156 Introduction - AIR CONDITIONING CASING AND COMPONENTS

Valid for versions with:Air Conditioner

Version with variable displacement compressor.

1, Outside air temperature sensor

2, Upper mixed air temperature sensor
3, Lower mixed air temperature sensor
4, Passenger compartment air temperature sensor
5, Electronic control unit
6, Mixer actuator
7, Distribution actuator
8, Electronic fan motor speed variator
9 , Fan motor
10, Recirculation flap actuator
11, Air conditioner compressor (variable displacement)
12, Electronic injection control unit
13, Four stage pressure switch
Valid for versions with:Air Conditioner

Air conditioner compressor

The compressor fitted on these versions is the variable capacity SANDEN SD7V16 type.
According to variations in the system load conditions - changing external temperature
and/or humidity or sharp variations in the engine load - the compressor processes the fluid

through a capacity which starting from the maximum value of 161.3 cm 3 /rev, is gradually
reduced to 10.4 cm 3 /rev: this solution is defined 'unlimited variable displacement';
it protects the evaporator against freezing so effectively that a frost sensor is not necessary.
The compressor is the alternating piston type: the variation in the capacity is achieved by
titling the connecting rod holder plate with a consequent variation in the piston stroke: the
movement of the plate is activated by an internal adjustment valve according to the balance
of pressure upstream and downstream of the compressor. In particular, a low inlet pressure
involves the shuttering of the compressor (reduced capacity), whilst a high pressure
involves operation at maximum power (maximum capacity).
Valid for versions with:Manual Air Conditioning

CONSTRUCTION FEATURES
TWIN LEVEL AUTOMATICALLY
CONTROLLED CLIMATE CONTROL
SYSTEM
The automatic climate control is managed by a control unit which, thanks to an extremely
sophisticated operating logic, is capable of controlling the temperature in two areas of the
passenger compartment, heating or cooling the incoming air so that it reaches the desired
temperature. It is also capable of demisting the windscreen surface and the side windows
relatively quickly which improves safety.
This performance is achieved thanks to the excellent software logic and the air distribution.

Location of system components

The diagram shows the location of the main components.

1 - Air conditioning compressor

2 - Pulley with compressor electro-magnet coupling
3 - Air conditioning condenser with drier filter incorporated
4 - 4 stage pressure switch
5 - Expansion vlve
6 - Evaporator unit
7 - Low pressure connector
8 - High pressure connector
9 - Temperature setting display
10 - Fan speed display
11 - Air distribution display
12 - Temperature selection knob
13 - Fan speed control knob
14 - Air distribution selection knob

Interior air circulation diagram

The diagram illustrates the circulation of the air in the passenger compartment.

1 - Upper fixed vent for defrosting or demisting windscreen

2 - Upper centre adjustable vent
3 - Fixed vents for defrosting or demisting side windows
4 - Adjustable centre vents
5 - Adjustable side vents
6 - Front footwell fixed vents
7 - Rear footwell fixed vents
8 - Adjustable rear vents

Conveyer/distributor unit
It consists of two modules which contain inside:

the fan
the evaporator
the heater radiator

The diagram below illustrates a cross section of the assembly

1 - Intake/recirculation air flap

2 - Electric fan
3 - Evaporator
4 - Air mixture flaps
5 - Heater radiator
6 - Air distribution flaps

A - Recirculation air flow

B - Outside air flow
C - Windscreen/side windows air flow
D - Centre and side vents air flow
E - Interior air vents flow
The electric fan directs the flow of outside air towards the interior of the vehicle.
The air introduced into the passenger compartment from the outside passes through a
combined filter, i.e. consisting of two layers:

the first 'particle' layer has the task of trapping the small particles of fine dust and
pollen
the second 'active charcoal' layer is designed to trap certain pollutant elements in the
atmosphere.

If, on the other hand, the recirculation function is activated, the special flap directs the flow
of air from the inside the pasenger compartment. The flow of air initally comes into contact
with the evaporator, then it partly or totally envelops the heater radiator, depending on the
position of the mixture flap. Lastly, the air is sent to the various vents depending on the
position of the upper, centre and lower distribution flaps. All the flaps are operated by
electric motors controlled by the control unit.

1 - Electric fan
2 - Evaporator
3 - Heater radiator
4 - Recirculation flap actuator
5 - Mixed air flap actuator
6 - Distribution flap actuator
7 - Combined filter element
8 - Fan electronic variator
All the flaps are opreated by special actuators and kinematic mechanisms controlled by the
control unit.

Electronic control unit

The diagram below illustrates the system controls.

1 - Compressor enabling/disabling button (orange LED)

2 - Recirculation control button (orange led)
3 - Temperature selection knob
4 - Internal fan speed control/off knob
5 - Air distribution selection knob
6 - Heated rear window control button (amber led)
7 - MAX-DEF function control button (amber led)
The climate control system automatically controls the temperature and ventilation with
recirculation.
The user can select the desired temperature within the limitations of the system.
The climate control system controls the temperature by heating or cooling air taken into the
passenger compartment to achieve the required level of comfort.
The following parameters/functions are adjusted on the manual control:

Temperature requested
Fan speed;
Distribution direction
Compressor disablement
Defrosting/demisting function
Recirculation.

