KONVEKTA KL20 facelift, KL20E facelift, KL20 Technical Manual

Konvekta AG

Konvekta AGKonvekta AG

Konvekta AG

Am Nordbahnhof 5 34613 Schwalmstadt Germany

 +49 ( 0 ) 66 91 / 76 – 0  +49 ( 0 ) 66 91 / 76 - 200  Info@konvekta.com www.konvekta.com

Technical Manual

Technical ManualTechnical Manual

Technical Manual

for KONVEKTA

for KONVEKTAfor KONVEKTA

for KONVEKTA

Air Condition

Air ConditionAir Condition

Air Conditioning Unit

ing Uniting Unit

ing Unitssss

- KL20

KL20 KL20

KL20 facelift

faceliftfacelift

facelift

With ABS cover

With ABS coverWith ABS cover

With ABS cover with cover plate

with cover platewith cover plate

with cover plate

---- KL20E

KL20E KL20E

KL20E facelift

faceliftfacelift

facelift

with ABS cover

with ABS coverwith ABS cover

with ABS cover

Contains information on:

Contains information on:Contains information on:

Contains information on:

-

Installation

InstallationInstallation

Installation

-

Operation

OperationOperation

Operation

-

Maintenance / Service

Maintenance / ServiceMaintenance / Service

Maintenance / Service

ID#: BEA

ID#: BEAID#: BEA

ID#: BEA----KL2

KL2KL2

KL2E132AA

E132AAE132AA

E132AA

Version: A0

Version: A0Version: A0

Version: A01111

EAKL2E132AA Edition: 26.04.2012 Page: 2/18

Contents

ContentsContents

Contents

Page:

•

Summary of dr

Summary of drSummary of dr

Summary of drawings (appendix)

awings (appendix)awings (appendix)

awings (appendix)

/ Notes

NotesNotes

Notes to the instruction

to the instruction to the instruction

to the instruction................................................................................ 3

• Introduction

IntroductionIntroduction

Introduction.................................................................................................................................................................. 4

1.Directives for Installation, Connection and Use

1.Directives for Installation, Connection and Use1.Directives for Installation, Connection and Use

1.Directives for Installation, Connection and Use ................................

................................................................

...............................................................

..............................................................

............................... 5555

2.

2.2.

2.Technical data air conditioning units

Technical data air conditioning unitsTechnical data air conditioning units

Technical data air conditioning units ................................

................................................................

...................................................

......................................

................... 6666

2.1.Compressor

(nur bei KL20E)

...................................................................................................................................6

3.

3.3.

3.Allgemeine Beschreibung

Allgemeine BeschreibungAllgemeine Beschreibung

Allgemeine Beschreibung................................

................................................................

.......................................

..............

....... 7777

4.General information on air conditioning unit

4.General information on air conditioning unit4.General information on air conditioning unit

4.General information on air conditioning unit ................................

................................................................

....................................

........

.... 8888

4.1.Operating Conditions.................................................................................................................................................8

4.2.Intended use .................................................................................................................................................................8

5.

5.5.

5.Installation preparation at the vehicle

Installation preparation at the vehicleInstallation preparation at the vehicle

Installation preparation at the vehicle ................................

................................................................

.................................................

..................................

................. 9999

5.1.Installation of air distribution plate ...................................................................................................................... 10

5.1.1.Installation of fan switch in the air distribution plate ................................................................................... 11

5.1.2.Installation of blower switch in the instrument panel (BEL-260STA003).............................................. 12

5.2.Installation of the air distribution plate in the vehicle..................................................................................... 13

5.3.Electrical connection................................................................................................................................................ 13

6.Positioning of the air conditioning components

6.Positioning of the air conditioning components6.Positioning of the air conditioning components

6.Positioning of the air conditioning components ................................

................................................................

..............................................................

............................................................

.............................. 14

1414

14

7.

7.7.

7.Operation

OperationOperation

Operation ................................

................................................................

..............................................................

............................................................

.............................. 14

1414

14

8.

8.8.

8.Maintenance / Service

Maintenance / ServiceMaintenance / Service

Maintenance / Service ................................

................................................................

..........................................

....................

.......... 15

1515

15

8.1.Service parts .............................................................................................................................................................. 15

•Pressure switch combination..................................................................................................................................... 15

8.2.Check refrigerant level............................................................................................................................................ 16

8.3.Compressor (only with KL20E facelift)............................................................................................................... 17

8.4.Condenser coil.......................................................................................................................................................... 17

8.5.Trouble shooting ...................................................................................................................................................... 17

9.

9.9.

9.Warranty Conditions

Warranty ConditionsWarranty Conditions

Warranty Conditions................................

................................................................

...........................................

......................

........... 18

1818

18

10.

10.10.

10.Waste disposal in accordance with legal provisions

Waste disposal in accordance with legal provisionsWaste disposal in accordance with legal provisions

Waste disposal in accordance with legal provisions................................

................................................................

.....................................................

..........................................

..................... 18

1818

18

11.

11.11.

11.History of modification

History of modificationHistory of modification

History of modification................................

................................................................

......................................

............

