AIR CONDITIONER

TRAINNING MANNUAL
BEHR INDIA LTD
BEHR
INDIA LTD
 BEHR INDIA LTD
Behr is German word. Behr is a group of companies who
manufacture
f automotive
i parts. Behr
B h IIndia
di lltd
d one company off behr
b h group.
Behr India is German collaborated company. In India Anad group took this
collaboration. In India behr start production in 1998, in pune.
Behr India is TS certified company.
company
Product of behr : Behr India ltd manufacture HVAC system. Behr is
O.E. supplier for Tata (for all models) and Mahindra. For Tata behr have
50% share but in Mahindra it is 100%. Other customers are Genral Motors,,
Ashok Leyland, Force Motors
Behr India ltd also Exporting heat exchanger unit (condenser and
cooling coil). Not only this but exporting Wiring Harness and some
component for Euro system to Germany.
Turn over of Behr is 250 cores.
 INDEX
¾ INTRODUCTION
¾ REFRIGERATION CYCLE
¾ MAIN COMPONENTS
¾ SAFTEY COMPONENTS
¾ FACTOR EFFECTING ON A/C
PERFORMANCE
¾ REFRIGERANTS AND PROPERTIES
¾ LEAK TEST
¾ PERFORMANCE TEST
¾ TRUBLE SHOOTING
WHAT IS A/C ?

1. TEMPERATURE

2. AIR PRESSURE

3 CLEAN AIR
3.

4 HUMIDITY
4.
REFRIGERATION
CYCLE
 MAIN PARTS
1. COMPRESSOR

2. CONDENSOR

3. EXPANSION VALVE

4. COOLING COIL

5. R/D BOTTLE
 COOLING COIL

C E
O X
M P
P A
R N
E T
S I
S O
O N
R V

CONDENSOR
 EXPENSION VALVE

LOW PR.
R/D BOTTLE

SUCTION LINE

COMPRESSOR
QUID LINE )

FIRE WALL
HIGH PR ( LIQ

ND. FAN
H

CON

A/C CYCLE
A/C CYCLE

z COMPRESSION

z CONDENSATION

z EXPANSION

z EVAPORATION
Cooling coil ANTIFREEZE SWITCH

Expansio
n valve
L.P.S.

H PS
H.P.S. PR SWITCH
PR.SWITCH
A/C CYCLE P-H DIAGRAM :-

c CONDENSATION b

d a
VAPORISATION

Temp
PARTS DISCRIPTION OF
A/C SYSTEM
¾COMPRESSOR
z DRAWS OFF VAPOUR
REFRIGERANTS FROM
EVAPORATOR
z RISE THE PRESSURE OF
VAPOUR REFRIGERANTS
z ALSO RISE THE
TEMPERATURE OF
REFRIGERANTS
¾CONDENSOR

z REMOVE THE
HEAT FROM
VAPOUR
REFRIGERANT
z CHANGE PHASE
OF GAS TO
LIQUID
 MULTIFLOW CONDENSER

IN

OUT
 Condenser Radiator

COOL AIR

HOT AIR

Condenser fan
 ¾RECIVER &
DRIER
z REMOVE DUST
PARTICLE FROM
REFRIGERANTS
z ABSORB
MOISTURE IF
ANY IN SYSTEM
z STORE THE GAS
IN IT
IT.
R/D BOTTLE PRESSURE SWITCH
REF. IN REF. OUT

BRASS WIRE MESH

DRIER
9DRIER USED IN R/D BOTTLE
z SILICA JEL

ADDITIONAL :-
z CALCIUM CHLORIDE
z CALSIUM CARBONATE
¾EXPENSION VALVE
z REDUCE PRESSURE
OF REFRIGERANTS
z REDUCE
TEMPERATURE
z REDUCE BOILING
POINT OF
REFRIGERANTS
z CONTROL THE QTY
OF REFRIGERANTS
FLOW TO COOLING
COIL
THERMOSTATIC EXPANSION VALVE

