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عدد المساهمات : 18928 التقييم : 35294 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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أخواني في الله أحضرت لكم كتاب Automotive Air-conditioning and Climate Control Systems Steven Daly BEng, BA (Hons), IEng, Cert Ed, MIMI, LAE, MSAE
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Contents Preface vii Acknowledgements viii Introduction: An overview of the automotive air-conditioning market, training and qualifications ix 1 Air-conditioning fundamentals 1 1.1 History of automotive air-conditioning systems 1 1.2 Introduction to heating and ventilation 6 1.3 The basic theory of cooling 26 1.4 Vapour compression refrigeration 39 1.5 Alternatives cycles 42 1.6 The air-conditioning system 57 1.7 The expansion valve system 58 1.8 The fixed orifice valve system (cycling clutch orifice tube) 59 1.9 Dual air-conditioning 61 2 Air-conditioning components 62 2.1 The compressor 62 2.2 The condenser 77 2.3 The receiver-drier/accumulator 81 2.4 The expansion valve/fixed orifice valve 84 2.5 The evaporator 89 2.6 Anti-frosting devices 91 2.7 Basic control switches 93 3 Air-conditioning electrical and electronic control 95 3.1 Electrical principles 95 3.2 Sensors and actuators 113 3.3 Testing sensors and actuators 159 3.4 Oscilloscope waveform sampling 172 3.5 Multiplex wiring systems 183 3.6 OBD and EOBD 188 3.7 How to read wiring diagrams 194 3.8 Automotive A/C manual control system (case study 1) 205 3.9 Automotive A/C auto temp control system (case study 2) 221 3.10 Automotive climate control system (case study 3) 238vi Contents 4 Diagnostics and troubleshooting 264 4.1 Initial vehicle inspection 264 4.2 Temperature measurements 266 4.3 Pressure gauge readings and cycle testing 267 4.4 A/C system leak testing 277 4.5 Sight glass 282 5 Service and repair 283 5.1 Servicing precautions 283 5.2 Refrigerant recovery, recycle and charging 288 5.3 System oil 310 5.4 System flushing 312 5.5 Odour removal 316 5.6 Retrofitting 317 5.7 Replacement and adjustment of compressor components 318 5.8 Fixed orifice valve remove and replace 335 6 The environment 337 6.1 Global warming 337 6.2 The ozone layer 338 7 Legislation 341 7.1 Historical perspective 341 7.2 US perspective 344 Appendices 352 Index 35 A/C modules and displays, 195, 196, 197 A/C registrations, 7 Absorption refrigeration, 57 Accumulator, 32, 54, 55, 56, 67, 69, 79, 88, 89, 93, 98, 99, 203, 213, 258, 280, 282, 288, 299, 300, 302, 305 Air distribution, 26, 27, 32, 34, 48, 60, 106, 152, 154–6, 164, 195, 196, 198, 207, 215, 219, 220, 252, 253, 284, 294 Air distribution unit, 27 Air filtration, 24, 25 Air inlets, 27 Air mix type, 22 Air outlets, 24, 27, 232 Air quality sensor, 136, 231, 233, 235 Air recirculation, 28, 120, 144, 197, 202, 255, 258 Air-conditioning, 6, 12, 15, 25, 33, 37, 38, 43, 64–6, 68, 69, 72, 73, 90, 230–2, 325, 