...... 18

1818

18

EAKL2E132AA Edition: 26.04.2012 Page: 3/18

SSSSummary of drawings (appendix) /

ummary of drawings (appendix) / ummary of drawings (appendix) /

ummary of drawings (appendix) / Information on the instructions

These instructions are valid for the air conditioning units’ type: KL20

KL20KL20

KL20 /

/ /

/ EEEE facelift

facelift facelift

facelift

Following documentations and designs are to add depending upon type of air conditioning system, the manual Documentation:

Documentation:Documentation:

Documentation:

•

Generally Safety instructions

TD00052A

• Instruction O-Ring connection AA07050122

• Maintenance Schedule WP07050621

Drawings

DrawingsDrawings

Drawings::::

KL20

KL20KL20

KL20 facelift

facelift facelift

facelift

KL20

KL20KL20

KL20 facelift

facelift facelift

facelift----cabin

cabincabin

cabin

KL20E

KL20EKL20E

KL20E fac

fac fac

faceeeelift

liftlift

lift

BKL 12V

BKL 12VBKL 12V

BKL 12V

24V

24V 24V

24V

BKL-0620122E14

BKL-0620242E17

BKL-0620122E13

BKL-0620242E16 - BKL-0350242E07

WWWWiring scheme

iring schemeiring scheme

iring scheme 24V

24V 24V

24V K1-200-165 K1-200-165 K1-200-148

WWWWiring scheme

iring schemeiring scheme

iring scheme 12V

12V 12V

12V K1-200-155 K1-200-155

Installation drawings

Installation drawingsInstallation drawings

Installation drawings KL2E14EZ KL2E13EZ KL2E07EZ

Air conditioner

Air conditionerAir conditioner

Air conditioner KL2E14G1 KL2E13G1 KL2E07G1

Air distribution plat

Air distribution platAir distribution plat

Air distribution plate high

e highe high

e high 59-AB0-015 59-AB0-015 59-AB0-015

Air distribution plate flat

Air distribution plate flatAir distribution plate flat

Air distribution plate flat 59-AB0-017 59-AB0-017 59-AB0-017

Expansion valve

Expansion valveExpansion valve

Expansion valve 14-001-081 14-001-081 14-001-081

Dryer/receiver unit

14-AA3-065 14-AA3-065 14-AA3-065

Pressure switch

combination

combination combination

combination 11-001-378 11-001-378 11-001-378

CCCCompressor SD5H09

ompressor SD5H09ompressor SD5H09

ompressor SD5H09 13-002-209

ET 12V

ET 12VET 12V

ET 12V

24V

24V 24V

24V

KL2E14ET

KL2E17ET

KL2E13ET

KL2E16ET

-

KL2E07ET

The machine corresponds

The machine corresponds The machine corresponds

The machine corresponds with

withwith

with the

the the

the safety provisions

safety provisionssafety provisions

safety provisions of the EC # 89/392/EWG i.d.F. 91/368/EWG and

of the EC # 89/392/EWG i.d.F. 91/368/EWG and of the EC # 89/392/EWG i.d.F. 91/368/EWG and

of the EC # 89/392/EWG i.d.F. 91/368/EWG and

93/44/EWG.

93/44/EWG.93/44/EWG.

93/44/EWG.

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 instruction, 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 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

ManufacturerManufacturer

Manufacturer: KONVEKTA AG, P.O. Box 2280, D

: KONVEKTA AG, P.O. Box 2280, D: KONVEKTA AG, P.O. Box 2280, D

: KONVEKTA AG, P.O. Box 2280, D----34607 Schwalmstadt

34607 Schwalmstadt34607 Schwalmstadt

34607 Schwalmstadt

EAKL2E132AA Edition: 26.04.2012 Page: 4/18

Introduction

IntroductionIntroduction

Introduction

These instructions have been written for installation- and maintenance staff of air conditioning units’ type KL20 facelift und KL20E facelift.

These instructions contain important information on installation, handling and operation of the a/c unit in order to support instructed personnel.

In this context, we refer implicitly to the compliance with our general installation guidelines. These can be

In this context, we refer implicitly to the compliance with our general installation guidelines. These can be In this context, we refer implicitly to the compliance with our general installation guidelines. These can be

In this context, we refer implicitly to the compliance with our general installation guidelines. These can be obtained from the Konvekta techn

obtained from the Konvekta technobtained from the Konvekta techn

obtained from the Konvekta techniiiical after sales service:

cal after sales service: cal after sales service:

cal after sales service: TKD@konvekta.com

TKD@konvekta.comTKD@konvekta.com

TKD@konvekta.com....

It contains:

It contains:It contains:

It contains:

o Operating instruction

Operating instructionOperating instruction

Operating instruction

o SSSSafety

afetyafety

afety infor

infor infor

information

mation mation

mation

o Maintenance

Maintenance Maintenance

Maintenance information

informationinformation

information

o drawings

drawingsdrawings

drawings

These 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 trouble shooting 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 compliance with these operating instructions increases operation reliability and service life of the air conditioning unit and reduces life cycle costs.

Please complete these instructions by adding the national provisions for prevention of accidents and

environmental protection....

You will certainly understand that we will not recognize any warranty claims due to improper handling, inadequate maintenance, applications that do not correspond with the determined use, utilization of unadmitted fuels or the non-observance of safety provisions. KONVEKTA will annul without prenotice all obligations concerning guarantee, service contracts etc. regardless if granted by KONVEKTA or its distributors in case other than original KONVEKTA spare parts or parts bought from KONVEKTA AG have been used for maintenance and repair. This operating instruction contains all necessary information to operate your air conditioner. In case you need more explanations please contact the next KONVEKTA service station.



On our website www.konvekta.com in category

>service<

you will find a survey of contact details of all our service

partners close to your location

.

EAKL2E132AA Edition: 26.04.2012 Page: 5/18

1.

1.1.

1. Directives for Installation, Connection and Use

Directives for Installation, Connection and UseDirectives for Installation, Connection and Use

Directives for Installation, Connection and Use

Please read carefully the following instructions before installing, connecting and operating the device. We assume no liability for incorrect handling and usage.

