KONVEKTA KL60CT/4 User manual

KONVEKTA AG

ID#: BA- KL6C502AA

P.O.Box 2280

34607 Schwalmstadt

GERMANY

e-mail: aftersales@konvekta.com Tel.: (+49) 6691/76-0

Internet: www.konvekta.com Fax.: (+49) 6691/76-200

Operating Instruction

for

KONVEKTA Air Conditioner

KL60CT/4/fully automatic version

With digital air conditioning control system KS105

• R134a

• 24Volt DC

• Compressor: FKX4 / KV4

FKX24 / KV5

FKX40 / KV6

BAKL6C502AA.doc

KONVEKTA AG

Edition: 12.07.2001

Page: 2/13

Contents

Page:

• Foreword ..............................................................................................................................3

• Notes to the Operating instruction .....................................................................................4

Technical data air conditioner ..........................................................................................5

1.1.

Pressure Switch................................................................................................................5

1.2.

Technical data compressors .............................................................................................5

1.2.1.

Type KONVEKTA KV4-KV6 ..........................................................................................6

1.2.2.

Type FKX.......................................................................................................................6

Determined use..................................................................................................................7

Working with air conditioning unit...................................................................................7

Task and function of air conditioning unit.......................................................................8

4.1.

Task of the air conditioning unit ........................................................................................8

4.2.

Function of the air conditioning unit ..................................................................................8

4.2.1.

Return Air/Mixed Air/Fresh Air Flap................................................................................8

4.2.2.

Evaporator Blowers........................................................................................................8

4.2.3.

Cooling Operation..........................................................................................................9

4.2.4.

Heating Process ............................................................................................................9

Operator Controls............................................................................................................10

5.1.

Operation panel / function of the keys............................................................................. 10

Maintenance / Servicing ..................................................................................................11

6.1.

Period of maintenance.................................................................................................... 11

6.2.

Return air grid.................................................................................................................11

6.3.

Condenser coil................................................................................................................ 11

Trouble check list ............................................................................................................12

Regulation of damages during the warranty period...................................................... 13

Adequate waste management......................................................................................... 13

Append.:

• KONVEKTA Service Stations

• Registration card / service proof

BAKL6C502AA.doc

KONVEKTA AG

Edition: 12.07.2001

Page: 3/13

Foreword

This operating instruction has been written for drivers, users and maintenance personnel of your air

conditioner.

It contains:

Operating instruction

Security informations

Registration card

This operating instruction has studied and applied from the first taking into operation and lateron

regularly by each person who is involved in handling the machine, e.g.:

Operation including trouble clearing, care and waste management of fuels and auxiliaries.

Maintenance, inspection, repair

Transportation

This makes the user’s training easier and troubles by unproper handling will be avoided. Compli-

ance with the Operating instruction by the maintenance personnel increases the reliability during

operation, increases the life time and reduces expenses for repair and loss of time.

The national prescriptions for accident prevention and environment protection are to be

added to this instruction.

The Operating instruction belong to the air conditioner . Please keep one copy handy in the

driver’s cabin.

You will certainly understand that we will not recognize any warranty claims due to unproper han-

dling, inadequate maintenance, applications that do not correspond to the determined use, utiliza-

tion of not admitted fuels, or the non-observance of security prescriptions.

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 contain all necessary information to operate your air conditioner. In case

you need more explanations please contact the next KONVEKTA service station

see hand book: „KONVEKTA Service Stations“

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KONVEKTA AG

Edition: 12.07.2001

Page: 4/13

NOTES TO THE OPERATING INSTRUCTION

This Operating instruction is valid for the air conditioners type:

• KL60CT/4/

When taking the unit into operation we recommend to add the following data.

This will also be important for your orders of spare parts, and in case of warranty.

Serial number of the unit:

Order No.: A (X) /

Year of construction: / (MM/JJ)

Date of first operation: / /(TT/MM/JJ)

The machine corresponds to the security prescriptions of the EC # 89/392/EWG i.d.F.

91/368/EWG and 93/44/EWG.

Due to the fact that scope of supply depends on the order, equipment of your product may

differ in some parts of description.

In case your product is equipped with details not shown or described in the operating in-

struction, your KONVEKTA -Service-Station will always be at disposal for informing you

about correct operation.

