Blower issue

[Rusty2009]

Automatic HVAC Description and Operation
The air temperature and the air delivery description and operation are divided into eight areas:


• HVAC Control Components


• Air Speed


• Air Delivery


• Heating and A/C Operation


• Recirculation Operation


• Automatic Operation


• Engine Coolant


• A/C Cycle


HVAC Control Components
HVAC Controls
The HVAC controls contain all switches that are required to control the functions of HVAC and serve as interface between the operator and the HVAC control module. The selected values are passed to the HVAC control module via LIN-Bus.


HVAC Control Module
The HVAC control module is a GMLAN device that interfaces between the operator and the HVAC system to maintain and control desired air temperature and air distribution settings. The battery positive voltage circuit provides power that the HVAC control module uses for keep alive memory. If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from keep alive memory. The body control module (BCM), which is the vehicle mode master, provides a device ON-Signal. The HVAC control module provides blower, air delivery mode and air temperature settings.


The HVAC control module supports the following features:


Feature
Availability

Afterblow
Yes

Purge
Yes

Personalisation
Yes

Actuator Calibration
Yes



Mode Actuator
The mode actuator is a 5-wire stepper motor. The HVAC control module supplies a 12 V reference voltage to the stepper motor and energises the 4 stepper motor coils with a pulsed ground signal. The stepper motor puts the mode flap into the calculated position in order to reach the selected position. The null point of the stepper motor will be calibrated, if the stepper motor is new. When the stepper motor is calibrated, the HVAC control module can drive the applicable coil to reach exactly the desired position of the flap.


Air Temperature Actuators
The interior temperature can be selected separately for the driver and passenger. For this purpose, two stepper motors are used that regulates two mixed air flaps independently of each other. The air temperature actuators are 5-wire stepper motors. The HVAC control module supplies a 12 V reference voltage to each stepper motor and energises the 4 stepper motor coils with a pulsed ground signal. The left air temperature actuator moves the left mixed air flap into the calculated position, in order to reach the selected temperature of the left temperature switch. The right air temperature actuator puts the right mixed air flap into the calculated position, in order to reach the selected temperature of the right temperature switch. The null point of the stepper motor will be calibrated, if the stepper motor is new. When the stepper motor is calibrated, the HVAC control module can drive the applicable coil to reach exactly the desired position of the flap.


Recirculation Actuator
The recirculation actuator is a 5-wire stepper motor. The HVAC control module supplies a 12 V reference voltage to the stepper motor and energises the 4 stepper motor coils with a pulsed ground signal. The stepper motor puts the recirculation flap into the calculated position in order to reach the desired position. The null point of the stepper motor will be calibrated, if the stepper motor is new. When the stepper motor is calibrated, the HVAC control module can drive the applicable coil to reach exactly the desired position of the flap.


Air Inlet Actuator
The air inlet actuator is a 5-wire stepper motor. The HVAC control module supplies a 12 V reference voltage to the stepper motor and energises the 4 stepper motor coils with a pulsed ground signal. The stepper motor moves the air inlet flap into the calculated position, in order to reach the selected position. The null point of the stepper motor will be calibrated, if the stepper motor is new. When the stepper motor is calibrated, the HVAC control module can drive the applicable coil to reach exactly the desired position of the flap.


Blower Motor Control Processor
The blower motor control processor controls the speed of the blower motor by increasing or decreasing the voltage drop on the ground side of the blower motor. The HVAC control module provides a low side pulse width modulation (PWM) signal to the blower motor control processor via the blower motor speed control circuit. As the requested blower speed increases, the HVAC control module increases the amount of time that the speed signal is modulated to ground. As the requested blower speed decreases, the HVAC control module decreases the amount of time that the signal is modulated to ground.


Air Quality Sensor
The HVAC control module detects exhaust gas by an air quality sensor. The air quality sensor is a 3-wire sensor with an ignition voltage circuit, a ground circuit and a signal circuit. The HVAC control module evaluates the information of the air quality sensor and closes the recirculation flap, while in automatic mode, as soon as the concentration of pollutants exceeds a predefined value.


Duct Temperature Sensors
The air temperature sensors are 2-wire negative temperature co-efficient thermistors. The sensors operate within a temperature range of -40 to +85°C (-40 to +185°F). The sensors are installed in the air distribution ducts and measure the temperature of the air that streams from the ducts. The HVAC control module uses these values to calculate the mixed air flap position.


