background image

 

 

WAKL5N0802A 

Edition: 07.02.2022 

Page: 4/18

 

 

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. BGV 29). 
Vehicles  are  only  allowed  to  be  maintained  in  compliance  with  the  generally  acknowledged 
rules of technology and observance of the maintenance and operating instruction of the manu-
facturer. In addition, maintenance, conversion or retrofitting works that need specific technical 
knowledge are to be carried out only by qualified companies. 

Directives for Installation, Connection and Use 

Please read carefully the following instructions before installing, connecting and operating the de-
vice. We assume no liability for incorrect handling and usage. 

 WARNING

 

 

 

CAUTION

 

MAKE THE CORRECT CONNECTIONS. 

Failure to make the proper connections may result in fire 
or product damage. 

USE ONLY SUITABLE VOLTAGE. 

The usage with a not suitable voltage may result in fire. 
Furthermore, a not suitable voltage may result in failure 
or product damage. 

TAKE CARE THAT WIRES NOT CARRY CURRENT 
WHILE CONNECTING. 

Connecting wires which carry current may result in elec-
trical shorts or product damage. 

ONLY USE WIRES WITH SUFFICIENT LARGE CROSS 
SECTIONS. 

Using wires with not sufficient large cross sections will 
exceed the current carrying capacity of the wires and 
result in fire or electric shock. 

DO NOT DISASSEMBLE OR ALTER. 

Doing so may result in an accident, fire or electric shock. 

DO NOT INSTALL IN LOCATIONS WHICH MIGHT 
HINDER VEHICLE OPERATIONS. 

Doing  so  may  obstruct  forward  vision  or  hamper  move-
ment and result in serious accident. 

DO NOT BLOCK VENTS OR RADIATOR PANELS. 

Doing  so  may  cause  heat  to  build  up  inside  and  may 
result fire. 

USE  THE  CORRECT  AMPERE  RATING  WHEN  RE-
PLACING FUSES. 

Failure to do so may result in fire or electric shock. 

DO  NOT  PLACE  HANDS,  FINGERS  OR  FOREIGN 
OBJECTS IN INSERTION SLOTS OR GAPS. 

Doing so may result in personal injury or damage to the 
product. 

AVOID HIGH FORCE EFFECTS. 

Do  not  expose  the  device  high  force  effects  or  strokes. 
Doing so may result in product damage. 

RANGE OF THESE DIRECTIVES. 

These  directives  apply  for  all  devices,  on  which  this  di-
rectives-sheet is added. One directives-sheet is sufficient 
per box. 
 

 

HAVE  THE  WIRING  AND  INSTALLATION  DONE  BY 
EXPERTS. 

The wiring and installation of this device requires special 
technical skill and experience and have to be done by ex-
perts. 

ARRANGE  THE  WIRING  SO  IT  IS  NOT  CRIMPED  OR 
PINCHED BY A SHARP METAL EDGE. 

Arrange the wiring so it will not be damaged. 

DO NOT INSTALL IN LOCATIONS WITH HIGH MOIS-
TURE OR DUST. 

Avoid installing the  device in  locations with  high incidence 
of  moisture  or  dust.  Moisture  or  dust  that  penetrates  into 
this device may result in product failure or damage. 

USE  SPECIFIED  ACCESSORY  PARTS  AND  INSTALL 
THEM SECURELY. 

Be sure to use the specified accessory parts. Use of other 
than designated parts may damage this device internally or 
may not securely install the device in place. 

HALT USE IMMEDIATELY IF A PROBLEM APPEARS. 

Failure  to  do  so  may  cause  personal  injury  or  damage  to 
the product. Return it to your authorized customer service. 

TEMPERATURE. 

Be  sure  the  environment-temperature  is  in  the  allowed 
range before turning the device on. 

USE  DEVICE  ONLY  FOR  SPECIFIED  APPLICATION 
AREA. 

Using the device for another purpose or in another applica-
tion area than the intended one, may result failure, product 
damage or injury. 

PRODUCT CLEANING. 

Use a soft  dry  cloth  for cleaning  the  device.  For  more  se-
vere  dirt,  please  dampen  the  cloth  with  water  only.  Any-
thing else has the chance of damage the product. 

TRANSPORT TERMS 

Handle  the  unit  with  care  at  any  time.  During  transport 
make  sure  that  the  unit  is  stored  safely  and  cannot  be 
damaged. If more than one unit are transported, every unit 
has to be packed singly to avoid that the unit’s damage one 
another.  
The forwarder is liable for all damages during transport. 

Summary of Contents for UL500EM

Page 1: ... Germany 49 0 66 91 76 0 49 0 66 91 76 200 Info konvekta com www konvekta com Maintenance and Repair Instruction for KONVEKTA Air Conditioners UL500 EM UL700 EM 2nd and 3rd Gen UL500 EM UL700EM With Wabco control system ID BWA KL5N0802A Version A02 ...

Page 2: ...ns on compressor for tightness 11 3 8 Fresh air recirculation air filter check for contamination if necessary replace 11 3 9 Oil level check of the compressor at the oil sight glass 12 3 10 Compressor oil exchange 12 4 Maintenance work on the electrical installations 13 4 1 Function check of the condenser fans 13 4 2 Function check of the evaporator blowers 14 4 3 Visual check of safety fuses 14 4...

Page 3: ...ation on the operating instructions This maintenance instruction is valid for the a c unit types UL500EM UL700EM 2nd and 3rd Generation and was exclusively written for maintenance personnel It contains Maintenance Plan Maintenance Instructions Operating Instructions Repair Instructions Maintenance and service works have to be carried out regularly as described in the maintenance schedule Bus No WP...

