KONVEKTA UL500, UL700, UL800 Operating Instructions 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 Instructions

for KONVEKTA

Air Conditioning units

UL500 / UL700 / UL800

with Wabco control system

R134a
24 Volt DC

ID#: BBA-KL6U022AA
Version: A03

BAKL6U022AA Edition: 28.02.2017 Page: 2/9

Contents

Page:

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

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

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

1.1. Air conditioner .................................................................................................................... 4

1.2. Compressors ..................................................................................................................... 5

2. Intended Use .................................................................................................................... 5

2.1. Operating Conditions ......................................................................................................... 5

3. Operation .......................................................................................................................... 5

3.1. Operation panel / function of the keys ................................................................................ 6

3.1.1. Flap for windshield/floor ..................................................................................................... 6

3.1.2. Desired value of front box temperature .............................................................................. 6

3.1.3. Blower speed ..................................................................................................................... 6

3.1.4. Smog ................................................................................................................................. 6

3.1.5. Heater passenger’s compartment ...................................................................................... 7

3.1.6. Additional heater ................................................................................................................ 7

3.1.7. Reheat ............................................................................................................................... 7

3.1.8. Driver’s seat air conditioning .............................................................................................. 7

3.1.9. General .............................................................................................................................. 7

4. Wartung ............................................................................................................................ 7

4.1. Troubleshooting ................................................................................................................. 8

5. Warranty Conditions ........................................................................................................ 8

6. Waste disposal in accordance with legal provisions .................................................... 9

7. History of modification .................................................................................................... 9

Appendix:

• Maintenance Schedule Bus WP07050618

BAKL6U022AA Edition: 28.02.2017 Page: 3/9

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 provi-

sions 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 improper han­dling, inadequate maintenance, applications that do not correspond with the determined use, utili­zation of non-admitted fuels or the non-observance of safety provisions.
KONVEKTA will annul without notice all obligations concerning guarantee, service contracts etc.
regardless if granted by KONVEKTA or its distributors in case other than original KONVEKTA
spare parts or parts bought from KONVEKTA AG have been used for maintenance and repair.
These operating instructions contain all necessary information to operate your air 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.

BAKL6U022AA Edition: 28.02.2017 Page: 4/9

Information on the operating instructions

These operating instructions are valid fort he air conditioners type:

 UL500  UL700  UL800

With Wabco control system



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/YY)

Date of first operation: ...................................................... (DD/MM/YY)

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 no­tice. 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

1.1. Air conditioner

Type

UL 500

UL 700

UL 800

Refrigerant

R 134a

GWP

1.430

Refrigerant quantity ca.

kg 8,5 9,5 10,5

Operating voltage

Volt DC 26 26 26

Power consumption

A 72 104 136

Cooling capacity

W 24.000 33.000 39.000

Evaporator – air volume

m3/h 4.320 6.480 8.640

BAKL6U022AA Edition: 28.02.2017 Page: 5/9

1.2. Compressors

Important:

To avoid leakage a the shaft seals of the compressor:

The compressor must be switched on every 4 weeks for about 15 minutes!
Even if the vehicles or the air conditioner has not been used for a longer period of time!

 Compressor is dependent on delivery, see nameplate on the compressor.

2. Intended Use

The KONVEKTA air conditioning unit is an air conditioning system that works with the ozone
friendly refrigerant R134a and which creates a pleasant and individually adjustable room 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.

2.1. 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
cupper- and aluminium components cannot 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.

3. Operation

Attention in case of roof top a/c units: Never switch on the a/c unit during car­wash!

Danger of accidents!

- 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 sun glare 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 per­formance of the air conditioning unit

BAKL6U022AA Edition: 28.02.2017 Page: 6/9

3.1. Operation panel / function of the keys

You operate the air conditioning unit via the original WABCO – control unit (see original
WABCO- operation instructions „ATC-CAN„)

For operation the driver can use 3 rotary potentiometer and maximal 5 keys. Depending on the
serial-model modification of the bus different control desks are used.
In order to release the driver from extensive adjustments for the passenger’s compartment he is
able to switch off the complete control for this area. All other functions on the control desk serve
for the individual adjustments of the driver’s cabin.

3.1.1. Flap for windshield/floor

The flap for windshield respectively floor are controlled according to the symbolism.

Arrow down:

flap for floor

The whole air is lead to the floor.

