AIR CONDITIONING SYSTEM

CONTENTS 2

▶ SPECIFICATION
▶ INSTALL LAYOUT
▶ COOLING CIRCUIT
▼ PARTS IN ENGINE COMPARTMENT
- CONDENSER
- COMPRESSOR
▼ PARTS IN CABINE
- HEATER UNIT
- EVAPORATOR UNIT
* AIR FILTER
* BLOWER MOTOR
* POWER TR
* BLOWER RELAY
▼ ACTUATORS
- INTAKE DOOR ACTUATOR
- TEMP. DOOR ACTUATOR
- MODE DOOR ACTUATOR
▼ SENSORS
- APT SENSOR
- FIN THERMO SENSOR
- INCAR SENSOR
- PHOTO SENSOR
- AMBIENT SENSOR
- AQS
- HUMIDITY SENSOR
▶ TEMPERATURE UNIT CHANGE
▶ CONTROL LOGIC
▼ SELF DIAGNOSIS
- DTC LIST & FAILSAFE
▶ PTC HEATER
PURPOSE OF FATC 3

● Automatic temperature control strategy in vehicle

Reference Inference Engine Blend door linear

Temperatures control (Max cool
+ Determined to Max hot)
Setting
- discharge
Temperature Blower speed
air temperature,
linear control
air volume, (Lo to Max Hi)
+
Ambient
- compressor on/
Compressor control
Temperature off, air discharge (ON/OFF )
and inlet mode to
+ Air discharge mode
In-car - reach & maintain
control(Vent, Bi level,
Temperature the cabin comfort Floor)

Air inlet mode

Sun load control(Fre/Rec)
SYSTEM COMPARISON 4

Items EF Sonata NF(Sonata)

Compressor HS Type (Fixed) VS Type (Variable)

Condenser, Receiver Drier Condenser, Receiver Drier
Condenser
Seperated Integrated
APT
Pressure Detecting Triple switch
(Automotive Pressure Transducer)

HVAC Mounting Instrument Type Semi Center Mounting

Cooling Fan 2 Fan (Raiditor, Condenser) 1 Fan

Cooling Fan Control Relay PWM(Pulse Width Modulation)

Diagnosis Controller Controller or Hi-Scan pro

SYSTEM COMPARISON 5

EF SONATA
HVAC UNIT

Heater unit Evaporator Blower unit

unit

NF HVAC UNIT
Blower unit

HVAC unit
SYSTEM COMPARISON 6

FATC Control Unit

Manual Control Unit

SYSTEM SPECIFICATION 7

Items θ 2.0 θ 2.4 λ3.3

VS
Type ← ←
(Variable Swash Plate)
Compressor Capacity 180cc ← ←

Oil PAG 150g ← ←

Type 6PK ← ←
Pulley
Pulley Diagram 120mm ← 125mm

Condenser Type Sub Cool ← ←

APT Sensor Type Mul ← ←

Expansion valve Type Block ← ←

Type R-134a ← ←
Refrigerant
Quantity(g) 550 ← ←
INSTALL LAYOUT 8

3
2
1

NO Parts Name
1 Blower Assembly
2 HAVC Assembly
3 Air conditioner Controller(FATC)
4 Condenser and Cooling Fan Assembly

5 4
5 Expansion valve(Block type)
6 APT Sensor
7 Compressor Assembly
8 Low Pressure Horse
9 High pressure Horse

8 9
7
COOLING CIRCUIT 9
COMPONENTS
CONDENSER 11

R-134A, Parallel Flow Type

Sub-Cool type

Parallel Flow Type

Function : The condenser changes the

refrigerant from the vapor of
high temperature, high
pressure to the liquid of high
temperature, high pressure.
COMPRESSOR (Variable Swash Plate) 12

Piston
Outlet chamber
(Pd)
Swash plate

Inlet chamber
(Ps)

Shaft

Control chamber Control Valve

(Pc)
COMPRESSOR (Variable Swash Plate) 13

Piston
Inlet chamber
Swash plate (Ps)

Outlet chamber
(Pd)

Shaft

Control
chamber (Pc)

Orifice Control Valve

 COMPRESSOR (Variable Swash Plate) 14

Operation

Control chamber Inlet chamber

pressure pressure

• Control chamber pressure > Inlet chamber pressure: Swash plate angle decrease
• Control chamber pressure = Inlet chamber pressure: Swash plate angle increase
 COMPRESSOR (Variable Swash Plate) 15

Operation

Outlet chamber

Control chamber
pressure increase

Control valve open Diaphragm (Ps)

• Inlet pressure is lower than standard value ( 2.0kgf/cm2).

