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,
P700 und P800
with control KS60
R134a
24 Volt DC
Versions:
−Recirculated Air
−Fresh Air
−Heating
ID#:
ID#: ID#:
ID#: BBA
BBABBA
BBA-
--
-KL60T12AB
KL60T12ABKL60T12AB
KL60T12AB
Ve
VeVe
Version: A10
rsion: A10rsion: A10
rsion: A10

BAKL60T12AB Edition: 19.07.2017 Page: 2/10
Contents
Page:
•Introduction .........................................................................................................................3
•Notes to the Operating instruction ....................................................................................4
1. Technical data..................................................................................................................4
1.1. Air conditioning units KL60(T), KL65(T), KL70T, KL75T, KL80T, KL85T............................4
1.2. Air conditioning units P700 and P800 ................................................................................5
1.3. Compressors .....................................................................................................................5
1.3.1. Type KVX40 ......................................................................................................................5
1.3.2. Type SD7H15 / HDC 33.....................................................................................................5
2. Intended use.....................................................................................................................5
3. General information a/c unit ...........................................................................................6
4. Operating elements .........................................................................................................6
4.1.1. Auto-test ............................................................................................................................6
5. Operation..........................................................................................................................7
5.1. Operation panel / function of the keys................................................................................7
5.2. Operation of a/c system .....................................................................................................7
5.3. Adjustment of temperature.................................................................................................7
5.4. Recirc. Air operation => only in case of a/c units with Rec. air flaps option ........................8
5.5. REHEAT activate / stop .....................................................................................................8
5.6. Display of air duct temperature ..........................................................................................8
5.7. Indicate outside temperature => only in case of a/c units with heating option ....................8
6. Maintenance / Servicing ..................................................................................................8
6.1. Oil change Compressor type KVX......................................................................................9
6.2. Return air grid....................................................................................................................9
6.3. Condenser coil...................................................................................................................9
6.4. Troubleshooting .................................................................................................................9
7. Warranty Conditions......................................................................................................10
8. Waste disposal in accordance with legal provisions ..................................................10
9. History of modification..................................................................................................10
Appendix:
Maintenance Schedule Bus WP07050618

BAKL60T12AB Edition: 19.07.2017 Page: 3/10
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 units’ type:
•KL60 •KL60T •KL65 •KL65T •KL70T •KL75T
•KL80T •KL85T •P700 •P800
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)

BAKL60T12AB Edition: 19.07.2017 Page: 4/10
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)
1.1. Air conditioning units KL60(T), KL65(T), KL70T, KL75T, KL80T, KL85T
Type
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 +50°C [W] 25.800 28.200 26.200 30.000 33.000 33.000 38.000 38.000
Heizleistung Q=100 [W] 35.400 35.400 35.400 45.000 45.000 / / /
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] 185 185 185 185 185 185 185 185
Weight of unit approx.:
- Return Air [kg] 155 175 190 220 200 220
- Fresh Air [kg] 160 182 200 220 210 220
- heating
[kg] 170 190 205 / / /

BAKL60T12AB Edition: 19.07.2017 Page: 5/10
1.2. Air conditioning units P700 and P800
Type
P 700
P 800
Operating voltage [V] 24 24
Refrigerant Typ R134a R134a
· quantity approx. [kg]
Current consumption [A] 104 136
Cooling capacity at +50°C [W] 33.000 39.000
Heating capacity Q=100 [W] 38.000 48.000
Air volume [m3/h] 6.480 8.640
Measurements:
- length [mm] 2.680 3.200
- width [mm] 2.100 2.100
- height [mm] 220 220
Weight of unit, Type:
- Return Air [kg]
- Fresh Air [kg]
- Heating
[kg]
1.3. 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 conditio-
ning unit is not used!
Compressor type depending on scope of delivery, see identification plate at compressor.
1.3.1. Type KVX40
Compressor Type
KVX40/470
KVX40/560
KVX40/655
Weight
1)
35 kg 35 kg 35 kg
Oil brand / quantity (liter)
Esteröl SE55/2 Esteröl SE55/2 Esteröl SE55/2
Magnetic clutch
2)
24V DC 24V DC 24V DC
1.3.2. Type SD7H15 / HDC 33
Compressor Type
SD7H15
HDC 33
Weight 7,5 kg 15,5 kg
Oil brand / quantity PAG / correspond-
ing to version
3)
ZXL
100PG/500cm³
Magnetic clutch
2)
24V DC 24V DC
1)
Weight without Electro-magnetic clutch (witch clutch app. + 10kg).
2)
ø depending on vehicle type
3)
List is attached to compressor,( Instruction no: TD00031A)
2. Intended use
The KONVEKTA air conditioning unit is an air conditioning system that works with the ozone
friendly refrigerant R 134a and which creates a pleasant and individually adjustable room tempera-
ture by means of forced convection. The determined use includes also the observance of the oper-
ating instructions as well as the proof of regular inspections.
Attention for SD7H15:
Only clockwise rotation

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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 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
4. 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 passen-
gers’ 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.
☛Note:
We recommend driving with automatic mechanism (Key S5, see 5.1). Additionally to the automatic
the following functions can be activated:
a) SMOG-flap manually, in order to prevent the entrance of exhaust fumes (in tunnels)
b) REHEAT-function to dehydrate the steamed up wind shield
4.1.1. Auto-test
If voltage supply to unit is interrupted, unit starts a self test immediately after reset. Here all en-
trances and exits are controlled:
Process of auto test will be show at the display:
1. Indication of all LED’s and display indication -88
2. Indication Software version: 03
3. Indication Configuration (DIP-Code, for example:)08
4. Indication of auto-test code 01, 02... etc.
After self-test, the actual temperature can be read on display.

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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. Operation panel / function of the keys
Short.
Function
D1
3-figure display
S1
required
room temperature
can be adjusted (increase) 16 to 28°C
S2
required
room temperature
can be adjusted (decrease) 16 to 28°C
S3
required
air volu
me
can be adjusted (increase), step 1 or 2 (resp. stepless adjustment)
S4
required
air volume
can be adjusted (decrease), step 1 or 2 (resp. stepless adjustment)
S5
A/C automatic
(A/C ON/OFF)
S6
Recirculated Air operation
Close resp. Open. Recirculated air flap; in case of closed recirculated air flap, LED in-
side key button is indicating.
5.2. 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) is lighting up. Operation of
the a/c system only after verification by qualified 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
5.3. Adjustment of temperature
If a/c-unit is operating, vehicle inside temperature can be adjust with key or , in a range of
16°C up to 28°C. In case of operating key (+) or (-), temperature can be increased or reduced. The
actual temperature can be read on display.
S1
D1 S3 S5
S2 S4 S6

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5.4. Recirc. Air operation => only in case of a/c units with Rec. air flaps option
In case of recirculated air operation (key S6 activated), the income of fresh air is interrupted and
the air inside the vehicle is going to be circulated which avoids that outside air, possibly dirty be-
cause of exhaust fumes (tunnel driving) has a chance to penetrate into interior room of the vehicle.
Start of the recirculated air operation: Press key S6, the LED-display will light up. This position
should not be adjusted very long. If windows are misting up, return air operation should be
switched off: If key S6 is pressed again the return air flap will be reactivated and fresh air opera-
tion restarted. The LED-display will go out.
Automatic: In case of a temperature difference of more than 5°C between the set temperature
(adjusted value) to the existing temperature the return air flaps switch to recirculated air operation.
Manual: If the button S6 is pressed, the recirculated air function of the return air flaps will be main-
tained independently from a temperature difference.
5.5. REHEAT activate / stop
=> Only for units with heating option.
Switching on of the air-conditioning system via button S5 afterwards the key S5 will be pressed
shortly twice (double click). REHEAT will be activated for a period of 20 minutes, the LED-display
will light up at the same time.
⇒Operation of the blowers at the highest speed level by key S3 (increase of the air flow output)
⇒Recirculated air operation must be switched off.
The premature termination of the REHEAT is possible by double-pressing the key S5.
5.6. Display of air duct temperature
=> Only for units with heating option.
While pressing buttons S1 and S6 actual air duct temperature is displayed for 2 seconds.
5.7. Indicate outside temperature => only in case of a/c units with heating option
=> Standard for units with heating, optional for units without heating starting software version 3.
While pressing buttons S1 and S4 actual outside temperature is displayed for 2 seconds.
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 mal-
function and so endanger operational reliability. We recommend having all works and modifications
carried out at an authorized KONVEKTA Service Station