WARNING

WARNING WARNING

WARNING

CAUTION

CAUTIONCAUTION

CAUTION

MAKE THE CORRECT CONNECTIONS.

MAKE THE CORRECT CONNECTIONS.MAKE THE CORRECT CONNECTIONS.

MAKE THE CORRECT CONNECTIONS. Failure to make the proper connections may result in fire or product damage.

USE ONLY SUITABLE VOLTAGE.

USE ONLY SUITABLE VOLTAGE.USE ONLY SUITABLE VOLTAGE.

USE ONLY SUITABLE VOLTAGE. The usage with a not suitable voltage may result in fire. Furthermore a not suitable voltage may result in failure or product damage.

TAKE CARE THAT WIRES NOT CARRY CU

TAKE CARE THAT WIRES NOT CARRY CUTAKE CARE THAT WIRES NOT CARRY CU

TAKE CARE THAT WIRES NOT CARRY CURRRRRENT

RENT RENT

RENT

WHILE CONNECTING.

WHILE CONNECTING.WHILE CONNECTING.

WHILE CONNECTING. Connecting wires which carry current may result in electrical shorts or product damage.

OOOONLY USE WIRES WITH SUFFICIENT LARGE CROSS

NLY USE WIRES WITH SUFFICIENT LARGE CROSS NLY USE WIRES WITH SUFFICIENT LARGE CROSS

NLY USE WIRES WITH SUFFICIENT LARGE CROSS

SE

SESE

SECCCCTIONS.

TIONS.TIONS.

TIONS. Using wires with not sufficient large cross sections will exceed the current carrying capacity of the wires and result in fire or electric shock.

DO NOT DISASSEMBLE OR ALTER.

DO NOT DISASSEMBLE OR ALTER.DO NOT DISASSEMBLE OR ALTER.

DO NOT DISASSEMBLE OR ALTER. Doing so may result in an accident, fire or electric shock.

DO NOT INSTALL IN LOCATIONS WHICH MIGHT

DO NOT INSTALL IN LOCATIONS WHICH MIGHT DO NOT INSTALL IN LOCATIONS WHICH MIGHT

DO NOT INSTALL IN LOCATIONS WHICH MIGHT HI

HIHI

HINNNNDER VEHICLE OPERATIONS.

DER VEHICLE OPERATIONS.DER VEHICLE OPERATIONS.

DER VEHICLE OPERATIONS. Doing so may obstruct forward vision or hamper movement and result in serious accident.

DO NOT BLOCK VENTS OR RADIATOR PANELS.

DO NOT BLOCK VENTS OR RADIATOR PANELS.DO NOT BLOCK VENTS OR RADIATOR PANELS.

DO NOT BLOCK VENTS OR RADIATOR PANELS. Doing so may cause heat to build up inside and may result fire.

USE THE CORRECT AMPERE RATING WHEN R

USE THE CORRECT AMPERE RATING WHEN RUSE THE CORRECT AMPERE RATING WHEN R

USE THE CORRECT AMPERE RATING WHEN RE-

E-E-

E-

PLACING FUSES.

PLACING FUSES.PLACING FUSES.

PLACING FUSES. Failure to do so may result in fire or electric shock.

DO NOT PLACE HANDS, FINGERS OR FOREIGN

DO NOT PLACE HANDS, FINGERS OR FOREIGN DO NOT PLACE HANDS, FINGERS OR FOREIGN

DO NOT PLACE HANDS, FINGERS OR FOREIGN OOOOBBBBJECTS IN INSERTION SLOTS OR GAPS.

JECTS IN INSERTION SLOTS OR GAPS.JECTS IN INSERTION SLOTS OR GAPS.

JECTS IN INSERTION SLOTS OR GAPS. Doing so may result in personal injury or damage to the product.

AVOID HIGH FORCE EFFECTS.

AVOID HIGH FORCE EFFECTS.AVOID HIGH FORCE EFFECTS.

AVOID HIGH FORCE EFFECTS. Do not expose the device high force effects or strokes. Doing so may result in product damage.

HAVE THE WIRING AND INSTALLATION DONE BY

HAVE THE WIRING AND INSTALLATION DONE BY HAVE THE WIRING AND INSTALLATION DONE BY

HAVE THE WIRING AND INSTALLATION DONE BY EEEEXXXXPERTS.

PERTS.PERTS.

PERTS. The wiring and installation of this device requires special technical skill and experience and have to be done by experts.

ARRANGE THE WIRING SO IT IS NOT CRIMPED OR

ARRANGE THE WIRING SO IT IS NOT CRIMPED OR ARRANGE THE WIRING SO IT IS NOT CRIMPED OR

ARRANGE THE WIRING SO IT IS NOT CRIMPED OR PINCHED BY A SHARP METAL EDGE.

PINCHED BY A SHARP METAL EDGE.PINCHED BY A SHARP METAL EDGE.

PINCHED BY A SHARP METAL EDGE. Arrange the wiring so it will not be damaged.

DO NOT INSTALL IN LOCATIONS WITH HIGH

DO NOT INSTALL IN LOCATIONS WITH HIGH DO NOT INSTALL IN LOCATIONS WITH HIGH

DO NOT INSTALL IN LOCATIONS WITH HIGH MOISTURE OR DUST.

MOISTURE OR DUST.MOISTURE OR DUST.

MOISTURE OR DUST. Avoid installing the device in locations with high incidence of moisture or dust. Moisture or dust that penetrates into this device may result in product failure or damage.

