2017

The investments made over the last two years have al-lowed KALORI to acquire

powerful tools for dimension-ing the components of our air conditioning and heating sys-tems. These tools are used on a daily basis to calculate, test, and improve existing installations as user requirements evolve towards ever greater perfor-mance. An important milestone has been reached, positioning KALORI as a leading manufac-turer for OEM developments. We are also continuing to ex-pand our range of standard components, with strong devel-opment in electrical units to sup-port vehicle manufacturers. Our role is to solve equations that improve driver comfort, our

teams combining savoir-faire with passion for guaranteed cus-tomer satisfaction.

Christian Micollet, CEO

Voie E - Z.I. de MariageF-69330 PusignanFranceTel.: +33(0)4 72 93 10 10Fax: +33(0)4 72 93 10 19

www.kalori.comkalori@kalori.comHeating & Air conditioning

Special & industrial vehicles

KALORI has set up new test facilities integrating thermodynamics software and a 90 m3 dual-compartment climate chamber, equipped with two testing stations.

Modeling comfort to save time… and money p.4

SIMULKA®Innovation

90°West communication - www.90west.fr • Photos: Kalori / Fotolia

Editorial

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Expansion General view ............................................. 3

SIMULKA® Modeling comfort to save time and money ......................................................... 4

COMPACT EVO2 KLIM FAI The smallest evaporator ....................... 6

Quality Leak tests for air conditioning ............ 6

China ............................................................7

New refrigerant .........................................7

Germany / Italy ..........................................7

Trade shows ...............................................7

Ambulances A fully integrated front panel .............. 8 Adapter plates for ADT ......................... 9 EASY FIT .................................................... 9

New products KLIMATOP KOMBI for ambulances....................................... 10 HK EVO4 .................................................. 10 PCK2 control panels .............................. 11 RK4 rooftop unit ..................................... 11

STOP&KOOL ...............................................12

POWER K .....................................................13

Electric vehicles Expansion of the range with the EHVACs ....................................14

KALORI TRIM LINE .....................................15

New on www.kalori.com Our online catalog ................................. 16

Contents

www.kalori.com

Stop the engine

& stay comfortable

Save money

while resting

or waiting

Stop&Kool Engine-independent compressor

The Stop&Kool is connected

to the original A/C system

3

The new 90 m3 test chamber, located next to the 300 m3 chamber, constitutes a homogeneous and exceptionally effective testing unit.

ExpansionGeneral viewFollowing the expansion work on our Pusignan site,

the areas have been redistributed. The new modeling workshop allows access for large-gauge vehicles. The

technicians from our Technical Intervention Department carry out the implementation of prototypes and the instrumentation of the vehicles before testing in a climatic test chamber. A frame lift allows for working comfortably on vehicles weighing up to 4.2 tons.Thermoforming activities now benefit from a dedicated space that will ensure their development linked to the manufacture of specific HVACs or housings meeting very small batch production needs.The production lines integrate compliance with lean manufacturing principles. They can manage more than 80 production orders per day, with an industrial organization that ensures both flexibility and rigor.

12,500 m² dedicated to driver comfort

In the foreground, more than 300 m² for the new modeling workshop

Hall 3 now houses two climatic test chambers

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Why this decision to invest in such cut-ting-edge facilities to develop air condition-ing systems for simple heavy equipment vehicles?

O.B.: Because user requirements evolve. While a few years ago a simple cooler in a driver's cab sufficed, today users do not understand why their work vehicles, in which they spend so much time, should be less comfortable than their own cars.

Back in 2006, KALORI invested in a 300 m3 climatic chamber. Was there really a need for this new 90 m3 chamber?

O.B.: Absolutely. Until now, we used an experi-ence-based approach to establish the power lev-els needed in different vehicles. We also relied on basic software, which gave an approximate result, the validation then being carried out in the climatic test chamber.

This method was satisfactory, but in some in-

stances it proved complicated to precisely es-tablish the needs of the vehicle. These cases in-volved heat inputs that were not always clear at the time of drawing up the specifications. And while we always met the results expected by our vehicle manufacturing customers, these were not without hold-ups related to additional testing that had to be carried out to determine the ideal HVAC.