IN

OUT
 ¾COOLING
COIL(EVAPORATOR)
z CHANGE LIQUID
REFRIGERANTS
TO VAPOUR
z MAKE AIR COOL
BY TRANSFERING
THE HEAT TO
REFRIGERANT
SAFETY DEVICES
 PROTECTION DEVICES
9 DUAL PRESSURE SWITCH

9 THERMOSTAT (ANTIFREEZE SWITCH)

9 THERMISTER (ONLY IN MPFI VEHICLE)

9 MICRO – SWITCH
 o DUAL PRESSURE
SWITCH

z TRIP OFF/ON A/C IF PRESSURE OF

GAS RISE AND GO DOMN
SPECIFIC.

9 OPERATING PRESSURE

LOW SIDE OFF < 2BAR ON > 3BAR

HIGH SIDE OFF – 32BAR ON – 27BAR

 DUAL PRESSURE SWITCH
TERMINAL

SPRING CASE

CONTACT POINT
HOUSING

O’RING DIAPHRAGM

PRESSURE
 THERMOSTAT
z PREVENT FORMATION OF
FROSTING IN COOLING COIL
FACTOR AFFECTING
ON
A/C
A/CP
PERFORMANCE
EFFECT OF SUBCOOLING :-

c’ c b

d
dd’ a

heat
EFFECT OF SUPERHEATING :-

c b b’

d a
a’

heat
EFFECT OF SUCTION PR. :-

c b b’

d Ps a
d’ a’
Ps’

heat
EFFECT OF DISCHARGE PR. :-

c’ Pd’ b’
c
Pd b

a
d dd’

heat
ACTUAL A/C CYCLE DIAGRAM. :-
f
g
Pd
h
j i
k
c
a Ps b e
d

heat
REFRIGERANTS
AND

PROPERTIES
INDEX
z INTRODUCTION
z TYPES
z PROPERTIES
z LEAK DETECTION
z COLOR CODE
DEFFINATION

The heat carrying media

employed in refrigerating system in
g
known as refrigerant.
Refrigerant absorb heat at
one p
place at low p
pressure and
temperature and reject at high
pressure and temperature.
PROPERTIES

z PHYSICAL PROPERTIES

z CHEMICAL PROPERTIES

z THERMAL PROPERTIES
9PHYSICALPROPERTIES

1. Leak tendency and detection

2 Viscosity and thermal conductivity
2.
3. Action with oil
4. Cost
5. Personal preference
p
 9CHEMICAL
ICALPPROPERTIES

z NON-FLAMMABLE
z NON
NON-EXPLOSIVE
EXPLOSIVE
z NON-TOXIC
z NON-REACTIVE
NON REACTIVE WITH
CONSTRUCTIVE MATERIAL
z DAMAGE TO REFRIGERATING
PRODUCT
 9THERMODYNAMIC
ICPPROPERTIES

z BOILING & CONDENSING PRESSURE

z FREEZING POINT (TEMPERATURE)
z LATENT HEAT
z VOLUME FLOW PER TON
z COEFFICIENT OF PERFORMANCE
AND POWER REQUIRED PER TON
 REF. FREEZING
TEMPERATURE
REFRIGERANT FREEZING TEMP(C)
( )
AMMONIA -77.3
CARBON DIOXIDE -56 6
-56.6
R - 11 -111
R - 12 -157.4
157 4
R - 22 -160.5
R – 134a -127.5
WATER 0
 PRESSURE V/S TEMPERATURE

50

40 PRESSURE(
PRESSURE

30 R-12)

20 PRESSURE
(R-134)
10
PRESSURE
0
-45 90
(R-22)
0
TEMPRATURE
- 45 TO 90 C
ANIL-BEHR
 LEAK DETECTION
z BUBBLE METHOD
z HALIDE TOURCH METHOD
z ELECTRONIC DETECTOR
z SPECIAL METHOD FOR DETECTION OF
AMMONIA AND SULPHER DIOXIDE
 COLOR CODING
OF
REFRIGERANT CYLINDER
 COLOUR CODE FOR REFRIGERANT
CYLINDERS
REF NMBR
REF.NMBR REF NAME
REF. CYL .COL.
COL COD

R – 11 CCl3F ORANGE
R – 12 CCl2F2 WHITE
R – 13 CClF3 PALE BLUE
R – 22 CHClF2 GREEN
R – 134a CH2FCF3 VOILET
R - 717 AMMONIA SILVER
 EFFECT OFMOISTURE
z CLOGING OF EXPANSION VALVE
z CORROSION OF TUBE
z CORROSION OF COMPRESSOR
z REDUCE THE COOLING EFFECT
z CLOG OF COOLING COIL
 AIR CONDITIONER
PERFORMANCE TEST
 1. OPEN DOOR TEST
¾ RECIRCULATION MODE
¾ VEHICLE SHOULD BE UNDER SHED
¾ BLOWER ON 3RD SPEED
¾ ENGINE RPM 1500 TO 2000
¾ ALL DOOR OPEN

IN OPEN DOOR TEST GRILL TEMPERATURE

SHOULD BE 10 DEGREE LESS THEN AMBIENT
TEMPERATURE.
 2. CLOSE DOOR TEST
¾ RECIRCULATION MODE
¾ VEHICLE SHOULD BE UNDER SHED
¾ BLOWER ON 3RD SPEED
¾ ENGINE RPM 1500 TO 2000
¾ ALL DOOR SHOULD CLOSED

IN CLOSE DOOR TEST GRILL TEMPERATURE

SHOULD BE LESS THEN 10 DEGREE CELCIUS IF
AMBIENT TEMPERATURE IS 40 DEGREE CELCIUS
WITHIN 10 MINUTES.
IM
P
ORTANT SERVICE
P
OINTS
COMPRESSOR OIL AMOUNT TO BE CHARGED
WHEN ANY SYSTEM PARTS REPLACED
(USE OIL DENSO-8 ONLY)

SYSTEM WITH COMP. 110CC :-

REPLACED PART AMOUNT OF OIL TO BE

CHARGED
EVAPORATOR 25 30
25-30cc
CONDENSOR 25-30cc
RECIVER/DRIER
/ 25-30cc
HOSES/PIPES 15-20cc
RECHARGING SYSTEM 15-20cc
COMPRESSOR OIL AMOUNT TO BE CHARGED
WHEN ANY SYSTEM PARTS REPLACED
(USE OIL DENSO-8 ONLY)

SYSTEM WITH COMP. 130CC :-

REPLACED PART AMOUNT OF OIL TO BE

CHARGED
EVAPORATOR 30 35
30-35cc
CONDENSOR 30-35cc
RECIVER/DRIER
/ 30-35cc
HOSES/PIPES 15-20cc
RECHARGING SYSTEM 15-20cc
 GAS QUANTITY TO BE CHRGED

GAG QUANTITY
DLS/DLE/LEI/INDIGO DLX/LXI
COMP.TYPE OIL TYPE OIL QTY SMALL R/D BIG R/D SMALL R/D BIG R/D
((CC)) ((GRAMS)) ((GRAMS)) ((GRAMS)) ((G.M.S))

130cc ZEXAL 750 800

140 ----- +/-20 -----
(ZEXAL) OIL +/-10
HS-130cc DENSO-8 ----- 800 640 810
140
+/-10 +/-20 +/-10
HS-110cc DENSO-8 620 640
120 ----- -----
+/-20
/ +/-20
TRUBLE SHOOTING
¾ A/C COOLING LESS (A/C NOT EFFECTIVE)
¾ A/C TRIPPING
¾ COMPRESSOR NOISE
¾ AIR DIRECTION MODE NOT WORKING
¾ BLOWER NOT WORKING
¾ GAS LEAKAGE
¾ BAD SMEEL ENTERING IN CABIN
¾ RADIATOR FAN NOT WORKING
WHEN SYSTEM IS NORMAL THEN PRESSURE

