The provided document is an Owner's Manual and Warranty Certificate for the Valeo AIR CONDITIONING ARTICULATED CITYBUS, specifically models CC 646 MS and CC 676 MS.
Function Description
The Valeo AIR CONDITIONING ARTICULATED CITYBUS system is designed to provide heating, ventilation, and cooling (HVAC) for commercial vehicles, particularly buses. It aims to maintain a comfortable and controlled internal temperature for passengers. The system utilizes a refrigerant-based cooling cycle and can include an optional heating function. Control is managed through SCB 400-410 or SCB2000 controllers, which allow for automatic or manual operation of cooling, heating, and fan speeds. The system is designed for reliability and ease of maintenance, with features like fault diagnosis and automated control.
Important Technical Specifications
The manual provides detailed technical specifications for both CC 646 MS and CC 676 MS models:
General Air Conditioning:
- Maximum Capacity:
- CC 646 MS: 218,500 BTU/h (64kW)
- CC 676 MS: 230,000 BTU/h (67kW)
- Evaporator Air Flow: 13,200 m³/h for both models
- Condenser Air Flow: 17,400 m³/h for both models
- Unit Weight (Ceiling, without integrated heating system):
- Condenser/Evaporator: 152 Kg for both models
- Evaporator: 91.5 Kg for both models
- Refrigerant Gas: R134a - 8.3 Kg for both models (gas load values may vary by application)
- Dimensions (L x W x H):
- Condenser/Evaporator: 3100 x 1698 x 225 mm for both models
- Evaporator: 1996 x 1698 x 225 mm for both models
Compressor:
- Type:
- CC 646 MS: Bock FK40 / 755 cm³
- CC 676 MS: Bock FK50 / 775 cm³
- Weight (without clutch):
- CC 646 MS: 31 Kg
- CC 676 MS: 42 Kg
Control System:
- Digital Electronic Control: Smart commands, automated control (maintains programmed temperature), manual or automatic fresh air flap control, and fault diagnosis alarms.
- Relay Board: High reliability, easy maintenance.
- Compressor: High performance, long durability.
- Blower/Fan: Low noise, high performance, long durability.
Components (Condenser):
- Condenser Central Closing (1)
- Extruded Aluminum C Profile (2)
- Condenser Coil (1)
- Axial 24V 12" Electronic Condenser Fan (6)
- Discharge Pipe Set (1)
- Front Finish Cover (1)
- Condenser Liquid Line Set (1)
- Liquid Tank / Drier Filter (1)
- Tank Liquid Line Set (1)
- Finishing Rubber (2)
- Condenser / Evaporator Base w/ Renewal (1)
- Condenser Electric Wiring Harness (1)
Components (Evaporator):
- Central Evaporator Closing (1)
- Front Finish Cover (1)
- Air Renewal Set With Filter (1)
- Air Renewal Filter Set (1)
- 24V Air Renewal Electric Engine (1)
- Evaporator Wire Harness (1)
- Electric Control Board 24V (1)
- TGEN 3.5 TR Expansion Valve (2)
- Right Evaporator Coil (1)
- Left Evaporator Coil (1)
- Evaporator Liquid Line Tube Set (1)
- Suction Tube Set (1)
- 24V Radial Fan (6)
Components (Compressor - BOCK FKX 40/755K - FKX 50/775K):
- BOCK FKX40/755K or BOCK FKX50/775K Compressor (1)
- Pulley 2A/2B (1)
- Compressor Valve Board Set (2)
- Compressor Oil Pump (1)
- Compressor Sealing Kit (1)
- FKX40 or FKX50 Piston Assembly (4)
- Compressor Roll Bearing (2)
- Compressor Oil (2)
- Compressor Clutch Assembly (1)
- Ball Roller Bearing (1)
- Magneto (1)
Components (Electric):
- SBU-400 Refrigeration Air Conditioning Controller (1)
- SBU-410 Air Conditioning Controller w/ Heating w/ Renewal (1)
- Electric Control Board 24V (1)
- Relay (variable quantity)
- High or Low Pressure Switch (1)
- External Temperature Sensor (1)
- NTC Anti Freeze Thermostat (1)
- 125A Fuse (1)
- Fuse Holder (1)
- 2CP4S-4 Temperature Sensor (1)
Usage Features
The air conditioning system can be operated using either SCB 400-410 or SCB2000 controllers, which offer both basic and full versions.
SCB 400-410 Controller:
- Display: Shows current room temperature and error warnings.
- Status Light: Indicates enabled functions (red light means enabled).
- On/Off Button: Switches the system ON and OFF.
- Auto Button: Activates automatic evaporator fan start-up.
- AC Button: Enables or disables the cooling function.
- Evaporator Fan Speed Button: Manual control of evaporator fan speed (increases from low to high, then cycles back to low).
- Evaporator Fan Speed Display: Shows current fan speed.
- Temperature Set-point Buttons (UP/DOWN): Adjusts the desired room temperature (17°C to 28°C in 0.5°C increments).
- Ventilation Button (SCB410 only): Controls the recirculation function (ON/OFF).
- Auto Mode: Automatically adjusts fan speed based on the desired temperature. If the fan speed is manually changed, auto mode is disabled.
- ON/OFF Air Conditioner Compressor: The compressor enables after condenser fans run for 10 seconds. It will run for at least 1 minute before shutting down, even if disabled immediately after enabling.
- Heating Mode (SCB410 only): Controlled by set-point and parameters P23 and P24, affecting floor convectors and SBU400 units.
- Ventilation Function: When disabled, external air enters the vehicle. Enabling can be automatic based on internal temperature and parameters P49/P50, or manually controlled.
- Faults (Errors): The display shows error codes (e.g., F00, F01) for various issues like low refrigerant, faulty sensors, or wiring problems, with corresponding solutions provided in the manual.
SCB2000 Controller:
- ON/OFF Button: Turns the product ON/OFF.
- AC Button: Indicates compressor readiness for operation.
- Increment/Decrease Set-point Buttons: Defines the desired room temperature.
- Auto Button: Activates automatic fan speed and air renewal mode.
- VENT Button: Manual speed control of evaporator fans.
- Re-Heat Button: Turns on/off the passenger window defroster.
- Air Recirculation Button: Turns on/off air recirculation on the bus.
Maintenance Features
The manual emphasizes the importance of preventive maintenance for optimal performance and warranty coverage.
Preventive Maintenance Frequency Check List:
- Weekly:
- Clean or change return air filter.
- Check belt stretchiness, compressor, and alternator alignment, observing wear.
- Check radiator reservoir water level (fill with water and additives if necessary, following OEM recommendations).
- Monthly:
- Accomplish weekly checks.
- Clean condenser capillary tube coil with water and neutral non-aggressive soap (protect electrical/electronic components).
- Check if evaporator hatches are closed.
- Check refrigerant charge (liquid display without bulb formation after 15 minutes).
- Check compressor oil level (3/4 to 1/4 full at oil display after 15 minutes).
- Test equipment operations: cool, fan (high/low), heat, dry (air renewing) modes.
- Lubricate compressor support components (articulation, axles, bushing, pulleys).
- Operate heating system for at least 30 minutes.
- Trimestral:
- Accomplish monthly checks.
- Measure exhaust suction pressure, temperature, and suction line condition.
- Check tightening of alternator potency cables, fuses, electric board, and start motor.
- Measure condenser and evaporator fan flow consumption (check air outflow).
- Measure electromagnetic clutch coil.
- Measure Voltage and Current from alternator.
- Semester:
- Accomplish trimestral checks.
- Clean evaporator capillary tube coil with water and neutral non-aggressive soap (protect electrical/electronic components).
- Clean evaporator drain.
- Check oil retainer felt of compressor sealing part.
- Check for leakages at coupling spots (oil, refrigerant).
- Check for loose, damaged, broken, worn, rusty, melting, cracked, or bad fractioning parts to the bus body.
- Yearly:
- Accomplish semester checks.
- Test compressor efficiency at 1500 RPM.
- Note compressor oil pressure at 1000 RPM.
- Check opening and closing pressures of high and low pressure switches.
- Check screws/bolts attaching compressor support and equipment, ensuring correct torque.
- Clean air conditioning body, removing dust/scrap from components: evaporator, condenser, clutch compressor, alternator, relay, and control board.
Specific Maintenance Recommendations:
- Refrigerant Gas R134a: Use only R134a. Do not spoil refrigerant into the atmosphere.
- Dry Filter: Replace every 3 years, or whenever refilling gas.
- Compressor Sealing Part: Operate AC in cool mode for at least 15 minutes every 15 days to lubricate the sealing part. Dispose of old oil according to regulations.
- Heating System: Enable frequently (once a month) to prevent particle buildup in the hot air shutoff valve seat. Check reservoir water level.
- Oil: Change air system oil every two years or 10,000 working hours, whichever comes first.
- Ducts: Clean air ducts every three months, or more frequently depending on usage and environment. This is the vehicle owner's responsibility.
- Pulley Belts: Maintain optimal tension to prevent overheating, skidding, and premature wear. Check tension after 48 working hours post-change. Use same brand, diameter/length assemblies. Avoid using new belts with old ones.
- Reconditioned Parts: Avoid using reconditioned parts as they can reduce efficiency, overcharge the electric system, cause early compressor failure, and pose fire risks.
Warranty Terms:
- Two-year warranty from installation date, provided installation is by an authorized third party (product only) or by VALEO Climatização do Brasil.
- Covers workmanship and spare parts for premature material/component defects.
- Repairs must be performed by a VALEO authorized technician.
- Warranty approval is subject to technical analysis.
- No claims accepted if the vehicle is in use after defect is found, or due to lack of parts/transport delay.
- Warranty Invalidated if: Installation/use not per VALEO technical recommendations, improper use, neglect, accident, external agent failures, lack of maintenance, unqualified repairs, altered/damaged warranty certificate/serial number, or use of non-original spare parts.
- Warranty Does Not Cover: Bus displacement for repairs, attendance in cities without authorized service providers (owner's responsibility for displacement costs), lack of proper preventive maintenance, and replacement of natural wear items (bearings, belts, filters, lubricating oil).
- Limited Warranty for Wear Items: Bearings (60,000km or 2 years), Belts (20,000km or 3 months), SEG Alternators (1 year, no mileage limit), Prestolite Alternators (2 years, no mileage limit).
- Does not cover loss of profits due to vehicle stoppage.
Equipment Identification:
- Customers must identify the model, series number, and manufacturing date when ordering spare parts. This information is found on the Warranty Certificate and ID tag.
- The ID tag includes Model, Date, Serial Number, Code, Refrigerant Gas Type (R134A), and Quantity (Kg).
Sustainability:
- Valeo promotes environmentally sound and safe disposal of products and components.
- Proper disposal contributes to environmental preservation and pollution reduction.
- Adheres to Law 12,305 / 2010 for environmentally adequate destination of components (parts, oil, refrigerant).
- Information on the Reverse Logistics Program is available on the Valeo website.
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