KONVEKTA KL40T/24V 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 / KL46T /
KL46S
with Wabco ATC-CAN control
Versions:
 24 Volt DC
 Fresh Air / Heating
ID#: BBA-KL40T12AF
Version: A06

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Contents
Page:
•Introduction .........................................................................................................................3
•Information on the operating instructions ........................................................................4
1. Technical data air conditioning unit...............................................................................4
1.1. Compressors .....................................................................................................................5
2. Determined use................................................................................................................5
3. General information a/c unit ...........................................................................................5
4. Operation..........................................................................................................................6
4.1. Control unit ........................................................................................................................6
4.2. Flap for windshield/floor .....................................................................................................7
4.3. Desired value of front box temperature ..............................................................................7
4.4. Blower speed.....................................................................................................................7
4.5. Smog .................................................................................................................................7
4.6. Heater passenger’s compartment ......................................................................................7
4.7. Additional heater................................................................................................................7
4.8. Reheat...............................................................................................................................7
4.9. Driver’s seat air conditioning ..............................................................................................7
4.10. General..............................................................................................................................7
5. Maintenance / Service .....................................................................................................8
5.1. Oil change Compressor type KVX......................................................................................8
5.2. Return air grid....................................................................................................................8
5.3. Condenser coil...................................................................................................................8
5.4. Troubleshooting .................................................................................................................9
6. Warranty Conditions........................................................................................................9
7. Waste disposal in accordance with legal provisions ..................................................10
8. History of modification..................................................................................................10
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 provisions 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 improper han-
dling, inadequate maintenance, applications that do not correspond with the determined use, utiliza-
tion of non-admitted fuels or the non-observance of safety provisions.
KONVEKTA will annul without notice 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 conditioning 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.
Information on the operating instructions
These operating instructions are valid for the a/c-units type:
•KL40T/24V •KL45T/24V •KL46T/24V •KL46S/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)

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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 identi-
fication 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 air conditioning unit
Type : KL40T KL45T KL46T / S
Refrigerant R134a
GWP 1.430
·- quantity
with front box [kgs] approx. 2,5 3,3
Operating voltage [Volt DC] 24
Current consumption (stageless) at 26V [Ampere] 53
Cooling capacity with KVX40/390
KVX40/560
KVX40/655K
KVX30 oderTM31
TM65
[Watt]
18.000
-
-
15.000
-
18.000
-
-
15.000
-
-
22.000
22.000
-
22.000
Heating capacity Q= 100 [Watt] 25.000
Evaporator – Air volume*, free-blowing [m
3
/h] stage-
less
4.400
Measurements:
- length [mm] 1.956 1.980 1.970
- width [mm] 1.367 1.836 1.836
-hight,
-depending on roof radius [mm] 216
193
225
201
227
185
Weight of unit, Version:
- Heating + Fresh Air [kgs] approx. 69 82 83 92
* With standard fans and/or blowers
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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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 conditioning unit is not used!
Kompressor Type TM 65 HDC 33 KVX40/655K
Weight (kgs) approx. 18,8 15,5 35
Oil brand
- quantity (kgs)
ZXL 100PG
1,5
ZXL 100PG
0,5
Esteröl SE55
2,0
Magnetic clutch
1
)
- Weight (kgs)
24V
1,382
12 / 24V DC 24V DC
Kompressor Type
KVX40/390 KVX40/560 KVX30/325
Weight (kgs) approx.
33 33 24,5
Oil brand
- quantity (kgs)
Esteröl SE55
2
Esteröl SE55
2
Esteröl SE55
2
Magnetic clutch
1)
- Weight (kgs)
12 / 24V DC
12
24V
13,2
12 / 24V DC
7,6
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.
3. General information 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.

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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. Operation
Attention in case of roof top a/c units: Never switch on the a/c unit during car-wash!
Danger of accidents!
- 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 sun glare 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 ac-
celerate the cooling down process. It possibly damages the control panel and so af-
fects the general performance of the air conditioning unit
4.1. Control unit
You operate the air conditioning unit via the original WABCO – control unit (see original
WABCO- operation instructions „ATC-CAN„)
For operation the driver can use 3 rotary potentiometer and maximal 5 keys. Depending on the seri-
al-model modification of the bus different control desks are used.
In order to release the driver from extensive adjustments for the passengers compartment he is able
to switch off the complete control for this area. All other functions on the control desk serve for the
individual adjustments of the driver’s cabin.
Flap windshield/floor
Frontbox tempera
ture
Blower speed Reheat
A
dditional heater
Heater passen-
gers compart-
ment
Driver’s seat clima
te
Smog

