KONVEKTA UL500EM Maintenance And Repair Instruction
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KONVEKTA UL500EM Maintenance And Repair Instruction

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Maintenance- and Repair-
for KONVEKTA Air Conditioners
UL500 EM/ UL700 EM 2nd and 3rd Gen.
ID#: BWA-KL5N0802A
Version: A02
Instruction
UL500 EM
With Wabco control system
UL700EM
Konvekta AG
Am Nordbahnhof 5
34613 Schwalmstadt
Germany
+49 ( 0 ) 66 91 / 76 – 0
+49 ( 0 ) 66 91 / 76 - 200
Info@konvekta.com
www.konvekta.com

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Summary of Contents for KONVEKTA UL500EM

  • Page 1 Maintenance- and Repair- Instruction for KONVEKTA Air Conditioners UL500 EM/ UL700 EM 2nd and 3rd Gen. UL500 EM UL700EM With Wabco control system Konvekta AG Am Nordbahnhof 5 34613 Schwalmstadt Germany ID#: BWA-KL5N0802A  +49 ( 0 ) 66 91 / 76 – 0 ...

  • Page 2: Table Of Contents

    Contents Page:  Introduction ........................3  Information on the operating instructions .................4  Directives for Installation, Connection and Use ..............5 1.Technical data ........................5 1.1. Air conditioning units ......................5 1.2. Pressure Switches ......................5 2.Maintenance plan .........................5 2.1. Overview of maintenance parts 2 generation ..............6 2.2.

  • Page 3: Introduction

    KONVEKTA will annul without prior 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.
  • Page 4 Attention is to be paid to:  All screw connections have to be checked on leak tightness.  Tightening torques for O-ring connections according to work instruction AA07050122.  Tightening torques for screws and nuts A2/A4 AA090019  Country or regional specific rules for accident prevention have to be followed (for Germany e.g.

  • Page 5: Directives For Installation, Connection And Use

    1. Technical data 1.1. Air conditioning units 2nd Gen. 3rd Gen. Type UL 500 EM UL 700 EM UL 500 EM UL 700 EM Refrigerant R 134a 1.430 Refrigerant without Frontbox approx. Refrigerant quantity with Frontbox approx. Volt Operating voltage Max.

  • Page 6: Overview Of Maintenance Parts 2 Generation

    2.1. Overview of maintenance parts 2 generation (UL500EM) Condenser coil Evaporator blower Condenser fan Air filter Air filter Dryer Sight glass 2.2. Overview of maintenance parts 3 generation (UL500EM) Condenser unit Evaporator blower Condenser fan Air filter Air filter Dryer...

  • Page 7: Maintenance Of The Refrigerant Circuit

    3. Maintenance of the refrigerant circuit 3.1. Check of refrigerant level in the sight glass of the roof unit Start air conditioner. The air conditioner is operated via the original controller of the vehicle (see original operating manual) Check the refrigerant level in the sight glass. To this, the cover must be opened to see the sight glass.

  • Page 8: Check Of The Refrigerant Receiver For Corrosion

    3.4. Check of the refrigerant receiver for corrosion Demount the middle cover in the back. The system may be also installed opposite to the driving direction. 2nd generation Refrigerant receiver 3rd generation Refrigerant receiver Make a visual inspection of the refrigerant receiver. If the receiver is corroded it has to be replaced! 3.5.
  • Page 9 Oil sight glass Manual shut-off valve: remove cap and bring into „shut off” position. Connect the red manometer (to atmospheric pressure) to service connection (1) of the service shut-off valve HD – high pressure – (2) and the blue manometer (to atmospheric pressure) to ser- vice connection (5) of the service shut-off valve ND –...

  • Page 10: Function Check Of High Pressure Switch (8)

    The filter dryer needs to be mounted as indicated (flow direction). The flow marker (arrow on the filter dryer) points the direction of expansion valve. Remove the protective caps on both sides of the filter dryer only immediately prior to mounting. Flow direction Evacuate the area between manual shut-off valve and magnetic valve at the service connection.

  • Page 11: Check Of Screw Connections On Compressor For Tightness

    Use an appropriate scaffold for carrying out maintenance works. Loosen the quick fasteners of the evaporator cover and open it. Quick fasteners Take out the air filters (2 pieces UL500EM und 3 pieces UL700EM per unit side). Clean or exchange filters.

  • Page 12: Oil Level Check Of The Compressor At The Oil Sight Glass

    3.9. Oil level check of the compressor at the oil sight glass Observe inspection glass at compressor for ca. 10-15 min while the compressor is ON. Refrigerant oil must be visible. In the case of under- or over-filling there is a risk of serious damage to the compressor. The oil should be clear and clean.

  • Page 13: Maintenance Work On The Electrical Installations

    Unscrew the oil filler screw. Suck out the old cooling machine oil with a suitable pump. Fill in new refrigerant oil and then mount the oil filler screw. Oil filler screw Oil sight glass Make sure you use the right sort of refrigerant oil and a new batch. After the refrigerant oil has been drained, it must be replaced with new oil immediately.

  • Page 14: Function Check Of The Evaporator Blowers

    4.2. Function check of the evaporator blowers Take the air conditioner into operation. Quick fasteners Open quick fasteners by rotating motion, open side covers. Function check of all evaporator blowers. Evaporator blowers Danger! Risk of injury! Take special care near hot, rotating or live parts. 4.3.

  • Page 15: Check The Control

    4.6. Check the control See the original instructions of the control! 5. Repair instructions for UL500 EM/ UL700 EM Because of its modular design the air conditioner UL500 EM / UL700 EM features a series of char- acteristics in mounting and demounting of the components. 5.1.

  • Page 16: Mounting Evaporator Blowers

    5.1.2. Mounting evaporator blowers Tilt the blower with the insert to the side facing the evaporator heat exchanger and put it into the bracket. Then fix the blower by slightly pressing the bracket. Attention! Do not pinch the cables and arrange them in a manner eliminating the risk of chafing! 5.2.
  • Page 17 The servicing element can be removed upward, in order to gain access to the flap actuator. The flap actuator is connected to the fresh air flap by a cap. It facilitates its removal to the side. Servicing element Flap actuator Cap of the flap actuator Assembly instructions: The shaft of the flap actuator and bracket of the flap are fitted to...

  • Page 18: Mounting And Demounting Of The Condenser Fans

    Perform the assembly in reverse order. 6. Warranty Conditions The current „General Warranty Conditions KONVEKTA AG“ will apply. A copy will be furnished by the warranty department. Please contact: GWL@konvekta.com. 7. Waste disposal in accordance with legal provisions After the phase of use the last proprietor is responsible for the adequate waste manage- ment.

This manual is also suitable for:

Ul700em

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