COMPUTERIZED UNIT FOR RECOVERY, RECYCLING, VACUUM, CHARGE AND FLUSHING. User s manual ENGLISH

Transcription

1 COMPUTERIZED UNIT FOR RECOVERY, RECYCLING, VACUUM, CHARGE AND FLUSHING User s manual ENGLISH

2 Wigam spa 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. Layout : Wigam S.p.A. Printed in Italy 1st edition: February

3 INDEX Safety precautions... 5 Layout drawing... 6 Hydraulic diagram... 9 Electric scheme Introduction to AMICA-SAE recovery unit Technical specifications Components description and standard equipment High vacuum pump Refrigerant bottle Distiller /separator Compressor Filters Flexible hoses Quick coupler valves Printer Temperature probes Pressure transducers Control module Functions programming Functions that can be performed Control panel Description of the control keys (ref. fig. 1) Preparing the unit AMICA-SAE for operation Checking the vacuum pump oil "Zero" scale check Filling refrigerant int the bottle Filling refrigerant into the internal bottle by means of recovery from the service bottle Emptying the internal bottle Recovery Preparing the vehicle for refrigerant recovery from the A/C system Refrigerant recovery for R=all Refrigerant recver for <> Draining of the oil extracted from the A/C system Evacuating and checking the A/C system for tightness Refilling oil and UV into the A/C system Warning Warning Oil refilling procedure in the A/C system Suggested oil quantities for refilling the vehicle air conditioner Warning UV refilling procedure in the A/C system Charging refrigerant into the A/C system Warning A/C system refrigerant charging procedure Checking the A/C system operating pressures Disconnecting the unit from the A/C system FLUSHING automatic function FIRE&GO automatic function AUTO function

4 15. Non condensable gases automatic discharge Routine maintenance Material for routine maintenance Periodic operations Replacing vacuum pump oil Replacing the filter driers Accessories and spare parts Dimensions and weight

5 WARNING Safety precautions a) 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. b) 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. c) Do not operate the unit with different refrigerant than the one it has been designed for. d) 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. e) Avoid skin contact; the low boiling temperature of the refrigerant (about -30 C) can cause freezing. f) Avoid breathing refrigerant vapours. g) It is recommended to wear suitable protections like safety glasses and gloves; contact with refrigerant may cause blindness and other personal injuries. h) 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. i) Always make sure that the unit is connected to a suitably protected mains supply provided with an efficient earth connection. j) 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. k) Operate the unit only in locations with suitable ventilation and a high number of air changes. l) 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. m) Never fill any tank with liquid refrigerant to more than 75% of its maximum capacity. n) 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. o) The equipment must always work under the operator s control. p) Protect the unit from dripping. q) Do not modify the calibration of safety valves and control systems. r) 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. 5

6 Layout drawing 6

7 7 ENGLISH

8 8 ENGLISH

9 Hydraulic diagram 9

10 Electric scheme 10

11 Legend EV1 Solenoid valve on oil draining line 45 Compressor oil distiller EV2 Solenoid valve on recovery line 46 Connecting hose between distiller and condenser EV3 Solenoid valve on UV charging line 47 Handle support EV4 Solenoid valve on vacuum pump suction line 48 Oil discharge bottle EV10 Solenoid valve on non condensable gases 49 UV charge bottle discharge line EV13 Solenoid valve on refrigerant charging line 50 Oil charge bottle EV19 Solenoid valve on oil charging line 52 High pressure hose EV20 Solenoid valve on oil return line to compressor 53 Low pressure hose EV24 Solenoid valve on low pressure line 54 Supply cable EV25 Solenoid valve on high pressure line 55 High pressure quick coupler 5 Condenser 56 Low pressure quick coupler 6 Vacuum pump 57 Manual discharge valve on distiller 7 Recovery compressor 58 Temperature probe 8 Fan 59 LOW gauge connecting hose 9 Compressor starting condenser 60 HIGH gage connecting hose 10 Control board 61 Printer paper 11 Printer 62 Bottle temperature probe 12 Warning light 63 Non condensable gases discharge valve 14 Display 64 Power card TR15 Central pressure transducer 65 Vacuum pump filling cap 16 Function keys 66 Vacuum pump sight glass 17 Safety pressure switch 67 Vacuum pump oil draining cap 18 Complete valves assembly 68 Upper nut scale lock 20 Refrigerant charging hose 69 Lower nut scale lock 21 Memory card CEL1 Refrigerant load cell - 100kg 22 Alphanumeric keyboard CEL2 Oil discharge load cell - 5kg 23 Refrigerant bottle valve (vapour) CEL3 Oil injection load cell - 5kg 24 Bottle service valve CEL4 UV injection load cell - 5kg 26 Refrigerant bottle valve (liquid) F1 Filter drier 27 Refrigerant bottle pressure gauge F2 Filter drier 28 Oil discharge hose (distiller) CV1 Check valve on suction line 29 Oil discharge hose (dosimeter) CV2 First check valve on compressor delivery line after distiller TR30 Bottle pressure transducer for non condensable CV3 Check valve on refrigerant charging line gases discharge 31 Refrigerant bottle CV4 Check valve on oil discharge line 32 Swivel wheel CV5 Check valve on oil charging line 33 Wheel Ø200 CV6 Check valve on UV charging line 34 UV injection hose CV7 Second check valve on compressor delivery line after distiller 35 Oil injection hose PWR Power switch 36 Hose for oil return to compressor VS1 Safety valve 38 Connecting hose between valve assembly and S1 Compressor service valve distiller 39 Hose on the bottle gauge S2 Refrigerant bottle service valve 40 Vacuum hose M1 Low pressure gauge 41 Hose on the compressor suction side M2 High pressure gauge 42 Connecting hose between distiller and filter M3 Bottle pressure gauge 43 Distiller/separator R14 Heater on the refrigerant bottle 44 Pipe union for filters connection 11

