KONVEKTA KL60 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 units
KL60 up to KL85T
with control KS310
R134a
24 Volt DC
Versions:
−Recirculated Air
−Fresh Air
−Heating
ID#: BBA-KL60T12AE
Version: A02

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Contents
ContentsContents
Contents
Page:
•Introduction .........................................................................................................................3
•Information on the operating instructions ........................................................................4
1. Technical data..................................................................................................................4
1.1. Air conditioning units KL60 (T), KL65 (T), KL70T, KL80T...................................................4
1.2. Technical data compressors ..............................................................................................4
1.2.1. Type KVX40 ......................................................................................................................5
2. Determined use................................................................................................................5
2.1. General information a/c unit ...............................................................................................5
2.2. Operating Conditions .........................................................................................................5
3. Operation..........................................................................................................................6
3.1. Description of display.........................................................................................................6
4. Description keys driver’s seat ........................................................................................7
5. Operation passengers compartment..............................................................................8
6. Generally Adjustments....................................................................................................9
6.1.1. Time adjustment ................................................................................................................9
6.1.2. Adjust starting time of the additional heating......................................................................9
7. Maintenance / Service ...................................................................................................10
7.1. Period of maintenance .....................................................................................................10
7.2. Oil change Compressor type KVX....................................................................................10
7.3. Return air grid..................................................................................................................11
7.4. Condenser coil.................................................................................................................11
7.4.1. Read trouble memory ......................................................................................................11
7.5. Self-test ...........................................................................................................................11
7.6. Troubleshooting ...............................................................................................................12
8. Warranty Conditions......................................................................................................12
9. Waste disposal in accordance with legal provisions ..................................................13
10. History of modification..................................................................................................13
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 con-
tract the safety instructions get integral 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 compli-
ance with these operating instructions increases operation reliability and service life of the air con-
ditioning unit and reduces life cycle costs.
Please complete these instructions by adding the national provisions for pre-
vention 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 improp-
er handling, inadequate maintenance, applications that do not correspond with the deter-
mined use, utilization of none-admitted fuels or the non-observance of safety provisions.
KONVEKTA will annul without prior 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 condi-
tioning unit. In case you need more explanations, please contact the next KONVEKTA ser-
vice 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 air conditioning unit’s type:
•
KL60
•
KL60T
•
KL65
•
KL65T
•
KL70T
•
KL75T
•
KL80T
•
KL85T
When taking the unit into operation we recommend adding the following data. This will also be
important 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.

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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)
1.1. Air conditioning units KL60 (T), KL65 (T), KL70T, KL80T
Type of Unit
KL60
KL60T
KL65
KL65T
KL70T
KL75T
KL80T
KL85T
Operating voltage
[V] 24 24 24 24 24 24 24 24
Refrigerant Typ R134a R134a R134a R134a R134a R134a R134a R134a
· quantity approx. [kg] 10 11 12 12 12,5 12,5
Current consumption
[A] 78 95 78 87 95 95 95 95
Cooling capacity at +42°C 25.800 / / /
Cooling capacity at +50°C [W] / 28200 26.200 30.000 33000 33.000 38000 38000
Heating capacity Q=100 [W] 35.400 35400 35.400 35.400 45000 / / /
Air volume [m3/h] 6.600 6.600 6.600 6.600 6.600 6.600 6.600 6.600
Measurements:
- length [mm] 3.675 4.175 4.175 4.175 4.545 4.545 4.545 4.545
- width [mm] 1.352 1.352 1.892 1.892 1.352 1.892 1.352 1.892
- hight [mm] 200 200 185 185 200 185 200 200
Weight of unit, Type:
- Return Air [kg] 155 175 190 220 200 220
- Fresh Air [kg] 160 182 200 220 210 220
- Heating [kg] 170 190 205 / /
1.2. Technical data 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 condi-
tioning unit is not used!

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1.2.1. Type KVX40
Compressor Type KVX40/470 KVX40/560 KVX40/655
Weight
1)
35 kg 35 kg 35 kg
Oil brand / quantity (liter)
Ester oil SE55/2 Ester oil SE55/2 Ester oil SE55/2
Magnetic clutch
2)
24V DC 24V DC 24V DC
1)
Weight without Electro-magnetic clutch (witch clutch app. + 10kg).
2)
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 Op-
erating instruction and the proof of regular inspections as well.
2.1. 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 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 windows/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 contaminants. If the outside air is contaminated
with gas, switch over to return air operation. The filter should be cleaned or replaced respective-
ly on a regular basis so that the capacity of the a/c unit is not affected.
−If you think that the air conditioning unit has been damaged switch it off immediately in order to
avoid further damage. The air conditioning unit may be taken into operation again only after it
has been checked at a 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.
2.2. Operating Conditions
NOTE:
KONVEKTA uses components made of copper and aluminium, which last a whole unit lifetime un-
der normal environmental conditions. Should the units be operated under aggressive environmen-
tal conditions, i.e. air containing salt-, phosphate- or ammoniac extremely, a corrosion of the cup-
per- and aluminium components cannot be ruled out. The cupper- and aluminium components of
the KONVEKTA systems are not suitable for such extreme application conditions. We indicate em-
phatically, 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.

