KONVEKTA KL60 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
Operating Instruction
for KONVEKTA air conditioning
units
- KL60 - KL70T
- KL80T
Version:
−12 / 24 Volt DC
−Recirculated Air
with control KS60/12V
ID#:
ID#: ID#:
ID#: BBA
BBABBA
BBA-
--
-KL5C232AA
KL5C232AAKL5C232AA
KL5C232AA
Version: A02
Version: A02Version: A02
Version: A02

BAKL5C232AA.doc Edition: 05.04.2011 Page: 2/11
Contents
Page:
•Introduction .........................................................................................................................3
•Notes to the Operating instruction ....................................................................................4
1. Technical data ....................................................................................................................5
1.1. Air conditioning unit............................................................................................................5
1.2. Pressure Switches .............................................................................................................5
2. Intended use .......................................................................................................................6
3. General information a/c unit ..............................................................................................6
3.1. Operating elements............................................................................................................6
4. Operation ............................................................................................................................7
4.1. Operation panel / function of the keys ................................................................................7
4.2. Operation of a/c system .....................................................................................................8
4.3. Adjustment of temperature.................................................................................................8
4.4. Storing of functions ............................................................................................................8
5. Maintenance / Servicing.....................................................................................................9
5.1. Return air grid ....................................................................................................................9
5.2. Condenser coil...................................................................................................................9
5.3. Troubleshooting ...............................................................................................................10
6. Warranty Conditions ........................................................................................................11
7. Adequate waste management .........................................................................................11
History of modification...........................................................................................................11
Append.:
 Maintenance Schedule WP07050618

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Introduction
These operating instructions are for driver, user and maintenance staff of a/c-unit.
It contents:
•Operating instructions
•Safety information
•Maintenance Schedule
Each person who is involved in handling the a/c-unit has to read and make use of these
operating instructions, before first start-up and after that regularly, e.g.:
•Operation including troubleshooting, maintenance and disposal of fuels and auxilia-
ries agency.
•Servicing (maintenance, inspection, repair)
•Transport
This makes the user’s training easier and troubles by improper handling will be avoided.
Compliance with the operating instruction by the maintenance personnel increases the
reliability during operation, increases the life time and reduces expenses for repair and
loss of time.
Add national orders to this operating instruction for accident prevention and
environment protection.
The Operating instruction is a part of your a/c-unit.
Always have a copy at hand in.
You will certainly understand that we will not recognize any warranty claims due to im-
proper handling, inadequate maintenance, applications that do not correspond to the de-
termined use, utilization of not admitted fuels, or the non-observance of security pre-
scriptions.
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.
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.

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Notes to the operating instruction
This Operating instruction is valid for the air conditioners type:
•KL60 /12V
•KL70T/24V
•KL80T/24V
When taking the unit into operation we recommend to add the following data.
This will also be important for your orders of spare parts, and in case of warranty.
Serial number of the a/c unit:...............................................
Order No.: ..................................................
Year of construction: .................................................. (MM/JJ)
Date of first operation: .................................................. (TT/MM/JJ)
The machine corresponds to the security prescriptions of the EC # 89/392/EWG
i.d.F. 91/368/EWG and 93/44/EWG.
Due to the fact that scope of supply depends on the order, equipment of your prod-
uct may differ in some parts of description.
In case your product is equipped with details not shown or described in the operat-
ing instruction, your KONVEKTA -Service-Station will always be at disposal for in-
forming you about correct operation.
In the course of further developments we reserve the right to technical modifications with-
out 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: KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt

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1. Technical data
1.1. Air conditioning unit
Type KL60 KL70T KL80T
Refrigerant R134a R134a R134a
- quantity approx. lbs
[kg]
22.1
[10]
26.5
[12]
27.6
[12.5]
Operating voltage Volt DC 12 24 24
Current consumption Ampere 129 95 95
Cooling capacity BTU/h
[Watt]
88090
[25800]
113000
[33000]
130000
[38000]
Air volume
@ 0 static pressure
[CFM]
[m
3
/h]
2825
4800
3885
6600
3885
6600
Measurements:
- length inch
[mm]
144.7
[3675]
178.9
[4545]
178.9
[4545]
- width inch
[mm]
53.2
[1352]
53.2
[1352]
53.2
[1352]
- height inch
[mm]
9.1
[230]
9.1
[230]
9.1
[230]
- weight lbs
[kg]
341.7
[155]
418.9
[190]
440.9
[200]
1.2. Pressure Switches
Type of switch Part no Switch-off pressure Switch-on pressure
Low pressure H11-001-357 0.3 ± 0.1 bar off 2.1 ± 0.2 bar on
Excess pressure H11-001-358 25.5 ± 0.5 bar off 18.0 ± 0.5 bar on

