KONVEKTA KL60 User manual

Konvekta AG
Am Nordbahnhof 5
34613 Schwalmstadt
Germany
+49 ( 0 ) 66 91 / 76
– 0
+49 ( 0 ) 66 91 / 76
– 200
[e-mail]
www konvekta com
Operating Instruction
for KONVEKTA air conditioning unit
KL60
Version:
12 Volt DC
2-circuit
Recirculated Air / Fresh Air
Heating
with control KS60/12V
ID#: BBA-KL60222AB
Version: A00

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 2/13
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 Conditions...........................................................................................................6
4. Operation with control KS60...............................................................................................7
4.1. General information .............................................................................................................7
4.2. Operation panel / function of the keys .................................................................................8
4.3. Storing of functions..............................................................................................................8
4.4. Operation of a/c system.......................................................................................................9
4.5. Adjustment of temperature...................................................................................................9
4.6. Recirc. Air operation ............................................................................................................9
4.7. REHEAT activate / stop.....................................................................................................10
4.8. Display of air duct temperature..........................................................................................10
4.9. Indicate outside temperature => only in case of a/c units with heating option...................10
5. Maintenance / Servicing....................................................................................................11
5.1. Return air grid....................................................................................................................11
5.2. Condenser coil...................................................................................................................11
5.3. Troubleshooting.................................................................................................................12
6. Warranty Conditions..........................................................................................................13
7. Adequate waste management...........................................................................................13
8. History of modification......................................................................................................13
Append.:
Maintenance Schedule WP07050618
Wirung diagram no. BK1-70T-128
KONVEKTA Service Stations

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 3/13
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.
see hand book: „KONVEKTA Service Stations“

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 4/13
Notes to the operating instruction
This Operating instruction is valid for the air conditioners type:
KL60 / 12V
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

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 5/13
1. Technical data
Important!
In vehicles that are equipped with an a/c unit with heating function the
heating medium has to consist of water/glycol – antifreeze protection
(conform the mixing ratio to manufacturers` instructions). This is abso-
lutely 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 unit
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
Type KL60
Refrigerant R134a
- quantity approx. lbs
[kg] 22.1 [10]
Operating voltage Volt DC 12
Current consumption Ampere 129
Cooling capacity BTU/h
[Watt] 88090 [25800]
Air volume
@ 0 static pressure [CFM]
[m3/h] 2825
4800
Measurements:
- length inch
[mm] 144.7 [3675]
- width inch
[mm] 53.2 [1352]
- height inch
[mm] 9.1 [230]
- weight lbs
[kg] 374.8 [170]

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 6/13
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 tem-
perature 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 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 dam-
age have it check at a KONVEKTA Service Station. Only after that you can take unit into op-
eration.
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 environ-
mental 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 ad-
vancing substances. see hand book:“KONVEKTA Service Stations“

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 7/13
4. Operation with control KS60
4.1. General information
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 opera-
tion. 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 to drive with automatic mechanism (Key S5, see 0). Additionally to the automatic
the following functions can be activated:
a) Recirculated – Fresh Air operation – close flap manually, in order to prevent the en-
trance of exhaust fumes (in tunnels)
b) REHEAT-function to dehydrate the steamed up wind shield
Auto-test
If voltage supply to unit is interrupted, unit starts a self test immediately after reset. All in- and out-
lets 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.
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.

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 8/13
4.2. 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)
S6
Recirculated Air operation
Close resp. open Recirculated air flap;
In case of closed recirculated air flap, LED inside key button is indicating.
4.3. Storing of functions
If ignition is turned off, the following data will be stored always:
-AUTO – function
-Desired temperature
S1 D1 S3 S5
S2 S4 S6
Control KS60/12V,
Part no.:
H11-005-401

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 9/13
4.4. 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 S5 „a/c automatic“ , LED inside key button
is indicated. Pressing key S5 again, air conditioner switched off. The blowers are regulated
automatically.
With key S3 or S4 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“
4.5. Adjustment of temperature
If a/c-unit is operating, vehicle inside temperature can be adjust with key S1 or S2 , 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.
4.6. Recirc. Air operation
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
because of exhaust fumes (tunnel driving) has a chance to penetrate into interior room of the ve-
hicle.
Starting 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 opera-
tion should be switched off:
If key S6 is pressed again the return air flap will be reactivated and fresh air operation 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
maintained independently from a temperature difference

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 10/13
4.7. REHEAT activate / stop
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 .
4.8. Display of air duct temperature
While pressing buttons S1 and S6 actual air duct temperature is displayed for 2 seconds.
4.9. Indicate outside temperature => only in case of
a/c units with heating option
While pressing buttons S1 and S4 actual outside temperature is displayed for 2 seconds.

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 11/13
5. Maintenance / Servicing
Service and maintenance works have to be executed on basis of “Maintenance Schedule, no:
WP07050618.
- Only qualified staff is allowed to carry out these works! -
For general instructions on repair – and maintenance works please contact via email:
[email protected]
Danger of accident!
The experts in charge of installation and maintenance works should at least be
trained in accordance with the EN 378 - part 4 and strictly obey the legal regula-
tions.
All works or modifications at the air conditioner which are improperly executed can
lead to function troubles and can jeopardize the operation safety. We recommend
having works and modifications only executed in a KONVEKTA service stationAl-
so the prescribed regular maintenance works should be executed in an authorized
KONVEKTA service station.
Before having the maintenance executed please read carefully the KONVKETA safe-
ty prescriptions (TD00052A), in order to avoid dangers and accidents!
see hand book„KONVEKTA Service Stations
source of supply: KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt
5.1. Return air grid
Reference to Maintenance Schedule Bus No. WP 07 05 06 18 Item WK13:
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
Reference to Maintenance Schedule Bus No. WP 07 05 06 18 Item WK03:
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.

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 12/13
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 switch-
board 
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 until pressure has stabilized 
leakage in a/c unit, lack of refri-
gerant check a/c unit for leakages, re fill refri-
gerant 
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 
=see hand book„KONVEKTA Service Stations
= by user

307BBAKL60222AB.doc Edition: 16.09.2008 Page: 13/13
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 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
„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 prescrip-
tions 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 skilled personnel is allowed to execute
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)
8. History of modification
version date name remark file
A00 16.09.08 Pfluger source file BAKL60222AB