The entire system can be switched OFF manually, completely deactivating the air
conditioning system, using the centre knob (except for the recirculation and heated rear
windscreen), insulating the passenger compartment from the outside ambient.
The MAX-DEF function makes it possible to group together a collection of actions which
allow both the windscreen and the rearscreen to be demisted quickly.

Control unit pin out

The electronic control unti has two connectors:
A) 26 pin connection
B) 26 pin connection

PIN

SIGNAL

A1

Fan temperature feedback signal

A2

N.C.

A3

Power earth NCL

A4

+30

A5

Side light positive

A6

N.C.

A7

Positive controlled by the ignition (INT)

A8

Positive controlled by the ignition (INT/A)

A9

Fan control PWM signal

A10

N.C.

A11

Compressor engagement request signal

A12

N.C.

A13

Diagnostic line K

A14

N.C.

A15

N.C.

A16

N.C.

A17

N.C.

A18

N.C.

A19

N.C.

A20

N.C.

A21

N.C.

A22

N.C.

A23

N.C.

A24

N.C.

A25

N.C.

A26

N.C.

B1

N.C.

B2

N.C.

B3

N.C.

B4

N.C.

B5

Heated rear windscreen demisting LED

B6

MAX DEF control

B7

Heated rear windscreen demisting control

B8

N.C.

B10

Mixer actuator B

B11

Mixer actuator B

B12

Mixture actuator A

B13

Mixture actuator A

B14

N.C.

B15

N.C.

B16

N.C.

B17

N.C.

B18

Recirculation actuator A

B19

Recirculation actuator A

B20

Recirculation actuator B

B21

Recirculation actuator B

B23

Coil distribution actuator A

B24

Coil distribution actuator A

B25

Coil distribution actuator B

B26

Coil distribution actuator B

Each time a new control unit is fitted, the flap actuator learning test must be carried out
using the diagnostic equipment and the unit must be personalized through
programming.

Fault diagnosis
The control unit uses sensor monitoring and adjustment software with actuator self-adaption
to record and store a series of anomalies and faults that could affect the system.
These stored errors may be read using an Examiner and connecting to the diagnostic socket.

Controls and functions

Air flow rate/control unit off knob
Turning the knobs in a clockwise direction increases the temperature, in an anti-clockwise
direction it decreases the temperature.
When the knob is turned anticlockwise to the end of its travel, the climate control unit goes
off.
With the compressor enabled, the minimum air flow rate is one bar, therefore it is not
possible to decrease the air flow rate below this value because the control unit would switch
off.

Passenger compartment temperature setting knobs

Turning the knobs in a clockwise direction increases the temperature, in an anti-clockwise
direction it decreases the temperature.

Air distribution control knob

When the knob is turned clockwise, the different air distribution modes are selected
cyclicaly (DEF, HEAT, FLOOR, BI_LEVEL, VENT, ecc,,).; when the knob is turned
anticlockwise, the system changes from VENT to BI_LEVEL etc..

Max def button

The MAX DEF procedure manages the flow rate and the distribution of the air with the aim
of demisting the windows as quickly as possible.

Air flow rate with 4 bars displayed

Distribution flap in DEF position
Mixer flaps set to maximum heating position
Forced air intake flap open (recycling off)
Compressor function enabled
Rear window demisting on

Heated rear windscreen

The rear defrosting is implemented both through the special button and through the MAX
DEF procedure.
The display of the function state is shown by the LED coming on/going off.
The function requesting the activation of the heated rear windscreen is only subordinate to
the key on. The HEATED REAR WINDSCREEN function is not memorized with the
ignition switched OFF.

Actuators
Stepping motors
The rotor which includes a certain number of pairs of permanent polymagnets, is in a rest
position (minimum magnetic energy) due to the polar configuration imposed by the outside
of the electro-magnetically energized stator.

1 - Rotor
2 - Stator A casing
3 - Stator B casing
4 - Winding A
5 - Winding B
If the reversal of polarity of the energizing windings is carried out correctly by the digitally
controlled orders, the rotor turns exactly one step in the direction selected and moves into a
new rest position.
In this case the energizing current is independent from the load and if it is applied with a
rapid sequence of pulses (frequency) the stepping movement is transformed into a
practically continuous movement.
As with direct current geared motors, the polarity of the stator windings is correctly
reversed by means of switches which are formed by electronic power stages in the control
unit.
The number of steps for each rotation results from the number of polar pairs (P) of the rotor
and the number of phases (m) for the stator.
The typical positioning accuracty for these geared motors is about 5% of the stepping
angle and is mainly not connected to the total of positioning steps i.e. the positioning angle.
The angular increments (usually > 1.8) can vary according to the task that the geared motor
has to perform. These types of geared motor are widely used in new systems.

