KONVEKTA UL500EM Maintenance And Repair Instruction Download Page 8

Page: 8 / 18

WAKL5N0802A

Edition: 07.02.2022

Page: 8/18

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

3rd generation

Make a visual inspection 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

Pressure switch

Refrigerant receiver

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...

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