Guangzhou Junliye Import&Export Co., Ltd. AUTOMOTIVE AIR CONDITIONER REFRIGERANT HANDLING SYSTEM
OPERATION MANUAL 1. Cautions: Wear the glove and eye protection glass to protect the skin and eyes from refrigerant. Operating near the fire and spark is prohibited. Don t expose this device into sunshine or rain. Avoid to contact with corrosive liquid and gas. Keep good ventilation of workshop. 2. Notation: 2.1. Warnings Read the manual carefully before using this device. Only for R134a. Check the refrigerant type before operation. The real working capacity of refrigerant cylinder should be 80% of its efficient capacity, to avoid the serious accident result from high pressure. Be sure that the high and low manual valve is off before connecting the device to the air conditioner. Don t put the hose near rotation and heating automobile parts such as electronic fan and radiator. Check the vacuum pump oil level in fixed period. The start times of recovering process should be less than 10 in one hour otherwise the compressor will be damaged. Don t let the child and people of insufficient mental development close with this device when it is running. Only for expert professional. Don t disassemble device without permission of manufacture. Don t put this device upside down. The refilling process would not work if the refrigerant in cylinder less than 1Kg. The working voltage is 220V, NEVER USE 380V voltage 1
2.2 Preparation before using: Loosen the nut as indicated. The nut is used to protect the scale from vibration during the transportation. We need to move the nut before we use this machine. There are two holes at the back of the machine. And we need to use a tool to loose the hex(agonal)screw. Please see the picture in the right. 3. Technical parameter: Refrigerant type: R134a Work temperature: -10 50 Power supply: AC 220V/60Hz Digital weight scale precision: 0.2%(FS) Speed of vacuumizing: 10.8M3/Hour Refrigerant cylinder capacity: 15Kgs Speed of recovering: Speed of refilling: 400g/min 1000g/min Net weight: Size(mm): 115Kg 790*640*1360mm 2
4. Device description: JLY540 is applied to R134a refrigerant handling. It can do the job of recovery, Vacuum, Leakage hunting, refilling and oil draining. Database for popular automobiles are available from this system. And also the operation result can be printed by the built-in printer. 4.1 Functions 1) Recovery: Recover the refrigerant from the A/C system and do refreshing before restore it into the cylinder, so it will avoid refrigerant contamination. 2) Vacuumizing: Vacuumize the A/C system, exhaust the moisture and air inside. 3) Refilling: Refill the refrigerant from the cylinder into the A/C system accurately. 4) Oil refilling: Renew the lubricant in the A/C system 5) Oil draining: automatically drain all the residual oil and purify that separated from the refrigerant during recovery. 6) Leakage hunting: Check if there is any leakage source by vacuum. 7) Air purge: exhaust the un-condensable gas. 3
4.2 Appearance Control panel High side & Low side connectors Oil draining bottle Fresh oil entry 4
4.3 Control Panel Cylinder Pressure Gauge LCD Printer Low Pressure Gauge Switch 4.4 Map of the key pad High Pressure Gauge 1 2 3 4 5 6 ( ) ( ) ( ) ( ) Exit Increase Decrease Enter Start on Start off 5
4.5 Interior Structure Vacuum pump Oil separator Charge hose Fresh oil bottle Cylinder Compressor 5. Manual Operation Method 5.1 Recovery Operation Step 1) Link red hose to the HP terminal and blue hose to LP terminal of JLY540, connect up another side with red and blue quick adaptors and close off these two adaptors at the same time. Then connect these adaptors to the A/C system, LP and HP side separately. Turn on the adaptors. 2) Upplug to 220V/50~60HZ power and switch on. Message reads: 6
= = = FUNCTTON = = = CYL.: XX.XX KG 1.MANUAL 2.AUTOMATIC 3.DATABASE 4.BASIC OPERATTON 3) Press or to select MANUAL, then press to enter next step: = = = MANUAL= = = CYL.: XX.XX KG 1.RECOVERY 2.VACUUM 3.CHARGE 4.VACUUM HUNTING 4) Press or and choose RECOVERY, then press to enter: ---RECOVERY--- STOP CYL.: XX.XXKG SET REAL REC. : xx.xx.kg REC : xx.xxkg 5) Press or to set the recovery amount, then press ON to start: ---RECOVERY--- RUN CYL.: XX.XXKG SET REAL REC. : xx.xx.kg REC : xx.xxkg 7