USE SPECIFIED ACCESSORY PARTS AND INSTALL

USE SPECIFIED ACCESSORY PARTS AND INSTALL USE SPECIFIED ACCESSORY PARTS AND INSTALL

USE SPECIFIED ACCESSORY PARTS AND INSTALL THEM SECURELY.

THEM SECURELY.THEM SECURELY.

THEM SECURELY. Be sure to use the specified accessory parts. Use of other than designated parts may damage this device internally or may not securely install the device in place.

HALT USE IMMEDIATELY IF A PROBLEM APPEARS.

HALT USE IMMEDIATELY IF A PROBLEM APPEARS.HALT USE IMMEDIATELY IF A PROBLEM APPEARS.

HALT USE IMMEDIATELY IF A PROBLEM APPEARS. Failure to do so may cause personal injury or damage to the product. Return it to your authorized customer service.

TEMPERATURE.

TEMPERATURE.TEMPERATURE.

TEMPERATURE. Be sure the environment-temperature is in the allowed range before turning the device on.

USE DEVICE ONLY FOR SPECIFIED APPLICATION

USE DEVICE ONLY FOR SPECIFIED APPLICATION USE DEVICE ONLY FOR SPECIFIED APPLICATION

USE DEVICE ONLY FOR SPECIFIED APPLICATION AREA.

AREA.AREA.

AREA. Using the device for another purpose or in another application area than the intended one, may result failure, product damage or injury.

PRODUCT CLEANING.

PRODUCT CLEANING.PRODUCT CLEANING.

PRODUCT CLEANING. Use a soft dry cloth for cleaning the device. For more severe dirt, please dampen the cloth with water only. Anything else has the chance of damage the product.

RANGE OF THIS DIREC

RANGE OF THIS DIRECRANGE OF THIS DIREC

RANGE OF THIS DIRECTIVES.

TIVES.TIVES.

TIVES. These directives apply for all devices, on which this directives-sheet is added. One directives-sheet is sufficient per box.

TRANSPORT TERMS

TRANSPORT TERMSTRANSPORT TERMS

TRANSPORT TERMS Handle the unit with care at any time. During transport make sure that the unit is stored safely and cannot be damaged. If more than one unit are transported, every unit has to be packed singly to avoid that the units damage one another. The forwarder is liable for all damages during transport.

EAKL2E132AA Edition: 26.04.2012 Page: 6/18

2.

2.2.

2. Technical data air conditioning units

Technical data air conditioning unitsTechnical data air conditioning units

Technical data air conditioning units

Type

TypeType

Type

KL20 facelift

KL20 faceliftKL20 facelift

KL20 facelift

ABS-cover

KL20 facelift

KL20 faceliftKL20 facelift

KL20 facelift

cover-plate

KL20E facelift

KL20E faceliftKL20E facelift

KL20E facelift

Refrigerant

R 134a R 134a R 134a

·- quantity approx.

kg

ca.

* * 0,7

Operating voltage

Volt DC

12 24

24

Cooling capacity

Watt

6.200 6.200 4.300

Air volume

m3/h

700 700 700

Current consumption

V / A

12V/28 24V/16

-

24V/68-751)

Measurements:

Measurements:Measurements:

Measurements:

- length

mm

932 724 1300

- width

mm

788 750 791

- height

mm

211 168 206

- weight

kg

23 23 53

1)

depending on outside temperature

*

* *

*  Note:

Note: Note:

Note:

At KL20 (bus and cabin) the quantity of refrigerant is depending on the vehicle and can only be de-

termined during filling of the a/c unit.

2.1.

2.1.2.1.

2.1. Compressor

CompressorCompressor

Compressor

(nur bei KL20E)

Konvekta code.: H13-002-209

Type SD5H09 / HB / ø 125 mm / 5PV

Oil brand / quantity

PAG / corresponding to version



List is attached to compressor (Instruction no: TD00031A)

Connection pressure side standard

3/4“ O-Ring

Connection suction side standard

7/8“ O-Ring

Capacity intake

ca. 50 Watt

Number of revolutions

400 bis max. 6.000 U/min.

Installation location

from vertical position max. 90° pivoting to both sides

Weight approx. 7,5 kg

 Note:

Note: Note:

Note:

At KL20 facelift (bus and cabin) the layout of the compressor is depending on the vehi-

cle.

EAKL2E132AA Edition: 26.04.2012 Page: 7/18

3.

3.3.

3. Allgemeine Beschreibung

Allgemeine BeschreibungAllgemeine Beschreibung

Allgemeine Beschreibung

• At the units KL20 facelift and KL20E facelift the optimum air quantity is adjustable via the fan switch in three levels.

• At the unit KL20 facelift the refrigerant pipes have to be passed from the a/c unit to the compres- sor.

• The unit KL20E facelift is pre-filled by the manufacturer with refrigerant R134a and electrically wired. Passing of refrigerant pipes to the engine is not necessary.

Type of unit:

Type of unit:Type of unit:

Type of unit: Connection to the vehicle:

Connection to the vehicle:Connection to the vehicle:

Connection to the vehicle:

KL20

KL20 KL20

KL20 facelift (

facelift (facelift (

facelift (cover plate

cover platecover plate

cover plate))))

–

E :

E :E :

E : connection electric

–

ext. comp.

ext. comp.ext. comp.

ext. comp.: Connection to the vehicle en-

gine or ext. compressor

KL20

KL20 KL20

KL20 facelift (ABS

facelift (ABSfacelift (ABS

facelift (ABS----Haube

HaubeHaube

Haube))))

–

E :

E :E :

E : connection electric

–

ext. comp.:

ext. comp.:ext. comp.:

ext. comp.: Connection to the vehicle en-

gine or ext. compressor

KL20 E

KL20 EKL20 E

KL20 E facelift

facelift facelift

facelift

–

E :

E :E :

E : connection electric

Completely filled with refrigerant

evaporator

condenser

evaporator

condens

er

evaporator

condenser

compre

s

sor

ext. comp.

EAKL2E132AA Edition: 26.04.2012 Page: 8/18

4.

4.4.

4. General information

General information General information

General information on air conditioning

on air conditioning on air conditioning

on air conditioning unit

unitunit

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.

− If you think that the air conditioning unit has been damaged switch it off immediately in order to avoid further damage. The air cond

The air condThe air cond

The air condiiiitioning unit may be taken into operation again only after it has been

tioning unit may be taken into operation again only after it has been tioning unit may be taken into operation again only after it has been

tioning unit may be taken into operation again only after it has been

checked at a KONVEKTA Service Station

checked at a KONVEKTA Service Stationchecked at a KONVEKTA Service Station

checked at a KONVEKTA Service Station....

4.1.

4.1.4.1.

4.1. Operating Conditions

Operating ConditionsOperating Conditions

Operating Conditions

NOTE:

NOTE:NOTE:

NOTE:

KONVEKTA uses components made of copper and aluminium, which last a whole unit lifetime under normal environmental conditions. Should the units be operated under aggressive environmental conditions, i.e. air containing salt-, phosphate- or ammoniac extremely, a corrosion of the cupper- and aluminium components can not be ruled out. The cupper- and aluminium components of the KONVEKTA systems are not suitable for such extreme application conditions. We indicate emphatically, that corrosion is not subject to warranties for defects. KONVEKTA does not take over any warranties for defect, neither for corrosion nor for consequential damage resulting there from, nor for damages caused by cleaning the systems with highly compressed or corrosion advancing substances

4.2.

4.2.4.2.

4.2. Intended

IntendedIntended

Intended use

use use

use

The KONVEKTA

KONVEKTAKONVEKTA

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 temperature by means of forced convection. The determined use includes also the observance of the operating instructions as well as the proof of regular inspections.



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

EAKL2E132AA Edition: 26.04.2012 Page: 9/18

5.

5.5.

5. Installation preparation at t

Installation preparation at tInstallation preparation at t

Installation preparation at the vehicle

he vehiclehe vehicle

he vehicle

Danger of accident!

Danger of accident!Danger of accident!

Danger of accident!

Qualified staff in charge of installation and maintenance have to be trained in accordance with EN

Qualified staff in charge of installation and maintenance have to be trained in accordance with EN Qualified staff in charge of installation and maintenance have to be trained in accordance with EN

Qualified staff in charge of installation and maintenance have to be trained in accordance with EN 378

378378

378----Part 4 and (EG) No.307 / 2008 and must strictly

Part 4 and (EG) No.307 / 2008 and must strictly Part 4 and (EG) No.307 / 2008 and must strictly

Part 4 and (EG) No.307 / 2008 and must strictly fo

fofo

folllllow the legal provisions

low the legal provisionslow the legal provisions

low the legal provisions

.

Any works or modifications at the air condi

Any works or modifications at the air condiAny works or modifications at the air condi

Any works or modifications at the air conditioner which are carried out i

tioner which are carried out itioner which are carried out i

tioner which are carried out immmmproperly can lead to

properly can lead to properly can lead to

properly can lead to

malfunction and so endanger operational reliability

malfunction and so endanger operational reliabilitymalfunction and so endanger operational reliability

malfunction and so endanger operational reliability

.

Before carrying out any maintenance works at your air conditioning unit, carefully read the KO

Before carrying out any maintenance works at your air conditioning unit, carefully read the KOBefore carrying out any maintenance works at your air conditioning unit, carefully read the KO

Before carrying out any maintenance works at your air conditioning unit, carefully read the KON-

N-N-

N-

VKETA safety provisions (TD00052A

VKETA safety provisions (TD00052AVKETA safety provisions (TD00052A

VKETA safety provisions (TD00052A )

) )

) in order to avoid

in order to avoid in order to avoid

in order to avoid any dangers and acc

any dangers and accany dangers and acc

any dangers and acciiiidents

dentsdents

dents

!!!!

Source of supply: KONVEKTA AG

KONVEKTA AGKONVEKTA AG

KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt

The way of installation is depending on the vehicle type, the instructions of the manufacturer have to be considered

!!!!

• Disconnect battery

Disconnect batteryDisconnect battery

Disconnect battery

• Remove inserted ceiling / contingently insulating material in the area of the air ducts.

• Mark out air duct breaches according to schematic drawing (hatched area on the drawing >> Re-

quired rooftop holes <<, please find drawing number of the respective a/c unit in the summary on

page 3) on the vehicle rooftop and then cut them out..

Do not damage supporting parts

Do not damage supporting parts Do not damage supporting parts

Do not damage supporting parts (e.g. roof arches, bra

(e.g. roof arches, bra(e.g. roof arches, bra

(e.g. roof arches, braccccings) or fixtures!

ings) or fixtures!ings) or fixtures!

ings) or fixtures!

!

• Align a/c unit (without cover) on the breaches and mark out the 8 mounting points for the unit.

• Remove a/c unit and place the drillings on the rooftop.

• Deburr / smoothen the cutting edges and drillings and seal with anti-corrosion coating.

• Prepare interior roof area, so that the air distribution plate can be mounted under the roof (see

point 5.1 , „Mounting of air distribution plate “)

• Tailor gaskets B14-AN2-416 according to drawing >>

>>>>

>>sealing of roof breaches<<

<< <<

<< and glue

on roof with gluing cement

• Put the a/c unit on the gaskets.

• Insert the input lead with the fan switch through the suction hole into the interior area of the roof.

• Mount the a/c unit with fastening material on the vehicle roof top.

• Seal all roof breaches with gluing cement!

EAKL2E132AA Edition: 26.04.2012 Page: 10/18

5.1.

5.1.5.1.

5.1. Installation of air distribution plate

Installation of air distribution plateInstallation of air distribution plate

Installation of air distribution plate

Before installation of the air distribution p

Before installation of the air distribution pBefore installation of the air distribution p

Before installation of the air distribution plate, the object has to be prepared as follows:

late, the object has to be prepared as follows:late, the object has to be prepared as follows:

late, the object has to be prepared as follows:

1. Put the gasket as shown in the picture into the air distribution plate and fix it with the plastic plugs. Attention:

Attention:Attention:

Attention: Gasket between the suction and exhaust part needs to be installed, otherwise an air shortcircuit and lowering of air conditioning performance will occur.

(BB-VW0-043)

Sealing

Fastening screws

5,5x22 /ISO7049

View wit

h

out

blower switch

Plastic fa

s

tener

Air distribution plate

EAKL2E132AA Edition: 26.04.2012 Page: 11/18

5.1.1. Installation of fan switch in the air distribution plate

Close one of the two existing holes in the air distribution plate with the rubber nozzle, Art. No.: H14-000260, label the other one with the label H25-001-063 for the fan switch.

Attention:

Attention:Attention:

Attention: 0 position (OFF) of the fan switch and 0-position of the label have to match!

OFF - off LOW - slow MED - medium HI - fast

Unplug the button with the clip at the fan switch; fit the switch with the two nuts which were delivered together with the switch to the air distribution plate. Then put the button including the clip back to the switch.

BB-ZW0-050

Button with spring

Rubber grommet

H14-000-260

Blower switch

B11-AA0-432

H14-000-260

H25-001-063

Nut for fastening the

blower switch

Nut for fastening the

blower switch

EAKL2E132AA Edition: 26.04.2012 Page: 12/18

5.1.2. Installation of blower switch in the instrument panel (BEL-260STA003)

For the installation of the blower switch in the instrument panel additional extra items (BEL-260STA003) are needed.

Procedure

ProcedureProcedure

Procedure:::: Detach the blower switch from the original wiring harness and remove the 5 blade terminal sockets from

the blade terminal housing with a removal tool. Now put the 5 cables with the blade terminal sockets of the wiring harness in the 6-polar blade terminal housing (H11-000-668, ST1.1). Install the blower switch at a suitable place at the dash board (as described in 5.1.1). Fix sticker H25-001063 for the blower switch. Install oilflex cable 5 x 2,5 qmm (H11-000-776) in the vehicle and insulate the cable ends. At the end of the wiring harness / a/c there are to be installed 5 blade terminals (H11-000-664), to the dashboard 5 blade terminal sockets (H11-000-663) have to be crimped. Plug the cables – as described in wiring scheme K1200-173 – into the connectors (ST1.1 – 6-polar, ST1 – 5-polar). Plug the 5-polar blade terminal housing on the blower switch installed at the dashboard.

Holes in the air distribution plate with 2x rubber grommet no. H14-000-260:

Rubber gro

m

met

no. H14-000-260

Rubber gro

m

met

no. H14-000-260

EAKL2E132AA Edition: 26.04.2012 Page: 13/18

5.2.

5.2.5.2.

5.2. Installation of the air distribution plate in the vehicle

Installation of the air distribution plate in the vehicleInstallation of the air distribution plate in the vehicle

Installation of the air distribution plate in the vehicle

Tighten the air distribution plate with the 12 delivered screws 5,5x22 / ISO7049 in the interior.

(BB-VW0-044)

5.3.

5.3.5.3.

5.3. Electrical connection

Electrical connectionElectrical connection

Electrical connection

The electrical supply takes place through the vehicle battery.

Carry out the connection in accordance with the connection scheme. The air conditioning unit is precabled. The following connections have to be made:

1. Install the two-pole safety fuse socket near the vehicle battery and connect it.

2. Carry out the cabling of the battery – safety fuses and the air conditioning unit in accordance with the cable cross-section indicated in the connexion scheme.

3. Insert the safety fuses in the fuse socket.

-

Clamp the vehicle battery

Clamp the vehicle batteryClamp the vehicle battery

Clamp the vehicle battery

Air suction

Air suctionAir suction

Air suction

Air outlet

Air outletAir outlet

Air outlet

Interior roof of

vehicle

Air distrib

u

tion

plate

Screw 5,5x22 /

ISO7049/vz.

Sealing

Blower switch

EAKL2E132AA Edition: 26.04.2012 Page: 14/18

Driving dire

Driving direDriving dire

Driving dire

cccc

tion

tiontion

tion

6.

6.6.

6. Positioning of the air conditioning components

Positioning of the air conditioning componentsPositioning of the air conditioning components

Positioning of the air conditioning components

1. Evaporator coil 1a. Radial blower 1b. Expansion valve 1c. Thermostat

2. Condenser coil 2a. Axial blower (condenser blower)

3. Dryer-collector-sight glass- unit with combined pressure switch

4. Electric

5. Driving unit complete with compressor SD5H09 - not to apply with KL20

not to apply with KL20not to apply with KL20

not to apply with KL20

7.

7.7.

