Can System User Manual
Contents
1. HELM O ot 30 86830 L SE T j 2 L ee ee eee Ess SSS LUNA SZLEX amp nr rrr ping Layout P CA COACHAIR BMS38BX1 A C System Operation amp Overview Manual BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 6 2 Major Components COMPONENT DETAILS AND FUNCTION Compressor ompresses low pressure low temperature refrigerant vapour to a high pressure high temperature gas condenser Sous Transfer heat from the refrigerant into the ambient air causing the high pressure high temperature gas to condense into a high pressure liquid CORGERSET Fans Draw air in the side grilles through the condenser coils and force it out through the other side grilles In case of high pressure the valve opens at 2 900 kPa to vent excess pressure to atmosphere The valve reseats at when the system pressure then reduces to 2 700 kPa RECO Tank Stores and separates high pressure liquid from the gas liquid mixture incoming from the condenser coils to ensure that only liquid refrigerant passes on to the TX valve Ball Valve ogether with the solenoid valve enables the Filter Drier2. Operation amp Overview Manual CA COACHAIR 1 3 System Layout The typical configuration of the installed BMS38BX1 A C system and it various components are shown in the following diagram DASH PANELS XT BMV5 5 ae ze ER v 5 5 XT DASH HARNESS mA LA w 7 CONTROL E i HARNESS a aoe Pei k INSULATED D P ua REFRIGERANT LN ENT LINE 1 2 e EE E AC UNT XT175 SULATED In s SOLENOID REFRIGERANT LINES 1 1 E 1 3 8 VALVE XT COMPRESSOR X BMV POWER CABLE POWER CABLE AE ae CONNECT TO BUS 00 BOWER SUPPLY 78 ALYE HOT WATER bi INSULATED REFRIGERANT LINES 3 4 LES taney LINE 5A INSULATED REFRIGERANT LINE FA WATER BOOSTER PUMP BUS ENGINE z REGULATOR BOCK oem Drawing No T3381007 Issue A 1 3 1 XT175 Roof Top Unit Drawing No T3381002 Issue 00 PRESSURE RECEIVER TX VALVES m HOT WATER 7 BALL SIGHT FILTER DRIER RELIEF TANKE w 1 TOANDFROM VALVE GLASS Fl ENGINE BAY F F ES ACCESS VALVE i Ae E TT T gt REFRIGERANT TO 7 VALVE DASH UNIT m AL VE id NC EV AP ORAT OR c ONDEN SER ELECTRICAL X WHEEL IL REFRIGERANT SOLENOID j E TO AND FROM VALVE MOTOR FAN COMPRESSOR HEATER COIL MOTOR Document Number S
3. 3 i 5 j 5 100710011 H03 5 1813828 N3 HSTTHNI EZ m T 1 MOTIV OL LNIAIND3 HO 3985 MO18 MOIS YSZ 01 7 1381108 381 IHL uu s 83111121230 3I10102 SHIM SNIOSO3Md MHSENDN 1 I aan ms l won n 38 ALON 5 t HE ET let is Bee perenne Fe ll L meon Wier OPI S UNI 2 LT rrr a E Ho P que eur eee UE og ssi NERO dE 5 a a mis lene B s i S o 2 5 d eos ls 7 4i 1 za a ewm bu ow AR vun S 7 PE m w ICE 1 I naues 7 In I 0 i l ow tx i HEBER e ire E E AMICUS acd Mr s i H 2018 8 PENA UE m Li MES NDLLO INNOO ns WOLLEN ASH 1 E f m aA Pd za EI TER Sa TT al FW adding SMe CA COACHAIR Manual rview BMS38BX1 A C System Operation amp Ove Diagram ring i 2 8 3 BMV5BX5 W The wiring for the driver s unit is shown below BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 2 8 4 Connect A C System to the Bus The driver s unit is powered through a six pin plug on the main harness The wiring on the bus required for this plug is shown below The plug on the bus is a Carroll male QK6BLT connecting to the equivalent female plug on the relay harness 22 BLE 1 5mm BLACK IGNITION ji F TO BUS
4. Coachair AN SES m TNR IN 4 D E L 4 _ Y A As T p E Rooftop Air Conditioner BMS38BX1 OPERATION MAINTENANCE amp OVERVIEW MANUAL Heat Cool Model with Drivers Unit Document Number SM424 3381 Revision No 00 Issue Date Oct 2006 Uncontrolled Copy Please refer to the Network for the current issue of this manual BMS38BX1 A C System Operation amp Overview Manual CA co ACHAIR me mem gt gt gt m Oct 30 2006 First Release CR 12098 Released 3 October 2006 Winfried Wirfler Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 2 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR NOTICE The information in this manual is subject to change without notice Coachair shall not be liable for technical or editorial errors or omissions contained herein No part of this manual may be photocopied or reproduced in any form without prior consent from Coachair Coachair CUSTOMER SUPPORT INQUIRIES Australia Malaysia China Telephone 61 2 9830 7132 60 3 61208760 86 519 5125568 Facsimile 61 2 9672 1082 60 3 61208712 86 519 5113086 Address 3 Distillers Place Lot No 9 Jalan Empat No 268 West Hehai Road Xinbei District Huntingwood 2148 Kawasan Perindustrian Australia Selayang Off Jalan Besar Changzhou City Bandar Selayang
5. Jiangsu P 68100 Selangor D E Malaysia WEB www aitransit com Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 3 CA COACHAIR IMPORTANT INFORMATION Use R134a Refrigerant Only The A C system is designed for use with R134a refrigerant Do not use any other refrigerant The use of any other refrigerant may result in damage to the A C unit and or compressor Use Ester Oil Only The A C system is designed for use with ester compressor oil Do not use any other lubricating oil The use of incorrect oil may result in damage to the A C unit and or compressor Handle Electronics With Care Do not attempt to remove repair or handle the climate control panel or any components in any way without referring to the correct procedures The electrical control panel houses sensitive equipment that may be damaged if handled incorrectly Refer to the CCC007 Climate Control System Manual for electronics service details Temperature Probes Each temperature probe in the unit is factory calibrated Use Probes as they have been allocated DO NOT swap or mix the probes as this may lead to unit damage and faulting 24V DC ONLY This unit is designed for a 24V DC electrical circuit ONLY Do not under any circumstances use another voltage as this may cause unit damage and faulting There is power to the motors all the time Never attempt to
