18 Air Conditioning - Free Download PDF Ebook

Service ManualChapter 18 - Air conditioning Air conditioning................................................................................................................................................. 18-3 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 LFR/en/version: 09 / 2007 1 R 9250 from 13466 MJFCIFSS 18 - 1 LFR/en/version: 09 / 2007 Service Manual 18 - 2 MJFCIFSS R 9250 from 13466 Service Manual Air conditioning Operating instructions for KL5 18 Air conditioning 18.1Operating instructions for KL5 18.1.1Technical data Operating voltage Refrigerant Cooling capacity Evaporator air volume Condenser air volume High pressure switch Low pressure switch Compressor 24 V DC R134a 10.000 Kcal / h 3000 m3 / h 4800 m3 / h 23,5±0,5 bar cut - off 16,0±0,5 bar on 0,1 bar cut - off 2,2 bar on 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 function. LFR/en/version: 09 / 2007 • • • • R 9250 from 13466 MJFCIFSS 18 - 3 Air conditioning Service Manual 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 18 - 4 SANDEN SD7H15 1 1/16´´ O-ring 1 1/16´´ O-ring 24 Volt DC - 5¼´´ 50 W From 400 to 6 000 (max.) Angle max. 45° PAG 207 cc 7,5 kg MJFCIFSS LFR/en/version: 09 / 2007 Type Inlet connection Outlet connection Magnetic coupling Power consumed RPM Mounting Oil Weight R 9250 from 13466 5Refrigeration scheme 1 2 3 4 5 6 7 8 Condenser High pressure switch Pressure valve Compressor Suction valve Low pressure switch Compensation line Capillary tube with sensor R 9250 from 13466 9 10 11 12 13 14 15 16 MJFCIFSS Evaporator Distributor Expansion valve Defrosting thermostat Sight glass Drier Manual cut-off valve Receiver 18 .1.Service Manual Air conditioning Operating instructions for KL5 LFR/en/version: 09 / 2007 18.5 . 6.6 MJFCIFSS R 9250 from 13466 .6Servicing 18. The refrigeration receiver has to be checked for outside damages twice a year (see Konvekta general conditions for sale and delivery under 8b). LFR/en/version: 09 / 2007 Attention! §10 of the decree for pressure tanks says that a periodical test by an expert (§32) has to be executed.1Return air grid Clean the return air grid in the cabin once a week.6. Refrigerant receiver.6.4Check refrigerant level • • • • Switch on unit (switch position S1 + S2 air conditioning).1. 18. • Blow threw the condenser coil with compressed air. On these conditions.2Condenser coil • Clean the condenser once a month. Especial attention should be paid to corrosion and mechanical damages.3Sight glass The sight glass is situated at the condenser. If air bubbles are formed : consult customer service agency. 18. If it is any how damaged. By this decree the pressure tanks are subdivided in test groups : admitted operational overpressure in bar «p».1. the refrigerant receiver is to be qualified in test group II.6. 18 .1.1. 18. • Remove the cover to the condenser space. its manufacture is subject to a special prescription (pressure tank decree from April 1989). it must be changed by reason of safety. pressure tank contents «p x l».1. Due to an operational overpressure in the receiver. Sight glass clear : refrigerant level all right. volume in litres «l». Those tests refer to an outside checking of the tanks in operation.Air conditioning Service Manual Operating instructions for KL5 18. 1. consult refrigeration expert compressor Replace ball bearing or complete compressor (consult refrigeration expert) A/C does not work Low pressure switch has switched off Ball bearing defective at LFR/en/version: 09 / 2007 Heavy noise at compressor R 9250 from 13466 MJFCIFSS 18 .7Trouble check list Trouble A/C does work No cooling capacity A/C does not work A/C does not work High pressure switch has switched off Cause Repair Thermostat is cut off Check inside temperature Reset thermostat Electric wiring disconnected Check electric connections at clutch Relay defective Check relay Loose drive belt Check drive belt at compressor Excessive pressure Check whether axial fans are running Press safety switch and clean condenser fins Excessive pressure caused by high external temperature Let unit run until pressure is stabilised Leak in unit Deficiency of refrigerant Check unit for leaks Recharge refrigerant. drier congested Replace drier.7 . consult refrigerant expert Negative pressure. renew drier.Service Manual Air conditioning Operating instructions for KL5 18. consult refrigeration expert Negative pressure. sieve expansion valve congested of Clean sieve. Air conditioning Service Manual LFR/en/version: 09 / 2007 Operating instructions for KL5 18 .8 MJFCIFSS R 9250 from 13466 . From Acid to Oxygen Important Konvekta Know-Hows Stand: 09/02 ID#: TKD-00041 KONVEKTA AG Postfach 2280 34607 Schwalmstadt GERMANY Tel. 06691/76111+76121 . 06691/76-0 Fax. in order to reach a better and smoother cooperation between Konvekta and its partners. with the following brochure. Tel.: (+49 ) 06691 76124 or 76164 Fax: (+49 ) 06691 76121 . Konvekta wants to give you a guideline on handling and servicing of Konvekta cooling units.Editorial Dear reader. We wish you a nice time while reading and would be grateful for any constructive recommendation on optimising this brochure. Lothar Stehl from the After Sales Department. Contact persons is Mr. 13. 