Remark: Press Off to stop the recovery program When the HP & LP hoses pressure is close to zero, the system will automatically enter the program of oil draining and remind to print or not. Messages come out : --- RECOVERY STOP--- CYL.: XX.XX KG SET REC. : xx.xx.kg REAL REC. : xx.xxkg NOTE: RECOVER FINISH, PRINTING? When the setting amount is equal to the real recovery amount, recovery program stops automatically. 5.2 Self-protection during the recovery process 1) When the HP hose and LP hose pressure is below 0.15MPA, the system will refuse to execute the command of recovery. And it will indicate that NO REFRIGERANT IN HOSE. 2) When the total recovery amount comes to 200KG, system will suggest to replace the filter drier. Users should re-set the recovery amount to be zero when they have changed a new one. 3) During the recovery, the system can stop automatically when cylinder pressure (CP pressure) is high to 1.75MPA. It will indicate CYLINDER PRESSURE HIGH. We cannot restart the recovery program until the pressure decreases to 1.3MPA. 4) The capacity of the cylinder is 15KGS. When there is no space any more, the system will refuse to recover. 5) Long time working can cause high temperature inside the equipment, and may cause the problem of failing to restore the refrigerant in the cylinder. In this case, please wait 15 minutes before you re-start recovery program. 8
5.3 Operation steps of vacuumizing and refrigeration oil refilling 1) Open the door at your right side before refilling. Twist off the cap of the funnel, then put oil into the oil bottle by the funnel. 2) Connect red hose to HP side and blue hose to LP side of the A/C system 3) Power on, and window indicates: = = = FUNCTTON = = = CYL.: XX.XX KG 1.MANUAL 2.AUTOMATIC 3.DATABASE 4.BASIC OPERATTON 4) Press or to come to MANUAL, then press to enter next step: = = = MANUAL= = = CYL.: XX.XX KG 1.RECOVERY 2.VACUUM 3.CHARGE 4.VACUUM HUNTING 5) Press or, choose VACUUM, press to enter next step: --- VACUUM --- STOP CYL.: xx.xxkg SET VAC. TIME : xx : xx MIN SET OIL CHARGE : xxxx g REAL VAC. TIME : xx: xxin REAL OIL CHARGE : xxxx g 9
6) Press to select the setting target, press or to set the parameter 7) When finish setting, press ON to vacuum or refill refrigeration oil. Remark: When there is no need to refill oil, please set the parameter to be 000g When need to refill oil, set the weight you want. And windows indicates as below: --- VACUUM --- RUN CYL.: xx.xxkg SET VAC. TIME : xx : xx MIN SET OIL CHARGE : 0000g REAL VAC. TIME : xx : xx MIN REAL OIL CHARGE : 0000g NOTE: CHARGING OIL When the oil is already charged, Press to exit, press to print When the pressure in the A/C system is high to 1.5MPA or above, the system will refuse to accept the order of vacummizing and also indicates HOSE PRESSURE TOO HIGH. 5.4 Operation steps of charging 1) Connect the HP hose (red) and LP hose (blue) to the corresponding side in the A/C system. 2) Power on, and window indicates: = = = FUNCTTON = = = CYL.: XX.XX KG 1.MANUAL 2.AUTOMATIC 3.DATABASE 4.BASIC OPERATTON 10
3) Press or for MANUAL, then press to enter next step: = = = MANUAL= = = CYL.: XX.XX KG 1.RECOVERY 2.VACUUM 3.CHARGE 4.VACUUM HUNTING 4) Press or for CHARGE, then press to enter next step: ---CHARGE--- STOP CYL.: XX.XXKG SET REAL CHARGE. : xx.xx.kg CHARGE : xx.xxkg 5) Press or to set the charging amount, then press ON to enter the charge program. Press to exit, or press to print. ---CHARGE--- STOP CYL.: XX.XXKG SET REAL CHARGE. : xx.xx.kg CHARGE : xx.xxkg NOTE: CHARGE FINISH, PRINTING? Remark: Refrigerant must be more than 1KG for starting the recharge program. Otherwise, it cannot work. When the charging speed is too slow, the system will suggest to Swith on A/C. 11
5.5 Operation steps of leakage hunting 1) Connect the HP hose (red) and LP hose (blue) to the corresponding side in the A/C system 2) Power on, and window indicates: = = = FUNCTTON = = = CYL.: xx.xxkg 1.MANUAL 2.AUTOMATIC 3.DATABASE 4.BASIC OPERATTON 3) Press or for MANUAL, then press to enter next step: = = = MANUAL= = = CYL.: XX.XX KG 1.RECOVERY 2.VACUUM 3.CHARGE 4.VACUUM HUNTING 4) Press or for VACUUM HUNTING, then press to enter next step: --- LEAK --- STOP CYL.: xx.xxkg SET VAC. TIME : xx : xx MIN REAL VAC. TIME : xx : xx MIN SET LEAKH TIME : xx : xx MIN REAL LEAKH TIME : xx : xx MIN 12
5) Press to select the target, press or to set the parameter. When setting finished, press ON to start leakage hunting Remark: System will give out the result saying A/C NON LEAKAGE or A/C LEAKINGE When the pressure inside the A/C system is high to 1.5MPA or above, system will give message HOSE PRESSURE TOO HIGH and refuse to go on leakage hunting. 6. Automatic Operation The main functions involves vacuumize & charge, recover, vacuumize and charge. The automatic operation step is basically the same as manual operation. And the self-protection function in manual operation is also used to the automatic operation. 6.1 Operation steps to vacuum and charge 1) Connect red hose to HP side and blue hose to LP side of the A/C system. 2) Power on, and window indicates: = = = FUNCTTON = = = CYL.: XX.XX KG 1.MANUAL 2.AUTOMATIC 3.DATABASE 4.BASIC OPERATTON 3)Press or for AUTOMATIC, then press to enter next step: = = = AUTOMATIC = = = CYL.: xx.xxkg 1.VACUUM + CHARGE 2. RECOVERY + VACUUM + CHARGE 13