Air mixture flap actuators

The actuators rotate the mixture flaps according to the control unit command.
A motor with a 12 volt supply controls the rotary movement of a drive pin which acts
directly on the mixture flaps.

SPECIFICATIONS:

nominal voltage 12V

nominal operating frequency 200 Hz
nominal speed 1.67 RPM
steps per revolution 7200 (7200 impulses for 1 revolution)
reduction ratio 300
coil resistance 84 ohm

Air distribution actuator

The actuator moves via a rack slide, with guiding splines which contain the bearings and
two levers; there are 5 possible positions for the distribution flaps:

Main: DEF, VENT, FLOOR

Combined: BILEVEL, HEAT.

SPECIFICATIONS:

nominal voltage 12V

nominal operating frequency 200 Hz
nominal speed 5 RPM
steps per revolution 2400 (2400 impulses per rev)
reduction ratio 100
coil resistance 70 ohm

Recirulation actuator
The recirculation actuator rotates the flap in the two dynamic air and recirculation extreme
positions wihout intermediate positions.
A motor with a 12 V supply controls the rotary movement of a drive pin which acts directly
on the flap. Reversing the polarity produces movement in the opposite direction

SPECIFICATIONS:

nominal voltage 12V

nominal operating frequency 200 Hz
nominal speed 5 RPM
steps per revolution 2400
reduction ratio 100
coil resistance 70 ohm

The closing of the flap takes place in < 2.5 secs

The feedback control on all the mixture, distribution and recirculation motors is carried out
by measuring the difference in the current absorbed by the coils supplied to identify a loss in
steps corresponding to a mechanical failure or sticking.
Each time a new actuator is fitted the learning test has to be carried out using the
diagnostic equipment.

Evaporator
The evaporator is a heat exchanger fitted inside the blower/distributor unit. It consists of an
aluminium structure with fins which increase the heat exchange surface.

The evaporator is smaller than the condenser.

The refrigerant in the evaporator changes from a liquid state to vapour which is slightly
overheated.
This change in state is produced by directing the hot, humid air which needs to be treated
onto the evaporator using fan. As the temperature of the air is higher than that of the
refrigerant, it gives off some of its heat; on cooling, the humidity contained condenses on
the evaporator fins in the form of droplets. They are collected in a chamber and discharged.
This produces cool, dehumidified air.
The effective cooling is due to the change in state of the coolant fluid from a liquid to a gas.
This change takes place with a great deal of heat absorption. The process takes place
extremely quickly because the liquid is introduced into the coil atomized and at low
pressure through the expansion valve jet.
It can therefore evaporate very rapidly along the coil, absorbing a considerable amount of
heat.
If the evaporator coils are not supplied with sufficient refrigerant, the evaporation is limited;
in this case, operation would be poor with an insufficient heat exchange.
In the opposite case, if the supply to the evaporator coils is too large, the evaporation of the
coolant in the coils would be incomplete. In this case, the coolant might return to the
compressor, in a liquid state, which would damage the compressor pistons and the valves. In
addition, under these circumstances, operation would be poor with insufficient heat
exchange. Too high a pressure reading on the inlet pressure gauge or excessive oozing from
the evaporator coils and the intake pipes, accompanied by poor evaporator cooling, indicate
that the coil is receiving excessive refrigerant.
The evaporator can receive air from inside the vehicle (recirculation air) or from the outside,
thereby producing an exchange of air inside the passenger compartment. The evaporator is
chemically treated to be resistant to corrosion.

Heater
This is a heat exchanger connected to the engine cooling circuit by means of special pipes:
one draws hot water from the engine and allows the heating of the air introduced into the
passenger compartment, the other allows the return of the coolant to the engine.

Interior fan
The fan that sends outside or recirculation air to the evaporator battery is controlled by a
permanent magnet electric motor. It is located inside the casing, near the evaporator; it
receives a 12 V supply and is operated at different speeds by an electronic governor located
nearby.

1 - Fan speed electronic governor

2 - Electric fan

Electronic governor
The different fan rotation speeds are controlled by an electronic governor fixed to the actual
duct. The governor controls the voltage and therefore the motor supply current consequently
controlling the fan speed and air cubic metres/hour.
In addition, the governor processes a feedback signal with a frequency proportional to the
fan rotation speed. It is used as a control signal for the rotation speed of the motor to
diagnose increases in temperature due to current absorption or excessive mechanical
resistance; in practice, any malfunctions.

Pollen filter
There is a combined type air filter (PARTICLES + ACTIVE CHARCOAL) for the
passenger compartment to improve comfort. The former makes it possible to prevent the
intake of pollen and pollutant particles into the passenger compartment; the latter reduces
the tiresome sensation produced by unpleasant smelling substances due to dampness
forming on the surfaces.

1 - Filter
2 - Cover
The main specifications of the filter element are:

high filtering capacity: the filter retains more than 55% of particles with dimensions
between 3 and 5 microns and more than 90% between 5 and 10 microns.
easy to replace.