10. 6. 30. 15. 11. 18. 17. 25. 24. 3. 22. 19. 29. 35. °F) GWP/ODP . 12. 21. Bar . 4.Contents 1. Description of abbreviations used with KONVEKTA products Compressor Condenser coil Liquid receiver Filter drier Sight glass Expansion valve Evaporator coil Pressure switch Manual shut-off valve Refrigeration scheme Refrigerant oils Refrigerant Leakage test Drying and evacuation Function of dry process Sketch of refrigerant circuit for charging Charging and evacuating of cooling machines The function of the lubricant in the compressor Installation instructions Air distribution General indications for repair and maintenance work Service and maintenance Instructions to charge air conditioners with R134a Conversion instructions from R12 to R134a for a/c`s with Bock-compressors Mounting instructions for re-usable hose fittings Inspection report Security during repair and maintenance work O-Ring fittings Bending radius for KONVEKTA refrigerant hose pipes Pressure switch Defrosting thermostat Compressor detail Conversion (Psi . 28. 23. 16. 5. 7. 26. 32. 9. 20. 14. 8. 31. 34. 33. 2. 27. °C . On the new generation of KL units we will add an 0 e. which may include a heating arrangement or not special series of compact heating. Abbreviations for those products do appear in documentation material. KL60 or KL70. "T" units are heaving a bigger condensor. stand by operation at FK & TK units in 220V or 380V .g.g. most of the time the KD will be outside and the VD inside two evaporator versions four evaporator versions day / night. KL6 is followed by letters e. The meaning of these abbreviations is as follows: A F R T C means means means means means I means Split means 2VD means 4VD means T/N means roof top unit flat design round and flat design e. Most of the names of Konvekta-products start with the following abbreviations.1. HKL FK TK TKH TKD VD KD UKD DKD HKD air conditioner. this letter refers to compact design and often means that the unit's capacity is weaker than other units of this class fully integrated unit separate VD & KD. air conditioning and heating systems which are composed of numerous original Konvekta parts. KL6AFT. ventilating (return & fresh air) and air conditioning units chilling units for temperatures down to 0°C deep freezing units for temperatures above and below 0°C deep freezing units with hydraulic drive deep freezing units with diesel engine drive evaporator and heating coils condenser under-floor condenser roof-top condenser horizontal condenser Capacity classes Air conditioner KL and HKL (HLK is an exemption) are numbered e. Description of abbreviations used for KONVEKTA-products Konvekta is manufacturer for refrigeration. FK2250 which are comparable to the cooling performance at the standard temperatures of 0°C inside and 30°C outside in watt.g.g. from KL1 to KL12 whereby a KL2 is smaller than a KL3. Version / kind of construction The description e.g.g. Kind of part KL HLK. at KL6ART for tropical use ( up to 55°C outside temperature ) on units without "T" the performance is given at 38°C outside. FK and TK units have higher number codes e. In case of stop and go or idle operation the main-engine speed has to be lift up to 1200 rpm. It is driven by a V-belt.Type of refrigerant After product-category. Co2 refrigerant R 404 2. /2 /3 /4 /5 /6 means means means means means refrigerant R 12 refrigerant R 22 refrigerant R 134a refrigerant R 744. capacity-class and version. 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. The outlaying of the main engine (pulley) size is to do as following: rpmmk x d2 D1 = -----------------rpm me D1 = diameter main-engine (pulley) . the type of refrigerant will be indicated in the product name. 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. In case of corrosion or mechanical damages the receiver bottle has to be replaced by reasons of explosion. The fins have to be free of dirt and damages. . While replacing. Inside the heavy liquid will go down to the bottomand the gas will stay on top. If one fan is defect. This is in order to insure that bubble free refrigerant is on the entrance-side of the E-valve. rpm of main-engine 3. The exit is marked with an "A" and the top side is marked with a button "oben". Liquid receiver Behind the condenser a liquid-receiver is installed. 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". otherwise there is an air short circuit which is pressing down the cooling-performance enormously.d2 = diameter compressor magnetic clutch rpm mk = max. 4. Condenser coil The air admitted fin condenser leads the thermal efficiency to the ambient air and condenses the gaseous refrigerant. take care of the mounting direction. it has to be replaced. possible rpm of compressor rpm me = max. If the sight glass is installed directly behind the filter drier thedrier could be stuffed as well. The expansion-valve takes the high pressured liquid refrigerant to low pressure. 6. sieves and filters are installed in the filter drier. Filter drier also have to be changed after each opening of the refrigerant circuit. 