6. 0 Ss BE EJ 0 8 Zi ONO 8 E S S OH NYA OF X VW M3HOSISS corti 9f I O m Lus zese l HAMOI NDLLWINSN 519226 Zosieees BE 30v4 ONILNTON fae U oe 370113580 S lt ES 102 H31V3H NOLL SN 2 0615 658 6E U3MO18 OL ES 1100 3 6 PP c JzS 75 Ot 2 Lu o m m A 00 CA COACHAIR BMS38BX1 A C System Operation amp Overview Manual Page 41 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Document Number SM424 3381 v t 701009 AB 036 0 7 9010140 SELNSINIOOO O3Qsva ds 11098 AJIHL ONO IV Was OL SI S WALI L 3LON FAIS FAME POE aq Op UE HAUSE Y Z OIN 9q 0 WE SPAM vf l payiasds asaya ssa SILON a ee 5 35713138 TT SAL DO Ye SHEL zu Tun aionaios on Y YY roni DNA MN d ar F Sd LEHL Tw NOLLWONIELUMI Ie C NOCERE NOL LS DCL LS CUL Bo ON Ice Wi nica Lele e jer ide J on BRISTOL G3 NIAC IN EMIO ONV NOSSO 111 GEE OO DOC MEY ELM 01 1 Abed LIEN L TENOLEVNHSIMI iT renee 538 2300 NI SNOISN3SINIC DHI Lote LAE LL UN d Sd 3110 5 JATHA 3107 GL ISTE AY JH UT x XOU aon g
7. 24V VE a 2 5mm RED AN ES 24V POWER P 3 2 8 5 Install Dash Panel and Harness The dash panel is to be installed on the vehicle dashboard with the cut out shown below 158 CUTOUT 12 x 12 CHAMFER TYP e Fixthe dash panel using the four mounting holes The dash harness connects from the dash panel to the relay harness on the evaporator unit control e Runthe cable along the shortest path e Secure the cable against vibration and shock e Keep the cable away from heat and electrical emissions Do not run the dash harness with the battery cable or any other electrical wiring unless it is unavoidable 2 8 6 Install Solenoid Valve Wiring The solenoid valve acts as surrogate compressor clutch for the driver s unit A 2 pin Carroll male QK2BSL connector is required on the cable connecting to the driver s unit Wiring should be as shown in Section 2 8 3 BMV5BX5 Wiring Diagram 2 8 7 Install Water Modulation Valve wiring The Coachair supplied cabling is used to connect the water modulation valve Harnesses should be as shown in Section 2 8 2 BMV5BX5 Harness Arrangement Detail 2 8 8 Check Operation of All Fans Check the operation and rotating direction of the evaporator blower immediately after installing the electrical harnesses before refrigerant charging BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR SECTION 3 Testing and Commissioning The commissioning
8. 8 Electrical SY SUC MN ase xes ERE vas RIVE WERDE M RII M EVI MIT Te IPIE an 17 SECTION 2 Installation mmm 19 2 1 Installation CHec NIS E RASA ETE EREE FRE SP MDPI TEN RM ESSI UN 19 2 2 Db EnsDOCEOLle uio eie ena a a a eae ee ee 19 2 3 Ducting amp Vent Distribution 5 5 61 nennen nnne 20 2 7 NMI MOUNINO a ee ere eee cet D UU 21 225 Sese oa B ga Speen T TEES 21 2 5 RETMIGEr ANON FADING assueta 22 2 7 Heating System Components nar nennen aane nen nnn aaa 22 2 5 EECC TNStGNAUOH E EE 23 SECTION 3 Testing and Commissioning eene 26 SECTION 4 Operating the A C Unit eem mmn 27 SECTION 5 Trouble Shooting een 28 SECTION 6 Maintenance Schedule enn nmn 33 SECTION 7 Maintenance Procedures 33 7 1 Pumping DOWD the 39 SLOW suse lS aie Opa SDs OS pa RS Se 33 7 2 Reclaiming 1 8100 70 o o 33 Fais NEU e EE 33 2 5 6 39090161 D r 33 7 5 Refrigerant Charging 33 7 6 Safety Device Checks 34 SECTION 6 Sale aerer E 35 8 1 Compre
9. BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 2 4 Unit Mounting Refer to the SM417 manual for the XT Unit The driver s unit is secured to the bus via 4 brackets 2 at the front and 2 at the rear Sufficient clearance is required at the back of the unit to allow the access cover to be removed for access to the de ice thermostat and evaporator motor Typically the unit must be removed from the return air side so the bulkhead it is attached to must also be removable or an alternate method of removal say by taking the bonnet off the bus must be identified 24 5 451 6 5 TYP r 7 1 eel test I Drawing No T3381507 Issue 00 2 5 Condensate Drains Refer to the SM417 manual for the XT Unit Included with the driver s unit are 16mm PVC pipe 2x aluminium tubes e 2x Drain nozzles e 4hose clips The standard configuration of drain hoses is shown below T dme 575 i Ta ae P db 6 1085 E apr SEE pow N Oh eA DETAIL A o 7 a o Lig o Em En H TF o e fre en y 2 M 2 i 2 FE N j ML 70000 i i 1 UNDERSIDE OF BUS 2 Lu i i j DETAUR Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 25 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR Drawing No 3381508 Issue 00 When
10. Date October 2006 Page 18 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR SECTION 2 Installation Refer to the SM417 manual for the XT Unit 2 1 Installation Checklist e Check off all items e Inspect the evaporator units and loose items e Check for correct preparation of mounting locations e Check the ducting and distribution vent system e Install the evaporator and loose items e Install the return air grille e Install the condensate drains e Install refrigeration piping e Connect the piping to the evaporator and piping panels e Connect the piping to the XT system e Install heating system components e Install driver dash panel e Install electrical harnesses e Pressure test of the system e Evacuate the system e Charge the system with refrigerant e Finalise heating system installation e Check safety devices e Complete post installation checklist 2 2 Unit Inspection Before beginning the installation perform a visual inspection of the units Check to make sure no damage has occurred during shipping e No external damage to the casing No damage to coil fins or other external components e 5 10 mm clearance between the condenser fan blade and top grille REPORT ANY VISIBLE DAMAGE Do Not Remove Sealing Caps Do not remove the refrigeration sealing caps before installing the unit The sealing flange is to be removed immediately before connecting the body