Arrow down/up: mid-position Air circulation is split up between floor and windshield.

Arrow up: flap for windshield The whole air is lead to the windshield

Symbol windshield: defrost Water valve completely opened; air to windshield; max-

imal blower speed.

The conversion is realized via characteristic curves which also facilitate intermediate positions.

3.1.2. Desired value of front box temperature

The blowout temperature of the front box can be set between 14 and 60º C.

3.1.3. Blower speed

The potentiometer serves for setting speed of the front box. The air velocity is increased by turn­ing the potentiometer clockwise.

3.1.4. Smog

With the smog key you can stop supply of fresh air for the whole bus. If smog function is activated
the key is illuminated. If this function is activated, the openings in the roof as well as the fresh air
flaps are closed for a certain time prescribed by the manufacturer.

Heater pas­sengers
compart-

Driver’s seat climate

Frontbox

temperat

ure

Smog

Flap windshield

/ floor

Reheat

Additional

heater

Blower

speed

BAKL6U022AA Edition: 28.02.2017 Page: 7/9

3.1.5. Heater passenger’s compartment

The driver doesn’t have the possibility to intervene in the fully automatic control of the passengers
compartment. This control is merely turned off during routes without passengers (e.g. transporta­tion of bus). If automatic function is activated the key is illuminated.

3.1.6. Additional heater

Normally the additional heater is turned on manually. If additional heater is activated, the key is
illuminated.

3.1.7. Reheat

With the key Dry / Reheat the air conditioning unit is put into operation. The air is dried by cooling
down and re-heating.

3.1.8. Driver’s seat air conditioning

Diese Funktion schaltet das Kältemittelmagnetventil bzw. die Kompressormagnetkupplung ein.
Bei aktivierter Klimaanlage leuchtet die Taste.

3.1.9. General

Roof ventilator: Roof ventilators are activated from a certain minimum speed of the roof evapora­tor blowers. In circulated air operation the roof ventilators are switched off.

4. Wartung

For maintenance works we refer to our maintenance instructions BWA-KL6U022AA, which have
been written exclusively for maintenance personal. 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

BAKL6U022AA Edition: 28.02.2017 Page: 8/9

4.1. Troubleshooting

Only qualified staff is allowed to carry out these works!

Trouble Cause Repair by authorized Service Station only

a/c is not
running

thermostat open

check inside temperature 

re-adjust thermostat 
electric connections disconnected check electric connections at switchboard
relay defective check relay, replace if necessary
defrost thermostat has switched off check evaporator blower, replace if neces-

sary
outside temperature too low (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 com-

pressor 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 out-

side temperature

run unit until pressure has stabilized

leakage in a/c unit, lack of refrigerant check a/c unit for leakages, refill refrigerant
low pressure, dryer clogged replace dryer
low pressure, screen of expansion

valve clogged

clean screen; replace dryer

Loud noise
at compres­sor

defective bearing at compressor replace either bearing or entire compressor
slack V-belt check V-belt at compressor drive



By operator

5. Warranty Conditions

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

BAKL6U022AA Edition: 28.02.2017 Page: 9/9

6. Waste disposal in accordance with legal provisions

After the phase of use the last proprietor is responsible for the adequate waste 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

• Law for waste circulation (KRW/AfgG))

• Resolution for the proofs of utilization and

removal

• Criminal Code (StGB) 28th section „crimi­nal acts against the environment” §326 ­Environment jeopardizing waste manage­ment

• Law of chemicals § 27 - penal prescriptions

•

Resolution for used oil

• Law of water balance

• Resolution for the waste management of old

cars and the adaptation of road prescrip­tions

• Resolution (EC) No. 2037/2000 of the Euro­pean Parliament and of the Council for ma­terials that affect the ozone layer

• 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

7. History of modification

V

ersion Date N

ame

Remark

File

A00 03.02.2010 B. Keßler Source file BAKL6U022AA

A01 21.01.2014 B. Keßler Added safety instructions (Foreword), Ma-

chinery Directive p.4 updated, updated risk of
accidents Pkt.4 and item 5 mail address

BAKL6U022AA

A02 03.11.2016 B. Keßler Item 1.2 pressure switches deleted BAKL6U022AA

A03 28.02.2017 B. Keßler Information on the operating instructions and

technical data expanded with F-gas­regulation

BAKL6U022AA