Service Manual

Chapter 18 - Air conditioning

Air conditioning................................................................................................................................................. 18-3
1 Operating instructions for KL5 .......................................................................................................... 18-3
1.1 Technical data ........................................................................................................................ 18-3
1.2 Function and operation of the unit .......................................................................................... 18-3
1.3 Handling of A/C ...................................................................................................................... 18-4
1.4 Compressor ............................................................................................................................ 18-4
1.5 Refrigeration scheme ............................................................................................................. 18-5
1.6 Servicing................................................................................................................................. 18-6
1.7 Trouble check list.................................................................................................................... 18-7
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 Service Manual Air conditioning
Operating instructions for KL5

18 Air conditioning

18.1Operating instructions for KL5

18.1.1Technical data

Operating voltage 24 V DC
Refrigerant R134a
Cooling capacity 10.000 Kcal / h
Evaporator air volume 3000 m3 / h
Condenser air volume 4800 m3 / h
High pressure switch 23,5±0,5 bar cut - off
16,0±0,5 bar on
Low pressure switch 0,1 bar cut - off
2,2 bar on
Compressor SANDEN SD7H15

18.1.2Function and operation of the unit

18.1.2.1Function of the unit

• It dehydrates the air.
• It creates a pleasant room temperature (7 - 10°C below outside temperature).
• It provides sufficient fresh air (units equipped with fresh air facility).

18.1.2.2Operation of the unit

• Air conditioner is only ready for work if vehicle engine is running.
• Air conditioner is switched on by control switch (S1 + S2).
• The desired room temperature is adjusted via potentiometer.
• If then adjusted temperature is achieved, the compressor switches off and the condenser fans stop func-
tion.
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Operating instructions for KL5

18.1.3Handling of A/C

18.1.3.1Operation instruments

Control potentiometers S1 and S2 :

S1 : Control of the ventilation speed.
S2 : Control of the temperature.

18.1.3.2Adjustments
• Turn the air conditioner fan manipulating S1.
• Turn on the air conditioner compressor and the condenser manipulating S2. The air conditioner can only
be turned on if the evaporator fan unit is turned on with S1.
• Adjust the desired air flow with S1.
• Adjust the desired temperature with S2.

18.1.4Compressor

Type SANDEN SD7H15

Inlet connection 1 1/16´´ O-ring
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Outlet connection 1 1/16´´ O-ring

Magnetic coupling 24 Volt DC - 5¼´´
Power consumed 50 W
RPM From 400 to 6 000 (max.)
Mounting Angle max. 45°
Oil PAG 207 cc
Weight 7,5 kg

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Operating instructions for KL5

18.1.5Refrigeration scheme

1 Condenser 9 Evaporator
2 High pressure switch 10 Distributor
3 Pressure valve 11 Expansion valve
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4 Compressor 12 Defrosting thermostat

5 Suction valve 13 Sight glass
6 Low pressure switch 14 Drier
7 Compensation line 15 Manual cut-off valve
8 Capillary tube with sensor 16 Receiver

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Operating instructions for KL5

18.1.6Servicing

18.1.6.1Return air grid

Clean the return air grid in the cabin once a week.

18.1.6.2Condenser coil
• Clean the condenser once a month.
• Remove the cover to the condenser space.
• Blow threw the condenser coil with compressed air.

18.1.6.3Sight glass
The sight glass is situated at the condenser.

18.1.6.4Check refrigerant level

• Switch on unit (switch position S1 + S2 air conditioning).
• Sight glass clear : refrigerant level all right.
• If air bubbles are formed : consult customer service agency.
• Refrigerant receiver.
Due to an operational overpressure in the receiver, its manufacture is subject to a special prescription (pres-
sure tank decree from April 1989). By this decree the pressure tanks are subdivided in test groups : admitted
operational overpressure in bar «p», volume in litres «l», pressure tank contents «p x l». On these conditions,
the refrigerant receiver is to be qualified in test group II.

Attention!
§10 of the decree for pressure tanks says that a periodical test by an expert (§32) has to be
executed. Those tests refer to an outside checking of the tanks in operation.
The refrigeration receiver has to be checked for outside damages twice a year (see Konvekta
general conditions for sale and delivery under 8b). Especial attention should be paid to corro-
sion and mechanical damages. If it is any how damaged, it must be changed by reason of sa-
fety.

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Operating instructions for KL5

18.1.7Trouble check list

Trouble Cause Repair

A/C does work Thermostat is cut off Check inside temperature

No cooling capacity Reset thermostat

Electric wiring disconnected Check electric connections at clutch

A/C does not work Relay defective Check relay

Loose drive belt Check drive belt at compressor

Excessive pressure Check whether axial fans are running

A/C does not work Press safety switch and clean condenser
fins
High pressure switch has
switched off Excessive pressure caused by Let unit run until pressure is stabilised
high external temperature

Leak in unit Check unit for leaks

Deficiency of refrigerant Recharge refrigerant, consult refrigerant
A/C does not work expert

Negative pressure, drier con- Replace drier, consult refrigeration expert

Low pressure switch has
gested
switched off
Negative pressure, sieve of Clean sieve; renew drier, consult refrigera-
expansion valve congested tion expert

Heavy noise at compres- Ball bearing at compressor Replace ball bearing or complete com-
sor defective pressor (consult refrigeration expert)
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Operating instructions for KL5

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From Acid
to
Oxygen

Important

Konvekta Know-Hows

Stand: 09/02

KONVEKTA AG
Postfach 2280
34607 Schwalmstadt
ID#: TKD-00041 GERMANY
Tel. 06691/76-0
Fax. 06691/76111+76121
Editorial

Dear reader,
with the following brochure, Konvekta wants to give you a guideline on handling and servicing of
Konvekta
cooling units, in order to reach a better and smoother cooperation between Konvekta and its
partners.
We wish you a nice time while reading and would be grateful for any constructive recommendation on
optimising this brochure.

