SECTION 7D FULL AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM FATC (Full Automatic Temperature Control) is full automatic heater and airconditioning system that detects incar temperature, ambient temperature, sun load and coolant temperature and controls airconditioner system blowing capacity, outlet temperature and intaking/outlet mode to maintain interior comfort. TABLE OF CONTENTS Specifications... 7D-2 Refrigerant... 7D-2 Evaporator Unit... 7D-2 Blower Unit... 7D-2 Compressor... 7D-2 Condenser... 7D-2 Receiver Drier... 7D-2 Pressure Switch... 7D-3 Air Filter... 7D-3 Heater Unit... 7D-3 Service Specifications... 7D-4 Fastener Tightening Specifications... 7D-4 Schematic and Routing Diagrams... 7D-5 Circuit Diagram... 7D-5 FATC Block Diagram... 7D-6 Component Locator... 7D-7 Ventilation System... 7D-7 Function Description... 7D-8 Diagnosis... 7D-9 Diagnosis Test... 7D-9 Maintenance and Repair... 7D-13 FATC Control Panel... 7D-13 Air Filter... 7D-16 Troubleshooting... 7D-17
7D-2 FATC-HAVC SPECIFICATIONS REFRIGERANT Capacity Type Description 650-750 g R134a EVAPORATOR UNIT Core Size (LxWxT) Core Type Expansion Valve Type Thermostat Resister Type Cooling Capacity Description 237.0 x 232.0 x 92.0 Aluminum plate Angle ON:4.5 ± 0.6 C, OFF:1.5 ± 0.6 C Aluminum plate 4,300 Kcal/h (AT 420 CMH) BLOWER UNIT Motor Type Motor Size Description Magnetic φ 70 x 145 COMPRESSOR Model Type Displacement (cc/rev.) PCD (Pulley Center Diameter) Oil Magnetic clutch output Description FK-II (DKV 14C) Vane rotary type 140.5 (cc/rev) φ 143 ZXL 200 PG (PAG Oil) 45 W CONDENSER Size (WxHxT) Capacity Type Description 650 x 339.2 x 22.0 11,000 Kcal/h Parallel Flow RECEIVER DRIER Material Capacity Desiccant Description Aluminum 250 cc XH-9 (35 g)
FATC-HAVC 7D-3 Type High (OFF) Low (ON) Replacement PRESSURE SWITCH AIR FILTER HEATER UNIT Description Direct OFF : 32 ± 2 Kgf/cm 2, DIFF : 6 ± 2 Kgf/cm 2 OFF : 2.0 ± 0.2 Kgf/cm 2, ON : 2.1 ± 0.2 Kgf/cm 2 Description Every 12,000 km (replace earlier if air pollution is heavy) Heater Core Type Heating Capacity Heater Core Size (L x W x T) Description 2-ROW 4,600 Kcal/h (AT 300 CMH) 219.5 x 151.8 x 52
7D-4 FATC-HAVC Incar Sensor Ambient Sensor Coolant Temperature Sensor SERVICE SPECIFICATIONS Input Section Resistance (25 C) Voltage Rating Current Rating Resistance (25 C) Voltage Rating Current Rating Resistance (25 C) Voltage Rating Current Rating Evaporator Unit Description 2.186 kω ± 0.07 kω 5 V 3 ma 1.0 kω ± 0.03 kω 5 V 3 ma 0.55 kω ± 0.02 kω 5 V 3 ma Intake Actuator Mode Actuator Mix Actuator Power TR Blower Motor Power Consumption Description Current Rating (at 12 V) 70 ± 30 ma LOCK Current Less than 500 ma Current Rating (at 12 V) 100 ± 40 ma LOCK Current Less than 500 ma Current Rating (at 12 V) 100 ± 40 ma LOCK Current Less than 500 ma Ic 30 A Pc 200 W 220 W FASTENER TIGHTENING SPECIFICATIONS N m Lb-Ft Lb-In Condenser Bolt Condenser Fan Nut Condenser Bolt Receiver Drier Pipe Bolt Receiver Drier Pipe Bolt (Condenser) Pressure Pipe Bolt Pressure Mounting Bolt 4-6 4-6 4-6 5-8 4-6 20-30 20-26 2.9-4.4 2.9-4.4 2.9-4.4 3.7-5.9 2.9-4.4 14.7-22.1 14.7-19.1 35.4-53.1 35.4-53.1 35.4-53.1 44.2-70.8 35.4-53.1 177.0-265.5 177.0-230.1
SCHEMATIC AND ROUTING DIAGRAMS FATC-HAVC 7D-5 CIRCUIT DIAGRAM KAA7D010