So the SIMULKA® program has allowed for saving time?

O.B.: Yes, because it defines the air condition-ing loop even before the finalized construction of the cab. SIMULKA® accurately calculates the required power levels, taking into account the pressure losses of the air distribution system, as well as the heat inputs, for example a hydraulic circuit or air from the engine cooling circuit if these parameters are correctly specified by the manufacturer.

Is the 90 m3 climate chamber also equipped with measuring systems?

O.B.: Yes. These testing stations accurately mea-sure the performance levels of the components used. The airflow and pressure curves are ob-tained with the air diffusion components, for example. These tests allow us to check the com-patibility of the units with the requirements for-mulated on the basis of the results of the calcu-lations. Optimal comfort cannot be ensured with the figures given in sales and marketing docu-mentation!

Is precision really that important? Wouldn't slight oversizing allow for obtain-ing acceptable temperatures inside the cab?

O.B.: Not always, and when this is the case, over-sizing often involves extra costs or requirements for too large a space, to the detriment of the fitting out of the cab. It is now possible, before prototyping the system, to precisely establish the

power levels required for the evaporator as well as the distribution of temperatures inside the cab depending on the location of the air diffusers.

With vehicles for which we have carried out a HVAC improvement study, we have often ob-served temperature disparities causing real dis-comfort.

While the average taken into account corre-sponded to the norm, the driver's face was too warm!

KALORI has set up new test facilities integrating thermodynamics software and a 90 m3 dual-compartment climate chamber, equipped with two testing stations.

Interview with Olivier Bontemps, the man behind the project, on the reason for this investment.

SIMULKA®

Modeling comfort to save time... and money

Olivier Bontemps, General Business Develop-ment Manager

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But these systems had been approved by the manufacturer?

O.B.: Time pressure during development or dead-lines for the presentation of a new product at an important trade show, for example, sometimes lead to making compromises in the results that were not thought possible at the start of the study.

Additionally, during climatic chamber tests, a good average temperature can be obtained with very low values at the feet and close to 30°C at the operator's head. Sometimes, faced with the modifications necessary to improve the result, the vehicle manufacturer declares himself sat-isfied, and this is perfectly understandable. Our role as equipment manufacturer is to seek the very best result, working in total transparency with the vehicle manufacturer.

How does your new process protect the vehi-cle manufacturer from these same errors?

O.B.: We encourage the manufacturer to think ahead. Air conditioning is one of the most expen-sive systems in a cab. To ensure value for money for the end customer, the air conditioning must work well. That means not necessarily limiting it to the regulatory threshold. A temperature dif-ference of 11°C means nothing when the outside temperature is 40°C... Who would want to work seven hours non-stop in an atmosphere at 29°C? And some users, notably the American market, actually require very low cab temperatures. The notion of comfort is therefore very subjective, and does not necessarily meet criteria consid-ered reasonable by some.

By tasking us with the modeling of their cab at the outset of the project, the vehicle manufactur-er allows us to determine the HVAC power levels. Together, we decide the location of the air diffus-

ers, and recalculate the performances obtained depending on any compromises that have been negotiated.

Does this mean that the SIMULKA® recom-mendations cannot be applied?

O.B.: Sometimes it is impossible, and it is im-portant to understand the impact of chang-ing a certain parameter by knowing upstream of the final tests what the result will be. A reduction in the condenser surface, if antici-pated, can be managed. And when the conse-quences are known from the outset, the results of the validation tests are never disappointing.

So this approach systematically results in specific development?

O.B.: Often, yes. And if the project is well under-

stood sufficiently in advance, we can use one of KALORI's standard range of HVACs, which are tiered in such a way as to meet most needs. This is a real opportunity.

The gain is significant because no development costs or investments in tools are needed. It also reduces the development time necessary.

Are there any other benefits to this invest-ment?

O.B.: A big one, namely the peace of mind that comes from being sure of the result, as well as compliance with the development schedule.

The precision is impressive, and the values ob-tained by the calculations are those found in the vehicle.

"The precision of the results is impressive"

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Using the input data, the SIMULKA® software calculates the heating and air conditioning power output curves which allow for obtaining the level of comfort defined in the specifications.

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To ensure the quality of installation of an air conditioning system, it is necessary to carry out certain tests.

The evaporators used by KALORI are 100% tested by their manufacturers. For any transformations they undergo in the assembly workshop (addition of an expansion valve, connecting pipes, etc.), they are tested again (100% of production) via a dedicated test bench. This check ensures a certain level of quality of KALORI deliverables. It does not, however, guarantee the leaktightness of the system delivered by the vehicle manufacturer to the user, or by the cab manufacturer to the vehicle manufacturer.

When an assembly delivered by KALORI is installed in a vehicle or in a cab, integration requires connection to connectors equipped with seals. Each connection presents a potential risk of leakage if the seal is incorrectly positioned, lubricated, or torqued.

The correct functioning of the air conditioning when it comes off the production line is not sufficient to detect these leaks. Indeed, an air conditioning system can work perfectly during the test (it "blows cold") but have a very small leak that will empty the circuit in just a few weeks or months.

The After-Sales Service is sometimes contacted for leak problems on vehicles. In two-thirds of cases, the leak is located on the connections made by the cab, vehicle or heavy equipment manufacturer.

What causes these leaks? The technician installed a seal; he no doubt properly lubricated it, and was certain that the connection was tight.

Despite his professionalism, the seal may have

become pinched or been slightly cut when tightening the connection. In appearance, the work was perfectly carried out, but the connection will leak. This leak, however, will be insufficient to be detected during the functional test.

To solve this problem, KALORI has designed a test system that allows for delivering controlled air conditioning at a correct level. This test bench also ensures the traceability of these tests.

This leak test is capable of detecting the slightest leak: our testing equipment is accurate to within 0.01 cc/min.

The assembly constitutes an investment, but it will avoid a good many maintenance call-outs.

Several manufacturers have already implemented it to carry out these checks.

This is the smallest evaporator on the market, ideal for UTVs (Utility Task Vehicles) or any other small vehicle where a dashboard-integrated installation is not possible. It can be connected to a conventional circuit (compressor + condenser + filter) or to a POWER K (external power unit integrating a condenser and a compressor) for electric vehicles.Control is direct on the front panel and the airflow is really very impressive for such a compact unit.

COMPACT EVO2 KLIM FAI The smallest evaporator

Quality : Leak tests for air conditioning

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Enguerran L'Hullier, the new Managing Direc-tor of Zhongshan KALORI, our Asian subsidiary, moved to China some 12 years ago. Specialized in plastic injection and industrial site manage-ment, he took over running the company in June 2016 to ensure the continuity of the work accomplished there by Alexandre Casson.

Enguerran's role is to prepare this unit with its staff of 50 people for the development of its pro-duction capacity, notably through the integra-tion of lean manufacturing principles.

This Chinese production line works in perma-nent contact with the industrial and production departments of the parent company.

Zhongshan KALORI was founded in 2007. This WFOE* is 100% owned by KALORI. It was Al-exandre Casson, at the time in charge of the design of parts manufactured via hard thermo-forming, who moved to China to ensure the im-plantation and general management of the site.

Our Chinese subsidiary today supplies part of the production of KALORI components.

*A WFOE (Wholly Foreign Owned Enterprise), also known as a WOFE, is a type of investment vehicle spe-cific to the People's Republic of China. It allows foreign investors to incorporate a foreign-owned limited liabil-ity company (the involvement of a mainland Chinese investor is not required).

The new refrigerant is gradually being introduced on certain vehicles. Since January 1st, 2017, the following categories of vehicles can no longer use R134a:

• N1: vehicles designed and manufactured for the transport of goods and with a maximum weight less than or equal to 3.5 tons.

• M1: vehicles designed and manufactured for transporting passengers and comprising no more than eight seats (in addition to the driver's seat).

Other vehicle categories are not currently concerned. We will keep you informed of developments.This new regulation therefore affects coachbuilders working on the vehicle bases concerned by the above categories.The two fluids being incompatible, the R1234yf requires the use of a specific oil and a dedicated filling post. The components of the refrigerant loop can, however, be adapted.KALORI has approved a range of compatible components and filling posts.

A sales office in Germany

Italy : Permanent presence

German manufacturers particularly appreciate the components and systems developed by KALORI. The need for us to provide them with in-country support was becoming increasingly essential. KALORI therefore set up a representative office in Cologne in September 2016. Clément Guyot, in charge of the office, is French and speaks fluent German. To contact him, call+49 176 47815297.

Bertrand Bac David is responsible for a large part of the Mediterranean area, notably in Italy, where he is very often on site to ensure effective representation throughout the peninsula. The KALORI catalog offering a wealth of solutions, it is essential to be able to discuss possible combinations with someone and to have permanent support ensuring the liaison in the case of specific developments.

China

New refrigerant HFO R1234yf

Trade shows: Where to meet KALORI this year.

• Conexpo: LAS VEGAS, March 7-11, 2017• Rettmobil: FULDA, May 10-12, 2017• Reas: MONTICHIARI, October 6-8, 2017• Agritechnica: HANOVER, November 12-18, 2017

Enguerran L'Hullier, General Manager of Zhongshan KALORI since June 2016

Alexandre Casson with Joël Pujol on the subsidiary construction site in 2007

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Ambulances :Cost and time savings on the agenda A fully

integrated front panel for cost savings

To achieve a very economical but nevertheless elegant installation, this new air

diffuser front panel integrates the flap louvers and the control panel.

This certified HVAC can be used on several chassis models without the need to install an electronic control unit.

This solution is intended for an economical installation, even though the result is rather high-end.

Emphasis has been placed on ease of installation, the KOOL and FALKON evaporators incorporating this same FAI front panel. The design integrates cleaning considerations, facilitated by gentle angles. Integration is simple: all that is needed is to make a cutout for the part comprising the louvers and the control panel.

The result is truly qualitative.

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Adapter plates for ADT

These mounting plates have been developed to perfectly fit the shape of the roof ribs on the Mercedes-Benz Sprinter,

the Renault Master and the Fiat Ducato. Once this mounting plate is in place, the rooftop ventilator can be installed on a flat surface.

This adapter plate comprises a track designed for taking a sealing gasket, which makes the work easier and allows for obtaining a good result, both visually and technically. Sealing is therefore easily achieved.

The assembly is pre-fitted for an air duct, a type of conduit that ensures that the air breathed is that of the compartment and not the air located between the roof and the ceiling of the compartment. The manufacturer can cut this duct to just the right dimension.

Using this mounting plate saves time and ensures repeatability, two important criteria in the coachbuilding industry where it is always difficult to standardize production given the variety of models.

The "Easy Fit" system

The mounting plate has a track for the precise and quick application of the

sealing gasket.

Mounting plate for: Mercedes-Benz Sprinter

Mounting plate for: Renault Master X62 Mounting plate for: Fiat Ducato, Peugeot Boxer, Citroën Jumper

The ADT 750 roof ventilator: design and sealing

A new system for easy and seamless integration of a roof ventilator on vehicles with ribbed roofs.

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Approval: KLIMATOP KOMBI for ambulancesThe Renault Master X62 equipped with a KLIMATOP KOMBI has passed the CEN 1789 approval tests.

The KLIMATOP, adopted for many years now by several ambulance manufactur-ers, is a practical solution to free up space in the patient compartment. This ad-vantage is even greater when this air conditioning unit also integrates heating. The low additional cost of the KLIMATOP is largely offset by the removal of the heating unit, leaving room for the fitting out of additional and precious storage spaces in the main compartment.

Added to this is the gain in weight since no other heating system is necessary, whether unit heaters or running off the vehicle's fuel.

This new version represents an additional opportunity to increase the competi-tiveness of coachbuilders.

The KLIMATOP KOMBI offers numerous advantages: space, weight, compliance with the CEN 1789 standard, and a competitive price.

KLIMATOP KOMBI: the solution of the future?

HK EVO4This new, very powerful evaporator (10.7 kW, 1300 m3/h) is ideal in small spaces (height of 120 mm). This low thickness allows it to be in-stalled under the roof for the air conditioning of a large cab.

Minibus manufacturers will also find a real advantage to this unit, which leaves a comfort-able passage height while ensuring sufficient airflow to ventilate the entire rear volume of the passenger space.

New products

Positioning of the sensors prior to the UTAC tests

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RK4: a 3.5 kW rooftop unitThe RK4 completes the KALORI range of rooftop units. It can be installed wherever the KANADA is too large. This unit comprises an evaporator, a condenser and a drier filter, and is perfect for small- and medium-sized cabs.

Connected to a conventional compressor (the ex-tremely compact K0060) or to a semi-hermetic electric compressor, it represents a fast and ele-gant solution. The RK4 also comes in an all-elec-tric version with an integrated electric compres-sor.

Developed in partnership with one of the leading actors on the market, the new PCK2 control panels perform the same functions as the PCK panels. The new control panels are more robust and clearly designed for heavy equipment and agricultural applications where absolute reliability is essential in all conditions.

A way for KALORI's R&D Department to capitalize on past experiences and thus to develop the perfect control panel for KALORI HVACs.

This new PCK2 works automatically, with a version that also ensures pressurization control.

The controls are intuitive, the design understated and efficient.

A three-button panel exists for controlling the direction of the air. It can be used with the MULTIFLUKS® system (electric flap device that allows for carrying out a very automotive installation on any vehicle).

The old PCK is retained, but only in its mechanical version with cable connections.

PCK2: New control panels

The PCK2 can be installed in place of the PCK. Pressurization control is optional.

The three-button model also controls the air direction lou-vers. TO BE used with the MULTIFLUKS® system that can be integrated on (almost) all of KALORI's HVACs.

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The objective of the STOP&KOOL auxiliary compressor is to limit the number of hours the engine spends running in

order to save on fuel consumption and reduce pollution.

Indeed, the value of a heavy equipment vehicle is indexed on the number of hours the engine spends running. With the STOP&KOOL, the engine only runs when the vehicle is working. Owners of vehicles equipped with this smart system amortize their investment in very little time. In addition, they integrate an eco-responsible attitude in line with corporate social responsibility (CSR) policies.

Heavy equipment vehicles are often subject to waiting times (loaders, for example) during which the driver is required to remain in his cab. Without the STOP&KOOL, the driver leaves the vehicle's engine running for the air conditioning to work. With the STOP&KOOL, the air conditioning works even when the engine is switched off.

The vehicle's battery level is monitored by a dedicated system. The operator is thus sure of being able to restart the vehicle whenever it is needed.

For the driver, the use of the air conditioning system remains the same: the air flows through the original air louvers with satisfactory power to regulate the temperature of the cab. The STOP&KOOL replaces the vehicle's compressor by an all-electric system connected to the original air conditioning of the vehicle via a smart system.

The cost savings are real, and the approach is well accepted by the driver since temperature comfort is achieved in absolute silence and without vibration!

Installation is possible at vehicle dealerships or at any good air conditioning specialist center.

"The cost savings are real"

STOP&KOOL Autonomous air conditioning, engine off

This unit measuring 378.5 x 278 x 171 mm ensures the air conditioning of the cab during breaks

The STOP&KOOL is connected to the original air condi-tioning system

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The POWER K comprises an electric compressor and a condenser with integrated filter.

This external power unit can be used with any evaporator from the KALORI range up to approximately 5 kW. It can be installed vertically or horizontally, a choice that must be specified when ordering as this conditions the position of the compressor.

While it is mainly installed in electric vehicles, the POWER K can also be used on vehicles with internal combustion engines on which it is difficult to install a compressor.

It is thus possible to carry out a 12V or 24V installation on a vehicle with an internal combustion engine using any conventional evaporator of the range. It is also possible to integrate the POWER K on a 24/48/72/80/300/600V electrically-driven vehicle. This involves the use of an HVAC from the EHVAC range, each evaporator of which incorporates an evaporator for R134a or R1234yf refrigerants as well as a PTC resistor of the required voltage.

It is also possible to ensure air conditioning using a 220V POWER K coupled with a 220VAC evaporator. In this case, the POWER K constitutes a real innovation due to its compactness, ideal for equipping a podium vehicle, a mobile library, or a tower crane.

Under the POWER K cover the components are beautifully arranged. The whole is extremely compact and accessible, proof of the maturity of the design of this type of unit at KALORI.

POWER KThe modular electric power unitThe problem: provide a high-perfor-mance electric air conditioning system that can be installed in any vehicleThe solution: POWER K (At KALORI, we say "Power times K"!)

POWER K + MK0

POWER K + SUPER K

For 12 or 24V engines

For electrically-driven vehicles

For stopped vehicles with 220V power supply

POWER K + FALKON

The POWER K incorporates an electric compressor and a condenser

POWER K 220V for stopped vehicles

14

FALKON VERTICAL FRONTThis evaporator or evaporator/heating system (KOMBI) is also available in an EHVAC hybrid version (R134a or R1234yf evaporator with a PTC resistor to equip electric vehicles).

This new version of the FALKON must be installed in a vertical position. The air diffuser also serves as a condensate collector. This collector has seven connectors for a Ø55 mm air duct. It is also possible, on request, to use connectors of different diameters, or to equip the FALKON FRONT with a MULTIFLUKS system that allows air distribution by sector as in a car. The FALKON Front EHVAC is already used in some airport vehicles. Despite its compactness, it has sufficient power and airflow to be used as a front box on an electric bus or minibus.

MK0 EHVACThe MK0 also exists in a hybrid version (R134a or R1234yf evaporator with a PTC resistor). It offers the ideal air conditioning for a medium-sized cab, electric car, electrically-driven municipal vehicle, hybrid heavy equip-ment vehicle, etc. Its multi-directional fan makes it easy to install.

Connected to the POWER K, it is a compact and efficient unit that can be easily adapted. For a more complete integration, separate components (electric compressor, condenser, etc.) can be used. Once again, the advice of KALORI technicians will be invaluable in order to achieve balance, and thus guarantee the performance of your installation.

Electric vehicles Expansion of the range with the EHVACs: KOOL, FALKON KALORI has created a range of electric hybrid evaporator units. In this EHVAC (Electric HVAC) range, the hot water circulation exchanger is replaced by a PTC resistor. These EHVACs are manufactured on the basis of the KOOL, FALKON, MK0, etc. A manufacturer wanting to develop a hybrid version of one of his vehicles could thus keep the same HVAC by using the EHVAC version of the chosen model. This is a great advantage because it has the same attachment points and uses the same air diffusion system.

The developers at KALORI's Engineering and Design Department boast substantial experience in electric heating and air conditioning, the first product developed dating from 1999.

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www.kalori.com

SIMULKA®

computing power

for your comfort

FALKON HVAC equipped with the MultifluKs®

air distribution system

Design and testing system

for a correct dimensioning

of HVAC early in the project

KALORI TRIM LINE

The TWIST base is an injected base de-signed to rotate the air diffuser through 360°. It is equipped with a KB louver avail-

able in black or with chrome edging.

The base is securely attached by two screws on the dashboard or the trim. It can be connected by a Ø40 to Ø75 mm straight duct connector or a Ø55 mm 45° connector.

For harsh environments, screw-fit or spring-fit air diffusers are best. A spring-fit louver re-

quires specific know-how to be integrated into the dashboard, but once in place it fits perfectly and will not move.

Otherwise, many grilles or diffusers are avail-able in screw-fit versions, such as the KA or the KD louvers.

"The quest for quality requires continual investment and ideas."

1. KG screw-fit louver

2. KA screw-fit louver

3. KD rectangular louver

1

2

3

The TWIST base rotates through 360°

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Save time with .stp files available on www.kalori.com

Since early 2017, 3D files of the components of the KALORI TRIMLINE range are available on the KALORI website.

Manufacturer R&D Departments can therefore have instant access to these .stp files to check component installation in real time.

The 3D files of heaters and HVACs will follow later in the year.

Manufacturers gain reactivity during component installation