7. Operation

OperationOperation

Operation

The blower switch to activate the blower is situated in the

The blower switch to activate the blower is situated in the The blower switch to activate the blower is situated in the

The blower switch to activate the blower is situated in the interior of the vehicle.

interior of the vehicle. interior of the vehicle.

interior of the vehicle. (See also 5.1.1 – Installa-

tion of blower switch in the air distributor plate)

− Start motor of the vehicle (see original instruction manual of the vehicle)

− Regulate air capacity through blower switch

• position 0 - OFF

• position 1 - minimum air volume

• position 2 - medium air volume

• position 3 - maximum air volume

1a

4

3

1

1c

1b

2

2a

5

EAKL2E132AA Edition: 26.04.2012 Page: 15/18

8.

8.8.

8. Maintenance / Service

Maintenance / ServiceMaintenance / Service

Maintenance / Service

Maintenance and service works have to be done in accordance with the

“Maintenance Schedule, no

:

WP07050621.



Only

Only Only

Only qualified staff

qualified staff qualified staff

qualified staff is allowed to

is allowed to is allowed to

is allowed to carry out

carry outcarry out

carry out these works

these works these works

these works!

! !

! ––––

Danger of accident!

Danger of accident!Danger of accident!

Danger of accident!

Qualified staff in charge of installation and maintenance have to be trained in accordance with EN

Qualified staff in charge of installation and maintenance have to be trained in accordance with EN Qualified staff in charge of installation and maintenance have to be trained in accordance with EN

Qualified staff in charge of installation and maintenance have to be trained in accordance with EN 378

378378

378----Part 4 and (EG) No.307 / 2008 and must strictly fo

Part 4 and (EG) No.307 / 2008 and must strictly foPart 4 and (EG) No.307 / 2008 and must strictly fo

Part 4 and (EG) No.307 / 2008 and must strictly folllllow the legal provi

low the legal provilow the legal provi

low the legal provisions.

sions.sions.

sions.

Any works or modifications at the air conditioner which are

Any works or modifications at the air conditioner which are Any works or modifications at the air conditioner which are

Any works or modifications at the air conditioner which are carried out i

carried out icarried out i

carried out immmmproperly can lead to

properly can lead to properly can lead to

properly can lead to

malfunction and so endanger operational reliability. We recommend having all works and modific

malfunction and so endanger operational reliability. We recommend having all works and modificmalfunction and so endanger operational reliability. We recommend having all works and modific

malfunction and so endanger operational reliability. We recommend having all works and modifica-

a-a-

a-

tions carried out at an authorized KONVEKTA Service Station

tions carried out at an authorized KONVEKTA Service Stationtions carried out at an authorized KONVEKTA Service Station

tions carried out at an authorized KONVEKTA Service Station



. The same applies to the reg

. The same applies to the reg. The same applies to the reg

. The same applies to the reguuuular

lar lar

lar

maintenance works as prescribed and specified in the maintenance certificate.

maintenance works as prescribed and specified in the maintenance certificate.maintenance works as prescribed and specified in the maintenance certificate.

maintenance works as prescribed and specified in the maintenance certificate. Before carrying out any maintenance works at your air conditioning unit, carefully read the

Before carrying out any maintenance works at your air conditioning unit, carefully read the Before carrying out any maintenance works at your air conditioning unit, carefully read the

Before carrying out any maintenance works at your air conditioning unit, carefully read the KO

KOKO

KON-

N-N-

N-

VKETA safety pr

VKETA safety prVKETA safety pr

VKETA safety provisions (TD00052A

ovisions (TD00052Aovisions (TD00052A

ovisions (TD00052A )

) )

) in order to

in order toin order to

in order to avoid any dangers and acc

avoid any dangers and acc avoid any dangers and acc

avoid any dangers and acciiiidents

dentsdents

dents!!!!



On our website www.konvekta.com in category

>service<

you will find a survey of contact details of all our service

partners close to your location



Source of supply: KONVEKTA AG

KONVEKTA AGKONVEKTA AG

KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt



When the air conditioning system is being opened during maintenance resp.

When the air conditioning system is being opened during maintenance resp. When the air conditioning system is being opened during maintenance resp.

When the air conditioning system is being opened during maintenance resp.

reparation works, the dryer

reparation works, the dryerreparation works, the dryer

reparation works, the dryer----collector

collectorcollector

collector----sight glass has to be exchanged!

sight glass has to be exchanged! sight glass has to be exchanged!

sight glass has to be exchanged!



The connexions have to be wetted with PAG

The connexions have to be wetted with PAG The connexions have to be wetted with PAG

The connexions have to be wetted with PAG oil before the installation of

oil before the installation of oil before the installation of

oil before the installation of

the wires.

the wires.the wires.

the wires.

8.1.

8.1.8.1.

8.1. Service parts

Service partsService parts

Service parts

• Axial- und radial blower

• Blower switch

• Dryer-collector-sight glass

• Thermostat (icing protection)

• Plug connection electric

• Compressor

• Pressure switch combination

Pressure switch combinationPressure switch combination

Pressure switch combination

The pressure switch combination is fitted to the dryer-collector-sight glass –unit.

Konvekta code no.: H11-001-378

Low pressure k

BAR

2,0 ± 0,2 off 2,1 ± 0,3 on

excess pressure

BAR

28,0 ± 2,0 off 21,0 ± 3,0 on

EAKL2E132AA Edition: 26.04.2012 Page: 16/18

8.2.

8.2.8.2.