326, 331, 336 Amp clamp, 122, 159, 208 Ampere, 104, 105 Armature, 138, 143, 144, 146, 150, 305, 308, 309, 312, 319, 321 Atoms, 100, 102, 103, 127, 326 Blower motor switch, 198, 206 Box type expansion valve, 91, 92 Break-out box, 139, 158, 168, 211 British Standard, 191 Brushless motor, 146 CAD, 16 CAE, 16 CAM, 16 CAN, 157, 175, 176, 179, 180–3, 186, 230, 231, 235, 238, 242–4 Carbon filter, 26 CCS system, 63, 64 CFD, 5, 16–19, 24 Charging cylinder, 277, 278 Circuit diagram, 188, 190, 222 CITB, 12 City and Guilds, 12 Climate, 6, 7, 12, 30, 38, 123, 125, 132, 167, 196, 197, 236, 242, 324 Clutch, 15, 65, 69, 79, 80, 81, 97, 98, 99, 140, 155, 164, 170, 171, 187, 200, 203–6, 209, 210, 211, 215, 216, 219, 221–3, 233, 235, 246, 258, 268, 304, 305, 307, 312, 313, 314 CO2, 6, 12, 14, 45, 52, 53, 56, 57, 175, 282, 297, 324, 327, 328, 329, 336 Colour coding, 190, 275 Commutator, 142, 143, 144, 146 Comparator, 283 Compound circuit, 100, 111, 112 Compressor cycling switch, 98, 209, 212 Compressor design, 56 Condenser, 12, 15, 51, 52, 54, 57, 66, 67, 69, 79, 83–7, 92, 93, 95, 99, 117, 138, 200, 203, 212, 213, 217, 253, 254, 262, 267, 270, 278, 279, 287, 290, 293, 298, 300, 306 Conduction, 40, 41 Continuity, 139, 160, 164, 210 Control valve, 21, 69, 72, 141, 200 Convection, 30, 40, 41, 48, 325 Cooler, 38, 41, 53–7, 69, 83 Data bus, 178, 179, 180, 181, 195, 215, 217, 244 Data link connector, 167, 186, 248 Data list, 139, 158, 197, 211, 249 DC motors, 148, 164 De-ice switch, 98 Demisting, 24, 28, 30, 54 Desiccant, 87, 89, 268, 270, 271, 299, 305 Design of an evaporator, 96 Diagnostic information, 182, 183, 267 DIN Standard, 139, 188, 221, 222, 241 Dry bulb, 49 Duty cycle ratio, 148, 149, 150, 154, 174, 217 ECC system, 229, 233, 235, 236, 237, 238, 241 Electromotive force, 104, 141 Electronic leak detection, 264 Index360 Index Engine coolant temperature sensor, 183, 211 Engine cooling fan, 205, 210 Enthalpy, 41, 51, 53, 54, 55, 59, 60 Environment, 6, 15, 38, 43, 53, 88, 146, 159, 236, 251, 264–6, 303, 326, 331, 335 EOBD, 3, 6, 182, 183, 185, 186, 259 EPR valve, 254 Evaporative cooling, 15, 61 Evaporator, 11, 15, 27, 30, 49, 50–7, 64–7, 69, 72, 74, 79–98, 117, 149, 154, 196, 203, 209, 213, 216, 217, 219, 222, 223, 226, 233, 235, 238, 242, 244, 250, 253, 254, 262, 263, 267, 271, 284, 290, 300, 303, 307 Evaporator sensor, 97 Excelsior cone, 15, 61 Exchanger, 20–2, 25, 27, 28, 30, 34, 36, 37, 41, 51, 53–6, 59, 60, 63, 83, 154, 196, 200, 202, 205, 207 Expansion valve system, 67, 69 Externally regulated compressor, 82 Fan, 18, 23, 24, 27, 30, 37, 48, 63, 64, 67, 83, 99, 110, 118, 124, 138, 148, 156, 176, 177, 191, 195, 197, 200, 203, 204, 210–12, 215–20, 222, 225, 226, 231, 235, 293, 306 Fault code, 37, 64, 156, 158, 159, 165, 167, 183, 187, 195, 197, 251, 252 Fault diagnostics, 165 Fixed orifice valve, 67, 69, 92, 93, 95, 252 Flux, 81, 134, 137, 140–2 Freon, 63, 324, 325, 326, 327, 330 Frequency, 