1. Air Conditioning (HVAC) Course Presentation
Oct 2005
Subtitle (Arial 22 to 24)
Class 390 Pendolino
Air Conditioning (HVAC) Course Presentation
File name : Presentation - all system
Modified: 10/10/05
B.McRae - Add keys to pictures on slides 9 & 28.
D. Bloor - Change picture on slide 6, add slide 7 to explain slide 6.
Basic Introduction training to level 3
- Add text to be highlighted here -

2. Reference/Name of Presentation/SN
Course Introduction
About Your Trainer
Fire Procedures
Lunch Break
Tea Times
Course Time Table
Insert Your Name Here
When the fire alarm rings go to Assembly Point in car park
From
One in the Morning Before practical work, and one in the afternoon before assessment
TBA
? What shift are you working?
Date of last change
Reference/Name of Presentation/SN

3. Reference/Name of Presentation/SN
Course Contents
Overview of the HVAC System.
Main components in HVAC.
Locations on the train.
Maintenance Examination
Download interrogation
Practical/Theory Assessment
Feedback
This course is a general introduction to the HVAC system on the Pendolino 390 Train system. This course will develop a basic understanding of a HVAC system and the cover the connection and control of some parts of the HVAC on the Car.
Date of last change
Reference/Name of Presentation/SN

4. Reference/Name of Presentation/SN
HVAC Overview
Simple HVAC system as seen in a home or office environment.
Refer to the next slide for the detailed operations.
Date of last change
Reference/Name of Presentation/SN

5. Reference/Name of Presentation/SN
HVAC Saloon Overview
Key to the Picture
1. Fresh air in
2. Hot air out from Condenser
3. Ambient air in for Condenser
4. Exhaust air out
5. Supply Air
6. Fresh air in
7. Hot air out from Condenser
8. Ambient air in for Condenser
9. Exhaust air out
10. Supply Air
Not Shown: Just below Item 5, 10 is the duct for the Return Air flow.
The vehicle HVAC module processes 4000m3 of air per hour, this equates to roughly 50 complete cycles of the internal air though the module each hour.
The air is processed in two identical Air Handlers, which are contained within the HVAC module at either end. Vehicle air enters the unit via a return grille in the vehicle ceiling where it is mixed with some new fresh air before being filtered, heated or cooled and then supplied back to the vehicle interior.
Cooling is achieved by passing the air over a cold surface in an air-to-refrigerant heat exchanger. A central refrigeration circuit, which serves both air handlers, processes the refrigerant, this circuit is called a vapour compression circuit and uses an efficient heat-carrying medium, a hydro-fluorocarbon compound, refrigerant R134A.
Key to the picture above
1. Fresh air in
2. Hot air out from Condenser
3. Ambient air for condenser in
4. Exhaust air out
5. Supply Air
6. Fresh air in
7. Hot air out from Condenser
8. Ambient air for condenser in
9. Exhaust air out
10. Supply Air
Not Shown: Just below Item 5, 10 is the duct for the Return Air flow.
Saloon HVAC Unit
Date of last change
Reference/Name of Presentation/SN

6. Reference/Name of Presentation/SN
Saloon Vehicle HVAC System
(Roof View)
Condenser Fans
Supply Air Out
Vehicle HVAC System General 22 ± 2C
The Vehicle HVAC System (above) is designed to maintain a saloon internal temperature of 22C with an adjustable set point of between 20°C and 24°C for each saloon. In other areas, such as the catering area, the system will maintain a temperature of 22C in heating mode and between 22C and 2.75°C above ambient in cooling mode. This is due to the exceptional ancillary heating effects of installed cooking equipment.
In order to meet these design conditions there are many different items of heating and cooling equipment installed throughout the various car types. In all cars cooling is achieved via a HVAC module installed centrally in the vehicle roof. The module filters, processes and delivers conditioned air to the vehicle continuously whenever the vehicle is powered up. The air may be heated or cooled as it is processed as required.
Condenser Coils
Date of last change
Reference/Name of Presentation/SN