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3. Operation
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 accelerate the
cooling down process. It possibly damages the control panel and so affects the general perfor-
mance of the air-conditioning unit
3.1. Description of display
At the display different symbols and numbers can be shown. By the green night illumination the
display is clearly readable at night. The operation is easy and clear
Symbols of driver’s seat
- function defrost wind shield
- activate a/c front box
- front box blower 7-stages
- air distribution at the wind shield
- air distribution drivers center
- air distribution at the foot space
- circulated air flap
- four-digit set / Actual – temperature control (degree or Fahrenheit)
Symbols of display
- time
- outside temperature
- faults code
- software version
- further adjustments
Symbols of passengers compartment
- Function automatic
- Function ECO
- Function Reheat
- Function convector
- Function compressor active
- Function stand-by heating activated
- circulated air flap
- evaporator blower 7-stages
- four-digit SET / Actual – temperature control (degree or Fahrenheit)

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4. Description keys driver’s seat
Key Function
S1
Air distribution/ De-
frost
Air distribution at the wind shield.
Front box blower wind shield active.
Prolonged activation of key:
Activation of the defrost –function for the front windshield blower switches
to 100% air volume.
Water valve opened 100%, front box is activated.
After turning off the DEFROST function, the settings switch back to the
function that was chosen before DEFROST function.
S2
Air distribution
Air distribution to the center.
Front box blower wind shield active.
Front box blower foot area active.
S3
Air distribution
Air distribution to the foot area.
Front box blower foot area active.
S4
Front box a/c
Activate front box a/c
The front box a/c can only be activated together with compressor ON.
S5
Return air flap
Operate the recir. air flap
Activation of return air flap.
Flap turns back to fresh air after 10 minutes.
S6
Blower
Adjust air volume
Setting of the front box blower is made in 7 stages.
When ignition is ON, the blower is limited to stage 3.
S7
Temp. adjustment
Adjustment of air delivery temperature
AUTO:
The desired temperature can be set in 10 stages from 10 to 90°C.
The temperature around the driver’s seat can be settled constantly by
proper positioning of the sensor in the front box.

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5. Operation passengers compartment
Key Function
S8
Blower
Manual adjustment of air volume
The adjustment of the evaporator blower is made in 7 stages.
When ignition is ON the blower is limited to stage 3.
Infinitely variable:
In case of infinitely variable evaporator blower the 7 stages in the software
are divided in 7 stages.
The speed of rotations modules are controlled infinitely variable in AUTO.
S9
Temperature ad-
justment
Adjustment of room temperature
The desired temperature can be set from 15 to 26°C.
By starting AUTO manually the desired temperature is set to a default-
value of 23°C
Emergency operation:
MAX: Via prolonged activation of key (+) or (-), the MAX. refrigeration or
heating is activated.
The automatic control is therefore deactivated.
Emergency operation is indicated in the display with the bars above or be-
low.
S10
Automatic
Automatic ON / OFF
Resetting and starting of the automatic control system in the passenger
compartment.
The automatic controls heating, ventilation and refrigeration depending up-
on the desired and actual temperature.
Via manually activation of AUTO the desired temperature is set to a default
value of 23°C.
The manual adjustments of the evaporator blower are canceled. With AU-
TO the a/c compressor switches off at an outside temperature of less than
8°C.
S11
Reheat
Activate REHEAT – function
With Reheat the compressor is switched on to dehydrate the air inside the
vehicle.
The roof heating system runs in order to maintain the temperature constant
inside the vehicle.
After 20min the Reheat function switches off automatically to AUTO.
With Reheat the a/c compressor switches off at an outside temperature of
less than 4°C.
S12
Eco
Compressor is stopped manually
In Reheat and AUTO function compressor is always blocked
S13 -Option
Convectors
Convector heating /driver’s seat heating is ready for operation
With key AUTO the regulation of the convector heating/ driver´s seat heat-
ing is ready for operation. With an outside temperature of 23°C (75 F) and
more the convectors are locked.
The desired temperature for the convectors is identically with the adjusted
room temperature.

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Key Function
S14
Programming
Change display from time to the outside temperature
By pressing key S14 the display indication changes from time to the out-
side temperature.
ICE WARNING FUNCTION:At an outside temperature less than 2°C dis-
play flashes up.
S15
Return air flap
Circulated air flap is manually brought to the circulated air position
Flap turns back to fresh air after 10 minutes.
S16 -Option
Additional heating
Adjustment of additional heating
Simultaneously the convector control is put in readiness.
6. Generally Adjustments
6.1.1. Time adjustment
Key Function
S1
+
S14
S9
With ignition OFF the time can be programmed.
By simultaneous pressing of S1 and S14 at display time flashes up.
With key S14 you choose the position, with key S 9 you can change the
position.
The weekday [day] is only needed when the additional heater should start
on a defined day.
1 = Monday 2 = Tuesday 3 = Wednesday 4 = Thursday
5 = Friday 6 = Saturday 7 = Sunday
After programming the time, the display switches back automatically
after 5 sec. to the time indication.
6.1.2. Adjust starting time of the additional heating
Key Function
S1
+
S16
S9
With ignition „OFF” the starting time of the additional heating can be
programmed
Via pressing simultaneously keys S 1 and S 16 the starting time is blinking.
With key S 16 you choose the position, with key S 9 you can change posi-
tion
Programming without day:
If start of the additional heating system should not depend from the week-
day, the adjustment is “0” (default adjustment) (every day).In the pre-
selection you have to enter the starting time and with ON / OFF you have
to choose, whether the additional heating systems should start the follow-
ing day.