Page 4: ...SES Failure to do so may result in fire or electric shock DO NOT PLACE HANDS FINGERS OR FOREIGN OBJECTS IN INSERTION SLOTS OR GAPS Doing so may result in personal injury or damage to the product AVOID HIGH FORCE EFFECTS Do not expose the device high force effects or strokes Doing so may result in product damage RANGE OF THESE DIRECTIVES These directives apply for all devices on which this di recti...

Page 5: ...e 3 Cooling cycle and components A B C D 3 1 Refrigerant level check at the inspection glass of the roof installation X 3 2 Air tightness check with leakage detector X 3 3 Condenser coil cleaning X 3 4 Refrigerant receiver check for corrosion X 3 5 Replacement of filter dryer functional test of low pressure switch X 3 6 Function check of high pressure switch X 3 7 Check of screw connections on com...

Page 6: ...nance parts 2nd generation 2 2 Overview of maintenance parts 3rd generation Sight glass Dryer Condenser fan Evaporator blower Air filter Air filter Condenser coil UL500EM Condenser unit Condenser fan Evaporator blower Air filter Dryer Sight glass Air filter UL500EM ...

Page 7: ...r cuit and maintenance the unit has to be tested for leaks This can be done during operation of the unit resp at a system pressure of approx 15 bar nitrogen with refrigerant portion Use only electronic leak detectors The usage of contrast agents for leak detection is not permitted and can cause warranty rejection 3 3 Cleaning of condenser coil Clean the condenser coil only when the vehicle engine ...

Page 8: ...ion of the refrigerant receiver If the receiver is corroded it has to be replaced 3 5 Replacement of filter dryer functional test of low pressure switch Open the evaporator cover on the right To get access to the filter dryer the left evaporator cover has to be opened Risk of getting injured by down falling parts Filter dryer Manual shut off valve Sight glass Magnetic valve Expansion valve Pressur...

Page 9: ...ated Depending on the pressure situation the compressor is switched on and off again so that the refrigerant can evaporate Set service shut off valve ND 6 in Stop Position turn spindle clockwise until stop The low pressure switch turns off the compressor when the pressure is 0 3 bar Restart ing of the air conditioning is possible provided that the pressure at the low pressure switch is above 2 1 b...

Page 10: ...lves of the manometer combination for approx 5 sec Pressure in the low pressure volume must exceed 2 1 bar other wise the air conditioner does not operate Low Pressure Malfunc tion Set the service shut off valves ND 6 and HD at the refrigerant compressor again to Normal turn spindle counter clockwise until stop Start the air conditioner and check for any leakage Attach or close and secure service ...

Page 11: ...e counter clockwise until stop Evacuate manometer hoses and detach 3 7 Check of screw connections on compressor for tightness Check all fixing screws on the compressor compressor mounting plate as well as the screws on the flange valves High Pressure 2 and Low Pressure 6 for tightness Screw torque of fixing screws 21 Nm Screw torque of flange valves 2 and 6 45 Nm 3 8 Fresh air recirculation air fi...

Page 12: ...reason the oil level may be different for every reading 3 10 Compressor oil exchange Whenever the refrigerant circulation system has been opened the filter dryer must be re newed see point 3 5 Switch on ignition Switch on the air conditioner into operation for approx 10 min First check refrigerant oil level at the sight glass Connect the blue manometer to atmospheric pressure to service connection...

Page 13: ...te the compressor via the service connections 1 and 5 at the service shut off valves HD high pressure 2 and ND low pressure 6 Refill the evacuated refrigerant amount Set service shut off valves ND 6 and HD 2 of the refrigerant compressor in Original Position turn valve counter clockwise until stop Evacuate manometer and de mount 4 Maintenance work on the electrical installations 4 1 Function check...

Page 14: ...hen finished UL500 EM UL700 EM 4 4 Plug connection check for tightness Open service cover in the passenger compartment below the right corner of the roof installation with a square spanner Check tight fit of plugs and electric connections Close Cover when finished 4 5 Visual check of electrical cables for abrasion Open quick fasteners and side covers Take fan plate of the condenser fans out and ch...

Page 15: ...rs Loosen the quick fasteners and open the evaporator cover hoods and secure them against falling The blower is furnished with an insert blower plate that is fitted into the bottom part of the unit 5 1 1 Demounting evaporator blowers Remove the blower with the insert blower plate from the bracket on the side facing the evaporator heat exchanger as shown by the arrow Disconnect the cable and replac...

Page 16: ...racket Then fix the blower by slightly pressing the bracket 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 servic ing element Actuators of flaps and servicing element Attention Do not pinch the cables and arrange them in a manner eliminating the risk of chafing ...

Page 17: ...y on the actuator shaft To do this the flap may be easily repositioned The reassembly is carried out in reverse order 5 3 Mounting und demounting of control node ATC CAN The WABCO control node is located in the evaporator part in driving direction right side and is mounted on an electric PCB with a fastening screw Unscrew the fastening screw remove the control unit Wabco upward and disconnect plug...

Page 18: ...ermany Resolution for dangerous substances Resolution for used oil Law for waste circulation KRW AfgG Law of water balance Resolution for the proofs of utilization and removal Resolution for the waste management of old cars and the adaptation of road prescriptions Criminal Code StGB 28th section criminal acts against the environment 326 Envi ronment jeopardizing waste management Resolution EC No 2...

Reviews: