TOP-COOL ECO-CLIMATEC, User Manual

Page 1: ...2012 Top Cool Products B V www top cool eu USER MANUAL ECO CLIMATEC...

Page 2: ...INSTALLATION INSTRUCTIONS 19 MAIN POWER CONNECTION 20 CONNECTOR PINS 22 OUTPUT CONTROL BOARD 23 INTPUT CONTROL BOARD 24 INTERIOR FAN CONNECTION 26 EXTERIOR FAN CONNECTION 27 TIPS 27 OPERATING INSTRUC...

Page 3: ...igh efficient heating process by creating a heat pump effect and using waste energy of other components in the vehicle The system is the solution to green minded vehicle builders that are looking for...

Page 4: ...summarized in the following schedule Obviously it can be used for many other options or additional purposes Applications modules for the ECO ClimaTEC system Definitions applicable in this manual ECO C...

Page 5: ...TCT 4 PP Power Pack series with 4 peltier elements per TCT unit Tube connections FC4 Frontpanel tube Connections 4x BC4 Backpanel tube Connections 4x FC2BC2 Frontpanel tube Connections 2x and Backpan...

Page 6: ...information 3 The ECO ClimaTEC can only be used in a specified temperature range because of the limitations of the cooling fluid See OPERATING LIQUIDS for more information 4 Do not use the system on a...

Page 7: ...ClimaTEC operating system consists of a number of identifiable system components Basic ECO ClimaTEC system in interior cooling mode A ECO ClimaTEC BMCS B Radiator fan combination for the exterior loop...

Page 8: ...nd connect the exterior radiator fan Step 3 Place and connect the interior radiator fan Step 4 Connect the tubing of the radiator with the ECO CLimaTEC See chapter Electrical Installation Instructions...

Page 9: ...tlet coupling exterior 7 Inlet coupling exterior 8 Outlet coupling interior 9 Inlet coupling interior Example positioning in vehicle 1 Main connection 1 Main connection 2 Input control board 5 Connect...

Page 10: ...strongly preferred to mount the system horizontally and not at an angle while the system is operating Ensure to mount the module to the chassis and secure the system tightly so it cannot move or shif...

Page 11: ...nt heat expel is maintained for the unit RADIATOR FAN COMBINATION EXTERIOR LOOP EEM Step 2 Place and connect the exterior radiator fan To create a high performance cooling system it is very important...

Page 12: ...ons such as parking It s recommended to mount the fan with its air drawing side onto the radiator It is also recommended to use a shroud for a better air flow RADIATOR FAN COMBINATION INTERIOR LOOP IE...

Page 13: ...sary loss of cooling power CONTROL BOARD The purpose of the control board is to control and to monitor the system while operating The control board may be connected to a temperature controller for reg...

Page 14: ...erating voltage V 12 VDC 12 VDC 24VDC Maximum Current on main Power Connection Amp 145 Amp 120 Amp 70 Amp Power supply W 12 x 145 min 1740 W 12 x 120 min 1440 W 24 x 70 min 1680 W LIQUID COUPLINGS The...

Page 15: ...CO ClimaTEC 3 8 tailpiece OD10 3 8 tailpiece OD16 3 8 1 4 3 8 3 8 3 8 1 2 3 8 3 4 Possible liquid connection couplings Outlet coupling to radiator interior Inlet coupling from radiator interior Outlet...

Page 16: ...ally be mounted into these liquid connectors These tailpieces did not come with the ECO ClimaTEC Except if you have also ordered a Mechanical installation kit For male BSP couplings it s strongly advi...

Page 17: ...quid flow and not on high pressure ca 1 bar 14 5 PSI Use appropriate tubing with an inner diameter of at least 10mm to create sufficient flow Allways keep the length of the tubing to a minimum and cov...

Page 18: ...is covered by a lid that is mounted onto the housing by four M4 socket screws A hex key with a width of 2 5mm can be used for mounting and demounting the screws Mounting the lid Socket screw Socket s...

Page 19: ...instructions describe how to electrically install an ECO ClimaTEC system The electric connections of the ECO ClimaTEC consist of the following parts 1 Main power connection Connector pins 2 Output con...

Page 20: ...the electric wires of the main connection onto the chassis or any other solid component of the vehicle near the main connection to prevent them from moving or vibrating and applying forces onto the c...

Page 21: ...ns TCT units 4 xTCT 4PP 15V10A 4 xTCT 4PP 24V13A 2 xTCT 4PP 15V10A 2 xTCT 4PP 24V13A Operating voltage V 12 VDC 12 VDC 24VDC Maximum Current on main Power Connection Amp 145 Amp 120 Amp 70 Amp Power s...

