Manual No.

: HD0030859
Model No. : TPW10BX1
Part Number : H0145650
Type : 10 kW Wall Mounted Packaged
Air Conditioning System

Application : Off Road, Mining

Issue : A
Released Date : Step 25, 2019
Released By : S. Kapur

HD0030859 - Technical Manual

 SIGMA AIR CONDITIONING PTY LTD

HEAD OFFICE, CUSTOMER SERVICE AND DISTRIBUTION CENTRE:

Knorr-Bremse Australia Pty Ltd

Trading as: Sigma Air Conditioning
23 – 29 Factory Street Granville NSW 2142
Australia

Customer Service Phone: +1 300 643 643

Australasia National Sales: +61 7 3713 9816
Order and Enquiry Email: mid.aus@sigma-hvac.com
Website: www.sigma-hvac.com

SALES AND SERVICE NETWORK – AUSTRALIA:

New South Wales- - Sydney

23 – 29 Factory Street Telephone No: +61 2 8863 6500
Granville NSW 2142
Australia

Victoria - Melbourne
9 Stoney Way Telephone No: +61 3 8353 6400
Derrimut VIC3030

Queensland - Brisbane
16 Machinery St Telephone No: +61 7 3713 7411
Darra QLD 4076

Queensland - Mackay
50 Enterprise Street Telephone No: +61 7 3713 9887
Paget, QLD 4740

Western Australia - Perth

33 Colin Jamieson Drive Telephone No: +61 8 9350 2400
Welshpool, WA 6106

Western Australia - Port Hedland

5 Rogers Street Telephone No: +61 8 9350 2400
Port Hedland, WA 6721

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HD0030859 – Technical Manual
 REVISION SHEET
The information contained hereon is for Head Office internal use only and is not to be
reproduced in conjunction with this manual.
Service Manual No. : HD0030859
Model No. : TPW10BX1
Part No. : H0145650

DATE ISSUE SECTION DESCRIPTION

25/09/2019 A All First Issue

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HD0030859 – Technical Manual
 TABLE OF CONTENTS
1. INTRODUCTION ............................................................................................................ 6
1.1 MODEL NUMBER DESIGNATION ........................................................................................ 6
2. GENERAL DESCRIPTION ............................................................................................. 7
2.1 EVAPORATOR SECTION ..................................................................................................... 6
2.2 CONDENSER SECTION ....................................................................................................... 6
3. UNIT SPECIFICATIONS ................................................................................................ 9
4. COMPONENT DESCRIPTION ..................................................................................... 10
4.1.1 COMPRESSORl ...................................................................................................... 10
4.1.2 CONDENSER COIL ................................................................................................. 10
4.1.3 RECEVIER DRIER WITH SIGHT GLASS ........................................................ 10
4.1.4 ElECTRICAL SWITCHES ........................................................................................ 10
4.1.5 HP & LP PRESSURE SWITCH .......................................................................... 10
4.1.6 CONDENSER FAN .................................................................................................. 11
4.1.7 EVAPORATOR FAN .............................................................................................. 111
5. INSTALLATION AND COMMISSIONING INSTRUCTIONS ......................................... 12
6. OPERATING INSTRUCTIONS..................................................................................... 13
7. FAULT DIAGNOSIS ..................................................................................................... 14
7.1 SYSTEM PRODUCES NO COOLING ................................................................................. 14
7.2 SYSTEM WILL NOT PRODUCE SUFFICIENT COOLING ................................................. 14
8. MAINTENANCE SCHEDULE....................................................................................... 15
8.1 EVERY MONTH OR 500 HOURS ....................................................................................... 15
8.2 EVERY TWO MONTHS OR 1000 HOURS ......................................................................... 15
8.3 EVERY FOUR MONTHS OR 2000 HOURS........................................................................ 15
8.4 EVERY 12 MONTHS OR 6000 HOURS .............................................................................. 15
8.5 EVERY TWO YEARS OR 12000 HOURS ........................................................................... 16
8.6 OFF SEASON MAINTENANCE .......................................................................................... 16
8.7 OVERHAUL…………………………………………………………………………………… 16
9. CLEAN THE FRESH AND RETURN AIR FILTERS ..................................................... 17
9.1 FRESH AIR FILTER ....................................................................................................... 157
9.2 ERETURN AIR FILTER ..................................................................................................... 158
10. WARRANTY ................................................................................................................ 17
11. SPARE PARTS LIST ................................................................................................... 20
11.1 SPARE PARTS LIST ........................................................................................................... 20
12. REFERENCE DRAWINGS ........................................................................................... 22

