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 Thermotronic
R134a
24V
Version:
•Return Air
ID#: BBA-KL60T12AD
Version: A06

BAKL60T12AD Edition: 18.07.2017 Page: 2/9
Contents
Page:
•Introduction .........................................................................................................................3
•Notes to the Operating instruction ....................................................................................4
1. Technical data..................................................................................................................4
1.1. Air conditioning units type KL60(T), KL65(T), KL70T, KL75T, KL80T, KL85T ....................4
1.2. Compressors .....................................................................................................................4
1.2.1. Type KVX40 ......................................................................................................................5
1.2.2. Type SD7H15 / HDC 33.....................................................................................................5
2. Intended use.....................................................................................................................5
2.1. General information A/C unit..............................................................................................5
2.2. Operating Conditions .........................................................................................................6
3. Operation..........................................................................................................................6
3.1. Function of the keys...........................................................................................................6
3.2. Operation of a/c system .....................................................................................................6
3.3. Temperature adjustment....................................................................................................6
4. Maintenance / Service .....................................................................................................7
4.1. Compressor type KVX .......................................................................................................7
4.2. Condenser coil...................................................................................................................7
4.3. Trouble shooting ................................................................................................................8
5. Warranty Conditions........................................................................................................8
Appendix:
 Maintenance Schedule 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 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 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.
The unit contains or needs fluorinated greenhouse gas for operation and is subject
to identification requirements in accordance with F-Gas Regulation 517/2014.

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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 type 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
Heater output Q=100 [W] 35.400 35.400 35.400 35.400 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 / / /
1.2. 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!
Compressor type depending on scope of delivery, see identification plate at compressor.

BAKL60T12AD Edition: 18.07.2017 Page: 5/9
1.2.1. Type KVX40
Compressor Type KVX40/470 KVX40/560 KVX40/655
Weight
1
)
35 kg 35 kg 35 kg
Oil brand / quantity (litres)
Esteröl SE55/2 Esteröl SE55/2 Esteröl SE55/2
Magnetic clutch
2)
24V DC 24V DC 24V DC
1.2.2. Type SD7H15 / HDC 33
Compressor Type SD7H15 HDC 33
Weight
7,5 kg 15,5 kg
Oil brand / quant
i
ty
PAG / corresponding 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 R134a 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.
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 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
Attention for
SD7H15:
Only clockwise rotation

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2.2. 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 cannot be ruled out. The cupper- and aluminium compo-
nents 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.
3. 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
3.1. Function of the keys
Operating elements are placed on dashboard:
S1
Switch ventilation Position
II
- ventilation fast
Position 0- OFF
Position I- ventilation slow
S2
Switch A/C on/off Position
0
- OFF
Position I - ON
Potentiometer
Temperature control Room temperature
3.2. Operation of a/c system
•Start vehicle engine (refer to orig. operating instruction of the vehicle).
•The air conditioner is switched on by means of switch „ S1- ventilation“ and „ S2- A/C“.
•Adjust air volume by means of switch „ S1- ventilation“ “Position „I“ resp. „II“.
•If only ventilation is requested, use „ S1- ventilation“
•By means of the „Potentiometer“ the required room temperature can be pre-chosen.
Note: The compressor can only operate, if switch „S2- A/C“.is in position „I“. If the desired tem-
perature is higher than the existing temperature or adjusted temperature is reached, compressor
switches off and condenser blowers stop running. If the desired temperature is lower than the ex-
isting temperature the compressor switches on.
3.3. Temperature adjustment
−The desired temperature is adjusted by means of the „Potentiometer“.
Potentiometer
S1 S2

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4. 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
4.1. Compressor type KVX
Reference to maintenance Schedule Bus No.: WP07050618 Item WK15:
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”).
4.2. Condenser coil
Reference to Maintenance Schedule Bus No.: WP07050618 Item WK10:
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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4.3. Trouble shooting
Only qualified staff is allowed to carry out these works!
Trouble Cause Repair by authorized Service Station

only
A/c is not
running
Thermostat open Check inside temperature

Re-adjust thermostat

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 neces-
sary
Outside temperature too low (possi-
ble icing of evaporator)
Switch on "ventilation" only
Evaporator coil dirty Clean evaporator coil with compressed air
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
Excess pressure (pressure too high) Check axial fans
Check fuses at switchboard
Clean condenser coil with compressed air
Low pressure, dryer clogged Replace dryer
Low pressure, screen of expansion
valve clogged
Clean screen; replace dryer
Magnetic clutch Check connections at magnetic clutch
Compressor does not compess Check high and low pressure, replace com-
pressor if necessary
Loud noise
at com-
pressor
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 operator
5. Warranty Conditions
The current „General Warranty Conditions” KONVEKTA AG“ will apply. A copy will be furnished by
the warranty department. Please contact [email protected]

BAKL60T12AD Edition: 18.07.2017 Page: 9/9
6. 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
7. History of modification
version
date name remark file
A01 27.05.04 Pfluger Added unit KL70T-B BAKL60T12AD
A02 04.10.04 Pfluger Added unit KL85T, changed name from KL70T-B to
KL75T BAKL60T12AD
A03 28.11.05 Pfluger Updated Item
4. / 5. BAKL60T12AD
A04 22.10.2007
B.Keßler Delete KL50(T), HKL5CT-HKL7CT and item 1.2 and
1.3.1; updated item 1.3; added item 2.2 BAKL60T12AD
A06 18.07.2017
B.Keßler File completely updated BAKL60T12AD