AIR CONDITIONING SYSTEM (HD)

2 General Information System General ItemsHD CompressorVS16M Refrigerant / Oil quantity500 / 150 g Condenser Sub cool type (Condenser, receiver drier integrated) Pressure detectingAPT (Automotive Pressure Transducer) Cooling fanSingle fan type Blower speed controlMOS-FET DiagnosisController or Hi-scan

3 Layout System Layout

4 Controller controller FATC Manual

5 Function of Controller 1. Temp. switch : Cool Warm 2. Blower switch : Speed 1 st 4 th 3. Mode switch* 4. Intake switch (FRE/REC) 5. A/C switch 6. Rear defog switch * Mode switch : MAX A/C VENT B/L FLOOR MIX DEF Front controller (Manual)

6 Function of Controller Controller (Auto) 1. DEF. switch 2. Rear Defog switch 3. A/C switch : REC fixed 4. Recirculation switch 5. Temp. switch : 63 (17.5 ) 89 (31.5 ), up/down by 1 (0.5 ) 6. Auto switch : Temp.,blower,mode, A/C,Intake control 7. Off switch : Blower off, A/C off (MODE, AQS, REC available) 8. Mode switch* 9. AQS switch : FRE/REC changed by air status 10. Blower switch : 8 step control * Mode switch : VENT B/L FLOOR MIX VENT

7 Blower switch Function Of Buttons (Manual) - Speed control : by resistor 0.50Ω 1.00Ω 1.40Ω Fuse Spring 190.0±7 PBF SPLDER HIMH ML LOW CIRCUIT OF DIAGRAM Blower switch

8 Mode switch Function Of Buttons (Manual) 1. Mode operation - MAX A/C : VENT, REC, A/C ON - VENT mode : VENT - B/L mode : B/L - FLOOR mode : FLOOR, FRE - MIX mode : MIX, FRE, A/C ON - DEF mode : DEF, FRE, A/C ON 2. Feedback voltage of mode actuator PositionF/B (V) MAX A/C0.3 VENT0.3 B/L1.4 FLOOR2.5 MIX3.6 DEF4.7

9 FRE/REC switch Function Of Buttons (Manual) - REC switch ON : REC mode - REC switch OFF : FRE mode - Intake door actuator control PositionF/B (V) FRE0.3 REC4.7

10 A/C and Temp switch Function Of Buttons (Manual) - Temp. actuator control : 16 steps - A/C output is controlled by evaporator sensor PositionF/B (V) Cool0.3 Warm4.7

11 Control Logic (Manual) 1. Mix/DEF logic - MIX/DEF mode select A/C ON, FRE - A/C ON/OFF and FRE/REC selection available 2. MAX A/C logic - MAX A/C mode select VENT, A/C ON, REC - A/C OFF and FRE selection is not available 3. EVAP logic -During A/C ON, A/C ON/OFF output is controlled by EVAP. Sensor 4. Actuator cut off logic - When an actuator can not go to target position actuator is cut off for protection. A/C OUTPUT OFF Diff: A/C OUTUT ON

12 Logic cancel & selection Select DEF mode Push REC button 5 times for 3 seconds See REC indicator flashes 3 times with 2Hz. Logic cancel & selection - Logic cancel : initialized by A/C OFF, FRE - Logic re-selected (at DEF mode) : initialized by A/C ON (indicator ON), FRE Control Logic (Manual)

13 Function Of Buttons (Auto) Function : When off switch is pushed ambient temperature and mode appear. 1. Mode and ambient temperature display OFF display

14 DEF mode operation - mode door : DEF position - intake door : FRE position (REC selectable) - A/C : on - prior to MAX COOL/HOT function 2. DEF mode control Function Of Buttons (Auto) 3. OFF switch System operation - blower speed : off - temp door : move to cool position after 20 sec delayed - A/C : off - intake door : FRE - AQS function : off

15 4. AQS control Function Of Buttons (Auto) System operation - Select the DEF during AQS ON : DEF is prior to AQS - MAX cool/hot is prior to AQS - When a preheating AQS : FRE position

16 5. Blower speed control System Operation (Auto) [Blower speed & motor voltage table] Speed Manual speed voltageAUTO speed voltage 1 st 3.8AUTO LO (4.5) 2 nd ~ rd ~ th ~ th ~ th ~ th ~ AUTO HI (10.6) 8 th B+

17 5. Blower speed control System Operation (Auto) Ambient temp.