24, 57, 63, 132, 134, 147, 148, 149, 150, 151, 153, 154, 159, 163, 171, 172, 173, 178, 217, 265, 324 Fully automatic control system, 156 Fusible plug, 87, 88 Gas cooler, 53–5, 57 Gas refrigeration, 59 Gateway, 181, 182 Germicidal lamp, 25 Global warming potential, 43, 44, 327, 328, 335 Greenhouse effect, 324 Growth, 7–11, 14 Handling refrigerant, 269, 279 Harness multiplug, 82 Heat, 15, 20–5, 28, 30, 33–43, 49, 51–67, 69, 83, 85, 86, 90–6, 99, 105, 109, 118, 124, 144, 149, 154, 177, 178, 196, 200, 202, 205, 207, 208, 217, 219, 220, 237, 253, 254, 263, 270–7, 299, 300, 302, 307, 324, 326 Heat exchanger, 15, 20–22, 25, 28, 34, 36, 37, 41, 51, 53, 54–6, 59, 60, 63, 83, 154, 196, 200, 202, 205, 207 Heat intensity, 38, 40 Heater assembly, 20, 22, 25, 132 Heater control module, 110, 194, 200, 202, 204, 207, 208, 210, 211 Heating, 15, 18, 20, 21, 24, 26, 29, 30, 33–7, 40, 41, 54, 56, 59, 63, 64, 120, 141, 195, 196, 202, 207, 229, 230, 231, 232, 238, 243, 277, 303 Humidity sensor, 135 ICE, 215, 217–19, 222, 226 Inductive speed sensor, 134 Institute of the Motor Industry, 12, 13 Insulators, 40, 103 Kyoto protocol, 328 Leak detector, 265, 266 Legislation, 6, 12, 16, 20, 44, 264, 327, 329 Linear potentiometer, 128, 129 Liquid charging, 278 MACS, 13 Magnetic clutch, 64, 68, 69, 82, 205, 252, 303 Manual control system, 155, 195, 198 Market, 6, 7, 9, 10, 15, 187, 189, 195, 214, 282, 293, 297, 329 Market growth, 7, 10 Matrix, 20, 196 Mineral oil, 43, 44, 83, 267, 297, 299, 305 Movement of electrons, 103 MS-CAN, 182, 186 Multimeter, 159, 160, 161 Multiplex wiring system, 97, 151 Natural flow ventilation, 15 Negative temperature coefficient, 97, 106, 109 Network, 115, 148, 155, 157, 164, 176, 178, 179, 181, 184, 198, 201, 231, 241, 244Index 361 OBD, 3, 6, 164, 165, 182, 183, 195, 259 Oil replacement, 44, 298 Oscilloscope, 82, 119, 131, 139, 158, 159, 163, 165, 169, 170, 175, 211, 225, 258, 259, 266 Ozone depletion potential, 44, 326 Ozone layer, 43, 325, 327 PAG, 43, 44, 47, 56, 83, 250, 266, 267, 297–9, 308, 318, 319, 322 Parallel flow condenser, 86 Peltier module, 63, 64 Permanent magnet, 128, 131–4, 143, 144, 146, 147, 219 Photoelectric, 103, 121 Piezoelectric, 103 Pollen filter, 24, 25, 148, 198, 214, 230, 235, 245 Position sensor, 127, 128, 148, 152, 182, 211, 219, 223 Positive temperature coefficient, 35, 106, 120 Potential difference, 101, 102, 104–6, 110, 112, 126, 162, 163, 211 Power distribution, 158 Power probe, 139, 157, 164, 208, 210, 211 Pressure gauge readings, 255, 260, 286, 293 Pressure relief valve, 79, 88 Pressure sensor, 99, 100, 124, 125, 126, 127, 135, 235, 246 Pressure switch, 64, 67, 88, 98, 99, 195, 200, 203, 204, 209, 210, 212, 213, 215, 216, 219, 222, 223, 252, 266, 278, 303 Protocol, 165, 178, 181, 183, 186 PTC element, 35, 120 R12, 42–7, 51, 83, 84, 89, 254, 257, 258, 261–4, 267, 270, 271, 275, 282, 295, 297, 298, 299, 324, 326, 330 R134a, 6, 15, 42–8, 51, 52, 53, 