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. In order to avoid problems with humidity and foreign particles inside the circuit. Expansion valve KONVEKTA uses thermostatic expansion-valves in most of the units. This is the cooling effect. A filter drier does not replace evacuating! The arrow symbols on the filter drier have to be placed in direction to the expansion-valve. This kind of expansionvalve works very exactly because it takes the temperature and the pressure behind the evaporator and it adjusts the difference to approx. Humidity in the unit does also produce corrosion damages and possible acids. liquid refrigerant must pass bubble-free through the sight glass in front of the expansion-valve. For this refrigerant needs heat. 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. 7. At this pressure the liquid refrigerant wants to expand into gas which means that the refrigerant requires heat. It is necessary to change the filter drier in air conditioning units once a year. Filter drier At evaporation temperatures of below O°C water deposits ice on the expansion-valve which leads tounit deficiency. Sight glass During operation. There is a particle sieve on the entrance side of the expansion valve. . Another possibility might be that these bubbles are air-instead of gas bubbles. On the new and on the mounted expansion-valves the adjustment is already done.5. in refrigeration and deep-freezing units twice a year because their capacity is limited. 7 K operation overheating. This means that the compressor is not working well. There is a defrosting thermostat at the evaporator coil which is cutting in and off the magnetic clutch. The collected refrigerant can be cleaned and re-prepared by refrigerant manufacturers. The refrigerant must be removed by suction of the unit compressor. 9. expansion valve or evaporator. The hot air touches the evaporator fins and delivers the heat across the fins and tube walls to the refrigerant. Manual shut-off valve If the refrigerant wanted to be collect in the condenser and in the receiver. Evaporator coil The evaporator is an air-admitted ventilator air cooler. If the pressure at the compressor on the low pressure side is more than 4.8. All blowers have to run in order to avoid air short circuit. a pressure switch shuts off the magnetic clutch. 10. By reason of the heat absorption the refrigerant evaporates. . the manual shutoff valve has to be shut.5 bar the compressor pressure switch (cp) gives current to an indicator lamp. the refrigerant must be emptied and collected in a special tank. In case of repair works at condenser or receiver. This is necessary in case of any works at drier. This prevents a destruction of the unit. The coil must be free of dirt and without damages. Pressure switch As soon as the maximum pressure at the high pressure side or the minimum pressure at the low pressure side is reached. 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 . the circuit of an air conditioner is not absolutely closed. They should be non-toxic. "R12" (exactly Dichlordifluormetan CCL2F2) . Refrigerant General marks: Every compression-cooling machine has refrigerant in its system. at a level of 100% inside the compressor circuit. 30 or more years. however. 13. The available "safety refrigerants" correspond widely which these requirements. The refrigerants for compression-cooling machines should have a small vapour volume. In case of pressureless compressors oil can directly be added into oil tank. If fill up of oil is necessary. necessary for compressor lubrication.g. 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. Therefore it is required to adjust oil and its quantity to the used quantity of refrigerant. it is only allowed to use the same kind of oil which is already used in the compressor. 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. 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. a high evaporation enthalpy and a low condensation pressure. Oil quantity should be amount to 10% of refrigerant weight. e. noncombustible and non-explosive. With flexible hoses. As nomination of these refrigerants the letter symbol "R" (refrigerant) is internationally used. Precondition for this is that the refrigerant circuit is closed. Refrigerant oils Due to technical reasons it is not possible to keep the oil. (The circuit in a household refrigerator is nearly 100% closed).12. which is normally filled in once and never removed or exchanged until the unit is dismantled after 10. The function ofthe compressor is to suck the " transport medium" from the evaporator and press it into the condenser. In case of a pressure reduction in the circuit. There are special leak searching detectors which can be used for HFCKW refrigerants realizing a refrigerant loss of 3-5g per year. The detection accuracy is about 1 gr/day. The leak searching lamp reacts to chlorine in the refrigerant and is therefore not suitable for R134a.14. With these methods any leaking gas being pressurized can be detected. There are: using foam and soap solutions as well as immersions into liquids. the leakage has to be detected. with a detection accuracy of 1 gr/year. Furthermore R134a already escapes from smaller leaks in comparison to R12. There are various methods to detect a leakage. Electronic leakage detectors have a much better sensitivity. The flame of a halogen test-lamp disintegrates the refrigerant and a colour appears from blue to green. 