Evaporator Temperature Sensor
The evaporator temperature sensor is a 2-wire negative temperature co-efficient thermistor. The sensor operates within a temperature range of -40 to +85°C (-40 to +185°F). The sensor is installed at the evaporator and measures its temperature. If the temperature drops under 3°C (38°F), the compressor will be switched off in order to prevent a frozen evaporator.


A/C Refrigerant Pressure Sensor
The A/C refrigerant pressure sensor is a 3-wire piezoelectric pressure transducer. A 5 V reference voltage, low reference, and signal circuits enable the sensor to operate. The A/C pressure signal can be between 0.2-4.8 V. When the A/C refrigerant pressure is low, the signal value is near 0 V. When the A/C refrigerant pressure is high, the signal value is near 5 V. The engine control module (ECM) converts the voltage signal to a pressure value. When pressure is too high or too low, the ECM will not allow the A/C compressor clutch to engage.


A/C Compressor
The A/C compressor is constantly belt driven. The performance of the A/C compressor is regulated per a lifting magnet in the A/C compressor. The HVAC control module supplies battery voltage to the A/C compressor. When the A/C switch is pressed, the HVAC control module provides a pulse width modulation (PWM) signal to the A/C compressor in order to command the performance of the A/C compressor. The performance of the A/C compressor is regulated according to adjusted interior temperature on the basis of characteristic lines. Therefore the HVAC control module grounds the A/C compressor with the PWM signal.


Windscreen Temperature and Inside Moisture Sensor
The windscreen temperature and inside moisture sensor includes the relative humidity sensor, windscreen temperature sensor and humidity sensing element temperature sensor.


This sensor assembly provides information about:


• Relative humidity level at windscreen (compartment side)


• Temperature of the windscreen inside (compartment side)


• Temperature of the humidity sensor element


The relative humidity sensor measures the relative humidity of the compartment side of the windscreen. It also detects the temperature of the windscreen surface on the passenger compartment side. Both values are used as control inputs for the HVAC control module application to calculate the fog risk on windscreen compartment side and ability to reduce fuel consumption by decreasing A/C compressor power to a minimum without causing any fog. The sensor will also enable partial recirculation mode in order to improve heat-up performance of the passenger compartment under cold ambient temperature conditions without the risk of mist build-up on the windscreen. The humidity sensor element temperature sensor supplies the temperature of the humidity sensor element. It is only needed if the thermal contact between the humidity sensing element and the inside windscreen surface is not sufficient.


Ambient Light/Sunload Sensor
The ambient light/sunload sensor includes the sunload sensor and passenger compartment temperature sensor.


This sensor assembly provides information about:


• Sun heat intensity


• Elevation


• Azimuth


• Passenger compartment temperature


The sunload sensor is connected to ground and to a 12 V clocked power supply through the HVAC control module. This clocked power supply is to power the sensor electronics and to work as a clock generator to the sunload sensor micro controller. The sensor uses a pulse signal for data identification and transferring the sun intensity measurement. At each positive transition from the clocked supply input, the sunload sensor micro controller will shift channels enabling new intensity measurement on the signal output to the HVAC control module. The signal voltage varies between 0-4 V.


The passenger compartment temperature sensor is a negative temperature co-efficient thermistor. A signal and low reference circuit enables the sensor to operate. As the air temperature increases, the sensor resistance decreases. The sensor signal varies between 0-5 V.


Bright or high intensity light causes the vehicles interior temperature to increase. The HVAC system compensates for the increased temperature by diverting additional cool air into the vehicle.


Air Speed
The fan control switch is part of the HVAC controls. The selected value of the blower switch position is sent to the HVAC control module via LIN-Bus.


The blower motor control module is an interface between HVAC control module and blower motor. The blower motor control module regulates supply voltage and ground circuits to blower motor. The HVAC control module provides a PWM signal to the blower motor control module in order to command the desired blower motor speed. The blower motor control module supplies battery voltage to the blower motor and uses the blower motor ground as a low side control to adjust the blower motor speed. The voltage amounts between 2-13 V and changes linear to the height of the PWM signal.


Air Delivery
The HVAC control module controls the distribution of air by the use of recirculation and mode actuator. The modes that may be selected are:


• Defrost


• Demist


• Panel


• Floor


The desired air distribution mode can be selected with the air distribution switches at the HVAC controls. The HVAC controls deliver the values to the HVAC control module via LIN-Bus. The HVAC control module controls the air distribution actuator so that it drives the flap to the calculated position. Depending on the position of the flap, air is distributed through various ducts leading to the outlets in the dash. Turning the mode flap to the defrost position, the HVAC control module will move the recirculation actuator to outside air, reducing window fogging. When defrost is selected, the blower motor will be activated, regardless of the coolant temperature. The HVAC control module enables a high volume of air delivered to the front defrost vents. A/C is available in all modes.


