Neumunster makes the difference in HVAC maintenance

In recent years, the importance of HVAC repairs has increased significantly. This is due to the fact that nowadays almost every vehicle is equipped with HVAC, which was not the case two decades ago. Back then, it was still possible to simply open a window in many vehicles. Passengers' demands in terms of comfort have also increased. Nowadays, a vehicle cannot be operated in summer temperatures without a functioning HVAC system in the driver's cab.

In passenger transport, one or two HVAC systems are often installed per carriage, which air-condition the entire carriage. If an HVAC system fails in midsummer, the corresponding carriages have to be closed to passengers. This shows how important functioning HVAC systems are and that their regular maintenance and repair is a high priority.

Expansion of the Neumunster maintenance depot to increase capacity
In order to meet the requirements and increase the capacity for HVAC systems, extensive remodelling measures were carried out in Neumunster. The former wheelset workshop was completely overhauled to create space for processing large compact systems. This involved closing off pits and tracks, laying new power lines, establishing utility connections and installing centralised supply systems and testing technology.

Although the conversion work is 85 percent complete, adjustments are still being made to further optimise the work areas. The constant adaptation process is necessary as new products are constantly being introduced and state-of-the-art test bays need to be created.

Locations for air conditioning system repairs and CoC alignment
The Neumunster Maintenance Depot is currently setting up a so-called Centre of Competence (CoC) for HVAC systems, which is intended to standardise processes that can also be adopted in other maintenance depots. In addition to Neumunster, the maintenance depots in Wittenberge, Dessau and Krefeld are also working on HVAC systems.

However, expertise is being concentrated and expanded at the lead maintenance depot in Neumunster. The aim is to also carry out trial dismantling and meaningful evaluations here in order to provide customers with optimum support. These services go beyond the standard tasks of a control centre. "In the CoC, we provide the customer with intensive support and suggest, for example, that we first take a look at the condition of a system together. We then draw up a sensible maintenance plan," explains Konstantin Schikowski, Head of Components Production in Neumunster. Daniel Krebs, specialist for air conditioning and compressed air supply from Central Product Management, adds: "The decision to expand Neumunster into a CoC gives the maintenance depot, and the air conditioning workshop in particular, the opportunity to place its expertise and maximum flexibility on the market. HVAC is one of the most important comfort components in passenger transport today and therefore requires optimum maintenance."

"Ultimately, we put the systems through their paces so that they can then be safely reinstalled in the vehicle. Our aim is to ensure that customers are satisfied with our service and that the HVAC systems function as faultlessly as possible," explains Schikowski.

Future developments and technologies
Neumunster is also planning to work on systems with alternative refrigerants such as propane in the future. Propane is more environmentally friendly than the currently used refrigerant R 134a, which has a higher GWP value (Global Warming Potential). Conversions of existing air conditioning systems to more modern refrigerants are also to be made possible. Implementation is expected to be possible from mid-2025.

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