AIR CONDITIONING SYSTEM

2 CONTENTS SENSORS - APT SENSOR - FIN THERMO SENSOR - INCAR SENSOR - PHOTO SENSOR - AMBIENT SENSOR - AQS - HUMIDITY SENSOR TEMPERATURE UNIT CHANGE CONTROL LOGIC SELF DIAGNOSIS - DTC LIST & FAILSAFE PTC HEATER SPECIFICATION INSTALL LAYOUT COOLING CIRCUIT PARTS IN ENGINE COMPARTMENT - CONDENSER - COMPRESSOR PARTS IN CABINE - HEATER UNIT - EVAPORATOR UNIT * AIR FILTER * BLOWER MOTOR * POWER TR * BLOWER RELAY ACTUATORS - INTAKE DOOR ACTUATOR - TEMP. DOOR ACTUATOR - MODE DOOR ACTUATOR

3 PURPOSE OF FATC Automatic temperature control strategy in vehicle Inference Engine Determined discharge air temperature, air volume, compressor on/ off, air discharge and inlet mode to reach & maintain the cabin comfort Setting Temperature In-car Temperature Ambient Temperature Sun load Reference Temperatures Blend door linear control (Max cool to Max hot) Blower speed linear control (Lo to Max Hi) Compressor control (ON/OFF ) Air discharge mode control(Vent, Bi level, Floor) Air inlet mode control(Fre/Rec)

4 SYSTEM COMPARISON

5 Heater unit Evaporator unit Blower unit EF SONATA HVAC UNIT HVAC unit Blower unit NF HVAC UNIT

6 SYSTEM COMPARISON FATC Control Unit Manual Control Unit

7 SYSTEM SPECIFICATION

8 INSTALL LAYOUT

9 COOLING CIRCUIT

COMPONENTS

11 CONDENSER R-134A, Parallel Flow Type Sub-Cool type Parallel Flow Type Function : The condenser changes the refrigerant from the vapor of high temperature, high pressure to the liquid of high temperature, high pressure.

12 COMPRESSOR (Variable Swash Plate) Swash plate Piston Shaft Control chamber (Pc) Control Valve Outlet chamber (Pd) Inlet chamber (Ps)

13 COMPRESSOR (Variable Swash Plate) Control Valve Control chamber (Pc) Inlet chamber (Ps) Outlet chamber (Pd) Piston Swash plate Shaft Orifice

14 COMPRESSOR (Variable Swash Plate) Operation Control chamber pressureInlet chamber pressure Control chamber pressure > Inlet chamber pressure: Swash plate angle decrease Control chamber pressureInlet chamber pressure Control chamber pressure = Inlet chamber pressure: Swash plate angle increase Control chamber pressure Inlet chamber pressure

15 COMPRESSOR (Variable Swash Plate) Operation Inlet pressure is lower than standard value ( 2.0kgf/cm 2 ). Diaphragm shrinking (Control valve open) Outlet gas enter to Control chamber (Control chamber pressure is increased.) Swash plate angle is decreased. Control chamber pressure increase Outlet chamber Diaphragm (Ps) Control valve open

16 COMPRESSOR (Variable Swash Plate) Operation Control chamber pressure decrease Outlet chamber Control valve close Inlet pressure is higher than standard value ( 2.0kgf/cm 2 ). Diaphragm expansion (Control valve close) Outlet gas can not enter to Control chamber (Control chamber pressure is decreased.) Swash plate tilting angle is increased.

17 COMPRESSOR (Variable Swash Plate) Operation Diagram Inlet pressure decreasing. Outlet chamber Inlet pressure < Control valve standard value Evaporator load decreasing Inlet pressure increasing. Inlet pressure > Control valve standard value Pressure detecting Standardize the inlet pressure Standardize the Venting temperature Clutch Cycling Prevention Iimprovement in Fuel Consumption Engine Surge Prevention Control chamber pressure increasing Control valve open Evaporator load increasing Pressure detecting Control chamberOutlet chamber Control valve close * Swash plate tilting angle decreasing. * Outlet flux decreasing. * Swash plate tilting angle increasing. * Outlet flux increasing. Control chamber pressure decreasing

18 HEATER & EVAPORATOR UNIT Vent DEF Foot Blower connecting Drain hose

19 EVAPORATOR UNIT

20 EVAPORATOR UNIT

21 EVAPORATOR AIR FILTER 1. DESCRIPTION Employing combination filter, dust and odor in the air is effectively removed. 2. LIFE TIME Filter replacement period is 5,000~12,000km. But this can be shorten if the road condition is bad causing more dust and black smoke in the air. 3. HOW TO REPLACE Remove the glove box. Pull the locking part of the air filter cover

22 BLOWER MOTOR ASSEMBLY + PIN- PIN Motor : magnet motor(φ70) Rated voltage : 12V Without load - speed : 3,300 rpm (min) - current : 3.0A (max) Temperature range in use : -30 ~ 80

