KONVEKTA KL40T User manual

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
Operating Instruction
for KONVEKTA Air Conditioning unit
KL40T / KL45T / KL45T
with control KS50
Versions:
 12 / 24 Volt DC
 Recirculated Air
 Fresh Air
 Heating
ID#: BBA-KL40T12AH
Version: A03

BAKL40T12AH Edition: 01.03.2017 Page: 2/14
Contents
Page:
•Introduction .........................................................................................................................3
•Information on the operating instructions ........................................................................4
1. Technical data..................................................................................................................4
1.1. Compressors .....................................................................................................................5
2. Determined use................................................................................................................5
3. Generally information for a/c unit...................................................................................6
3.1. Operating Conditions .........................................................................................................6
4. Introduction control KS50 ...............................................................................................6
4.1. Installation .........................................................................................................................6
4.2. Demounting .......................................................................................................................7
5. Operation..........................................................................................................................7
5.1. Description of the display (LCD symbols)...........................................................................7
5.2. Switch on air conditioning unit............................................................................................8
5.3. Switch off air conditioning unit............................................................................................8
5.4. Setting of the desired temperature.....................................................................................8
5.5. Manual adjustment of the blowers......................................................................................9
5.6. ECON operation ................................................................................................................9
5.7. Fresh and recirculating air operation................................................................................10
5.8. Demisting operation.........................................................................................................10
5.9. Changeover temperature display mode ...........................................................................11
5.10. Switch the temperature indication to °Fahrenheit.............................................................12
6. Maintenance / Servicing ................................................................................................12
6.1. Oil change Compressor type KVX....................................................................................12
6.2. Return air grid..................................................................................................................12
6.3. Condenser coil.................................................................................................................13
6.4. Troubleshooting ...............................................................................................................13
7. Warranty Conditions......................................................................................................14
8. Waste disposal in accordance with legal provisions ..................................................14
9. History of modification..................................................................................................14
Appendix:
•Maintenance Schedule Bus WP07050618

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Introduction
These operating instructions have been written for drivers, operators and the maintenance staff
of your air conditioning unit.
In this context, we refer implicitly to the compliance with our general installation guide-
lines. These can be obtained from the KONVEKTA technical after sales service:
[e-mail].
Please observe our valid safety instructions, available under www.konvekta.de/asv.html. In
case of order placement or any other conclusion of contract the safety instructions get inte-
gral part of the contract.
These operating 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 troubleshooting 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 com-
pliance 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 provi-
sions for prevention of accidents and environmental protection.
These instructions are part of the air conditioning unit. Always
have a copy at hand in the driver’s cabin.
You will certainly understand that we will not recognize any warranty claims due to un-
proper handling, inadequate maintenance, applications that do not correspond with the
determined use, utilization of unadmitted fuels or the non-observance of safety provi-
sions.
KONVEKTA will annul without prenotice all obligations concerning guarantee, service
contracts etc. regardless 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.
These operating instructions contain all necessary information to operate your air condi-
tioning unit. 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.

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Information on the operating instructions
These operating instructions are valid for the a/c-units type:
•KL40T/12V •KL45T/12V •KL46T/12V
•KL40T/24V •KL45T/24V •KL46T/24V
When taking the unit into operation we recommend adding the following data. This will also be im-
portant for your orders of spare parts, and in case of warranty.
Serial number of the unit: ......................................................
Order No.: ......................................................
Year of construction: ...................................................... (MM/JJ)
Date of first operation: ...................................................... (TT/MM/JJ)
The machine is in accordance with the EC machinery directive 2006/42/EC.
The unit contains or needs fluorinated greenhouse gas for operation and is subject
to identification requirements in accordance with F-Gas Regulation 517/2014.
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 in-
struction, 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 preno-
tice. 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: KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt
1. Technical data
Important!
In vehicles that are equipped with an a/c unit with heating function the heating medium has to con-
sist of water/glycol – antifreeze protection (conform the mixing ratio to manufacturers` instructions).
This is absolutely necessary to prevent the heaters from frost damage!
(The prevalent antifreeze filling of the vehicle manufacturers goes down to -40°C)

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Type
:
KL40T
KL45T
KL46T
Refrigerant R134a
GWP 1.430
·- quantity
with front box
[kgs] approx. 2,5
3,3
2,5
3,3
2,5
3,3
Operating voltage
resp.
[Volt DC] 12
24
12
24
12
24
Current consumption (3-stage) at 13V:
(3-stage) at 26V:
(stageless) at 26V
[Ampere]
88
44
53
88
44
53
88
44
53
Cooling capacity with KVX40
KVX30 or TM31
TM21
[Watt]
18.000
15.000.
12.000
18.000
15.000.
12.000
21.000
-
-
Heating capacity Q= 100 [Watt] 25.000 25.000 25.000
Evaporator – Air volume*, free-blowing [m
3
/h] 3-stage
stageless
4.000
4.400
4.000
4.400
4.000
4.400
Measurements:
- length [mm] 1.966 1.985 1.985
- width [mm] 1.368 1.336 1.336
-hight,
-depending on roof radius [mm] 221
188
234
188
239
193
Weight of unit, Version:
- Recirculated Air [kgs ] approx. 65,5 78,5 81
- Fresh Air [kgs ] approx. 66,5 79,5 82
- Heating [kgs ] approx. 69 82 84
* With standard fans and/or blowers
1.1. Compressors
Important 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 condition-
ing unit is not used!
Compressor type depending on scope of delivery, see identification plate at compressor.
Kompressor Typ KVX40/390 KVX30/325 HDC 33 TM21
Weight (kgs) approx. 33 24,5 15,5 9,7
Oil brand
- quantity (kgs)
Esteröl SE55
2
Esteröl SE55
2
ZXL 100PG
0,5
ZXL 100PG
0,18
Magnetic clutch
1)
- Weight (kgs)
12 / 24V DC
12
12 / 24V DC
7,6
12 / 24V DC 12 / 24V DC
1)
ø depending on vehicle type
2. Determined use
The KONVEKTA air conditioner represents an air conditioning system that works with the ozone
friendly refrigerant R 134a and which creates a pleasant and individually adjustable room tempera-
ture by means of forced convection. The determined use includes also the observance of the Oper-
ating instruction and the proof of regular inspections as well.

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3. Generally information for a/c unit
Attention in case of roof top a/c units:Never switch on the a/c unit during car-wash!
The a/c unit is operational with running engine only.
At cooling operation the humidity inside the vehicle is decreased, which avoids steamed up win-
dows. The a/c 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 windows and 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.
The filter in the return air grid (optional) retains pollution. If the external air is contaminated with
gas switch over to return air operation. The filter should be cleaned or replaced respectively on a
regular basis so that the capacity of the a/c unit is not affected.
If you think that the a/c unit is damaged, switch it off immediately. To avoid further damage
have it check at a KONVEKTA Service Station

. Only after that you can take unit into operation.

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
3.1. Operating Conditions
NOTE: KONVEKTA uses components made of copper and aluminium, which last a whole unit life-
time under normal environmental conditions. Should the units be operated under aggressive envi-
ronmental conditions, i.e. air containing salt-, phosphate- or ammoniac extremely, a corrosion of the
cupper- and aluminium components can not be ruled out. The cupper- and aluminium components
of the KONVEKTA systems 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, neither for corrosion nor for consequential damage resulting there from,
nor for damages caused by cleaning the systems with highly compressed or corrosion advancing
substances.
4. Introduction control KS50
The KS50 is a climate controller for air
conditioning systems in modern vehicles.
Due to its compact design the controller
can be mounted easily in the dash board
of the vehicle. The clear arrangement of
the symbols and the easy handling re-
lieve the driver and meet all demands of
optimal air conditioning control.
4.1. Installation
1. Choose suitable mounting place (the controller must not be exposed to direct solar radiation
through the windshield) and prepare a mounting cutout; width = 90,2 mm, height = 43,0 mm.
2. After the installation (wires laid out along the vehicle and 24-polar connecting plug positioned in
the dashboard control seat) plug the connection plug on the controller.
3. Insert the controller in the mounting cutout until the lateral mounting brackets lock.

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4.2. Demounting
1. Open the accordant cover in the dash board to get access to the back side of the controller.
2. Press the mounting brackets together, either by hand or with a tool, and push the controller for-
ward.
3. Take off the plug and remove the controller.
5. Operation
Danger of accident!
– Focussing your attention on the road traffic is of top priority
– Only operate your air conditioning unit when the traffic situation allows it
– Make sure you can clearly recognize and read all operation- and display-elements at any time
– Protect all displays against irritating sunglare and any other optical disturbances
– Please note that the control panel keys have not been designed for heavy stressing
– Excessive or fast pressing of the keys for adjusting the set temperature does not accelerate the
cooling down process. It possibly damages the control panel and so affects the general perfor-
mance of the airconditioning unit
5.1. Description of the display (LCD symbols)
Symbol Acceptation of the display symbols
1 Ambient temperature is displayed
2 Room temperature is displayed
3 4-digit 7-segment display for various
values
4 Display of operating hours
5 Warning: an error is recorded
6 Recirculating air operation is activated
7 Automatic blower control is activated
8 Bar display for blower speed in manual
blower control mode
9 Manual blower control is activated
10 Demisting operation is activated
11 Cooling operation is activated
12 ECON operation is activated