11. On Off Illuminates when the A C system is providing cooling operation When switched on the Switch compressor clutch engages regardless of ambient conditions 4 1 2 Damper Motor Controller There are three lights green orange amp red on the damper motor controller which operate as follows e Green Blinking Damper moving to top position e Green Solid Damper in top position e Orange Blinking Damper moving to bottom position e Orange Solid Damper in bottom position e Red fault present Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 30 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR SECTION 5 Trouble Shooting Refer to SM417 amp SM423 manuals for operating the XT175 Unit e Where there is a conflict between instructions the XT175 instruction should take priority e For the Driver s A C system to provide cooling the XT175 must be put into A C mode and be operating 5 1 1 System will not start COMPLAINT INDICATION CAUSE REMEDY Electrical eompaanerib will Bown fuse 7 Check all terminals for la not operate Braken or disconnected wires Pesca Replace fuse conte switch in Main contol such te OFF position DRIVER ar DEMET podton 5 1 2 System produces no Heating COMPLAINT INDICATION CAUSE REMEDY 5 Sim hise fuse Check all terminals Ne Hot
12. details The XT175 and BMV5BX5 unit should use 3 4 water pipe The booster pump should be installed between the motor and the take off to both units See the diagram in Section 1 6 1 Refrigeration Piping and Connections Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 26 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 2 8 Electrical Installation Refer to the SM417 manual for the XT Unit 2 8 1 Typical Wiring Harness Layout BMS38BX1 BES DASH PANEL XT DASH PANEL m eet ue i CACHAN LATE COSTROLLUEM 2 E E i Gd 0 Md e uw o o A 9 oj a 78 UNIT lt ROOFTOP UNIT 25 AMP CONTROL PANEL FUSE E Soe POWER i voc L e EP IGNITION ES me tk DASH EARTH WATER VALVE A BOOSTER B E wi BOOST PUMP 3 S 3 x 754 DAMPER Ei CONTROLLER i m S AMF FUSE c d 4 COMPRESSOR CLUTCH HP SWITCH e BUS BATTERY BUS BUILDERS SUPPLY Drawing No 3381008 Issue A 2 8 2 BMV5BX5 Harness Arrangement Detail The harness arrangement for the driver s unit is shown below CHARGE POT ANG OM OFF R R SWITCH b SWITCHES 3 73 E z 4 PIN
13. installing drain hoses the following notes must be adhered to e Route drain hoses to the bottom of the bus but to an area protected from road dirt and mechanical damage e Do not route the flow line uphill e Use correct size hose clamps and tighten securely e Make sure that there are no kinks or restrictions in the hoses at any point e Install drain nozzles to prevent air drawing up the drain hoses 2 6 Refrigeration Piping The diagram in Section 1 6 1 Refrigeration Piping and Connections shows the refrigeration piping circuit Refer to SM417 manual for typical detail on installing and connecting refrigeration piping 2 6 1 Refrigeration Piping Considerations For installation of the refrigeration piping Coachair recommends the following Only use the recommended pipe sizes SUCTION PIPING 1 3 8 OD copper XT175 unit 7 8 OD copper 5 8 in vertical rise BFW5BX5 DISCHARGE PIPING 1 1 8 OD copper LIQUID LINE 1 2 OD copper BMV5BX5 unit 2 6 2 Suction amp Discharge Piping Panels The driver s unit has two piping panels supplied loose These contain the components required for the suction and discharge lines for the driver s unit The water modulating valve is also included on the suction panel These panels should be installed and connected as per the refrigeration diagram Drawing No T3381501 Issue 00 Drawing No 13381502 Issue 00 2 7 Heating System Components Refer to SM417 manual for typical water piping
14. the 6 pin plug from the evaporator unit to the bus battery Coachair recommends that a 25A slow blow fuse is installed on the power supply line as close as possible to the battery pack See Section 2 8 4 Connect A C System to the Bus Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 17 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 8 2 Ground Connection The ground line is a black cable in the 6 pin plug from the evaporator unit to the bus frame chassis See Section 2 8 4 Connect A C System to the Bus Use a Multi Meter Only DO NOT make a bridge connection between any terminals or use a test light This may cause serious electrical damage to the unit and or injury Use a multi meter only 1 8 3 Temperature Probes Evaporator De Ice Probe The evaporator thermostat has a probe which is inserted into the fins of evaporator coils to measure the actual coil temperature The de ice probe are housed in stainless steel shafts to provide adequate strength amp protection as well as optimum contact with the coil fins 1 8 4 De Ice Control Should the evaporator coil temperature drop too low ice may begin to form on the coils blocking airflow and compromising A C unit operation To prevent this situation the thermostat reduces cooling by cutting power to the clutch and unloaders if available when the coil te
15. 200 8 2 Drivers Unit Dash Panel O DEMIST CA HIGH O q CLIMATE CONTROLLER ep LS OFF MED O OD 8 DRIVER Low O J Part Number AS279354 Complete Dash Panel LIRE EAE fse tT j S2793055 Dash Panel metalwork Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 38 Page 0 Please refer to the Network for the current issue of this manual Uncontrolled Copy i INO ONES ss ASTS0W S AA OS3 oddewv SOWELL SLAIN dasr T134 2353 MAN zz OO JO POUR ES HL LS TUROL V F 1 3 LICEAT 34 DM CTA AUN HOSEN ZID MOWING ped decus 311 Hc ke 2 caet Lee A NOUNS fd EH CAI nee 3 11 501180 OL IHN AH awe 3 1 98 LON CO 7 05 90 3 21 E NES 3 01 01 A 1 2 559 13808 5 Hu SOSLBECS yy 8021805 SLIN 2 15 226 ES 3 LID NOISNSLXS NOD dvAS LEGLBEESV EJ R m 319NI amp ZIL di 12 Jdid 8WOMN E ade 1 DE YSO1 AWAKL r l Jit 8 Er far x 9 amp ATRN3SSV TIVI 2 69088 89825 5 EA LRATEN3SSV
16. 3 manuals for operating the XT175 Unit e Where there is a conflict between instructions the XT175 instruction should take priority e For the Driver s A C system to provide cooling the XT175 must be put into A C mode and be operating 4 1 1 Using the Dash Panel Coachair supplies a dash panel for driver control of the driver s unit The dash panel features three switches and a rotary control Fan Speed 21 AIC 00 Sach Temperatura Conin Mode Switch Selects the A C system operating mode between OFF DEMIST and A C Set switch to Set switch to Set switch to lower upper position middle position position In DRIVER mode the unit provides ventilation cooling heating operation depending on the temperature control setting and the return air temperature Fans operate at the selected speed In DEMIST mode the unit operates at the heating level selected with or without cooling depending on the temperature control setting and the return air temperature Fans operate at the selected speed An output signal for an external damper motor is also provided Illuminate when the switch is set to DEMIST or A C to indicate operation Mode Lights Fan Speed Switch Selects the operating speed of the fan blowers during DEMIST and A C modes Set switch to Set switch to Set switch to lower upper position middle position position Temperature Provides for adjustment of the set point temperature Control A C
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18. 5 ABZ TID S PLUGI PLUGI 1 L m PER mo OT Nt Bun imm Cem RELAYS c PIN 06 DAMPER simm PLUGE EN CONTROLLER 15 PIN 320358 summ PLUGE pu 1 13 Samm 6 PIN 3 SCR To BUS 1 350mm 700mm p 2150mm 207 WATER VALVE WIRING HARNESS oe i6 PIN ASSERTS IS Pe TER M EX WATER VALVE 7 2 t PIN CONTROLLER 3 ir FUSE 87 ccc BOX A3278158 EVAPFAN 2000mm SOLENOID Fiume MOTOR 4 PIN 2 PIN Drawing No AS338150 Issue A Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 27 Page 27 Page 28 Uncontrolled Copy Please refer to the Network for the current issue of this manual Document Number SM424 3381 Issue Date October 2006 E c 1 1C GPL OO AC LLANO CI A Y BO N LO ON 82151371 1 aL 317 CALLA EINOLA I HELD DIM REHEAT E I ee 119171 FO REJE EJ Ea 0910 69 _ HSINL ONY 14 117 Ald ee WoO va tv a 8 9 0 SPAG seaNcNYNCINMWOS Tv zean v 30 1571 MW HOSS THO a2 AMON S 48 CO3JAO0 ddv GO HEL 51813011000 035 3 13 NOLIN 790000 I JILVINJHOS 7723 euomnseudejuy Any n ne HOLON 007 23 no 4 i J 1 e us 115813 HOLDIN dadio CI SXBS ANB oo SOLON NY I 1001 64 was BU Leib Hs EI 7 MALAE SEER HA OD la van HC LME 311887 I ETT NENNT NN
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20. Ar Produced TE Broken or d disconnected Em MN System produces na hiea ting Heater vabre pot not operating properly E o Valve inb I Chock for clean cut fareign matter if jammed ar b Main control switch in Salman monte swich OFF position to DRIVER ar DEMI Set point control knob Rotate set point knob ert to cool position ta heat position 5 1 3 System only Partially Heats COMPLAINT p INDICATION CAUSE E REMEDY System Bus engine not Engine coolant is walt until engine heats warm enough till wanning u warms up Heater vahe l a partially jammed _ Check rapiace heater valve or valve contiolier Check for clean out foreign matter if jammed or blocked Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 32 Page 33 Uncontrolled Copy Please refer to the Network for the current issue of this manual Document Number SM424 3381 Issue Date October 2006 u po Jose jo pue WPAN angezedou fuessaou oeda 10 eday JOPOU uEpjoygJode 3 Joyo Qj MOY JUIN 2343 a i wp eoepdos J0 Way pure moway E ex2opq aug jo duod ye Bugso mo WORMS uq YIN yo OL aunssaud afueuasiqg r 0 aimp quesabyy panog 7 SA pe wg urep pue SACL SS ubi aGreyesp pue
21. LETS 5 x PSO NOM SPIGOT3 DEMIBT ONLY HEAD amp FEET SUPPLY AIR OUTLETS 250 NOM SPIGOTS AKG ONLY SUPPLY AIR OUTLET 1 050 NOM SPIGOT AAS amp DEMIST Qe ur lm Py T al y s IG nn HEATER OUT rac Bot OO TUBE i SERVICE as 00 TUBE REAR VIEW DUCT MOUNTING HOLES TAPPED M 518771 CONDENSATE DRAIN BOTH SIDES Drawing No T3381502 Issue 00 e When operational the unit produces the following airflow e Return air from the bus cabin is drawn by the supply fan through the return air filter Supplied by the Bus Body Builder into the unit e The air is conditioned as it passes through the evaporator and heater coils inside the unit The evaporator coil cools and dehumidifies the air The heater coil heats the air The type and amount of air conditioning provided is controlled by the driver according to the water valve setting e The conditioned supply air is discharged from the unit through the A C or DEMIST outlets by an electrically operated damper This switches the main airflow between the driver outlets and the windscreen outlet e Five air outlets on the top of the unit are provided for supplying air to the windscreen during DEMIST mode The airflow from these outlets is to be ducted by the bus body builder towards the windscreen e Four air openings are provided on the return air side of the unit for supplying air to the driver duri