8.2. Check refrigerant level

Check refrigerant levelCheck refrigerant level

Check refrigerant level

Check the refrigerant level at the sight glass of the dryer-collector unit:

1. Switch a/c unit on.

2. The set temperature must be lower than the actual inside temperature, so that compressor is engaged.

Sight glass

Sight glassSight glass

Sight glass:

Cause

CauseCause

Cause Remedy

RemedyRemedy

Remedy

Bild: BB-YW0-029

Forming of bubbles in the sight glass

 Lack

LackLack

Lack of r

r r

reeeefrigerant

frigerantfrigerant

frigerant!!

!!!!

!!

AAAAttention

ttentionttention

ttention !

! !

!

In case there is too little refrigerant in the system, an increase in bubble formation can be observed in the sight glass. In this case it is necessary to switch off the system immed

to switch off the system immedto switch off the system immed

to switch off the system immedi-

i-i-

i-

ately

atelyately

ately in order to avoid damages at the compressor.

Contact

ContactContact

Contact KONVEKTA Service Station

KONVEKTA Service StationKONVEKTA Service Station

KONVEKTA Service Station



!!!!

–

refill refrigerant

–

check a/c unit for leakages

Free of bubbles!

Amount of refrigerant is o.k.....



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.

Safety valve

Sight glass

Protective cap

Locking srew

EAKL2E132AA Edition: 26.04.2012 Page: 17/18

8.3.

8.3.8.3.

8.3. CCCCompressor (

ompressor (ompressor (

ompressor (only with

only withonly with

only with KL20E

KL20E KL20E

KL20E facelift

faceliftfacelift

facelift))))

The compressor is installed in the unit and is driven through a poly-V-belt by the driving unit. Please pay attention to a faultless tension of the V-belt. The air conditioning unit being activated, the magnetic clutch is being activated and the compressor works. When the air conditioning unit is shut off, the magnetic clutch runs along without activity.

Important

ImportantImportant

Important::::

To avoid leakages at the shaft seal of the compressor

To avoid leakages at the shaft seal of the compressorTo avoid leakages at the shaft seal of the compressor

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 conditioning unit is not used!

8.4.

8.4.8.4.

8.4. Condenser coil

Condenser coilCondenser coil

Condenser coil

After taking into operation the condenser, a regular cleaning is necessary. Always keep condenser coil fins clean. Severe soiling causes excess pressure within the a/c-unit system and it automatically stops working.

Attent

AttentAttent

Attention:

ion: ion:

ion:

The condenser coil fins have to be cleaned with compressed air at least twice a year, in case of severe soiling more often

The fins of the condenser battery must not be deformed. De-

formed fins have to be erected with a fin comb....

8.5.

8.5.8.5.

8.5. Trouble shooting

Trouble shootingTrouble shooting

Trouble shooting

Trouble

TroubleTrouble

Trouble Cause

CauseCause

Cause

Repair

RepairRepair

Repair –––– by authorized Service St

by authorized Service St by authorized Service St

by authorized Service Staaaation only

tion only tion only

tion only 

electric connections disconnected

-

check electric connections

defective fuse

• check fuse, replace if necessary

Blower switch defective

• check blower switch, V-belt if necessary

excess pressure 3. clean condenser coil

low pressure, dryer clogged

-

replace dryer 

low pressure, screen of expansion valve clogged

-

clean screen; replace dryer 

a/c is not running

leakage in a/c unit, lack of refrigerant

-

check a/c unit for leakages

-

refill refrigerant and

and and

and replace dryer! 

a/c runs, switches off

excess pressure caused by high outside temperature

-

run unit, until pressure has stabilized

defective bearing at compressor

-

replace either bearing or entire compressor

Loud noise at compressor

magnetic clutch

-

check connections at magnetic clutch 

Loud noise at V-belt

worn V-belt slack V-belt

-

replace V-belt 

-

retighten V-belt 



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.

Picture: erecting fins

Picture: erecting finsPicture: erecting fins

Picture: erecting fins

EAKL2E132AA Edition: 26.04.2012 Page: 18/18

9.

9.9.

9. Warranty Conditions

Warranty ConditionsWarranty Conditions

Warranty Conditions

The current „General Warranty Conditions” KONVEKTA AG“ will apply. A copy will be furnished by the warranty department. Please contact: gwl@konvekta.com

gwl@konvekta.comgwl@konvekta.com

gwl@konvekta.com

.

10.

10.10.

10. Waste disposal in accordance with legal provisions

Waste disposal in accordance with legal provisionsWaste disposal in accordance with legal provisions

Waste disposal in accordance with legal provisions

After the phase of use the last proprietor is responsible for the adequate waste management. The environmental regulations in the exporting country must be observed. The following list contains the most important regulating literature, valid for the Federal Rep. of Germany:

-

Resolution for dangerous substances

-

Resolution for used oil

-

Law for waste circulation (KRW/AfgG))

-

Law of water balance

-

Resolution for the proofs of utilization and 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 prescriptions

-

Resolution to prohibit certain ozone destroying halo-

gen hydrocarbons. The used refrigerant endangers the environment. When dealing with refrigerants the existing prescriptions and regulations are to be followed. Only skilled personnel are 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)

11.

11.11.

11. History of modification

History of modificationHistory of modification

History of modification

Ve

VeVe

Verrrrsion

sionsion

sion Date

DateDate

Date Name

NameName

Name Remark

RemarkRemark

Remark file

filefile

file

A00 12.10.2011 B. Keßler Source file EAKL2E132AA

A01 26.04.2012 B. Keßler Point 2: The refrigerant charge of KL20E facelift is to

be corrected from 1,3 kg to 0,7 kg.

EAKL2E132AA

KONVEKTA KL20 facelift, KL20E facelift, KL20 Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual