KONVEKTA KL40T, KL45T, Kl46T Operating Instruction

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

KL40T / KL45T / Kl46T

with control K5

Versions:

 12 / 24 Volt DC
 Recirculated Air
 Fresh Air
 Heating

ID#: BBA-KL40T12AB
Version: A06

BAKL40T12AB Edition: 02.03.2017 Page: 2/14

Contents

Page:

• Introduction ......................................................................................................................... 3

• Information on the operating instructions ........................................................................ 4

1. Technical data .................................................................................................................. 4

1.1. Compressors ..................................................................................................................... 5

2. Determined use ................................................................................................................ 5

3. Generally information for a/c unit ................................................................................... 6

3.1. Operating Conditions ......................................................................................................... 6

4. Introduction control K5 ................................................................................................... 6

5. Operation .......................................................................................................................... 7

5.1. Operation panel / function of the keys ................................................................................ 7

5.2. A/C operation ON / OFF .................................................................................................... 8

5.2.1. Manual adjustment of the blower speed ............................................................................. 9

5.3. Heating operation fully automatic => only in case of a/c units with heating option .............. 9

5.3.1. Manual heating operation => only in case of a/c units with heating option ...................... 10

5.4. REHEAT activate / stop => only for in case of a/c units with heating option ..................... 10

5.5. Switch Recirc. Air operation => only in case of a/c units with Rec. air flaps option ........... 11

5.6. Change over of the temperture indication to ° Fahrenheit ................................................ 11

6. Maintenance / Service ................................................................................................... 11

6.1. Trouble indication in the display ....................................................................................... 12

6.1.1. Trouble at the temperature sensor F0 (room sensor, blue): ............................................. 12

6.1.2. Trouble at the temperature sensor F1 (air outlet, yellow): ................................................ 12

6.2. Oil change Compressor type KVX .................................................................................... 12

6.3. Return air grid .................................................................................................................. 12

6.4. Condenser coil ................................................................................................................. 12

6.5. Troubleshooting ............................................................................................................... 13

7. Warranty Conditions ...................................................................................................... 13

8. Waste disposal in accordance with legal provisions .................................................. 14

9. History of modification .................................................................................................. 14

Appendix:

• Maintenance Schedule Bus WP07050618

BAKL40T12AB Edition: 02.03.2017 Page: 3/14

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 guide­lines. 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 contract 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 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.

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 un­proper 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.

These operating instructions contain all necessary information to operate your air con­ditioning unit. 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.

BAKL40T12AB Edition: 02.03.2017 Page: 4/14

Information on the operating instructions

These operating instructions are valid for the

a/c-units

type:

• KL40T/12V • KL45T/12V • KL46T/12V

• KL40T/24V • KL45T/24V • KL46T/24V

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.

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: 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 con­sist 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)

BAKL40T12AB Edition: 02.03.2017 Page: 5/14

Type

: KL40T KL45T KL46T

Refrigerant

R134a

1.430

·-

quantity

with front box

[kgs] approx.

2,5
3,3

2,5
3,3

2,5
3,3

Operating voltage

resp.

[Volt DC]

12
24

12
24

12
24

Current consumption

(3-stage) at 13V:

(3-stage) at 26V:

(stageless) at 26V

[Ampere]

88
44
53

88
44
53

88
44
53

Cooling capacity

with KVX40

KVX30 or TM31

TM21

[Watt]

18.000

15.000

12.000

18.000

15.000.

12.000

21.000

-

-

Heating capacity Q=

100

[Watt] 25.000 25.000 25.000

Evaporator

– Air volume

*

,

free-blowing

[m3/h] 3-stage
stageless

4.000

4.400

4.000

4.400

4.000

4.400

Measurements:

- length

[mm] 1.966 1.985 1.985

- width

[mm] 1.368 1.336 1.336

-

hight,

- depending on roof radius

[mm]

221
188

234
188

239
193

Weight

of unit, Version:

-

Recirculated Air

[kgs ] approx. 65,5 78,5 81

-

Fresh Air

[kgs ] approx. 66,5 79,5 82

-

Heating

[kgs ] approx. 69 82 84

* With standard fans and/or blowers

1.1. 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 condition­ing unit is not used!

 Compressor type depending on scope of delivery, see identification plate at compressor.

