non-aggressive soup to cooper and aluminum). See note (**)
3 - Clean the evaporator drain.
4 - Check out the oil retainer felt of the compressor sealing part.
5 - Look carefully, if there is any leakage at coupling spots: oil leakage, refrigerant leakage.
Check if there are any loose, free, damaged, broken, worn parts, rusty, melting, cracked or bad fractioning to the bus body.
1-Accomplishthesemesterchecklist.
2 - Test the compressor efficiency at 1500 RPM.
3 - Make notes about the compressor oil pressure at 1000 RPM.
4 - Check the opening and closing pressures of high and low pressure switches.
5 - Check the screws or bolts that attach the compressor support and equipment, checking the right torque.
6 - Clean the air conditioning body getting rid of any dust/scrap at components: evaporator, condenser, clutch compressor, alternator, alternator,
relay and control board. See note (**)
IMPORTANT: If you do not accomplish the preventive maintenance check list as above, it implies to total or partial loss of warranty coverage.
(**): when cleaning using water, protect electrical and electronic components to prevent damage.
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.
WEEKLY
MONTHLY
NOTES (*): if necessary, fill it in with water and additives, follow the recommendations of the OEM Body Builder.
YEARLY
SEMESTER
TRIMESTRAL
CC 336 - CC 356
5
SAY NO TO RECONDITIONED PARTS
ATTENTION: under no circumstances, refrigerant cannot be spoiled at the
atmosphere.
IMPORTANT: check reservoir water level. If necessary, fill it in with water
and additives, follow the recommendations of the OEM Body Builder.
PREVENTIVE MAINTENANCE
- Refrigerant Gas R134a
VALEO Climatização do Brasil - Veículos Comerciais S/A products apply for
R 134a. The se of different type of gas, low quality or from unknown brands will
cause low performance from the refrigeration and damage the equipment
components. - 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.
- Pulley Belts
In order to increase the lifetime of the belts, the strength/stretchiness must be
as low as possible, but working, not leaving them skidding without any friction.
Too low stretchiness on the pulley belts can cause overheat and too much
skidding, causing early break.
Too much stretched belts diminish their lifetime and from roll bearing and from
sleeves, this problem can cause engine interior and compressor damage.
After changing the belts, check their stretchiness back again after 48 working hours.
It is recommended not use different brands. Install assemblies with the same
diameter/length of the series and do not apply new belts beside old ones.
Putting the assembly into action without one or two belts for a long time can
cause a damage inside the “v” groove of the pulley. It will cause wear in that
“v” groove, so the new belt may not be stretched accordingly.
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!
- Oil
We recommend you that you shall preventively change the air system oil every
two years or 10.000 working hours, whatever becomes first.
- 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.
- Heating system
We recommend that you enable the heating system frequently (once a month)
to prevent the buildup of solid system particles that lodge in the hot air shutoff
valve seat.
- Compressor Sealing Part
In order to avoid leakage at the sealing part of the compressor due to lack of
lubrication, then the air conditioning must be working at cool mode for at least
15 minutes, once every 15 days.
The sealing part is lubricated by the compressor oil and in its normal operation
allows a small leakage of 0.05 ml per hour under operation.
Check frequently the reservoir and/or felt then remove the excess of it.
Dispose the old oil as your Country regulations and laws.
CC 336 - CC 356
6
PREVENTIVE MAINTENANCE - EQUIPMENT IDENTIFICATION (ID)
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.
The following items are in charge of the OEM Plant (Bus Body Builder).
•
Driver´s evaporator
:
Problems with any driver´s air conditioning component, leakage, bad working or
operation.
IMPORTANT: l
clean 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.
• Alternator/Compressor Support:
Excess or lack of torque at attaching screws/bolts. Assembly is out of project
designs. Pulleys are not aligned, excess or lack of stretchiness at the belts and
pulleys.
• Gas Charge Process:
Leakage test procedure. Vacuum process and refrigerant gas charge.