56, 58, 83, 84, 87, 89, 213, 228, 250, 254, 256, 257, 258, 261, 262, 263, 267, 270, 271, 275, 279, 282, 295, 297, 299, 305, 306, 322, 324, 326, 329, 336 R744, 2, 53, 54, 56 Radiation, 40, 41, 109, 124, 195, 217, 326 Receiver drier, 15, 52, 66, 86–8, 91, 125, 126, 127, 130, 217, 278, 280, 288, 299, 300, 302 Recirculation air actuator, 207, 208 Recirculation damper, 215, 219 Recycled refrigerant, 271, 272 Refrigerant charging, 226 Refrigerant identifier, 282, 283, 332 Refrigerant loss, 46, 324 Refrigerant recovery, 13, 274, 308, 331, 335 Relative humidity, 15, 30, 48, 49, 50 Relay, 64, 97, 98, 137, 138, 139, 140, 149, 158, 161, 164, 178, 184, 186, 200, 203, 204, 205, 207, 209, 210, 211, 216, 219, 221–3, 226, 229, 239, 246 Resistance, 35, 97, 103, 105, 107–20, 126, 127, 128, 129, 135, 139, 140, 144, 157, 159, 160, 161, 163, 170, 181, 205, 211, 244, 245, 297, 326 Resistor pack, 176, 177, 195, 198, 204, 206 Resistors in parallel, 110, 112, 115, 116 Resistors in series, 107, 108, 113, 123 Retrofitting, 297, 333, 335 Rheostat, 215, 217, 222, 225 Saturated vapour, 51, 54, 55, 67, 92 Schematic, 153, 188, 189, 195, 206, 222, 241, 243 Semiconductors, 103 Sensible heat, 39, 40 Serial tester, 139, 158, 159, 164–6, 168, 175, 258 Serial testing, 211 Service connectors, 44, 275, 278, 280 Service operation, 264, 273 SID, 215, 217 Sight glass, 87, 261–3, 267, 268, 277, 278 Solenoid operated water control valve, 155 Solenoids, 178 Solidworks, 16 Specific heat capacity, 39 Specification, 16, 19, 34, 57, 58, 119, 155, 156, 169, 170, 195, 305, 312 Speed sensor, 132, 134, 149, 171, 211, 215 Stepper motor, 144, 146, 147, 150, 151, 154, 164, 196, 206, 215, 219, 229, 233, 236 Strain gauge, 126 Sub cooled, 83 Substitutes, 44, 331 Sun load sensor, 121, 122, 124 Superheated, 51, 53, 55, 66, 92, 95 Swash plate, 71, 72, 73, 75, 82 Symbols DIN, 190 System flushing, 299 System oil, 258, 282, 287, 298 Technical data, 165, 225, 298 Temperature blend door, 28, 29, 32 Temperature comparisons, 253 Thermostatic expansion valve, 87, 90, 254362 Index Tracer dye, 213, 250, 258, 262, 267, 290, 299 Training providers, 12 UK registrations, 9 UV, 89, 109, 195, 229, 252, 264, 265, 267, 299 Vacuum, 22, 31, 32, 42, 63, 70, 126, 175, 264, 266, 273, 274, 276, 277, 278, 287–90, 305 Vane type compressor, 76, 77, 81 Vapour charging, 278 Variable capacity compressor, 69 Variable orifice valve, 92, 199 Variable reluctance, 147, 151, 164, 172 Velocity, 17, 31 Voltage, 35, 37, 57, 61, 62, 63, 64, 82, 97–113, 117, 119–34, 136, 139, 141, 144, 146, 148, 150, 154, 158–80, 182, 184, 189, 200, 202, 204, 206, 207, 209, 210, 211, 217–19, 222, 223, 225, 226, 234, 236, 237, 242, 244, 245, 249 Watt, 104 Waveform, 82, 119, 130, 150, 154, 169, 170, 177, 178, 244, 245, 266 WDS, 166, 167, 178, 180 Wet bulb, 49, 50 Wiggle test, 159, 163, 252Plate 1 System layout for A/C and heat pump operation
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