23 BLOWER SPEED CONTROL DEVICE 1. POWER TRANSISTOR

24 BLOWER SPEED CONTROL DEVICE POWER TRANSISTOR INSPECTION METHOD 1 M Battery IG2 Blower Motor Measure voltage v CONTROLLER Power TR High Speed Blower Relay B C E * Condition: IG ON, FATC ON

25 BLOWER SPEED CONTROL DEVICE POWER TRANSISTOR INSPECTION METHOD 2 M Battery IG2 Blower Motor Measure voltage v CONTROLLER Power TR High Speed Blower Relay B C E v * Condition: IG ON, FATC OFF Measure voltage: Variable (up/down blower speed switch) * Caution: Do not pull off the TR during blower operation.

ACTUATORS OUTPUT ACTUATOR OPERATION & INSPECTION

27 INTAKE ACTUATOR Intake Actuator Location

28 INTAKE ACTUATOR Intake actuator AB M

29 TEMPERATURE DOOR ACTUATOR Temperature Control Door Actuator Location

30 TEMPERATURE DOOR ACTUATOR CoolWarm 4.7V 0.3V 2.5V * Feedback line open or short: : MAX Cool : MAX Warm Temp. actuator AB M

31 TEMPERATURE DOOR ACTUATOR M M TEMP DOOR ACTUATOR controls the position of the temperature blend door based on the voltage signal from the FATC module. Potentiometer inside actuator sends a feedback signal to the controller and controller cuts off the the voltage signal coming from the controller when the required door position is achieved. [POTENTIOMETER CHARACTERISTICS] 2±2 COOL HOT 4.7V 0.3V

32 MODE DOOR ACTUATOR

33 MODE DOOR ACTUATOR VENT 4.5V 0.4V 2.45V B/LFLOORMIXDEF 1.63V 3.5V Mode actuator AB M

SENSORS INPUT SENSOR OPERATION

35 FIN SENSOR 1. DESCRIPTION Fin sensor is installed in the evaporator in order to detect the temperature of evaporator. It prevents evaporator from freezing. 2. FIN SENSOR LOCATION : inserted into the evaporator pin

36 FIN SENSOR CHARACTERISTICS OF FIN SENSOR ON/OFF TEMPERATURE: 0.6 OFF 2.1 ON

37 FIN SENSOR AB Fin thermo sensor

38 Humidity sensor In-car sensor IN-CAR SENSOR The in-car sensor is located on the crash pad as shown in the picture. It contains a thermister, which measures the temperature of the air inside the passenger compartment. It senses the passenger compartment temperature, changes the resistance value, and enters the corresponding voltage into the automatic temperature control module (FATC).

39 IN-CAR SENSOR In-car sensor AB M IG 2

40 PHOTO SENSOR The photo sensor is located on the center of crash pad assembly. It contains a photovoltaic (sensitive to sunlight) diode.

41 PHOTO SENSOR AB

42 AMBIENT SENSOR The ambient temperature sensor is located in front of the condenser fan shroud. This sensor detects the temperature of outside air and sends voltage signals to the controller. AQS sensorAmbient sensor

43 AMBIENT SENSOR AB Ambient sensor [Sensor characteristics]

44 AIR QUALITY SYSTEM The Air Quality System detects exhaust gas of neighboring vehicles and intercepts automatically. AQS controls the inlet of car automatically and can be easily installed to the existing vehicle. Manual operation is also available. AQS sensorAmbient sensor

45 AIR QUALITY SYSTEM * LOCATION: In front of condenser

46 AIR QUALITY SYSTEM IG 12V Output GAS detected (REC) Normal (FRE) M ccwcw Intake Actuator FATC CONTROL MODULE - Normal 5V - Gas detected 0V AQS

47 HUMIDITY SENSOR Humidity sensor detects the relative humidity of the cars cabin. This sensor converts it into the voltage signal and sends the signal to the FATC controller. 1. SENSOR CHARACTERISTICS

48 HUMIDITY SENSOR AB

49 APT SENSOR The APT (Automotive Pressure Transducer) is a capacitive– based sensor, it senses the pressure of the refrigerant that provides a linear voltage output directly proportional to applied pressure. Evaporator Condenser Comp. Receiver Expansion valve APT SENSOR - Engine Idle Control - Cooling Fan Control - Compressor Control - High Pressure Cut-out - Low Pressure Cut-out PWM Multi Speed Cooling fan ECU (Engine Control Unit)

50 APT SENSOR

51 APT SENSOR Refrigerant pressure Connector Base Terminal (3EA) Flexible Circuit Ceramic Substrate Ceramic Diaphragm O - Ring Silver Epoxy Pin RTV * Flexible circuit changes the pressure to voltage. * Ceramic diaphragm detects the refrigerant pressure.

