KONVEKTA KL20 facelift User manual

Konvekta AG
Konvekta AGKonvekta AG
Konvekta AG
Am Nordbahnhof 5
34613 Schwalmstadt
Germany
 +49 0 ) 66 91 / 76 – 0
 +49 0 ) 66 91 / 76 - 200
 [email protected]
www.konvekta.com
Technical Manual
Technical ManualTechnical Manual
Technical Manual
for KONVEKTA
for KONVEKTAfor KONVEKTA
for KONVEKTA
Air Condition
Air ConditionAir Condition
Air Conditioning Unit
ing Uniting Unit
ing Units
ss
s
-KL20
KL20 KL20
KL20 facelift
faceliftfacelift
facelift
With ABS cover
With ABS coverWith ABS cover
With ABS cover with cover plate
with cover platewith cover plate
with cover plate
-
--
- KL20E
KL20E KL20E
KL20E facelift
faceliftfacelift
facelift
with ABS cover
with ABS coverwith ABS cover
with ABS cover
Contains information on:
Contains information on:Contains information on:
Contains information on:
- Installation
InstallationInstallation
Installation
- Operation
OperationOperation
Operation
- Maintenance / Service
Maintenance / ServiceMaintenance / Service
Maintenance / Service
ID#: BEA
ID#: BEAID#: BEA
ID#: BEA-
--
-KL2
KL2KL2
KL2E132AA
E132AAE132AA
E132AA
Version: A0
Version: A0Version: A0
Version: A01
11
1

EAKL2E132AA Edition: 26.04.2012 Page: 2/18
Contents
ContentsContents
Contents
Page:
• Summary of dr
Summary of drSummary of dr
Summary of drawings appendix)
awings appendix)awings appendix)
awings appendix) / Notes
NotesNotes
Notes to the instruction
to the instruction to the instruction
to the instruction................................................................................ 3
•Introduction
IntroductionIntroduction
Introduction.................................................................................................................................................................. 4
1.Directives for Installation, Connection and Use
1.Directives for Installation, Connection and Use1.Directives for Installation, Connection and Use
1.Directives for Installation, Connection and Use ................................
................................................................
................................................................
................................................................
...............................................................
..............................................................
............................... 5
55
5
2.
2.2.
2.Technical data air conditioning units
Technical data air conditioning unitsTechnical data air conditioning units
Technical data air conditioning units ................................
................................................................
................................................................
................................................................
................................................................
................................................................
...................................................
......................................
................... 6
66
6
2.1.Compressor nur bei KL20E) ...................................................................................................................................6
3.
3.3.
3.Allgemeine Beschreibung
Allgemeine BeschreibungAllgemeine Beschreibung
Allgemeine Beschreibung................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
.......................................
..............
....... 7
77
7
4.General information on air conditioning unit
4.General information on air conditioning unit4.General information on air conditioning unit
4.General information on air conditioning unit ................................
................................................................
................................................................
................................................................
................................................................
................................................................
....................................
........
.... 8
88
8
4.1.Operating Conditions.................................................................................................................................................8
4.2.Intended use .................................................................................................................................................................8
5.
5.5.
5.Installation preparation at the vehicle
Installation preparation at the vehicleInstallation preparation at the vehicle
Installation preparation at the vehicle ................................
................................................................
................................................................
................................................................
................................................................
................................................................
.................................................
..................................
................. 9
99
9
5.1.Installation of air distribution plate ...................................................................................................................... 10
5.1.1.Installation of fan switch in the air distribution plate ................................................................................... 11
5.1.2.Installation of blower switch in the instrument panel BEL-260STA003) .............................................. 12
5.2.Installation of the air distribution plate in the vehicle ..................................................................................... 13
5.3.Electrical connection................................................................................................................................................ 13
6.Positioning of the air conditioning components
6.Positioning of the air conditioning components6.Positioning of the air conditioning components
6.Positioning of the air conditioning components ................................
................................................................
................................................................
................................................................
..............................................................
............................................................
.............................. 14
1414
14
7.
7.7.
7.Operation
OperationOperation
Operation ................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
..............................................................
............................................................
.............................. 14
1414
14
8.
8.8.
8.Maintenance / Service
Maintenance / ServiceMaintenance / Service
Maintenance / Service ................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
..........................................
....................
.......... 15
1515
15
8.1.Service parts .............................................................................................................................................................. 15
•Pressure switch combination ..................................................................................................................................... 15
8.2.Check refrigerant level............................................................................................................................................ 16
8.3.Compressor only with KL20E facelift)............................................................................................................... 17
8.4.Condenser coil.......................................................................................................................................................... 17
8.5.Trouble shooting ...................................................................................................................................................... 17
9.
9.9.
9.Warranty Conditions
Warranty ConditionsWarranty Conditions
Warranty Conditions................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
...........................................
......................
........... 18
1818
18
10.
10.10.
10.Waste disposal in accordance with legal provisions
Waste disposal in accordance with legal provisionsWaste disposal in accordance with legal provisions
Waste disposal in accordance with legal provisions................................
................................................................
................................................................
................................................................
.....................................................
..........................................
..................... 18
1818
18
11.
11.11.
11.History of modification
History of modificationHistory of modification
History of modification................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
................................................................
......................................
............
...... 18
1818
18

