Technical manual

for
air-conditioning heating system
Liebherr Excavator B-Line

R134a
24 Volt DC

Konvekta AG
Am Nordbahnhof 5
34613 Schwalmstadt
Germany

✆ +49 ( 0 ) 66 91 / 76 – 0
ID#: BEA-78B28702A +49 ( 0 ) 66 91 / 76 - 200
Version: A00 [email protected]
www.konvekta.com
 Contents
Page:
• Directives for Installation, Connection and Use ......................................................................3
• Introduction ............................................................................................................................4
• Information on the operating instructions ................................................................................5
1. Purpose and function of the air-conditioning heating system ..................................... 5
2. Technical data .................................................................................................................. 5
2.1. Air-conditioning heating system ......................................................................................... 6
3. Positioning of the air-conditioning and heating components in the machine............. 6
3.1. Air-conditioning heating system VD2142/4......................................................................... 7
3.1.1. Air-conditioning heating system components ..................................................................... 7
3.2. Air filter box ........................................................................................................................ 8
3.2.1. Air filter box components ................................................................................................... 8
3.3. Control unit ........................................................................................................................ 9
3.3.1. Terminal pin assignment .................................................................................................... 9
3.3.2. Error code description ...................................................................................................... 10
3.3.3. Functions of operating and indication elements ............................................................... 11
3.4. Wiring scheme VD2142 ................................................................................................... 13
3.5. Condenser ....................................................................................................................... 14
3.5.1. Condenser unit components ............................................................................................ 14
3.5.2. Pressure switch ............................................................................................................... 15
3.5.3. Condenser coil ................................................................................................................. 15
3.6. Compressor Sanden SD7H15 ......................................................................................... 15
4. Air distribution ............................................................................................................... 16
4.1. Air intake.......................................................................................................................... 16
4.2. Air outlet .......................................................................................................................... 17
4.3. Air filter ............................................................................................................................ 18
5. Refrigerant circuit .......................................................................................................... 19
6. Electrical system ........................................................................................................... 19
7. General information a/c unit ......................................................................................... 20
7.1. Determined use ............................................................................................................... 20
8. Maintenance / Servicing ................................................................................................ 21
8.1. Period of maintenance ..................................................................................................... 21
8.2. Return air grid .................................................................................................................. 21
8.3. Condenser coil ................................................................................................................. 21
8.4. Troubleshooting ............................................................................................................... 22
9. Warranty Conditions...................................................................................................... 22
10. Waste disposal in accordance with legal provisions .................................................. 23
11. History of modification .................................................................................................. 23
12. Appendix ........................................................................................................................ 24

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 Directives for Installation, Connection and Use
Please read carefully the following instructions before installing, connecting and operating the
device. We assume no liability for incorrect handling and usage.

WARNING CAUTION
MAKE THE CORRECT CONNECTIONS. HAVE THE WIRING AND INSTALLATION DONE
Failure to make the proper connections may result BY EXPERTS.
in fire or product damage. The wiring and installation of this device requires
USE ONLY SUITABLE VOLTAGE. special technical skill and experience and have to be
The usage with a not suitable voltage may result in done by experts.
fire. Furthermore a not suitable voltage may result ARRANGE THE WIRING SO IT IS NOT CRIMPED
in failure or product damage. OR PINCHED BY A SHARP METAL EDGE.
TAKE CARE THAT WIRES NOT CARRY Arrange the wiring so it will not be damaged.
CURRENT WHILE CONNECTING. DO NOT INSTALL IN LOCATIONS WITH HIGH
Connecting wires which carry current may result in MOISTURE OR DUST.
electrical shorts or product damage. Avoid installing the device in locations with high
ONLY USE WIRES WITH SUFFICIENT LARGE incidence of moisture or dust. Moisture or dust that
CROSS SECTIONS. penetrates into this device may result in product
Using wires with not sufficient large cross sections failure or damage.
will exceed the current carrying capacity of the USE SPECIFIED ACCESSORY PARTS AND
wires and result in fire or electric shock. INSTALL THEM SECURELY.
DO NOT DISASSEMBLE OR ALTER. Be sure to use the specified accessory parts. Use of
Doing so may result in an accident, fire or electric other than designated parts may damage this device
shock. internally or may not securely install the device in
DO NOT INSTALL IN LOCATIONS WHICH place.
MIGHT HINDER VEHICLE OPERATIONS. HALT USE IMMEDIATELY IF A PROBLEM
Doing so may obstruct forward vision or hamper APPEARS.
movement and result in serious accident. Failure to do so may cause personal injury or
DO NOT BLOCK VENTS OR RADIATOR damage to the product. Return it to your authorized
PANELS. customer service.
Doing so may cause heat to build up inside and TEMPERATURE.
may result fire. Be sure the environment-temperature is in the
USE THE CORRECT AMPERE RATING WHEN allowed range before turning the device on.
REPLACING FUSES. USE DEVICE ONLY FOR SPECIFIED
Failure to do so may result in fire or electric shock. APPLICATION AREA.
DO NOT PLACE HANDS, FINGERS OR Using the device for another purpose or in another
FOREIGN OBJECTS IN INSERTION SLOTS OR application area than the intended one, may result
GAPS. failure, product damage or injury.
Doing so may result in personal injury or damage to PRODUCT CLEANING.
the product. Use a soft dry cloth for cleaning the device. For more
AVOID HIGH FORCE EFFECTS. severe dirt, please dampen the cloth with water only.
Do not expose the device high force effects or Anything else has the chance of damage the product.
strokes. Doing so may result in product damage.