The rear window demister does not affect the HVAC system.


Heating and A/C Operation
The purpose of the heating and A/C system is to provide heated and cooled air to the interior of the vehicle. The A/C system will also remove humidity from the interior and reduce windscreen fogging. Regardless of the temperature setting, the following can affect the rate that the HVAC system can achieve the desired temperature:


• Recirculation actuator setting


• Difference between inside and desired temperature


• Blower motor speed setting


• Mode setting


When the A/C switch or the AUTO switch is pressed, the HVAC controls send a signal to the HVAC control module via LIN-Bus. The HVAC control module evaluates this signal and sends an A/C request signal to the ECM via CAN-Bus. The ECM checks all preconditions before releasing and if all conditions are met sends a release signal back to the HVAC control module. The A/C compressor is activated by the HVAC control module. The HVAC control module supplies battery voltage to the A/C compressor. When the A/C switch is pressed, the HVAC control module provides a pulse width modulation (PWM) signal to the A/C compressor in order to command the performance of the A/C compressor. The performance of the A/C compressor is regulated according to adjusted interior temperature on the basis of characteristic lines. Therefore the HVAC control module grounds the A/C compressor with the PWM signal.


The following conditions must be met in order to activate the A/C compressor:


• Battery voltage is between 9-18 V


• Engine coolant temperature is less than 124°C (255°F)


• Engine speed is greater than 600 RPM


• Engine speed is less than 5 500 RPM


• A/C high side pressure is between 269-2 929 kPa (39-425 PSI)


• Throttle position is less than 100%


• Evaporator temperature is greater than 3°C (38°F)


• ECM does not detect immoderate torque load


• ECM does not detect insufficient idle quality


• The ambient temperature is above 1°C (34°F)


The sensor information is used by the ECM to determine the following:


• The A/C high side pressure


• An A/C system load on the engine


• An immoderate A/C high side pressure


• The heat load at the A/C condenser


The air streams into the passenger compartment through the heater core and the evaporator core. The air temperature actuator drives the mixed air flap to induce the airflow. If the interior temperature should be increased, the mixed air flap is put into the position in which more air streams through the heater core. If the interior temperature should be decreased, the mixed air flap is put into the position in which more air streams through the evaporator core.


Recirculation Operation
The recirculation switch is integrated into the HVAC controls. The selected recirculation switch position is sent to the HVAC control module via LIN-Bus. The HVAC control module controls the air intake through the air inlet actuator and recirculation actuator. In the recirculation mode the air inlet flap closes and the recirculation flap opens in order to circulate the air within the vehicle. In fresh air mode the air inlet flap opens and the recirculation flap is closed again in order to route outside air into the vehicle. Recirculation is only available if the defrost mode is not active. When the defrost mode is active, the recirculation actuator opens the recirculation flap and the air inlet actuator opens the air inlet flap and outside air is circulated to the windscreen to reduce fogging.


In automatic mode the values of the windshield temperature and inside moisture sensor are used as control inputs for the HVAC control module application to calculate the fog risk on passenger compartment side of the windshield compartment side. The A/C compressor and the defrost mode are activated to prevent or remove fog on the passenger compartment side of the windscreen.


The HVAC control module evaluates the information of the air quality sensor and closes the recirculation flap while in the automatic mode as soon as the concentration of pollutants exceeds a predefined value.


Automatic Operation
In automatic operation, the HVAC control module maintains the comfort level inside of the vehicle by controlling the A/C compressor clutch, the blower motor, the air temperature actuators, mode actuator and recirculation actuator.


To put the HVAC system in automatic mode, the following is required:


The auto switch must be activated.
The air temperature switch must be in any other position than full hot or full cold position.
Once the desired temperature is reached, the blower motor, mode, recirculation and temperature actuators automatically adjust to maintain the temperature selected. The HVAC control module performs the following functions to maintain the desired air temperature:


• Monitors the following sensors:


- Ambient air temperature sensor


- Lower left air temperature sensor


- Lower right air temperature sensor


- Upper left air temperature sensor


- Upper right air temperature sensor


- Windscreen temperature and inside moisture sensor


- Ambient light/sunload sensor


- Air Quality sensor


• Regulate blower motor speed


• Position the air temperature actuators


• Position the mode actuator


• Position the recirculation actuator


• Position the air inlet actuator


• Request A/C operation


• Control of the A/C compressor


When the warmest position is selected in automatic operation the blower speed will increase gradually until the vehicle reaches normal operating temperature. When normal operating temperature is reached the blower stays on high speed and the air temperature actuators stays in the full heat position.


