CONTENTS

CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Purpose of air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Principle of the cold loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Current cold loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Air conditioning activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

THE COLD LOOP IN THE WORKSHOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

COOLANT CIRCUIT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Coolant Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Links between components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Passenger compartment air distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

COLD LOOP TRAINING 1

 INTRODUCTION
INTRODUCTION

History
Starting in the 1950s, manufacturers started using heat produced by the engine to
improve passenger comfort by heating the passenger compartment. But passengers
still suffered from the heat during the summer.

It was in the 1970s that the Renault 16 was first equipped with manual air conditioning.
Climate control would provide even more comfort in the Renault 25. Since then,
passenger comfort levels have been continuously improved. Some vehicles are
equipped with air conditioning including right/left regulation that is electronically
controlled.

Purpose of air conditioning

Air conditioning maintains vehicle passengers in optimum comfort and safety
conditions. Temperature comfort depends on an individual's perception of several
parameters:
- the temperature of the air surrounding the individual,
- air speed and turbulence levels in the passenger compartment,
- ambient hygrometry,
- the perception of insolation,
- the activity of the individual and his or her metabolism.

The basic principle consists of continuously circulating a flow of temperature-treated air

through the passenger compartment. Passengers can adjust 3 main parameters:
- the temperature of blown air,
- the air flow,
- the direction of air flow.

COLD LOOP TRAINING 3

 Introduction

Principle of the cold loop

Creation of a coolant circuit

We start with a reservoir of fluid under

high pressure (1). We make this high
pressure drop thanks to a calibration
component (2) called the expansion 3 2 4
valve. The fluid (3) is converted into fluid/
low pressure vapour (4). This 1 6
phenomenon is accentuated via a 5
component that facilitates vaporisation (5)
of the fluid by increasing surface contact CONFTH-M0304SF0150

with the outside environment. This

exchanger is called the evaporator (6).

We now add a component that activates the

passage of air through the evaporator: the
passenger compartment fan (1). It can use
either external air or air from the passenger
compartment. 1
CONFTH-M0304SF0151

In summary, the circuit starts with the reservoir in the form of high pressure fluid at
ambient temperature. The expansion valve suddenly decreases the pressure; then, the
fluid gradually evaporates as it contacts the walls of the evaporator. When exiting the
evaporator, the fluid is thus in gaseous form at low pressure and low temperature. We
have now created "cold air".

However, this system has a disadvantage. The reservoir

becomes empty.

The goal is to operate in a closed loop. To do this, we must

convert the low pressure vapour into high pressure vapour,
and this is the role of the compressor.

CONFTH-M0304SF0152

4 COLD LOOP TRAINING

Introduction

Then, we must convert this 3

vapour from gaseous form (1) to
liquid form (2). This function is
performed by an exchanger: the
condenser (3) (with help from
the engine cooling fan(s) (4)).

1
4
CONFTH-M0304SF0153
2

1
CONFTH-M0304SF0154

Evaporation and expansion are used to convert a fluid from liquid form to gaseous form
(cold air production (1)). Compression and condensation allow us to reverse the
phenomenon of heat production (2).

COLD LOOP TRAINING 5

 Introduction

Pressure, temperature and fluid state

Gas
20 bars Gas
110°C 3 bars
5°C
Gas
20 bars 35°C
110°C

35°C 35°C 70°C

10°C
38°C
70°C Gas
3 bars
3°C
Liquid/gas
3 bars
-1°C
Liquid
19 bars
60°C

CONFTH-M0304SF0113

Liquid
19 bars
60°C

External air.
Pulsed filtered air.
Air conditioning.
High pressure.
Low pressure.

For each step shown in the previous pages, there is a thermodynamic conversion:
- Gas/liquid,
- Temperature,
- Pressure.