RANGE OF THESE DIRECTIVES. TRANSPORT TERMS

These directives apply for all devices, on which this Handle the unit with care at any time. During
directives-sheet is added. One directives-sheet is transport make sure that the unit is stored safely and
sufficient per box. cannot be damaged. If more than one unit are
transported, every unit has to be packed singly to
avoid that the units damage one another.
The forwarder is liable for all damages during
transport.

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 Introduction

These operating instructions have been written for drivers, operators and maintenance staff of your
air-conditioning unit.
In this context, we refer implicitly to the compliance with our general installation guidelines.
These can be obtained from the KONVEKTA technical after sales service:
[email protected].
Please observe our valid safety instructions, available under www.konvekta.de/asv.html. In
case of order placement or any other conclusion of contract the safety instructions get
integral part of the contract.
These operating instructions have to be read carefully and made use of before the first start-up and
after that regularly by each person who is involved in handling the machine:

⇒ Operation including troubleshooting and waste disposal of fuels and auxiliary agents.
⇒ Servicing, inspection, repair.
⇒ Transport.

This facilitates the handling and avoids trouble caused by improper operation. Working in
compliance with these operating instructions increases operation reliability and service life of the
air-conditioning unit and reduces life cycle costs.

Please complete these instructions by adding the national provisions for prevention
of accidents and environmental protection.
These instructions are part of the air-conditioning unit. Always have a copy at hand
in the driver’s cabin.

You will certainly understand that we will not recognize any warranty claims due to improper
handling, inadequate maintenance, applications that do not correspond with the determined use,
utilization of non-admitted fuels or the non-observance of safety provisions.
KONVEKTA will annul without 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.
These operating instructions contain all necessary information to operate your air-conditioning unit.
In case you need more explanations please contact the next KONVEKTA service station .

On our website www.konvekta.com in category >service< you will find a survey of contact details of all our
service partners close to your location.

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 Information on the operating instructions
These operating instructions are valid for the air-conditioning unit’s type:
VD2142/4
B58-100-997
When taking the unit into operation we recommend adding the following data. This will also be
important for your orders of spare parts, and in case of warranty.

Serial number of the unit: ...........................................

Order No: A (X) / ..........................................

Year of construction: .................. / .............. ................. (MM/JJ)

Date of first operation: .................. / ............../................. (TT/MM/JJ)

The machine is in accordance with the EC machinery directive 2006/42/EC.

Due to the fact that scope of supply depends on the order, equipment of your product may differ in
some parts of description.
In case your product is equipped with details not shown or described in the operating instruction,
your KONVEKTA Service Station will always be at disposal for informing you about correct
operation.
In the course of further developments we reserve the right to technical modifications without notice.
Guarantee and liability conditions of KONVEKTA AG’s general business conditions are not
enlarged by the above notes.
Indications and photos should neither be copied and circulated nor used for competitor’s purposes.
All rights according to the copyright remain expressly reserved.