EAKL2E132AA Edition: 26.04.2012 Page: 3/18
S
SS
Summary of drawings appendix) /
ummary of drawings appendix) / ummary of drawings appendix) /
ummary of drawings appendix) / Information on the instructions
These instructions are valid for the air conditioning units’ type: KL20
KL20KL20
KL20 /
/ /
/ E
EE
E facelift
facelift facelift
facelift
Following documentations and designs are to add depending upon type of air conditioning system, the man-
ual
Documentation:
Documentation:Documentation:
Documentation:
• Generally Safety instructions TD00052A
•Instruction O-Ring connection AA07050122
•Maintenance Schedule WP07050621
Drawings
DrawingsDrawings
Drawings:
::
:
KL20
KL20KL20
KL20 facelift
facelift facelift
facelift KL20
KL20KL20
KL20 facelift
facelift facelift
facelift-
--
-cabin
cabincabin
cabin
KL20E
KL20EKL20E
KL20E fac
fac fac
face
ee
elift
liftlift
lift
BKL 12V
BKL 12VBKL 12V
BKL 12V
24V
24V 24V
24V
BKL-0620122E14
BKL-0620242E17
BKL-0620122E13
BKL-0620242E16
-
BKL-0350242E07
W
WW
Wiring scheme
iring schemeiring scheme
iring scheme 24V
24V 24V
24V K1-200-165 K1-200-165 K1-200-148
W
WW
Wiring scheme
iring schemeiring scheme
iring scheme 12V
12V 12V
12V K1-200-155 K1-200-155
Installation drawings
Installation drawingsInstallation drawings
Installation drawings KL2E14EZ KL2E13EZ KL2E07EZ
Air conditioner
Air conditionerAir conditioner
Air conditioner KL2E14G1 KL2E13G1 KL2E07G1
Air distribution plat
Air distribution platAir distribution plat
Air distribution plate high
e highe high
e high 59-AB0-015 59-AB0-015 59-AB0-015
Air distribution plate flat
Air distribution plate flatAir distribution plate flat
Air distribution plate flat 59-AB0-017 59-AB0-017 59-AB0-017
Expansion valve
Expansion valveExpansion valve
Expansion valve 14-001-081 14-001-081 14-001-081
Dryer/receiver unit 14-AA3-065 14-AA3-065 14-AA3-065
Pressure switch combination
combination combination
combination 11-001-378 11-001-378 11-001-378
C
CC
Compressor SD5H09
ompressor SD5H09ompressor SD5H09
ompressor SD5H09 13-002-209
ET 12V
ET 12VET 12V
ET 12V
24V
24V 24V
24V
KL2E14ET
KL2E17ET
KL2E13ET
KL2E16ET
-
KL2E07ET
The machine corresponds
The machine corresponds The machine corresponds
The machine corresponds with
withwith
with the
the the
the safety provisions
safety provisionssafety provisions
safety provisions of the EC # 89/392/EWG i.d.F. 91/368/EWG and
of the EC # 89/392/EWG i.d.F. 91/368/EWG and of the EC # 89/392/EWG i.d.F. 91/368/EWG and
of the EC # 89/392/EWG i.d.F. 91/368/EWG and
93/44/EWG.
93/44/EWG.93/44/EWG.
93/44/EWG.
Due to the fact that scope of supply depends on the order, equipment of your product may differ in some
parts of description.
In case your product is equipped with details not shown or described in the operating instruction, your
KONVEKTA -Service-Station will always be at disposal for informing you about correct operation.
In the course of further developments we reserve the right to technical modifications without prenotice.
Guarantee and liability conditions of KONVEKTA AG’s general business conditions are not enlarged by the
above notes.
Indications and photos should neither be copied and circulated nor used for competitor’s purposes. All
rights according to the copyright remain expressly reserved.
Manufacturer
ManufacturerManufacturer
Manufacturer: KONVEKTA AG, P.O. Box 2280, D
: KONVEKTA AG, P.O. Box 2280, D: KONVEKTA AG, P.O. Box 2280, D
: KONVEKTA AG, P.O. Box 2280, D-
--
-34607 Schwalmstadt
34607 Schwalmstadt34607 Schwalmstadt
34607 Schwalmstadt

EAKL2E132AA Edition: 26.04.2012 Page: 4/18
Introduction
IntroductionIntroduction
Introduction
These instructions have been written for installation- and maintenance staff of air conditioning units’ type
KL20 facelift und KL20E facelift.
These instructions contain important information on installation, handling and operation of the a/c unit in
order to support instructed personnel.
In this context, we refer implicitly to the compliance with our general installation guidelines. These can be
In this context, we refer implicitly to the compliance with our general installation guidelines. These can be In this context, we refer implicitly to the compliance with our general installation guidelines. These can be
In this context, we refer implicitly to the compliance with our general installation guidelines. These can be
obtained from the Konvekta techn
obtained from the Konvekta technobtained from the Konvekta techn
obtained from the Konvekta techni
ii
ical after sales service:
cal after sales service: cal after sales service:
cal after sales service: T[email protected]
[email protected][email protected]
[email protected].
..
.
It contains:
It contains:It contains:
It contains:
oOperating instruction
Operating instructionOperating instruction
Operating instruction
oS
SS
Safety
afetyafety
afety infor
infor infor
information
mation mation
mation
oMaintenance
Maintenance Maintenance
Maintenance information
informationinformation
information
odrawings
drawingsdrawings
drawings
These instructions have to be read carefully and made use of before the first start-up and after that regularly
by each person who is involved in handling the machine:
•Operation including trouble shooting and waste disposal of fuels and auxiliary agents.
•Servicing, inspection, repair
•Transport
This facilitates the handling and avoids trouble caused by improper operation. Working in compliance with
these operating instructions increases operation reliability and service life of the air conditioning unit and
reduces life cycle costs.
Please complete these instructions by adding the national provisions for prevention of accidents and
environmental protection.
..
.
You will certainly understand that we will not recognize any warranty claims due to improper handling, ina-
dequate maintenance, applications that do not correspond with the determined use, utilization of unadmit-
ted fuels or the non-observance of safety provisions.
KONVEKTA will annul without prenotice all obligations concerning guarantee, service contracts etc. re-
gardless if granted by KONVEKTA or its distributors in case other than original KONVEKTA spare parts or
parts bought from KONVEKTA AG have been used for maintenance and repair. This operating instruction
contains all necessary information to operate your air conditioner. In case you need more explanations
please contact the next KONVEKTA service station

.

On our website www.konvekta.com in category >service< you will find a survey of contact details of all our service
partners close to your location
.