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HD0030859 – Technical Manual
 LIST OF FIGURES

Figur Drawing No. Description Page

e
2-1 TPW10BX1 AC Unit 8
11-1 H0139212-L(1) Parameter Drawing (1) 23
11-2 H0139212-L(2) Parameter Drawing (2) 24
11-3 H0139212-L(3) Spare Parts List 25
11-4 H0139212-L(4) Components (Exploded View) 26
11-5 H0139212-E Electrical Schematic Diagram 27
11-6 H0139212-R Refrigeration and Hydraulic Schematic Diagram 28

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HD0030859 – Technical Manual
1. INTRODUCTION
The Sigma Air conditioning’s packaged air conditioners have been designed
and developed for off road applications. They have been refined to suit the
most severe application of vibration, shock loads and high ambient.
The units are constructed to mining standards featuring ease of service and
using the highest quality components. Features include packaged air
conditioner which can be coupled with a remote compressor.
The air conditioner operates on 24 VDC power supply.
Due to concern over environmental damage from using traditional refrigerants,
the air conditioners have been developed to use R134a refrigerant.

1.1 MODEL NUMBER DESIGNATION

T P W 10 B X 1

Sequence Number (1 first of type)

Refrigerant X - R134a

Voltage A - 12V DC
B - 24V DC

Cooling Capacity kW ( Nominal)

Mounting Type C - Ceiling

F - Floor
R - Roof
W - Wall

System
Component C - Condenser
F - Evaporator
P - Package
U - Unit

Product Code E - Economy

T - Truck//Bus
H - Hybrid

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HD0030859 – Technical Manual
2. GENERAL DESCRIPTION
The sheet metal case assembly of TPW10BX1 air conditioning unit is divided
into evaporator section, condenser section and compressor section. See
Figure 2-1.

2.1 EVAPORATOR SECTION

The evaporator section houses the following components:
• One Evaporator coil
• Evaporator supply air fans (4 scrolls and 2 motors)
• TX valve
• Thermostat
• De-ice thermostat
• Fresh air filter (option to fit either side)
• On the rear side of the evaporator case, an evaporator access panel is
provided for accessing the components and performing the
maintenance activities.
• On the front side of the evaporator case, supply air and return air cut-
outs are provided which are connected to coach wall with seals around
it.
• Return air filter is mounted inside the coach for accessing and replacing.
• Thermostat and the model switch are all inside the return air section,
and the mode switch is accessible and operable from inside the coach.

2.2 CONDENSER SECTION

The Condenser section houses the following components:
• Twin axial flow propeller fans
• One condenser coil

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HD0030859 – Technical Manual
 Figure 2-1 TPW10BX1 Air Conditioning Unit

ITEM DESCRIPTION ITEM DESCRIPTION

1 Lifting Lug 6 Evaporator Access Panel

2 Fresh Air intake 7 Condenser Exhaust Air Grille

3 Supply Air Seal 8 Condenser Section

4 Return Air Seal 9 Condenser Intake Air Grille

5 Evaporator Section 10 Compressor Section

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3. UNIT SPECIFICATIONS

Model………………………………………………... TPW10BX1
Type…………………………….……………………. Vertical Package
Cooling Capacity (Nominal)……………….………. 10 kW
Ambient: 31.0oCDB /20.5oC WB
Interior: 23.0oC DB /16.9oC WB