Kompressor Typ

KVX40/390

KVX30/325

HDC 33

TM21

Weight (kgs) approx. 33 24,5 15,5 9,7
Oil brand

- quantity (kgs)

Esteröl SE55 2 Esteröl SE55

2

ZXL 100PG

0,5

ZXL 100PG

0,18

Magnetic clutch

1)

- Weight (kgs)

12 / 24V DC

12

12 / 24V DC

7,6

12 / 24V DC

12 / 24V DC

1)

ø depending on vehicle type

2. Determined use

The KONVEKTA air conditioner represents an air conditioning system that works with the ozone
friendly refrigerant R 134a and which creates a pleasant and individually adjustable room tempera­ture by means of forced convection. The determined use includes also the observance of the Oper­ating instruction and the proof of regular inspections as well.

BAKL40T12AB Edition: 02.03.2017 Page: 6/14

3. Generally information for 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 win-

dows. 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.

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 environmental
conditions, i.e. air containing salt-, phosphate- or ammoniac extremely, a corrosion of the cupper­and 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. Introduction control K5

The air conditioning control K5 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 passengers’
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. Control board K5
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 is also activated.

Auto-test

After activation the control unit performs an auto-test which lasts 20 seconds. Only after finishing
this test the control outputs of the unit are unblocked.
Afterwards the adjusted temperature is indicated.

BAKL40T12AB Edition: 02.03.2017 Page: 7/14

5. Operation

Risk of accident!

• Priority must be given to the traffic.

• Do only operate your air conditioner if the traffic situation does allow it.

• Please make sure that all operation and indicating elements can be recognized and read proper-

ly.

• Protect the displays and all indicating instruments against sun rays and other optical faults.

• Take into consideration that the keys at the control are not designed for extreme demands.

• An excessive or quick pressing of the keys for temperature adjustment does not accelerate the

cooling process but leads possibly to damage on the operation panel and spoils the total func­tioning of your air conditioner.

5.1. Operation panel / function of the keys

 Note: After the switching on the control is adjusted to the set value stored before it was

switched off.

3 4 5

6

7 11 12

1 2 8 13 10 9

(BBZW0038)

1

Key for switching the control ON/OFF.

2

Key for reduction of the selected temperature set

ting;

Alternatively: Manual adjustment „slow speed“.

3

Key for switching ON/OFF the a/c operation.

4

Key for increasing the desired room temperature

setting; Alternatively: Manual adjustment "high

speed“

5

LED lamp indicates that a/c operation is activated.

6

LED lamp indicates that circulated air function is ac­tivated.

7

LED lamp indiactes that a manual set-up was affect­ed.

8

4-digit seven-segmental display for indica

tion of the

selected room temperature (°Celsius or °Fahrenheit);

Alternatively: Error code indication in case of trouble.

9

Key for switch-over fresh air- / circulated air opera­tion.

10

Shift-key fan speed manual / automatic.

11

Key for switching the REHEAT-operation ON/OFF.

12

Shift-key heating operation manual / automatic.

13

Illuminated display indicates the fan speed (in 10%­s

teps); Alternatively: Indication of the heating valve

position.

BAKL40T12AB Edition: 02.03.2017 Page: 8/14

5.2. A/C operation ON / OFF

Start vehicle engine (refer to orig. operating instruction of the vehicle).
Note: If only the vehicle ignition was switched on without starting the

vehicle engine, the blower speed will be reduced to the lowest level
after 10 min. in order to prevent a considerable discharge of the vehi­cle battery.

Software- and control unit number is indicated for 5sec.

Switch ON control:
Note: After activation the control unit performs an auto-test which lasts

20 seconds. Only after finishing this test the control outputs of the unit
are unblocked.

Press key

The last selected desired temperature, e.g. B. 28°C is indicated:

Switch ON a/c operation:

By pressing key you can select the desired temperature down­wards (e.g. from 28°C up to 21°C = press 7 times).

The new set-value will be shown in the display:

The a/c operation is activated since the room temperature exceeds the
set-value by 7K. The blower speed is 100%, since the difference be­tween room temperature and set value exceeds 3K.
In case the room temperature and set value are roughly equal the
blower speed will be reduced and after the room temperature and set
value have reached the same level the evaporator blowers will operate
at the lowest possible speed.