7D-6 FATC-HAVC FATC BLOCK DIAGRAM INCAR SENSOR VFD AMBIENT SENSOR MAX HI RELAY WATER TEMPERATURE SENSOR SUN LOAD SENSOR POWER T/R BLOWER MOTOR TEMPERATURE SWITCH BLOWER SWITCH MODE SWITCH DEFROSTER SWITCH C O N T R O L ECU MIX ACTUATOR COMPRESSOR MIX DOOR INTAKE SWITCH AUTO SWITCH A/CON SWITCH U N I T INTAKE ACTUATOR Airconditioner output INTAKE DOOR OFF SWITCH MODE ACTUATOR MODE DOOR TEMP DOOR POSITION FEEDBACK VOLTAGE POWER TRANSISTOR COLLECTOR VOLTAGE
FATC-HAVC 7D-7 COMPONENT LOCATOR VENTILATION SYSTEM KAA7D020
7D-8 FATC-HAVC FUNCTION DESCRIPTION 1. AUTO switch By pressing the AUTO switch, set temperature, AUTO, fan speed, air source, air flow mode will be appeared on the VFD display. Following items will be controlled automatically according to set temperature. - Mode and intake door - Temperature door - Blower fan speed - Compressor ON/OFF control When AUTO switch is released, other functions will be controlled automatically except for manually selected switches. 2. MODE switch By pressing the MODE switch while the AUTO switch is turned ON, AUTO indicator light will go off and air flow mode will be controlled manually in the order of VENT B/L FLR MIX VENT. 3. OFF switch Press this switch and the airconditioner system will be turned OFF. 4. Temperature UP/DOWN switch This switch is a switch increasing or decreasing set temperature and position of the temperature door will be automatically controlled according to set temperature and outlet temperature will be controlled by adjusting blending ratio of cold and hot air. By operating the switch, set temperature will be increased/decreased by 0.5 C. Set temperature range is 17-32 C. Max. cold function will be performed at set temperature of 17 C and max. hot function will be performed at set temperature of 32 C. When pressed more than 1 second, it will be automatically UP/DOWN by interval of 0.28 sec. after 1 second. When it changed 17.5 C 17 C, 31.5 C 32 C and DOWN switch is pressed after 17 C or UP switch is pressed after 32 C, there will be operating sounds 3 times during 0.1 sec. 5. DEFROST switch By pressing this switch, DEF will turn on and mode door will be fixed at DEF. Recirculation/fresh air switch will be fixed as FRESH. When airconditioner is turned ON and ambient temperature is less than 1.5 C, the airconditioner will be turned off. Selection of airconditioner OFF is possible by manual. 6. A/C switch The airconditioner system will be turned ON or OFF by pressing this switch. 7. Recirculation fresh air switch Air intake will be automatically switched to recirculation or fresh air (REC FRE) by pressing this switch. 8. Blower switch (UP/DOWN) Blower speed can be controlled by manual and if fan UP/DOWN switch is pressed when AUTO mode is selected, fan speed will UP/DOWN based on current fan level. When 6 segments are turned on, it is max. HI operation. When pressed more than 1 second, it will be automatically UP/DOWN by interval of 0.28 sec. after 1 second. When segment is changed stage 2 stage 1 (LO), stage 5 stage 6 (HI) and HI switch is pressed in HI status or DOWN switch is pressed in LO status, there will be operating sounds 3 times during 0.1 sec. When switch is operated in OFF status, it will be operated as stage 1 (1 segment display).
