AIR CONDITIONING SYSTEM

2 CONTENTS ACTUATORS - INTAKE DOOR ACTUATOR - TEMP. DOOR ACTUATOR - MODE DOOR ACTUATOR SENSORS - 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 PARTS LOCATION INSTALL LAYOUT COOLING CIRCUIT PARTS IN ENGINE ROOM - CONDENSER - COMPRESSOR - RECEIVER & DRIER - TRIPLE SWITCH FATC INPUT & OUTPUT PARTS IN CABIN - HEATER UNIT - EVAPORATOR UNIT * AIR FILTER * BLOWER MOTOR * POWER TR * BLOWER RELAY

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 SPECIFICATION

5 PARTS LOCATION A : A/C Relay B : AQS Sensor C : AMB. Sensor D : Photo Sensor E : FIN Thermo Sensor F : In-car Sensor G : FATC Controller H : High Blower Relay I : Power TR J : Humidity Sensor K: Blower Relay A B C E G H D I K F,J

6 INSTALL LAYOUT

7 COOLING CIRCUIT Blower Motor Evaporator Expansion Valve Heat absorbed Compressor Condenser Heat removed Receiver Drier

PARTS IN ENGINE ROOM

9 CONDENSER R-134A, Parallel Flow 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.

10 COMPRESSOR (SWASH PLATE TYPE)

11 COMPRESSOR (SWASH PLATE TYPE) Discharge valve Valve plate Suction valve Piston Swash plate Shaft seal Shaft Ball

12 COMPRESSOR (SWASH PLATE TYPE) : Release the high pressurized refrigerant and oil - Operating pressure: 35.3~42.2kg/ SAFETY VALVE (Pressure Relief Valve)

13 RECEIVE AND DRIER 3) Vapor Bubble Separation 2) Refrigerant Storage Vapor Liquid DESICCANT FILTER PAD FUNCTION 1) Refrigerant Purification

14 TRIPLE SWITCH

15 TRIPLE SWITCH Medium (3) Medium (4) Low & High (1) Low & High (2) LowHigh Middle (1) (3) (4) (2) Electric Diagram Low & high switch : Compressor control Middle switch : Condenser fan control High Middle Low ECM

16 TRIPLE SWITCH Pressure (Kg/cm 2 ) CompressorCondenser FanRemark ON OFF 2.3 ~ ~ ~ 26.0 ~ ~ 2.0 Pressure increasing Pressure decreasing Excessive pressure 1. COMPRESSOR & CONDENSER FAN CONTROL TABLE

17 TRIPLE SWITCH LOW & HIGH SWITCH (kg/cm 2 ) MIDDLE SWITCH (kg/cm 2 ) ON OFF 14.0± ±0.8 ON OFF 2.0± ±0.2526±2.0 32±2.0 (High switch) (Low switch) (Middle switch) 2. SWITCH ON & OFF RANGE

18 TRIPLE SWITCH MM A/C COMP. MID HIGH/ LOW A/C output B+ A/C ON input A/C pressure switch input FIN SENSOR A/C RELAY CON. FAN A/C relay control ECM FATC CONTROL MODULE

19 FATC INPUT & OUTPUT CONTROL MODULE CONTROL MODULE AQS SENSOR AMB SENSOR FIN SENSOR INCAR SENSOR PHOTO SENSOR HUMIDITY SENOSR MIX PBR INTAKE SWITCH TEMP. SWITCH BLOWER SWITCH MODE SWITCH OFF SWITCH AUTO SWITCH A/C SWITCH AQS SWITCH DEF SWITCH DISPLAY HI SPEED BLOWER RELAY HI SPEED BLOWER RELAY POWER TR TEMP ACTUATOR MODE ACTUATOR ECM MIX DOOR MODE DOOR COMPRESSOR INPUT OUTPUT BLOWER SPEED INTAKE ACTUATOR AQS CONTROL INTAKE ACTUATOR AQS CONTROL INTAKE DOOR

PARTS IN CABIN

21 HEATER UNIT Function : When engine coolant is allowed to flow through the heater core, heat from the coolant is transferred to the cooler air flowing through the fins of the heater core and into the passenger compartment.

22 HEATER UNIT FRE REC BLOWER MOTOR EVAPORATOR HEATER CORE FLOOR MODE DOOR VENTMIX DEF INTAKE DOOR TEMP. DOOR (MAX HOT)

23 HEATER UNIT FRE REC BLOWER MOTOR EVAPORATOR HEATER CORE FLOOR MODE DOOR VENTMIX DEF INTAKE DOOR TEMP. DOOR (MAX COOL)

24 EVAPORATOR UNIT

25 EVAPORATOR UNIT

26 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 Air filter cover Air filter

27 EVAPORATOR AIR FILTER CAUTION!! Make sure that mark on the filter.

28 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

29 BLOWER SPEED CONTROL DEVICE 1. POWER TR Blower relay High speed blower relay Power TR

30 BLOWER SPEED CONTROL DEVICE POWER TR AND PIN ASSIGNMENT Base CollectorEmitter

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

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

33 BLOWER SPEED CONTROL DEVICE 2. HIGH SPEED BLOWER RELAY

ACTUATORS OUTPUT ACTUATOR OPERATION & INSPECTION

35 INTAKE ACTUATOR Intake Actuator Location

36 * Check the voltage pressing the intake switch INTAKE ACTUATOR FATC M CCWCW REC FRE REC FRE TERMINAL NO. NO. 1NO. 2MODE V 21