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Key Function
Programming with day:
If the additional heating system should start on defined days, it has to be
programmed for the respective day (1-7 Monday to Sunday).
In the pre-selection you have to enter the starting time and day and with
ON / OFF you have to choose, whether the additional heating system
should start on the chosen day.
Seven different times can be programmed, for example:
Pre-selected time 1: MO 8.00 h
Pre-selected time 5: FR 8.00 h
Pre-selected time 2: TU 6.00 h
Pre-selected time 6: SA 9.45 h
Pre-selected time 3: WE 7.30 h
Pre-selected time 7: SU 9.00 h
Pre-selected time 4: TH 5.00 h
After programming the starting time and additional heating system, the dis-
play switches back automatically after 5 sec. to the time indication.
If a pre-selection is activated, at setting “ignition OFF” additionally to the
time indication the next starting time appears on the display.
7. 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 (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 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
7.1. Period of maintenance
At least once a year - only by refrigerant expert
1)
•Check unit for leakages.
•Retighten fixing screws of compressor and bracket at the engine.
•Check electrical connections.
•Check refrigerant Level at sight glass. (If air bubbles are formed - consult service station)
•Check hoses and electric cables on possible damages.
•exchange drier
•Check blower motors and fans at evaporator and condenser
7.2. Oil change Compressor type KVX
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 Technical data, point 1.2.1).

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7.3. Return air grid
Clean the return air grid in the passenger area monthly and in case of enormous dirt weekly.
7.4. Condenser coil
Make sure that fins of condenser are clean. In case of enormous dirt the over pressure starts to be
built up inside the air conditioning system which leads to an automatic operating interruption.
Note:
Regular cleaning should be executed 2 times per year. In case of enormous dirt more than 2
times (blow through the condenser coil with compressed air).
7.4.1. Read trouble memory
Key Function
S1
+
S10
S9
With ignition „OFF” the trouble memory can be read at the display. With
keys S1+S10 the actual fault can be shown [E 20].
With key S10 the fault can be deleted.
With key S9 the next fault can be shown.
If there is no defect, the display shows E---.
If an error is indicated, please let the unit check immediately by a “KONVEKTA service
station”.
7.5. Self-test
If the voltage supply is interrupted, the unit runs a self-test after applying voltage. During
the self-test all inputs and outputs are checked.
If the sub-stations are not connected with the control unit after applying voltage, they will
switch over to emergency operation.
Roof-top station:
- Blower on low level
- Circulated air flap on circulated air
Water station:
- Additional heating ON

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7.6. Troubleshooting
Only qualified staff is allowed to carry out these works!
Trouble Cause Repair only by refrigeration expert
A/c is not
running
Electric wiring disconnected Check wiring at switch plate
Relay defective Check relay and replace, if necessary
Defrosting thermostat cuts off Check evaporator blower and replace, if
necessary
Too low outside temp.
(possible icing of evaporator)
Switch on "ventilation" only
2)
Dirt on evaporator coil Clean evaporator coil with compressed air
Too high pressure Check if axial fans are running
Check fuses
Clean condenser coil with compressed air
Too high pressure caused by high
outside temperature
Let unit run until pressure is stabilized
2)
Leak in unit, deficiency or refrigerant Check unit for leaks
Recharge refrigerant,
Low pressure, drier clogged Replace drier
Too low pressure, screen of expan-
sion valve clogged
Clean screen; renew drier
Strong noise
at compres-
sor
Slack V-belt Check V-belt at compressor drive
Magnetic clutch Check connections at magnetic clutch
Compressor does not compress Check pressure at suction and pressure
side, possibly exchange compressor
Defect bearing on compressor. Replace ball bearing or complete compres-
sor only
 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 operator
8. 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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9. Waste disposal in accordance with legal provisions
After the phase of use the last proprietor is responsible for the adequate waste manage-
ment. 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 „cri-
minal acts against the environment”
§326 – Environment jeopardizing waste
management
•
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 pre-
scripttions
•
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
10. History of modification
Version
Date Name Remark File
A00 20.10.2003
Pfluger Source file BAKL60T12AE
A01 29.10.2007
B.Keßler Facts of units HKL7T-HKL8T killed; facts of KV4-KV6
killed, facts of KL65(T),KL75T, KL85T, item 1 and 0
added; item 1.2 and general texts updated
BAKL60T12AE
A02 12.07.2017
B. Keßler File completely updated. BAKL60T12AE