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5.2. Switch on air conditioning unit
By pressing key Blowers Plus (1) the A/C is switched on.
Press
After switching on the controller carries out a self-test. The software version
(here: 1.0) as well as the operating mode (here: A) are indicated for approx.
3 sec.
After this the operating hours of the A/C unit are displayed for
approx. 3 sec.
The operating hours are indicated as figure until the thousands
digit. For every ten thousand digit a bar is displayed additionally
(for 20000 e.g. two bars, here: 20286 hours).
Now the A/C is ready for operation. The last stored setting is displayed.
5.3. Switch off air conditioning unit
By pressing the key Blowers Minus (2) longer than 2 seconds the A/C is
switched off.
While the key is pressed the display changes temporarily. This is
no fault, no settings are changed.
Press and hold
Now the A/C is switched off.
5.4. Setting of the desired temperature
The set temperature is displayed (here: 22°C). Digits 1 to 3 show the set
temperature, the last digit the unit °Celsius or °Fahrenheit.
Adjustment of the set temperature with key Set Temperature Plus (8).
Press twice
The new set temperature is indicated, here 24°C.
By pressing the key Set Temperature Minus (7) the temperature
can be decreased.

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5.5. Manual adjustment of the blowers
The controller is in automatic blower operation mode. The AUTO symbol (7)
is indicated.
To decrease the blower speed press the key Blowers Minus (2).
Press
The AUTO symbol disappears. The Blower symbol (9)
and the current speed
in a bar diagram are displayed (here 40%).
In manual blower operation mode the blower speed can be ad-
justed with the keys Blower Plus (1) and Blower Minus (2) be-
tween the minimum speed and 100%.
The automatic blower operation mode can be activated again by pressing
key AUTO (3).
Press
The controller is in automatic blower mode. The AUTO symbol (7) is indicat-
ed
5.6. ECON operation
The ECON symbol (12) is not displayed. A/C operation is activated; the
Frosting symbol (11) indicates that the unit is in cooling mode at the mo-
ment.
The ECON mode can be activated by pressing and holding key Set Temper-
ature Minus (7).
While the key is pressed the display changes temporarily.
This is no fault, no settings are changed.
Press and hold
Now the ECON mode is activated and the ECON symbol (12) is displayed.
In ECON mode the compressor is locked. The A/C operates
only in ventilation and heating mode.
The ECON mode can be switched off by pressing and holding key Set Tem-
perature Minus (7).
Press and hold
The ECON symbol (12) disappears. Now the A/C mode is active again and
the compressor is switched on by the controller if required.
Depending on the type of control mode and type of A/C unit, the blower speed can be
adjusted in manual blower mode either in 10% steps, in three steps or in two steps.

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5.7. Fresh and recirculating air operation
In fresh air operation mode the air flap is open, a defined share of fresh air is
supplied into the interior.
By pressing key Recirculating Air (5) the recirculating air mode is activated.
Press
The symbol for Recirculating Air (6) is displayed.
In recirculating air mode the fresh air flap is closed, no fresh air
is supplied.
By pressing key Recirculating Air (5)
once again the mode is switched back
to fresh air operation.
Press
Fresh air mode is activated again.
5.8. Demisting operation
If the windows are steamed up, the demisting mode can be activated.
Press key Demisting (4) to activate demisting operation mode.
Press
The symbol Demisting (10) on the display indicates that the demisting mode
is activated.
In demisting mode the compressor is operating and the blower
speed is raised to 100%.
If the key Demisting (4) is pressed again, the demisting mode gets deactivat-
ed.
Press
Demisting mode is deactivated.
If the ambient temperature is cold, the ECON mode should be activated to provide a
comfortable climate in the vehicle and to save energy. .
Dependent on the configuration of the controller, it is also possible that the system
changes automatically from recirculating to fresh air mode after a defined period of time.

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5.9. Changeover temperature display mode
In normal operation the set temperature is displayed (here 22°C).
By pressing the key MODE (6) the display changes over to ambient tem-
perature.
Press
The current ambient temperature (here 32°C) is displayed. The symbol Am-
bient Temperature (1) appears.
By pressing key MODE (6) again the display changes back to inside temper-
ature indication.
Press
The current inside temperature (here 23°C) is indicated. The symbol Inside
Temperature (2) appears.
By pressing key MODE (6) once again the display changes over to set tem-
perature indication.
Press
The set temperature is displayed.
Dependent on the configuration of the controller, after a defined period of time the demisting
mode is deactivated automatically.
When the demisting mode is activated the blower speed is increased to 100%. The speed
can be adjusted manually on demand. But to reach maximum demisting performance the
blower speed should not be decreased.
If the set temperature is adjusted while the ambient or inside temperature is indicated, the
display changes over to set temperature for some seconds.
Dependent on the configuration of the controller, the display changes over automatically
from ambient or inside temperature to the set temperature after some seconds.

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5.10. Switch the temperature indication to °Fahrenheit
The adjusted set temperature is indicated in °Celsius:, e.g. 22 °C.
To change the display to °Fahrenheit press and hold key AUTO (3).
Press and hold
Then press key MODE (6) and let loose both keys.
Press and let loose
The display changes over to °Fahrenheit.
When this key combination is pressed again, the display
changes back to °Celsius.
6. Maintenance / Servicing
Please arrange regular dates for maintenance works and services with a KONVEKTA service sta-
tion, as indicated in maintenance schedule bus no. WP07050618.
- Only qualified staff is allowed to carry out these works! -
For general instructions on repair – and maintenance works please contact via email:
[e-mail]
Danger of accidents!
Qualified staff in charge of installation and maintenance have to be trained in accordance
with EN 378-Part 4 and (EG) No.307 / 2008 and must strictly follow the legal provisions.
Any works or modifications at the air conditioner which are carried out improperly can lead
to malfunction and so endanger operational reliability. We recommend having all works and
modifications carried out at an authorized KONVEKTA Service Station

.
Before carrying out any maintenance works at your air conditioning unit, carefully read the
KONVKETA safety provisions (TD00052A

)in order to avoid any dangers and accidents!

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, P.O. Box 2280, D-34607 Schwalmstadt
6.1. Oil change Compressor type KVX
First oil change at the first maintenance of the vehicle and then approx. every 3 years. At every oil
change the oil suction strainer has to be cleaned. Observe the oil quantity according to the com-
pressor type (s. item 1.1).
6.2. Return air grid
Clean the return air grid in the passenger area monthly. In case of enormous dirt weekly.
The setting of the temperature unit is persistent, also when the controller is switched off.

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6.3. Condenser coil
Always keep condenser coil fins clean. Severe soiling causes excess pressure within the a/c-unit
system and it automatically stops working.
Attention:
The condenser coil fins have to be cleaned with compressed air at least once a year, in case of se-
vere soiling more often.
6.4. Troubleshooting
- Only qualified staff is allowed to carry out these works! -
Trouble Cause Repair only by refrigeration expert

a/c is not running
magnetic clutch / compressor
is not switched on
•check inside temperature, adjust new if
necessary

•check connections at magnetic clutch
electric connections discon-
nected
•check electric connections at switch-
board
relay defective •check relay,replace if necessary
defrost thermostat has
switched off
•check evaporator blower,replace if
necessary
outside temperature too low
(possible icing of evaporator) •switch on "ventilation" only
evaporator coil dirty •clean evaporator coil with compressed
air
excess pressure (pressure too
high)
•check axial fans
•check fuses at switchboard
•clean condenser coil with compressed
air
LED flashes
up
excess pressure caused by
high outside temperature
•run unit until pressure has stabilized
leakage in a/c unit, lack of re-
frigerant
•check a/c unit for leakages,
•refill refrigerant
low pressure, dryer clogged •replace dryer
low pressure, screen of expan-
sion valve clogged •clean screen; replace dryer
compressor does not compress
•check high and low pressure, replace
compressor if necessary
Loud noise at
compressor
defective bearing at compres-
sor
•replace either bearing or entire com-
pressor
slack V-belt •check V-belt at compressor drive

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

By user

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7. Warranty Conditions
The current „General Warranty Conditions KONVEKTA AG“ will apply. A copy will be furnished by
the warranty department. Please contact [email protected]
8. Waste disposal in accordance with legal provisions
After the phase of use the last proprietor is responsible for the adequate waste management.
The environmental 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) 28th section „crimi-
nal acts against the environment” §326 -
Environment jeopardizing waste manage-
ment
•
Resolution (EC) No. 2037/2000 of the Europe-
an Parliament and of the Council for materials
that affect the ozone layer
•
Law of chemicals § 27 - penal prescriptions
•
Resolution to prohibit certain ozone destroying
halogen hydrocarbons.
The used refrigerant endangers the environment. When dealing with refrigerants the existing pre-
scriptions and regulations are to be followed. Only qualified staff is 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).

Source of supply:
- Bundesanzeiger
- Beuth Verlag
- dtv (Deutscher Taschenbuch Verlag
9. History of modification
Version
Date Name Remark File
A00 25.05.2011
B. Keßler Source file BAKL40T12AH
A01 30.11.2015
B. Keßler Updated EC machinery directive. BAKL40T12AH
A02 04.07.2016
B. Keßler Added KL46T BAKL40T12AH
A03 01.03.2017
B. Keßler Information on the operating instructions and
technical data expanded with F-gas-regulation
BAKL40T12AH