ENGINE SPEED : 1500-2000rpm

AMBIENT TEMP : 30-35 C
BLOWER SPEED : 3rD
TEMP CONTROL : MAX COOLING

PRESSURE CONDITION :

LOW SIDE HIGH SIDE

2-3bar 16-18bar
INSUFFICIENT REFRIGERANT
z PRESSURE IS LOW ON BOTH
THE LOW PRESSURE AND
HIGH PRESSURE
z AIR COMES OUT IS NOT COOL.

9PRESSURE STATUS :

PRESSURE IN LOW SIDE < 1.5 bar

PRESSURE IN HIGH SIDE < 15 bar

 REFRIGERANT FAIL TO CIRCULATE
z WHEN COMPLETELY CLOGGED UP VACUUM IS
IMMEDIATELY INDICATED ON LOW PRESSURE
SIDE
z WHEN SLIGHTLY CLOGGED UP VACUUM IS
GRADUALLY INDICATED ON THE LOW PRESSURE
SIDE

9PRESSURE STATUS :
PRESSURE IN LOW SIDE - VACUUM

PRESSURE IN HIGH SIDE < 14bar

M
OISTURE ENTERED IN SYSTEM

z THE AIR CONDITIONOR OPERATES

NORMALLY AT THE BEGINNING, BUT
OVER THE TIME,
TIME VACUUM IS
INDICATED ON THE SUCTION SIDE

9PRESSURE STATUS :
SUCTION PRESSURE - VACUUM

HIGH SIDE PRESSURE – 16-18bar

COMP
RESSOR COMP
RESSON FAILURE

z PRESSURE IN SUCTION SIDE IS HIGH AND ON

HIGH SIDE PRESSURE IS LOW
z WHEN A/C IS SWITCH OFF THE HIGH AND LOW
PRESSURE EQUALISE FREQUINTLY.

9PRESSURE STATUS :
SUCTION PRESSURE > 2.5bar
HIGH SIDE PRESSURE < 14bar
SYSTEM
MOVERCHARGED,
OVERCHARGED, OR INSUFFICIENT
CONDENSOR COOLING

z PRESSURE IS HIGH ON BOTH

SUCTION SIDE AND HIGH
PRESSURE SIDE

9PRESSURE STATUS :

SUCTION PRESSURE > 2.5bar

2 5bar

HIGH SIDE PRESSURE > 18bar

AIR ENTERED IN THE SYSTEM

z PRESSURE IS HIGH ON BOTH SUCTION

SIDE AND HIGH PRESSURE SIDE
z SUCTION SIDE HOT IN TOUCH

9PRESSURE STATUS :

SUCTION SIDE > 2.5bar

2 5b

HIGH SIDE PRESSURE > 18bar

EXPENSION VALVE OPEN TOO FAR
z PRESSURE IS HIGH
ON SUCTION SIDE
z FROST APPEARS
ON SUCTION SIDE

9PRESSURE STATUS :

SUCTION PRESSURE > 2.5bar

HIGH SIDE PRESSURE - NORMAL

 INDICA HVAC CIRCUIT
E1
- +
60A

BATT
12V IGNTION SW.

10A

IGN
RELAY

E5

IC4
E3 IC4
C0ND.
FAN
M IC5
HP
BL0WER.
SW.
M M0T0R
E4 ANTI-
ANTI
ICE SW

BL.RES.
A/C
SW
C0MPRESS0R
E2
CLUTCH
E6
 INDIGO HVAC CIRCUIT
E1
- +

BATT
12V IGNTION SW.

10A

IGN
RELAY

E5

IC4
E3 IC4
C0ND.
FAN
M IC5
HP
BL0WER.
SW.
M M0T0R
E4 ANTI-
ANTI
ICE SW

BL.RES.
A/C
SW
C0MPRESS0R
E2
CLUTCH
E6
THANKS