18 MIX/DEFOG logic System Operation (Auto) 1. Operation - Mode door : MIX or DEFOG - Intake door : FRE (REC is selectable) - Prior to MAX HOT/COOL function 2. A/C cut off - By evaporator sensor operation - Ambient temperature below 0 (A/C select indicator & compressor off) [ By evaporator A/C ON/OFF ] [ By ambient sensor A/C ON/OFF ] A/C OUTPUT OFF A/C OUTPUT ON (EVAP, SENSOR TEMP) Off : 0.6 ± 0.3 A/C OUTPUT OFF A/C OUTPUT ON Diff : 3 (AMB temp.) Off : 0 (AMB temp.) Diff : 1.5

19 System Operation (Auto) Logic cancel & selection Select DEF mode Keep pressing A/C button and push REC button 5 times for 3 seconds See REC indicator flashes 3 times with 2Hz. Logic cancel & selection FUNCTIONDEF/MIXOFF LOGIC A/CONOFF INTAKEFRE LOGIC CANCEL A/CPREVIOUSOFF INTAKEPREVIOUS 12 Keep press/Push 5times

20 Temperature Unit Change * Setting unit: (Battery disconnection) * How to operate Keep pressing Press for 3 seconds or more Temp unit change:

21 Blower motor 1. Front blower motor - Capacity : 220W - Wheel size : Ø147 X 75H - Rotational direction : CCW Components (Auto, Manual) - +

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

23 HVAC (Heating, Ventilation and Air Conditioning) Components (Auto, Manual) MODE ACTUATOR HEATER CORE WATER TEMP SENSOR (FATC ONLY) EVAP SENSOR CONNECTOR TEMP ACTUATOR

24 HVAC (Heating, Ventilation and Air Conditioning) 2. Blower unit Components (Auto, Manual) INLET ACTUATOR AIR FILTER COVER BLWR MOTOR FET(FATC) RESISTOR(MANUAL)

25 Cooling Fan * Depending on the fuel type of the engine, Coolant temperature 'A' can be changed as follows. A/CON S/WA/CON Pressure Vehicle Speed {KPH} Coolant Temperature [ ] Remarks -30 A ON P 15.5 f/ G ALLOFFHIGH 15.5 f/ G > P 12 f/ G V

26 MOS FET (Metal Oxide Semiconductor Field Effect Transistor) Components (Auto) PinFunction 1Drain 2Source 3Gate Blower speedVm 1 st 3.8 V 2 nd 4.9 V 3 rd 6.1 V 4 th 7.2 V 5 th 8.3 V 6 th 9.5 V 7 th 10.6 V 8 th Batt Vm Vds Blower motor DrainFET assy Source Gate HTR control FATC / Manual

27 MOS FET (Metal Oxide Semiconductor Field Effect Transistor) Components (Auto) MOS FET (Metal Oxide Semiconductor Field Effect Transistor) is composed of Metal, Oxide and Semiconductor. There are NPN type and PNP type as the semiconductor part. NPN type is called N-channel and PNP type is called P channel. An oxide film is put to the semiconductor of NPN or PNP and metal is put onto it as the gate. Transistor controls an output current by the input current. However, in case of FET, it controls an output current by input voltage. To handle an MOS FET, it needs an attention. Because the oxidation insulation film is thin, this film is easy to destroy in the high voltage of the static electricity and so on.

28 MOS FET (Metal Oxide Semiconductor Field Effect Transistor) Components (Auto) [N-channel MOS FET] When positive voltage is applied to the gate of the N-channel MOS FET, the electrons of N-channel of source and drain are attracted to the gate and go into the P-channel semiconductor among both. With the move of these electrons, it becomes the condition like spans a bridge for electrons between drain and source. The size of this bridge is controlled by the voltage to apply to the gate.

29 Components (Manual) Resistor 0.50Ω 1.00Ω 1.40Ω FUSE SPRING 190.0±7 PBF SPLDER HIMH ML LOW CIRCUIT OF DIAGRAM

30 APT (Automotive Pressure Transducer) Components (Auto, Manual) 1. Specification - Supply voltage : 5.0V - Operating temp. : -40 ~ Pressure range : 0 ~ 32 Kgf/ 2. Characteristics Approximately 4.8V Approximately 0.2V Normal Operating range OUTPUT (Vdc) Pressure (kg/ )

31 Components (Auto) Ambient sensor & AQS In-car & Humidity sensor Photo sensor Water temperature sensor AQS sensorAmbient sensor

32 Fresch air DEF DOOR VENT DOOR FOOT DOOR PTC Heater EVAPORATOR PTC HEATER HEATER CORE Heater core with PTC heater

33 PTC Heater 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) Block diagram 3* : PTC relay 3 will be off if battery power is 11.5V or less

34 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 : Below 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

35 PTC Heater 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. PTC Heater operation check

36 Failsafe (Manual) NOITEMFAILURE CONDITIONFAILSAFE 1Evaporator sensor Less than 0.1V or Higher than 4.9V Compressor OFF 2 Temp. door potentiometer Fix at the position 3 Mode door potentiometer 4 Intake door potentiometer Failsafe mode

37 Failsafe (FATC) NOITEMFAILUREFAILSAFE 1In-car sensor Short to battery or open Replaced by 25 2Ambient sensor Replaced by 20 3Evaporator sensor Replaced by -2 4Water temperature sensor Replaced by -2 5Temp. door potentiometer 17 ~ 24.5 : fix to MAX COOL 25.0 ~ 32 : fix to MAX HOT 6Mode door potentiometer At Vent mode : fix to Vent mode At other mode : fix to DEF mode 7Intake door potentiometer Fix to FRE / REC mode 8Photo sensorCorrection control inhibited 9AQSControl inhibited 10Humidity sensorReplaced by humidity 10% A/C sensor failsafe mode

38 Failsafe (FATC) DTC reading procedure Press AUTO Press OFF Press mode 4 times Keep pressing Ignition switch : OFFON Press the MODE switch more than 4 times within 2 seconds during pressing the OFF switch. Return to original condition Self-diagnosis (Step operation by A/C SW) Self-diagnosis (Continuous operation) After graphic symbol display blinks 3times, start self-diagnosis

39 Failsafe (FATC) DTC list (Binary code displayed on the controller) DTCDESCRIPTION 00NORMAL 11 INCAR SENSOR OPEN 12 INCAR SENSOR SHORT 13 AMBIENT SENSOR OPEN 14 AMBIENT SENSOR SHORT 15 WATER TEMP SENSOR OPEN 16 WATER TEMP SENSOR SHORT 17 EVAP SENSOR OPEN 18 EVAP SENSOR SHORT 19 TEMP DOOR POTENTIOMETER OPEN/SHORT(DRIVER SIDE) 20 DEFECTIVE TEMP DOOR POTENTIOMETER 21 MODE DOOR POTENTIOMETER OPEN/SHORT(DRIVER SIDE) 22 DEFECTIVE MODE DOOR POTENTIOMETER 23 HUMIDITY SENSOR OPEN 24 HUMIDITY SENSOR SHORT

40 Failsafe (FATC) DTCDESCRIPTION 25INTAKE DOOR POTENTIOMETER OPEN/SHORT 26DEFECTIVE INTAKE DOOR POTENTIOMETER 27AQS SENSOR OPEN 28AQS SENSOR SHORT 31DEFECTIVE AQS SENSOR DTC list (Binary code displayed on the controller)

41 Hi-scan (current data) – 8 items Diagnosis

42 Hi-scan (Actuator test) Diagnosis

43 Hi-scan (Actuator test) Diagnosis

44 Diagnosis Hi-scan (Actuator test)

45 Diagnosis Hi-scan (Actuator test)

46 Intake door value change Diagnosis

47 Diagnosis Identification check