6 COLD LOOP TRAINING

Introduction

Circuit location

3 2 10 6 7 8

CONFTH-M0304SF0110

4 5 1 9

The compressor (1) is activated by the user. The compressor, powered by the vehicle
engine, compresses the fluid. This compression increases the pressure and
temperature of the gas. The heat is dissipated in the condenser (3) thanks to the air
that is pulsed by the engine cooling fan (4). The fluid is converted into liquid; this is
condensation. The liquid flows through the dehydration canister (5) where it is filtered
and dried into water. The fluid renters the expansion valve (7), where it is partially
vaporised. This is called expansion. The remaining vaporisation takes place in the
evaporator (8). This is called evaporation. When exiting, the fluid at low pressure and
in gaseous state is aspirated by the compressor.

To protect the components, the circuit includes pressure (2) and temperature (9)
sensors.

For maintenance, the circuit includes filling orifices (6 and 10).

COLD LOOP TRAINING 7

 Introduction

Current cold loops

Currently, there are two cold loops. They differ at two points:
- The principle of the dehydration canister changes, as well as its location in the
circuit.
- The principle of the expansion component changes.

Air conditioning activation

To activate the air conditioning, the AC

button (1) and passenger compartment
ventilation (2) must be switched on. In
the case of climate control, the AC
button must be pressed.

8 COLD LOOP TRAINING

 THE "COLD LOOP"
IN"COLD
THE THE WORKSHOP
LOOP" IN THE WORKSHOP

General recommendations
Before performing work on the system, it is very important to be aware of these
recommendations:
- always wear gloves and safety glasses with side protectors when handling coolant
fluid (risk of burns and projections),
- all work on the coolant system must be performed under good ventilation
conditions. Do not store refrigerant in a well, pit, or room that is tightly closed,
- at temperatures above 100 °C, e.g. caused by a hot point, the fluid breaks down
and produces a highly irritating gas. Performing welding or soldering work on
installed air conditioning system components is prohibited,
- Smoking near the refrigerant circuit is prohibited.

Passage in ovens after painting and work near painting ovens may be performed as
long as the temperature does not exceed 80 °C.

General maintenance
The following operations should be performed every year:
- clean and blow out the condenser and engine cooling system radiator,
- check that condensation water evacuation is not blocked.

For unpleasant odours, an antibacterial treatment is recommended.

COLD LOOP TRAINING 9

 The "Cold Loop" in the workshop

Refrigerant fluid charge should be checked according to information in the

maintenance records. The identification of gas used is listed on a label.

Documentation
The reference material is an indispensable "tool". This is particularly true when working
on components that can be hazardous for the technician and the environment.

Before starting work, consult the reference material on the Dialogys tool.
This will always provide you with updated reference material. Also, check
for any available Technical Notes.

10 COLD LOOP TRAINING

The "Cold Loop" in the workshop

Thermometer

A thermometer is used to verify correct system

installation. The reading is taken under specific
conditions at the vent outlet.

CLIP fault finding tool

This function is used to check the operation

of the cold loop. When performing
maintenance, it can be used to view statuses,
parameters and faults.

COLD LOOP TRAINING 11

 The "Cold Loop" in the workshop

CLIMTEST II (AIRCODIAG)
This measurement device is used to check the operation of the cold loop. It includes
various sensors (pressure, temperature and hygrometry).

Note
Engine heat may affect readings. Therefore, temperature sensors must be placed
in locations that are exposed to engine thermal radiation as little as possible.

Recovery, recycling and charging station

This device is used to perform automatic

or manual internal maintenance of the
cold loop. It can be used to quickly test
operation by interpreting pressure gauge
readings. For preventive maintenance, it
can be used to:
- recover coolant,
- create a vacuum on the system,
- recover and inject compressor oil,
- charge the system.

12 COLD LOOP TRAINING

The "Cold Loop" in the workshop

Two types of leak detectors

- Sound detector:

In the presence of refrigerant, this device

emits a signal that can be used to locate
the leak area.

- Ultraviolet lamp detector:

This device comes in a case kit. The case

kit includes: an ultraviolet lamp, a pair of
special goggles, an injection kit and a
fluorescent reagent fluid (tracer). The
lamp is used to locate refrigerant leaks.