Refrigerant…………………………………………. R134a

Power Supply………………………………………. 24 V DC

Current Draw (Nominal)…………………………… 43 Amps

Supply Air Volume (2) ……………………………… 350 L/s (High Speed)

Fresh Air Volume …………………………………… 100 L/s

Condenser Fans: 2 off, each ……………………… 8.0 A, 24 VDC

Evaporator Fans: 2 off, each ……………………… 11.0 A, 24 VDC
Unit Rating Maximum………………………………… 55A 24VDC
Dimensions…………………………………………… 770mm W x 500mm D x 1550 H
Hydraulic Oil Supply……………. ………………… 30 L/min at 100 bar for each AC Unit
AC Unit Weight……………………………………… 160 kg

Refrigerant Charge………………………………… 2.0 kg

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4. COMPONENT DESCRIPTION
The packaged unit consists of the following major components.

• Refrigeration assembly
o Compressor
o Condenser coil
o Receiver Drier with Sight Glass
o HP & LP Pressure Switches
o TX Valve
o Evaporator Coil
• Electrical switches see figure 11-1
• Condenser Fan
• Evaporator Fan

4.1.1 Compressor
The main function of the compressor is to compress the refrigerant gas
increasing the refrigerant pressure.
4.1.2 Condenser Coil
Condensing of refrigerant is the change of state of the refrigerant from gas to
liquid. The condenser receives the high pressure, high temperature refrigerant
gas from the compressor and condenses it to a high temperature liquid. The
refrigerant has heat removed, as it travels along the condenser tubes changing
the gas to a liquid. The liquid refrigerant then flows to the receiver drier.

4.1.3 Receiver Drier with Sight Glass

The receiver drier is of fully welded construction, fitted with an integral sight
glass. The receiver drier serves as a reservoir for the storage of high pressure
liquid produced in the condenser. It also functions as a filter/drier by means of
a dehydrating agent combined with filtration system to trap minute particles of
moisture and foreign material which may have entered the refrigeration
system. Receiver drier has sight glass used to check the correct refrigerant
charge.

4.1.4 Electrical Switches

They are provided on the plenum to select the operation mode. These are
deliberately inaccessible so that they are only adjusted in the service
workshop.

4.1.5 HP & LP Pressure Switch

This is installed on the compressor discharge port and suction port ensure
compressor safety on high and low pressure.

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4.1.6 Condenser Fans
The function of the condenser fan is to push air between the condenser tubes
to remove heat from the condenser coils.
The Axial fans are selected to achieve minimum noise levels. These
condenser fans have inbuilt electrical protection.

4.1.7. Evaporator Fans

The function of the evaporator fans are to draw mixed return air and fresh air
through the evaporator coil. This cool air then becomes the Supply Air passing
into the Passenger Area to maintain comfort conditions.

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5. INSTALLATION AND COMMISSIONING INSTRUCTIONS
The following below are instructions to install the TPW10BX1 air conditioner to the bus:
1. Identify the location on the bus wall for mounting the air conditioning unit.
2. Ensure the mounting holes and locating pins have been added to the bus wall as
per figure 11-1
3. Distinguish the left and right installation positions of two units on the vehicle, on
each unit move the inlet blanking plate opposite the Fresh Air Inlet. Locate the
Fresh Air Inlets facing each other between the two AC Units.
4. Lift the air conditioning unit with a suitable lifting device and place it on the two
locating pins welded to the Bus Wall Frame.
5. Make sure that the supply air and return air cut-outs on the Bus wall are aligned
with the cut-outs on the air conditioning unit with the seal properly fixed in between.
6. Fix and tighten ten M10 bolts and washers (supplied with unit) to secure the air
conditioning unit to the Bus. Torque to 63 Nm.
7. Please consider not use a sealant around the extruded rubber seal.
8. Install the return air filter assembly on the inside wall of the Bus Cabin.
9. Connect the three hydraulic oil hoses to the Air Conditioning Unit. Pressure fitting
5/8 “ BSPP, Return fitting ¾“ BSPP and drain fitting ¼“ BSPP.
10. Locate the electrical plug, and then insert the plug into the unit.
11. Use the commissioning procedure supplied to ensure each unit functions as
designed, separately and both together
12. A copy of recorded information on the commissioning sheet is to be sent to Sigma
Engineering. Email to mid.sigma-hvac.com

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6. OPERATING INSTRUCTIONS
The AC unit is operated by the thermostat controller located inside the Return
Air Duct. This thermostat is programmed to run the AC unit using the bus
temperature set point. The thermostat is behind the Return Air Filter Assembly
where it can be easily reached by service personnel opening the assembly
inside the bus.
The unit is designed to run automatically when switched onto “Ventilation” or
“Auto” modes. Access to switches should rarely be necessary and adjustment
should be restricted to service personnel only.
The compressor on this machine is hydraulically driven and runs only when
cooling is required. Otherwise the unit runs in “VENT” mode.
When set to “Vent” the SA fan only will run.

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7. FAULT DIAGNOSIS
7.1 SYSTEM PRODUCES NO COOLING
INDICATION POSSIBLE CAUSE REMEDY
Electrical components will 1. Blown fuse. 1. Replace fuse.
not operate. 2. Broken or 2. Check all terminals for
disconnected electrical loose connections. Check
wire. wiring for hidden breaks.
Condenser/Evaporator 1. Motor disconnected or 1. Check current flow to
fan motor inoperative. required service. motor. Replace if
inoperative.
System tripping low 1. Leak in system. 1. Apply static charge,
pressure 2. Evaporator fan leak test system, and
inoperative. repair leak as necessary.
3. TX valve faulty. 2. Check and repair or
replace evap. fan if
inoperative.
3. Check and replace if
required.
System tripping on high 1. Condenser Coil 1. Clean condenser coil.
pressure blocked. 2. Repair or replace if
2. Condenser fan inoperative.
inoperative.

7.2 SYSTEM WILL NOT PRODUCE SUFFICIENT COOLING

INDICATION POSSIBLE CAUSE REMEDY
Bubbles in sight glass. 1. Insufficient refrigerant 1. Recharge system until
(Note: an occasional in system. bubbles disappear (or are
bubble is OK) minimal) and gauge
readings stabilise to
specifications.

Head pressure normal, 1. TX valve stuck in open 1. Check and Replace TX

suction pressure high and position. valve.
evaporator flooding. 2. Compressor faulty 2. Replace compressor

Icing on suction line and 1. Evaporator fan airflow 1. Increase the

evaporator coil. too low or fan faulty. evaporator fan speed or
2. Return Air Filter or repair or replace the fan if
Duct blocked. faulty.
2. Clear blockage.
Compressor slow/not 1. Hydraulic drive not 1. Check hydraulic hoses
running. connected or poor oil and Power Take Off
delivery. function

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8. MAINTENANCE SCHEDULE
8.1 EVERY MONTH OR 500 HOURS
Run the AC unit
• Inspect the AC unit mounting.
• Observe any obvious damage to pipework.
• Check to see all hoses and wiring are secured correctly and no sign of any
damage.
• Clean the Return and Fresh Air Filters.

8.2 EVERY TWO MONTHS OR 1,000 HOURS

In addition to above as in 8.1
• Check the hoses, wiring and pipework for abrasion and wear.
• Observe any noise coming from condenser / evaporator fans. Take
appropriate action as required. Rectify or replace.
• Observe any noise coming from compressor or the hydraulic motor. Take
appropriate action as required. Rectify or replace.
• Check any of the mountings coming loose. Tighten as required.
• Check pipework for any sign of leakage at joints. Rectify or replace as
required.
• Check the system charge whilst air conditioner is in operation based on the
operating pressures and liquid sub-cooling for R134a. Note that the liquid
line sight glass may sometimes have a milky appearance. This does not
indicate system undercharge.
• Clean the Return Air Filter.

