Valeo Citysphere S Installation Instructions Manual

AIR CONDITIONING

CITYSPHERE S
Standard

Installation instructions

Rev. 06/2014
Id.No. 11120621A

Content Citysphere S

Content

1. Safety information and regulations ...................................... 3

1.1. General safety regulations .............................................. 3

1.2. Safety instructions for maintenance ................................ 3

2. Preparation for installation .................................................... 5

2.1. Safety instructions .......................................................... 5

2.2. Conditions for assembly .................................................. 5

2.3. Preparations on vehicle’s roof ......................................... 5

2.4. Roof cut-outs .................................................................. 5

2.5. Fastening drill holes ........................................................ 6

2.6. Cleaning the vehicle’s roof and the AC unit ..................... 7

3. Mounting the air-conditioning unit ....................................... 8

3.1. Applying the adhesive ..................................................... 8

3.2. Position the air-conditioning unit ..................................... 9

3.3. Fastening the unit ........................................................... 9

4. Connecting the air-conditioning unit .................................. 10

4.1. Connecting the refrigerant / water piping ....................... 10

4.2. Hook-up ........................................................................ 10

4.3. Evacuation and charging of the refrigerant cycle ........... 12

5. Troubleshooting ................................................................... 13

5.1. General ......................................................................... 13

5.2. Cause of faults in the electrical system ......................... 13

5.3. Cause of faults in the air-conditioning system ............... 13

5.4. Dealing with problems in the refrigerant circuit .............. 13

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Citysphere S Safety information and regulations

1. Safety information and regulations

• The rooftop air-conditioning system has been designed and built
in accordance with EC Directives.

• The system is safe if it is installed properly and used according to
the installation and service instructions.

• If the Citysphere S is retrofitted, the empty weight and possibly
the height of the vehicle are changed. Then, within the scope of
the German Road Traffic Licensing Regulations (StVZO) an
official acceptance inspection and an appropriate entry into the
vehicle documents according to Section 19 of the StVZO is
required. Outside the scope of the StVZO can apply appropriate
rules. The vehicle owner is responsible for the entry in the vehicle
file.

• The general safety regulations for the prevention of accidents
have to be observed strictly. “General safety regulations” beyond
the scope of these regulations are detailed below.

• The specific safety regulations are highlighted in the individual
chapters resp. procedures.

1.1. General safety regulations

• Non-compliance with the installation manual and its included
notes will lead to liability exclusion by Spheros. The same applies
to unskilled repairs or repairs not using original spare parts.

• Electrical wiring and operating elements of the air-conditioning
system must be arranged in the vehicle in such a way that their
correct functioning cannot be impaired under normal operating
conditions.

1.2. Safety instructions for maintenance

• If faults develop in the refrigerant circuit, the system must be
tested and repaired by an authorized specialist repair shop
according to the rules. Under no circumstances may refrigerant
be discharged into the atmosphere.

• Never heat refrigerant cylinders with a naked flame.

• Liquid refrigerant must never be allowed to come into contact with

body parts. The safety data sheet must be observed.

• Always wear protective clothing and goggles when handling
refrigerant.

ATTENTION

• The vehicle load capacity is diminished by the weight of the
additional components.

• A placard with the vehicle’s new total height is to be installed in
the drivers field of vision.

WARNING

• Do not perform soldering or welding directly on components of
the closed refrigerant circuit or in its vicinity. The heating will
cause a rise in the circuit pressure. There is a danger of
explosion.

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Safety information and regulations Citysphere S

• Before performing any work allow the system to cool down
completely. Risk of injury due to burns on the condenser,
compressor and refrigerant hoses.

• Installation, maintenance and repair work must be carried out by
duly qualified personnel. Such work may only be undertaken with
the engine off and the power supply switched off.

• The battery must be disconnected before starting the work.

• Do not wear metal jewellery (bracelets, watches, necklaces, rings)

when working on the air-conditioning system.

Certification

• The electro-magnetic compatibility (EMC) has been checked.

• Standard requirements of the ECE Regulation R10 Rev. 03 are

complied.

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Citysphere S Preparation for installation

Warning!

Danger of severe injuries or
fatal fall!

Caution!

Danger of cut injuries due to
sharp metal edges!

2. Preparation for installation

2.1. Safety instructions

• The safety instructions outlined on pages 3 and 4 must be read
and noted before starting work.

• Installation should be performed by someone well versed in auto
mechanics/auto electrics.

2.2. Conditions for assembly

• Before assembling and operating the air-conditioning system(s),
the vehicle's power supply must be checked for sufficient capacity,
and must be upgraded if necessary.

• A free generator capacity of 65 A (max. current consumption per
unit) must be at disposal per unit to be constructed. This capacity
must be guaranteed at idle speed, and at the same time at
maximum engine compartment temperature (low speed and high
ambient temperature diminish the output of generators).

2.3. Preparations on vehicle’s roof

When working on the bus roof or on any hoisting equipment,
scaffolding etc. suitable safety precautions must be taken to
prevent falls.

Wear protective gloves!

2.4. Roof cut-outs

The required roof cut-outs (opening for refrigerant connection and
electrical interfacing) must be clearly indicated on the roof. Make
the roof cut-out using suitable tools. Cut edges should be deburred
and protected against corrosion.

NOTE:

Interface drawings can be obtained from Spheros!

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