Press key,

LED lights up , a/c op-

eration activated

Adjusted temperature e.g.:

is indicated.

press key 7xtimes

new set-value:

will be indicated and stored
after 5sec.

Switch Off a/c operation:

Press key , LED

goes out, a/c operation is
switched OFF

0 − 2 F

28 C

28

C

21 C

BAKL40T12AB Edition: 02.03.2017 Page: 9/14

5.2.1. Manual adjustment of the blower speed

The set value will be indicated in the display.

e.g. 21°C:

The blower speed will be indicated by an illuminat­ed display.

e.g. speed 100%:

Push shift-key „fan speed manual/automatic“:

Press key

:

LED „manual adjustment“ is lighting up

Reduction of the blower speed:

e.g. press 6 times :

New fan speed will be indicated:

− After 5 sec. the new fan speed will be
stored.

− The new fan speed will be indicated.

The automatic blower speed is deactivated.

Note: By pressing again the fan key the automatic
operation will be reactivated. The fan speed is
regulated depending on the difference between
the existing and set value.

Press key

:

LED „manual adjustment“ goes out.

Automatic blower speed is activated

.

5.3. Heating operation fully automatic =>

only in case of a/c units with heating option

− Basis: Actual existing room temperature of 10 °C

Desired temperature is indicated:

e.g. 21°C:

Blower speed actually 100%, will be indicated with
an illuminated display.

e.g. speed 100%:

Heating operation is activated since the room temperature is 11K below the set value. The evap­orator blower operates with the lowest possible speed. The blower speed will be increased since
the room temperature is more than 3 K below the set value. A requirement therefore is that the
air outlet temperature is higher than the set value. When room temperature and set value reach
roughly the same level the fan speed will be reduced. After room temperature and set value have
reached exactly the same level the evaporator blower will operate at the lowest possible speed.
The heating valve is 100% opened. When room temperature and set value reach roughly the
same level the heating valve will be cycle timed - see PID- performance. The air outlet tempera­ture will be constantly kept at the level necessary to achieve the preselected set value.

21 C

21 C

BAKL40T12AB Edition: 02.03.2017 Page: 10/14

5.3.1. Manual heating operation

=> only in case of a/c units with heating option

Press shift-key heating operation:

Press key , LED „manual Adjustment“

is lighting up

„H“ for manual adjustment of the heating valve will

be indicated in the display.

The valve control will be indicated by an illuminated
display.

Display 100%:

Reduction of the heating valve adjustment:

− heating valve adjustment 30% will be indicated
and after 5 sec. the new value will be stored.

− Automatic heating is deactivated.

e.g. press key 7 times:

:

New heating valve
adjustment 30% will be
indicated:

Note: By pressing again the heating key the auto­matic operation will be reactivated. The heating
valve will be switched on/off automatically depend­ing on the difference between existing value and
set value.

Press key

:

LED „manual Adjustment“ goes out
Automatic heating is activated

.

5.4. REHEAT activate / stop

=> only for in case of a/c units with heating option

Note: In the REHEAT- operation the compressor is constantly operating in order to dehumidify the
air. If required the heating is switched on by the control panel in order to prevent that the selected
room temperature changes.
REHEAT- operation is restricted to max. 10 min. After 10 min. the REHEAT operation is stopped by
the control panel. REHEAT will be activated for a period of 10 minutes.

Activate REHEAT operation

„rH“ will be indicated in the display:

Press key , REHEAT -operation is acti­vated

Blower speed 100% will be indicated with an illumi­nated display.

Blowerspeed 100%:

REHEAT Betrieb deaktivieren

Press again , REHEAT - operation is
deactivated

Set temperature value will be indicated e.g.21°C:

Blower speed of actually 60% will be indicated with
an illuminated display.

e.g. blower speed 60%:

H

21

21 21

21

CCCC

rH

BAKL40T12AB Edition: 02.03.2017 Page: 11/14

5.5. Switch Recirc. Air operation

=> only in case of a/c units with Rec. air flaps option

In case of recirculated air operation, 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 vehicle.
If windows are misting up, return air operation should be switched off:

Switch over from circulated air operation to fresh air
operation.

Note: If key is pressed again the fresh air flap
will be reactivated and circulated air operation
restarted (LED-display will light up).