7. Reference/Name of Presentation/SN
Heating Arrangement
Heating Arrangement
All heating is direct by electric resistance elements (above). It is achieved via several different units dependent upon the car type; most cars have some or all of the following heating equipment:
Body side electric convector heaters
Fan assisted electric heaters
Toilet and Corridor body side convector heaters.  
In the saloon seating areas, body-side convector heaters are installed; similar convector heaters are installed in the toilet areas and also in corridor areas. The vestibule areas have fan-assisted heaters installed. All these heating devices supply heated air at low level.
Heating in the HVAC module is achieved via mineral insulated electrical resistance heater elements, these are positioned downstream of the cooling coils to heat the air just before it leaves the module. The HVAC module only supplies heated air at high level through the ceiling ductwork diffusion system. 1
Circulated Heat Flow (Heat or Cool)
Convected Heat Flow (Heat only) 2
Date of last change
Reference/Name of Presentation/SN

8. Reference/Name of Presentation/SN
General Arrangement of Saloon Long Body Side Heater
Long Heater Element
Vehicle Body-Side Heaters
These units are installed at floor level in the saloon seating areas with a shorter variant installed in the standard and disabled toilets and also in the vestibule area opposite disabled toilets. They comprise of a hairpin shaped sheathed mineral insulated electric heater element fitted to terminal box. The heater causes natural convection currents through the body-side grille; having no moveable parts they provide a silent and highly reliable heat source. They are wired together in parallel groups to give typically four separate areas of heating control in the saloon. The body-side heaters operate independently in the ancillary and toilet areas.
Low Level Sensor
Date of last change
Reference/Name of Presentation/SN

9. Reference/Name of Presentation/SN
HVAC Overview
Train Configuration
Here are two drawings which show:
Sensors positions in a Car
Air flow in a Car
Exhaust Air
In actual fact the extract air is not strictly kept separate, as it comes together with the re-circulated air (return) in both ends of the module, before parting again. This is not so critical as the air temperature from both air extract and re-circulated air are the same.
Air Processing, Heating & Cooling
The air is processed in two identical Air Handlers, which are contained within the HVAC module at either end. Return air enters the unit via a return grille in the vehicle ceiling where it is mixed with some new fresh air before being filtered, heated or cooled and then supplied back to the vehicle interior. Cooling is achieved by passing the air over a cold surface in an air-to-refrigerant heat exchanger. A central refrigeration circuit, which serves both air handlers, processes the refrigerant, this circuit is called a vapour compression circuit and uses an efficient heat-carrying medium, a hydro-fluorocarbon compound, refrigerant R134A.
Exhaust Air/Extract Air
Extract air is drawn from the end vestibules, electrical cubicles and toilet
compartments. In order to facilitate this there are transfer grilles from the
saloon to the vestibule areas. From there it is ducted to the vehicle HVAC
module air handlers and then expelled to atmosphere by an exhaust air fan.
The extract air is kept separate from the fresh air and re-circulated air.
Fresh Air
Fresh air is introduced to the vehicle via the HVAC module.
Date of last change
Reference/Name of Presentation/SN

10. Reference/Name of Presentation/SN
TMS View of HVAC
Prelim. Health Check on Saloon (/Cab) Space temperatures or Fresh Air (Sensor) readings.
HVAC is sub-system code 0 in 2nd column (Train Status) of Main Menu Maintenance Screen.
Selecting 0 gives you the key HVAC health screen and shows the Saloon equipment
Problems are always shown up as yellow boxes : hence the following saloon HVAC status picture shows the B car is not communicating with TMS, for whatever reason : maybe FIP lead is disconnected. Therefore cannot tell from TMS alone whether this HVAC system is healthy at this time or not.
Simplest thing to try (first) for any fault condition is :
Trip & re-set PC104 controller– toggle either ‘control cct.’ single pole breaker 61F145 (K8A) at left hand end of Liebherr front/hinged panel or Alstom CB-HVCS (‘HVAC Saloon’).
Date of last change
Reference/Name of Presentation/SN