Contact persons is
Mr. Lothar Stehl from the After Sales Department,
Tel.: (+49 ) 06691 76124 or 76164
Fax: (+49 ) 06691 76121
 Contents

1. Description of abbreviations used with KONVEKTA products

2. Compressor
3. Condenser coil
4. Liquid receiver
5. Filter drier
6. Sight glass
7. Expansion valve
8. Evaporator coil
9. Pressure switch
10. Manual shut-off valve
11. Refrigeration scheme
12. Refrigerant oils
13. Refrigerant
14. Leakage test
15. Drying and evacuation
16. Function of dry process
17. Sketch of refrigerant circuit for charging
18. Charging and evacuating of cooling machines
19. The function of the lubricant in the compressor
20. Installation instructions
21. Air distribution
22. General indications for repair and maintenance work
23. Service and maintenance
24. Instructions to charge air conditioners with R134a
25. Conversion instructions from R12 to R134a for a/c`s with Bock-compressors
26. Mounting instructions for re-usable hose fittings
27. Inspection report
28. Security during repair and maintenance work
29. O-Ring fittings
30. Bending radius for KONVEKTA refrigerant hose pipes
31. Pressure switch
32. Defrosting thermostat
33. Compressor detail
34. Conversion (Psi ; Bar ; °C ; °F)
35. GWP/ODP
1. Description of abbreviations used for KONVEKTA-products

Konvekta is manufacturer for refrigeration, air conditioning and heating systems which are
composed of numerous original Konvekta parts. Abbreviations for those products do appear
in
documentation material. Most of the names of Konvekta-products start with the following
abbreviations.

Kind of part

KL air conditioner, which may include a heating arrangement or not

HLK, HKL special series of compact heating, ventilating (return & fresh air)
and air conditioning units
FK chilling units for temperatures down to 0°C
TK deep freezing units for temperatures above and below 0°C
TKH deep freezing units with hydraulic drive
TKD deep freezing units with diesel engine drive
VD evaporator and heating coils
KD condenser
UKD under-floor condenser
DKD roof-top condenser
HKD horizontal condenser

Capacity classes

Air conditioner KL and HKL (HLK is an exemption) are numbered e.g. from KL1 to KL12
whereby a KL2 is smaller than a KL3. On the new generation of KL units we will add an 0
e.g. KL60 or KL70.
FK and TK units have higher number codes e.g. FK2250 which are comparable to the
cooling
performance at the standard temperatures of 0°C inside and 30°C outside in watt.

Version / kind of construction

The description e.g. KL6 is followed by letters e.g. KL6AFT.

The meaning of these abbreviations is as follows:

A means roof top unit

F means flat design
R means round and flat design e.g. at KL6ART
T means for tropical use ( up to 55°C outside temperature )

on units without "T" the performance is given at 38°C outside.

"T" units are heaving a bigger condensor.
C means this letter refers to compact design and often means that the unit's
capacity is weaker than other units of this class
I means fully integrated unit
Split means separate VD & KD, most of the time the KD will be outside and the VD inside
2VD means two evaporator versions
4VD means four evaporator versions
T/N means day / night, stand by operation at FK & TK units in 220V or 380V
Type of refrigerant

After product-category, capacity-class and version, the type of refrigerant will be indicated in
the product name.

/2 means refrigerant R 12
/3 means refrigerant R 22
/4 means refrigerant R 134a
/5 means refrigerant R 744, Co2
/6 means refrigerant R 404

2. Compressor

The main component of a unit is an open compressor which transports the refrigerant within
the
circuit and compresses the refrigerant to an energetic higher level. It is driven by a V-belt.

If there are more than 800 mm between the middle of the main-engine and the magnetic
clutch it is necessary to install a tension-pulley into the slack side of the V-belt. In case of
stop and go or idle
operation the main-engine speed has to be lift up to 1200 rpm. The outlaying of the main
engine
(pulley) size is to do as following:

rpmmk x d2
D1 = ------------------
rpm me

D1 = diameter main-engine (pulley)

d2 = diameter compressor magnetic clutch
rpm mk = max. possible rpm of compressor
rpm me = max. rpm of main-engine

3. Condenser coil

The air admitted fin condenser leads the thermal efficiency to the ambient air and condenses
the
gaseous refrigerant.
The fins have to be free of dirt and damages. If one fan is defect, it has to be replaced,
otherwise
there is an air short circuit which is pressing down the cooling-performance enormously.

4. Liquid receiver

Behind the condenser a liquid-receiver is installed. Inside the heavy liquid will go down to the
bottomand the gas will stay on top. Due to a pipe (inside of the liquid-receiver from the
bottom to the exit)
the liquid refrigerant will be guided to the exit which is marked with an "A". This is in order to
insure
that bubble free refrigerant is on the entrance-side of the E-valve.
In case of corrosion or mechanical damages the receiver bottle has to be replaced by
reasons of
explosion. While replacing, take care of the mounting direction. The exit is marked with an
"A" and
the top side is marked with a button "oben".
5. Filter drier

At evaporation temperatures of below O°C water deposits ice on the expansion-valve which
leads tounit deficiency. Humidity in the unit does also produce corrosion damages and
possible acids.
In order to avoid problems with humidity and foreign particles inside the circuit, sieves and
filters are installed in the filter drier.
It is necessary to change the filter drier in air conditioning units once a year, in refrigeration
and
deep-freezing units twice a year because their capacity is limited. Filter drier also have to be
changed after each opening of the refrigerant circuit. A filter drier does not replace
evacuating!

The arrow symbols on the filter drier have to be placed in direction to the expansion-valve.