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. . Besides there exists the possibility ( in case of Fluor-Chloride-Hydrocarbon) to detect leakages by use of chemical and electrical methods. 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. Leakage test For the combined pressure and leakage test procedure. When the desired vacuum of 1 Torr has been reached. It is common procedure to evacuate the unit to a final stand vacuum of 1 Torr = 1. because the coils and gear of the compressor would be damaged.0399 mbar. it is also done to control the tightness over a certain waiting-time.013 mbar) and absolutely at 100°. It is always recommendable to warm up the vacuum pump while suction valve is closed and then only start with the evacuation procedure. The exact time for the evacuation and drying process cannot be predicted. 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. which should achieve a vacuum below 30 Micron = 0. Function of dry process Water evaporates at normal ambient pressure (1. already at nearly 7°C ambient temperature.g. but the . For this purpose a vacuum pump is being used.33 m bar = 0. at 10 mbar. 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. If the unit has been mounted with the necessary carefulness.00113 bar.5 m bar. the valve between vacuum pump and unit must be closed. the boiling point of water is reached.15. There are sometimes interruptions during the evacuation procedure. Another important factor during this procedure represents the drying of the unit. The motor-driven compressor should ot be used to evacuate the unit. water evaporates e. this could leadto various consecutive damages. At an ambient temperature of 20° C and a pressure about 22. If pressure is reduced. 16. suitable to evacuate and charge cooling units. Just traces of humidity within the refrigerant-circuit can mix with the refrigerant and the oil. it will not take long to suck offthe complete humidity.00003 bar) end pressure. There are practical and economic combined units available. 516 121.8 1013.4 -31. the evacuating process is supported by the so called vacuum break (filling of the circuit with dried nitrogen).737 23.0 80.0 50.671 0.474 196. While operating with vacuum break the filled in.0 60.653 72.2 -51. Boiling temperature in °C Absolut-pressure in mbar 100.033 0.421 30.776 33.017 0.7 -67.482 467.0 30.8 15.0 70.016 3.4 22.0 26.711 13.7 24.0 96.6 17.226 307.7 7.1 -37. dried nitrogen does absorb the humidity out of the refrigerant circuit which can then be exhausted in common with the nitrogen.368 10.2 0.334 0.000 703.342 1.947 691.026 6. As it is difficult to get vapor out of the unit's vacuum.2 20.079 26.whole quantity of water does not evaporate at once.0 -6.395 20.0 40.167 0.0 11.1 -56.003 .053 16.524 41.1 90.1 -14. 17. Charging and evacuating of cooling machines . Sketch of refrigerant circuit for charging 18. especially in case of expensive refrigerants and bigger oil quantities it is advisable to save the refrigerant for re-use. 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). For units in operation. The "riming" of the suction line is no sign for the judgement of the charging state. 19.The charging of refrigerant into the dried. to give nitrogen to the circuit (approx. So during the repair nitrogen streams out of the open points and avoids the penetration of air and humidity. refrigerant can only be charged as vaporized refrigerant to the suction side. it is possible. The requirements for the lubrication would be . Soldering and welding jobs should be executed under blowing which a small quantity of nitrogen. Mostly. this means that the suction line should only be a few degrees warmer than the evaporation temperature indicated at the manometer. In case of simple mechanical procedures for example replacing of a part with fittings. In this case the vacuum time is shortened. Evacuating during repair: During repair works cooling machines have to be discharged off refrigerant in most cases.5 bar). especially for deep-freezing units. after recycling of refrigerant. It is necessary to control the weight of the refrigerant during charging. The function of the lubricant in the compressor The lubricant in a compressor has to meet with exact thermic requirements. because an overcharging could happen. evacuated and oilfilled machines is being done under various conditions. For re-use the refrigerant needs to be discharged by a recycling unit. It has to be observed that the volume of intake to the unit is not exceeding. They are higher than in any comparable power or working machine. 0. considerably simplified if it would only remain in the crank chamber and at the gear components. but there are still additional tasks. The oil serves for the hydrodynamical power transmission. Therefore in the circuit of a compressor cooling machine there is always a binary mixture consisting of refrigerant and oil in circulation. the compressor oil delivery is stronger than during continous operation. for transmission of hydrostatical power at various parts of the cooling compressor. 