In the course of further developments we reserve the right to technical modifications without

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

BAKL6C502AA.doc

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Edition: 12.07.2001

Page: 5/13

1. Technical data air conditioner

Type KL60CT/4

Refrigerant R134a

·- quantity approx. kg

Operating voltage Volt DC 24

Current consumption A 65

Cooling capacity W 22.000

Air volume m

/h 28.000

Measurements: 4.800

- length mm

- width mm 2.596

- height mm 1.800

Weight of unit, kg 215

170

1.1. Pressure Switch

Low pressure switch 0,3 ± 0,1 bar off 2,1 ± 0,2 bar on

High pressure switch 25,5 ± 0,5 bar off 18,0 ± 1,0 bar on

1.2. Technical data compressors

Important:

In order to avoid leakages on shaft packing of the compressor you have to distinguish two different

cases:

1. If the vehicle itself is withdrawn from operation for a longer time, it is also not necessary to switch

on the compressor.

2. If the vehicle is used for a longer time without using the cooling unit, it is recommended to acti-

vate the compressor every two weeks. Otherwise the shaft packing of the compressor could be

damaged by vibrations of the motor.

Refrigerant R134a

The chlorine-free refrigerant R 134a is used for charging the air conditioner. The traditional refriger-

ant R 12 is replaced by R 134a. Air conditioners already charged with R 12 should not be recharged

nor newly charged with R 134a. This is also valid for components used with R 12. They should not

at all be used in units to be charged with R 134a.

Mineral oils used in units with R 12 must not be used in units with R 134a. In this case synthetic oils

are to be used. The application of mineral oils in connection with R 134a would cause a break down

of the compressor, as the miscibility of mineral oil and R 134a and, thus the refrigerant circuit, are

not ensured.

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Edition: 12.07.2001

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1.2.1. Type KONVEKTA KV4-KV6

Compressor Type KV 4* KV 5 KV 6*

Weight

32 kg 32 kg 32 kg

Oil brand / quantity Esteröl SE55 / 2l Esteröl SE55 / 2l Esteröl SE55 / 2l

Magnetic clutch

24V DC 24V DC 24V DC

1.2.2. Type FKX

Compressor Type FKX40/

465/555/650

FKX4 FKX24

/465/650*

Weight

35 kg 45 kg 39 kg

Oil brand / quantity Esteröl SE55 / 2l Esteröl SE55 / 2l Esteröl SE55 / 2l

Magnetic clutch

24V DC 24V DC 24V DC

1) Weight without Electro-magnetic clutch (witch clutch app. + 10kg).

2) ø depending on vehicle type

* for articulated bus

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Edition: 12.07.2001

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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 tempera-

ture by means of forced convection. The determined use includes also the observance of the Oper-

ating instruction and the proof of regular inspections as well.

3. Working with air conditioning unit

• ACTIVATING CONDITIONS:

Control system does only work if ignition/D + and release of switch S362 are applicable. If one of

the 3 signals is interrupted, control system starts to close all outlets.

• SELF CONTROL:

If control system on 24VDC is connected, self control is started in order to execute a trouble check

of the whole system.

•

Short circuit of the digital outlets

•

Re-registration from compressor and return air flap

•

Sensor data

•

Internal system

Setpoint room temperature:

If automatic control system of the a/c unit is switched on, control system starts to calculate a com-

fortable room temperature measured on basis of the outside temperature.

Outside temperature: Setpoint room temperature:

-30°C up to 25°C Between approx. 22°C and 24°C

25°C up to 30°C approx. 3K below outside temperature

30°C up to 70°C approx. 27°C

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Edition: 12.07.2001

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4. Task and function of air conditioning unit

4.1. Task of the air conditioning unit

− to dehumidify the air

− comfortable room temperature

− to guarantee sufficient fresh air

4.2. Function of the air conditioning unit

− A/C unit only operable with running engine

− A/C unit has to be switched on by air conditioning switch (S362)

− Room temperature is reached automatically in dependence of the outside temperature

− Defrosting thermostat (on evaporator), low pressure switch (on evaporator) and high pressure

switch (on condenser) do supervise cooling circuit.

− In case of disturbance compressor is automatically interrupted. Signal light „disturbance air con-

ditioning„ (H218 red) is flashing up. See Chapter 7, (Fault indicators and corrective action).

− In case of an eventual damage of the a/c unit - operation should immediately be inter-

rupted to avoid consequential damages. It’s recommended to contact one of KONVEKTA’s

Service Stations

and the unit should first be taken into operation again after it has been

checked through specialists.

4.2.1. Return Air/Mixed Air/Fresh Air Flap

In dependence to the outside temperature, air flap is automatically changing to return-, mixed- or

fresh air.

Outside temperature: - 30°C up to approx. 10°C Circulated Air

10°C up to approx. 18°C Mixed Air

18°C up to approx. 23°C Fresh Air

23°C up to approx. 28°C Mixed Air

28°C up to approx. 70°C Circulated Air

4.2.2. Evaporator Blowers

The evaporator blowers are continuously activated through difference of room temperature. Control

response of 40% up to 100% air performance works at approx. 2°C above setpoint temperature.

During heating process, it is permanently air conditioned with 30% air performance.

Blower Reduction Activated Through Tacho-Contact:

Blowers are reduced by tacho-contact (below 5km/h + 24 Volt) at 40% air performance and after

release they are immediately adjusted to run slowly and uniformly, if required also with higher

speed range.

see hand book „KONVEKTA Service Stations “

BAKL6C502AA.doc

KONVEKTA AG

Edition: 12.07.2001

Page: 9/13

4.2.3. Cooling Operation

The compressor is working in dependence of room temperature.

Compressor ON 100% 2°C above setpoint temperature

Compressor OFF 100% 1°C below setpoint temperature

Both condenser fans are also activated.

In case of switching on the a/c unit, rotational speed of condenser fans is increasing continuously

from 0 - 100% specially by means of starting modules .

If pressure of refrigerant circuit is exceeding 17 bar, condenser fans work with maximum rotational

speed. If pressure drops under 12 bar, rotational speed is reduced to 50% by means of pressure

switch (rotational speed/condenser fan).

NOTE: Pressure Switch (rotational speed/condenser fan „P„) placed on condenser

Set up 17 bar on

12 bar off

Starting module placed on electric mounting plate inside return air suction.

4.2.4. Heating Process

Digital outlet heating performance:

If heating is required in roof-and floor area, the digital outlet starts to work, in order to open the main

water valve. The digital outlet has a coast down time of 10 minutes maximum. If heating-and cooling

performance is required, outlet „heating performance„ is automatically in operation.

Roof-Heating:

The roof top unit is equipped with a water valve driven with a direct current motor. Depending on

status of the pole, valve will be opened or close. In order to avoid that valve is opened or closed

immediately, controlling works with time cycle.

Valve OPEN -> 1 sec. Valve CLOSED -> 1 sec.

STOP -> 25 sec. STOP -> 2 sec.

Heating Floor:

Heaters equipped with a mixing valve (de-energized open, which means digital outlet ON, valve

closed!) working with time cycle depending on heating performance and a water pump transport-

ing water into heating circuit. The water pump has a coast down time of 10 minutes after the last

heating process.

Underseat-Heater with 2 step collector switch, which is automatically switching to heat perform-

ance (0/1/2) which always starts to work in dependence to the measured floor-area-temperature.

Step 1 on: approx. 4 K below setpoint temperature

Step 2 on: approx. 6 K below setpoint temperature

Step 2 off: approx. 4 K below setpoint temperature

Step 1 on: approx. 2,5 K below setpoint temperature

BAKL6C502AA.doc

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Edition: 12.07.2001

Page: 10/13

5. Operator Controls

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 prop-

erly.

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

− Take into consideration that the keys at the operation panel are not designed for extreme de-

mands.

− An excessive or quick pressing of the keys / potentiometers for temperature adjustment does not

accelerate the cooling process but leads possibly to a damage on the operation panel and spoils

the total functioning of your air conditioner.

5.1. Operation panel / function of the keys

(BBZW0014) (BBZW0015)

S362 H218 S363 S411

a/c switch signal lamp switch Reheat Smog switch

disturbance

REHEAT:

Humidity Extraction

While activating switch „Reheat (S363)„, compressor starts to work for 20 minutes, which let

temperature in channel go down. Then heating valve is opened until setpoint temperature in

the channel is reached.

SMOG/RETURN AIR

If smog switch (S411) is activated, return air-, /mixed air-/ fresh air flap changes to position

return air, even if air flap position is e.g. adjusted to fresh air position.

Note: After a while switch has to be readjusted to position mixed - or fresh air.

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