22. M424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 8 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 4 System Parameters 1 4 1 XT175 Roof Top Unit Drawing No T3381001 Issue 00 0 6 3800 Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 9 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 4 2 BFW5BX5 Evaporator Unit Drawing No T3381501 Issue 00 ole OSE ME DUCT MOUNTING CENTRES 8 PLACES 14 5 TYP o DRAIN TYP BOTH SIDES Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 10 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 5 Air Flow The XT175 roof top and Driver s unit are not connected on the air side Refer to the SM417 manual for the XT Unit The Driver s unit utilises cooling and heating functions to deliver conditioned air to the driver and or windscreen as determined by the control settings The unit is designed to be mounted under the dash in front of the bus driver This positioning is shown in Section 1 3 System Layout LIQUID LINE 5 FEMALE O RING CONNECTION 58 18 THREAD SUCTION LINE 12 FEMALE O RING CONNECTION 718 18 THREAD SUPPLY AIR OUT
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24. al Issue Date October 2006 Page 16 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 6 5 Clutch The Lang KK73 1 23 160mm diameter electromagnetic clutch is recommended to be used with the A C system Further details can be found in the compressor manual and at wwwealang com The cross section of a typical clutch is illustrated below 1 7 Heating System The XT175 roof top and Driver s units heating systems can operate independently Refer to the SM417 manual for how a typical heating system works The booster pump is controlled by the XT75 climate control system but is typically not required for the Driver s unit when it is operating alone 1 8 Electrical System Refer to the SM417 manual for the XT Unit The XT175 roof top and Drivers Unit are not connected electrically The Driver s Unit requires the XT175 Unit to be in cooling mode with the compressor clutch engaged for then to provide cooling All system operations are controlled by the dash panel and the relays on the evaporator unit Refer to diagram in the Section 2 8 Electrical Installation The evaporator coil thermostat allows the system to disengage the electro magnetic compressor clutch should the temperature drop too low This is intended to prevent ice from forming on the coil Once the coil temperature rises clutch operation is re enabled 1 8 1 Power Supply UNIT VOLTAGE IS 24 V DC The power supply line is the red cable in
25. do repairs on motors or motor wiring without manually breaking the correct circuit breaker first Black Heat Sink The black heat sink built onto the ESP109 PCB is at earth potential DO NOT under any circumstances place an earth or a bridge circuit on the heat sink as this will cause serious unit damage DO NOT use a test light Use a suitable multimeter only DO NOT push the red reset button for more than 2 seconds as this could provide unintentional access to the CCC007 memory settings 3M424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Page 4 BMS38BX1 A C System Operation amp Overview Manual WARNING WARNING X I CAUTION I CAUTION A WARNING I CAUTION 1 CAUTION 1 CAUTION Document Nun Issue Date BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR CONTENTS SECTION 1 System Details 6 LL WENO O TT T TL 6 FEZ SPCC ICAU ONS EES 7 OE SE ay OUG 8 1 4 System 11606185 und ned wean Rc vto v x t c o i t p EEEE EEE 9 ESAF ON TERT 11 1 6 Refrigeration 5 5661 isecscasiscsescessetesasinaceseencasisasescneseieaesacasneesseavientessanseneiaianases 13 EA Meana SVE OT SR SG ETE 17 1
26. e CA COACHAIR 8 5 Other Components BMV5BX5 fett 52500 7 8 Pressure Regulator 531354 12 Filter Drier earthen Pet Hunter 55202 2 Solenoid Valve 668140 Coil for solenoid Valve mE 51724 Ball Valve Ball Valve 5 8 Solder si Solder 744991 BALL VALVE BALL VALVE 1 2FTOFBSP si FTOF BSP 517713 Ball Valve 1 2 Solder _ 2 Part Number Part Number 518006 FLARE NUT PLAIN 1 2 F10010 RRV117 Schrader Valve Assembly n T uw a T om az n perme patna VALVE 320959 Water Valve Controller 320958 Actuator Motor Controller Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 42 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR Bort Naaber _ Part er 522259 Vave 4way o 4 way AS279368 52703660 WATER VALVE WATER VALVE LOOM Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 43
27. e relief vents should be provided for constant air distribution to the windscreen head and feet regions Refer to Section 1 4 2 BFW5BX5 Evaporator Unit Drawing No 3381501 Issue 0 Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 21 BMS38BX1 A C System Operation amp Overview Manual CA CO ACHAIR Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 22 Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 23 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 2 3 4 Seal the Air Openings Seal the return air and supply air openings against water and air leakages using a good quality non drying type sealant This seal ensures there is no air leakage or foreign matter water dust can enter into the bus from this area 2 3 5 Return Air Grille Install the return air grille in the return air opening If the return air grille and filter assembly is to be provided by the body builder or installer the following recommendations should be followed e The grille should be of a hinged or removable type so as to provide easy access into the unit evaporator section e The return air filter restriction should be less than 30 Pa 1 5 m s air velocity