LED light up, recirculated air operation is

active

Press key

,

LED is not lighting, fresh air operation

restarted



Note: After the switching on the control is adjusted to the set value stored before it was switched

off.

5.6. Change over of the temperture indication to ° Fahrenheit

Switch over:

Note: By pressing the „-“ and „circulated air“-key
the temperature indication switches over to Celsius
again.

press constantly, afterwards press the

key

Preselected set temperature value will be indi­cated in ° Fahrenheit.

6. Maintenance / Service

Please arrange regular dates for maintenance works and services with a KONVEKTA service sta­tion, 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 (EC) 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 mal­function 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

5 0 F

BAKL40T12AB Edition: 02.03.2017 Page: 12/14

6.1. Trouble indication in the display

ATTENTION:
In case of trouble indication in the display (F0 resp. F1) the control panel is not ready for op­eration. Operation of the a/c system only after verification by qualified a KONVEKTA-Service­Station



.

6.1.1. Trouble at the temperature sensor F0 (room sensor, blue):

A trouble at the room temperature sensor will be indicated by a flashing
display.

The control panel is not ready for operation. Only after the fault-finding and removal (for ex.
cable rupture, short-circuit, sensor not connected) the control panel can be operated again.

6.1.2. Trouble at the temperature sensor F1 (air outlet, yellow):

A trouble at the air outlet temperature sensor will be indicated by a
flashing display.

The control panel is not ready for operation. Only after the fault-finding and removal (for ex.
cable rupture, short-circuit, sensor not connected) the control panel can be operated again.

6.2. Oil change Compressor type KVX

Reference to maintenance Schedule Bus No.: WP 07 05 06 18 Item WK16:

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 com­pressor type (s. item 1.1).

6.3. Return air grid

Reference to Maintenance Schedule Bus:

Clean the return air grid in the passenger area monthly, in case of enormous dirt weekly.

6.4. Condenser coil

Reference to Maintenance Schedule Bus No.: WP 07 05 06 18 Item WK06:

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.

F 0

F 1









BAKL40T12AB Edition: 02.03.2017 Page: 13/14

6.5. Troubleshooting

Trouble Cause Repair by authorized Service Station only

a/c is not
running

thermostat open

− check inside temperature1

− re-adjust thermostat1

electric connection disconnected

−

check electric connections at switch-

board

relay defective

−

check relay, replace if necessary

defrost thermostat has switched off

−

check evaporator blower, replace if nec-

essary
outside temperature too low (possible
icing of evaporator)

−

switch on „ventilation“ only

evaporator coil dirty

−

clean evaporator coil with compressed

air
magnetic clutch

−

check connections at magnetic clutch

compressor does not compress

−

check high and low pressure, replace

compressor if necessary
excess pressure (pressure too high)

−

check axial fans

− check fuses at switchboard

− clean condenser coil with compressed

air
excess pressure caused by high out­side temperature

− run unit until pressure has stabilized1

leakage in a/c unit, lack of refrigerant

−

check a/c unit for leakages

− refill refrigerant
low pressure, screen of expansion
valve clogged

−

clean screen; replace dryer

Loud noise at
compressor

defective bearing at compressor

−

replace either bearing or entire com-

pressor

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

7. Warranty Conditions

The current „General Warranty Conditions KONVEKTA AG“ will apply. A copy will be furnished by
the warranty department. Please contact [e-mail]

BAKL40T12AB Edition: 02.03.2017 Page: 14/14

8. 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 (EC) No. 2037/2000 of the Euro-

pean Parliament and of the Council 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 pre­scriptions 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

Version Date Name Remark File

A00 07.03.2007 S. Pfluger source file BAKL40T12AB

A01 09.07.2007 B.Keßler Added KL45T and technical data BAKL40T12AB

A02 20.11.2007 B.Keßler Fact 1.1 has now been replaced and added

Fakt 1 “Important”

BAKL40T12AB

A03 18.03.2009 B. Keßler Pkt.1.2 updated; TM31 replaced by HDC 33 BAKL40T12AB

A04 17.02.2016 B. Keßler File completely revised (EC machinery directive,

pressure switches deleted…)

BAKL40T12AB

A05 23.06.2016 B. Keßler Added KL46T BAKL40T12AB

A06 02.03.2017 B. Keßler Information on the operating instructions and

technical data expanded with F-gas-regulation

BAKL40T12AB