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2. Intended use
The KONVEKTA air conditioning unit is an air conditioning system that works with the ozone friendly refrig-
erant 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.
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 windows.
−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 ba-
sis 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.
3.1. Operating Conditions
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 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 conse-
quential damage resulting there from, nor for damages caused by cleaning the systems with highly com-
pressed or corrosion advancing substances.
3.2. Operating elements
The air conditioning control KS60 is a control and regulation device for air conditioners in modern buses.
The bus driver is relieved from all questions of an optimum air conditioning in the passengers’ compartment
by a simple and clear handling. All functions of the a/c unit are adjustable by different key-buttons. Every
button has an indicating lamp, called LED used as a control function of the buttons or in case of operating.
LED is shining red if button is pressed or if unit is in operation. Control board KS60 is connected onto the
original dash board lightning of the vehicle. This means that in case of running vehicle lamp, night lightning
of control board (LED green) is also activated.
Auto-test
If voltage supply to unit is interrupted, unit starts a self test immediately after reset. All in- and outlets are
checked. After self-test, actual temperature can be read on display (if ignition is ON), or…
if ignition is OFF an LED flashes on display.

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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4. Operation with control KS60
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 per-
formance of the airconditioning unit.
4.1. Operation panel / function of the keys
Short.
Function
D1 3-figure display
S1 required room temperature can be adjusted (increase) 59 to 82.4°F
S2 required room temperature can be adjusted (decrease) 59 to 82.4°F
S3 required air volume can be adjusted (increase), step 1 or 2 -manually
S4 required air volume can be adjusted (decrease), step 1 or 2 -manually
S5 A/C automatic (A/C ON/OFF)
S1
D1
S3
S5
S2
S4
S6
-
OUT OF FUN
C
TION
Control KS60/12V,
Part no.:
H11-005-401

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4.2. Operation of a/c system
−Start vehicle engine (refer to orig. operating instruction of the vehicle).
−The air conditioner is activated by means of key „ a/c automatic“ , LED inside key button is
indicated. Pressing key S5 again, air conditioner switched off. The blowers are regulated auto-
matically.
−With key or the required air volume can be adjusted manual.
ATTENTION:
In case of trouble in the a/c cooling circuit the LED-display (key S5, see 5.3) is lighting
up. Operation of the a/c system only after verification by qualified a KONVEKTA-Service-
Station

.

see hand book :“KONVEKTA Service Stations“
4.3. Adjustment of temperature
If a/c-unit is operating, vehicle inside temperature can be adjust with key or , in a range of
59°F up to 82.4°F. In case of operating key (+) or (-), temperature can be increased or reduced.
The actual temperature can be read on display.
4.4. Storing of functions
If ignition is turned off, the following data will be stored always:
-AUTO – function
-Desired temperature

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5. 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.
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.
- 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 ac-
cordance with EN 378-Part 4 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 acci-
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, P.O. Box 2280, D-34607 Schwalmstadt
5.1. Return air grid
Clean the return air grid in the passenger area monthly. In case of enormous dirt weekly.
Important:
- If the filter is soiled, the cooling performance of the air conditioner will decrease.
In case the a/c unit will be operated continuously with dirty filter, the evaporator blowers and
cooling compressor will be damaged
- It is not allowed to operate the air conditioner without filter.
- If filter is defective, filter must replace!
5.2. 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 severe soiling more often.

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5.3. Troubleshooting
- Only qualified staff is allowed to carry out these works! -
Trouble Cause Repair
only by refrigeration expert

a/c is not
running
thermostat open
•check inside temperature
•re-adjust thermostat


electric connections discon-
nected
•check electric connections at
switchboard

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 run, until pressure ishas stabi-
lized

leakage in a/c unit, lack of re-
frigerant
•check a/c unit for leakagess,
•recharge r fill refrigerant

low pressure, dryer clogged •replace dryer

low pressure, screen of expan-
sion valve clogged •clean screen; replace dryer

magnetic clutch •check connections at magnetic clutch

compressor does not compress •check high and low pressure, replace
compressor if necessary

Loud noise
at compres-
sor
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

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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]
7. Adequate waste management
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 re-
moval
Resolution for the waste management of old cars and
the adaptation of road prescriptions
Criminal Code (StGB) 28th section „criminal acts
against the environment” §326 - Environment
jeopardizing waste management
Resolution (EWC) No.3093/94 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 prescriptions
and regulations are to be followed . Only skilled personnel is allowed to carry out these works!
Water endangering substances - acc. to §§19g-19l - are solid, liquid, and gaseous substances. e.g.: min-
eral and tar oils (cooling oils), halogen containing organic combinations (refrigerants)
8. History of modification
ver-
sion date name remark file
A00 10.07.06 Pfluger source file BAKL5C232AA
A01 04.10.07 Pfluger Added units KL70T & KL80T/24V, Temperature in Fahren-
heit
Canceled techn.data unit HKL5CT
BAKL5C232AA
A02 19.02.09 Pfluger Modified techn.data KL60 BAKL5C232AA