EAKL2E132AA Edition: 26.04.2012 Page: 5/18
1.
1.1.
1. Directives for Installation, Connection and Use
Directives for Installation, Connection and UseDirectives for Installation, Connection and Use
Directives for Installation, Connection and Use
Please read carefully the following instructions before installing, connecting and operating the device. We
assume no liability for incorrect handling and usage.
WARNING
WARNING WARNING
WARNING CAUTION
CAUTIONCAUTION
CAUTION
MAKE THE CORRECT CONNECTIONS.
MAKE THE CORRECT CONNECTIONS.MAKE THE CORRECT CONNECTIONS.
MAKE THE CORRECT CONNECTIONS.
Failure to make the proper connections may result in
fire or product damage.
USE ONLY SUITABLE VOLTAGE.
USE ONLY SUITABLE VOLTAGE.USE ONLY SUITABLE VOLTAGE.
USE ONLY SUITABLE VOLTAGE.
The usage with a not suitable voltage may result in fire.
Furthermore a not suitable voltage may result in failure
or product damage.
TAKE CARE THAT WIRES NOT CARRY CU
TAKE CARE THAT WIRES NOT CARRY CUTAKE CARE THAT WIRES NOT CARRY CU
TAKE CARE THAT WIRES NOT CARRY CUR
RR
RRENT
RENT RENT
RENT
WHILE CONNECTING.
WHILE CONNECTING.WHILE CONNECTING.
WHILE CONNECTING.
Connecting wires which carry current may result in
electrical shorts or product damage.
O
OO
ONLY USE WIRES WITH SUFFICIENT LARGE CROSS
NLY USE WIRES WITH SUFFICIENT LARGE CROSS NLY USE WIRES WITH SUFFICIENT LARGE CROSS
NLY USE WIRES WITH SUFFICIENT LARGE CROSS
SE
SESE
SEC
CC
CTIONS.
TIONS.TIONS.
TIONS.
Using wires with not sufficient large cross sections will
exceed the current carrying capacity of the wires and
result in fire or electric shock.
DO NOT DISASSEMBLE OR ALTER.
DO NOT DISASSEMBLE OR ALTER.DO NOT DISASSEMBLE OR ALTER.
DO NOT DISASSEMBLE OR ALTER.
Doing so may result in an accident, fire or electric
shock.
DO NOT INSTALL IN LOCATIONS WHICH MIGHT
DO NOT INSTALL IN LOCATIONS WHICH MIGHT DO NOT INSTALL IN LOCATIONS WHICH MIGHT
DO NOT INSTALL IN LOCATIONS WHICH MIGHT
HI
HIHI
HIN
NN
NDER VEHICLE OPERATIONS.
DER VEHICLE OPERATIONS.DER VEHICLE OPERATIONS.
DER VEHICLE OPERATIONS.
Doing so may obstruct forward vision or hamper
movement and result in serious accident.
DO NOT BLOCK VENTS OR RADIATOR PANELS.
DO NOT BLOCK VENTS OR RADIATOR PANELS.DO NOT BLOCK VENTS OR RADIATOR PANELS.
DO NOT BLOCK VENTS OR RADIATOR PANELS.
Doing so may cause heat to build up inside and may
result fire.
USE THE CORRECT AMPERE RATING WHEN R
USE THE CORRECT AMPERE RATING WHEN RUSE THE CORRECT AMPERE RATING WHEN R
USE THE CORRECT AMPERE RATING WHEN RE-
E-E-
E-
PLACING FUSES.
PLACING FUSES.PLACING FUSES.
PLACING FUSES.
Failure to do so may result in fire or electric shock.
DO NOT PLACE HANDS, FINGERS OR FOREIGN
DO NOT PLACE HANDS, FINGERS OR FOREIGN DO NOT PLACE HANDS, FINGERS OR FOREIGN
DO NOT PLACE HANDS, FINGERS OR FOREIGN
O
OO
OB
BB
BJECTS IN INSERTION SLOTS OR GAPS.
JECTS IN INSERTION SLOTS OR GAPS.JECTS IN INSERTION SLOTS OR GAPS.
JECTS IN INSERTION SLOTS OR GAPS.
Doing so may result in personal injury or damage to the
product.
AVOID HIGH FORCE EFFECTS.
AVOID HIGH FORCE EFFECTS.AVOID HIGH FORCE EFFECTS.
AVOID HIGH FORCE EFFECTS.
Do not expose the device high force effects or strokes.
Doing so may result in product damage.
HAVE THE WIRING AND INSTALLATION DONE BY
HAVE THE WIRING AND INSTALLATION DONE BY HAVE THE WIRING AND INSTALLATION DONE BY
HAVE THE WIRING AND INSTALLATION DONE BY
E
EE
EX
XX
XPERTS.
PERTS.PERTS.
PERTS.
The wiring and installation of this device requires special
technical skill and experience and have to be done by
experts.
ARRANGE THE WIRING SO IT IS NOT CRIMPED OR
ARRANGE THE WIRING SO IT IS NOT CRIMPED OR ARRANGE THE WIRING SO IT IS NOT CRIMPED OR
ARRANGE THE WIRING SO IT IS NOT CRIMPED OR
PINCHED BY A SHARP METAL EDGE.
PINCHED BY A SHARP METAL EDGE.PINCHED BY A SHARP METAL EDGE.
PINCHED BY A SHARP METAL EDGE.
Arrange the wiring so it will not be damaged.
DO NOT INSTALL IN LOCATIONS WITH HIGH
DO NOT INSTALL IN LOCATIONS WITH HIGH DO NOT INSTALL IN LOCATIONS WITH HIGH
DO NOT INSTALL IN LOCATIONS WITH HIGH
MOISTURE OR DUST.
MOISTURE OR DUST.MOISTURE OR DUST.
MOISTURE OR DUST.
Avoid installing the device in locations with high incidence
of moisture or dust. Moisture or dust that penetrates into
this device may result in product failure or damage.
USE SPECIFIED ACCESSORY PARTS AND INSTALL
USE SPECIFIED ACCESSORY PARTS AND INSTALL USE SPECIFIED ACCESSORY PARTS AND INSTALL
USE SPECIFIED ACCESSORY PARTS AND INSTALL
THEM SECURELY.
THEM SECURELY.THEM SECURELY.
THEM SECURELY.
Be sure to use the specified accessory parts. Use of other
than designated parts may damage this device internally or
may not securely install the device in place.
HALT USE IMMEDIATELY IF A PROBLEM APPEARS.
HALT USE IMMEDIATELY IF A PROBLEM APPEARS.HALT USE IMMEDIATELY IF A PROBLEM APPEARS.
HALT USE IMMEDIATELY IF A PROBLEM APPEARS.
Failure to do so may cause personal injury or damage to
the product. Return it to your authorized customer ser-
vice.
TEMPERATURE.
TEMPERATURE.TEMPERATURE.
TEMPERATURE.
Be sure the environment-temperature is in the allowed
range before turning the device on.
USE DEVICE ONLY FOR SPECIFIED APPLICATION
USE DEVICE ONLY FOR SPECIFIED APPLICATION USE DEVICE ONLY FOR SPECIFIED APPLICATION
USE DEVICE ONLY FOR SPECIFIED APPLICATION
AREA.
AREA.AREA.
AREA.
Using the device for another purpose or in another appli-
cation area than the intended one, may result failure,
product damage or injury.
PRODUCT CLEANING.
PRODUCT CLEANING.PRODUCT CLEANING.
PRODUCT CLEANING.
Use a soft dry cloth for cleaning the device. For more
severe dirt, please dampen the cloth with water only.
Anything else has the chance of damage the product.
RANGE OF THIS DIREC
RANGE OF THIS DIRECRANGE OF THIS DIREC
RANGE OF THIS DIRECTIVES.
TIVES.TIVES.
TIVES.
These directives apply for all devices, on which this direc-
tives-sheet is added. One directives-sheet is sufficient per
box.
TRANSPORT TERMS
TRANSPORT TERMSTRANSPORT TERMS
TRANSPORT TERMS
Handle the unit with care at any time. During transport
make sure that the unit is stored safely and cannot be
damaged. If more than one unit are transported, every
unit has to be packed singly to avoid that the units dam-
age one another.
The forwarder is liable for all damages during transport.