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. The thermic requirements the lubricant has to meet. noise reduction. wave shaft packing. have been considerably increased during the last years. as there are gear bearings. disipation of heat. Compressors with centrifugal lubrication deliver more oil into the circuit than compressors with pump lubrication. . piston-cylinderskirts. The main duties of the lubricant in the compressor are the reduction of friction and wear and tear. working valves and operative gaskets. The oil delivery into the circuit is different high and depends largely on the compressorconstruction. At high evaporation temperatures the oil delivery is stronger than at lower evaporation temperatures. for removal of avrasion particles. When starting. increase of tightness. There should never exist any connections between air return. Due to thermical reasons inside this temperature.and air outblow. If there is stop and go traffic. humidity and dirt. 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. in order to ensure. Together with our units we deliver refrigerant hosepipes which are suitable for a temperature range from –40°C to +121°C. the iderling speed has to be lifted up to 1. In case of placing the refrigerant pipes inside the air duct. that the water can run down at any time. the parts have to be warmed up to the ambient temperature before opening. It is always better to install copper pipes and in the case of using R 22 it is absolutely necessary. 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. Regarding the technical datas of the manufacturer this is set between +4% to -4%. Rigit pipes have to be closed carefully after cleaning. Take care to physical appearance during installation of these hose pipes. Because then the water cannot go down to the outside. because there is a possible shortening of this hose pipes ( e. 40mm at 1000mm of hose pipe ). range hoses are becominglonger and shorter. During the mounting time the refrigerant pipes and components have to be closed in order to prevent entrance of air. 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.g. (driving up and down a hill).20. In order to prevent the refrigerant parts from entering of humidity. that the oil will be carried back to the compressor by refrigerant. the technician has to follow some installation instructions. because only when all components of the refrigerant circuit are absolutely clean and dry. a siphon has to be installed in front of them. . Installation instructions In order to guarantee that a cooling unit is running frictionless. The condenswater drainage pipes have to be installed in a way. it is necessary to insulate them. in order to avoid new entrance of humidity and dust. a reliable operation of the unit is given.200 rpm. 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. Otherwise the compressor could get liquid strokes. In case that upclimbing suction pipes are unavoidable. The refrigerant pipes especially the suction pipe has to be mounted downward in direction to the compressor. KL 60 KL 70 .5 dm² KL 6 . 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 2.21.KL 12 .0 dm² . Air distribution Air ducts have to be insulated.5 dm² KL 5 2 x 3.KL 1200 2 x 4.KL 7 . Check compressor bracket on the vehicle engine for damages and fastening. Before mounting. 7. 10. . Too much oil influences the refrigeration capacity and less oil influences the working life of the compressor negatively. 4. When exchanging a heat exchanger. General indications for repair and maintenance work 1. Service and maintenance 1. fittings or components carefully. all o-rings and tube fittings as well as hose fittings have to be lubricated with compressor oil (Esther-oil or PAG-oil). for example evaporator or condenser. Never keep the refrigeration circuit longer open to the atmosphere than necessary. 23. 12. Only open compressor valves if the density of the system is established. For tube and hose connection please do always use 2 spanners. the drier should in any case always be exchanged. 9. 2. the components have to be added again. The work at refrigeration circuits should only be done with unobjectionable tools in order to avoid a destruction of connections. 14. 11. If an A/C unit is opened. 3. As the compressor oils are very hygroscopic. has to be installed in the refrigerant circuit. 13. 5. 2. Remove the protecting caps only directly before mounting. Check complete unit for damages. if they are damaged. do not use them. 8.22. keep the oils only in shut oil-cans. Never try to repair bent and burst tubes. Check the connections of the tubes. Please use new o-rings for each mounting. After tightening of all connections the drier. as the last construction part. The fittings have to be tightened only according to the tightening torque moment. the oil which has fallen away by exchanging. 6. so that tube ends will not be damaged. check suction air . 11. 14. Check condition. 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. After having installed the filter/drier receiver unit the control ball should swim in the middle. Check all hose fittings and couplings for leakages. Connect manometer to the compressor and check pressure. Filter/drier and filter/drier/receiver units have to be replaced when opening the refrigeration circuit. 5. Check installation of hoses and cables on the box bodies/ driver's cabin. at least once a year. Air circulation within the air distribution plate must be avoided (partition for suction air and exhaust air must be provided). 13. 8 . 6. Clean condenser coil and replace any damaged condensor coils. Check operation of evaporator blowers and condensor fans. 4. standard sight glasses should be bubble-free. 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 necessary. For units operated with main power supply also check the electric installation. Check electric switch plate. a partition plate has to be installed. Check fastening of evaporator unit. 8. In case of any deviation in colour of the conductor these will have to be replaced and possibly also the relays. . Check compressor fastening. 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. Air ducts for suction air and exhaust air must not be blocked up. alignment and tension of V-belt. 9.3.10 K. . 7. Check temperature on the evaporator unit. 15. For roof-top-units check air circulation. Put cooling unit into operation and check quantity of refrigerant. Excessive upsetting of oil and upward climbing suction hoses should be avoided. 10. 12.check exhaust air = difference in temperature should be min. Check fastening of condensor unit. 16. if any. 17. Check at pressure gauge if all hand wheels are closed. . 9. 22. Connect service adapter at suction side with blue hand wheel 2. Clean return air filter. Check setting and function of defrosting thermostat. 21. 23. 6. Connect service adapter at discharge side with red hand wheel (hand wheels at service adapters must totally be turned counterclockwise until stop) 3. if necessary replace it. Check V-belt from the electric motor to the main powered compressor. 7. Instructions to charge air conditioners with R134a 1. Connect last hose below black hand wheel via pressure reducer to nitrogen bottle. 20. 26. Check fastening and function of the mains powered compressor (cooling down also with mains powered compressor). For units with hot gas defrosting please do also check function of solenoid and return valves. Connect red suction hose below red hand wheel from pressure gauge to red service adapter. 25. Check pressostat for condensor fans for shift mode fast/slow. 24. 19. 20 bar.18. 8. Connect yellow hose below yellow hand wheel from pressure gauge to two-step vacuum pump. 4. 27. 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. Turn hand wheels at both service adapters clockwise until stop in order to open the valves. 24. Open valve at nitrogen bottle (only via pressure reducer). pressure approx. 5. Check filter gaze (on the evaporator). Connect blue suction hose below blue hand wheel from pressure gauge to blue service adapter. Check condense-water outlet. Check pressure switches. Open black and red hand wheel at pressure gauge and charge the unit with nitrogen until a pressure of approx.Put temperature sensors at air outlet and air suction 24. 3. 11. Close blue hand wheel at pressure gauge. Close red hand wheel.5 to 5.Set blowers at full speed .Close windows and doors . (If the system is equipped with a combined receiver/drier the white pearl should swim in the upper third). 26. 13.o bar at suction side is reached. Close refrigerant bottle. 19. Remove hose from nitrogen bottle and open red. Start engine and air conditioner. (max. Switch engine and unit off and check again for leaks. Check leakages with electronic leak detector. Charge the unit with refrigerant until pressure compensation of suction and discharge line is achieved. In case of existing leaks. Open valve at refrigerant bottle and open black and red hand wheel. (indicator pressure gauge) 18. 23.10. 25. 14. start again with item 14. Switch vacuum pump off and observe pressure gauge if vacuum is maintained. These indications are standard values and might be influenced by solar radiation. Open blue hand wheel and charge the system with refrigerant until sight glass is free of bubbles. After having eliminated the leak. . drain nitrogen from the unit. 20. After leakproofness. In this particular case proceed as described under items 9. After having reached sufficient vacuum (both indicators at pressure gauge at -1) close all hand wheels at pressure gauge. Open blue hand wheel and increase pressure on suction side. 15. Temperature difference between air outlet and air suction should be 8 to 10° C (according to unit type). Preparations for test run: . 22. Activate vacuum pump and open all hand wheels. based on an ambient temperature of 20° C. Connect hose to refrigerant bottle. Let unit run at medium engine speed for about 20 minutes. no or only insufficient vacuum is reached. 10 bar) Leakage test with leakage liquid or soapsuds. 16. 17. to 12. 21. 12. blue and black hand wheel. Put dust cabs on all valves. Renew filter drier. 25. Open the valves and put unit into operation. 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. Blow out all remaining mineral oil from the system by means of nitrogen. Fill in refrigerant R134a hereafter. depending on the compressor. 2. Suck off refrigerant R12 for recycling. 30. Do not use oil rests after they have been opened for a longer time. Suck off and recycle remaining refrigerant from the compressor. 3. 4. execute oil change and evacuate this area of the unit. Install e-valve for R134a. 8. Fill in Ester-oil. 11. Check again for leaks. as well as a new receiver and filter-drier. 9. Dismount filter-drier. 28. Fit back the bottom plate by using a new gasket. Affix labels indicating kind of oil and refrigerant. It is absolutely necessery to take care that oil tins stay close until they are used. dismounting can be necessary. 12. Conversion instructions of refrigerant R12 to R134a for a/c with Bock-compressors 1. 7. Remove the bottom plate of the oil tray and clean compressor from inside. 29. Change identification plate and fix additionally another plate an the compressor whith should inform about the kind of oil and refrigerant. 10. 5. Discharge refrigerant oil of compressor. 1-2 hours. Let unit run for approx.27. Turn out hand wheels at both service adapters (counterclockwise) and remove. Note: Ester-oil is very hygroscopic. receiver and high pressure switch. Evacuate unit to 50 Micron and keep it at this valve for at least 3 hours. E-Valve. . 6. 2. Mark cutting line by using colour or tape. A vise. Clamp fittings support in and screw hose in counter-clockwise direction up to 1 mm before the hose end is touching the fitting. Screw nipple at hexagon into support and hose in clockwise direction until nipple comes slightly to . Cutting of hoses 1. Cut hose rectangularly with cutting machine or fine toothed saw.26. a steel saw and a set of screw spanners are available in every workshop. Remove rubber remainders and wire point. The instructions show the easy way to handle the re-usable fittings with the corresponding refrigerant hoses. 3. Take hose from roll without causing kinks. 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. Grease hose core and nipple thread plentifully with refrigerant oil. Demounting in reverse sequence.sit in the support. 27. Do n o t tighten! 4. Inspection Report Customer: . Check all hose pipes and clean. cleaning of the vehicle () () .density/cooling system at 15 bar 15 min.placement of the refrigerant hoses () () .: Unit Type: Vehicle Type: Chassis No. Refrigerant oil in the compressor: Type: Quantity: gr.interior panelling () () .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.placement of the condenser water pipes () () .installation . continuous running () () .air outlet nozzles () () .fixing of the unit () () .sealing of the cover () () .placement of electrical wiring () () .fixing of the compressor console () () .Unit No. 15 bar/continuous running () () .compressor bracket fixing () () . Assembly Company: Mechanic: -----------Stamp --------------Name Revision and Insprection Result: -------------------------------identification plate attached: yes/no Deficiency yes / no .sealing unit/rupture () () .: Km-reading: Voltage: System Voltage: 220V ( ) 380 V ( ) Freon: R 12 ( ) R 502 ( ) R 22 ( ) R134a ( ) Filling Capacity: gr.mountage of the refrigerant hoses () () . additional generator a) performance: amp b) type/no.Deficiency yes / no .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 .: c) fixing of the generator d) V-belt tension e) V-belt alignment . place switch in an upward position and let the pressure rise. Point insertion legible on filling armature.) Check .) Check .Inspection instruction: 1. Start unit and read point insertion on filling armature. .low pressure switch Close shut off valve. In new roof-top and integrated units disconnect the condenser blower.high pressure switch In roof-top-units condenser cover with support. 2. During work-manship with electric short circuit danger.) The working place has to be ventilated! b. During the work with refrigerants. or medical help! f.28.) Never turn out safety switch! . 3. if all components are in regular condition.) Never fill up refrigerant containers.) Do not expose refrigerant containers to direct heat absorption sas. never try to put the hand into rotating parts. They must not be heated up to more than 50°C! g. the battery power supply has to be disconnected.) Before making a leakage test with dried nitrogen.7). refrigerants comes into the eyes. Security during repair and maintenance work 1. Therefore. 2. avoid direct contact! e.) Refrigerants must not get in touch with human skin.) If. h.) When cleaning the engine of the vehicle equipped with air conditioning. the following safety precautions have to be observed completely: a. burst the refrigerant container. therefore please wear protective glasses and protective gloves. but rinse with plenty of water and after that consult a doctor. Filling cylinders and automatic filling stations should only be filled up to the indicating range (space factor 0. act very carefully because the air conditioning parts must not be exposed to direct water vapor. k. do not rub. During operational tests.) Never expose refrigerants to burning objects! c. j. d. due to carelessness.) In case of direct heat absorption on refrigerant containers the thereby intensified pressure can open the safety valves or can. it has to be checked.) As the refrigerants freezes the skin during the evaporation under atmosphereic pressure. at the worst. never use open flames to dry the containers. i. 225mm .3-42. 80mm GH 414 H12-000-703 NW12 min. Bending radius for KONVEKTA refrigerant hose pipes Kind of hose Konvekta part no.7-47. 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 13.1-4.5 Nm (4.0 kpm) 7/8" 27 35.3 kpm) 1 1/16" 32 40. 90mm GH 494 H12-000-213 NW20 min.5-11.5-39.5 kpm) M36x2 41 165-175 Nm (16.3 Nm (1. 160mm GH 494 H12-000-214 NW25 min.5 kpm) 30.5-17.0 Nm (3. 194mm GH 494 H12-000-216 NW32 min.3-4. 75mm GH 414 H12-000-702 NW10 min.8 kpm) M30x2 36 105-115 Nm (10. size of hose bending radius GH 414 H12-000-701 NW8 min.4-2.3 Nm (3.6-4.6-20.29. 85mm GH 414 H12-000-704 NW16 min.1 kpm) 3/4" 32. 0 low pressure switch H11-000-348 2.0 0.5 R134a double pressostat combined pressure switch (3-step) clutch (UD) (ÜD) KD-Fan 1 1 2 2 4 4 1 2 od.31. 1.0 FK2200 (ÜD) (UD) FK2500 (ÜD) (UD) TK3300 (ÜD) (UD) 4 1 4.2 21.0 8.5 4.3 1.95 -0.0 25.0 0.0 H11-000-326 17. 4 1 4 1 1 2 2 4 4 H11-000-384 3.0 4 4.4max.0 -0.2 0.0 6.5 7. input output fault -------------------------------------------------------------------------------low pressure (UD) H11-000-312 0.0 0.2 1.0 1 4 condenser H11-000-316 15.0 4 1 2+3 1 2+3 1 2+3 4 2+3 4 2+3 4 2+3 double pressostat A/C R22 (ÜD) (UD) 2 H11-000-302 21.0 1 4 1 4 2 3 .3 1 H11-000-302 17.2 21.1 2.5 4.0 -0.2 21.25 compressor (CP) R12 low pressure (UD) R12 high pressure (ÜD) R12 pressostat KD-fan H11-000-314 4.0 4 4.2 2.3 1.6 0.0 12.5 19±1 15±1 sw/ge sw br br/sw H11-000-302 17. ON/bar OFF/bar diff.5 R134a pressure switch test H11-000-349 4.3 1.1 R134a high pressure switch H11-000-347 18.0 21.5±0.2 1.5 18±1.2 1.0 H11-000-326 12.3 1 4.5 4.3 1 H11-000-302 17.0 -0.5 25±1.2 0.1 ÜD = HP (high pressure) UD = LP (low pressure) 25.0 0.0 5.5 1 4 H11-000-315 2.3 1. Pressure switch pressure switch switch pressures clamp marking -------------------------------------------------------------------------------part-No. unit type temp. diff.5°C +1. Defrosting thermostat Defrosting thermostat adjustment of a/c and freezing units pos.5°C H11-000-386 .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 (not adjustable) -3. manufacturer part-no.32. clamp marking input output fault -------------------------------------------------------------------------------air condition 1 KL 1 . 000 L+R 134a 2.000 L+R 134a 2.000 L+R 22 1. Compressor detail Type Displacement Weight Max.800 H14-000-443 FK26 670 55 3.33.800 3.000 L+R 134a 2.7 5.800 AC:KES 100 H14-001-435 TK: KS46 3.R Operating Oil (cc) (kg) Speed wise Speed Quantity Oil rpm rpm cm3 -------------------------------------------------------------------------------- 1 Standard Bock TM31HD 313 10.500 H14-002-426 FKX40 555 32 N=3.000 R 134a 500 FK4 466 65/45 3.000 L+R 134a 2.300 L+R 12 FK5 846 92/43 2.850 2.300 H14-000-443 55 100 PG TK:KS46 Triton SE55 3.600 H14-000-443 FKX4 466 2.600 AC:KES 100 H14-001-435 65/45 3.000 L+R 134a 2.000 Triton SE55 K=3.500 H14-002-426 FKX40 650 31 3.000 L+R 12 FK4 466 65/45 2.000 Triton SE55 K=3.600 H14-002-426 FK5 846 92/73 2.000 H14-002-426 AC = air conditioner TK = deep freezing unit L = counter clockwise R = clockwise Triton SE55 Triton SE55 .400 L+R 22 1.500 L+R 22 1.000 L+R 134a 3.300 TK:KS46 3.500 H14-002-426 FKX40 465 32 N=3.300 AC:KES 100 H14-001-435 FKX26 670 FKX40 385 33 N=3.500 3.000 L+R 12 FK26 550 55 3.000 Triton SE55 K=3. turn. 3 6.7 4.000 R 134a DKS26 255 14.5 5.000 R 12 Oil for use with R404a: SEZ32 H14-003-403 AC = air conditioner TK = deep freezing unit L = counter clockwise R = clockwise 500 500 100 PG Suniso 5GS .000 L+R 12 175 AC:KES 100 H14-001-435 SD 510 HD 161 4.000 L+R 134a 4.500 3.000 SD7H15 155 6.25l H14-002-454 Zexel DKS26 255 14.500 3.1 6.5 7.5 7.800 H14-002-426 Triton SE55 4NFY 644 42 3.000 R 12 135 H14-000-443 SD5H14 138 5.R Operating Oil (cc) (kg) Speed wise Speed Quantity Oil rpm rpm cm3 ------------------------------------------------------------------------------- 2 Standard Bitzer 4PFY 541 42 3.25l H14-003-404 Original Sanden Oil PAG for R134a is SP20 5 Suniso 5GS 0.9 6.800 H14-002-426 Triton SE55 3 Nippondenso 7SB16 4 161.000 L+R 134a 2. turn.05 6.000 R 134a TK:KS46 175 Reniso PAG46 207 0.000 R 134a 120ñ15 PAG-ND8 Sanden SD 508 HD 138 5.000 L+R 134a 2.Type Displacement Weight Max. 0 . when they are mixtures of liquid and vapor (inside condenser and evaporator).0 1.34. GWP/ODP Combination Chemical form ODP GWP FCKW11 CCL3F 1. 35.1°C = 14°F Further more it is possible to read corrosponding temperatures and pressures of listed refrigerants.6PSI = -10. 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. 0.057 0. .37 H-FKW 134a CH2F-CF3 0 0.25 .042 .0.4 H-FCKW 22 CHClF2 0.92 .8 .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.FCKW12 CCl2F2 0.0.34 .0 2.1.3. 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