Manufacturer: KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt

1. Purpose and function of the air-conditioning heating system

• To have the desired room temperature in the cabin.
• Reheat (fast dehumidification of the cabin during in-between season/winter).
• Variable air outlet via claps and blower regulation.
• Filtered intake for circulated and fresh air.

2. Technical data

Important!
In vehicles that are equipped with an a/c unit with heating function the heating medium has to
consist of water/glycol – antifreeze protection 50/50 %. This is absolutely necessary to prevent the
heaters from frost damage! (The prevalent antifreeze filling of the vehicle manufacturers goes
down to -40°C)

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 2.1. Air-conditioning heating system
Type KL2/4
Refrigerant R 134a
·- quantity approx. kg 0,900
Operating voltage Volt DC 24
Cooling capacity VD2142/4 Watt 7.500
Heating capacity VD2142/4 Watt 6.000
Condenser- capacity Watt 11.000
Compressor Sanden (Scope of delivery LMD) SD7H15

3. Positioning of the air-conditioning and heating components in the

machine

Air-conditioning heating system Konvekta item number. LFR identity number

1. Air-conditioning heating system VD2142/4 B78-075024B287 11832047
2. Air distribution box B58-001-997 11823537
3. Control unit H11-006-441 11832046
4. Condenser B35-A50-019 11828837
5. Compressor (scope of delivery Liebherr)
The air-conditioning heating system is located in the floor of the cabin and it is placed behind the
driver’s seat.
The following service parts are checked in the The following service parts are checked under the
cabin cabin
• Complete air-conditioning heating system • Expansion valve
• Blower
• Icing sensor
• Plug connections electric
• Modulating motors
• Filter for circulated air
• Control unit

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3.1. Air-conditioning heating system VD2142/4
The air-conditioning heating system is located in the base plate of the cab just behind the driver's
seat.

Installation location
in cab

3.1.1. Air-conditioning heating system components

Servomotor
C-pillar Evaporator coil sensor

Fan

Evaporator coil with

Exp.-valve

Servomotor
Footwell Servomotor
Servomotor/ Temperature mixing flap
Side wall / front
Heating
heat exchanger

Sensor
Mixing chamber

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3.2. Air filter box
The air filter box is located in located in the left side wall facing the direction of travel.

Installation location
in cab

3.2.1. Air filter box components

Illustration without cover plate

Fresh- /
Recirculation air filter

Fresh air flap

Sensor recirculating air

Servomotor
fresh air flap

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3.3. Control unit
Also refer to 1100644101A for operating instructions

3.3.1. Terminal pin assignment

20-pin plug-in connector

16-pin plug-in connector

20-pin plug-in connector

Pin Name Description

1 Servomotor side wall PIN +
2 Servomotor side wall PIN -
3 Servomotor fresh air flap PIN +
4 Servomotor fresh air flap PIN -
5 Compressor outlet 24V DC
6 Feedback pressure switch
7 High-power level detection input port (backup)
8 Sensor COM GND
9 Sensor COM GND
For controller and servomotor
10 GND
temperature flap
11 Compressor ON signal
12 Sensor COM GND
13 GND For software update
14 TVCC For software update
15 NRST For software update
16 SWIM For software update
17 NC
18 Backlight
19 DC power supply 24V DC
20 DC power supply 24V DC

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16-pin plug-in connector

Pin Name Description

1 Feedback servomotor temperature flap
2 Feedback servomotor temperature flap + 5V DC
3 Servomotor temperature flap PIN +
4 Servomotor temperature flap PIN -
5 Servomotor C-pillar PIN +
6 Servomotor C-pillar PIN -
7 Servomotor footwell PIN +
8 Servomotor footwell PIN -
9 Icing sensor
10 Exhaust temperature sensor
11 Intake temperature sensor
12 Parking heater
13 Ignition terminal 15
14 PWM signal for evaporator blower
15 Servomotor driver PIN A (optional)
16 Servomotor driver PIN B (optional)

3.3.2. Error code description

Error No. Name Possible causes

Room temperature
F0 Sensor defective, broken cable, not connected
sensor
Blow temperature
F1 Sensor defective, broken cable, not connected
sensor
F2 Icing sensor Sensor defective, broken cable, not connected
Motor defective, faulty feedback, broken cable, not
F3 Temperature mixing flap
connected, flap mechanically jammed

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3.3.3. Functions of operating and indication elements
Key functions:

12
2; C
10; A
3; D
11
8; B
5
9

1
6
7

In order to use the additional functions, the respective button must be pressed for 5 seconds.