12 12 ENGLISH

13 1. Introduction to AMICA-SAE recovery unit AMICA-SAE 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. AMICA-SAE is equipped with a microprocessor which 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 TECHNICAL SPECIFICATIONS Model AMICA-SAE Refrigerant R134a Maximum storage capacity 20 kg Refrigerant reserve 2 kg Maximum recovery rate 0,3 kg/min Oil maximum capacity 200 g Oil reserve 30 g Additive maximum capacity 200 g Additive reserve 30 g Power supply 230/1/50 Power input 700 W Storage temperature C Ambient working temperature C Degree of protection IP24 Noise level < 70dB (A) The maximum refrigerant quantity available for charging is calculated by subtracting 2 kg from the weight of the refrigerant contained in the bottle and indicated on the display max kg for charging = kg in bottle - 2 kg Model AMICA-SAE Connections 3/8 sae with quick couplers 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 REFRIGERANT BOTTLE Maximum capacity kg 20 Weight of empty bottle kg 12 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. 13

14 2.3. 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 2.4. COMPRESSOR The compressor is of the hermetic type FILTERS Each anti-acid filter drier has a water absorption capacity of 40 g 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. AMICA-SAE unit features hoses with quick coupler valves 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 2.8. 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 TEMPERATURE PROBES 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 The unit is also equipped with an internal temperature probe which measures the instant temperature of the refrigerant bottle PRESSURE TRANSDUCERS The unit is equipped with 2 pressure transducers (inside the unit).they enable to control all the automatic functions of the unit (recovery, vacuum, automatic non condensable gases discharge, etc.). The working range is between -1 and +21 bar 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, to the 4 electronic scales and to the pressure transducers, AMICA-SAE unit is completely computerized and controlled by means of the keyboard located on the upper panel. AMICA-SAE 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. 14

15 2.12. FUNCTIONS PROGRAMMING a) 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 b) 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. c) It is possible to modify the refrigerant charge by means of the keyboard or using the DATABASE of the unit FUNCTIONS THAT CAN BE PERFORMED a) AMICA-SAE unit allows to perform the functions singly one after the other, being able to modify the relevant values b) AMICA-SAE 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) AMICA-SAE 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) AMICA-SAE 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 VACUUM 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. 15

16 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 DESCRIPTION OF THE CONTROL KEYS (REF. FIG. 1) a) Ref. 16: 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 b) Numeric keys ref. 22: allow to modify the values of the functions to perform c) UP/DOWN key: allows to modify the values of the functions to perform d) ENTER key: must be used to confirm the modified values e) MENU key: used to see the pages of the unit s inside parameters on the display (ref. 14) PRINT PLATE: by typing the car s number plate on the numeric keys (ref. 22), 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 UNIT OF MEASUREMENT DATABASE UPDATE: allows to update the database inside the unit 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 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. f) START/STOP key: : used to start or stop the unit s functions g) Ref. 21 (Memory Card): space used for the introduction of the MEMORY CARD h) Ref. M3: pressure gauge for pressure inside the bottle i) FEED key: used to reprint the final report j) Ref. 12: alarm LED that lights up every time a function or a value are not regular k) Ref. 11: printer 16

17 4. Preparing the unit AMICA-SAE 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 CHECKING THE VACUUM PUMP OIL 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 (indicated in red on the below drawing) 4.2. "ZERO" SCALE CHECK After having unlocked the scale: a) Connect the unit to the power supply b) Turn the PWR 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 e 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 key 6 on the control module g) Digit password 7249 h) Select, by means of the relevant key, the scale to recalibrate i) Follow very carefully the instructions that appear on the display j) When the re-calibration operations are over, press the C/EXIT key 4.3. FILLING REFRIGERANT INT THE BOTTLE When all the above mentioned preliminary operations have been performed, the recommended quantity of about 6 7 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 FILLING REFRIGERANT INTO THE INTERNAL BOTTLE BY MEANS OF RECOVERY FROM THE SERVICE BOTTLE a) Connect the unit to the power supply b) Make sure that all valves on the control panel are closed and that the PWR switch is in position 0 c) Position the service bottle so that liquid refrigerant will come out (bottle with tube upright, bottle without tube upside down) 17

18 d) Remove the quick coupler ref. 55 (HIGH) from the HP hose (ref. 52) and provide to possible suitable adapters e) Connect the HP hose (ref. 52) to the service bottle f) Turn the PWR switch to position I g) Press the Vacuum key (led starts blinking): select the HIGH side; the set vacuum time appears on the display (to modify the set values see 3. "Control panel ). Set a vacuum time of 5 minutes, this is to evacuate the hose ref. 52 h) Press the START key in order to start the vacuum cycle. The display will show VACUUM TIME REMAINING TIME i) Press any key to return to the initial screen or press the FEED key to print the report of the function j) Press the Recovery key (led starts blinking): the display shows the following screen: RECOVER ALL MAX RECOV hypothetical value (to modify the set values see 3. Control panel ) k) By means of the UP key or with the numeric keys, set 06.00, which is the refrigerant quantity in kg that will be transferred into the unit s bottle (To modify the set values see 3. "Control panel"). l) Slowly open the valve of the bottle m) 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 n) Close the valve of the service bottle o) Press the Recovery key (led starts blinking): the display shows the following screen: RECOVER ALL MAX RECOV hypothetical value (to modify the set values see 3. Control panel ") p) Press the START key to start recovering the refrigerant inside the hose and wait for the automatic stop of the recovery unit q) Press any key to return to the initial screen or press the FEED key to print the report of the function r) Disconnect the hose ref. 52 from the service bottle s) Remount the quick coupler valve ref. 55 (HIGH) on the hose ref. 52 t) Press the Vacuum key (led starts blinking): select the HIGH side; the set vacuum time appears on the display (to modify the set values see 3. "Control panel ). u) Press the START key in order to start the vacuum cycle. The display will show VACUUM TIME REMAINING TIME v) Leave the vacuum pump running for about 5 minutes w) After 5 minutes, press the STOP key to stop the pump; press the STOP key again to exit from the Vacuum Test function. x) Press any key to return to the initial screen or press the FEED key to print the report of the function y) Turn the PWR switch to position 0 if the unit will not be used immediately EMPTYING THE INTERNAL BOTTLE a) Make a vacuum in an external bottle able to contain the refrigerant there is in the internal bottle b) Remove the unit s right cover c) Connect the hose ref.52 to the S2 service connection situated on the internal bottle, after you have removed the protection cap. d) By means of the service hose supplied with the unit, connect the valve of the external bottle (previously evacuated) to the valve ref. 24 of the internal bottle and close the valve ref. 23 e) Open the valve ref. 24 and the one on the external bottle f) Start the automatic function Recover All selecting the HIGH working side to empty the internal bottle completely; recovery will stop automatically at the end of refrigerant recovery inside the unit. g) Close the valve ref. 24 and the valve on the external bottle, disconnect the service hose and remount the protection. h) Connect the hose ref. 53 to the S1 compressor service connection after you have removed the protection cap and open the LOW valve on the control panel. 18

19 i) Start the Vacuum function, selecting the HIGH working side and perform vacuum and vacuum test for about 30 minutes. j) At the end of the Vacuum and Vacuum test function, disconnect the hose ref. 52 from the S2 service connection, remount the protection cap and go on with the scale calibration (see 4.3) k) Disconnect the hose ref. 53 from the S1 service connection and remount the protection cap. l) At the end of operations, open again the 23 valve and remount the unit s cover. 5. Recovery WARNING!!! When the Recovery function has been started, it will only last max. 60 minutes. In case the pre-set quantity of refrigerant has not been recovered within 60 minutes, the unit will stop automatically and the alarm message will appear on the display 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 ( revolutions/min) for at least 20 minutes. a) d) Turn the vehicle engine off and have the A/C system fan run at maximum speed and start recovery operations 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 -0,4 bar. a) Make sure that all valves are closed and that the PWR main switch is in position 0 b) Connect the valve ref. 56 of the hose ref. 53 to the A/C system low pressure service connection c) Connect the valve ref. 55 of the hose ref. 52 to the A/C system high pressure service connection d) Turn the power on by turning the PWR main switch to position I e) Press the Recovery key (led starts blinking); choose the working side (LOW HIGH LOW+HIGH): the following screen will appear on the display: RECOVERY ALL 19

20 MAX RECOV hypothetical value f) Press the START key: the unit will start recovering the refrigerant, the ked on the Recovery key will turn 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) When pressure inside the system reaches about 0.7 bar, the unit will automatically perform the discharge of the possible oil recovered. When the discharge is completed, the recovery function will start again. h) At the end of recovery, the unit stops automatically and waits for 2 minutes. i) If during these 2 minutes the pressure inside the A/C system rises beyond 0,6 bar, the unit will automatically start another recovery cycle j) The unit will perform maximum 3 recovery cycles. If the pressure inside A/C system still rises beyond 0,6 bar even after the third recovery cycle, the unit will automatically stop the operations and the alarm message will be displayed. k) If after the 2 minutes the pressure does not rise beyond 0,6 bar the unit will automatically stop and the screen corresponding to the function will be displayed l) At the end of the function, the summarizing screen will appear on the display: RECOVERED REFRIGERANT OIL DISCHARGED m) At the end of the function, the unit will print a report (the print can be repeated) WARNING The bottle of the recovery unit has a maximum capacity of 20 kg of refrigerant. If the maximum level is reached during recovery (the alarm message appears on the display), the unit will stop automatically. Transfer the refrigerant from the bottle to a suitable external tank (see procedure at 4.3.2) 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 functions 5.3. REFRIGERANT RECVER FOR <>0.000 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 PWR main switch is in position 0 b) Connect the valve ref. 56 of the hose ref. 53 to the A/C system low pressure service connection c) Connect the valve ref. 55 of the hose ref. 52 to the A/C system high pressure service connection d) Turn the power on by turning the PWR main switch to position I e) Press the Recovery key (led starts blinking); choose the working side (LOW HIGH LOW+HIGH): the following screen will appear on the display: RECOVERY ALL MAX RECOV 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 key 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. 20

21 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 hoses ref. 52 and 53 from the A/C system k) Press the Recovery key (led starts blinking): the following screen will appear on the display: RECOVERY ALL MAX RECOV 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) When pressure inside the system reaches about 0.7 bar, the unit will automatically perform the discharge of the possible oil recovered. When the discharge is completed, the recovery function will start again n) At the end of recovery, the unit stops automatically and waits for 2 minutes. o) If during these 2 minutes the pressure inside the A/C system rises beyond 0,6 bar, the unit will automatically start another recovery cycle p) The unit will perform maximum 3 recovery cycles. If the pressure inside A/C system still rises beyond 0,6 bar even after the third recovery cycle, the unit will automatically stop the operations and the alarm message will be displayed q) If after the 2 minutes the pressure does not rise beyond 0,6 bar the unit will automatically stop and the screen corresponding to the function will be displayed: RECOVERED REFRIGERANT OIL DISCHARGED r) At the end of the function, the unit will print a report (the print can be repeated WARNING The bottle of the recovery unit has a maximum capacity of 20 kg of refrigerant. If the maximum level is reached during recovery (the alarm message appears on the display), the unit will stop automatically. Transfer the refrigerant from the bottle to a suitable external tank (see procedure at 4.3.2) 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 During the recovery function, when pressure inside the system reaches 0,7 bar, the unit will automatically perform the draining of the oil extracted from the A/C system into the graduated bottle ref. 48. The operator will then have to write down the quantity of drained oil, which must be refilled 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 21

22 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 PWR switch is in position 0 b) Connect the valve ref. 56 of the hose ref. 53 to the A/C system low pressure service connection c) Connect the valve ref. 55 of the hose ref. 52 to the A/C system high pressure service connection d) Turn the PWR switch to position I e) Press the Vacuum key, choose the working side (LOW HIGH LOW+HIGH): the previously set vacuum time will appear on the display (to modify the set values, see 2.11 "Control module"). f) Press the START key to start the vacuum cycle while the display will show VACUUM TIME REMAINING TIME g) 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. h) When the pre-set time is over, the function will stop automatically and the Vacuum test will start for 3 minutes. i) 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 3 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 22

23 8. Refilling oil and UV 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. WARNING 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 WARNING Before performing an oil charge, check that there is a higher quantity of oil in the graduated bottle ref. 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 30g of safety spare. Qoil charge = Q in the bottle 30g 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 PWR switch is on I b) Press the OIL CHARGE key and choose the working side (LOW HIGH LOW+HIGH): the following screen will appear on the display OIL CHARGE 30 g MAX CHARGE 120 g hypothetical value OIL RECOVERED 0 g c) Set the quantity by means of the numeric keys or of the arrows and confirm by pressing the Enter key 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. 23

24 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. WARNING Before performing a UV charge, check that there is a higher quantity of UV in the graduated bottle ref. 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 f) Make sure that all the valves on the control panel are closed and that the PWR switch is on I a) Press the UV CHARGE key and choose the working side (LOW HIGH LOW+HIGH): the following screen will appear on the display UV CHARGE 30 g MAX CHARGE 120 g hypothetical value b) Set the quantity by means of the numeric keys or of the arrows and confirm by pressing the Enter key c) Press the START key: the unit starts the UV charge, the led on the UV CHARGE key is on and the display shows: UV CHARGE UV UV AVAILABLE d) After having charged the pre-set UV quantity, the function stops automatically and the summarizing screen appears on the display: UV CHARGE 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 9. Charging refrigerant into the A/C system 9.1. WARNING 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 4.4. " Filling refrigerant into the bottle"). NB. The quantity of refrigerant available for charging is equal to the refrigerant in the bottle minus 2Kg Qcharge = Qin bottle - 2Kg 24

25 9.2. A/C SYSTEM REFRIGERANT CHARGING PROCEDURE a) Make sure that all the valves on the control panel are closed and that the PWR switch is on I b) Press the REFRIGERANT CHARGE key, choose the working side (LOW HIGH LOW+HIGH): the following screen will appear on the display R134 CHARGE MA CHARGE hypothetical value c) To modify the set values see 2.11 "Control module" d) Press the START key: the unit will start to pre-charge the hoses and the current function will be displayed e) 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. g) 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) Start the motor and turn the A/C system b) Connect the valve ref. 56 of the hose ref. 53 to the A/C system low pressure service connection c) Connect the valve ref. 55 of the hose ref. 52 to the A/C system high pressure service connection d) Wait a few minutes to enable the pressures to stabilize. e) Make sure that values of the pressures correspond to those supplied by the A/C system manufacturer f) To disconnect the hoses, see the following section. 11. Disconnecting the unit from the A/C system At the end of refrigerant charge and of the system operating pressures check, it is necessary to disconnect the unit from the A/C system. To start the procedure, it is necessary to keep the START key pressed for more than 3 seconds The following screen will appear on the display: Disconnection function 1= ON/OFF Low 2= ON/OFF High STOP= Leave a) Start the car s motor and turn the A/C system on b) Disconnect the valve ref. 55 of the hose ref. 52 from the A/C system high pressure connection c) Regulate the refrigerant flux inside the system by means of keys 1 and 2 d) Continue until you have a pressure close to 1 2 bar on both pressure gauges e) Disconnect the valve ref. 56 of the hose ref. 53 from the A/C system low pressure connection A/C and leave the function by means of the STOP key f) Turn the A/C system off g) Perform a recovery cycle to remove the refrigerant (vapour) inside the hoses h) Perform a recovery cycle to suck the refrigerant from the hoses; the unit is now immediately ready for the next operation 25

26 i) Turn the unit off (PWR switch on 0) j) Reposition hoses ref. 53 and 52 in their supports k) Carefully screw the protection caps on the A/C system service valves l) Carefully check the A/C system for leaks by means of a leak detector NB. 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. 12. 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 previously. a) Make sure that all the valves on the control panel are closed and that the PWR switch is on I b) Press the FLUSHING key, choose the working side (LOW HIGH LOW+HIGH): the following screen will appear on the display: NR. CYCLES 3 programmable value VACUUM TIME 30 programmable value R134a AVAIL kg hypothetical value (To modify the set values see 2.11 "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 f) The function will stop when the system to be flushed will be completely flooded g) After the FLOODING cycle, the unit will perform a RECOVERY/RECOVERY TEST/OIL DISCHARGE cycle. h) The cycle will be repeated according to the number of cycles previously set 13. 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 to charge into the A/C system. The function performs the following functions automatically: 1. Refrigerant recovery (All) 2. Oil discharge 3. Vacuum (30 ) and Vacuum Test 4. Oil charge (same quantity discharged during recovery) 5. UV charge (7 g 1 dose) 6. Refrigerant charge (quantity se by the user) a) Make sure that the PWR switch is on I b) Press the FIRE&GO key, choose the working side (LOW HIGH LOW+HIGH): 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 2.11 "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 on the display 26

27 14. 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. a) Make sure that the PWR switch is on I b) Press the AUTO key, choose the working side (LOW HIGH LOW+HIGH: the led of the function blinks and the display shows the following screen: R134a recovery programmable VACUUM programmable OIL programmable UV programmable R134a charge programmable 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 on the display. 15. Non condensable gases automatic discharge Each time the unit is turned on, it checks automatically if it is necessary to effect the non condensable gases discharge from the internal refrigerant bottle. WARNING When you turn on the unit, you may hear a puff of air coming from inside the unit. 16. Routine maintenance 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 SW PERIODIC OPERATIONS a) Check all swivel connections for tightening every 10 operations b) 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 REPLACING 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") with the unit s hoses NOT connected to any A/C system b) Turn the recovery unit off by turning the PWR switch to position 0 and disconnect the power cord; strictly observe the sequence of operations c) Remove the plastic cover d) Remove the drain plug located at the bottom of the pump (ref. 67) 27

28 e) Completely drain the oil f) Screw the drain plug on again (ref. 67) g) Remove the filler plug situated on top of the pump (ref. 65) h) Slowly refill the pump with oil until the level covers half of the sight glass located on the side of the pump (ref. 66) i) Screw the filler plug back and remount the cover ATTENZIONE Do not pollute environment with oil; it is a special waste and must be disposed of according to the regulations in force REPLACING THE FILTER DRIERS This operation is announced with an alarm message on the display when the unit is turned on. a) Filters replacement must be made at the end of a recovery cycle. b) Turn the recovery unit off by turning the PWR switch to position 0 and disconnect the power cord; strictly observe the sequence of operations c) Remove the 2 screws inside the basin and then the 6 screws of the cover d) Remove the F1 and F2 filter driers, by disconnecting the connections ref. 41, 42, 44 ATTENZIONE Do not pollute environment with the used filters; they are special wastes and must be disposed of according to the regulations in force. 28 j) Install two new filter driers k) Connect the valve ref. 56 to the S1 compressor service connection

29 l) Plug the unit and turn the PWR switch to position I m) Press the Menu key on the control panel n) Press 7 Service o) Digit password 5011 and press 2 Recovery p) Follow the procedure on the display step by step and type in the serial numbers of the new filters. q) At the end of the procedure, perform a vacuum cycle of about 30 minutes (see 7. "Evacuating and checking the A/C system for tightness ) selecting only the LOW working side r) Disconnect the valve ref. 56 from the S1 connection s) Remount the protective cap on the S1 connection t) Screw the screws back and remount the cover 17. Accessories and spare parts Ref. F1 F2 K1L SW68 G19020 G19030 Description XH412 antiacid 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 29

30 18. Dimensions and weight Net weight with empty internal bottle: 85 kg 30

31 WIGAM S.p.A. Loc.Spedale 10/b Castel San Niccolò (AR) Italy Tel / 5011 Fax / Declaration of conformity We, signers of this declaration, declare under our own exclusive responsibility, that unit, model: AMICA-SAE and all its versions manufactured in our company and to be used for: refrigerant gas recovery, recycling and charge Are planned according to the following directives prescriptions: 2006/42/EEC Machines directive 89/336/EEC and following modifications 92/31 EEC and 93/68 EEC (Directive on electromagnetic compatibility) 2006/95/EEC Directive on low voltage IEC (EN 60034) General standards on single phase electric, rotative machines Castel San Niccolò 14/12/09 Gastone Vangelisti (President)

32 Loc.Spedale 10/b Castel San Niccolò (AR) ITALY Tel Fax ufficio.tecnico@wigam.com