28. f yry uanang 10 p10d eA payiojg aie Addins poo Aran AO sbaeugasip put 0 jag Jie pax o g COMMO E 7 O nis 8 aaen 10 Buneaas XL swaysks afugua ened yea mops oy anp aired pue xea ayr201 ja WO my ASS ssejb gy fis ur 6 0038003 CA COACHAIR BMS38BX1 A C System Operation amp Overview Manual 5 1 4 System produces No Cooling compressor operative Page 34 unc i aBvey3sip 66 woqesdo up ys BENS SIC cn 718 Issue Date October 2006 Uncontrolled Copy Please refer to the Network for the current issue of this manual Document Number SM424 3381 uBiq pue 45y uonans 5 1 5 System provides only Partial Cooling CA COACHAIR BMS38BX1 A C System Operation amp Overview Manual Page 35 Date October 2006 Issue of this manual t issue efer to the Network for the curren ntrolled Copy Please r Unco Document Number SM424 3381 sse suus uj sapqqna marrsead uon ns Ja abuejasip yB usages u asjou Buipquimg Uon suue 3 pe seco cua Gul pruaaa ree aappayad i 5 1 6 System is excessively noisy CA COACHAIR BMS38BX1 A C System Operation amp Overview Manual Page 36 Uncontrolled Copy Please refer to the Network for the current issue of this manual Document Number SM424 3
29. for the passenger area e One under dash type evaporator unit BFW5BX5 and associated piping and harnesses collectively referred to as BMV5BX5 providing A C cooling and heating and demisting airflow e An off engine mounted compressor e Two driver s dash panels each controlling either the roof unit or the Driver s system e Generic installation fittings The BMS38BX1 system has the following key features e Light weight construction e Standard operating voltage of 24 V DC e Use of environmental friendly R134a refrigerant e Efficient use of engine heat for heating requirements 1 1 1 Hierarchy of Manuals The BMS38BX1 A C system units are drawn from the Coachair product family Manuals already exist for the XT roof top unit and these have been retained as discrete documents to allow timely updates of information as products are refined and improved There are significant differences between the driver s unit described in the existing manual SM348 2793 Dash A C Unit Installation Operation amp Maintenance Manual and the BCI unit As such the relevant information from that manual plus any additional information has been incorporated into this manual Manual BMS38BX1 Complete Bus A C System SM424 3381 BMS38BX1 Operation amp Maintenance amp Overview of A C System and Special items Overview Manual XT175 Roof Top Unit SM417 3283 XT Bus amp Coach A C Installation Operation Installation Operation amp Maintena
30. he reclaim process 7 3 Pressure Testing Note The solenoid valves in both systems have to be energised to open 7 4 System Evacuation Note The solenoid valves in both systems have to be energised to open 7 5 Refrigerant Charging Note Ensure both systems are run when charging the system Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 37 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 7 6 Safety Device Checks Be Ready to Shut Down the System Take care while checking the pressure switch operation You must be ready to shut down the system immediately if the pressure switches do not operate correctly Personal injury and damage to the A C WARNING equipment could result from a large build up of pressure e Pressure switch test can be done with just the XT175 system operating e Check both the XT175 and Driver s Unit de ice sensors Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 38 BMS38BX1 A C System Operation amp Overview Manual CA COAC H Al R SECTION S8 Spare Parts Refer to SM425 manual for typical XT175 spares 8 1 Compressor Area BMS38BX1 ah j i li ou E BN Part Number Part Number Bock FKX50 775K Compressor SLC004 Lang KK73 1 23 Clutch 295
31. ing Down the System Pumping down the system involves pumping the refrigerant into the condenser and receiver 1 Connect a manifold gauge to the suction service valve 2 Run both A C units 3 Close the unit ball valve near the receiver 4 5 Disable the low pressure switch by bridging the contacts Check the operating pressures When the suction pressure reaches 7 kPa vacuum shut down the A C unit If the pressure rises rapidly this indicates that there is still some residual refrigerant in the compressor crankcase If this is the case run the A C system again and check that the reaches 7 kPa vacuum Do not reduce the pressure on the low side of the system any further as a slight positive pressure will reduce the chance of contaminants rushing into the system when it is opened 6 When the pressure remains at 7 kPa vacuum on system shutdown or raise very slowly close the compressor discharge valve 7 2 Reclaiming Refrigerant Correct evacuation and containment of the refrigerant enables the refrigerant to be re used and reduces pollution In order to remove and store the refrigerant from the A C system a commercial refrigerant recovery unit is required Refer to the manufacturers instructions for the operation of the recovery unit With the check valve installed in the unit the reclaim hoses need to be connected to either the service port at the receiver the solenoid valves in both systems have to be energised to open during t
32. mperature drops too low 1 8 5 Driver s Dash Control Panel The driver manually controls the A C system with the driver dash panel The Dash Panel is connected to the relay harness on the evaporator unit and features controls for e Selecting the operating mode of the A C system between OFF DEMIST and A C e Adjusting the blower fan speed e Setting the desired amount of reheating of the conditioned air 1 8 6 Refer to 3 1 1De Ice Operation Driver s Unit A thermostat probe is located in the fins of the evaporator coil The coil temperature is monitored by the thermostat to detect low temperatures and prevent icing of the coils To check the de ice operation run the A C system Open the evaporator access cover or stop the evaporator blowers by removing their relays from the circuit This will cause the evaporator coil temperature to drop quickly and activate the safety cut out e As the coil de ice probe temperature drops the solenoid valve should close at 3 C e As the coil de ice probe temperature rises the solenoid valve should open at 1 C e If necessary adjust the thermostat so that the valve operates at the required temperature Operating the A C Unit 1 8 7 Harness Arrangement Refer to Section 2 8 2 BMV5BX5 Harness Arrangement Detail 1 8 8 Wiring Diagram Refer to Section 2 8 3 BMV5BX5 Wiring Diagram Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue
33. nce amp Maintenance Manual Information SM425 3283 XT A C Unit Spare Parts Manual Spare Parts SM423 3283 CCC007 Climate Control System Manual Operation amp Control BMV5BX5 Drivers Unit SM424 3381 BMS38BX1 Operation amp Maintenance amp Installation Operation Maintenance amp Spare Overview Manual Parts Information 09704 FKX50 775K Bock Compressor Manual Maintenance of Bock Compressor KK73 1 Lang Clutch Operating Instructions Maintenance of Lang Clutch Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 6 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 2 Specifications The following specifications are correct for the A C system at the time of printing Combined 40 kW 35 C ambient 27 19 C DB WB Mixed Air XT175 35 kW BMV5BX5 Combined XT175 BMV5BX5 XT175 Unit 3810mm long x 1940mm wide x 235mm high BFW5BX5 Unit 350mm high x 500mm wide x 350mm deep XT175 Unit 265 kg BFW5BX5 Unit 14 kg Compressor with Clutch 54 kg Refrigerant R134a Compressor Bock FKX50 775K reciprocating 6 cylinder design 775 cc engine driven Maximum speed 3 500 rpm Lang KK73 1 23 2xSPB 160mm OD electro magnetic Compressor Clutch 9 J Airflow XT175 1 444 s 5 200 m hr at high speed free blow BFW5BX5 200 I s 720m hr at high speed free blow 24 V DC nom Max 30 V DC co
34. ng A C mode The airflow from this outlet is to be ducted by the bus body builder towards the driver face body area e One foot outlet on the side of the unit supply air during A C and DEMIST modes In A C and DEMIST modes air exits from the two side outlets The airflow from the two side outlets is not affected by the position of the shutter Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 11 CA COACHAIR Air flow only during A C Air flow only during DEMIST Air flow during A C amp DEMIST Return Air In The airflow from these outlets is to be ducted by the bus body builder towards the driver s feet area or may be blocked off as required Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 12 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 6 Refrigeration System The refrigeration system for the BCI system is based on the XT system described in the SM417 manual There is a 1 2 liquid line take off in the XT unit which supplies cooled refrigerant to the BFW5BX5 driver s evaporator Unit The suction line from the driver s unit then returns under the passenger floor to the engine mounted compressor A solenoid valve is used to stop flow to the Driver s unit when cooling is not required This solenoid valve is ope
35. nt 45 V DC momentary 20 V DC Min Operating Voltage Current Draw Combined 77A max XT175 62A max BFW5BX5 12A max Clutch 2 6A max See SM417 manual 0 CEU TE Evaporator Unit For XT see SM417 Manual For Drivers Unit Coil 1 off rifle copper tube with high efficiency aluminium fins Motor 1 off medium duty long life permanent magnet type double shaft steel ball bearings Fans 2 off double inlet rotor E For XT see SM417 Manual For Drivers Unit Internally equalized block valve Expansion Valve z See SM417 manual Drier Receiver Safety Features High and low pressure cut out safety switches Electrical de ice thermostat Electrical protection fuses Climate Controller For XT see SM417 Manual For Drivers Unit Driver controlled modulating water valve See SM417 manual 7 Casing For XT see SM417 Manual For Drivers Unit Primarily constructed of 2 0 mm aluminium ensuring resistance to corrosion and physical damage due to its robust design Corrosion Protection For XT see SM417 Manual For Drivers Unit The casing is chemically prepared for paint application to all internal and external surfaces Ester Oil Type Fuchs Reniso Triton SE 55 Or Equivalent Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 7 BMS38BX1 A C System
36. of the A C system must be carried out by Coachair Service personnel or authorised agents e Refer to the SM417 manual for Testing and Commissioning details e The XT175 unit must be in cool mode for the Driver s A C system cooling to be tested e To balance the systems the pressure regulator on the Driver s Units suction line should be adjusted On initial start up this should be in the fully open position to provide maximum flow to the Driver s Units 3 1 1 De Ice Operation Driver s Unit A thermostat probe is located in the fins of the evaporator coil The coil temperature is monitored by the thermostat to detect low temperatures and prevent icing of the coils To check the de ice operation run the A C system Open the evaporator access cover or stop the evaporator blowers by removing their relays from the circuit This will cause the evaporator coil temperature to drop quickly and activate the safety cut out e As the coil de ice probe temperature drops the solenoid valve should close at 3 C e As the coil de ice probe temperature rises the solenoid valve should open at 1 e f necessary adjust the thermostat so that the valve operates at the required temperature Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 30 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR SECTION 4 Operatin the A C Unit Refer to SM417 amp SM42