• Diaphragm shrinking → (Control valve open)
• Outlet gas enter to Control chamber (Control chamber pressure is increased.)
• Swash plate angle is decreased.
 COMPRESSOR (Variable Swash Plate) 16

Operation

Outlet chamber

Control chamber
pressure decrease

Control valve close

• Inlet pressure is higher than standard value ( 2.0kgf/cm2).

• Diaphragm expansion → (Control valve close)
• Outlet gas can not enter to Control chamber (Control chamber pressure is decreased.)
• Swash plate tilting angle is increased.
 COMPRESSOR (Variable Swash Plate) 17

Operation Diagram
• Standardize the inlet pressure
• Standardize the Venting temperature
• Clutch Cycling Prevention
• Iimprovement in Fuel Consumption
• Engine Surge Prevention

Control chamber * Swash plate tilting angle decreasing. * Swash plate tilting angle increasing. Control chamber
pressure increasing * Outlet flux decreasing. * Outlet flux increasing. pressure decreasing

Control chamber Outlet chamber Outlet chamber Control chamber

Inlet pressure < Control valve standard value Inlet pressure > Control valve standard value

Control valve open Control valve close

Inlet pressure decreasing. Inlet pressure increasing.

Pressure detecting Pressure detecting
Evaporator load decreasing Evaporator load increasing
HEATER & EVAPORATOR UNIT 18

Vent DEF

Foot

Blower connecting

Drain hose
EVAPORATOR UNIT 19
EVAPORATOR UNIT 20
EVAPORATOR AIR FILTER 21

1. DESCRIPTION
Employing combination filter, dust and odor in the air is effectively removed.

2. LIFE TIME
Filter replacement period is 5,000~12,000km. But this can be shorten if
the road condition is bad causing more dust and black smoke in the air.

3. HOW TO REPLACE
① Remove the glove box.
② Pull the locking part of the air
filter cover
BLOWER MOTOR ASSEMBLY 22

Motor : magnet motor(φ70)

① Rated voltage : 12V

② Without load
- speed : 3,300 rpm (min)
- current : 3.0A (max)

③ Temperature range in use

: -30 ~ 80
+ PIN - PIN
BLOWER SPEED CONTROL DEVICE 23

1. POWER TRANSISTOR
BLOWER SPEED CONTROL DEVICE 24

③ POWER TRANSISTOR INSPECTION METHOD 1

Blower Relay * Condition: IG ON, FATC ON

Battery Measure voltage v
IG2
Blower
M
Motor

Blower speed Voltage(V)

C Power TR

CONTROLLER
1 step 3.8V
2 step 4.9V
High Speed
3 step 6.1V
Blower Relay B 4 step 7.2V
5 step 8.3V
E 6 step 9.5V
7 step 10.6V
8 step B+
BLOWER SPEED CONTROL DEVICE 25

④ POWER TRANSISTOR INSPECTION METHOD 2

Blower Relay * Condition: IG ON, FATC OFF

Battery
IG2
Blower
M
Motor
Measure voltage v
C Power TR

CONTROLLER
High Speed
Blower Relay B

E v Measure voltage:
Variable (up/down
blower speed switch)

* Caution: Do not pull off the TR during blower operation.

 ACTUATORS

OUTPUT ACTUATOR OPERATION & INSPECTION

INTAKE ACTUATOR 27

Intake Actuator Location

INTAKE ACTUATOR 28

A B

Terminal Function
B-1 Sensor source (5V)
B-12 Sensor ground
A-24 Sensor feedback signal
M
A-23 Intake actuator(REC)
A-22 Intake actuator(FRE)

Intake actuator
TEMPERATURE DOOR ACTUATOR 29

Temperature Control Door Actuator Location

TEMPERATURE DOOR ACTUATOR 30

A B
4.7V

2.5V

M 0.3V

Temp.
actuator Cool Warm

* Feedback line open or short: 17 24.5 : MAX Cool 25 32 : MAX Warm

 TEMPERATURE DOOR ACTUATOR 31

TEMP DOOR ACTUATOR controls the position of the temperature blend

door based on the voltage signal from the FATC module. Potentiometer inside
actuator sends a feedback signal to the controller and controller cuts off the
the voltage signal coming from the controller when the required door position
is achieved.