FATC-HAVC 7D-9 DIAGNOSIS DIAGNOSIS TEST FATC airconditioner system has self-diagnosis function. Turn the ignition switch ON and press intake switch more than 4 times within 2 seconds while the AUTO switch is pressed, then it will diagnose incar sensor, ambient sensor, water temperature sensor and temperature actuator for open/short and will display numerical fault code on the set temperature display of VFD. KAA7D030 1 AUTO Switch 2 Fresh/Recirculation Switch 3 OFF Switch 4 Airconditioner Switch 5 VFD (Vaccum Fluorescent Display)
7D-10 FATC-HAVC Self-diagnosis Method Ignition switch ON Press the intake switch more than 4 times within 2 seconds while pressing the AUTO switch Self-diagnosis will start after turning off all displays on VFD for 2.5 seconds Press AUTO Self-diagnosis items check (continuous action) Press OFF Press AUTO Self-diagnosis items check (step action) Press OFF Airconditioner control Diagnosis Item and Fault Code 00 : normal 11 : incar Sensor Open 12 : incar Sensor Short 13 : ambient Sensor Open 14 : ambient Sensor Short 15 : coolant Sensor Open 16 : coolant Sensor Short 17 : temperature Actuator Open/Short 18 : temperature Actuator Drive Fault
FATC-HAVC 7D-11 Self-diagnosis Display 1. Data will be displayed at the set temperature display as 2-digit number during self-diagnosis function and other set temperature displays will be OFF. 2. Display of self-diagnosis fault code will be blinking fault code number in the intervals of 0.5 sec. 3. Following fault code number will be displayed at the set temperature display during self-diagnosis function. 4. If no defective, normal display number (00) will blink. Display during continuous action A. Normal or 1 fault (00 or 11) B. Multiple faults (11, 13, 15...) Display during step action A. Normal or 1 fault : the same as continuous action B. Multiple faults
7D-12 FATC-HAVC Fault Safety Function FATC airconditioner system not only performs selfdiagnosis but also has safety function against faults if there is open or short in the incar sensor, ambient sensor, water temperature sensor and temperature door potentiometer. NO. Item Defects Fault safety function 1 2 3 4 Incar sensor Ambient sensor Water temperature sensor Temperature door potentiometer Open or short Open or short Open or short Open or short Control When substituted 25 C Control When substituted 20 C Perform heating maneuver control function under refrigeration maneuver control entering conditions and release after 10 minutes. Set temperature 17-24.5 C : max. COLD position Set temperature 25-32 C : max. HOT position
FATC-HAVC 7D-13 MAINTENANCE AND REPAIR FATC CONTROL PANEL KAA7D070 1 AUTO Switch 2 MODE Switch 3 OFF Switch 4 Temperature UP/DOWN Switch 5 Defrost Switch 6 Airconditioner Switch 7 Fresh/Recirculation Switch 8 Blower Switch (UP/DOWN) 9 VFD (Vacuum Fluorescent Display)
7D-14 FATC-HAVC Pin Number and Connection Circuit KAA7D080 Connector A Connector B Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Connection circuit Rheostat Tail lamp Battery (+) Power TR (B) Power TR (C) Temperature actuator (CCW) IG2 Ground Airconditioner switch ground HI speed relay Photo sensor (+) Photo sensor (-) Temperature actuator F/B Temperature actuator (CW) IG2 Ground Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Connection circuit Incar sensor (+) Ambient sensor (+) Coolant sensor (+) Sensor voltage 5V Sensor ground Intake (ambient) Intake (incar) - - - VENT B/L FLR MIX DEF - - - - -
E F FATC-HAVC 7D-15 Removal & Installation Procedure 1. Turn the ignition switch to OFF position. 2. Remove two screws on the cover of shift lever box. KAA7D090 3. Unscrew the screw from the center panel, pull out each switches and remove the center panel. 4 60 8 10 80 100 KAA7D100 4. Unscrew the 6 screws and remove the audio control panel assembly. KAA7D110 5. Unscrew the 4 screws and remove the airconditioner control panel assembly. 6. Installation should follow the removal procedure in the reverse order. KAA7D120
7D-16 FATC-HAVC AIR FILTER Removal and Installation Procedures Replacement Interval Every 10,000 km Notice: Replace earlier if air pollution is heavy. 1. Open the glove box and pull it inward to release the upper left and right locking portion. Notice: Remove the glove box by unscrewing lower 2 screws, if necessary. KAA7D130 2. Press the 2 filter cover holds and remove the air filter cover. 3. Remove the 2 air filters. Notice: For installation, remember the installed direction of the air filter before removal. KAA7D140
TROUBLESHOOTING Check and Service FATC-HAVC 7D-17 Incar sensor is a sensor that detects interior air temperature and a thermistor that decreases its resistance when temperature up and increases when temperature down. 1. Check that there are incar sensor fault code (11,12) by using self-diagnosis function. KAA7D150 2. Disconnect incar sensor 2-pin connector that installed on inner lower instrument panel cover of driver s side and remove the sensor. KAA7D160 3. Check that measured resistance value among incar sensor terminals is as shown in the right side graph. Notice: Measure resistance value by soaking the sensor in the ice water and check changes in resistance values after soaking it in the very hot water. 4. If resistance value is out of specification, replace the incar sensor. KAA7D170 5. Install the sensor and turn the ignition switch to ON position and check that voltage between No. 12A terminal of incar sensor and body (-) is 5V. 6. Check current between the No. 12B and 12A connector terminals of the incar sensor and the No. 1 and 5 connector terminals of the airconditioner control unit and repair the wire if defective. KAA7D180