Note: in case the installation is bad, VALEO Agent Authorized Service Net will
have to call the OEM Plant first, then get an authorization to do the service,
print and issue the Invoice of repairs.
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.
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.
The refrigerant gas amount can vary
according to application.
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.
CC 336 - CC 356
7
OPERATING THE AIR CONDITIONER
1- Operating the Air Conditioner
Note: illustrative drawing.
16 14
2
8
1
15
7
6
13
11
13
5
4
3
12
17
9
9
10
15
11
CC 336 - CC 356
8
Condenser Fan
Condenser fan and the compressor will only work at
“Cool Mode”.
Refrigerant Fluid
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
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.
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.
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
increase, then the compressor puts it into the condenser.
MECHANIC SYSTEM
Compressor Operation
It is started up by the vehicle engine though a
pulley-and-belt system and put into action by an
electromagnetic clutch when air conditioning is
operating at “Cool Mode”.
Air refrechment
This permits the entry of the exernal in order to expel
unwanted odors and impurities from the vehicle.
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.
Temperature Sensor
The interior temperature is measured by the
temperature sensor placed at the air return spot.
Pressure Switches
Pressure switches are electric devices that monitor the air
conditioning equipment operation pressure. Every time a
strong change happens from the NORMAL temperature,
they turn off the compressor immediately to avoid break.
Observation: pressures are always monitored, even if the
air conditioning is turned off.
ELECTRIC SYSTEM
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.
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.
Relay Board
Relay board has the controller controls, condenser fan
control, evaporator control and compressor control.
Air filter
Air return filter retains impurities from air avoiding
any block of dirt at evaporator capillary tubes and
coil.
Air circulation
Air being cooled by the evaporator, then it follows
to the bus interior through fans.
Drain
It is a way to get the condensed moisture from
evaporator tubes from the condensed tray to putting
out.
MECHANIC SYSTEM
ELECTRIC SYSTEM
1
2
3
4
5Expansion Thermostatic Valve
6
7
8
9
10
11 17
12
13
14
15
16
AIR CONDITIONING OPERATION
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.
CC 336 - CC 356
9
CONTROLLERS
The SBU400 and SBU410 controllers are systems designed to control HVAC
components (heating, ventilation, cooling). In buses, for example, for ceiling air
conditioning systems, it is composed of control parts installed on the panel
(control device such as human-machine interface) and a relay board.
Controllers are available in basic (SBU400) and full (SBU410) versions. In the
basic version, the control element allows the user to control the air conditioning
system with cooling functions.
The full version has an optional heating function in addition to those standard
ones provided and can be cooling and ventilation. The controller for cooling
function can operate automatically. For this, the user simply has to set the
desired room temperature and turn on the air conditioner.
The operation described above applies to the following air conditioning systems:
SBU400:
• Air conditioning system (AC)
SBU410:
• air conditioning system (AC)
• with cooling and ventilation (VAC) function
• with cooling and heating (HAC) function
• with heating, ventilation and air conditioning (HVAC) function
The SBU400 and SBU410 AC controllers have basically the same components.
See below Functions and description.
2- SBU 400-410 Controllers 2.1- Control Panel Description
SBU400 SBU410
Item Description Function
1 Display Current room temperature and an error
warning.
2 Status light It shows an enabled function
(red status light on means it is enabled).
3 On/off button ON and OFF switch from control panel.
4 Auto button Evaporator Fan Automatic Start Up.
5 AC button Enable or Disable the cooling function.
6Evaporator fan speed button Evaporator Fan Manual Speed Control.
7Evaporator fan speed display It shows the current speed of evaporator fans.
8Temperature desired UP (set-point) button You can INCREASE the right temperature you
want to leave into the room.
9Temperature desired DOWN (set-point) button You can DECREASE the right temperature you
want to leave into the room.
10 Ventilation button On and OFF the recirculation function.
11 Free button Free.
CC 336 - CC 356
1
3
9
8
5
4
2
6
7
2
2
3
5
4
2
2
2
1
9
8
6
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10 11
10
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1
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