Page 22: ...ir description are listed below 1 Exterior connection for LED Level to Low 2 Exterior connection for LED No Flow 3 Temperature controller 4 Temperature controller 5 Cooler Switch 6 Common Switch 7 Hea...

Page 23: ...n 3 Temperature controller 4 Temperature controller 1 2 3 4 Connector MSTBT 2 5 4 STF 5 08 1805327 The ECO ClimaTEC consists of a couple of safety controllers the electric connector above gives the ab...

Page 24: ...ng and heating Whether to cool or heat depends on the position of the three position rocker switch For cooling and heating the switch must be connected as described in the following picture Cooler Com...

Page 25: ...cooling the TCT units are shut down The rest of the system is still running this results in a need of less electric power and lower cooling performance 0 off passive This means that the TCT units for...

Page 26: ...e radiator fan combinations are not standard components of the ECO ClimaTEC and can therefore separately be connected to the ECO ClimaTEC Keep in mind that this connection works on the same voltage as...

Page 27: ...integration this connetion has to be secured by an additional safety fuse The fan connection can handle a maximum current of 5A 30VDC TIPS 1 Electrical work should be performed by a qualified operator...

Page 28: ...wed to remove any other plugs than the pointed out ones in the following picture The plugs may not be removed because they are meant for sealing a built in air chamber that prevents the reservoirs fro...

Page 29: ...d in the different loops interior and exterior is maximal 4 liters each This means the reservoir tubes and radiator This prevents exceeding the maximal acceptable internal pressure of the reservoir du...

Page 30: ...revent the reservoir from overflowing it is recommended to fill the reservoirs while the pumps of the ECO ClimaTEC are activated This can be done after the module is electrically connected 2 Note Ther...

Page 31: ...ure the main power is ready to be started 2 Check the liquid level in the reservoirs after the ECO ClimaTEC has been operative for one hour 3 Check again if there is no leakage at the couplings after...

Page 32: ...iquid used is operating near its freezing temperature The fluid will always freeze inside the TCT units first and is not notable It is not allowed to regulate the system in a mode that is operating ab...

Page 33: ...fill opening is clear of contamination to prevent the ECO ClimaTEC from running on contaminated cooling fluid Replace or clean the filter if it is not clean 5 The radiator and fan must be cleaned whe...

Page 34: ...e limiter has shut down the module Wait until the cooling unit has cooled down below 35 C The ECO ClimaTEC is not heating cooling correctly Power capacity shortage Check the applied voltage and curren...

Page 35: ...CT unit has cooled down to a temperature of approximately 35 C At room temperature this takes about 20 min LEVEL SWITCH The level switch checks the liquid level inside the reservoirs If the level of t...

Page 36: ...can be done by removing the plug on top of the reservoirs and refilling the reservoirs with cooling fluid see picture Refilling the reservoirs AIR BUFFER The reservoirs contain an integrated air buffe...

Page 37: ...n this manual contact Top Cool for instructions or confirmation 2 If there is doubt about a sufficient flow you can use a flow switch a flow meter or flow indicator like a propeller in the flow to vis...

Page 38: ...38 TECHNICAL DATA DIMENSIONS Dimensions 382 x 363 x 184 5mm Weight 18kg unfilled depending on model Top Front Side view dimensions in mm...

Page 39: ...inless steel Cooling fluid Water MEG Mono Ethylene Glycol Reservoir content 1 Liter each Main dimensions 382 x 363 x 184 5mm Weight unfilled 18kg Optional components Electric installation kit Mechanic...

Page 40: ...concerning the electric wiring and power you will need electrical equipement Important information action to be taken concerning installation of the ECO ClimaTEC and maintenance to the total system yo...

Page 41: ...zone 2 and zone 22 potential gas and dust explosions According to the requirements of the Directive ATEX Directive 94 9 EG The products are in conformity with ATEX under the following guidelines Ex II...

Page 42: ...hazardous substances RoHS listed substances Common used materials for food applications The parts of the unit contains the following common used materials in food applications Polypropylene PP Ceramic...

Page 43: ...maTEC can be transported in any orientation when the system is not filled The system must be stored in an ambient that is 5 degrees higher than the liquids freezing point Only a completely empty syste...

Page 44: ...rranty period warranty is given to the module for defects in material and workmanship under condition that 1 All the precautions installation operation and security instructions are strictly followed...

Page 45: ...l specifications at time of print We reserve the right to change any specifications or notes to this manual or described products without notice Nothing of this manual may be exposed copied made publi...

Page 46: ...B V v2 00 Original Version www top cool eu Inventors of the Top Cool Technology Top Cool Products B V Groesweg 37B Maasbree The Netherlands Tel 31 77 465 01 42 Fax 31 77 465 01 43 Web www top cool eu...