52 APT SENSOR Ceramic Substrate Glass seal Ceramic Diaphragm ASIC PRESSURE VOLTAGE SourceGuardDetect Signal Conditioner Ceramic Sensing Element

53 APT SENSOR DETECT SOURCE GUARD (GND) d * The main function of APT sensor is detecting the refrigerant pressure (distance d). Ceramic Substrate PRESSURE Ceramic Substrate Glass Seal Ceramic Diaphragm

54 APT SENSOR A. There is 0.2V(not 0V), if the refrigerant line pressure has gone to 0, for communication to engine ECM. (0V means poor contact or open circuit) B. There is 4.8V, even if the line pressure is over the standard value (high pressure). (5V means short circuit) Approximately 0.2V Pressure (kg/ ) Approximately 4.8V Normal Operating range OUTPUT (Vdc)

55 APT SENSOR APT sensor AB ECMECM 5V

56 WATER TEMPERATURE SENSOR

57 WATER TEMPERATURE SENSOR WTS sensor AB

58 COOLING FAN PWM Motor ShroudFan

59 COOLING FAN * 1.0kgf/cm2 = psi

60 TEMPERATURE UNIT CHANGE * Setting unit: (Battery disconnection) Temp unit change: * How to operate Keep pressing Press for 3 seconds or more

61 CONTROL LOGIC 1. In-car temperature correction When the in-car sensor detects a sudden steep temperature change, controller corrects the temperature differences slowly. - 1 up / 4sec delay - 1 down / 4sec delay 2. Ambient temperature correction When the ambient sensor detects a sudden steep temperature change, controller corrects the temperature differences slowly. - 1 up / 3 min delay (ex. Underground, tunnel) - 1 down / 4sec delay

62 CONTROL LOGIC 3. Heat radiation correction When the photo sensor detects a sudden steep solar radiation change, controller compensates it slowly (W/m 2) / 1 min delay (W/m 2) / 5 min delay 4. Temp. door control Temp. door angle (0% ~ 100%) is automatically controlled according to the selected temperature and other sensor signals. : Available selected temperature range - MAX COOL: 17 - MAX HOT: , 0.5 step (62 90, 1 step)

63 CONTROL LOGIC 5. Blower speed control - AUTO mode: linear control - MANUAL mode: 7 step control 6. Mode control - AUTO: Mode changes automatically according to the selected temperature and other sensor signals. - Manual: Mode changes when the mode switch is selected. VENT B/L FLOOR MIX VENT

64 CONTROL LOGIC 7. Intake door mode - The Fresh/ Recirculation door state can be changed at AUTO mode according to the input data combination. 8. Compressor ON/OFF control (AUTO mode) - Fin sensor: lower 0.5 Compressor OFF over 3 Compressor ON 9. Max. Warm function (When 32 is selected at AUTO mode) Temp door: Max. Warm side Mode door: Floor mode Intake door: Fresh mod Compressor: Off Blower speed: Auto high

65 CONTROL LOGIC 10. Max. Cool function (When 17 is selected at Auto mode) Temp door: Max. Cool side Mode door: VENT mode Intake door: REC mode Compressor: ON Blower speed: Max. High FATC - Auto Mode - A/C ON - FIN sensor > 30 Condition Output - Blower Speed: Auto low: 12 seconds Auto low Auto high: 30 seconds Control 11. Warm Air Prevention Function (Initial A/C operation)

66 CONTROL LOGIC 12. CELO (COLD ENGINE LOCK OUT) FUNCTION OPERATING CONDITONS 1. Ambient temp Water temperature: below Mode: Auto or Floor 4. Blower: Auto Operation release - When the occupant operates DEF switch. - When the occupants select Max. cool(17 ). - When the detected temperature by WTS exceeds 73.

67 CONTROL LOGIC 12. CELO (COLD ENGINE LOCK OUT) FUNCTION Water coolant temperature Mode Blower Volt DEF MIX Auto control Auto low Blower speed is depended on ambient temperature. Auto high

68 CONTROL LOGIC 13. MIX / Defrost control 1. Mode door: Mix or Def 2. Intake door: Fresh mode (REC mode can be selected.) 3. Compressor: - It depends on the evaporator temperature. - If ambient temperature is below 3.5, A/C OFF. (General market) * On (North America market only) 4. Def function has higher Priority than Max. Hot/Cool function. 5. Def function has higher Priority than Mix Mode.

69 DIAGNOSIS Ignition switch : OFFON Return to original condition Press the MODE switch more than 4 times within 2 seconds during pressing the OFF switch. After graphic symbol display blinks 3times, start self-diagnosis. Self-diagnosis (Step operation) Self-diagnosis (Continuous operation) Press AUTO Press OFF

70 DIAGNOSIS DTC LIST & FAILSAFE

71 DIAGNOSIS Using Hi-scan pro The FATC module communicates with high-scan and diagnosis test feature will detect electrical malfunction and provide error codes for system components with suspected failures.

72 DTC LIST & FAILSAFE