Automatic A/C-Service Unit
Automatic A/CA/C-Service Unit
Coolius 4000 Bus
Art.Art.-No. 0900700605
Instruction manual
WOW! GmbH Künzelsau reserves the right to discontinue, or change at any time specifications or designs
without notice and without incurring obligations according to her policy of always improving her products.
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
Automatic A/C-Service Unit
CONTENTS
Layout drawing ....................................................................................................................... 5
Electric scheme ...................................................................................................................... 9
Legend ................................................................................................................................... 10
1. Introduction to Coolius 40000 BUS recovery unit ...................................................... 12
1.1
2.
Technical specifications................................................................................................................... 12
Components description and standard equipment .................................................... 12
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
3.
High vacuum pump ......................................................................................................................... 12
Refrigerant charging pump .............................................................................................................. 12
Refrigerant bottle............................................................................................................................. 12
Distiller - separator .......................................................................................................................... 13
Compressor .................................................................................................................................... 13
Filters .............................................................................................................................................. 13
Flexible hoses ................................................................................................................................. 13
Quick coupler valves ....................................................................................................................... 13
Printer ............................................................................................................................................. 13
Temperature probe ......................................................................................................................... 13
Control module ................................................................................................................................ 13
Functions programming ................................................................................................................... 13
Functions that can be performed ..................................................................................................... 14
Control panel.................................................................................................................. 15
3.1
4.
Description of the control keys ......................................................................................................... 15
Preparing the unit Coolius 4000 BUS for operation.................................................. 16
4.1
4.2
4.3
4.4
4.4.1
4.4.2
5.
Checking the vacuum pump oil level................................................................................................ 16
Unlocking the scale ......................................................................................................................... 16
"Zero" scale check .......................................................................................................................... 17
Filling refrigerant into the bottle ....................................................................................................... 17
Filling refrigerant into the internal bottle by means of recovery from the service bottle ...................... 17
Emptying the internal bottle ............................................................................................................. 19
Recovery ........................................................................................................................ 20
5.1
5.2
5.3
6.
7.
8.
Preparing the vehicle for refrigerant recovery from the A/C system .................................................. 20
Refrigerant recovery for R= all ......................................................................................................... 20
Refrigerant recovery for R<>00.00................................................................................................... 21
Draining of the oil extracted from the A/C system...................................................... 22
Evacuating and checking the A/C system for tightness ............................................ 22
Refilling oil into the A/C system ................................................................................... 23
8.1
8.2
8.3
8.4
8.5
8.6
9.
Warning .......................................................................................................................................... 23
Warning .......................................................................................................................................... 23
Oil refilling procedure in the A/C system .......................................................................................... 23
Suggested oil quantities for refilling the vehicle air conditioner ......................................................... 24
Warning .......................................................................................................................................... 24
UV refilling procedure in the A/C system .......................................................................................... 24
Charging refrigerant into the A/C system ................................................................ 25
9.1
9.2
10.
11.
12.
13.
14.
Warning .......................................................................................................................................... 25
A/C system refrigerant charging procedure ...................................................................................... 25
Checking the A/C system operating pressures ....................................................... 25
FLUSHING automatic function .................................................................................. 26
FIRE&GO automatic function .................................................................................... 26
AUTO function ............................................................................................................ 27
Operations before disconnecting the unit from the A/C system ........................... 27
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
Automatic A/C-Service Unit
15.
15.1
15.2
15.3
15.4
16.
17.
Routine maintenance ................................................................................................. 28
Material for routine maintenance ..................................................................................................... 28
Periodic operations ......................................................................................................................... 28
Changing the vacuum pump oil ....................................................................................................... 28
Replacing the filter driers ................................................................................................................. 29
Accessories and spare parts .................................................................................... 30
Dimensions and weight ............................................................................................. 30
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Automatic A/C-Service Unit
WARNING
Safety precautions
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
This equipment is designed for trained personnel only, who must know the
refrigeration fundamentals, cooling systems, refrigerants and
possible damage that pressurized equipment may cause.
Carefully read the instructions contained in this manual; strict
observance of the procedures described is fundamental to the operator’s
safety, the perfect state of the unit and constant performances as
declared.
Do not operate the unit with different refrigerant than the one it has
been designed for.
Before performing any operation, make sure that the hoses used for
connections have been previously evacuated and that they do not
contain non-condensable gases.
Avoid skin contact; the low boiling temperature of the refrigerant (about -30°C)
can cause freezing.
Avoid breathing refrigerant vapours.
It is recommended to wear suitable protections like safety glasses and
gloves; contact with refrigerant may cause blindness and other personal
injuries.
Do not operate near open flames and hot surfaces; the high temperatures
decompose the refrigerant releasing toxic and caustic substances which
are hazardous for the operator and the environment.
Always make sure that the unit is connected to a suitably protected mains
supply provided with an efficient earth connection.
Before performing maintenance operations or when the unit will not be used
for a long period of time, turn the unit off by turning the main switch to 0
and disconnect the power supply cord; absolutely follow the
sequence of operations.
Operate the unit only in locations with suitable ventilation and a high
number of air changes.
Before disconnecting the unit, make sure that the cycle has been
completed and that all valves are closed in order to avoid release of
refrigerant to the atmosphere.
Never fill any tank with liquid refrigerant to more than 75% of its maximum
capacity.
During operations avoid release of refrigerant to the environment; this
precaution is required by international environmental standards and is essential to avoid
difficult leak detection in a refrigerant polluted environment.
The equipment must always work under the operator’s control.
Protect the unit from dripping.
Do not modify the calibration of safety valves and control systems.
If you recover refrigerant from a cooling system equipped with a water
evaporator and/or condenser, it is necessary to drain water from the
evaporator and/or condenser or to keep the circulation pump running
during the entire recovery operation in order to avoid frosting.
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Automatic A/C-Service Unit
Layout drawing
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Automatic A/C-Service Unit
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Automatic A/C-Service Unit
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Automatic A/C-Service Unit
Hydraulic diagram
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Automatic A/C-Service Unit
Electric scheme
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Automatic A/C-Service Unit
Legend
1 - EV1
2 - EV2
3 - EV3
4 - EV4
5
6
7
8
10 - EV10
12
13 - EV13
15
17
18
19 - EV19
20 - EV20
21
22 – EV22
23
24
25
60
61
62
64
65
66
67
68 - M1
69 - M2
71 - PRT
72 - MC
74– CEL3
75– CEL2
76 - R14
77– CEL4
78 - S2
79 - VS1
80– CEL1
81 - CV5
82 - CV1
83 - CV3
27
30
31
34
35
Solenoid valve on oil draining line
Solenoid valve on recovery line
Solenoid valve on UV charging line
Solenoid valve on vacuum pump suction line
Condenser
Vacuum pump
Recovery compressor
Fan
Solenoid valve on vacuum test line
Warning light
Solenoid valve on refrigerant charging line
Pressure / vacuum switch
Safety switch
Vacuum switch
Solenoid valve on oil charging line
Solenoid valve on oil return line to compressor
Refrigerant charge hose - Pump liquid suction
Solenoid valve on recovery line (2° line)
Valve on the refrigerant bottle
Bottle service valve
Connecting hose between bottle assembly and
bottle
Bottle pressure gauge
Electrical box
Refrigerant bottle
UV injection capillary tube
Oil injection capillary tube
39
40
41
42
43
44
45
48
49
50
Bottle pressure gauge capillary tube
Vacuum tube
Compressor suction side hose
Distiller - filters hose (1° line)
Distiller – separator hose (1° line)
Double nut
Compressor lubricant distiller
Oil drain bottle
UV dosimeter
Oil dosimeter
89 (1-2)
90 - F2
91- EV24
92- EV25
93
94
95 - F1
96
97
100
51
Heater switch
101 - CV21
52
53
54
55
High pressure service hose
Low pressure service hose
Main power cable
High pressure connection valve
102
103 – F21
104 – F22
105 – S11
56
Low pressure connection valve
106 – EV40
58
Temperature probe
107
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84 - CV6
85 - S1
86 - CV4
87 - R5
88 - CV2
Electronic card on control panel
Paper for printer
Black plastic basin
Electronic card power with cables
Right panel
Left panel
Main power switch
Low pressure gauge
High pressure gauge
Printer
Memory card
OIL injection load cell - 5kg
OIL drain load cell - 5kg
Heater on the refrigerant bottle
UV injection load cell - 5kg
Refrigerant bottle service connection
Safety valve – non condensable gases
Load cell - 100kg
Check valve on oil charging line
Check valve on suction line
Check valve on refrigerant charging
line
Check valve on UV charging line
Compressor service connection
Check valve on oil draining line
Heater on the distiller
Check valve on compressor discharge
line
Oil discharge capillary tube
Filter drier
Solenoid valve – LOW line
Solenoid valve – HIGH line
LP gauge connection capillary tube
HP gauge connection capillary tube
Filter drier
Safety valve connection capillary tube
Safety valve – non condensable gases
Valve on the refrigerant bottle in
charging line
Check valve on compressor suction
line (2° line)
Distiller – separator (2° line)
Filter drier (2° line)
Filter drier (2° line)
Compressor service connection (2°
line)
Solenoid valve on oil return line to
compressor (2° line)
Recovery compressor (2° line)
Automatic A/C-Service Unit
108
109 – CV22
123
124
Central wheel
Front swivel wheel
110
111
Compressor lubricant distiller (2° line)
Check valve on compressor discharge line (2°
line)
Condenser (2° line)
Fan (2° line)
125
129 (1-2)
112 – EV21
Solenoid valve on oil draining line (2° line)
130
113 – CV24
Check valve on oil draining line (2° line)
131
114
115
Manual oil discharge valve on distiller (1° line)
Manual oil discharge valve on distiller (2° line)
132
133
116
117
135
136
137
Vacuum pump plug
119 – R25
Electrical motor for Refrigerant charge pump
Safety pressure switch on refrigerant charging
line
Refrigerant bottle service connection (Vapour
side)
Heater on the distiller (2° line)
Compressor suction hose (2° line)
Connecting hose between condenser
and bottle
Connecting hose between distiller and
condenser (1°line)
Connecting hose between distiller condenser (2° line)
Distiller suction line hose (2° line)
Connecting hose between distiller filter (2° line)
Vacuum pump oil discharge
Vacuum pump sight glass
140
121
122
Distiller suction line hose (1° line)
Rear wheel with brake
141
143
Connecting hose between positivedisplacement pump and valves
assembly
Refrigerant charge pump
Connecting hose between valves
assembly and input valves
118
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Automatic A/C-Service Unit
1.
Introduction to Coolius 4000 BUS recovery unit
Coolius 4000 BUS unit permits quick and efficient recovery of refrigerant from the A/C system,
refrigerant recycling, system evacuation, check for tightness, additive or lubricant injection, the
subsequent charge with refrigerant, measurement of the operating pressures.
Coolius 4000 BUS unit permits the control of all the functions by means of 4 electronic scales, which
control respectively: oil discharged from the A/C system, refrigerant charge, oil charge and additive
charge.
1.1
TECHNICAL SPECIFICATIONS
Coolius 4000 BUS model
R134a refrigerant
Maximum storage capacity
40 kg
Refrigerant reserve
4 kg
Maximum recovery rate
0,8 kg/min
Maximum refrigerant charging rate
4÷5 l/min
Oil maximum capacity
500 g
Oil reserve
50 g
Additive maximum capacity
200 g
Additive reserve
30 g
Power supply
230/1/50
Power input
1400 W
Storage temperature
-10 ÷ +50 °C
Ambient temperature
0 ÷ 40 °C
Degree of protection
IP24
Noise level
< 70dB (A)
Maximum refrigerant charge
The maximum refrigerant quantity available for charging is calculated by subtracting 4 kg from
the weight of the refrigerant contained in the bottle and indicated on the display
max kg for charging = kg in bottle - 4 kg
Model
Coolius 4000 BUS
Connections
3/8” sae with quick coupler valves
2.
Components description and standard equipment
2.1
HIGH VACUUM PUMP
Essential component for extracting from the cooling system the residues of technical gases used for
pressing, ambient air and vapour contained in it as well as water possibly formed through vapour
condensation.
The high vacuum pump the unit is equipped with is rotary vane type, lubricated by oil injection. It is dual
stage and has a swept volume of 180l/min.
2.2
REFRIGERANT CHARGING PUMP
Rotary gear pump enables to have high refrigerant charging rates
2.3
REFRIGERANT BOTTLE
Maximum capacity
kg
40
Weight of empty bottle
kg
19
It is provided with two connections, one of which with tube (liquid refrigerant) and one without tube
(vapour refrigerant), safety valve, non-condensable gas purge and heater belt with thermostat.
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Automatic A/C-Service Unit
2.4
DISTILLER - SEPARATOR
Single body construction, featuring:
- distillation chamber with automatic flow control
- separating chamber for the oil removed from compressor, provided with a device for automatic return at
the end of the cycle
- heat exchanger chamber outlet gas / recovered refrigerant
2.5
COMPRESSOR
The compressor is of the hermetic type.
2.6
FILTERS
Each anti-acid filter drier has a water absorption capacity of 40 g.
2.7
FLEXIBLE HOSES
Their flexibility assures easy connection in any situation. They withstand A/C system operating
pressures and maintain their passage section even when operating in vacuum.
Coolius 4000 BUS unit features hoses with quick coupler valves.
2.8
QUICK COUPLER VALVES
Mounted on the hose ends and provided with a coloured operating ring (blue = low pressure, ref. 56; red
= high pressure, ref. 55) for quick identification.
2.9
PRINTER
The printer allows to print on standard paper with a chart size of 57mm width a report with the values
programmed by the operator and executed by the unit, with the possibility to re-print the report.
2.10
TEMPERATURE PROBE
The unit is equipped with a temperature probe (with range from -10°C to +50°C), which allows to check
the ambient temperature at any time. The probe is equipped with a 2,5mt long cable.
2.11
CONTROL MODULE
When the unit is turned on (PWR switch to position I), the display shows:
• The quantity in kg of refrigerant container in the bottle (see 1.1 “Technical specifications”)
• the quantity (in grams) of oil contained in the container
• the quantity (in grams) of additive contained in the container
• the temperature of the probe connected to the equipment
Thanks to the microprocessor and the 4 electronic scales, Coolius 40000 BUS unit is completely
computerized and controlled by means of the keyboard located on the upper panel.
Coolius 4000 BUS unit is provided with a large size display to allow for good reading even with bad
illumination; the 4-line display (with 20 characters each) allows the reading of the parameters connected
to the selected function and, if necessary, it indicates the operating or functioning alarms.
2.12
FUNCTIONS PROGRAMMING
By pressing the function keys, the display will show the screen where you can modify the values. The
display gives all necessary explanations to be able to perform this operation.
The values can be modified by means of the number keyboard (and in this case the value entered must
be confirmed with the ENTER key) or of the UP/DOWN key. In both cases, after modification, the display
will indicate the key to press in order to start the function .
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Automatic A/C-Service Unit
It is possible to modify the refrigerant charge by means of the keyboard or using the DATABASE of the
unit.
2.13
FUNCTIONS THAT CAN BE PERFORMED
a) Coolius 4000 BUS unit allows to perform the functions singly one after the other, being able to
modify the relevant values
b) Coolius 4000 BUS unit allows to have a completely automatic programme, called AUTO, controlled
by the operator, with the following functions
• Refrigerant RECOVERY
• RECOVERY TEST
• DISCHARGE of OIL recovered from the system
• VACUUM and VACUUM TEST
• OIL CHARGE
• UV CHARGE
• REFRIGERANT CHARGE
c) If the operator does not want to perform a function, he must set a value of 0.0 during programming.
d) Coolius 4000 BUS unit allows to have a programme called FIRE & GO, with which the unit will
perform automatically the same functions as the ones in the AUTO programme; the only exception
is that only the refrigerant charge value can be modified.
e) Coolius 4000 BUS unit allows to perform the A/C system flushing with R134a. By pressing the
START key, the unit will perform the following functions automatically:
• VACUUM and VACCUM TEST (this function is performed only at the first cycle)
• SYSTEM FLOODING
• REFRIGERANT RECOVERY
• OIL DISCHARGE ( this function is performed at the first and last cycle)
f) Should there be an alarm signal during any automatic or single function, the function will stop and
the alarm message will be stored on the display.
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Automatic A/C-Service Unit
3.
Control panel
The upper panel of the unit contains all control elements needed for operation, checking for tightness
and measuring the A/C system operating pressures.
fig.1
3.1
DESCRIPTION OF THE CONTROL KEYS
o
o
o
o
o
Ref. 11: when pressed, they enhance the function to perform or to modify. From the left, you will find the
following functions: RECOVERY/RECYCLING, VACUUM, OIL CHARGE, UV CHARGE,
REFRIGERANT CHARGE, FLUSHUNG, FIRE&GO, AUTO
The numeric keys ref. 16 allow to modify the values of the functions to perform
The UP / DOWN key ref. 89 allows to modify the values of the functions to perform
The ENTER key ref. 98 must be used to confirm the modified values
The MENU key ref. 22 is used to see the pages of the unit’s inside values on the display (ref. 28):
• PRINT PLATE: by typing the car’s number plate on the numeric keys (ref. 16), the
number plate will be printed on the report at the end of the functions
• LANGUAGE: it is possible to modify the unit’s language, by typing the corresponding
number appearing on the display
• DATABASE UPDATE: allows to update data
• DATE AND HOUR: allows to modify the date and hour mentioned on the printed report
• SCALES CALIBRATION: must be used each time the operator wants to re-calibrate one
of the four scales
• SERVICE: constants that are inside the unit and are protected by PASSWORD
1. PASSWORD 2006 allows to modify the print heading of the report
2. PASSWORD 5011 allows to reset the counters concerning maintenance
3. PASSWORD 9376 allows to reset simultaneously the 4 scales
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Automatic A/C-Service Unit
o
o
o
o
o
o
4.
START/STOP key, ref. 26: used to start or stop the unit’s functions
Ref. 72: space used for the introduction of the MEMORY CARD
Ref. 27: pressure gauge for pressure inside the bottle
Ref. 14: used to reprint the final report
Ref. 12: alarm LED that lights up every time a function or a value are not regular
Ref. 71: Printer
Preparing the unit Coolius 4000 BUS for operation
WARNING
The presence of the synoptic sticker does not exempt the operator from carefully reading this manual and strictly
observing the described procedures
4.1
CHECKING THE VACUUM PUMP OIL LEVEL
Before checking the oil level, the unit must be placed on a level surface and its power supply must be
turned off.
Check that the vacuum pump oil level covers half of the sight glass (see drawing on page 28).
4.2
UNLOCKING THE SCALE
WARNING
If the following procedure is not performed, correct operation of the unit will be completely compromised.
Always empty the internal bottle before performing the tare (see 4.5.2)
Loose the 4 plastic knobs situated under the unit’s basis until standstill.
The 4 plastic knob must be screwed again until standstill before any move for which important
oscillations of the unit are expected.
Plastic knobs
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Automatic A/C-Service Unit
4.3
"ZERO" SCALE CHECK
After having unlocked the scale:
a) Connect the unit to the power supply
b) Turn the 67 switch to position
c) Make sure that the bottle is empty
d) Wait at least 5 minutes so that the bottle/scale assembly stabilizes before proceeding; The display
must show a value between 00.00 e 00.50. If the value is lower or higher than the above indicated
one, the scale must be reset by acting on the electronic control module as follows:
e) Press the MENU key: the screen with the different functions that can be performed will appear on
the display
f) Press the key 6 on the control module and select, with the relevant key, the scale to re-calibrate.
g) Carefully follow the instructions that appear on the display
h) At the end of the re-calibration operations, press the C/EXIT key
4.4
FILLING REFRIGERANT INTO THE BOTTLE
When all the above mentioned preliminary operations have been performed, the recommended quantity
of about 10÷ 12 kg of refrigerant must be filled into the unit, The recommended quantity enables the
refrigerant recovery from the A/C system and its following charge.
4.4.1 FILLING REFRIGERANT INTO THE INTERNAL BOTTLE BY MEANS OF RECOVERY FROM THE
SERVICE BOTTLE
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
Connect the unit to the power supply
Make sure that all valves on the control panel are closed and that the 67 switch is in position 0
Position the service bottle so that liquid refrigerant will come out (bottle with tube upright,
bottle without tube upside down)
remove the 55 quick coupler valve (red valve) from the 52 high pressure hose or use the
suitable adapters
Connect the 52 hose to the service bottle
Turn the 67 switch to position I
Push the V key: the led starts blinking and the set vacuum time appears on the display (to
modify the set values – see 2.10 "Control module").
Press the START key in order to start the vacuum cycle. The display will show:
• VACUUM TIME
• REMAINING TIME
Leave the vacuum pump running for about 5 minutes
After 5 minutes, press the STOP key to stop the pump; press the STOP key again to exit from
the Vacuum Test function
Press any key to return to the initial screen or press the FEED key to print the report of the
function
Press the R key, the led starts blinking and the display shows the following screen (to modify
the set values – see 2.10 "Control module")
• RECOVERY ALL
• MAX RECOV. 12.000 hypothetical value
By means of the UP key or with the numeric keys, set 10.00, which is the refrigerant quantity
in kg that will be transferred into the unit’s bottle (To modify the set values – see 2.10 "Control
module") Slowly open the valve of the bottle
Press the START key to start recovery; the unit will stop automatically as soon as the
previously set quantity has been transferred into the unit’s bottle.
Close the valve of the service bottle
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Automatic A/C-Service Unit
p)
q)
r)
s)
t)
u)
v)
w)
x)
y)
z)
aa)
Press the R key, the led starts blinking and the display shows the following screen (to modify
the set values – see 2.10 "Control module"):
• RECOVERY ALL
• MAX RECOV. 12.000 hypothetical value
Press the START key to start recovering the refrigerant inside the hose and wait for the
automatic stop of the recovery unit.
Press the STOP key twice to exit from the RECOVERY function
Press any key to return to the initial screen or press the FEED key to print the report of the
function
Disconnect the 52 hose from the service bottle
Remount the 55 quick coupler valve (red) on the 52 flexible hose
Press the V key, the led starts blinking and the set vacuum time appears on the screen (to
modify the set values – see 2.10 "Control module")
Press the START key in order to start the vacuum cycle. The display will show:
• VACUUM TIME
• REMAINING TIME
Leave the vacuum pump running for about 5 minutes
After 5 minutes, press the STOP key to stop the pump; press the STOP key again to exit from
the Vacuum Test function.
Press any key to return to the initial screen or press the FEED key to print the report of the
function
Turn the 67 switch to position 0 if the unit will not be used immediately
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Automatic A/C-Service Unit
4.4.2 EMPTYING THE INTERNAL BOTTLE
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
Make a vacuum in an external bottle able to contain the refrigerant there is in the internal bottle
Remove the unit’s rear panel and the cover
Connect the 52 hose to the 78 service connection situated on valve assembly, after you have
removed the protection cap.
By means of the service hose supplied with the unit, connect the valve of the external bottle
(previously evacuated) to the 118 service connection of the internal bottle and close the 23 valve
Open the 24 valve and the valve on the external bottle
Start the automatic Recovery function to empty the internal bottle completely. Recovery will stop
automatically
Close the 24 valve and the valve on the external bottle, disconnect the service hose from the 118
service connection and remount the protection cap.
Connect the 53 hose to the 85 - 105 compressor service connection after you have removed the
protection cap and select the LOW side on the control panel.
Start the vacuum and vacuum test function for about 120 minutes
At the end of the Vacuum and Vacuum test function, disconnect the 53 hose from the 78 service
connection, remount the protection cap and proceed with the scale calibration (see 4.4)
Disconnect the 53 hose from the 85 - 105 compressor service connection and remount the
protection cap.
At the end of operations, open again the 23 valve and remount the rear panel and the cover.
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5.
Recovery
WARNING
During Recovery, set the LOW and HIGH valves on the control panel so that the input pressure never rises over
5 bar.
When the Recovery function has been started, it will only last max. 120 minutes. In case the pre-set
quantity of refrigerant has not been recovered within 120 minutes, the unit will stop automatically and the
alarm message will appear on the display.
5.1
PREPARING THE VEHICLE FOR REFRIGERANT RECOVERY FROM THE A/C SYSTEM
The preliminary preparation of the vehicle facilitates the separation of refrigerant and lubricant and
prevents the latter from being dragged.
a)
Turn on the engine with closed hood. Turn the A/C system on and have it run for some minutes.
b)
Open the hood and set the A/C system fan to maximum speed.
c)
Have the vehicle engine run slowly (800 - 1200 revolutions/min) for at least 20 minutes.
d)
Turn the vehicle engine off and have the A/C system fan run at maximum speed and start
recovery operations .
5.2
REFRIGERANT RECOVERY FOR R= ALL
This function allows the total recovery of the refrigerant. The unit automatically stops, when the A/C
system reaches a residual internal pressure of -0,2 bar.
a) Make sure that all valves are closed and that the 67 main switch is in position 0
b) Connect the 56 valve of the 53 hose to the A/C system low pressure service connection.
c) Connect the 55 valve of the 52 hose to the A/C system high pressure service connection
d) Turn the power on by turning the 67 main switch to position I
e) Press the R key (blinking led): the following screen will appear on the display:
• RECOVERY ALL
• RECOV. MAX 12.000 hypothetical value
f) P the START key: the unit starts refrigerant recovery, the led of the R key is on and the display
shows:
• the refrigerant quantity that is being recovered
• the refrigerant contained in the stocking bottle
• the number of recovery cycles performed
If there is no refrigerant, the function will not be activated and the alarm message will appear on the
display
g) At the end of recovery, the unit stops automatically and waits for 5 minutes.
h) If during these 5 minutes the pressure inside the A/C system rises beyond 0,4 bar, the unit will
automatically start another recovery cycle
i) The unit will perform maximum 5 recovery cycles. If the pressure inside A/C system still rises beyond
0,4 bar even after the third recovery cycle, the unit will automatically stop the operations and the
alarm message will be displayed
j) If after the 5 minutes the pressure does not rise beyond 0,4 bar, the unit will automatically stop and
will automatically start the oil discharge and the screen corresponding to the function will be
displayed
k) At the end of the function, the summarizing screen will appear on the display:
• RECOVERED REFRIGERANT
• OIL DISCHARGED
l) At the end of the function, the unit will print a report (the print can be repeated)
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Automatic A/C-Service Unit
WARNING
The bottle of the recovery unit has a maximum capacity of 40 kg of refrigerant.
If the maximum level is reached during recovery (the alarm message 40.00 appears on the display), the unit will
stop automatically. Transfer the refrigerant from the bottle to a suitable external tank (see procedure at 4.5.2)
WARNING
When the functions have come to an end, the unit goes back to the summarizing screen. Press any key to
exit and return to the initial screen or press the FEED key to print the report of the function.
5.3
REFRIGERANT RECOVERY FOR R<>00.00
This function allows the recovery of a preset quantity of refrigerant, the unit automatically stops, when
the preset quantity has been recovered.
a) Make sure that all valves are closed and that the 67 main switch is in position 0
b) Connect the 56 valve of the 53 hose to the A/C system low pressure service connection.
c) Connect the 55 valve of the 52 hose to the A/C system high pressure service connection
d) Turn the power on by turning the 67 main switch to position I
e) Press the R key (blinking led): the following screen will appear on the display
• RECOVERY ALL
• RECOV. MAX 12.000 hypothetical value
f) By means of the numeric keys or the UP/DOWN key, select the quantity of refrigerant to recover
g) Press ENTER to store the value set with the numeric keys
h) Press the START key to start recovery; if there is no refrigerant, the function will not be activated
and the alarm is displayed.
i) When the preset quantity of refrigerant has been recovered, the unit stops automatically and the
quantity of recovered refrigerant is displayed. Press any key to exit from the function and return to
the initial screen.
NB : : If during the function the unit stops before having recovered the refrigerant quantity
previously selected on the display, the alarm message will be displayed.
j) Disconnect the 53 and 52 hoses form the A/C system
k) Press the R key (blinking led): the following screen will appear on the display
• RECOVERY ALL
• RECOV. MAX 12.000 hypothetical value
l) Press the START key, the unit starts recovery, the led of the R key is on and the display shows:
• RECOVERY
• R134a refrigerant quantity that is being recovered
• R134A refrigerant quantity contained in the bottle
• number of recovery cycles performed
m) At the end of recovery, the unit stops automatically and waits for 5 minutes .
n) If during these 5 minutes the pressure inside the A/C system rises beyond 0,4 bar, the unit will
automatically start another recovery cycle
o) The unit will perform maximum 5 recovery cycles. If the pressure inside A/C system still rises beyond
0,4 bar even after the third recovery cycle, the unit will automatically stop the operations and the
alarm message will be displayed
p) If after the 5 minutes the pressure does not rise beyond 0,4 bar, the unit will automatically stop and
will automatically start the oil discharge and the screen corresponding to the function will be
displayed
q) At the end of the function, the summarizing screen will appear on the display:
• RECOVERED REFRIGERANT
• OIL DISCHARGED
r) At the end of the function, the unit will print a report (the print can be repeated)
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Automatic A/C-Service Unit
WARNING
The bottle of the recovery unit has a maximum capacity of 40 kg of refrigerant.
If the maximum level is reached during recovery (the alarm message 40.00 appears on the display), the unit will
stop automatically. Transfer the refrigerant from the bottle to a suitable external tank (see procedure at 4.5.2)
WARNING
When the functions have come to an end, the unit goes back to the summarizing screen. Press any key to
exit and return to the initial screen or press the FEED key to print the report of the function.
6.
Draining of the oil extracted from the A/C system
At the end of RECOVERY, the draining of the oil extracted from the A/C system will automatically be
effected into the graduated bottle 48.
The operator will then have to write down the quantity of drained oil, which must be recharged
afterwards.
WARNING
Do not pollute environment with oil ; it is a special waste and must be disposed of according to the regulations
in force.
7.
Evacuating and checking the A/C system for tightness
This operation serves to remove any trace of ambient air, water vapour and other possibly contained non
condensable gases from the A/C system, so that it is possible to fill it with refrigerant. A possible
deterioration of the vacuum level after this operation indicates that there are air infiltrations which would
turn into refrigerant leaks after having charged the A/C system.
a) Make sure that all valves on the control panel are closed and that the 67 switch is in position 0
s) Connect the 56 valve of the 53 hose to the A/C system low pressure service connection.
b) Connect the 55 valve of the 52 hose to the A/C system high pressure service connection
c) Turn the 67 switch to position I
d) Press the V key: the set vacuum time will appear on the display (to modify the set values – see 2.10
"Control module")
e) Press the START key to start the vacuum cycle while the display will show:
• VACUUM TIME
• REMAINING TIME
f) Check on the display that the remaining time value is not blinking and that the countdown starts
within 5-10 minutes; if this is not the case, stop evacuation and find the leak in the circuit.
g) When the pre-set time is over, the function will stop automatically and the Vacuum test will start for
5 minutes.
h) If the Vacuum Test function ends without having displayed any message, it means that the system
evacuation came to a successful conclusion and the system is ready to perform the charge; on the
contrary if, during the 5 minutes of Vacuum Test the alarm message appears on the display; it
means that there are leaks in the circuit, which must be found and repaired.
WARNING
When the functions have come to an end, the unit goes back to the summarizing screen. Press any key to exit
and return to the initial screen or press the FEED key to print the report of the function.
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Automatic A/C-Service Unit
8.
Refilling oil into the A/C system
After A/C system evacuation and before refrigerant charging, the unit will perform automatically the oil
charge that was set previously (see 8.3)
8.1
W ARNING
Lubricant is highly hygroscopic. To avoid contamination, always keep the bottles well closed and open
them only before use.
Oil injection must be performed only when the A/C system is properly evacuated.
8.2
W ARNING
Before performing an oil charge, check that there is a higher quantity of oil in the graduated
bottle 50 than the one needed for the charge.
N.B. the oil quantity available to perform the charge is equal to the contents of the graduated
bottle minus 50g of safety spare.
Qoil charge = Q in the bottle – 50g
8.3
OIL REFILLING PROCEDURE IN THE A/C SYSTEM
a) Make sure that all the valves on the control panel are closed and that the 67 switch is on I
b) Press the OIL CHARGE key: the following screen will appear on the display:
• OIL CHARGE
30 g
• MAX CHARGE
120 g hypothetical value
• OIL RECOVERED
0 g
c) If the operator does not want to refill oil into the system, set a value of 0.00 on the display (to modify
the set values – see 2.10 "Control module")
d) Press the START key: the unit starts the oil charge, the led on the OIL CHARGE key is on and the
display shows:
• OIL CHARGE
• OIL
• OIL AVAILABLE
e) After having charged the pre-set oil quantity, the function stops automatically and the summarizing
screen appears on the display:
• OIL CHARGE
• OIL
WARNING
When the functions have come to an end, the unit goes back to the summarizing screen. Press any key to exit
and return to the initial screen or press the FEED key to print the report of the function.
WARNING
Do not pollute environment with oil; it is a special waste and must be disposed of according to the
regulations in force.
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Automatic A/C-Service Unit
8.4
SUGGESTED OIL QUANTITIES FOR REFILLING THE VEHICLE AIR CONDITIONER
According to the type of A/C system component you have replaced, you need to fill in the lubricant
quantity indicated below, even if no oil has been extracted during recovery.
Evaporator:
50 cc
Condenser:
30 cc
Liquid receiver:
10 cc
Pipelines:
10 cc
In any case, the operator must follow the instructions of the A/ system manufacturer.
8.5
W ARNING
Before performing a UV charge, check that there is a higher quantity of UV in the graduated
bottle 49 than the one needed for the charge.
N.B. the UV quantity available to perform the charge is equal to the contents of the graduated
bottle minus 30g of safety spare.
QUV charge = Q in the bottle – 30g
8.6
UV REFILLING PROCEDURE IN THE A/C SYSTEM
a) Make sure that all the valves on the control panel are closed and that the 67 switch is on I
b) Press the UV CHARGE key: the following screen appears on the display:
• UV CHARGE
30 g
• MAX CHARGE
120 g hypothetical value
c) If the operator does not want to refill UV in the system, set a value of 0.00 on the display (to modify
the set values – see 2.10 "Control module")
d) Press the START key: the unit starts UV charge, the led on the UV CHARGE key is on and the
display shows:
• UV CHARGE
• UV
• UV AVAILABLE
e) After having charged the pre-set UV quantity, the function stops automatically and the summarizing
screen appears on the display:
• UV CHARG E
• UV
WARNING
When the functions have come to an end, the unit goes back to the summarizing screen. Press any key to exit
and return to the initial screen or press the FEED key to print the report of the function
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Automatic A/C-Service Unit
9.
Charging refrigerant into the A/C system
9.1
W ARNING
Before performing a charging operation, check the quantity of refrigerant available in the bottle; the bottle
must contain more refrigerant than needed for charging. If it does not, do not charge the A/C system and
fill refrigerant into the bottle (see 4.5. " Filling refrigerant into the bottle ").
NB.
9.2
The quantity of refrigerant available for charging is equal to the refrigerant in the
bottle minus 4Kg
Qcharge = Qin bottle – 4 Kg
A/C SYSTEM REFRIGERANT CHARGING PROCEDURE
a)
b)
c)
d)
e)
f)
g)
Make sure that all the valves on the control panel are closed and that the 67 switch is on I
Press the REFRIGERANT CHARGE key, the following screen will appear on the display:
• R134 CHARGE
1.550
• MAX CHARGE
15.500 hypothetical value
To modify the set values – see 2.10 "Control module"
Now open the working side
Press the START key: the unit will start to pre-charge the hoses and the current function will be
displayed.
At the end, the unit will start to charge REFRIGERANT, the led on the REFRIGERANT
CHARGE key is on and the display shows:
• R134a CHARGE
• R134a
• R134a AVAIL.
After the pre-set refrigerant quantity has been charged, the function stops automatically and
summarizing screen appears on the display:
•
R134a CHARGE
•
R134a
WARNING
When the functions have come to an end, the unit goes back to the summarizing screen. Press any key to exit
and return to the initial screen or press the FEED key to print the report of the function.
10.
Checking the A/C system operating pressures
a)
b)
Wait a few minutes to enable the pressures to stabilize.
Make sure that values of the pressures correspond to those supplied by the A/C system
manufacturer A/C
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Automatic A/C-Service Unit
11.
FLUSHING automatic function
This operation allows to flush (with R134a) any A/C system.
The FLUSHING automatic function will perform: a VACUUM and VACUUM TEST cycle, a FLOODING
cycle, a RECOVERY cycle, an OIL DISCHARGE cycle. These functions will be repeated according to
the number of cycles set.
a) Make sure that all the valves on the control panel are closed and that the 67 switch is on I
b) Press the FLUSHING key: the following screen will appear on the display:
• NR. CYCLES
3
programmable value
• VACUUM TIME
30’
programmable value
• R134a DISP.
12.000Kg.
hypothetical value
To modify the set values – see 2.10 "Control module"
c) Press the START key: the unit will start the VACUUM cycle and the display will show:
• VACUUM TIME
• REMAINING TIME
d) At the end of VACUUM and VACUUM TEST, the A/C system will be flooded automatically and the
display will show:
• SYSTEM FLOODING
e) The function will stop when the system to be flushed will be completely flooded
f) After the FLOODING cycle, the unit will perform a RECOVERY/RECOVERY TEST/OIL
DISCHARGE cycle
g) The cycle will be repeated according to the number of cycles previously set.
12.
FIRE&GO automatic function
FIRE&GO function is a pre-set function which allows to perform an automatic and complete cycle of all
the functions at the values pre-set by default. It is possible to modify only the value of the refrigerant
charge.
a)
Make sure that all the valves on the control panel are closed and that the 67 switch is on I
b)
Press the FIRE&GO key: the led of the function blinks and the display shows the screen for
the modification of the refrigerant quantity (to modify the set values – see 2.10 "Control
module").
c)
Press the START key to start the function
d)
At the end of the function, the report will be printed
e)
Should there be an alarm signal during the automatic function, the unit will stop at the relevant
function and indicate the alarm.
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Automatic A/C-Service Unit
13.
AUTO function
The AUTO function allows the operator to build a personalized program, by setting the values of the
functions. The functions are then performed automatically. The values introduced in the AUTO function
will be stored by the unit until next modification.
a)
Make sure that all the valves on the control panel are closed and that the 67 switch is on I
b)
Press the AUTO key: the led of the function will blink and the following screen will appear on
the display:
• Recovery R134
programmable
• VACUUM
programmable
• OIL
programmable
• UV
programmable
• R134a
programmable
c)
d)
e)
14.
Press the START key to start the AUTO function
At the end of the function, the unit will print the report
Should there be an alarm signal during the automatic function, the unit will stop at the relevant
function and indicate the alarm on the display
Operations before disconnecting the unit from the A/C system
a)
b)
c)
d)
e)
f)
g)
h)
i)
NB.
With the A/C system compressor on, disconnect the 52 hose.
Press the START key for more than 4 seconds in order to open the LOW and HIGH inlet solenoid
valves; the led of the STOP key will light and the following writing will appear on the display:
DISCONNECTING MODE - LOW AND HIGH VALVES OPEN
As soon as the pressures on the high and low pressure gauges are the same and do not exceed
2÷3 bar, press the STOP key (the led will remain on, and also the led of the START key will light);
the following writing will appear on the display:
DISCONNECTING ENDED - LOW AND HIGH VALVES CLOSED
Disconnect the 52 hose from the A/C system
Perform a recovery cycle to extract the remaining refrigerant from the hoses, so that the unit is
immediately ready for the next operation.
Turn the unit off (67 power switch on 0).
Reposition both service hoses in their supports.
Carefully screw the protection caps on the A/C system service valves.
Carefully check the A/C system for leaks by means of a leak detector.
The introduction of tracer additives and the following use of a UV leak detector will make
it easier to locate the point of the possible leak in the future.
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Automatic A/C-Service Unit
15.
Routine maintenance
15.1
MATERIAL FOR ROUTINE MAINTENANCE
n°1 filter drier, model XH412
n°1 bottle of oil for vacuum pump, model K1L
n°1 bottle of oil for compressor, model SW32
15.2
PERIODIC OPERATIONS
a)
b)
15.3
Check all swivel connections for tightening every 10 operations
Check the vacuum pump oil level; the oil must be changed at least every 20 hours of operation
or once every six months even if the unit is not used frequently. The pump must be off when
checking the oil level.
CHANGING THE VACUUM PUMP OIL
The oil must be changed every time the alarm message appears on the display.
The oil also needs to be changed whenever it becomes cloudy. Contaminated oil reduces vacuum pump
performances and irreversibly damages its mechanical components.
All draining and refilling operations must be performed when the pump is turned off.
To avoid reduction of the pump efficiency and to maintain its performances, use only K1L oil for
maintenance.
a)
Before draining the oil have the pump run for at least 10 minutes (see 7. "Evacuating and
checking the A/C system for tightness” point g) with hoses connected to the unit
b)
Turn the recovery unit off by turning the 67 switch to position 0 and disconnect the power
cord; strictly observe the sequence of operations.
c)
Remove the rear panel
d)
Remove the drain plug (135) located at the bottom of the pump
e)
Completely drain the oil
f)
Screw the drain plug (135) on again
g)
Remove the filler plug (137) situated on top of the pump
h)
Slowly refill the pump with oil until the level covers half of the sight glass (136) located on the
side of the pump
i)
Screw the filler plug back and remount the rear panel.
WARNING
Do not pollute environment with oil; it is a special waste and must be disposed of according to the regulations in
force.
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Automatic A/C-Service Unit
15.4
REPLACING THE FILTER DRIERS
The replacement must be made at the end of a recovery cycle.
a)
Turn the recovery unit off by turning the PWR switch to position 0 and disconnect the
power cord; strictly observe the sequence of operations
b)
Remove the 2 screws inside the “basin” and then the 6 screws of the cover
c)
Remove the 90, 95, 103, and 104 filter driers
WARNING
Do not pollute environment with the used filters; they are special wastes and must be disposed of according
to the regulations in force.
d)
e)
f)
g)
h)
i)
h)
j)
Install the new filter driers by replacing the gaskets inside the swivel connections ref. 41, 42, 125
and 133
Connect the 56 valve to the 85 compressor service connection on line 1
Plug the unit and turn the 67 switch to position I
Perform a vacuum cycle for about 30 minutes (see 7. “Evacuating and Checking the A/C system
for tightness” – point g)) (LOW side selected)
Repeat the operation from e) on the 105 compressor service connection on line 2
Disconnect the 56 valve from the 105 connection
Remount the protective caps on the 85 and 105 connections
Screw the screws back and remount the cover
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Automatic A/C-Service Unit
16.
17.
Accessories and spare parts
Ref.
Description
95 - F1, 90 - F2, 103 - F21, 104 - F22
K1L
SW68
G19020
G19030
XH412 anti-acid filter drier
Mineral oil for vacuum pump, 1.000cc bottle
Synthetic oil for vacuum pump - HFC134, 1.000cc bottle
Kit of gaskets for 1/4''SAE flexible hoses - 10pcs
Kit of gaskets for 3/8''SAE flexible hoses - 10pcs
Dimensions and weight
Net weight with empty internal bottle : 160 kg
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Automatic A/C-Service Unit
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Automatic A/C-Service Unit
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