Hybrid Conversion Kit Procedure Guide

Transcription

1 Automotive Air Conditioning Hybrid Conversion Kit Procedure Guide TM autoclimate

2 COPYRIGHT INFRINGEMENT NOTICE Autoclimate Limited. All rights reserved. No part of this manual, publication or text may be reproduced in any material form (including photocopying scanning or storing in any medium by electronic means and whether in permanent or temporary form) without the written permission of the copyright owner. Applications for permission to reproduce the whole or any part or parts of this manual, publication or text should be addressed to the copyright owner at its registered office, Unit 37, Atcham Business Park, Atcham, Nr Shrewsbury, Shropshire SY4 4UG. You are advised that doing, permitting or allowing any unauthorised act in relation to a copyright work may result in a civil claim for damages and/or criminal prosecution. To the extent permitted by law neither Autoclimate Limited not any of its directors or employees will be liable in negligence or for breach of contract or otherwise for any direct indirect incidental or consequential loss or damage resulting from any person acting, omitting to act or refraining from acting in reliance on the material contained in this manual, publication, text and any written or oral advice or instruction given in relation to or in consequence of it. Foreword This manual is intended for use by a fully qualified technician who has undertaken a recognised training programme covering the principles and fundamentals of vehicle air conditioning or Module 1 of our structured training programme. It is imperative that any service or repair work carried out on a vehicles air conditioning system is performed by technicians who are fully conversant in the health and safety issues relating to the handling of refrigerant, oils and associated substances. The aim of this manual is to offer general guidance on the procedures involved in refrigerant flushing. Procedures may vary by vehicle manufacturer, we therefore recommend that you refer to the relevant OEM technical data prior to commencing. Whilst this manual has been written around the ROBINAIR REFRIGERANT MANAGEMENT SYSTEM (AC690PRO) the fundamental procedures remain the same for other equipment types. Please check with Autoclimate technical support if you are unsure whether the equipment you are using meets the recommended level of specification. Disclaimer The contents of this publication are correct at time of publication. Autoclimate Limited reserves the right to vary, modify or change any of its products, services or specifications including those described or referred to in this publication at any time without prior notice.

3 Automotive Air Conditioning Hybrid Conversion Kit Procedure Guide Table of Contents 1. Service Preparations & Precautions 4 2. Introduction 5 3. Evacuation & Flushing 6 4. Hybrid Conversion Kit Parts 11

4 1. Service Preparation & Precautions Read all instructions before carrying out the flushing procedure. Health & Safety / Personal Protection When handling refrigerant or carrying out repairs to an automotive air conditioning system it is recommended that eye protection and protective gloves are worn. Extreme caution must be taken not to allow any refrigerant to come into contact with the skin and especially the eyes. Liquid refrigerant (R134a) evaporates at C (depending on atmospheric pressure), because it evaporates quickly, it removes heat (freezes) anything it comes into contact with. Refrigerant pressure whilst flushing should not exceed 15Bar. Care must also be taken to avoid breathing refrigerant or system lubricant vapour. Exposure may irritate eyes, nose and throat. Use only approved Automotive Air Conditioning Service Equipment. Your Refrigerant Management Station (RMS) should be compatible with the refrigerant being used. Avoid carrying out Air Conditioning service repair work in any small un-ventilated area to avoid asphyxiation. We strongly recommend that all servicing technicians refer to their appropriate Health & Safety file for more detailed information. Working Practice Ensure that protective covers are applied to the vehicle before commencing any work. The battery must be disconnected to prevent accidental starting of the engine and the possibility of personal injury if access to service connectors are in close proximity to fans, belts etc. Make sure that tools, measuring equipment and parts to be fitted are clean and dry. Keep all necessary equipment and tools within easy reach so that the system is not left open any longer than is absolutely necessary. Before undoing any refrigerant lines, joints or connectors, clean off any dirt, moisture, oil etc. in order to prevent contamination of the system. Any O rings disturbed by undoing unions must always be renewed after lubricating with the correct refrigerant oil prior to fitment. When removing O rings from couplings, care must be taken not to scratch the sealing face. It is recommended that the receiver drier / accumulator is replaced if the system has been open to the atmosphere for extended periods is physically damaged or has been in service for more than 2/3 years (manufacturer dependant). Do not remove plugs from new components until each component is ready to be installed into the a/c system, this will limit the amount of air and moisture entering the system. When adding refrigerant oil, ensure that any filling equipment (hose, container, etc.) is clean and dry. The oil container must be sealed immediately after use. To ensure the system works correctly after servicing, the system must be evacuated (vacuumed) for a minimum of 30 minutes before recharging. This will remove (by dehydration) any moisture from the system. One of the most important requirements when filling the air conditioning system is to use clean refrigerant. Any foreign matter including air, moisture, dirt etc. in the air conditioning circuit will have an adverse effect on refrigerant pressures and impair the system performance. After every repair or service procedure, the system must be leak checked to identify any leaks that may be present. If any leaks are found, the refrigerant within the system must immediately be recovered and the leak repaired. 4