Key functions Additional functions

Button to release the air-conditioning A Switching from ° C to ° F
1
operation.
Button to set the desired cab temperature / B Display brightness setting in 8 steps
2
display brightness upwards.
Button to set the desired cab temperature / C Max. heating
3
display brightness downwards.
Button to activate and deactivate the D Max. cooling
4
controller.
Switching button for ventilation flap front /
5
driver OPEN / CLOSE
6 Switching button for defrost mode
Switching button for fresh air / recirculation
7
mode
Switching button for rear ventilation flap
8
OPEN / CLOSE
Switching button for footwell ventilation flap
9
OPEN / CLOSE
10 Button to turn on automatic operation
Button to set the desired blower speed
11
downwards.
Button to set the desired blower speed
12
upwards.

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Meaning of displays:

2
9

10 8

6
3 7

1
4 5

Indicators / displays
1 Indicator indicates compressor is turned on 6 Indicator indicates rear air flap is open
Indicator indicates power supply is ensured Indicator indicates foot flap is open
2 7
and the self-test is completed
Indicator indicates windshield / driver flap is Counter indicates that automatic mode is
3 8
open turned on
Indicator indicates that DEFROST mode is Display for the blower speed settings
4 9
turned on
Indicator indicates that system only works Display for the set temperature
5 10
with circulating air

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3.4. Wiring scheme VD2142

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 Risk of accident!
− Priority must be given to the traffic.
− Only operate your air conditioner if the traffic situation allows it.
− Please make sure that all operation and indicating elements can be recognized and read
properly.
− Protect the displays and all indicating instruments against sun rays and other optical faults.
− Take into consideration that the keys at the operation panel are not designed for extreme
demands.
− Excessive or quick pressing of the keys for temperature adjustment does not accelerate the
cooling process but leads possibly to damage on the operation panel and spoils the total
functioning of your air conditioner.

3.5. Condenser
The condenser unit is located to the left in front of the motor fan facing the direction of travel.

Condenser unit

3.5.1. Condenser unit components

2-fold pressure switch

Safety valve

Drier-receiver unit

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3.5.2. Pressure switch
OFF ON
Low pressure BAR 2.0 ± 0.2 2.1 ± 0.3
Overpressure BAR 28.0 ± 2.0 21.0 ± 3.0

3.5.3. Condenser coil

It is important to ensure that the fins of the condenser are clean. Heavy soiling causes
overpressure in the air-conditioning system and leads to the system shutting down prematurely.

Note!
Regular cleaning (blowing out with compressed air) should be performed. In heavy dirt conditions,
the capacitor bank must be checked daily for dirt and cleaned if necessary.

3.6. Compressor Sanden SD7H15

Type: SD7H15

Installation and start-up of the compressor have to be carried out conform to Sanden
guidelines.
The compressor is mounted on the engine of the vehicle which drives the compressor by a poly-v-
belt. It has to be taken care that the tension of the v-belt is correct.
When the air-conditioning system is switched on, the magnetic clutch is being activated and the
compressor is working.
When the air-conditioning system is switched off, the magnetic clutch works without being
activated.

Important:
To avoid leakages at the shaft seal of the compressor:
The compressor should be started every 4 weeks for approx. 15 minutes!
This also applies when the vehicle is not into operation for a longer period or when the air-
conditioning unit is not used!

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4. Air distribution
Air discharge openings are controlled via control unit in the fitting board.

Preset air flow:

• in heating operation, outlet floor and windshield / driver
• in air-conditioning operation, outlet ducts in the back wall of the cabin, windshield / driver
• according to the principle: cool head and warm feet

Note!
Air flow distribution can be adapted to the driver's needs. Only not all flaps can be closed, though.

4.1. Air intake

The air-conditioning unit is working with 10% fresh air.
Fresh air is also detachable, this clap is controlled via control board.