. The same applies to the regular
maintenance works as prescribed and specified in the maintenance certificate.
Before carrying out any maintenance works at your air conditioning unit, carefully read the
KONVEKTA 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

BAKL60T12AB Edition: 19.07.2017 Page: 9/10
6.1. 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 chapter: “Technical data compressor”).
6.2. 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.
- It is not allowed to operate the air conditioner without filter.
- If filter is defective, filter must replace!
- In case the a/c unit will be operated continuously with dirty filter, the evaporator blowers will be
damaged
- Due to a reduction of the evaporator air flow, the a/c function „defrosting“ will be activated more
often resulting in a decrease of the cooling capacity and damage of the cooling compressor!
6.3. 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.
6.4. Troubleshooting
- Only qualified staff is allowed to carry out these works! -
Trouble
Cause
Repair
only by refrigeration expert

a/c is not run-
ning
magnetic clutch / compressor is not
switched on
check inside temperature, adjust new if nec-
essary 
check connections at magnetic clutch
electric connections disconnected 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 (possi-
ble 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 flash-
es up
excess pressure caused by high out-
side temperature run unit until pressure has stabilized
leakage in a/c unit, lack of refrigerant
check a/c unit for leakages, refill refrigerant
low pressure, dryer clogged replace dryer
low pressure, screen of expansion
valve clogged clean screen; replace dryer
compressor does not compress check high and low pressure, replace com-
pressor if necessary
Loud noise at
compressor
defective bearing at compressor replace either bearing or entire compressor
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

BAKL60T12AB Edition: 19.07.2017 Page: 10/10
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 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 „crimi-
nal acts against the environment” §326 –
Environment jeopardizing waste manage-
ment
•
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 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
9. History of modification
V
ers
i
on
D
ate
N
ame
R
emark
F
ile
A01 03.12.02 Pfluger Added units HKL50T and HKL60T. BAKL60T12AB
A02 30.09.03 Pfluger Removed in chapter 5.4: automatic adjustment to recirculat-
ed air operation in case of high outside temperatures
(28°C); added text recirc. Air flap with automatic and manu
al
mechanism; Added unit KL70T-B.
BAKL60T12AB
A03 25.11.03 Pfluger Added units HKL7T and HKL8T BAKL60T12AB
A04 17.03.04 Pfluger Added unit HKL6T BAKL60T12AB
A05 04.10.04 Pfluger Added unit KL85T, changed name from KL70T-B to KL75T BAKL60T12AB
A06 21.06.05 Pfluger Updated Item
6. / 7. BAKL60T12AB
A07 06.10.05 Pfluger Chapter 2.9: Display of outside air temperature: starting
software version 3- optional for units without heating BAKL60T12AB
A08 23.10.2007
B.Keßler Technical facts updated; KL50(T) and units HKL5CT and
HKL7CT killed; facts of KV4-6 killed; added units P700 and
P800; added item 1 and 1.3 “important”
BAKL60T12AB
A09 29.04.2009
B. Keßler
1.4.2 TM31 replaced by HDC 33. BAKL60T12AB
A10 19.07.2017
B. Keßler
File updated (F-gas….) BAKL60T12AB