8.3 EVERY FOUR MONTHS OR 2,000 HOURS

In addition to above as in 8.2
• Clean the condenser coil with low pressure compressed air or with a
vacuum cleaner. Make sure that excessive pressure is not used which
may damage the coil fins (More frequent service may be required in dusty
applications). Warm soapy water can also be used to remove dirt.
• Connect gauges and check the system pressures.
8.4 EVERY 12 MONTHS OR 6,000 HOURS
In addition to as in 8.3 above
• Clean the evaporator coil, all fans and inside the unit of any dust /debris.
• Evacuate, charge and test the functioning of Anti Idle/ DC system.
• Replace the fresh air and return air filter media.
• For improved reliability, fans in the unit should be replaced after every 6000
hrs (or before if there is a sign of physical damage)

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8.5 EVERY 2 YEARS OR 12,000 HOURS
In addition to as in 8.4 above
• Consideration should be given to replacing the compressor, flexible
coupling and hydraulic motor as an assembly, depending upon
maintenance experience.

8.6 OFF SEASON MAINTENANCE

Sigma recommends that the air conditioning system should be run for a
minimum of five minutes each week regardless of the season. This is a means
of ensuring that the compressor seals are well lubricated to prolong their
service life. The compressor should be checked for suction, discharge
pressures and any unusual noise coming from it. These are not repairable units
and should be replaced if required.
Note: For any repairs, ensure a qualified technician is employed.
Follow the maintenance schedule as above to keep the AC unit in top
condition.

8.7 OVERHAUL
This unit should be overhauled every 6 to 8 years with new refrigeration
components, breakers, contactors, relays, pressure switches, etc being
replaced

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9. CLEAN THE FRESH AND RETURN AIR FILTERS
9.1 Fresh Air Filter Cleaning
Light contaminations
• With the filter media in retaining frame, conduct a low pressure air blow
through.
Heavy contaminations
• With the filter media in retaining frame, conduct a low pressure air blow
through.
• Remove the filter media and wash with soapy water and dry it naturally
in the air.
Operation:
1. Remove 4off x M5 screws, then remove rain separator with filter together
from AC unit.

2. Remove the filter up from separator frame with handle.

3. Clean the filter with air blow or immerse in soapy water according to the
level of filters contamination.

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 4. Assembly is a reversal of the above.

9.2 Return Air Filter Cleaning

Light contaminations
• With the filter media in retaining frame, conduct a low pressure air blow
through.
Heavy contaminations
• With the filter media in retaining frame, conduct a low pressure air blow
through.
• Remove the filter media and wash with soapy water and dry it naturally
in the air.
Operation:
1. Remove 4off x M5 screws, then remove FA filter from AC unit.

2. Remove filter media from the frame,

3. Clean the filter with air blow or immerse in soapy water according to the
level of filters contamination.
4. Assembly is a reversal of the above.

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10. WARRANTY
The Sigma Air Conditioning units supplied in this instance are covered by the
following Warranty Clause:
“We warrant all 'TPW10BX1' units to be of good material and undertake
to replace at our authorised works, any component proven defective in
workmanship or material within a period of 12 months from date of start-
up or 15 months from date of despatch, whichever occurs first.
During these warranty periods, we will repair or replace, at our option,
faulty parts or faulty workmanship without labour charge, at our
authorised works.
Should field service be required, travelling time, transport costs, including
hiring of trucks, fork lift trucks, cranes, mechanical handling equipment
and any overtime payment will be to the purchaser's account.
This warranty does not cover the fusion of electric motors caused by the
failure of electric overload protection control devices, even where such
motors or devices form part of the equipment supplied by us.
Warranty claims will not be accepted on loss of refrigerant.
Interference with the equipment by unskilled or unauthorised personnel,
alterations to normal factory settings of controls, or failure to observe
normal installation, start-up maintenance and/or service instructions as
delineated in this appropriate manual, or as considered normal practice
for air conditioning equipment, will void this warranty.
Fair wear and tear, damage by misuse or operating the equipment at
ambient temperatures or with electrical power characteristics outside of
the ranges indicated in our specification shall be excluded as shall be
consequential damage”.
It should be specifically noted that the Warranty is null and void if the units are
operated with incorrect electrical characteristics, not maintained as set out
herein, and if the control settings are altered from those laid down in this
Manual.

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 11. SPARE PARTS LIST
11.1 SPARE PARTS LIST

Material Noted on
Item Description Qty. Comment
code Drg No.
COMPRESSOR, FLEX COUPLING, Sold as a complete
1 H0017489 1
HOUSING, HYD MOTOR ASSY Assembly
2 EVAPORATOR FAN ASSY H0156797 2 with cable, with plug
3 CONDENSER FAN ASSY H0156798 2 with cable, with plug
4 EVAPORATOR COIL H0139217 1
5 CONDENSER COIL H0139972 1
6 DRYER FILTER RECEIVER AU531411 1
7 CHECK VALVE 654D003 1
8 SOLENOID VALVE BODY 654098 1
9 SOLENOID VALVE COIL AU668140 1
10 TX VALVE AU521537 1
11 HP SWITCH H0156794 1 with cable, with plug
12 LP SWITCH H0156795 1 with cable, with plug
13 SEALING RUBBER SUPPLY AIR H0139910 1
14 SEALING RUBBER RETURN AIR H0139909 1
15 DE-ICE THERMOSTAT UE016 1
DISCHARGE REFRIGERANT
16 H0141844 1
HOSE
17 SUCTION REFRIGERANT HOSE H0141843 1
18 PRESSURE OIL HOSE H0173490 1
19 RETURN OIL HOSE H0173492 1
20 DRAIN OIL HOSE H0141060 1
THERMOSTAT 12-24VDC WITH
21 AU681925 1
SENSOR + POT
CIRCUIT BREAKER 25A PUSH
22 AU641065 1
PULL
RELAY 20A 24VDC 5 PIN
23 AU661484 1
CHANGEOVER
24 RELAY 20A 24VDC 5 PIN AU661483 1
RELAY BASE 5 PIN (PANEL
25 ERR023 1
MOUNT)
CIRCUIT BREAKER 10A PUSH
26 AU641C107 1
PULL
CIRCUIT BREAKER 15A PUSH
27 AU641C110 1
PULL
28 CONNECTING PLUG, HVAC SIDE H0175399 1
CONNECTING PLUG, CUSTOMER
29 H0175400 1
SIDE
30 SELECTOR SWITCH H0143675 1

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 VALVE 5/8 TUBE # 10 R134a
31 AU230C012 1
SUCTION
VALVE 1/2 TUBE # 8 R134a
32 AU230C011 1
DISCHARGE
33 RETURN AIR FILTER MEDIA G3 H0143292 1
34 AIR FILTER ELEMENT H0142578 1

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12. REFERENCE DRAWINGS
DRAWING NO. DESCRIPTION
H0139212-L (1) Parameter Drawing 1
H0139212-L (2) Parameter Drawing 2
H0139212-L (3) Spare Parts List
H0139212-L (4) Components (exploded view)
H0139212-E Electrical Schematic Diagram
H0139212-R Refrigeration and Hydraulic Schematic Diagram

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 Figure 12-1 H0139212-L (1) Parameter Drawing 1
HD0030859 - Technical Manual
 Figure 12-2 H0139212-L (2) Parameter Drawing 2
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 Figure 12-3 H0139212-L (3) Spare Parts List
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 Figure 12-4 H0139212-L (4) Components (exploded view)
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 Figure 12-5 H0139212-E Electrical Schematic Diagram
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 Figure 12-6 H0139212-R Refrigeration and Hydraulic Schematic Diagram
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