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Summary of Contents for KONVEKTA UL500
- Page 1 Maintenance – and Repair Instruction for KONVEKTA Air Conditioners UL500 – UL800 3.Gen. Konvekta AG Am Nordbahnhof 5 34613 Schwalmstadt Germany ID#: BWA-KL5N3502A +49 ( 0 ) 66 91 / 76 – 0 +49 ( 0 ) 66 91 / 76 - 200 Version: A01 ...
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Page 2: Table Of Contents
4.5. Plug connection check for tightness .................. 17 4.6. Visual check of electrical cables for abrasion ..............17 4.7. Check the control ......................17 5.Repair instructions for UL500 - UL800 ................18 5.1. Demounting and mounting of evaporator blowers ............. 18 5.1.1. Demounting evaporator blowers ..................18 5.1.2. -
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: Directives For Installation, Connection And Use
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. Torque figures for bolts, screws A2/A4 AA090019 Country or regional specific rules for accident prevention have to be followed (for Germany e.g. -
Page 5: Technical Data
1. Technical data 1.1. Air conditioning units UL 500 UL750 UL800 Type UL 700 Refrigerant R 134a * R 134a * R 134a * R 134a * 1.430 1.430 1.430 1.430 Refrigerant quantity approx. ¹ Refrigerant quantity with Frontbox¹ Operating voltage Volt DC Current consumption Cooling capacity... -
Page 6: Maintenance Plan
2. Maintenance plan Pos. Maintenance and repair schedule Cooling cycle and components Refrigerant level check at the inspection glass of the roof installation Air tightness check with leakage detector Condenser coil cleaning Refrigerant receiver check for corrosion Replacement of filter dryer - functional test of low pressure switch Function check of high pressure switch Check of screw connections on compressor for tightness Condition check of compressor V-belt... -
Page 7: Overview Maintenance Parts
2.1. Overview maintenance parts Condenser unit Refrigerant receiver Axial ventilator Air filter Air filter Dryer Sight glass Evaporator blower WAKL5N3502A Edition: 13.12.2021 Page: 7/21... -
Page 8: 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 9: 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 direc- tion. Make a visual inspection of the refrigerant receiver. If the receiver is corroded it has to be replaced! Refrigerant receiver 3.5. - Page 10 Connect the red manometer (to atmospheric pres- sure) to service connection (1) of the service shut- off valve HD – high pressure – (2) and the blue ma- nometer (to atmospheric pressure) to service con- nection (5) of the service shut-off valve ND – low pressure –...
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Page 11: Function Check Of High Pressure Switch (8)
Mount a new filter dryer. Put filter dryer according to the flow direction (arrow) into seating and fas- ten. 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. -
Page 12: Check Of Screw Connections On Compressor For Tightness
The high pressure switch (8) can alternatively be checked with the diagnostics device “Star Diagnostics”. This method also requires prior connection of the pressure manometers (HD and ND) to the refrigerant compressor, in order to read the switch-off and re-switch-on points. Danger! Attention! The service shut-off valve on the refrigerant compressor (ND and HD) must not be closed (turned clockwise until stop) when the refrigerant... -
Page 13: Check V-Belt On The Compressor For Tension
Loosen the quick fasteners of the evaporator cover and open it. Quick fasteners Take out the air filters (UL500 – 4 pieces, UL700 – 6 pieces, UL750 – 6 pieces’ front vehicle + 6 pieces’ rear end of vehicle and UL800 – 8 pieces). -
Page 14: Compressor Oil Exchange
Since the installation position of the compressor can be different (inclined positions), it is advisable to check the oil level in both sight glasses. The oil level must be visible at least in one sight glass. Danger! Risk of injury! Be particularly careful when working close to hot, rotating or energized parts. -
Page 15: Maintenance Work On The Electrical Installations
Unscrew the oil drain screw und and drain the cooling machine oil. Mount oil drain screw with new oil seal. Tightening torque: Oil drain screw compressor oil M10 x 30: 60 Nm Oil filler screw Oil sight glass Oil drain screw Unscrew the oil filler screw and fill in new refrigerant oil. -
Page 16: Function Check Of The Evaporator Blowers
Open service covers in the passenger compartment below the roof installation with a square span- ner. Take fuses one-by-one out of their sockets, check and put back again. Close cover when finished. UL500 UL700 F1-F11 = 15A F1-F6 = 15A... -
Page 17: Plug Connection Check For Tightness
UL800 F1-F14 = 15A F15 = 7,5A Für Gelenkzug: UL700 VD UL750 F1-F6 = 15A F1-F6 = 15A F9-F12 = 15A F15 = 7,5A 4.5. Plug connection check for tightness Check tight fit of plugs and electric connections. 4.6. Visual check of electrical cables for abrasion Open quick fasteners and side covers. -
Page 18: Repair Instructions For Ul500 - Ul800
5. Repair instructions for UL500 - UL800 Because of its modular design the air conditioner UL500 - UL800 features a series of characteris- tics in mounting and demounting of the components. 5.1. Demounting and mounting of evaporator blowers Loosen the quick fasteners and open the evaporator cover /hoods and secure them against falling. -
Page 19: Demounting And Mounting Of The Flap Servo-Motors
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. Demounting and mounting of the flap servo-motors Actuators of flaps are installed on the right and left side of the evaporator, near the filters installed with a servicing element. -
Page 20: Mounting Und Demounting Of Control Node
Servicing element The reassembly is carried out in reverse order. Flap actuator Cap of the flap actuator Air flap 5.3. Mounting und demounting of control node The control node is located in the evaporator part (in driving direction right side) and is mounted on an electric PCB with a fastening screw. -
Page 21: Warranty Conditions
Service panel condenser fans 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.
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