5 Hybrid Conversion Kit Procedure Guide 2. Introduction Automotive Air Conditioning The Technical Differences The Components Where is the motor? The Consumables UV dye The Solution The A/C systems in alternatively fuelled vehicles are different from those in standard combustion vehicles. Because of this, your standard A/C service machine may not work on these types of vehicles. Compressors in electric vehicles and some hybrids are powered by a high-voltage three phase electric motor. This is different to a traditional compressor which is driven from the vehicle crankshaft through a drive belt. As a result of having a high voltage part on the vehicle, different health and safety procedures must be followed. The electric motor is located inside the compressor case and is in contact with the refrigerant oil. The refrigerant oil that the vehicle manufacturer specifies will have unique electrical properties that will protect you from an electric shock from the motor. The additives in the OE oil reduce the electrical conductivity of the oil (it becomes more of an insulator). Due to the component technical differences, ordinary PAG refrigerant oils (PAG 46, 100 and 150) cannot be introduced into electric and many hybrid A/C systems. Oil types specified by the vehicle manufacturer must be used. The use of the wrong oil will contaminate the A/C system; the severity of the damage will depend on whether or not you switch the A/C on. As little as 1% contamination can lead to electrical problems such as fault codes or, in extreme cases, total vehicle shutdown. UV leak detection dye that is used in standard combustion vehicles should not be added to systems that use an electric compressor. The adding of any standard UV dye can considerably reduce the refrigerant oil s electrical insulation properties. For those already with an A/C machine The Hybrid Conversion Kit is a cost effective way of allowing you to service electric or hybrid vehicles. Self-fitted, the kit sits on the side of the machine. Pre-packed bottles of either hybrid oil or dye are then attached to the kit ready for injection into the A/C system. When the machine has carried out a vacuum on the A/C system you are working on, simply turn the valve on the kit and the oil / UV dye will be introduced into the system meaning no mess, no contamination of the vehicle a/c system, or the machine s internal system and the customer can have their A/C fully serviced. This method allows you to work quickly, efficiently and cleanly on both standard combustion vehicle A/C systems and alternatively fuelled vehicle A/C systems. For more information

6 3. Evacuation & Flushing Initial preparation Before commencing please refer to Section 1 Service Preparations & Precautions. This procedure requires the hybrid oil injector to be fitted to the RMS. If not fitted please refer to the Hybrid Oil Injector Fitting Guide. Important. When carrying out the recharge procedure the Refrigerant Management Station (RMS) is required to be used in manual mode. Important. Ensure there is a minimum of 5kg of refrigerant in the RMS (1). Drain the waste oil bottle on the RMS. 1 TANK IN OIL OUT OIL kg 0000 ml 0000 ml Important. Ensure the liquid flushing output valve is closed ( O position) (2). 2 6

7 Automotive Air Conditioning Hybrid Conversion Kit Procedure Guide Connect the hose flushing tee piece (3) to the liquid flushing output. 3 Connect the high (Red) and low (Blue) service couplers (4) to the hose flushing tee piece adaptor. 4 4 Vacuum both service hoses (Red/Blue) for 1min (5). Both gauges should show a pressure below zero. 5 5 When the vacuum has finished close the high (Red) and low (Blue) panel valves (If fitted) (6). 6 6 For more information

8 Ensure there are no leaks. Check that the gauges do not rise after the vacuum procedure has stopped (7). 7 7 Turn the liquid flushing output valve to open ( I position) (8). 8 Open the high (Red) and low (Blue) panel valves (9) (If fitted). 9 9 Activate the recovery function on your RMS. When the RMS has finished the self clear process it will start to recover. SELF CLEARING 8

9 Automotive Air Conditioning Hybrid Conversion Kit Procedure Guide After 3 minutes of recovery turn the flushing output valve to closed ( O position) (10). 10 When the RMS has finished recovering the refrigerant, the RMS will carry out an oil drain. OIL DRAIN & PRESSURE CHECK IN PROGRESS When the oil drain procedure has finished disconnect the high (Red) and low (Blue) couplers from the flushing tee piece. The RMS is ready to be used on a hybrid vehicle. Important. Do not use the RMS in automatic mode. Ensure the following steps are carried out in manual modes. Important. Ensure that the RMS oil inject valve is set to the closed position ( O ) (11). If required, carry out a manual recovery on the hybrid vehicle. 11 Carry out a manual vacuum (Standard vacuum times apply). For more information

10 After the vacuum procedure has finished turn the hybrid oil inject valve to open ( I position) (12) until the amount of oil that is required has been injected, then close the hybrid oil inject valve ( O position) (13) Carry out a manual recharge (If your RMS requests to inject oil, select NO). When the recharge is complete return the service hoses back to the RMS. This procedure should be carried out before working on a hybrid vehicle with an electric compressor. CHARGING OIL? 1 - YES 2 - NO 10

11 Automotive Air Conditioning Hybrid Conversion Kit Procedure Guide 4. Hybrid Conversion Kit Parts 2 5 3/4 1 POS Part No. Description QTY Hose Flushing adaptor assembly Oil / Dye injector to suit AC690 RMS Hybrid Oil 68 cst Suitable for Electric Compressors Hybrid UV Dye MG Adaptor for use with U-View Hybrid Oil & UV Dye Fitting Guide for Hybrid Kit Procedure Guide for Hybrid Kit 1 For more information

12 Autoclimate Ltd Head Office & Development Centre 37 Atcham Business Park Shrewsbury SY4 4UG Tel: Fax: Disclaimer The contents of this publication are correct at time of publication. Autoclimate Limited reserves the right to vary, modify or change any of its products, services or specifications including those described or referred to in this publication at any time without prior notice. Document Ref: v.1.0 October 2012 TM autoclimate