6. Sight glass

During operation, liquid refrigerant must pass bubble-free through the sight glass in front of
the expansion-valve.

If bubbles occur it mostly means loss of refrigerant but there is also the possibility of
overheated
refrigerant due to a defect condenser fan or stuffed fins. Another possibility might be that
these
bubbles are air-instead of gas bubbles. If the sight glass is installed directly behind the filter
drier thedrier could be stuffed as well.

7. Expansion valve

KONVEKTA uses thermostatic expansion-valves in most of the units. This kind of expansion-
valve
works very exactly because it takes the temperature and the pressure behind the evaporator
and it
adjusts the difference to approx. 7 K operation overheating.
On the new and on the mounted expansion-valves the adjustment is already done. It is
important to
take the original expansion-valve with the original adjustment in order to avoid damages of
the
compressor concerning liquid or less performance. There is a particle sieve on the entrance
side
of the expansion valve.

The expansion-valve takes the high pressured liquid refrigerant to low pressure. At this
pressure the liquid refrigerant wants to expand into gas which means that the refrigerant
requires heat. For this
refrigerant needs heat. This is the cooling effect.
8. Evaporator coil

The evaporator is an air-admitted ventilator air cooler. The hot air touches the evaporator fins
and
delivers the heat across the fins and tube walls to the refrigerant. By reason of the heat
absorption
the refrigerant evaporates.

The coil must be free of dirt and without damages. All blowers have to run in order to avoid
air short circuit.

There is a defrosting thermostat at the evaporator coil which is cutting in and off the
magnetic clutch.

9. Pressure switch

As soon as the maximum pressure at the high pressure side or the minimum pressure at the
low
pressure side is reached, a pressure switch shuts off the magnetic clutch.
This prevents a destruction of the unit. If the pressure at the compressor on the low pressure
side is more than 4,5 bar the compressor pressure switch (cp) gives current to an indicator
lamp.
This means that the compressor is not working well.

10. Manual shut-off valve

If the refrigerant wanted to be collect in the condenser and in the receiver, the manual shut-
off valve has to be shut. This is necessary in case of any works at drier, expansion valve or
evaporator. The
refrigerant must be removed by suction of the unit compressor.

In case of repair works at condenser or receiver, the refrigerant must be emptied and
collected in a
special tank. The collected refrigerant can be cleaned and re-prepared by refrigerant
manufacturers.
11. Refrigeration Scheme

1 compressor 2 condenser

3 receiver 4 drier

5 sight glass 6 expansion valve

6a compensation line 6b capillar tube with sensor

7 evaporator 8a low pressure switch

8b high pressure switch 9 manual cut-off valve

10 suction valve 11 pressure valve

12 defrosting thermostat 13 distributor

12. Refrigerant oils

Due to technical reasons it is not possible to keep the oil, necessary for compressor
lubrication, at a level of 100% inside the compressor circuit. Therefore it is required to adjust
oil and its quantity to
the used quantity of refrigerant. Oil quantity should be amount to 10% of refrigerant weight. If
fill up
of oil is necessary, it is only allowed to use the same kind of oil which is already used in the
compressor. Even the used oil for hose connections has to be the same kind of oil used for
the
compressor because a mixture of different oils can cause lumping and other chemical
reactions.

In case of pressureless compressors oil can directly be added into oil tank, pressureless
refrigerant units can be filled directly at pressure side or it is also possible to put the oil into
pressure side of
refrigerant unit while evacuating.

13. Refrigerant

General marks:
Every compression-cooling machine has refrigerant in its system, which is normally filled in
once
and never removed or exchanged until the unit is dismantled after 10, 30 or more years.
Precondition for this is that the refrigerant circuit is closed. (The circuit in a household
refrigerator is nearly 100% closed).

With flexible hoses, however, the circuit of an air conditioner is not absolutely closed. The
function ofthe compressor is to suck the " transport medium" from the evaporator and press it
into the
condenser. Within this circuit the refrigerant changes permanently its state of aggregation in
the
evaporator from a liquid to a vaporous state and in the condenser from a vaporous to a liquid
state.

The refrigerants for compression-cooling machines should have a small vapour volume, a
high
evaporation enthalpy and a low condensation pressure. They should be non-toxic, non-
combustible and non-explosive. The available "safety refrigerants" correspond widely which
these requirements.
As nomination of these refrigerants the letter symbol "R" (refrigerant) is internationally used,
e.g. "R12" (exactly Dichlordifluormetan CCL2F2)
14. Leakage test

For the combined pressure and leakage test procedure, it is always recommendable to fill the
A/C
unit with the required test pressure of 22 bar with dry nitrogen, whereby the nitrogen has to
be takenfrom a reduction valve at the nitrogen container only.

In case of a pressure reduction in the circuit, the leakage has to be detected. There are
various
methods to detect a leakage. With these methods any leaking gas being pressurized can be
detected. There are: using foam and soap solutions as well as immersions into liquids.
Besides
there exists the possibility ( in case of Fluor-Chloride-Hydrocarbon) to detect leakages by use
of
chemical and electrical methods. The flame of a halogen test-lamp disintegrates the
refrigerant and a colour appears from blue to green. The detection accuracy is about 1
gr/day.
Electronic leakage detectors have a much better sensitivity, with a detection accuracy of 1
gr/year.
It is not possible to use usual electronic leak detectors for R 134a because these sensors are
not
sufficient enough to realize refrigerants without chlorine components.
The leak searching lamp reacts to chlorine in the refrigerant and is therefore not suitable for
R134a. Furthermore R134a already escapes from smaller leaks in comparison to R12.
There are special
leak searching detectors which can be used for HFCKW refrigerants realizing a refrigerant
loss of
3-5g per year.
15. Drying and Evacuation

The purpose of evacuation of cooling units working with R-refrigerants is not only to create a
vacuum for the charging with refrigerant, it is also done to control the tightness over a certain
waiting-time. Another important factor during this procedure represents the drying of the unit.
Just
traces of humidity within the refrigerant-circuit can mix with the refrigerant and the oil; this
could leadto various consecutive damages.
The motor-driven compressor should ot be used to evacuate the unit, because the coils and
gear of the compressor would be damaged.