COLD LOOP TRAINING 13

 COMPONENTS
OF THE COOLING
CIRCUIT
COMPONENTS OF THE COOLING CIRCUIT

Coolant fluids
Coolant fluids are not naturally occurring compounds. Therefore, they are synthetically
manufactured and have the special property of absorbing a large quantity of heat.

In 1974, a hypothesis was advanced for the first time, according to which the
accumulation of chlorine from CFC emissions (chlorofluorocarbon) in the upper
atmosphere could cause damage to the ozone layer and warming of the earth's surface
(greenhouse effect).

Among CFCs that can contribute to destruction of the ozone layer, Freon (R12), used
as a refrigerant in automobile air conditioning systems, is estimated to be responsible
for 20%.

Therefore, automotive manufacturers have decided to use R134a coolant as a

substitute for R12 coolant. It does not contain chlorine and therefore does not harm the
ozone layer. In addition, its estimated contribution to the greenhouse effect is far lower
than that of R12 (by roughly a factor of 12).

R134a fluid
R134a fluid started replacing R12 fluid use in automobiles in January 1993. It belongs
to the HFC (hydrofluorocarbon) family of compounds. It is odourless, colourless and
non-flammable.

R12 fluid must never be mixed with R134a fluid. Switching a vehicle from
R12 fluid to R134a fluid requires adaptation of the coolant circuit.

ª Possible test:
Refrigerant.
- Refrigerant change frequency (information taken from maintenance records).

COLD LOOP TRAINING 15

 Components of the cooling circuit

Compression

Compressors

The compressor is the engine component of the circuit. It is a pump that uses
mechanical energy supplied by the vehicle engine to increase the pressure in the
coolant circuit. The compressor aspirates gas at the evaporator exit, then pulses it to
the condenser after increasing its pressure to the correct operating value. It provides
fluid circulation in the loop.

Suction. 1 Identification is made via a label

Discharge. attached to the body.
1 Electromagnetic clutch.
2 Compressor body.
3 Cylinder head.
4 Control valve.

16 COLD LOOP TRAINING

Components of the cooling circuit

The compressor is attached to the engine (1) and driven by a belt (2). Its rotation is
powered via an electromagnetic clutch (3) which transmits engine movement to the
compressor shaft.
This clutch controls compressor operation. It is identical for all types of compressors,
and made up of the following main components:
- a pulley (3) that moves freely via a bearing (6),
- a clutch back-plate (1) that is part of the compressor shaft (5),
- an electromagnet (2) in the shape of a crown, attached to the body of the
compressor (4) and inserted in the pulley.

5
CONFTH-M0304SF0101

1 6 3 2 4

COLD LOOP TRAINING 17

 Components of the cooling circuit

When the electromagnet (2) receives electrical power, it attracts the clutch back-plate
(1) against the free pulley (3). Therefore, the compressor shaft (5) is part of the pulley
and drives it in rotation.

Compressor operation is controlled by the computer.

ª Possible tests:
Electromagnetic clutch.
- Condition of the belt (wear and tension).
- Connection and condition of the connector.
- Visual inspection of the compressor engagement.
- Electrical voltage test.
- Resistance test.

There are two types of compressors:

- fixed capacity compressors,
- variable capacity compressors.

18 COLD LOOP TRAINING

Components of the cooling circuit

Fixed capacity compressors

Fixed capacity compressors compress a constant volume of gas with each rotation. On
the compressor, coolant power is regulated by alternating compressor engagement
and stopping (cycling). Generally, it includes 5 or 7 pistons.

1 Clutch and driver pulley.

2 Bearing back-plate.
3 Oscillating back-plate.
4 Pistons.
5 Valves.
6 Cylinder head.

1 Suction. 4 Oscillating back-plate.

2 Discharge. 5 Cam lobe.
3 Piston. 6 Shaft.

The shaft (6) and cam lobe (5) rotate. They transmit their movement to the oscillating
back-plate (4). The angle of this back-plate determines the stroke of the pistons (3).
The piston chambers are closed by the cylinder head which includes suction valves
and discharge valves that connect to their respective pipes. These two pipes are
connected as follows: one is connected to the high pressure section going to the
condenser, and the other is connected to the low pressure section coming from the
evaporator.