EAKL2E132AA Edition: 26.04.2012 Page: 6/18
2.
2.2.
2. Technical data air conditioning units
Technical data air conditioning unitsTechnical data air conditioning units
Technical data air conditioning units
Type
TypeType
Type KL20 facelift
KL20 faceliftKL20 facelift
KL20 facelift
ABS-cover
KL20 facelift
KL20 faceliftKL20 facelift
KL20 facelift
cover-plate
KL20E facelift
KL20E faceliftKL20E facelift
KL20E facelift
Refrigerant R 134a R 134a R 134a
·- quantity approx. kg ca. * * 0,7
Operating voltage Volt
DC
12
24
12
24
24
Cooling capacity Watt 6.200 6.200 4.300
Air volume m
3
/h 700 700 700
Current con-
sumption
V / A 12V/28
24V/16
12V/28
24V/16
-
24V/68-75
1)
Measurements:
Measurements:Measurements:
Measurements:
- length mm 932 724 1300
- width mm 788 750 791
- height mm 211 168 206
- weight kg 23 23 53
1)
depending on outside temperature
*
* *
* 

 Note:
Note: Note:
Note: At KL20 bus and cabin) the quantity of refrigerant is depending on the vehicle and can only be de-
termined during filling of the a/c unit.
2.1.
2.1.2.1.
2.1. Compressor
CompressorCompressor
Compressor nur bei KL20E)
Konvekta code.: H13-002-209
Type SD5H09 / HB / ø 125 mm / 5PV
Oil brand / quantity PAG / corresponding to version
 List is attached to compressor Instruction no: TD00031A)
Connection pressure side standard 3/4“ O-Ring
Connection suction side standard 7/8“ O-Ring
Capacity intake ca. 50 Watt
Number of revolutions 400 bis max. 6.000 U/min.
Installation location from vertical position max. 90° pivoting to both sides
Weight approx. 7,5 kg


 Note:
Note: Note:
Note: At KL20 facelift bus and cabin) the layout of the compressor is depending on the vehi-
cle.

EAKL2E132AA Edition: 26.04.2012 Page: 7/18
3.
3.3.
3. Allgemeine Beschreibung
Allgemeine BeschreibungAllgemeine Beschreibung
Allgemeine Beschreibung
•At the units KL20 facelift and KL20E facelift the optimum air quantity is adjustable via the fan switch
in three levels.
•At the unit KL20 facelift the refrigerant pipes have to be passed from the a/c unit to the compres-
sor.
•The unit KL20E facelift is pre-filled by the manufacturer with refrigerant R134a and electrically
wired. Passing of refrigerant pipes to the engine is not necessary.
Type of unit:
Type of unit:Type of unit:
Type of unit: Connection to the vehicle:
Connection to the vehicle:Connection to the vehicle:
Connection to the vehicle:
KL20
KL20 KL20
KL20 facelift
facelift facelift
facelift cover plate
cover platecover plate
cover plate)
))
)
– E :
E :E :
E : connection electric
– ext. comp.
ext. comp.ext. comp.
ext. comp.: Connection to the vehicle en-
gine or ext. compressor
KL20
KL20 KL20
KL20 facelift ABS
facelift ABSfacelift ABS
facelift ABS-
--
-Haube
HaubeHaube
Haube)
))
)
– E :
E :E :
E : connection electric
– ext. comp.:
ext. comp.:ext. comp.:
ext. comp.: Connection to the vehicle en-
gine or ext. compressor
KL20 E
KL20 EKL20 E
KL20 E facelift
facelift facelift
facelift
– E :
E :E :
E : connection electric
Completely filled with refrigerant
evaporator
condenser
evaporator
condens
er
evaporator
condenser
compre
s
sor
ext. comp.
ext. comp.

EAKL2E132AA Edition: 26.04.2012 Page: 8/18
4.
4.4.
4. General information
General information General information
General information on air conditioning
on air conditioning on air conditioning
on air conditioning unit
unitunit
unit
Attention in case of roof top a/c units: Never switch on the a/c unit during
car wash!
−The air conditioning unit is operational with running engine only.
−At cooling operation the humidity inside the vehicle is decreased, which avoids steamed-up windows.
−The air conditioning unit works most effectively with windows and doors shut. If, however, the interior
of the standing vehicle has been heated up severely by exposure to sunlight, short-time opening of win-
dows/doors may accelerate the cooling down process.
−At high outside temperature and humidity, condensate might drip off the evaporator and make a puddle
under the vehicle. This is quite normal and no sign for a leakage.
−If you think that the air conditioning unit has been damaged switch it off immediately in order to avoid
further damage. The air cond
The air condThe air cond
The air condi
ii
itioning unit may be taken into operation again only after it has been
tioning unit may be taken into operation again only after it has been tioning unit may be taken into operation again only after it has been
tioning unit may be taken into operation again only after it has been
checked at a KONVEKTA Service Station
checked at a KONVEKTA Service Stationchecked at a KONVEKTA Service Station
checked at a KONVEKTA Service Station.
..
.
4.1.
4.1.4.1.
4.1. Operating Conditions
Operating ConditionsOperating Conditions
Operating Conditions
NOTE:
NOTE:NOTE:
NOTE:
KONVEKTA uses components made of copper and aluminium, which last a whole unit lifetime under
normal environmental conditions. Should the units be operated under aggressive environmental condi-
tions, i.e. air containing salt-, phosphate- or ammoniac extremely, a corrosion of the cupper- and alumin-
ium components can not be ruled out. The cupper- and aluminium components of the KONVEKTA sys-
tems are not suitable for such extreme application conditions. We indicate emphatically, that corrosion
is not subject to warranties for defects. KONVEKTA does not take over any warranties for defect, nei-
ther for corrosion nor for consequential damage resulting there from, nor for damages caused by clean-
ing the systems with highly compressed or corrosion advancing substances
4.2.
4.2.4.2.
4.2. Intended
IntendedIntended
Intended use
use use
use
The KONVEKTA
KONVEKTAKONVEKTA
KONVEKTA air conditioning unit is an air conditioning system that works with the ozone friendly
refrigerant R 134a and which creates a pleasant and individually adjustable room temperature by means
of forced convection. The determined use includes also the observance of the operating instructions as
well as the proof of regular inspections.

On our website www.konvekta.com in category >service< you will find a survey of contact details of all our service
partners close to your location

EAKL2E132AA Edition: 26.04.2012 Page: 9/18
5.
5.5.
5. Installation preparation at t
Installation preparation at tInstallation preparation at t
Installation preparation at the vehicle
he vehiclehe vehicle
he vehicle
Danger of accident!
Danger of accident!Danger of accident!
Danger of accident!
Qualified staff in charge of installation and maintenance have to be trained in accordance with EN
Qualified staff in charge of installation and maintenance have to be trained in accordance with EN Qualified staff in charge of installation and maintenance have to be trained in accordance with EN
Qualified staff in charge of installation and maintenance have to be trained in accordance with EN
378
378378
378-
--
-Part 4 and EG) No.307 / 2008 and must strictly
Part 4 and EG) No.307 / 2008 and must strictly Part 4 and EG) No.307 / 2008 and must strictly
Part 4 and EG) No.307 / 2008 and must strictly fo
fofo
fol
ll
llow the legal provisions
low the legal provisionslow the legal provisions
low the legal provisions .
Any works or modifications at the air condi
Any works or modifications at the air condiAny works or modifications at the air condi
Any works or modifications at the air conditioner which are carried out i
tioner which are carried out itioner which are carried out i
tioner which are carried out im
mm
mproperly can lead to
properly can lead to properly can lead to
properly can lead to
malfunction and so endanger operational reliability
malfunction and so endanger operational reliabilitymalfunction and so endanger operational reliability
malfunction and so endanger operational reliability .
Before carrying out any maintenance works at your air conditioning unit, carefully read the KO
Before carrying out any maintenance works at your air conditioning unit, carefully read the KOBefore carrying out any maintenance works at your air conditioning unit, carefully read the KO
Before carrying out any maintenance works at your air conditioning unit, carefully read the KON-
N-N-
N-
VKETA safety provisions TD00052A
VKETA safety provisions TD00052AVKETA safety provisions TD00052A
VKETA safety provisions TD00052A

)
) )
) in order to avoid
in order to avoid in order to avoid
in order to avoid any dangers and acc
any dangers and accany dangers and acc
any dangers and acci
ii
idents
dentsdents
dents !
!!
!
Source of supply: KONVEKTA AG
KONVEKTA AGKONVEKTA AG
KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt
The way of installation is depending on the vehicle type, the instructions of the manufacturer have to be
considered !
!!
!
•Disconnect battery
Disconnect batteryDisconnect battery
Disconnect battery
•Remove inserted ceiling / contingently insulating material in the area of the air ducts.
•Mark out air duct breaches according to schematic drawing hatched area on the drawing >> Re-
quired rooftop holes <<, please find drawing number of the respective a/c unit in the summary on
page 3) on the vehicle rooftop and then cut them out..
Do not damage supporting parts
Do not damage supporting parts Do not damage supporting parts
Do not damage supporting parts e.g. roof arches, bra
e.g. roof arches, brae.g. roof arches, bra
e.g. roof arches, brac
cc
cings) or fixtures!
ings) or fixtures!ings) or fixtures!
ings) or fixtures! !
•Align a/c unit without cover) on the breaches and mark out the 8 mounting points for the unit.
•Remove a/c unit and place the drillings on the rooftop.
•Deburr / smoothen the cutting edges and drillings and seal with anti-corrosion coating.
•Prepare interior roof area, so that the air distribution plate can be mounted under the roof see
point 5.1 , „Mounting of air distribution plate “)
•Tailor gaskets B14-AN2-416 according to drawing >>
>>>>
>>sealing of roof breaches<<
<< <<
<< and glue
on roof with gluing cement
•Put the a/c unit on the gaskets.
•Insert the input lead with the fan switch through the suction hole into the interior area of the roof.
•Mount the a/c unit with fastening material on the vehicle roof top.
•Seal all roof breaches with gluing cement!