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4.2. Flap for windshield/floor
The flap for windshield respectively floor are controlled according to the symbolism.
Arrow down:
F
lap for floor
The whole air is lead to the floor
Arrow down/up:
M
id
-
position
Air circulation is split up between floor and windshield.
Arrow up
F
lap for windshield
The whole air is lead to the windshield.
Symbol windshield
D
efrost
Water valve completely opened; air to windshield; max-
imal blower speed.
The conversion is realized via characteristic curves which also facilitate intermediate positions.
4.3. Desired value of front box temperature
The blowout temperature of the front box can be set between 14 and 60º C.
4.4. Blower speed
The potentiometer serves for setting speed of the front box. The air velocity is increased by turning
the potentiometer clockwise.
4.5. Smog
With the smog key you can stop supply of fresh air for the whole bus. If smog function is activated
the key is illuminated. If this function is activated, the openings in the roof as well as the fresh air
flaps are closed for a certain time prescribed by the manufacturer.
4.6. Heater passenger’s compartment
The driver doesn’t have the possibility to intervene in the fully automatic control of the passengers
compartment. This control is merely turned off during routes without passengers (e.g. transportation
of bus). If automatic function is activated the key is illuminated.
4.7. Additional heater
Normally the additional heater is turned on manually. If additional heater is activated, the key is illu-
minated.
4.8. Reheat
With the key Dry / Reheat the air conditioning unit is put into operation. The air is dried by cooling
down and re-heating.
4.9. Driver’s seat air conditioning
This function activates the refrigerant magnetic valve respectively the compressor magnetic clutch.
Key is illuminated if a/c system is activated.
4.10. General
Roof ventilator: Roof ventilators are activated from a certain minimum speed of the roof evaporator
blowers. In circulated air operation the roof ventilators are switched off.

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5. Maintenance / Service
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 (EC) 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 mal-
function 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
5.1. Oil change Compressor type KVX
Make first oil change at the first maintenance of the vehicle, 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 (see chapter: “Technical data compressor”).
5.2. Return air grid
Clean the return air grid in the passenger area monthly, in case of enormous dirt weekly.
5.3. Condenser coil
Always keep condenser coil fins clean. Severe soiling cause’s 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 severe soiling more often.

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5.4. Troubleshooting
- Only qualified staff is allowed to carry out these works! –
Trouble Cause Repair by authorized Service Station only
a/c is not
running
magnetic clutch / compressor is not
switched on
−
check inside temperature,,adjust new if
necessary 1
−check connections at magnetic clutch
electric connection disconnected
−
check electric connections at switch-
board
relay defective
−
check relay, replace if necessary
defrost thermostat has switched off
−
check evaporator blower, replace if nec-
essary
outside temperature too low (possible
icing of evaporator)
−
switch on „ventilation“ only
evaporator coil dirty
−
clean evaporator coil with compressed
air
compressor does not compress
−
check high and low pressure, replace
compressor if necessary
magnetic clutch
−
check connections at magnetic clutch
compressor does not compress
−
check high and low pressure, replace
compressor if necessary
excess pressure (pressure too high)
−
check axial fans
−check fuses at switchboard
−clean condenser coil with compressed
air
excess pressure caused by high out-
side temperature
−run unit until pressure has stabilized
1
leakage in a/c unit, lack of refrigerant
−
check a/c unit for leakages
−refill refrigerant
low pressure, dryer clogged
−
replace dryer
Loud noise at
compressor
defective bearing at compressor
−
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
6. Warranty Conditions
The current „General Warranty Conditions KONVEKTA AG“ will apply. A copy will be furnished by
the warranty department. Please contact [email protected]

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7. 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 man-
agement
•
Resolution (EC) No. 2037/2000 of the Euro-
pean Parliament and of the Council for mate-
rials that affect the ozone layer
•
Law of chemicals § 27 - penal prescrip-
tions
•
Resolution to prohibit certain ozone destroy-
ing 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
8. History of modification
Version
Date Name Remark File
A00 11.07.2007
B. Keßler
source file BAKL40T12AF
A01 21.11.2007
B. Keßler
Added item 1 and item 1.1 updated BAKL40T12AF
A02 21.04.2009
B. Keßler
Point 1.2 updated; TM31 replaced by HDC 33 BAKL40T12AF
A03 29.06.2016
B. Keßler
Added KL46T and technical data updated BAKL40T12AF
A04 01.03.2017
B. Keßler
Information on the operating instructions and
technical data expanded with F-gas-regulation
BAKL40T12AF
A05 30.11.2017
B. Keßler
Added KL46S and technical data updated BAKL40T12AF
A06 20.03.2018
B. Keßler
Point 1.1 HGX34e/315 deleted, added
KVX40/655K
BAKL40T12AF