COLD LOOP TRAINING 19

 Components of the cooling circuit

Variable capacity compressors

Variable capacity compressors continuously adjust the volume of compressed gas
according to the demand for cold air from the system. The flow rate is variable.

The advantages of this compressor include:

- avoiding engine irregularities associated with cycling of the compressor clutch,
mainly on vehicles with low cubic capacity,
- maintaining a constant temperature in the evaporator, which is kept at near-
freezing. The temperature of passenger compartment blown air remains stable,
- improving dehumidification of passenger compartment air,
- decreasing the vehicle's fuel consumption,
- increasing compressor operating life.

CONFTH-M0304SF153

The capacity is modified by varying the angle of the oscillating back-plate, which
causes increased or decreased piston stroke. This back-plate variation is achieved by
controlling the pressure difference between the suction pressure and the pressure
reached in the body of the compressor. The control valve regulates this pressure
difference.

20 COLD LOOP TRAINING

Components of the cooling circuit

When the demand for cold air is large,

the suction pressure (1) exceeds the
valve regulation value (4) (roughly 2
bars). This keeps gas flowing between
the suction chamber (3) and the body
of the compressor (5). Thus, there is
no longer a pressure difference
between the two chambers. The
pistons (6) travel the maximum
distance (maximum cubic capacity).

When the demand for cold air is small, the

suction pressure (1) drops below the
valve value (4). This opens the passage
between the discharge chamber (2) and
the body of the compressor (5). The
control valve reduces the flow between
the suction chamber and the body of the
compressor. The increased pressure
difference blocks piston return (6) in the
suction phase. The value of the oscillating
back-plate angle (7) thereby decreases
piston stroke. The volume of compressed
gas decreases.

COLD LOOP TRAINING 21

 Components of the cooling circuit

The variable capacity is provided by the control valve. Its role is to regulate the pressure
in the body of the compressor, causing the oscillating back-plate to move. There are
two types of control:

Tyres Electrical

2 1 3 4 5

CONFTH-M0304SF0115
2
1

X Y
CONFTH-M0304SF0105
To discharge (high pressure)
From the compressor body.
To suction (low pressure).
It is composed of:
- a body(1),
- an elastic capsule (2), with variations
in pressure modifying its length,
- a rod (3) that allows the capsule to
adjust passage (X) and passage (Y)
by moving the ball (4) against the
spring (5).
In the system of components, only the
electromagnet (1) replaces the capsule.
The control valve is electrically controlled
by the computer. It receives a command
signal (2). This control takes the form of a
modulated pulsed current and the
capacity will depend on the cyclic ratio of
this signal. The control valve is controlled
according to the evaporator temperature
and the pressure in the high pressure
circuit.

The electrically controlled variable capacity compressor is not protected

if the refrigerant fluid level is low. In fact, a loss of refrigerant is effectively
interpreted by the air conditioning computer as a loss of performance. In
this case, it therefore increases the compressor capacity to maintain the
cooling performance within the passenger compartment. This situation
may damage the compressor, which is no longer correctly lubricated.
Computer programming to evaluate the refrigerant load is used to prevent
compressor locking.

ª Possible tests:
The compressor.
- Check for leaks.
- Check pressures (low pressure and high pressure).
- Check the electrical vale (voltage and resistance).
- Check for mechanical noise.

22 COLD LOOP TRAINING

Components of the cooling circuit

Compressor oil
The compressor is designed so that some oil circulates in the coolant system.

Due to this, the oil contained in the compressor performs several functions:
- lubricating moving parts (compressor and expansion valve),
- helping to cool the compressor,
- reinforcing component sealing (compressor, union, seal, etc.),
- evacuating impurities.