4.7V

2±2
M
M

0.3V

COOL HOT

[POTENTIOMETER CHARACTERISTICS]
MODE DOOR ACTUATOR 32
MODE DOOR ACTUATOR 33

4.5V
A B
3.5V
2.45V
1.63V
0.4V
M
VENT B/L FLOOR MIX DEF
Mode
actuator
 SENSORS

INPUT SENSOR OPERATION

FIN SENSOR 35

1. DESCRIPTION
Fin sensor is installed in the evaporator in order to detect the temperature
of evaporator. It prevents evaporator from freezing.

2. FIN SENSOR
① LOCATION
: inserted into the evaporator pin
FIN SENSOR 36

② CHARACTERISTICS OF FIN SENSOR

Temp. (°C) Resistance (kΩ)
-30 176.34

-20 97.75
-10 55.85

0 32.91
20 12.51

40 5.31
60
2.48
80 1.25

③ ON/OFF TEMPERATURE: 0.6 OFF

2.1 ON
FIN SENSOR 37

A B

Terminal Function
B-6 Sensor source (5V)
B-12 Sensor ground
Fin thermo
sensor
IN-CAR SENSOR 38

The in-car sensor is located on the crash pad as shown in the picture. It
contains a thermister, which measures the temperature of the air inside the
passenger compartment. It senses the passenger compartment
temperature, changes the resistance value, and enters the corresponding
voltage into the automatic temperature control module (FATC).

Humidity
sensor

In-car
sensor
IN-CAR SENSOR 39

A B

IG 2

Terminal Function
B-5 Sensor source (5V)
B-12 Sensor ground
B-17 Motor ground M

In-car sensor
PHOTO SENSOR 40

The photo sensor is located on the center of crash pad assembly.

It contains a photovoltaic (sensitive to sunlight) diode.
PHOTO SENSOR 41

A B

Terminal Function
B-1 Sensor source (5V)
B-15 Sensor ground
AMBIENT SENSOR 42

The ambient temperature sensor is located in front of the condenser fan

shroud. This sensor detects the temperature of outside air and sends
voltage signals to the controller.

AQS sensor Ambient sensor

AMBIENT SENSOR 43

A B

[Sensor characteristics]

Ambient sensor
AIR QUALITY SYSTEM 44

The Air Quality System detects exhaust

AQS sensor Ambient sensor
gas of neighboring vehicles and
intercepts automatically. AQS controls
the inlet of car automatically and can be
easily installed to the existing vehicle.
Manual operation is also available.

SPECIFICATION
Operating voltage 9 ~ 16V DC
Rated voltage 12V DC
Operating temperature -30 ~ 105℃
Gasoline engine gas CXHY, CO,C6H6…
Detectable gas
Diesel engine gas NOX, SO2
Reaction time less 1 sec
AIR QUALITY SYSTEM 45

* LOCATION: In front of condenser

AIR QUALITY SYSTEM 46

FATC AQS
CONTROL
IG 12V
MODULE

Output
- Normal → 5V
GAS - Gas detected → 0V
detected
(REC)

M
Intake
Actuator
Normal
cw ccw
(FRE)
HUMIDITY SENSOR 47

Humidity sensor detects the relative humidity

of the car’s cabin. This sensor converts it into
the voltage signal and sends the signal to the
FATC controller.

1. SENSOR CHARACTERISTICS
%RH ref SPECIFICATION(Hz)
10 7060
20 6950
30 6855
40 6750
50 6645
60 6540
70 6410
80 6275
90 6100
HUMIDITY SENSOR 48

A B

Terminal Function
B-1 Sensor source (5V)
B-4 Sensor input(5~10hz)
B-12 Sensor ground
APT SENSOR 49

The APT (Automotive Pressure Transducer) is a capacitive–

based sensor, it senses the pressure of the refrigerant that
provides a linear voltage output directly proportional to
applied pressure.
Expansion valve

Evaporator

Comp.

Condenser Receiver
APT SENSOR
- Engine Idle Control
PWM Multi Speed - Cooling Fan Control
Cooling fan - Compressor Control
- High Pressure Cut-out
- Low Pressure Cut-out
ECU
(Engine Control Unit)
APT SENSOR 50
APT SENSOR 51

Connector Base

Terminal (3EA)
RTV
Flexible Circuit
Pin

Ceramic Substrate
Silver Epoxy
Ceramic Diaphragm
O - Ring

Refrigerant pressure

* Flexible circuit changes the pressure to voltage.