37 TEMPERATURE DOOR ACTUATOR Temperature Control Door Actuator Location

38 TEMPERATURE DOOR ACTUATOR FATC M MICOM 5V (+) CoolWarm 4.7V 0.3V TEMP S/W 2.5V * Feedback line open or short: : MAX Cool : MAX Warm 17 32

39 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

40 MODE DOOR ACTUATOR Mode Door Actuator Location

41 MODE DOOR ACTUATOR FATC M MICOM 5V (+) VENT 4.5V 0.4V MODE S/W 2.45V B/LFLOORMIXDEF 1.63V 3.5V

SENSORS INPUT SENSOR OPERATION

43 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

44 FIN SENSOR CHARACTERISTICS OF FIN SENSOR ON/OFF TEMPERATURE: 0 ~ 0.5 OFF 3.5 ~ 4 ON

45 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).

46 IN-CAR SENSOR INSPECTION Type : Activity In-Car Sensor Resistance characteristic NTC( Negative Thermal Coefficient) * MEASUREMENT

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

48 PHOTO SENSOR INSPECTION 60w ^ ^ (Over 0.45V ) 10 ~ 15cm Characteristics of photo sensor

49 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.

50 AMBIENT SENSOR FATC MICOMMICOM 5V Sensor Ground Voltage Detection b a INSPECTION Reference Voltage * Resistance between a & b Resistance characteristic: (NTC: negative thermal coefficient)

51 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.

52 AIR QUALITY SYSTEM * LOCATION: In front of condenser * AQS SWITCH

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

54 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

55 HUMIDITY SENSOR HUMIDITY LOGIC Humidity range(control) (not control) Humidity range(not control) AMB:2 AMB:4 There is no Humidity control when AUTO 32 selected. There is no Humidity control,if humidity sensor s output is below 5,850hz or over 7,220hz.

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

57 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

58 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)

59 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

60 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

61 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)

62 CONTROL LOGIC 12. CELO (COLD ENGINE LOCK OUT) FUNCTION OPERATING CONDITONS 1. Ambient temp Indoor temp. – ambient temp Mode auto 4. Blower auto Under the theses conditions, floor mode operates and blower motor runs low speed to avoid a direct contact of cold air from outside with occupants. FUNCTION PROHIBITION - - When the occupant operates Blower switch. - - Indoor temp. – ambient temp. > 10 - When the occupants select Max. cool(17 ).

63 CONTROL LOGIC CELO (COLD ENGINE LOCK OUT) CHECK Blower Motor Mode DEF Auto (Floor) Auto High Auto Low A60 seconds Ambient Temp. ( ) Time (A) ~ ~ ~ ~ min. 6 min. 4 min. 2 min.

64 CONTROL LOGIC 13. Compressor control A. Compressor control for evaporator temperature Function : Protect compressor during winter season Control pattern : 1 3 Comp. off Comp. on B. Compressor control for ambient temperature Function : Protect compressor during winter season Control pattern : 2 4 Comp. off Comp. on

65 CONTROL LOGIC 14. Defrost control Mode door: Defrost mode Intake door: Fresh mode (REC mode can be selected.) Compressor: - It depends on the evaporator temperature. - If ambient temperature is below 2, A/C OFF. Def function has higher Priority than Max. Hot/Cool function. Def function has higher Priority than Mix Mode.

66 SELF DIAGNOSIS Ignition switch : OFFON Return to original condition Press the OFF switch more than 4 times within 2 seconds during pressing the AUTO switch After VFD display blinks 3times per 0.5 seconds, start self-diagnosis. Self-diagnosis (Step operation) Self-diagnosis (Continuous operation) Press AUTO Press OFF

67 DTC LIST & FAILSAFE

68 PTC HEATER Heating theory : To use the battery power supply, to be ignited in heater assembly, heating the air.

69 PTC HEATER PTC Heater operation condition * Engine rpm: Over 700 RPM * Ambient temperature : Below 5 * Battery voltage : 8.9V -OFF, 12.5V -ON * Engine coolant temperature : Over 70 * Blower motor: ON * Operating time: 6o minutes PTC ON PTC OFF 600(rpm)700(rpm) PTC ON PTC OFF 8.9 (V)12.49 (V) PTC Heater operation pattern * Engine rpm: * Battery voltage

70 PTC HEATER Block diagram Engine ECM Heater/ Air conditioner Controller Relay # 1 Relay # 2 Relay # 3 Relay operation Blower motor operating signal Relay operation signal Operation condition Satisfaction PTC 1(15 seconds) PTC 1 + 2(15 seconds) PTC (15 seconds)

71 PTC HEATER HEATER CORE AIR DEF DOOR VENT DOOR FOOT DOOR PTC HEATEREVAPORATOR

72 PTC HEATER PTC Heater operation check 1. Method Mode: Vent, Bi-level or Floor Temperature: Full warm (HI) Blower motor: Off (Press Off button) Air intake switch: Press the intake switch for 5 seconds. 2. Control LCD display blinks 30seconds per 0.5seconds. Blower switch: Press the blower switch. PTC Heater relay 2 and 3 operates for 30seconds. 3. Operation release Press A/C or Intake switch, or ignition switch off. After PTC Heater operation for 30 seconds, it will turns off automatically. It will go to initial condition (A/C off, Fresh mode), when PTC Heater operation checks release.