For this purpose a vacuum pump is being used, which should achieve a vacuum below
30 Micron = 0,0399 mbar.

There are practical and economic combined units available, suitable to evacuate and charge
cooling units.

It is always recommendable to warm up the vacuum pump while suction valve is closed and
then
only start with the evacuation procedure.

For this working procedure vacuum pumps have to be used in accordance to the size of each
unit
with a suction performance of more than 100 L/min and less than 30 micron (0,00003 bar)
end
pressure.

It is common procedure to evacuate the unit to a final stand vacuum of

1 Torr = 1,33 m bar = 0,00113 bar.

The exact time for the evacuation and drying process cannot be predicted. There are
sometimes
interruptions during the evacuation procedure.

At an ambient temperature of 20° C and a pressure about 22,5 m bar, the boiling point of
water is
reached. If the unit has been mounted with the necessary carefulness, it will not take long to
suck offthe complete humidity.

When the desired vacuum of 1 Torr has been reached, the valve between vacuum pump and
unit must be closed.

16. Function of dry process

Water evaporates at normal ambient pressure (1.013 mbar) and absolutely at 100°. If
pressure is
reduced, water evaporates e.g. at 10 mbar, already at nearly 7°C ambient temperature, but
the
whole quantity of water does not evaporate at once. As it is difficult to get vapor out of the
unit's
vacuum, the evacuating process is supported by the so called vacuum break (filling of the
circuit
with dried nitrogen). While operating with vacuum break the filled in, dried nitrogen does
absorb the humidity out of the refrigerant circuit which can then be exhausted in common
with the nitrogen.

Boiling temperature Absolut-pressure

in °C in mbar

100,0 1013,000
96,1 703,947
90,0 691,482
80,0 467,226
70,0 307,474
60,0 196,516
50,0 121,653
40,0 72,524
30,0 41,776
26,7 33,421
24,4 30,079
22,2 26,737
20,6 23,395
17,8 20,053
15,0 16,711
11,7 13,368
7,2 10,026
0,0 6,016
-6,1 3,342
-14,4 1,671
-31,1 0,334
-37,2 0,167
-51,1 0,033
-56,7 0,017
-67,8 0,003
17. Sketch of refrigerant circuit for charging

18. Charging and evacuating of cooling machines

The charging of refrigerant into the dried, evacuated and oilfilled machines is being done
under
various conditions.

For units in operation, refrigerant can only be charged as vaporized refrigerant to the suction
side.

It has to be observed that the volume of intake to the unit is not exceeding, because an
overcharging could happen.

It is necessary to control the weight of the refrigerant during charging.

During proper operation of the unit the receiver should be 1/3 filled with liquid refrigerant, the
evaporator has to be filled to the maximum (based on the precalculated evaporation
temperature),
this means that the suction line should only be a few degrees warmer than the evaporation
temperature indicated at the manometer.

The "riming" of the suction line is no sign for the judgement of the charging state, especially
for
deep-freezing units.

Evacuating during repair:

During repair works cooling machines have to be discharged off refrigerant in most cases.

Mostly, especially in case of expensive refrigerants and bigger oil quantities it is advisable to
save
the refrigerant for re-use.

For re-use the refrigerant needs to be discharged by a recycling unit.

Soldering and welding jobs should be executed under blowing which a small quantity of
nitrogen.

In case of simple mechanical procedures for example replacing of a part with fittings, it is
possible,
after recycling of refrigerant, to give nitrogen to the circuit (approx. 0,5 bar).

So during the repair nitrogen streams out of the open points and avoids the penetration of air
and
humidity. In this case the vacuum time is shortened.

19. The function of the lubricant in the compressor

The lubricant in a compressor has to meet with exact thermic requirements. They are higher
than in any comparable power or working machine. The requirements for the lubrication
would be
considerably simplified if it would only remain in the crank chamber and at the gear
components.

But in fact is is being pumped into the circuit together with the circulating refrigerant and it
has to
come back to the compressor again.

Therefore in the circuit of a compressor cooling machine there is always a binary mixture
consisting of refrigerant and oil in circulation. The thermic requirements the lubricant has to
meet, have been
considerably increased during the last years.

The oil delivery into the circuit is different high and depends largely on the compressor-
construction.

Compressors with centrifugal lubrication deliver more oil into the circuit than compressors
with
pump lubrication.

When starting, the compressor oil delivery is stronger than during continous operation.

At high evaporation temperatures the oil delivery is stronger than at lower evaporation
temperatures.

The main duties of the lubricant in the compressor are the reduction of friction and wear and
tear,
but there are still additional tasks.

The oil serves for the hydrodynamical power transmission, disipation of heat, increase of
tightness, noise reduction, for removal of avrasion particles, for transmission of hydrostatical
power at various parts of the cooling compressor, as there are gear bearings, piston-cylinder-
skirts, wave shaft
packing, working valves and operative gaskets.
20. Installation instructions
In order to guarantee that a cooling unit is running frictionless, the technician has to follow
some
installation instructions.

During the mounting time the refrigerant pipes and components have to be closed in order to
prevent entrance of air, humidity and dirt, because only when all components of the
refrigerant
circuit are absolutely clean and dry, a reliable operation of the unit is given. In order to
prevent the
refrigerant parts from entering of humidity, the parts have to be warmed up to the ambient
temperature before opening.

The refrigerant pipes especially the suction pipe has to be mounted downward in direction to
the
compressor. Otherwise the compressor could get liquid strokes. In case that upclimbing
suction
pipes are unavoidable, a siphon has to be installed in front of them, in order to ensure, that
the oil
will be carried back to the compressor by refrigerant.
Together with our units we deliver refrigerant hosepipes which are suitable for a temperature
range
from –40°C to +121°C. Due to thermical reasons inside this temperature, range hoses are
becominglonger and shorter. Regarding the technical datas of the manufacturer this is set
between +4% to
-4%. Take care to physical appearance during installation of these hose pipes, because
there is a
possible shortening of this hose pipes ( e.g. 40mm at 1000mm of hose pipe ). The technician
has to add hose length during mounting and to place fixing points in that way that the hose
pipes are still
keeping their flexibility.

The condenswater drainage pipes have to be installed in a way, that the water can run down
at any
time. (driving up and down a hill).

At the end of a drainage pipe there has to be installed a lip-valve in order to protect that air
can passthrough the hosepipe to the evaporator. Because then the water cannot go down to
the outside.

There should never exist any connections between air return- and air outblow.

It is always better to install copper pipes and in the case of using R 22 it is absolutely
necessary.

In R 22 units there has to be installed also one non-return valve on the high pressure side as
close
as possible to the compressor.

While soldering of copper pipes the pipes have to be filled with Nitrogen from the inside in
order to
avoid copper plating and also the pollution of the pipe inside. Rigit pipes have to be closed
carefully after cleaning, in order to avoid new entrance of humidity and dust.

In case of placing the refrigerant pipes inside the air duct, it is necessary to insulate them.
If there is stop and go traffic, the iderling speed has to be lifted up to 1.200 rpm.
21. Air distribution

Air ducts have to be insulated. The square measure of the air distribution has to be as
follows:

Kind of a/c quantity and size

of each airduct

KL 3 1 x 2,5 dm²

KL 4 2 x 2,5 dm²

KL 5 2 x 3,5 dm²

KL 6 - KL 7 - KL 12 - KL 60 2 x 4,0 dm²
KL 70 - KL 1200
22. General indications for repair and maintenance work

1. Before mounting, all o-rings and tube fittings as well as hose fittings have to be lubricated
with
compressor oil (Esther-oil or PAG-oil).

2. Please use new o-rings for each mounting.

3. For tube and hose connection please do always use 2 spanners, so that tube ends will not
be
damaged.

4. The fittings have to be tightened only according to the tightening torque moment.

5. As the compressor oils are very hygroscopic, keep the oils only in shut oil-cans.

6. Remove the protecting caps only directly before mounting.

7. Check the connections of the tubes, fittings or components carefully, if they are damaged,
do not use them.

8. After tightening of all connections the drier, as the last construction part, has to be installed
in
the refrigerant circuit.

9. Never keep the refrigeration circuit longer open to the atmosphere than necessary.

10. Never try to repair bent and burst tubes.

11. When exchanging a heat exchanger, for example evaporator or condenser, the oil which
has
fallen away by exchanging, the components have to be added again. Too much oil
influences
the refrigeration capacity and less oil influences the working life of the compressor
negatively.

12. If an A/C unit is opened, the drier should in any case always be exchanged.

13. Only open compressor valves if the density of the system is established.

14. The work at refrigeration circuits should only be done with unobjectionable tools in order
to
avoid a destruction of connections.

23. Service and maintenance

1. Check complete unit for damages.

2. Check compressor bracket on the vehicle engine for damages and fastening.
3. Check compressor fastening.

4. Check condition, alignment and tension of V-belt.

5. Check refrigerant hoses and cables for chafe marks in the area of vehicle engine and the
gear
unit as well as on the chassis and clear the same, if any.
It is also important to check for sufficient spacing in the area of any parts becoming hot
during
operation like for instance the exhaust pipe; if necessary, a partition plate has to be
installed.
Excessive upsetting of oil and upward climbing suction hoses should be avoided.
Check installation of hoses and cables on the box bodies/ driver's cabin.

6. Check all hose fittings and couplings for leakages.

7. Check fastening of condensor unit.

8. Clean condenser coil and replace any damaged condensor coils.

9. Check fastening of evaporator unit.

10. Check operation of evaporator blowers and condensor fans.

11. Check electric switch plate. In case of any deviation in colour of the conductor these will
have to be replaced and possibly also the relays.

12. Put cooling unit into operation and check quantity of refrigerant. After having installed the
filter/drier receiver unit the control ball should swim in the middle, standard sight glasses
should be bubble-free.
Filter/drier and filter/drier/receiver units have to be replaced when opening the
refrigeration
circuit. If they are operating more than one year they may become clogged due to
excessive absorption of moisture soakage!
Filters and driers should be replaced regularly, at least once a year.

13. Connect manometer to the compressor and check pressure.

14. For roof-top-units check air circulation.

15. Air circulation within the air distribution plate must be avoided (partition for suction air and
exhaust air must be provided).
Air ducts for suction air and exhaust air must not be blocked up.

16. Check temperature on the evaporator unit.

- check suction air
- check exhaust air
= difference in temperature should be min. 8 - 10 K.

17. For units operated with main power supply also check the electric installation.
18. Check fastening and function of the mains powered compressor (cooling down also with
mains
powered compressor).

19. Check V-belt from the electric motor to the main powered compressor.

20. In case there is a DWM-Copeland compressor installed to be operated with main power
supply,
oil balancing pipes must be provided between the crankcase of the main powered
compressor
and the T-piece on the suction side.

21. For units with hot gas defrosting please do also check function of solenoid and return
valves.

22. Check setting and function of defrosting thermostat.

23. Check pressostat for condensor fans for shift mode fast/slow.

24. Check pressure switches.

25. Check condense-water outlet.

26. Check filter gaze (on the evaporator).

27. Clean return air filter, if necessary replace it.

24. Instructions to charge air conditioners with R134a

1. Connect service adapter at suction side with blue hand wheel

2. Connect service adapter at discharge side with red hand wheel (hand wheels at service
adapters must totally be turned counterclockwise until stop)

3. Connect blue suction hose below blue hand wheel from pressure gauge to blue service
adapter.

4. Connect red suction hose below red hand wheel from pressure gauge to red service
adapter.

5. Connect yellow hose below yellow hand wheel from pressure gauge to two-step vacuum
pump.

6. Connect last hose below black hand wheel via pressure reducer to nitrogen bottle.

7. Check at pressure gauge if all hand wheels are closed.

8. Turn hand wheels at both service adapters clockwise until stop in order to open the valves.

9. Open valve at nitrogen bottle (only via pressure reducer); pressure approx. 20 bar.
10. Open black and red hand wheel at pressure gauge and charge the unit with nitrogen until
a
pressure of approx. 3,5 to 5,o bar at suction side is reached.

11. Open blue hand wheel and increase pressure on suction side. (max. 10 bar) Leakage
test with
leakage liquid or soapsuds.

12. After leakproofness, drain nitrogen from the unit. Remove hose from nitrogen bottle and
open
red, blue and black hand wheel.

13. Connect hose to refrigerant bottle.

14. Activate vacuum pump and open all hand wheels. In case of existing leaks, no or only
insufficient vacuum is reached. In this particular case proceed as described under items
9. to 12. After having eliminated the leak, start again with item 14.

15. After having reached sufficient vacuum (both indicators at pressure gauge at -1) close all
hand
wheels at pressure gauge.

16. Switch vacuum pump off and observe pressure gauge if vacuum is maintained.

17. Open valve at refrigerant bottle and open black and red hand wheel. Charge the unit with
refrigerant until pressure compensation of suction and discharge line is achieved.
(indicator pressure gauge)

18. Close red hand wheel.

19. Check leakages with electronic leak detector.

20. Start engine and air conditioner.

21. Open blue hand wheel and charge the system with refrigerant until sight glass is free of
bubbles. (If the system is equipped with a combined receiver/drier the white pearl should
swim in the
upper third). Close refrigerant bottle.

22. Close blue hand wheel at pressure gauge.

23. Preparations for test run:

- Close windows and doors

- Set blowers at full speed
- Put temperature sensors at air outlet and air suction

24. Let unit run at medium engine speed for about 20 minutes.

25. Temperature difference between air outlet and air suction should be 8 to 10° C
(according to unit type), based on an ambient temperature of 20° C.

These indications are standard values and might be influenced by solar radiation.

26. Switch engine and unit off and check again for leaks.
27. Turn out hand wheels at both service adapters (counterclockwise) and remove.

28. Put dust cabs on all valves.

29. Check again for leaks.

30. Affix labels indicating kind of oil and refrigerant.

25. Conversion instructions of refrigerant R12 to R134a for a/c

with Bock-compressors

1. Suck off refrigerant R12 for recycling.

2. Dismount filter-drier, E-Valve, receiver and high pressure switch.

3. Blow out all remaining mineral oil from the system by means of nitrogen.

4. Discharge refrigerant oil of compressor, depending on the compressor, dismounting can

be
necessary. Remove the bottom plate of the oil tray and clean compressor from inside.
Fit back the bottom plate by using a new gasket.

5. Fill in Ester-oil.

6. Install e-valve for R134a, as well as a new receiver and filter-drier.

7. Evacuate unit to 50 Micron and keep it at this valve for at least 3 hours.
Fill in refrigerant R134a hereafter.

8. Let unit run for approx. 1-2 hours.

9. Close manual shut off valves before the second oil change and move refrigerant by means
of compressor out of the evaporator and filter-drier into condenser and receiver. Suck off
and
recycle remaining refrigerant from the compressor.

10. Renew filter drier, execute oil change and evacuate this area of the unit.

11. Open the valves and put unit into operation.

12. Change identification plate and fix additionally another plate an the compressor whith
should
inform about the kind of oil and refrigerant.

Note: Ester-oil is very hygroscopic. It is absolutely necessery to take care that oil tins stay
close until they are used. Do not use oil rests after they have been opened for a longer
time.
26. Mounting Instructions

Re-usable screw fittings with KONVEKTA refrigerant hoses

Installation of hose piping

With the refrigerant hoses and the re-usable fittings you are able to compose and mount high
qualityhose pipes without any auxiliary means. A vise, a steel saw and a set of screw
spanners are
available in every workshop.
The instructions show the easy way to handle the re-usable fittings with the corresponding
refrigerant hoses.

Cutting of hoses

1. Take hose from roll without causing kinks. Mark cutting line by using colour or tape. Cut
hose
rectangularly with cutting machine or fine toothed saw. Remove rubber remainders and
wire point.

Clamp fittings support in and screw hose in counter-clockwise direction up to 1 mm before

the
hose end is touching the fitting.

2. Grease hose core and nipple thread plentifully with refrigerant oil.

3. Screw nipple at hexagon into support and hose in clockwise direction until nipple comes
slightly to
 sit in the support. Do n o t tighten!

4. Check all hose pipes and clean.

Demounting in reverse sequence.

27. Inspection Report

Customer:
Unit No.: Unit Type:
Vehicle Type: Chassis No.: Km-reading:
Voltage: System Voltage: 220V ( ) 380 V ( )
Freon: R 12 ( ) R 502 ( ) R 22 ( ) R134a ( )
Filling Capacity: gr.
Refrigerant oil in the compressor:
Type: Quantity: gr.
Assembly Company: Mechanic:

------------ ---------------
Stamp Name

Revision and Insprection Result:

-------------------------------

-identification plate attached: yes/no

Deficiency
yes / no

- sealing unit/rupture () ()
- fixing of the unit () ()
- density/cooling system at 15 bar 15 min.
continuous running () ()
- sealing of the cover () ()
- placement of the refrigerant hoses () ()
- mountage of the refrigerant hoses () ()
- placement of electrical wiring () ()
- placement of the condenser water pipes () ()
- interior panelling () ()
- installation - air outlet nozzles () ()
- cleaning of the vehicle () ()
- fixing of the compressor console () ()
- compressor bracket fixing () ()
- a) compressor position () ()
b) attachment of magnetic clutch () ()
c) resistor for magnetic clutch () ()
d) V-belt tension () ()
e) V-belt alignment () ()
size:
f) V-belt tension at high pressure
ca. 15 bar/continuous running () ()
 Deficiency
yes / no

- additional generator
a) performance: amp
b) type/no.:
c) fixing of the generator () ()
d) V-belt tension () ()
e) V-belt alignment () ()
- switch board fixing () ()

Operational control
-------------------

a) condenser blower () ()
b) evaporator blower phase I () ()
phase II () ()
phase III () ()
c) defrosting thermostat () ()
d) room thermostat () ()
e) high pressure switch () ()
f) low pressure switch () ()
g) actuation switch () ()
h) pilot lamp () ()
i) magnetic valve () ()
j) distance thermometer () ()
k) bus electric (light, radio) () ()
l) total functions () ()

Comments: ___________________________________________________

___________________________________________________

___________________________________________________

Result of the Inspection Report:

Without deficiency: ()
Minor deficiency: ()
Considerable deficiency ()

DELIVERY RELEASE YES/NO

*****************************

------------------------------- -----------------

Place Date Signature

Inspection instruction:

1.) Check - high pressure switch

In roof-top-units condenser cover with support, place switch
in an upward position and let the pressure rise.
In new roof-top and integrated units disconnect the condenser blower.

Point insertion legible on filling armature.

2.) Check - low pressure switch

Close shut off valve.
Start unit and read point insertion on filling armature.
28. Security during repair and maintenance work

1. During work-manship with electric short circuit danger, the battery power supply has to be
disconnected.

2. During operational tests, never try to put the hand into rotating parts.

3. During the work with refrigerants, the following safety precautions have to be
observed completely:
a.) The working place has to be ventilated!
b.) Never expose refrigerants to burning objects!
c.) Refrigerants must not get in touch with human skin, therefore please wear protective
glasses and protective gloves.
d.) As the refrigerants freezes the skin during the evaporation under atmosphereic pressure,
avoid
direct contact!
e.) If, due to carelessness, refrigerants comes into the eyes, do not rub, but rinse with plenty
of
water and after that consult a doctor, or medical help!
f.) Do not expose refrigerant containers to direct heat absorption sas. They must not be
heated up to more than 50°C!
g.) In case of direct heat absorption on refrigerant containers the thereby intensified pressure
can
open the safety valves or can, at the worst, burst the refrigerant container. Therefore,
never use
open flames to dry the containers.
h.) When cleaning the engine of the vehicle equipped with air conditioning, act very carefully
because the air conditioning parts must not be exposed to direct water vapor.
i.) Never fill up refrigerant containers. Filling cylinders and automatic filling stations should
only be
filled up to the indicating range (space factor 0,7).
j.) Before making a leakage test with dried nitrogen, it has to be checked, if all components
are in
regular condition.
k.) Never turn out safety switch!
29. O-ring fittings

The O-ring fittings used on KONVEKTA R 134a units have to be tightened with a special
torque

fitting size spanner size Newtonmeter (Nm)

5/8" 17 or 19 13,6-20,3 Nm (1,4-2,1 kpm)

3/4" 32,5-39,3 Nm (3,3-4,0 kpm)
7/8" 27 35,3-42,0 Nm (3,6-4,3 kpm)
1 1/16" 32 40,7-47,5 Nm (4,1-4,8 kpm)
M30x2 36 105-115 Nm (10,5-11,5 kpm)
M36x2 41 165-175 Nm (16,5-17,5 kpm)

30. Bending radius for KONVEKTA refrigerant hose pipes

Kind of hose Konvekta size of hose bending radius

part no.

GH 414 H12-000-701 NW8 min. 75mm

GH 414 H12-000-702 NW10 min. 80mm
GH 414 H12-000-703 NW12 min. 85mm
GH 414 H12-000-704 NW16 min. 90mm
GH 494 H12-000-213 NW20 min. 160mm
GH 494 H12-000-214 NW25 min. 194mm
GH 494 H12-000-216 NW32 min. 225mm
31. Pressure switch
pressure switch switch pressures clamp marking
--------------------------------------------------------------------------------

part-No. ON/bar OFF/bar diff. input output fault

--------------------------------------------------------------------------------

low pressure (UD) H11-000-312 0,95 -0,3 1,25 1 4 2

compressor (CP) H11-000-314 4,5 4,0 0,5 1 4

R12
low pressure (UD) H11-000-315 2,2 0,2 2,0 1 4 2
R12
high pressure (ÜD) H11-000-316 15,0 21,0 6,0 1 2 4
R12
pressostat KD-fan H11-000-326 12,0 8,0 4,0 1 4

condenser H11-000-326 17,0 12,0 5,0 1 2 od. 4

low pressure switch H11-000-348 2,2 0,1 2,1 1 4 2

R134a
high pressure switch H11-000-347 18,0 25,5 7,5 1 2 4
R134a
pressure switch test H11-000-349 4,5 4,0 0,5 1 4

R134a
double pressostat
combined pressure H11-000-384
switch (3-step)
clutch (UD) 3,4max. 1,5±0,5 sw/ge
(ÜD) 18±1,5 25±1,5 sw
KD-Fan 19±1 15±1 br br/sw

FK2200 (ÜD) H11-000-302 17,2 21,2 4,0 1 4 2+3

(UD) 1,0 -0,3 1,3 1 4 2+3
FK2500 (ÜD) H11-000-302 17,2 21,2 4,0 1 4 2+3
(UD) 1,0 -0,3 1,3 1 4 2+3
TK3300 (ÜD) H11-000-302 17,2 21,2 4,0 1 4 2+3
(UD) 1,0 -0,3 1,3 1 4 2+3

double pressostat A/C R22

(ÜD) H11-000-302 21,0 25,0 4,0 1 4 3

(UD) 0,6 0,1 0,5 1 4 2

ÜD = HP (high pressure)
UD = LP (low pressure)
32. Defrosting thermostat

Defrosting thermostat adjustment of a/c and freezing units

pos. unit type temp. diff. manufacturer part-no. clamp marking

input output fault
--------------------------------------------------------------------------------
air condition

1 KL 1 - 7/12 +1 5 RANCO H11-000-304 1 4 2

2 HLK +1 5 RANCO H11-000-304 1 4

--------------------------------------------------------------------------------

Return air defrosting

3 FK 35-65 T/N
FK 2300-3000 +1 8 FANAL H11-000-357 1 4
--------------------------------------------------------------------------------

Hotgas defrosting
4 FK 2000 T/N
FK 2100 T/N +10 3 FANAL H11-000-357 1 2

5 TK 3600 +10 5 FANAL H11-000-357 1 2

6 FK 2200 +15 0 FANAL H11-000-357 1 2

7 FK 2500 +15 0 FANAL H11-000-357 1 2

8 TK 3300 +15 0 FANAL H11-000-357 1 2

--------------------------------------------------------------------------------
off on

9 New air conditioner -3,5°C +1,5°C H11-000-386

(not adjustable)
33. Compressor detail

Type Displacement Weight Max. turn- R Operating Oil Standard

(cc) (kg) Speed wise Speed Quantity Oil
rpm rpm cm3
--------------------------------------------------------------------------------

1 Bock
TM31HD 313 10,7 5.000 R 134a 500 100 PG

FK4 466 65/45 3.000 L+R 12 2.600 AC:KES 100

H14-001-435

FK4 466 65/45 2.400 L+R 22 1.850 2.600 TK:KS46

H14-000-443

FKX4 466 65/45 3.000 L+R 134a 2.600 Triton SE55

H14-002-426

FK5 846 92/73 2.300 L+R 12 3.800 AC:KES 100

H14-001-435

FK5 846 92/43 2.000 L+R 22 1.500 3.800 TK: KS46

H14-000-443

FK26 670 55 3.000 L+R 12 3.300 AC:KES 100

H14-001-435

FK26 550 55 3.500 L+R 22 1.800 3.300 TK:KS46

H14-000-443

FKX26 670 55 3.000 L+R 134a 3.300 Triton SE55

FKX40 385 33 N=3.000 L+R 134a 2.000 Triton SE55

K=3.500 H14-002-426

FKX40 465 32 N=3.000 L+R 134a 2.000 Triton SE55

K=3.500 H14-002-426

FKX40 555 32 N=3.000 L+R 134a 2.000 Triton SE55

K=3.500 H14-002-426

FKX40 650 31 3.000 L+R 134a 2.000 Triton SE55

H14-002-426

AC = air conditioner TK = deep freezing unit

L = counter clockwise R = clockwise
Type Displacement Weight Max. turn- R Operating Oil Standard
(cc) (kg) Speed wise Speed Quantity Oil
rpm rpm cm3
-------------------------------------------------------------------------------

2 Bitzer
4PFY 541 42 3.000 L+R 134a 2.500 3.800 Triton SE55
H14-002-426

4NFY 644 42 3.000 L+R 134a 2.500 3.800 Triton SE55

H14-002-426

3 Nippondenso
7SB16 161,5 7,05 6.000 R 134a 120ñ15 PAG-ND8

4 Sanden
SD 508 HD 138 5,1 6.000 L+R 12 175 Suniso 5GS
AC:KES 100
H14-001-435

SD 510 HD 161 4,7 4.000 R 12 135 TK:KS46

H14-000-443

SD5H14 138 5,3 6.000 L+R 134a 4.000 175 Reniso PAG46

SD7H15 155 6,9 6.000 R 134a 207 0,25l H14-003-404

Original Sanden Oil PAG for R134a is SP20 0,25l H14-002-454

5 Zexel
DKS26 255 14,5 5.000 R 134a 500 100 PG

DKS26 255 14,5 7.000 R 12 500 Suniso 5GS

Oil for use with R404a: SEZ32 H14-003-403

AC = air conditioner TK = deep freezing unit

L = counter clockwise R = clockwise
34. Conversion

From psi in bar and

degree C (°C) in Fahrenheit (°F)

In order to simplify and show the conversion

of psi in bar and of °C to °F draw a vertical
line on the desired marking and read the
other markings.

Example: R134a

1Bar = 14,6PSI = -10,1°C = 14°F

Further more it is possible to read corrosponding

temperatures and pressures of listed refrigerants,
when they are mixtures of liquid and vapor (inside
condenser and evaporator).

35. GWP/ODP

Combination Chemical form ODP GWP

FCKW11 CCL3F 1,0 1,0

FCKW12 CCl2F2 0,92 - 1,0 2,8 - 3,4

H-FCKW 22 CHClF2 0,042 - 0,057 0,34 - 0,37

H-FKW 134a CH2F-CF3 0 0,25 - 0,29

Kohlendioxid CO2 0 1300 times lower than R134a

ODP = Ozone depletion potential

GWP = Global warming potential

Further more CO2 is a natural gas and doesn't have to be produced.

Notice

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