Air conditioning Electrical Wiring Harness and Sensor Connection Cable

1. Electrical wiring harness system
‌Composition and function‌
The air conditioning electrical wiring harness consists of power cord, signal cord, grounding cord and connectors, which are used to connect compressors, fans, controllers and other components to achieve power transmission and equipment control‌.
‌Power cord‌: Provides working voltage for the air conditioning system. The cross-sectional area of ​​the copper core wire needs to be selected according to the power (such as 4 square millimeters for cabinets above 3 hp). ‌Signal wire‌: Transmits control instructions (such as start and stop, mode switching), usually using multi-core shielded wire to reduce electromagnetic interference‌.

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‌Key points for design and selection‌
‌Wire characteristics‌: It needs to meet the requirements of high temperature resistance, oil resistance, flame retardancy, 등. The engine compartment wiring harness is often wrapped with corrugated tubes or plastic cloth to cope with harsh environments‌. ‌Color identification‌: Follow international standards (such as red for live wire, blue for neutral wire, and yellow and green for ground wire), which is convenient for installation and troubleshooting‌.

2. Sensor harness system
‌Core functions and components ‌
The sensor harness connects the temperature and humidity sensors and the controller to transmit environmental parameters to realize the automatic adjustment function of the air conditioner.
‌Power line ‌: Provides 5V or 24V working voltage for the sensor, and needs to be wired independently to avoid interference.
‌Signal line ‌: Transmits the temperature and humidity data collected by the sensor, and the cable needs to be shielded to ensure signal accuracy.

‌Installation and protection requirements ‌ ‌Anti-interference design ‌: The signal line and the power line are laid in separate casings, maintaining a spacing of more than 30cm; the shielding layer needs to be reliably grounded. ‌Environmental adaptability ‌: The sensor harness needs to be made of corrosion-resistant and anti-aging materials, and the outdoor part needs to be equipped with a waterproof sheath. ‌

3. Key application scenarios ‌New energy vehicle air conditioning system ‌
High-voltage harnesses (such as air conditioning compressor harnesses) need to meet high voltage resistance (more than 300V) and high current carrying capacity, and use orange sheath logo ‌
‌Intelligent temperature control system‌
Real-time feedback of environmental data through the sensor harness, combined with the controller to achieve automatic switching of cooling/heating mode (such as red and white wires control heating, red and yellow wires control cooling)‌.

4. Common problems and maintenance
‌Poor contact‌: Oxidation or loosening of the connector may cause signal interruption, and the terminal tightness needs to be checked regularly and the contacts need to be cleaned‌.
‌Insulation failure‌: High temperature or wear can easily cause the insulation layer of the harness to break, and flame-retardant materials need to be used and direct contact with the refrigerant pipe should be avoided‌.

The reliability and long-term stability of the air conditioning harness system can be ensured through reasonable selection, standardized installation and regular maintenance‌.