The type of oil used for fluid R134a is synthetic. It differs according to the compressor
and is specified in the documentation.

Coolant circuit oils are hygroscopic*. During work, oil contact with the
surrounding air must be minimised as much as possible. The humidity
absorbed by the oil is introduced in the circuit (compressor, expansion
valve, dehydration canister).

* Hygroscopic: can absorb humidity from the air.

ª Possible test:
Compressor oil.
- Top up the oil when recovering fluid and/or replacing a component.

COLD LOOP TRAINING 23

 Components of the cooling circuit

Condensation
Condenser

bfroide-M0903SF0023
1

The purpose of the condenser (1) is to dissipate the heat accumulated during gas
evaporation and compression. Once it is cooled, the gas becomes a liquid and remains
under high pressure. To improve thermal exchange, the fluid is exposed to air flow
produced by the engine cooling fans and vehicle movement. This step allows for fluid
expansion.

CONFTH-M0304SF0109

This exchanger is composed of several parallel channels.

The input diameter is larger than the output diameter since the fluid enters in a gaseous
state and exits in liquid form.

ª Possible tests: - Component cleanliness.

- Cleanliness of fins.
The condenser.
- Check for leaks.
- Evaluation of upstream/downstream
temperatures.

24 COLD LOOP TRAINING

Components of the cooling circuit

Principle of condensation
When vapour (1) enters into contact with a
cold surface (2), it condenses. This means
that it returns to liquid form (3). This
phenomenon can be seen by placing a
cover over a pan of boiling water (4).

Cooling fan assembly

bfroide-M0903SF0050

The initial function is to prevent engine overheating by forcing the passage of air
through the engine cooling system radiator. For the air conditioning function, the engine
cooling fan(s) (1) is/are switched on and force the passage of air through the
condenser. Thermal exchange is improved.

COLD LOOP TRAINING 25

 Components of the cooling circuit

Blower fan Suction fan

3 1 2 3
1

CONFTH-M0304SF0106
CONFTH-M0304SF0105

1 Ventilation fan.
2 Condenser.
3 Radiator.
Î Air flow.

One or two engine cooling fan(s) is/are located in front of or behind the condenser.
Depending on the installation, the engine cooling fan(s) operate(s) by discharging or
aspiration. The system includes several speeds.

ª Possible tests:
The engine cooling fan(s).
- Connection and condition of the connector.
- Resistance measurement.
- Voltage measurement.

26 COLD LOOP TRAINING

Components of the cooling circuit

Dual cooling fans

On vehicles equipped with two engine cooling fans, serial/parallel installation can be
used to achieve two ventilation speeds.

The two engine cooling fans are powered by the power circuit of three relays. The first
(A) acts as a switch, and is activated as soon as the compressor kicks in. When in
resting position, the other two relays (B or C) provide the electrical connection between
the two engine cooling fans. These engine cooling fans are connected in series and
rotate at half-speed.

A B C

M M

mot 1 mot 2

CONFTH-M0304SF0156
When the circuit pressure increases, the computer powers the control circuit of relays
(B) and (C). Relay (B) grounds the first motor which supplies its power. Relay (C) sends
a positive signal to the second motor which is still grounded. The serial installation now
becomes parallel and the two motors operate at maximum speed.

A B C

M M

mot 1 mot 2
CONFTH-M0304SF0157

COLD LOOP TRAINING 27

 Components of the cooling circuit

Single engine cooling fan

On vehicles equipped with only one engine cooling fan, serial/parallel installation can
be achieved by using a resistor. The installation resembles the one described above,
except that a resistor replaces one of the engine cooling fans. The computer controls
relay (A). This relay supplies the engine cooling fan via a resistor. The motor operates
at low speed.

CONFTH-M0304SF0158
When the pressure increases in the coolant circuit, the computer controls the relay (B);
the tab is moved and transmits power directly to the engine cooling fan. The resistor is
short circuited and the motor operates at maximum speed.