Description
1 Suction recirculating air
2 Suction fresh air

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4.2. Air outlet
Air is let out through air ducts, which are located in the side wall facing the direction of travel. In the
footwell the air is let out below the driver's seat.

Description
1 Windshield / driver outlet
2 C-pillar outlet
3 Footwell outlet

1 2

2 1 3

Blow-air nozzles
C-pillar

Blow-air nozzles
Windshield/driver

Blow-air nozzles
Footwell

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4.3. Air filter

The fresh-air or circulating air filter is located to the left of the driver's seat facing the direction of
travel. Remove the cover to change or clean the filter.

Air filter position

Cover

Konvekta item number LBH Ident-No.

1 Fresh-air or circulating air H14-006-447 11 83 13 31
filter F7

Important:
• There is a fresh-air and circulating air filter in the air intake box that must be cleaned at regular
intervals (see maintenance schedule for service intervals).
• Air flow in the air-conditioning heating unit is not possible when filters are soiled. Consequence:
the air-conditioning ices up and the system switches off.
• If the filters are not installed, the evaporator becomes soiled in a short time. And it is no longer
possible to clean the evaporator coil.

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5. Refrigerant circuit

NW10

NW8

LP HP
NW16

Coolant water
Flow
Heating
Coolant water
Return flow

6. Electrical system
The air-conditioning heating system is wired according to attached switching plan no. BK1-013-
066.
Switch off user. You can find out which fuse belongs to the unusual user with the help of the fuse
table. Please pull out the appropriate fuse. Replace the melted fuse (distinguishable by melted
metal strip) by a new one of the same strength.

Remark:
If the replaced fuse melts once again after a short time, the electrical units have to be checked
immediately by an authorized KONVEKTA – service station. Never “repair“ fuses! This might
cause other damage to the electrical system!

Fuse table:
See switchboard driver’s seat.

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7. General information a/c unit
− A/C unit is only operating with running engine.
− In case of cooling, humidity in the interior part of the vehicle goes down which prevents misting
up of windows.
− The a/c unit works most effectively if windows and doors are closed. If interior room of the
vehicle is enormously warmed up, a short time opening of windows/doors might help to
accelerate cooling progress.
− In case of high outside temperature and high humidity it might be the case that condenses water
drips off condenser which causes a small water collection under the vehicle. This is quite normal
and no signal for leakage.
− The filter in the return air grid retains dirt. Circulated air adjustment should be chosen in case of
dirty gaseous air from outside. Elements of the return air grid have to be exchanged according
to the stipulated times of service plan in order to possibly avoid performance reduction of the a/c
system.
− In case of an eventual damage of the a/c unit - operation should immediately be
interrupted to avoid consequential damages. It’s recommended to contact one of
KONVEKTA’s Service Stations and the unit should first be taken into operation again
after it has been checked through specialists.
1 On our website www.konvekta.com in category >service< you will find a survey of contact details of all
our service partners close to your location.
Note:
We recommend driving with automatic mechanism..
Additionally to the automatic the following functions can be activated:
a) Fresh air flap manually, in order to prevent the entrance of exhaust fumes.
b) DEFROST function to defog the steamed up windshield

7.1. Determined use

The KONVEKTA Air-conditioning heating system represents an air-conditioning system that works
with the ozone friendly refrigerant R 134a and which creates a pleasant and individually adjustable
room temperature by means of forced convection. The determined use includes also the
observance of the Operating instruction and the proof of regular inspections as well

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8. Maintenance / Servicing
Maintenance and service works have to be done in accordance with the “Maintenance Schedule,
Item no: WP07050621 “
- Only qualified staff is allowed to carry out these works! -
For general instructions on repair – and maintenance works please contact via email:
[email protected]

Danger of accidents!
Qualified staff in charge of installation and maintenance have to be trained in accordance
with EN 378-Part 4 and (EC) No.307/2008 and must strictly follow the legal provisions.
Any works or modifications at the air conditioner which are carried out improperly can lead
to malfunction and so endanger operational reliability. We recommend having all works and
modifications carried out at an authorized KONVEKTA Service Station .
Before carrying out any maintenance works at your air-conditioning unit, carefully read the
KONVKETA safety provisions (TD00052A ) in order to avoid any dangers and accidents!
On our website www.konvekta.com in category >service< you will find a survey of contact details of all
our service partners close to your location.
Source of supply: KONVEKTA AG, P.O. Box 2280, D-34607 Schwalmstadt