EAKL2E132AA Edition: 26.04.2012 Page: 10/18
5.1.
5.1.5.1.
5.1. Installation of air distribution plate
Installation of air distribution plateInstallation of air distribution plate
Installation of air distribution plate
Before installation of the air distribution p
Before installation of the air distribution pBefore installation of the air distribution p
Before installation of the air distribution plate, the object has to be prepared as follows:
late, the object has to be prepared as follows:late, the object has to be prepared as follows:
late, the object has to be prepared as follows:
1. Put the gasket as shown in the picture into the air distribution plate and fix it with the plastic plugs.
Attention:
Attention:Attention:
Attention: Gasket between the suction and exhaust part needs to be installed, otherwise an air short-
circuit and lowering of air conditioning performance will occur.
BB-VW0-043)
Sealing
Fastening screws
5,5x22 /ISO7049
View wit
h
out
blower switch
Plastic fa
s
tener
Air distribution plate

EAKL2E132AA Edition: 26.04.2012 Page: 11/18
5.1.1. Installation of fan switch in the air distribution plate
Close one of the two existing holes in the air distribution plate with the rubber nozzle, Art. No.: H14-000-
260, label the other one with the label H25-001-063 for the fan switch.
Attention:
Attention:Attention:
Attention: 0 position OFF) of the fan switch and 0-position of the label have
to match!
OFF - off
LOW - slow
MED - medium
HI - fast
Unplug the button with the clip at the fan switch; fit the switch with the two nuts which were delivered
together with the switch to the air distribution plate. Then put the button including the clip back to the
switch.
BB-ZW0-050
Button with spring
Rubber grommet
H14
-
000
-
260
Blower switch
B11
-
AA0
-
432
H14
-
000
-
260
H25
-
001
-
063
Nut for fastening the
blower switch
Nut for fastening the
blower switch

EAKL2E132AA Edition: 26.04.2012 Page: 12/18
5.1.2. Installation of blower switch in the instrument panel BEL-260STA003)
For the installation of the blower switch in the instrument panel additional extra items BEL-260STA003)
are needed.
Procedure
ProcedureProcedure
Procedure:
::
:
Detach the blower switch from the original wiring harness and remove the 5 blade terminal sockets from
the blade terminal housing with a removal tool. Now put the 5 cables with the blade terminal sockets of the
wiring harness in the 6-polar blade terminal housing H11-000-668, ST1.1).
Install the blower switch at a suitable place at the dash board as described in 5.1.1). Fix sticker H25-001-
063 for the blower switch.
Install oilflex cable 5 x 2,5 qmm H11-000-776) in the vehicle and insulate the cable ends. At the end of the
wiring harness / a/c there are to be installed 5 blade terminals H11-000-664), to the dashboard 5 blade
terminal sockets H11-000-663) have to be crimped. Plug the cables – as described in wiring scheme K1-
200-173 – into the connectors ST1.1 – 6-polar, ST1 – 5-polar).
Plug the 5-polar blade terminal housing on the blower switch installed at the dashboard.
Holes in the air distribution plate with 2x rubber grommet no. H14-000-260:
Rubber gro
m
met
no. H14-000-260
Rubber gro
m
met
no. H14-000-260

EAKL2E132AA Edition: 26.04.2012 Page: 13/18
5.2.
5.2.5.2.
5.2. Installation of the air distribution plate in the vehicle
Installation of the air distribution plate in the vehicleInstallation of the air distribution plate in the vehicle
Installation of the air distribution plate in the vehicle
Tighten the air distribution plate with the 12 delivered screws 5,5x22 / ISO7049 in the interior.
BB-VW0-044)
5.3.
5.3.5.3.
5.3. Electrical connection
Electrical connectionElectrical connection
Electrical connection
The electrical supply takes place through the vehicle battery.
Carry out the connection in accordance with the connection scheme. The air conditioning unit is pre-
cabled. The following connections have to be made:
1. Install the two-pole safety fuse socket near the vehicle battery and connect it.
2. Carry out the cabling of the battery – safety fuses and the air conditioning unit in accordance with
the cable cross-section indicated in the connexion scheme.
3. Insert the safety fuses in the fuse socket.
- Clamp the vehicle battery
Clamp the vehicle batteryClamp the vehicle battery
Clamp the vehicle battery
Air suction
Air suctionAir suction
Air suction
Air outlet
Air outletAir outlet
Air outlet
Interior roof of
vehicle
Air distrib
u
tion
plate
Screw 5,5x22 /
ISO7049/vz.
Sealing
Blower switch

EAKL2E132AA Edition: 26.04.2012 Page: 14/18
Driving dire
Driving direDriving dire
Driving dire
c
cc
c
tion
tiontion
tion
6.
6.6.
6. Positioning of the air conditioning components
Positioning of the air conditioning componentsPositioning of the air conditioning components
Positioning of the air conditioning components
1. Evaporator coil
1a. Radial blower
1b. Expansion valve
1c. Thermostat
2. Condenser coil
2a. Axial blower condenser blower)
3. Dryer-collector-sight glass- unit with combined pressure switch
4. Electric
5. Driving unit complete with compressor SD5H09 - not to apply with KL20
not to apply with KL20not to apply with KL20
not to apply with KL20
7.
7.7.
7. Operation
OperationOperation
Operation
The blower switch to activate the blower is situated in the
The blower switch to activate the blower is situated in the The blower switch to activate the blower is situated in the
The blower switch to activate the blower is situated in the interior of the vehicle.
interior of the vehicle. interior of the vehicle.
interior of the vehicle. See also 5.1.1 – Installa-
tion of blower switch in the air distributor plate)
−Start motor of the vehicle see original instruction manual of the vehicle)
−Regulate air capacity through blower switch
•position 0 - OFF
•position 1 - minimum air volume
•position 2 - medium air volume
•position 3 - maximum air volume
1a
4
3
1
1c
1b
2
2a
5

EAKL2E132AA Edition: 26.04.2012 Page: 15/18
8.
8.8.
8. Maintenance / Service
Maintenance / ServiceMaintenance / Service
Maintenance / Service
Maintenance and service works have to be done in accordance with the “Maintenance Schedule, no :
WP07050621.
 Only
Only Only
Only qualified staff
qualified staff qualified staff
qualified staff is allowed to
is allowed to is allowed to
is allowed to carry out
carry outcarry out
carry out these works
these works these works
these works!
! !
! –
––
–
Danger of accident!
Danger of accident!Danger of accident!
Danger of accident!
Qualified staff in charge of installation and maintenance have to be trained in accordance with EN
Qualified staff in charge of installation and maintenance have to be trained in accordance with EN Qualified staff in charge of installation and maintenance have to be trained in accordance with EN
Qualified staff in charge of installation and maintenance have to be trained in accordance with EN
378
378378
378-
--
-Part 4 and EG) No.307 / 2008 and must strictly fo
Part 4 and EG) No.307 / 2008 and must strictly foPart 4 and EG) No.307 / 2008 and must strictly fo
Part 4 and EG) No.307 / 2008 and must strictly fol
ll
llow the legal provi
low the legal provilow the legal provi
low the legal provisions.
sions.sions.
sions.
Any works or modifications at the air conditioner which are
Any works or modifications at the air conditioner which are Any works or modifications at the air conditioner which are
Any works or modifications at the air conditioner which are carried out i
carried out icarried out i
carried out im
mm
mproperly can lead to
properly can lead to properly can lead to
properly can lead to
malfunction and so endanger operational reliability. We recommend having all works and modific
malfunction and so endanger operational reliability. We recommend having all works and modificmalfunction and so endanger operational reliability. We recommend having all works and modific
malfunction and so endanger operational reliability. We recommend having all works and modifica-
a-a-
a-
tions carried out at an authorized KONVEKTA Service Station
tions carried out at an authorized KONVEKTA Service Stationtions carried out at an authorized KONVEKTA Service Station
tions carried out at an authorized KONVEKTA Service Station



. The same applies to the reg
. The same applies to the reg. The same applies to the reg
. The same applies to the regu
uu
ular
lar lar
lar
maintenance works as prescribed and specified in the maintenance certificate.
maintenance works as prescribed and specified in the maintenance certificate.maintenance works as prescribed and specified in the maintenance certificate.
maintenance works as prescribed and specified in the maintenance certificate.
Before carrying out any maintenance works at your air conditioning unit, carefully read the
Before carrying out any maintenance works at your air conditioning unit, carefully read the Before carrying out any maintenance works at your air conditioning unit, carefully read the
Before carrying out any maintenance works at your air conditioning unit, carefully read the KO
KOKO
KON-
N-N-
N-
VKETA safety pr
VKETA safety prVKETA safety pr
VKETA safety provisions TD00052A
ovisions TD00052Aovisions TD00052A
ovisions TD00052A

 )
) )
) in order to
in order toin order to
in order to avoid any dangers and acc
avoid any dangers and acc avoid any dangers and acc
avoid any dangers and acci
ii
idents
dentsdents
dents!
!!
!

On our website www.konvekta.com in category >service< you will find a survey of contact details of all our service
partners close to your location

Source of supply: KONVEKTA AG
KONVEKTA AGKONVEKTA AG
KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt
 When the air conditioning system is being opened during maintenance resp.
When the air conditioning system is being opened during maintenance resp. When the air conditioning system is being opened during maintenance resp.
When the air conditioning system is being opened during maintenance resp.
reparation works, the dryer
reparation works, the dryerreparation works, the dryer
reparation works, the dryer-
--
-collector
collectorcollector
collector-
--
-sight glass has to be exchanged!
sight glass has to be exchanged! sight glass has to be exchanged!
sight glass has to be exchanged!
 The connexions have to be wetted with PAG
The connexions have to be wetted with PAG The connexions have to be wetted with PAG
The connexions have to be wetted with PAG oil before the installation of
oil before the installation of oil before the installation of
oil before the installation of
the wires.
the wires.the wires.
the wires.
8.1.
8.1.8.1.
8.1. Service parts
Service partsService parts
Service parts
•Axial- und radial blower
•Blower switch
•Dryer-collector-sight glass
•Thermostat icing protection)
•Plug connection electric
•Compressor
•Pressure switch combination
Pressure switch combinationPressure switch combination
Pressure switch combination
The pressure switch combination is fitted to the dryer-collector-sight glass –unit.
Konvekta code no.: H11-001-378
Low pressure k BAR 2,0 ± 0,2 off 2,1 ± 0,3 on
excess pressure BAR 28,0 ± 2,0 off 21,0 ± 3,0 on

EAKL2E132AA Edition: 26.04.2012 Page: 16/18
8.2.
8.2.8.2.
8.2. Check refrigerant level
Check refrigerant levelCheck refrigerant level
Check refrigerant level
Check the refrigerant level at the sight glass of the dryer-collector unit:
1. Switch a/c unit on.
2. The set temperature must be
lower than the actual inside
temperature, so that compressor
is engaged.
Sight glass
Sight glassSight glass
Sight glass: Cause
CauseCause
Cause Remedy
RemedyRemedy
Remedy
Bild: BB-YW0-029
Forming of bubbles in the sight
glass


 Lack
LackLack
Lack of r
r r
re
ee
efrigerant
frigerantfrigerant
frigerant!!
!!!!
!!
A
AA
Attention
ttentionttention
ttention !
! !
!
In case there is too little refrigerant in the
system, an increase in bubble formation can
be observed in the sight glass. In this case it
is necessary to switch off the system immed
to switch off the system immedto switch off the system immed
to switch off the system immedi-
i-i-
i-
ately
atelyately
ately in order to avoid damages at the com-
pressor.
Contact
ContactContact
Contact KONVEKTA Service Station
KONVEKTA Service StationKONVEKTA Service Station
KONVEKTA Service Station



!
!!
!
– refill refrigerant
– check a/c unit for leakages
Free of bubbles!
Amount of refrigerant is o.k..
..
.

On our website www.konvekta.com in category >service< you will find a survey of contact details of all our service
partners close to your location.
Safety valve
Sight glass
Protective cap
Protective cap
Locking srew

EAKL2E132AA Edition: 26.04.2012 Page: 17/18
8.3.
8.3.8.3.
8.3. C
CC
Compressor
ompressor ompressor
ompressor only with
only withonly with
only with KL20E
KL20E KL20E
KL20E facelift
faceliftfacelift
facelift)
))
)
The compressor is installed in the unit and is driven through a poly-V-belt by the driving unit. Please pay
attention to a faultless tension of the V-belt.
The air conditioning unit being activated, the magnetic clutch is being activated and the compressor works.
When the air conditioning unit is shut off, the magnetic clutch runs along without activity.
Important
ImportantImportant
Important:
::
:
To avoid leakages at the shaft seal of the compressor
To avoid leakages at the shaft seal of the compressorTo avoid leakages at the shaft seal of the compressor
To avoid leakages at the shaft seal of the compressor:
::
:
The compressor should be started every 4 weeks for approx. 15 minutes!
This also applies when the vehicle is not into operation for a longer period or when the air conditioning unit
is not used!
8.4.
8.4.8.4.
8.4. Condenser coil
Condenser coilCondenser coil
Condenser coil
After taking into operation the condenser, a regular cleaning is
necessary. Always keep condenser coil fins clean. Severe soiling
causes excess pressure within the a/c-unit system and it automati-
cally stops working.
Attent
AttentAttent
Attention:
ion: ion:
ion: The condenser coil fins have to be cleaned with com-
pressed air at least twice a year, in case of severe soiling more of-
ten
The fins of the condenser battery must not be deformed. De-
formed fins have to be erected with a fin comb.
..
.
8.5.
8.5.8.5.
8.5. Trouble shooting
Trouble shootingTrouble shooting
Trouble shooting
Trouble
TroubleTrouble
Trouble Cause
CauseCause
Cause Repair
RepairRepair
Repair
–
––
– by authorized Service St
by authorized Service St by authorized Service St
by authorized Service Sta
aa
ation only
tion only tion only
tion only

electric connections disconnected - check electric connections
defective fuse •check fuse, replace if necessary
Blower switch defective •check blower switch, V-belt if necessary
excess pressure 3. clean condenser coil
low pressure, dryer clogged
- replace dryer

low pressure, screen of expansion
valve clogged
- clean screen; replace dryer

a/c is not running
leakage in a/c unit, lack of refriger-
ant
- check a/c unit for leakages
- refill refrigerant and
and and
and replace dryer!

a/c runs, switches off excess pressure caused by high
outside temperature
- run unit, until pressure has stabilized

defective bearing at compressor - replace either bearing or entire compressor
Loud noise at compres-
sor magnetic clutch
- check connections at magnetic clutch

Loud noise at V-belt worn V-belt
slack V-belt
- replace V-belt

- retighten V-belt


On our website www.konvekta.com in category >service< you will find a survey of contact details of all our service
partners close to your location.
Picture: erecting fins
Picture: erecting finsPicture: erecting fins
Picture: erecting fins

EAKL2E132AA Edition: 26.04.2012 Page: 18/18
9.
9.9.
9. Warranty Conditions
Warranty ConditionsWarranty Conditions
Warranty Conditions
The current „General Warranty Conditions” KONVEKTA AG“ will apply. A copy will be furnished by the
warranty department. Please contact: [email protected]
[email protected][email protected]
[email protected] .
10.
10.10.
10. Waste disposal in accordance with legal provisions
Waste disposal in accordance with legal provisionsWaste disposal in accordance with legal provisions
Waste disposal in accordance with legal provisions
After the phase of use the last proprietor is responsible for the adequate waste management. The envi-
ronmental regulations in the exporting country must be observed.
The following list contains the most important regulating literature, valid for the Federal Rep. of Germany:
- Resolution for dangerous substances - Resolution for used oil
- Law for waste circulation KRW/AfgG)) - Law of water balance
- Resolution for the proofs of utilization and
removal
- Resolution for the waste management of old cars and
the adaptation of road prescriptions
- Criminal Code StGB) 28
th
section „criminal
acts against the environment” §326 – Envi-
ronment jeopardizing waste management
- Resolution EWC) No.3093/94 for materials that af-
fect the ozone layer
- Law of chemicals § 27 – penal prescriptions - Resolution to prohibit certain ozone destroying halo-
gen hydrocarbons.
The used refrigerant endangers the environment. When dealing with refrigerants the existing prescriptions and regula-
tions are to be followed. Only skilled personnel are allowed to carry out these works !
!!
!
Water endangering substances – acc. To §§19g-19l – are solid, liquid, and gaseous substances. E.g.: mineral and tar oils
cooling oils), halogen containing organic combinations refrigerants)
11.
11.11.
11. History of modification
History of modificationHistory of modification
History of modification
Ve
VeVe
Ver
rr
rsion
sionsion
sion Date
DateDate
Date Name
NameName
Name Remark
RemarkRemark
Remark file
filefile
file
A00 12.10.2011 B. Keßler Source file EAKL2E132AA
A01 26.04.2012 B. Keßler Point 2: The refrigerant charge of KL20E facelift is to
be corrected from 1,3 kg to 0,7 kg.
EAKL2E132AA