37. piping As supplied the unit is sealed and pressurised to 350 400 kPa Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 19 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 2 3 Ducting amp Vent Distribution System An appropriately designed bus air ducting and distribution system is essential for efficient and trouble free operation of the A C system Use the guidelines given 1 2 3 1 Return Air Interface Six bolts are used to secure the return air duct to the Unit The interface is shown below 41 39 INTERFACE OPENING Ma DUCT MOUNTING CENTRES 6 PLACES 7 z g a amp g n i 8 d A DIMENSIONS SHOWN E 20 SEAL TYP ae IN BOXES REQUIRE Zi10MM x 3MM HIGH n ui m CLEARANCE FOR PROTRUDING RIVET HEADS z L 4 PLACES 8 i be 2n few I a LLL ALLS ETEA LLL ALLA SALLE PEEPS ALAA PEALE z L mm mme s us 235 5 MNTG CENTRES 235 5 MNTG CENTRES 9 4 T S NOTE SEAL TO BE USED BETWEEN UNIT INTERFACE AND DUCT WHEN MOUNTING INDICATED IN HATCHED AREA Drawing No T2793004 Issue 00 2 3 2 Vent Arrangement Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 20 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 2 3 3 Sufficient non closing typ
38. rated as a de facto compressor clutch for the driver s unit 1 6 1 Refrigeration Piping and Connections Drawing No T3381005 Issue A Component List Cm pewr sumvanmown i a wont wwrernoouamovavese 18 Ca pewr xw E S Cmpewr e IT Cz i jme aer 1 o usos eno Se Weem Ts fuera 2 KS ES um uw EAL mum ES rum E37 um ES COMPRESSOR XT UNIT XT UNIT FILTER DRIER 3 4 XT UNIT WATER BLEED VALVE m INIM FC c Z Z a 4 au ii c en LIQUID MOISTURE INDICATOR 3 4 7 in en S on ag XT UNIT TX VALVE 5 8 EVAPORATOR COIL CONDENSER COIL COMPRESSOR BOCK FKX50 7 75K TEM PART No DESCRIPTION oh XT UNIT LIQUID RECEIVER 3 4 2042 668140 SOLENOID VALVE 1 2 mi 28 ERSO38 PRESSURE SWITCH HIGH MV UNIT TY ITEM PART No DESCRIPTION 0 uS JBE 3 Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 13 Page 14 Uncontrolled Copy Please refer to the Network for the current issue of this manual ep 2 EA m m sy 8 sy oy ay 2171107 30 Ru ee m NC MOS pal
39. res not to much refrigerant cycles through the Driver s units Pressure Regulator Unit Connections Suction and discharge refrigeration pipelines are connected to the unit by leak proof flanges The connections are made at the unit base inside the vehicle on the nearside or off side air supply roof opening or at the back of the unit outside the vehicle Compressor Piping is connected to the compressor via hoses with flange connections Connections Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 15 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR 1 6 3 Safety Devices High and Low Pressure Switches The compressor high and low pressure switches on the compressor feed signals to the Coachair Climate Controller If the refrigeration system pressures become abnormally high or low the climate controller will cut out the clutch LP Switch Cut out 40 kPa Cut in 175 kPa HP Switch Cut out 2 070 kPa Cut in 1 380 kPa 1 6 4 Compressor The Bock FKX50 775K compressor is recommended to be used with the A C system Further details can be found in the compressor manual and at www bock de os E ae zi E pains Compressor 75K 2990 1 000 0 100 67 33 Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manu
40. ssor Area BMS38BX 35 8 2 Drivers Unit Dash 836 ENEE VR P 35 8 3 Evaporator Unit Assembly BFWB5BX5 cceceeseceseeeeeseseneestaeeeeesenenseaeaneesenenes 36 8 4 Driver s Unit Assembly BMV5BX5 nennen nennen nennen nnns 37 8 5 Other Components BMV5BX5 nennen nennen nnne ne nnns ran nenas 38 Document Number SM424 3381 Uncontrolled Copy Please refer to the Network for the current issue of this manual Issue Date October 2006 Page 5 BMS38BX1 A C System Operation amp Overview Manual CA COACHAIR SECTION 1 System Details 1 1 Introduction This manual is a guide to the operation maintenance and spare parts for the BMS38BX1 bus air conditioning system manufactured by Coachair as specifically developed for Bus amp Coach International The BMS38BX1 air conditioning system consists of a high performance XT175 roof top A C system for passenger comfort combined with a BMV5BX5 driver s A C system for driver comfort and demisting the windscreen The BMS38BX1 air conditioning system is a split system comprising of components that are designed to be integrated into the bus during its manufacture The BMS38BX1 system includes the following primary components units e A roof mounted evaporator condenser unit XT175 providing A C cooling and heating
41. to be isolated from the system for removal amp replacement without loss of refrigerant from the system Solenoid Valve Eliminates liquid refrigerant migration from the low pressure side of the system to compressor sump during off cycle protecting the compressor against damaging liquid Slugging The solenoid valve is in a closed position when the A C system is off Filter Drier Filters and removes moisture and foreign particles from the refrigerant The valves either side of the Filter Drier enable easy replacement with reduced gas loss Sight Glass Indicates the refrigerant level and moisture content in the system he positioning of the sight glass allows for easy viewing from inside the bus saloon area through the Return Air Plenum Regulates the refrigerant flow into the evaporator coil by expanding the liquid from a high pressure high temperature liquid to a low temperature low pressure liquid Evaporator Coils P ransfers heat from the air to the refrigerant causing the low pressure low temperature liquid to evaporate in the evaporator into a low pressure vapour As air passes through the coil it is cooled and dehumidified Evaporator Draws air into the unit through the return air amp fresh air openings through the Blowers evaporator coils and directing it into the supply air openings 6006 Prevents return of liquid refrigerant from the condenser to the compressor when the A C system is inoperative Ensu
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