A
B

M
CONFTH-M0304SF0159

28 COLD LOOP TRAINING

Components of the cooling circuit

Refrigerant pressure sensor

In order to view the pressure in the circuit, a sensor is located on the high pressure line.

It can be installed on:

- the dehydration canister,
- the high pressure tube,
- the condenser.

Its role is to protect the components from abnormal values and adjust the condensation
pressure. It is capacitive type.
bfroide-M0903SF0049

This sensor continuously informs the computer of the current pressure in the circuit.
The signal is used by the computer to:
- Manage the circuit pressure safety functions. The compressor is engaged if
the pressure is greater than 27 bars or less than 2 bars.

COLD LOOP TRAINING 29

 Components of the cooling circuit

- Calculate the power absorbed by the compressor. The computer uses the
signal from the pressure sensor and the compressor rotation speed to anticipate
load variations produced by the compressor.
- Implement the accelerated idle request. To improve air conditioning
performance when idling, when the high pressure exceeds 13 bars, the injection
computer increases the idle speed level.
- Control the cooling fan assembly. Operation of the engine cooling fan(s)
depends on the pressure. In addition, on some vehicles, vehicle speed is taken
into account.

ª Possible tests:
The pressure sensor.
- Connection and condition of the connector.
- Fault finding tool conformity.
- Resistance measurement.
- Voltage measurement.

30 COLD LOOP TRAINING

Components of the cooling circuit

Expansion

Expansion valve

This serves two functions:

- send the fluid from high to low pressure: this is expansion,
- continuously adjust the quantity of fluid expanded according to the evaporator
outlet temperature.

The expansion valve is located close to the evaporator. There are two types:
- orifice-type expansion valve,
- thermostatic expansion valve.

COLD LOOP TRAINING 31

 Components of the cooling circuit

Orifice-type expansion valve

It is located in the pipe between the condenser and evaporator.

It is composed of:
- A plastic body (1).
- An input and output filter (2).
- A calibrated tube (3).

The calibrated orifice has a direction of fitting. The fluid arrives at the entry (B) by
crossing the filter (2). The fluid is partially vaporised in the calibrated orifice (3). It exits
in (A) to the evaporator.

32 COLD LOOP TRAINING

Components of the cooling circuit

It only plays a role in expansion. Complete evaporation of fluid is not controlled. This
means that an accumulator is required on the low pressure line, upstream of the
compressor.

ª Possible tests:
The calibrated orifice.
- Evaluation of upstream/downstream temperatures.
- Component cleanliness.

Thermostatic expansion valve

The lower section of the thermostatic

expansion valve is composed of an inlet
pipe (1) regulated by a valve (2), while the
upper section is composed of an outlet pipe
(3) and a thermostatic capsule (4).

The thermostatic capsule contains a dilatable fluid (5) as well as a plunger (6) exposed
to the temperature of the fluid exiting the evaporator (7). If this temperature is high, the
fluid contained in the plunger expands, pressure in the capsule increases and the
diaphragm pushes the plunger down. The plunger opens the valve, and expansion and
evaporation increase: the temperature drops quickly in the evaporator, causing
contraction of the dilatable fluid. The valve closes and the cycle starts over.

Note

Note that the spring holding the valve is pre-loaded in the factory and the
expansion valve cannot be repaired or adjusted.

ª Possible tests:
The thermostatic expansion valve.
- Evaluation of upstream/downstream temperatures.
- Component cleanliness.
- Check for leaks.

COLD LOOP TRAINING 33

 Components of the cooling circuit

Principle of expansion
When a fluid is kept under pressure, for example in a tyre, and this pressure is quickly
released, cold air is produced at the valve.

This phenomenon is called fluid expansion, and causes heat to be absorbed from the
surrounding air.

In conclusion, for a given pressure, the quicker the expansion, the more cold air is
produced.

34 COLD LOOP TRAINING

Components of the cooling circuit

Evaporation
Evaporator

bfroide-M0903SF0025
The evaporator (1) is located after the expansion component. It is integrated into the
passenger compartment air circuit.

It evaporates the fluid released by the expansion valve. The fluid absorbs the heat
calories of pulsed air. The air cools and condenses on the walls of the evaporator. The
air entering the passenger compartment is slightly humid. The condensation water is
channelled to the outside of the vehicle. After stopping, it is normal to find traces of
water under the vehicle.

The evaporator is a plate type evaporator.

bfroide-M0903SF0026

ª Possible tests: - Component cleanliness.

- Cleanliness of fins.
The evaporator.
- Check for leaks.
- Evaluation of upstream/downstream
temperatures.

COLD LOOP TRAINING 35

 Components of the cooling circuit

Principle of evaporation

R E L
AT O
H
W O
LC A

bfroide-M0903SF0014
Conversion of a fluid from the liquid state to the gaseous state is called evaporation.
However, the speed of evaporation depends on the type of liquid. For example, if you
dab water on your skin, this creates a feeling of coolness and the water takes time to
dry. If you use alcohol instead, the fluid evaporates faster, and the sensation of
coolness is greater.

Evaporator sensor

The evaporator sensor is located on the fins of the evaporator at the coldest point. It is
fitted on vehicles equipped with a fixed capacity compressor. This sensor is a negative
temperature coefficient thermistor.

Note

Some vehicles equipped with a variable capacity compressor use an evaporator

sensor. In this case, it is a safety element that is only rarely used (compressor
failure).

36 COLD LOOP TRAINING

Components of the cooling circuit

Its role is to measure the temperature of the air blown through the evaporator in order
to prevent the evaporator from freezing.

Air is cooled as it passes through the evaporator. If the temperature is below 0 °C, the
moisture condensed on the walls of the evaporator freezes. This blocks the passage of
air. To prevent this phenomenon, the compressor is disconnected if the temperature is
close to 0 °C. The compressor is reconnected when the temperature increases. This is
called "cycling".

ª Possible tests:
The evaporator sensor.
- Connection and condition of the connector.
- Fault finding tool conformity.
- Resistance measurement.

COLD LOOP TRAINING 37

 Components of the cooling circuit

Filtration
Dehydration canister
Installed in series in the cooling circuit, the reservoir is a component that has no
influence on cooling status changes (pressure, temperature, etc.). There are two types
of reservoir:
- Dehydration canister,
- Accumulator/Dryer.

Dehydration canister

The dehydration canister is placed between the condenser and the thermostatic
expansion valve. It is installed in series on the high pressure circuit.

1 Fluid inlet.
2 Maintaining screen.
3 Filter.
4 Desiccant material.
5 Plunger tube.
6 Fluid outlet.

38 COLD LOOP TRAINING

Components of the cooling circuit

It performs three functions:

- absorbs the variations in volume due to variations in temperature, as well as the
pulses created by the compressor (fluid reservoir and expansion bottle),
- filters any particles suspended in the fluid to avoid clogging the expansion valve
(filter),
- eliminates humidity contained in the refrigerant (dryer).

Accumulator/Dryer

The accumulator/dryer is placed between the evaporator and the compressor. It is

installed in series on the low pressure circuit.

Like the dehydration canister, the accumulator/dryer performs the following functions:
- filters impurities contained in the circuit,
- dries the refrigerant,
- provides buffer capacity to absorb variations in volume.

Note

If the accumulator/dryer is present on the low pressure circuit, the circuit is

equipped with a calibrated orifice.

COLD LOOP TRAINING 39

 Components of the cooling circuit

In addition, the use of a calibrated orifice does not guarantee total evaporation of the
fluid exiting the evaporator. The accumulator/dryer traps any traces of fluid.

Î Input from the evaporator.

Î Output to the compressor.
1 Liquid.
2 Liquid and gas.
3 Filter.
4 Desiccant material.

Regardless of the type of reservoir (dehydration canister or accumulator/

dryer), it must always bereplaced after prolonged exposure of the circuit.

ª Possible tests:
The dehydration canister.
- Check for leaks.
- Evaluation of upstream/downstream temperatures.