8.1. Period of maintenance

At least once a year - only by refrigerant expert :

• Check unit for leakages.
• Retighten fixing screws of compressor and bracket at the engine.
• Check electrical connections.
• Check refrigerant Level at sight glass. (If air bubbles are formed - consult service station)
• Check hoses and electric cables on possible damages.
• Exchange drier
• Check blower motors and fans at evaporator and condenser

8.2. Return air grid

Clean the return air grid in the driver’s cabin monthly. In case of enormous dirt weekly!

8.3. Condenser coil

Make sure that fins of condenser are clean. In case of enormous dirt over pressure starts, to be
built up inside the air-conditioning system, this leads to an automatic operating interruption.

Note:
Regular cleaning should be executed 2 times per year. In case of enormous dirt more than 2
times (blow through the condenser coil with compressed air).

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8.4. Troubleshooting

Only qualified staff is allowed to carry out these works! –

Trouble Cause Repair only by refrigeration expert 1

a/c is not running - electric wiring disconnected - check wiring
- fuse defective - check fuses and replace, if necessary
- Switchboard defective - replace switchboard
- too high pressure - clean condenser coil with compressed
air
- low pressure - replace drier only by refrigeration
expert
- drier clogged - clean expansion valve, and replace, if
necessary only by refrigeration
expert
- low pressure, - check unit for leaks
unit does work, - Exp.-Valve is clogged - recharge refrigerant (replace drier!)
but turns off only by refrigeration expert
unit does work , Temperature mixing valve - Check temperature mixing flap
but no cooling defective - switch off heating
capacity - Heating on -
strong noise at - Defect bearing on compressor. - replace compressor, only by
compressor refrigeration expert
- magnetic clutch defect - replace magnetic clutch
whistling noise on - V-belt worn off - replace V-belt
the V-belt
On our website www.konvekta.com in category >service< you will find a survey of contact details of all
our service partners close to your location
2By operator

9. Warranty Conditions
The current „General Warranty Conditions KONVEKTA AG“ will apply. A copy will be furnished by
the warranty department. Please contact [email protected].

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10. Waste disposal in accordance with legal provisions
After the phase of use the last proprietor is responsible for the adequate waste
management. The environmental regulations in the exporting country must be observed.
The following list contains the most important regulating literature, valid for the Federal Rep. of
Germany:
• Resolution for dangerous substances • Law of water balance
• Law for waste circulation (KRW/AfgG) • Resolution for the waste management of old
• Resolution for the proofs of utilization cars and the adaptation of road prescriptions
and removal • Resolution (EC) No. 2037/2000 of the
• Criminal Code (StGB) 28th section European Parliament and of the Council for
„criminal acts against the environment” materials that affect the ozone layer
§326 - Environment jeopardizing waste • Resolution to prohibit certain ozone destroying
management halogen hydrocarbons
• Resolution for used oil • Law of chemicals § 27 - penal prescriptions
The used refrigerant endangers the environment. When dealing with refrigerants the existing
prescriptions and regulations are to be followed. Only skilled personnel are allowed to carry out
these works!
Water endangering substances - acc. to §§19g-19l - are solid, liquid, and gaseous substances.
e.g.: mineral and tar oils (cooling oils), halogen containing organic combinations (refrigerants)

Source of supply:
- Bundesanzeiger
- Beuth Verlag
- dtv (Deutscher Taschenbuch Verlag

11. History of modification

Version Date Name Remark File
A00 23.02.2016 Völker Source file EA78B28702A

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12. Appendix

Drawings:
• Evaporator 78B287G1
• Control unit 11006441
• Air distribution box 58100997G1
• Condenser 35A50019

Documentations:
• Spare part list VD2142/4/24V 78B287ET
• Spare part list air distribution box 58100997ET
• Spare part list condenser unit 35A50019ET
• Wiring scheme BK1-013-066
• Safety instructions TD-00051A
• Maintenance schedule WP070050621

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