* Ceramic diaphragm detects the refrigerant pressure.
APT SENSOR 52

VOLTAGE

Signal Conditioner

ASIC
Source

Detect
Guard

Ceramic Sensing Element

Ceramic Substrate

Glass seal
Ceramic Diaphragm

PRESSURE
APT SENSOR 53

GUARD (GND)
DETECT

SOURCE

Ceramic Substrate Ceramic Substrate

Glass
Seal
Ceramic Diaphragm
PRESSURE

* The main function of APT sensor is detecting the refrigerant pressure (distance d).
APT SENSOR 54

5 Approximately 4.8V
OUTPUT (Vdc)

Approximately
Normal
0.2V Operating range
0

1.0 32.6 Pressure (kg/㎠)

A. There is 0.2V(not 0V), if the refrigerant line pressure has gone to 0, for communication to
engine ECM. (0V means poor contact or open circuit)
B. There is 4.8V, even if the line pressure is over the standard value (high pressure).
(5V means short circuit)
APT SENSOR 55

A B

5V
E APT sensor
C
Terminal Function M

A-3 A/C operating signal(12V)

A-4 A/C switch signal(12V)
WATER TEMPERATURE SENSOR 56
WATER TEMPERATURE SENSOR 57

A B

Terminal Function
B-7 Sensor source(5V)
B-12 Sensor ground
WTS sensor
COOLING FAN 58

Shroud Fan

PWM
Motor
COOLING FAN 59

A/Con Pressure Vehicle Engine coolant temperature(℃)

switch switch speed(KPH) -30 82 94 96 98 101 103 105 109 115
V < 45 10 35
40 50
OFF - 45 ≤ V < 80 10 70 80 90
80 < V 10
60
V < 45 10 30 35
40 50
Pressure < Middle 1 45 ≤ V < 80 10
80 < V 10
80 90
ON V < 45 70
Middle 1 ≤ Pressure < Middle
45 ≤ V < 80 10 40 50
2 60
80 < V 10
Middle 2≤ Pressure ALL 90

Air conditioner pressure ON * 1.0kgf/cm2 = 14.22 psi

Middle 1 12.0kgf/cm2
Middle 2 15.5kgf/cm3
TEMPERATURE UNIT CHANGE 60

Temp unit change:

* Setting unit: (Battery disconnection)

* How to operate

Press for 3 seconds

Keep pressing
or more
CONTROL LOGIC 61

1. In-car temperature correction

When the in-car sensor detects a sudden steep temperature change,
controller corrects the temperature differences slowly.

-1 up / 4sec delay
-1 down / 4sec delay

2. Ambient temperature correction

When the ambient sensor detects a sudden steep temperature change,
controller corrects the temperature differences slowly.

-1 up / 3 min delay (ex. Underground, tunnel)

-1 down / 4sec delay
CONTROL LOGIC 62

3. Heat radiation correction

When the photo sensor detects a sudden steep solar radiation change,
controller compensates it slowly.

- 350 → 1000 (W/m2) / 1 min delay

- 350 ← 1000 (W/m2) / 5 min delay

4. Temp. door control

Temp. door angle (0% ~ 100%) is automatically controlled according to
the selected temperature and other sensor signals.

: Available selected temperature range

- MAX COOL: 17
- MAX HOT: 32
- 17 ↔ 32 , 0.5 step (62 ↔ 90 , 1 step)
CONTROL LOGIC 63

5. Blower speed control

- AUTO mode: linear control
- MANUAL mode: 7 step control

6. Mode control
- AUTO: Mode changes automatically according to the selected
temperature and other sensor signals.
- Manual: Mode changes when the mode switch is selected.

VENT → B/L → FLOOR → MIX → VENT

CONTROL LOGIC 64

7. Intake door mode

- The Fresh/ Recirculation door state can be changed at AUTO mode
according to the input data combination.

8. Compressor ON/OFF control (AUTO mode)

- Fin sensor: lower 0.5 ▶ Compressor OFF
over 3 ▶ Compressor ON

9. Max. Warm function (When 32 is selected at AUTO mode)

▶ Temp door: Max. Warm side
▶ Mode door: Floor mode
▶ Intake door: Fresh mod
▶ Compressor: Off
▶ Blower speed: Auto high
CONTROL LOGIC 65

10. Max. Cool function (When 17 is selected at Auto mode)

▶ Temp door: Max. Cool side
▶ Mode door: VENT mode
▶ Intake door: REC mode
▶ Compressor: ON
▶ Blower speed: Max. High

11. Warm Air Prevention Function (Initial A/C operation)

Condition Control Output

- Auto Mode - Blower Speed:

FATC • Auto low: 12 seconds
- A/C ON • Auto low ▶ Auto high:
- FIN sensor > 30 30 seconds
CONTROL LOGIC 66

12. CELO (COLD ENGINE LOCK OUT) FUNCTION

OPERATING CONDITONS
1. Ambient temp. ＜ 10
2. Water temperature: below 73
3. Mode: Auto or Floor
4. Blower: Auto

Operation release
- When the occupant operates DEF switch.
- When the occupants select Max. cool(17 ).
- When the detected temperature by WTS exceeds 73 .
CONTROL LOGIC 67

12. CELO (COLD ENGINE LOCK OUT) FUNCTION

DEF
Mode
MIX

Auto control

Auto high

Blower speed is depended on

ambient temperature.

