YILKAR YK 400 User manual
EN
YK 400
YILKAR
Installation Instruction
SSH.MT.01.10 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
00
15.03.2023
H.Kübra Şahin
First publication
REVISION NO
PUBLISH DATE
REVISING PERSON
REASON FOR REVISION
SSH.MT.01.10 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
Contents
1 Warranty and Liability ................................................................................................1.
1.2 Security and Legal Regulations ................................................................................
3.Overview ...............................................................................................................................
4. Installation of Yılkar YK 400 ................................................................................................
2 Definition and Technical Information.....................................................................................
4.1 General Assembly Diagram .......................................................................................
4.3 Hoses and Fitting .......................................................................................................
4.3.1 Air Conditioner Hoses and Fitting Connections ..............................................
3.2 General Description ....................................................................................................
3.1 YK 400 Overwiew ......................................................................................................
4.2 YK 400 Unit Mounting ..............................................................................................
4.2.1 YK 400 Unit Dimensions ................................................................................
4.2.2 Unit Positioning and Roof Mounting ...............................................................
1.2.1 ECE R-10 .....................................................................................................
2.1 What is the YK 400? ...........................................................................................
2.2 How does it work? ..............................................................................................
2.3 YK 400 Technical Data .......................................................................................
4.3.1.1. Air Conditioner Hoses ........................................................................
4.4 Electrical Connections ................................................................................................
4.4.2 Wiring and Circuit Diagram ............................................................................
4.4.1 Control Unit Mounting ......................................................................................
4.4.3 Control Unit Owerview ....................................................................................
3.1.1 YILKAR Monoblock Unit ..................................................................................
4.3.1.2. Fitting Sets ........................................................................................
4.3.1.3. Hose and Fitting Mounting ................................................................
4.4.4 Control Unit Operation ....................................................................................
4.4.4.2 Heating (Optional) ...............................................................................
4.4.4.3 Ventilating ............................................................................................
4.4.4.1 Cooling ................................................................................................
4.5 Fiber Cover Mounting ................................................................................................
Introduction...........................................................................................................................1.
5. Commissioning the Air Conditioner .......................................................................................
6. Spare Parts List ....................................................................................................................
7. Usage and Maintenance Recommendations .......................................................................
6.1. Cover Spare Parts .....................................................................................................
6.2. Condenser Spare Parts .............................................................................................
6.4. Other Spare Parts ......................................................................................................
1
2
3
4
5
6
3
4
4
6
6
7
10
10
18
9
9
10
19
19
19
23
25
26
20
21
21
26
26
26
31
32
34
28
30
31
36
6.3. Evaporator Spare Parts .............................................................................................33
1. Introduction
This instruction is part of the YK 400 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.
1
You can scan the QR code for Yılkar Klima communication.
EN
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
2
EN
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:
1.2 Security and Legal Regulations
Read this service manual carefully before operating your YK 400 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.
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.
1.2.1 ECE-R 10
3
EN
2. Definition and Technical Information
YK 400 is an innovative designed roof top air conditioner developed for air conditioning
12 mt buses.
The unit, which is easy to install, includes a condenser and two evaporators, right and
left. These units need to be mounted on the roof of the vehicle and connected to the
compressor via hoses with R134a refrigerant circulation.
With its aerodynamic design, this unit only increases the height of the vehicle by 27 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 35-40 kW, can have a heating function by joining the heat exchanger device.
Your air conditioner can use the waste heat generated in your vehicle's engine 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 400 is universal, compact and economical with all its features.
2.1 What is YK 400 ?
4
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 400
Compressor
BOCK FK40X/560K-655K
Cooling Power
35 - 40 kW
(34121 - 52888 BTU/h)
(8598 - 13327 kcal/h)
Oil Type
PAG 100 oil
Oil Amount
2 lt
Refrigerant / Amount
R 134 a / 7000 ± 500 gr
Evaporator Fan Flow Rate
7200 m³/h (for 6 Blower Motors)
Condenser Fan Flow Rate
8800 m³/h (for 4 Axial Fans)
Pressure Switch
Low pressure / 0,5-1,5 bar
Fan Control / 13-16 bar
High pressure / 21,5-28,5 bar
Dimensions
(Width x Length x Height)
2080 / 1930 / 1780 * 2450 * 270 mm
(Width is optional according to vehicle roof.)
Weight (Without Mounting Kit)
200 kg
Maximum Total Electricity Intake
85 A @24 VDC
2.3 YK 400 Technical Data
5
Table.1 YK 400 Technical Data
EN
1
3
MONOBLOCK UNIT - YK 400
1 PCS
310.02.YK400.01
1
MONOBLOCK GROUP - YK 400
1 PCS
500.23.YK400.01
2
AIR SUCTION GRILL COMPLETE - YK 400
2 PCS
501.24.HEIPL.01
3
HOSE - STEEL WIRE - SPIRAL 12 MM
25 MT
108.02.HC00M.12
2
3. Overview
3.1 YK 400 Overview
6
3.1.1. YILKAR Monoblock Unt
EN
Table of contents
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