Technical informations - Safety instructions	download

A U R O R A
Konrad G. Schulz GmbH & Co.KG
Südring 4
D-69427 Mudau
Tel.: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com

we reserve the right to make modifications

The following risks are the result of risk analysis for standard units:

• Thermal dangers, for example danger of burning on the heat exchanger, evaporator and condenser, the connections and the resistance.
• Electrical dangers, for example inappropriate cable laying and installation, short circuit and cablefire because of missing fuse protection and units with high nominal voltage or supply voltage.
• Mechanical dangers, for example danger of cutting at possible and not avoidable sharp and edges or tapered screws.
• Dangers at incorrectly installation, for example not required torque or no adequate maintenance.

The following advises and the advises contained in the safety instructions in the units technical information's have to be followed at installation and operation. The Installer and the operator have to read this advises and instructions before installation and starting.

Dangers at non-observance of the safety instructions:
At non-observance of the safety instructions dangers for persons and products are possible and the loss of all claim for damages can be the result.
The following dangers are possible if the safety instructions are non-observed:

• of important product functions
• dangers for people because of thermal, electrical and mechanical influences.

The rules for the prevention of accidents as well as other recognises technical and labour medical security regulations must be observed.

• The products have to used only according to the intended use. The products shall not used in improper environment. Please pay attention to the Technical supplement to guarantee.
• Before using the products ensure that regulations and laws are strictly adhered according to the countries. Pay also attention to instructions dependant to the countries, for example danger of fire (soldering, welding).
• If AURORA-products can cause material damages or dangers to people the customer have to be made additional external safety precautions. This safety precautions have to ensure a defined operation state also in case of failures (examples are protection grilles, isolation tubes).
• AURORA products have only to be installed in vehicles and machines that fulfil the safety requirements for vehicles and machines. Examples are in the vehicle or machine installed fire drencher, emergency hammer, protection devices against falling objects or fluids.
• In emergency situations switch off the unit.

• Do not reach into the operating unit and never stick objects into the blowers.
• If air flaps are free approachable, use vehicle side rebuildings (for example protection grilles) as a protection against intervention into the air flaps.
• There is a danger of bruising at the self calibration of water valves with servo motor and EVKS. Do not reach into the self calibration.
• Do not use nozzles into the area of the drivers head.
• On the evaporator, the condenser and the heat exchanger are sharp fins.
• Be careful with long wire cables with pointed ends. The rolled wire cables are suspended. Be careful by taking off the packing.
• Residual pressure may still remain even after the unit has been emptied. This should initially be released with extreme care by first slowly loosening the connections.

• Pay attention to necessary vehicle-sided fuses according to circuit diagram or technical information of the heater or the air conditioning unit.
• Use only original fuses with required amperage.
• Electrical connections shall only be made in a voltage-free state. The laying of cables have to be made carefully especially in the area of bowden cable actuations.
• Check the proper state of the electrical connections in regularly periods.
• Maintenance-work only if the blower-motor is stagnant.
• Cut the blower from the current circuit to avoid injuries.
• Before opening the cover of a air conditioning unit disconnect the battery.
• Electrical cables and operation elements of heaters or air conditioning units have to be installed into the vehicle in such way that a faultless function under normal conditions is guaranteed.
• Pay attention to the safety instructions for PTC radiators in chapter 5.

• Attention! Danger of burning! Please do not get into contact with the heat exchangers and its connections. Cooling tubes and cooling hoses can be hot and stand under pressure. Be careful by touching them. This also applies to the resistance on the blower when working at the opened unit and the construction part has not completely cooled down.
• Isolate the free approachable connection tubes.

Please pay attention to the safety instructions in chapter 0. and 1.

Qualification of personnel: Installation, maintenance work and repairs must only be done by wellinformed and authorised specialists.
Works on unit shall only be done in a not-running state. Take off defect parts immediately.
Faults have to be eliminated instantly.
The safety instructions in the Technical information of the units have to be read before installation.