Auto low
Blower
Volt

45 50 73 Water coolant temperature

CONTROL LOGIC 68

13. MIX / Defrost control

1. Mode door: Mix or Def

2. Intake door: Fresh mode (REC mode can be selected.)
3. Compressor: - It depends on the evaporator temperature.
- If ambient temperature is below 3.5 , A/C OFF.
(General market)
* On (North America market only)
4. Def function has higher Priority than Max. Hot/Cool function.
5. Def function has higher Priority than Mix Mode.
DIAGNOSIS 69

Ignition switch : OFF→ON

Press the MODE switch more than 4 times

within 2 seconds during pressing the OFF
switch.

After graphic symbol display blinks 3times,

start self-diagnosis.

Self-diagnosis (Continuous operation)

Press OFF
Press AUTO Press AUTO

Self-diagnosis (Step operation)

Press OFF
Return to original condition
DIAGNOSIS 70

DTC LIST & FAILSAFE

DTC
Description Failsafe
Code
00 Normal -
11 Open In-car sensor circuit
25 °C Fixed
12 Short In-car sensor circuit
13 Open Ambient sensor circuit
20 °C Fixed
14 Short Ambient sensor circuit
15 Open Water temp. sensor circuit
- 2 °C Fixed
16 Short Water temp. sensor circuit
17 Open Fin sensor circuit
- 2 °C Fixed
18 Short Fin sensor circuit
19 Open or shorted Temp. door potentiometer Setting temp. 17~24.5 °C : MAX Cool
20 Defective Temp. door potentiometer Setting temp. 25~32 °C : MAX Hot
21 Open or shorted Mode door potentiometer Vent mode : Vent mode Fixed
22 Defective Mode door potentiometer Other mode : Def mode Fixed
23 Open Humidity sensor circuit
Humidity 10% Fixed
24 Short Humidity sensor circuit
25 Open or shorted Intake door potentiometer FRE mode: FRE mode Fixed
26 Defective Intake door potentiometer REC mode: REC mode Fixed
27 Open AQS sensor circuit AQS OFF
28 Short AQS sensor circuit Intake door: Maintain intake door cndition
31 Defective AQS sensor just before select AQS switch
DIAGNOSIS 71

Using Hi-scan pro

The FATC module communicates with high-scan and diagnosis
test feature will detect electrical malfunction and provide error
codes for system components with suspected failures.
DTC LIST & FAILSAFE 72

NO DTC DTC ITEM NO DTC DTC ITEM

1 B1200 HUMIDITY SENSOR-OPEN 12 B1246 TEMP. DOOR FEEDBACK- SHORT

2 B1201 HUMIDITY SENSOR-SHORT 13 B1249 MODE DOOR FEEDBACK-OPEN

3 B1202 WATER TEMP. SENSOR-OPEN 14 B1250 MODE DOOR FEEDBACK-SHORT

4 B1203 WATER TEMP. SENSOR-SHORT 15 B2406 DEFECTIVE TEMP DOOR MOTOR

5 B1233 INCAR TEMPERATURE SENSOR-SHORT 16 B2409 DEFECTIVE MODE DOOR MOTOR

6 B1234 INCAR TEMPERATURE SENSOR-OPEN 17 B1208 INTAKE DOOR FEEDBACK-OPEN

7 B1237 AMBIENT TEMPERATURE SENSOR-SHORT 18 B1209 INTAKE DOOR FEEDBACK-SHORT

8 B1238 AMBIENT TEMPERATURE SENSOR-OPEN 19 B2408 DEFECTIVE INTAKE DOOR MOTOR

9 B1241 FIN THERMO SENSOR-SHORT 20 B1257 AQS SENSOR -OPEN

10 B1242 FIN THERMO SENSOR-OPEN 21 B1258 AQS SENSOR - SHORT

11 B1245 TEMP. DOOR FEEDBACK-OPEN 22 B1259 DEFECTIVE AQS SENSOR