40 COLD LOOP TRAINING

Components of the cooling circuit

Links between components

Pipes connect the various components in the loop to transfer the fluid. These links are
composed of:
- piping,
- filling valves,
- connectors,
- seals.

Piping
The circuit is composed of:
- rigid pipe (aluminium or steel),
- flexible hose (rubber),
- noise absorbers (buffer capacity).

COLD LOOP TRAINING 41

 Components of the cooling circuit

Special notes on flexible hoses

1 Neoprene: contact with fluid and

compatible with oil.
2 Nylon: dual leak-protection barrier.
3 Braided polyethylene: pressure
resistance and flexibility.
4 Butyl: resistance to external
constraints.

Note

Depending on the location of pipes in the circuit, the passage diameter changes:
- Large diameter for the gaseous circuit.
- Small diameter for the liquid circuit.

ª Possible tests:
The pipes.
- Check for leaks.
- Pipe cleanliness.

Filling valve
CONFTH-M0304SF136

The functions of the valve include:

- allowing connection (1) of the filling station,
- opening the circuit (2) to facilitate fluid changes, vacuum pressurisation and filling,
- ensuring the air-tightness of these connection points.

42 COLD LOOP TRAINING

Components of the cooling circuit

The circuit is fitted with one or two valves.

Dual valve installation: Installing a valve:

One valve is placed in the high pressure section It is located in the low pressure circuit.
between the condenser and the expansion valve.
The other valve is positioned in the low pressure
section between the evaporator and the
compressor.
The diameters for connecting to the filling station
hoses are different to avoid confusion.

1
CONFTH-M0304SF0107

CONFTH-M0304SF0108
3

The valve is closed by the spring (1). When connecting to the filling station, the
connection acts on the tappet (2) compressing the spring (1). The valve opens. When
connecting and disconnecting, the action (3) is performed in such a way that the circuit
is never in contact with the ambient air.

ª Possible tests:
Filling valves.
- Check for leaks.
- Valve tightening.

COLD LOOP TRAINING 43

 Components of the cooling circuit

Unions

The unions must provide maximum sealing. In fact, they must resist the operating
pressure. There are two types of mountings for the pipes and components of the
circuit:
- clipped end pieces (1),
- bracketed end pieces (2).

ª Possible tests:
The unions.
- Check for leaks.
- Check the tightening.

Seals

Circuit sealing is provided by rubber O-rings.

Note

Removed seals must be replaced.

Before fitting, the seals must be coated with compressor oil. This action provides
the following:
- facilitates positioning for tightening,
- produces a better seal.

44 COLD LOOP TRAINING

 Components of the cooling circuit

Passenger compartment air distribution

Functions of the air blower

Depending on the position

selected by the user, the air is
either:
- re-heated,
- re-cooled,
- recycled.

Air quality
The pulsed air system (external air pulsed into the passenger compartment) carries
large quantities of exhaust gas, soot, dust particles and pollen. To correct for this
disadvantage, some vehicles are fitted with a filter. This decreases the quantity of dust
and pollen typically introduced into the passenger compartment by 90%.
CONFTH-M0304SF0112

COLD LOOP TRAINING 45

 Components of the cooling circuit

Within this pollution, we must distinguish between "particles" and "gas". In fact, the filter
must be composed of different materials in order to handle the different pollution types.

Particle filtration Odour filtration

The particles to be filtered include:

- soot, The odours to be absorbed include:
- pollen. - exhaust gas,
The filter uses a fibrous support to trap the - combustion residues.
particles suspended in the aspirated air. This The filter contains activated charcoal integrated
support is made of polypropylene and has an into the filter element.
electrostatic effect (particle magnet).

There are two types of filters:

- particle filters,

CONFTH-M0304SF0141
- particle and odour filters.
CONFTH-M0304SF0142

ª Possible tests:
The air conditioning filter.
- Visual inspection.
- Frequency according to maintenance records.

46 COLD LOOP TRAINING