4) Press or for VACUUM+CHARGE, then press to enter next step: AUTO MODEL1 STOP CYL.: xx.xxkg SET VAC. TIME SET OIL CHARGE SET REF CHARGE : xx : xx MIN : xx.xx g : xx.xx KG 5) Press to select the target, press or to set the parameter. When finish setting, press ON to start vacuum and charging. Remark: When finish vacuumizing and charging, system will ask users to print or not. When we need to charge refrigeration oil, please firstly put oil into the oil bottle. Otherwise, please set the oil charge to be 0000g. 6.2 Operation method of recovery, vacuum and charging The operation step is basically the same as vacuum+charge. Please refer to vacuum+charge operation step. 7. The calibration of weight scale 7.1. The method of setting weight scale 1) Get the weight ready of 15.30kg 2) Remove the storage cylinder from the scale pan 14
3) Switch on and the LCD window as below: = = = FUNCTTON = = = CYL.: XX.XXKG 1.MANUAL 2.AUTOMATIC 3.DATABASE 4.BASIC OPERATTON 4) Press and button at the same while, window shows: = = =RESET = = = CYL.: XX.XXKG 1 DRYER AND FILTER 2.VACUUM PUMP OIL 3.SCALE 4.UNITS 5.STATUS: XXX KG 5) Press or to select SCALE, press and message comes out: = = =WEIGHT SCALE = = = CYL.: XX.XXKG 1 REFRIGERANT SCALE RESET 2.REFRIGERANT SCALE CALIBRATE 3.OIL SCALE RESET 4.OIL SCALE CALIBRATE 6) Press or to select REFRIGERANT SCALE RESET, press and a message saying that RESET IS FINISHED. Press or to choose REFRIGERANT SCALE CALIBRATE and the press : = = =CALIBRATE = = = CYL.: XX.XXKG REFRIGERANT WEIGHT SCALE: WEIGHT ON SCALE : XX.XXKG WEIGHT CALIBRATION: XX.XXKG 15
7) Press or, set the weight to be 15.30KG and then press, the window shows: = = =CALIBRATE = = = CYL.: 15.30KG REFRIGERANT WEIGHT SCALE: WEIGHT ON SCALE : 15.30KG WEIGHT CALIBRATION: 15.30KG Calibration is finished and press exit key to exit. 7.2. Calibration of refrigeration oil 1) Prepare a weight of 500g 2) Refer to 7.1. for the calibration step 8. Recall the Database The database is helpful to the technicians. It provides the data of all kind of popular automobile of the refrigerant charging amount refrigeration oil charging amount. It saves much time to the technicians. Power on and press or to choose DATABASE, press to enter and check. 9. Replace the filter drier The system will make total of the recovery amount automatically. When the amount comes to 200KG, the system will indicates the users to replace the filter drier. Replacement steps: 1) Must plug off, in order to avoid any electric shock 16
2) Remove the filter drier and install a new one. Pay attention the the direction when install. 3) Finishing the replacement, upplug and turn on the machine. Press in the same while, LCD window says: = = RESET = = = CYL.: xx.xx KG 1. DRIER AND FILTER: 2. VACUUM PUMP OIL : 3. SCALE: 4. UNITS STATUS: 000 KG Press or to selet DRIER AND FILTER, press to set zero of the filter drier lifetime. When finish setting, the status wil change to 200 KG. 10. Change Vacuum pump oil Must use the original pump oil or oil recommended by manufacture When the oil level is reach the minimum position, pump oil should be added. If the oil level is too high, it should be drained by unfastening the draining screw System could accumulate the vacuum time. When the value reach to 9000 minutes, system would remind changing the pump oil. The over would be displayed when the power is on and system would not start vacuum process. When the color of pump oil is changed to white, it must be changed. Change stage: 1:Before changing, run the vacuum process for 1 minute to be sure that the pump is in hot condition. Open the draining screw to drain the oil into a container. 2: Unplug the power cable and remove the backboard of device. Unfasten the oil entrance lid and add oil into the pump until the oil level is higher than the minimum position, fasten the screw. 3:After changing vacuum pump oil, it should switch the power on and press the 17
and key in same time to enter reset menu and press menu key to select vacuum oil item, press the and key in same time again to reset the working time. Guangzhou Junliye Import & Export Co., Ltd. ADD:Baiyun District,Guangzhou,China. Tel:86-20-86394322 Phone NO.+8613925106748 EMAIL:lilichen@431tool.com 18