• Wear necessary protecting equipment at installation, maintenance and repairs as protection against sharp edges and pointed screws.
• Use suitable tools and working clothes (protecting equipment) for repairs, mainte-nance and installation.
• Wearing unsuitable working clothes there is a danger of get stuck and permeation.
• Pay attention for the necessary torque at connecting the fittings and screws.
• Fix the hoses with suitable clamps and with torque required from the producer.
• Fix long cable sets with clamps to avoid risk of stumbling.
• Attention at installation of the insertion frame for CBE/CBM and SRE. There is a risk of squeezing.
• Maintenance work have to be done in regularly intervals.
• Check of the fixing, leak control and laying of the hoses and fittings. The hose fixings are to be tightened if necessary.
• Change water and oil hoses if the material is not in order. In the case of maintenance the hoses with cooling medium have to changed very carefully.
• When connecting the water hoses use suitable hose clips and tighten them with the required torque.

• Lift and transport the heating and air conditioning units only on the housings.
• Don't lift or transport the device on the expansion valve or the cable sets. Don't pull at the cable sets. Otherwise the plugs can tear off.
• Protect the products against moisture and mechanical damages during transport and storage.
• Use suitable and unobjectionable lifting devices and load lifting members.
• By working on the roof of vehicles take care for the prevention of accidents. Use working platforms or scaffolding.
• Only use suitable hoisting facilities that are free of dirt, snow or ice.

• Air inlets must be positioned, that under normal operating conditions no exhaust fumes from the engine or another heater unit could be drawn into the cab.
• During the recirculation operation, there must be air intake without any hindrance. The unit should not be installed that dust could be directly drawn in from the floor by the air intake. The recommended height above the floor is > 30 mm.
• Ensure a suitable flow of outside air.

• Pay attention to the producer-details and the safety data sheet.·
  
• Hands/body must be washed immediately with a suitable handwashing paste and water.
• Do not use solvent.

• The instructions issued by the vehicle/engine manufacturer must be observed.
• Switch off the machine/vehicle and protect against starting before works into the engine compartment.
• Refrigerant R134a in according to DIN 8960 must be used for all compressors.
• The EC Safety Data Sheet for R134a must be observed.
• All refrigerant must be drained from the system by suction before opening the refrigerant circuit.
• The unit is under no circumstances to be rinsed with compressed air!
• Damaged compressors must not be installed.
• Secure heavy compressor against falling off. Use suitable handling tools.
• When installing compressors, the manufacturer's instructions on installation position must be observed.
• The compressor must be positioned correctly on the mounted and secured properly.
• The compressor mount must be attached to the engine block at a suitable point. The mount points provided by the engine manufacturer must be used.
• Torque must be taken into account when tightening screws and connections.
• The V belt must be tensioned as instructed. It is advisable to use a tensiometer to measure this.

• Take care for security at laying the connection cables. The cables have not be stressed, kinked or damaged.
• Use only cable that is valid for using in vehicles and with adequate width.
• Lay cables in protective covers if possible and connect the cables properly for example with cable binders.
• Use rubber bushings for laying the cables through sheets.
• Protect connections against moisture.
• Pay attention to the vehicle producers guidelines for connection of the current supply.
• Use only original fuses with required amperage.

• The unit must always be emptied before any work is carried out on the refrigeration circuit. This may only be done by specialist personnel.
• Please follow the safety data sheet for refrigerant R134a.
• Do not discharge refrigerant to the environment.
• Liquid refrigerant must not come into contact with the skin.
• Safety glasses must be worn when handling refrigerants.
• If there are failures in the refrigerant circuit the unit must be checked and repaired by a specialised workshop.
• The resulting condensate shall not used as drinking water.
  

CAUTION! Risk of explosion!

• Never carry out soldering or welding work directly on parts in the closed refrigeration circuit or in its vicinity. Due to the strong heating effect the pressure will increase within the unit giving a risk of explosion.
• Refrigerant bottles must never be thrown around or subjected to lengthy periods of sunshine or other heat sources when filled. The highest permitted temperature of a filled refrigerant bottle must not exceed 45°C.

CAUTION! Risk of contamination!

• It is essential that the refrigeration system is kept free from chlorine and substances containing chlorine, as well as oils and greases. Consequentially it is necessary to invest in separate evacuation and filling systems which are exclusively used for R134a.

• Air conditioning units must only be filled by wellinformed personnel of an authorised specialists workshop.
• Fill the unit with refrigerant according to the instructions of the maker of the filling station.

CAUTION!
Voltage peaks and overload impulses in the power supply, also if they are temporary or shorttime in milliseconds, can damage electric and electronic parts such as servo motors or control units. These voltage peaks and overload impulses have to be avoided under all circumstances, if needed with additional components.

The following listed safety measures must be unconditionally observed, in order to avoid and prevent damage to components as well as to the cable set:

• No external voltage should be connected to the control outputs.
• If, for testing purposes, the board voltage is directly fed at the motor, the circuit has to be separated from the motor beforehand.
• Only start the engine if the batteries are firmly connected.
• Don't disconnect the batteries when the engine is running.
• Don't use a boost charging device to start the engine.
• Only use separate batteries for help in starting.
• Don't start the vehicle with an external charging unit.
• For fast charging the batteries the battery terminals must be removed. Follow the fast charging device instructions.
• The control unit connections may only be withdrawn or plugged on again with the electrical system switched off.
• Incorrect connection of the control unit supply voltage (e.g. wrong battery terminal connections) can lead to destruction of the control unit.
• Always withdraw the device plug when testing the connected components.
• Always use the test software, if available, provided for testing the outputs.
• Only use appropriate test leads for measurements on the plugged connections.
• Telephones and radio devices, which are not connected to an outside aerial can lead to functional faults on the vehicle electronics and thus endanger the operating safety.
• Fixed radio aerials without sufficient ground surfaces (plastic roof) will cause considerable interference through mismatching in the vehicle.
• If sufficient ground surfaces cannot be found then window aerials (adhesive aerials) should be used.
• When carrying out welding work the earth cable from the electrical welding unit must be connected directly onto the vehicle part to be welded.
• When carrying out electrical welding work the battery terminals must be removed and the two cables (+ and -) firmly fixed to one another.
• When carrying out work, which could lead to electrostatic charging of vehicle parts (e.g. spraying on the plastic underseal) any electronic components attached to the control electronics in the vicinity (e.g. external sensors) must be unplugged.
  

Temperature compatibility of electronic components:

• The indicated permitted temperatures of control units must not be exceeded.
  
• If temperatures over the max. permitted temperature are anticipated control units must be removed.

General:
Not every malfunction will result in the part or complete breakdown of the unit. In order to test the condition of the relevant unit the following must be carried out:

• Switch off the engine and ignition.
  
• Withdraw all plugs from the unit and replace them after approx. 10 seconds.
  
• Wait for the unit to carry out a "self-test" if present.
  
• Check the functioning of the installation again.
  

• Use PTC radiator only at running blower.
  
• Switch off the device immediately if the function is not normal.
  
• Don't change the original version of the device. Aurora Konrad G. Schulz GmbH & Co. KG take no charge for possible consequences of changes.
  
• Possible modifications only at your own risk.
  
• Pay attention to higher inrush current (slow characteristic fuses are necessary).
  
• All metal parts on the PTC radiator are voltaged. Secure against touching.
  
• Operating with to little air flow can alloy the function and the lifetime of the device.
  
• The operation in aggressive environment is not valid.
  
• The PTC radiator shall only used for heating of moving air.
  
• Minimal distances must be valid with the national Instructions.
  
• A evaporator must not be installed. The condensate can cause short circuits.
  
• At installation pay attention to necessary free space. If the device is covered there is the risk of fire.
  
• Protect the connection plug against water or mechanical damages.
  
• If the PTC radiator is free accessible, a cleaning of the PTC radiator from dust and dirt is necessary to protect against risk of fire.
  

Repeated inspections of electrical safety:
Electrical equipment underlie regularly safety inspections according to instruction BGV A2 of the employers liability insurance association. The tester have to be a electrotechnical instructed person.

• A defective device / part shall never be set in operation.
  
• Defects have to be marked and durable eliminated.
  
• There have to be a inspection of the machine or vehicle before first starting.
  
• Check all accessories such as compressor brackets and operation elements. The accessories must not have loose parts, abrasion, cracks, leakage or other damages.
  
• Pay attention to persons working on or under the machine or vehicle before starting.
  Before starting these persons have to be warned.
  
• Attention at working with hot operating materials. There is a risk of burning or scalding.

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