7D-18 FATC-HAVC Ambient Sensor Ambient sensor is a sensor that detects ambient temperature and a thermistor that decreases its resistance when temperature up and increases when temperature down. 1. Check that there are ambient sensor fault code (13,14) by using self-diagnosis function. KAA7D190 2. Disconnect ambient sensor 2-pin connector that installed on front right side of the frame and remove the sensor. KAA7D200 3. Check that measured resistance value among ambient sensor terminals is as shown in the right side graph. Notice: Measure resistance value by soaking the sensor in the ice water and check changes in resistance values after soaking it in the very hot water. 4. If resistance value is out of specification, replace the ambient sensor. KAA7D210 5. Install the sensor and turn the ignition switch to ON position and check that voltage between No. 10 terminal of the ambient sensor and body (-) is 5V. 6. Check current between the No. 10 and 9 connector terminals of the ambient sensor and the No. 2 and 5 connector terminals of the airconditioner control unit and repair the wire if defective. KAA7D220
Water Sensor FATC-HAVC 7D-19 Water sensor is a thermistor that detects engine coolant temperature to operate the blower speed to LO when water temperature is less than 50. 1. Check that there are water sensor fault code (15,16) by using self-diagnosis function. KAA7D230 2. Disconnect water sensor 2-pin connector that installed on the heater unit of inner instrument panel and remove the water sensor. KAA7D240 3. Check that measured resistance value among water sensor terminals is as shown in the right side graph. Notice: Measure resistance value by soaking the sensor in the ice water and check changes in resistance values after soaking it in the very hot water. 4. If resistance value is out of specification, replace the water sensor. KAA7D250 5. Install the sensor and turn the ignition switch to ON position and check that voltage between No. 7a terminal of the water sensor and body (-) is 5V. 6. Check current between the No. 7a and 7b connector terminals of the water sensor and the No. 3 and 5 connector terminals of the airconditioner control unit and repair the wire if defective. KAA7D260
7D-20 FATC-HAVC Sun load Sensor Sun load sensor is a photo diode that detects lights. Resistance of diode can be measured as current by using multimeter according to increasing sun loads. 1. Check current on the circuits between the sun load sensor and the airconditioner control unit. KAA7D270 2. Turn the ignition switch to ON position and check that voltage between No. 13a terminal of the sun load sensor and vehicle ground is 5V. KAA7D280 3. Measure current between No. 13a terminal of the sun load sensor and No. 11 terminal of the control unit and check it is as shown in the below graph. 4. If current value is out of specification, replace the sun load sensor. KAA7D290 KAA7D300
FATC-HAVC 7D-21 Fault : intake (recirculation/fresh air) door inoperative Remove the glove box. Disconnect 3-pin connector of the intake mode actuator and turn the ignition switch to ON position. KAA7D310 Measure voltage between 6c terminal positive pole (+) and body (-). Wiring side connector Measured voltage is 12V. Yes Turn the ignitin switch OFF and disconnect harness of the intake actuator. No Check No. 24 fuse (15A) in the box. Check that it operates toward each direction after connecting the battery to the 6C terminal of intake actuator and ground 6A & 6B to the body. Intake actuator is normal. Yes Disconnect 20-pin connector from the airconditioner control unit. No Repair and replace the intake actuator. Check intake actuator linkage and door for proper operation and repair if necessary. Check current between the intake actuator (6A, 6B) and the airconditioner control unit (6,7). Is there current? Yes No Repair open wire between the intake actuator and the control unit. Replace the good control unit and re-check. If no fault, replace the control panel.
7D-22 FATC-HAVC Fault : air flow does not change toward panel side. Remove the center panel of the instrument panel. Disconnect 8-pin connector of the mode actuator and turn the ignition switch to ON position. KAA7D350 Measure voltage between 8I terminal positive pole (+) and body (-). Measured voltage is 12V. Yes Turn the ignition switch OFF and disconnect harness of the mode actuator. No Check No. 24 fuse (15A) in the fuse box. Check that it operates toward each directions when ground is connected to terminal (8J, 8H, 8F, 8D, 8B) of the mode actuator alternatively. Mode actuator is normal. Yes Disconnect 20-pin connector from the airconditioner control unit. No Repair and replace the mode actuator. Check the intake actuator linkage and door for proper operation and repair if necessary. Check current between the mode actuator (8J, 8H, 8F, 8D, 8B) and the airconditioner control unit (11, 12, 13, 14, 15). Is there current? Yes No Repair open wire between the mode actuator and the control unit. Replace the good control unit and re-check. If no fault, replace the control panel.