When the coldest position is selected in automatic operation the blower stays on high and the air temperature actuators stay in full cold position. The mode actuator remains in the panel position and the recirculation actuator will remain in the recirculation position.


Under cold ambient temperatures, the automatic HVAC system provides heat in the most efficient manner. The operator can select an extreme temperature setting but the system will not warm the vehicle any faster. Under warm ambient temperatures, the automatic HVAC system also provides air conditioning in the most efficient manner. Selecting an extreme cool temperature will not cool the vehicle any faster.


In automatic mode the values of the windscreen temperature and inside moisture sensor are used as control inputs for the HVAC control module application to calculate the fog risk on the passenger compartment side of the windscreen and ability to reduce fuel consumption by decreasing A/C compressor power to a minimum without causing any fog. The A/C compressor and the defrost mode are activated to prevent or remove fog on the passenger compartment side of the windscreen. The sensor will also enable partial recirculation mode in order to improve heat-up performance of the passenger compartment under cold ambient temperature conditions without the risk of mist build-up on the windscreen.


The HVAC control module evaluates the information of the air quality sensor and closes the recirculation flap while in the automatic mode, as soon as the concentration of pollutants exceeds a predefined value.


Engine Coolant
Engine coolant is the essential element of the heating system. The thermostat controls the normal engine operating coolant temperature. The thermostat also creates a restriction for the cooling system that promotes a positive coolant flow and helps prevent cavitation.


Coolant enters the heater core through the inlet heater hose, in a pressurised state. The heater core is located inside the HVAC module. The ambient air drawn through the HVAC module absorbs the heat of the coolant flowing through the heater core. Heated air is distributed to the passenger compartment, through the HVAC module, for passenger comfort. Opening or closing the air temperature flap controls the amount of heat delivered to the passenger compartment. The coolant exits the heater core through the return heater hose and recirculates back to the engine cooling system.


A/C Cycle
Refrigerant is the key element in an air conditioning system. R-134a is presently the only Environmental Protection Agency approved refrigerant for automotive use. R-134a is a very low temperature gas that can transfer the undesirable heat and moisture from the passenger compartment to the outside air.


The compressor builds pressure on the vapour refrigerant. Compressing the refrigerant also adds heat to the refrigerant. The refrigerant is discharged from the compressor, through the discharge hose, and forced to flow to the condenser and then through the balance of the A/C system. The A/C system is mechanically protected with the use of a high pressure relief valve. If the A/C refrigerant pressure sensor fails or if the refrigerant system becomes restricted and refrigerant pressure continued to rise, the high pressure relief will pop open and release refrigerant from the system.


Compressed refrigerant enters the condenser in a high temperature, high pressure vapour state. As the refrigerant flows through the condenser, the heat of the refrigerant is transferred to the ambient air passing through the condenser. Cooling the refrigerant causes the refrigerant to condense and change from a vapour to a liquid state.


The condenser is located in front of the radiator for maximum heat transfer. The condenser is made of aluminium tubing and aluminium cooling fins, which allows rapid heat transfer for the refrigerant. The semi-cooled liquid refrigerant exits the condenser and flows to the Receiver/Dehydrator(R/D).


The R/D contains desiccant that absorbs moisture that may be in the refrigerant system. The R/D also acts as a storage vessel to ensure that a steady flow of liquid reaches the thermal expansion valve. The refrigerant exits the R/D and flows through the liquid line to the thermal expansion valve.


The thermal expansion valve is located at the front of dash and attaches to the evaporator inlet and outlet pipes. The thermal expansion valve is the dividing point for the high and the low pressure sides of the A/C system. As the refrigerant passes through the thermal expansion valve, the pressure on the refrigerant is lowered. The thermal expansion valve also meters the amount of liquid refrigerant that can flow into the evaporator.


Refrigerant exiting the thermal expansion valve flows into the evaporator core in a low pressure, liquid state. Ambient air is drawn through the HVAC module and passes through the evaporator core. Warm and moist air will cause the liquid refrigerant boil inside of the evaporator core. The boiling refrigerant absorbs heat from the ambient air and draws moisture onto the evaporator. The refrigerant exits the evaporator through the suction line and back to the A/C compressor, in a vapour state, and completing the A/C cycle of heat removal. At the A/C compressor, the refrigerant is compressed again and the cycle of heat removal is repeated.


The conditioned air is distributed through the HVAC module for passenger comfort. The heat and moisture removed from the passenger compartment will also change form, or condense, and is discharged from the HVAC module as water.