Equipment for the recharge of car A/C systems. Use and Maintenance manual Ver. 0.1
Blank Page CAP. 1 - INDEX 2 / 75 ENGLISH
CAP. 1 - INDEX CAP. 1 - INDEX... 3 CAP. 2 - GENERAL INSTRUCTIONS... 5 2.1 GENERAL NOTES...5 2.2 MANUFACTURER IDENTIFICATION...5 2.3 TECHNICAL SERVICE CENTERS...5 2.4 MARKING...5 CAP. 3 - SAFETY CONDITIONS... 6 3.1 IMPORTANT INFORMATION ON PERSONAL SAFETY...6 3.1.1 Definitions...6 3.1.2 Precautions For Operators Safety...7 3.2 IMPORTANT INFORMATION ON TOOL SAFETY...12 3.3 GENERAL INSTRUCTIONS...13 3.4 SAFETY DEVICES...15 CAP. 4 - MANUAL STRUCTURE AND USE... 16 4.1 MANUAL USE...16 4.2 SYMBOLS...17 4.2.1 Safety...17 4.2.2 Marking...17 4.3 GLOSSARY OF TERMS...18 4.4 GUIDELINES FOR THE HANDLING OF REFRIGERANT...19 4.4.1 Precautions for refrigerant storage...19 4.4.2 Conditions of refrigerant and system...19 4.4.3 Recycling capacity...20 CAP. 5 - GENERAL DESCRIPTION... 21 5.1 EXTERNAL VIEW OF CLIMA-8500 EVO - FRONT SIDE...22 5.2 INTERNAL VIEW OF CLIMA-8500 EVO - FRONT SIDE...23 5.3 RIGHT SIDE VIEW OF CLIMA-8500 EVO...24 5.4 LEFT SIDE VIEW OF CLIMA-8500 EVO...25 5.5 TOP FRONT VIEW CLIMA-8500 EVO...26 5.6 USER S INTERFACE...27 5.7 ACCESSORIES COMING WITH THE TOOL...28 5.8 OPTIONAL ACCESSORIES...28 CAP. 6 - TECHNICAL FEATURES... 29 CAP. 7 - INSTALLATION... 31 7.1 EQUIPMENT INSTALLATION...31 7.1.1 Unpack CLIMA-8500 EVO...31 7.1.2 Preparation for use...32 7.2 IMPORTANT INFORMATION ON ELECTRIC STORAGE BATTERIES (BATTERIES, ETC.)...33 7.3 DURING USE...34 7.4 WHEN THE TOOL IS NOT USED...34 7.5 CLEANING DISMANTLING AND DISPOSAL...35 CAP. 8 - COMMISSIONING... 36 8.1 CONNECTIONS...36 8.2 RECHARGE OF THE INTERNAL VESSEL...37 8.3 OIL CHARGE CELLS ZERO CHECK...38 8.4 NEW OIL BOTTLE FILLING...39 8.5 TRACER BOTTLE FILLING...40 CAP. 9 - MENU STRUCTURE... 41 CAP. 10 - SETUP... 43 ENGLISH 3 / 75 CAP. 1 - INDEX
CAP. 11 - A/C SYSTEM RECHARGE... 45 11.1 PRELIMINARY OPERATIONS...45 11.2 NON CONDENSABLE GASES DISCHARGE...45 11.3 ZERO TOLERANCE MODE...46 CAP. 12 - AUTOMATIC CYCLES... 47 12.1 PRELIMINARY OPERATIONS...47 12.2 DATABASE...47 12.3 LAST RECHARGE CYCLE...49 12.4 PREVIOUSLY SAVED RECHARGE CYCLE...50 CAP. 13 - MANUAL CYCLES... 51 13.1 PRELIMINARY OPERATIONS...51 13.2 RECOVERY PHASE...51 13.3 SYSTEM VACUUM PHASE...52 13.4 OIL INJECTION PHASE...53 13.5 TRACER INJECTION PHASE...54 13.6 REFRIGERANT INJECTION PHASE...54 13.7 FLUSHING PHASE...56 13.8 PRESSURE CHECK...57 13.9 HOSES EMPTYING...58 CAP. 14 - STORAGE IN CASE OF LONG STOPS... 59 CAP. 15 - MAINTENANCE... 60 15.1 LEAK TEST...62 15.2 REPLACEMENT OF VACUUM PUMP OIL...63 15.3 DRYER FILTER REPLACEMENT...65 15.4 COUNTERS...66 15.5 STORAGE VESSEL FILLING...67 15.6 PRINTER MAINTENANCE...69 15.7 PERIODICAL CHECKS...71 CAP. 16 - DISPOSAL... 74 16.1 EQUIPMENT DISPOSAL...74 16.2 RECYCLED MATERIALS DISPOSAL...74 CAP. 17 - SPARE PARTS... 75 CAP. 1 - INDEX 4 / 75 ENGLISH
CAP. 2 - GENERAL INSTRUCTIONS 2.1 GENERAL NOTES All rights reserved. Total or partial copy of this manual is prohibited under any form, either paper forms or electronic forms. BRAIN BEE SPA and resources used for the drawing up of this manual will not be held responsible for the incorrect use of the manual while they guarantee that information in the manual have been duly checked. Products undergo constant control and improvement, hence we reserve the right to modify information herein without notice. 2.2 MANUFACTURER IDENTIFICATION CLIMA-8500 EVO is an equipment being manufactured by: Brain Bee S.p.A. Via Quasimodo, 4/a 43126 Parma (Italy) Tel. +39 0521 954411 Fax +39 0521 954490 e-mail contact@brainbee.com internet http://www.brainbee.com 2.3 TECHNICAL SERVICE CENTERS As to the technical service centers for CLIMA-8500 EVO, please contact your reseller or directly Brain Bee S.p.A Technical Service. 2.4 MARKING The CLIMA-8500 EVO equipment has been manufactured in compliance with the Community Directives listed in the Declaration of Conformity supplied with the pressure equipment. The equipment falls in the PED risk category II (97/23/EC). Pressure equipment shall undergo checks before commissioning and periodical checks during operation, in compliance with the rules and law provisions in force in the country where the equipment is used. The characteristic data of the equipment are indicated on the specific data plate applied onto the equipment side part. It is prohibited to remove damage or tamper with the equipment data plate. ENGLISH 5 / 75 CAP. 2 - GENERAL INSTRUCTIONS
CAP. 3 - SAFETY CONDITIONS 3.1 IMPORTANT INFORMATION ON PERSONAL SAFETY 3.1.1 Definitions DANGEROUS AREAS: Any area within or close to the equipment implying risk for the safety and health of exposed persons. EXPOSED PERSON: Any person completely or partially standing in a dangerous area. OPERATOR: The person/s in charge of operating the appliance for the set purpose. OPERATORS CLASSIFICATION The operator can be classified according to two main categories, which, in some cases, refer to one single person: The operator charged with the equipment operation has the duty to: o Start and check the machine automatic operation; o Carry out simple setting operations; o Remove the causes of equipment stop not implying breakings of members but simple operation anomalies. The operator charged with the machine maintenance is a qualified technician who can intervene on the machine, with guards open, and on mechanic and electrical members to carry out setting, maintenance and repair operations. USER Body or person legally responsible for the equipment. CAP. 3 - INDEX 6 / 75 ENGLISH
3.1.2 Precautions For Operators Safety GENERAL PRECAUTIONS All the operators shall not be under the effect of tranquillizers, drugs or alcohol when performing their job Before starting their job, operators shall be perfectly aware of the position and operation of all the controls indicated on the use manual. Always pay attention to any danger sign affixed on the installation and within the company of the user. The employer is responsible for the spreading of this document to the whole personnel that is going to work on the equipment. Besides the obligation to strictly comply with the instructions contained in this manual, the operators shall inform their heads on any deficiency or potentially dangerous situation that might occur. In case of machine malfunctioning, check the procedures outlined in the various chapters. Always refer to the safety standards adopted by the company employing the equipment with a view to avoiding useless risks. ENGLISH 7 / 75 CAP. 3 - SAFETY CONDITIONS
RISK OF ASPHYXIA GASOLINE ENGINES Exhaust gases of gasoline vehicles contain carbon monoxide, a colourless and odourless gas which, if inhaled, can cause serious physical problems. Special attention is always required when working within pits, as exhaust gases components are heavier than air and consequently deposit on the bottom of the pit. Attention shall be paid to natural gas vehicles as well. DIESEL ENGINES Diesel engine exhaust gas composition is not always the same. It can change according to: type of engine, intake, conditions of use and fuel composition. Diesel exhaust is made up of gases (CO, CO 2, NO X and HC) and particulate (soot, sulphates, etc.); the small particles of carbon making up soot remain suspended in the air and can thus be breathed. Toxic components, albeit in small quantities, are present as well. SAFETY MEASURES: - Always ensure good ventilation and air aspiration (especially in the pits). - In closed premises, always start the exhaust gas aspiration system. RISK OF SMASHING If the vehicles are not correctly secured by means of mechanic devices, the operator might get smashed against a working bench or against a wall. Even the equipment placed on unstable supports might fall and squash the operator s limbs. SAFETY MEASURES: - Make sure the vehicle has been secured by pulling the hand brake and locking the wheels. - Make sure the equipment has been positioned on a stable support and, in case of trolley, that its wheels have been locked before use. CAP. 3 - INDEX 8 / 75 ENGLISH
RISK OF INJURY Engines, both working and in standstill, include moving parts (belts or other parts) which might injure hands and arms. In the vehicles, the cooling fan starts automatically by means of a temperature sensor even when the engine is off; always pay attention when operating close to it and disconnect it if needed. SAFETY MEASURES: - When the engine is turned on, do not put hands into the moving parts area. - When operating close to electrically started fans, let the engine cool down beforehand and then remove the fan plug from the engine. - Keep the testing tools connection cables far from the engine moving parts. RISK OF BURN When intervening on the engine, protect face, hands and feet with suitable protective devices, avoid contact with hot surfaces, such as sparking plugs, radiators, pipings of the cooling system and electromechanic sensors. Catalytic mufflers reach extremely high temperatures and can cause burns or fires. Attentions shall thus be paid to avoid touching these objects without suitable precautions. SAFETY MEASURES: - Wear protective gloves. - Let cool down the engine and other independent accessories, if any. - Do not install testing tools connection cables over or close to hot parts - Do not keep the engine turned on once checks have been completed. ENGLISH 9 / 75 CAP. 3 - SAFETY CONDITIONS
RISK OF FIRE OR EXPLOSION When carrying out operations on the fuel system (injectors, fuel and gasoline pump, etc.) there is risk of fire or explosion due to the fuels employed and/or vapours formed by them. SAFETY MEASURES: - Disable start. - Let the engine cool down. - Do not use free flames or sparks sources. - Do not smoke. - Collect the outflowing fuel. - Start the aspiration units in closed premises. RISK RELATING TO NOISE LEVEL During measurements on the vehicle, noise levels can exceed 90dB. Such noise levels can be reached with ultrasonic cleaning or with the vehicle s engine high rpm. If a person is exposed to such noise sources for a long period of time, this can cause irreversible hearing damage. SAFETY MEASURES: - The operator shall adopt personal protective equipment (safety ear muffs). - The operator shall also protect from noise the working stations close to the areas where test on the vehicle. CAP. 3 - INDEX 10 / 75 ENGLISH
RISK RELATING TO DANGEROUS VOLTAGE Civil or industrial electric power distributions, as well as vehicles electric systems, do imply dangerous voltages. When an operator is in contact with testing tools or live parts of the engine, risk of electrocution exists. For instance, this might be caused by cables with damaged insulation (ex. Bites of animals on power cords). This is especially true of the vehicle starting system and testing tools connections. SAFETY MEASURES: - Connect the testing tools to an electric socket safety relay and correctly grounded. - For the testing tool connection, use exclusively the cables provided with the tool itself, making sure insulation is not damaged. - Make sure the testing tool is grounded before turning it on. - When carrying out interventions on the electrical system of a vehicle (connection of testing tool, replacement of starting system parts), supply voltage shall be unplugged (ex. battery). - During checks and setting operations with the engine turned on, attention shall be paid to avoid touching those vehicle live components (for instance the starting system) without the suitable precautions (for instance insulating gloves). RISK OF INTOXICATION The pipes that are used for exhaust gases sampling if subject to high temperatures (exceeding 250 C or due to fires) release a highly toxic gas which, in case of inhalation, can be harmful for health. SAFETY MEASURES: - In case of inhalation, immediately contact a doctor. - To remove combustion residues wear neoprene or PVC gloves. - Fire residues can be neutralized with a calcium hydroxide solution. This leads to the formation of calcium fluoride that can be removed with water. ENGLISH 11 / 75 CAP. 3 - SAFETY CONDITIONS
3.2 IMPORTANT INFORMATION ON TOOL SAFETY When using the tool, the following operations are not allowed as they might cause, under certain circumstances, danger for persons and cause permanent damage to the tool itself. - Do not remove or make unreadable labels, signs and/or dangers signs placed on the tool and in the area nearby. - Do not disable the machine safety devices - Use exclusively original fuses with the required ampere capacity! In case of electric supply anomalies, the machine shall be powered off immediately. Defective fuses shall not be repaired or excluded but replaced with fuses of the same type. - The machine electrical connections shall be inspected at regular intervals. Defects, such as slackened connections or burnt cables or cables with damaged insulation, shall be immediately removed and replaced. - Non authorized personnel must not open the equipment. Within the tool there are parts that, if touched, can cause electrocution: power off before opening the tool to carry out repair operations. CAP. 3 - INDEX 12 / 75 ENGLISH
3.3 GENERAL INSTRUCTIONS Pressure equipment undergoes checks before commissioning and periodical checks during operation in compliance with rules and law provisions in force in the country where the tool is used. The operator shall be responsible for the UNIT use in compliance with rules in force in their country. The UNIT is a tool designed for recovery and recycling of R134a refrigerant of A/C systems of cars. This unit is to be used exclusively by duly trained operators having a good knowledge on cooling, cooling systems, refrigerants and possible damages caused by pressure equipment. The careful reading of this manual by the user is necessary for the correct and safe use of the unit. The user shall not be entitled to open the Unit since maintenance operations are reserved to the authorised service center. PERSONAL SAFETY: Use coolant R134a only. The mixture with other types of coolant causes sever damage to the A/C and cooling systems and to the service equipment. It is advisable to wear suitable protections such as goggles and gloves; the contact with the coolant may cause blindness and other body injuries to the operator. Avoid the contact with skin; the low boiling temperature (about 30 C) may cause burns. Avoid inhaling of the coolant fumes. Do not expose it to the direct sunbeams and rain. Use the station in ventilated rooms. Do not smoke near the station and during the operations. Use the station clear of heat sources, open flames and/or sparks. Further medical and safety information may be obtained from the lubricants and coolants producers. CLIMA-8500 EVO SAFETY: Before carrying out connections between the unit and a A/C system or external tank, be sure that all the valves are closed. Before disconnecting the unit, be sure that the phase is completed and all the valves are closed so that the coolant is not dispersed in the atmosphere. Do not change the calibration of the safety valves and control systems. Do not use external tanks or other storage containers that are not homologated or without safety valves. Do not leave the unit live unless it is used in the near future; cut off the power supply before a long period of inactivity of the unit. The unit shall have to be always attended. The unit shall have not to be used in an explosion-risk environment. ENGLISH 13 / 75 CAP. 3 - SAFETY CONDITIONS
HOSES: Hoses may contain coolant under pressure. Always connect the CLIMA-8500 EVO hoses with quick coupler of RED color on the HP side (high pressure) of the A/C system. Always connect the CLIMA-8500 EVO hoses of BLUE color on the LP side (low pressure) of the A/C system. Disconnect the hoses with extreme caution. COOLANT: The car service equipment and A/C systems containing R134a should not be tested using compressed air. Some mixtures of air and HCF 134a showed to be inflammable at high pressures. These mixtures are potentially hazardous and show fire and explosion risks that may cause both personal and material damage. Check the type of coolant used by the A/C system on the vehicle use book. WORKING ENVIRONMENT: The unit must operate in open places or rooms with a good ventilation (at least 4 changes of air per hour). Work away from open flames and hot surfaces; the coolant breaks down at high temperatures releasing toxic and aggressive substances which are harmful to both the operator and the environment. Avoid inhaling the system coolants and oils. The exposure may irritate both the eyes and the respiratory tract. OPERATING CONDITIONS: do not expose to and do not use the unit in case of rain or other adverse weather conditions. STOP FOR LONG PERIOD: The unit shall be stored in a safe place, disconnected from the electric network, sheltered from excessive temperatures, humidity and risk of collision with objects that may damage it. Be sure that the valves on the internal tank are closed. For making the unit operate again follow the activation process only after opening the internal tank valves again. CAP. 3 - SAFETY CONDITIONS 14 / 75 ENGLISH
3.4 SAFETY DEVICES CLIMA-8500 EVO is equipped with the following safety devices: SAFETY PRESSURE SWITCH: it stops the compressor in case of excessive pressure. OVERPRESSURE VALVES: they intervene when the pressure inside the system reaches an excessive level. DISCONNECTING SWITCH: It allows the safety sectioning of the electric line for the maintenance interventions and emergency stop ANY TAMPERING WITH THE ABOVE-MENTIONED SAFETY DEVICES IS PROHIBITED. Should any of the above-mentioned safety rules not be observed, every type of warranty on the station shall lapse. ENGLISH 15 / 75 CAP. 3 - SAFETY CONDITIONS
CAP. 4 - MANUAL STRUCTURE AND USE 4.1 MANUAL USE Carefully read this manual before starting the equipment. This manual is aimed at providing the user with all the information required for a correct use of the equipment and to enable the user to manage it in the safest and most independent way. It includes information concerning the technical side, operation, machine stop, maintenance, spare parts and safety. Before carrying out any operation on the equipment, operators and qualified technicians shall carefully read the instructions outlined in this manual. In case of doubts on the correct interpretation of the instructions, please contact our technical service to obtain the required clarifications. This manual is integral part of the equipment; the purchaser shall keep it with the utmost care; it shall be placed closed to the equipment, within a specific container and, above all, it shall be protected from anything that might jeopardize its readability. This manual shall accompany the equipment in case this is passed on to a new user. The content of this manual has been drawn up in compliance with the guide lines of the UNI standard 10893:2000. Diffusion, modification or use of this manual for own aims is forbidden. When drawing up the manual, few but clear warning symbols have been selected for an easier and simpler consultation. CAP. 4 - MANUAL STRUCTURE AND USE 16 / 75 ENGLISH
The operations that might result in situations potentially harmful for the operators are highlighted by means of the symbol alongside Such operations can cause serious physical damage. Operations requiring particular attention are highlighted by means of the symbol alongside. Such operations shall be carried out correctly to avoid causing damage to objects or to the surrounding environment. This symbol also highlights which information special attention shall be paid to. Operations requiring careful reading of the instructions outlined in the use and maintenance manual are highlighted by means of the symbol alongside. 4.2 SYMBOLS This paragraph describes the safety-related symbols that might be present on the external part of the equipment. 4.2.1 Safety ALTERNATING CURRENT SAFETY GROUNDING CONSULT THE INSTRUCTION MANUAL WARNING! RISK OF ELECTROCUTION WARNING!: DO NOT TRY REMOVING THE COVER (this operation can be carried out exclusively by qualified technicians) 4.2.2 Marking EC CONFORMITY MARKING ENGLISH USE 17 / 75 CAP. 4 - MANUAL STRUCTURE AND
4.3 GLOSSARY OF TERMS To favour the reading of this manual we have prepared the list of most important technical terms used in the manual. Refrigerant: Cooling fluid used in the most modern car A/C systems. The refrigerant used by the station is R134a (CH2FCF3), chemical name: 1,1,1,2-tetrafluoroethane. A/C system: car conditioning system. Unit: CLIMA-8500 EVO equipment for car A/C systems. External bottle: Refrigerant bottle used to fill the internal vessel. Internal vessel: Vessel for refrigerant storage. Phase: Performance of a single function. Cycle: Performance of each function in sequence. Recovery: Removal of refrigerant under any condition from a tool and charge of refrigerant into a bottle external to the A/C system without any refrigerant analysis or treatment. Recycling: Reduction of contaminants from used refrigerants by means of oil separation, removal of non condensable gases and single or multiple passage through elements allowing reduction of humidity, acidity, and particulates. Disposal: removal of refrigerant aimed at storage for the next distribution or at delivery to disposal centers. Vacuum: Draining of non condensable gases and humidity from and A/C system by means of a vacuum pump. Oil injection: Injection of oil into the A/C system to restore the correct amount indicated y the manufacturer. Charge: Charge of refrigerant inside the A/C system as per indication of the manufacturer. Non condensable gases: Vapor phase air accumulation in the refrigerant drawn from A/C systems or bottles. CAP. 4 - MANUAL STRUCTURE AND USE 18 / 75 ENGLISH
4.4 GUIDELINES FOR THE HANDLING OF REFRIGERANT 4.4.1 Precautions for refrigerant storage The Refrigerant to be removed from a system has to be carefully handled so as to prevent or minimize mixing of several refrigerants. The unit is specially reserved to the use of refrigerant R134a. Vessels used for storage of refrigerants shall be dedicated to each specific refrigerant to prevent mixing of several refrigerants. Vessels shall be free from oil or other contaminants and clearly marked so as to identify the refrigerant contained. WARNING: For handling, use and storage of Refrigerant R134a, ask the refrigerant supplier for the technical and safety data sheets and comply with their requirements. 4.4.2 Conditions of refrigerant and system Life and age of the system can be of relevance to decide whether to recycle the refrigerant from a system. Installation procedures and maintenance interventions carried out during the system life have a remarkable effect on the refrigerant quality. Systems which have not been duly cleaned or drained might have high levels of contamination in the refrigerant and oil. If the life of the system is not known, the recovered refrigerant has to be at least recycled before being recharged into the system. In case the operators are not sure on the refrigerant contamination level, preliminary checks can be carried out by means of a special kit for acidity and humidity measurement. ENGLISH USE 19 / 75 CAP. 4 - MANUAL STRUCTURE AND
4.4.3 Recycling capacity Filtering systems of the recycling unit have to be replaced regularly to preserve the recycling equipment performance. However, even if all elements indicate there is no need to recycle the refrigerant, recycling has to be carried out in any case. Before recharging refrigerant gas into the system the latter has to be cleaned and drained. Procedures indicated in this manual have to be complied with to ensure the system is free from contamination before charging the refrigerant into the system. Units have to be cleaned and serviced on a regular basis, notably in case they have been used with highly contaminated refrigerant: it is very important to prevent contamination from the previous operation from affecting next operations. CAP. 4 - MANUAL STRUCTURE AND USE 20 / 75 ENGLISH
CAP. 5 - GENERAL DESCRIPTION The state-of-the-art technology applied for the project, production, and innovative design makes CLIMA-8500 EVO an extremely new unit, boasting a user-friendly and reliable performance of all operations. CLIMA-8500 EVO is typically used for vehicles containing up 2-3 kg of refrigerant. However, since the vessel can hold up to 16,5 kg it is possible to recharge also vehicles containing a higher amount of refrigerant. The users run no risk if they comply with the general safety rules indicated in this manual and they use and service the unit correctly. CLIMA-8500 EVO is suitably packed by the manufacturer. ENGLISH 21 / 75 CAP. 5 - GENERAL DESCRIPTION
5.1 External view of CLIMA-8500 EVO - front side 1 3 2 4 1. Bottle of the oil to be charged 250 cc 2. Bottle of oil recovered 250 cc 3. Bottle for Tracer 250 cc 4. Castor wheels, with brake CAP. 5 - GENERAL DESCRIPTION 22 / 75 ENGLISH
5.2 Internal view of CLIMA-8500 EVO - front side 8 9 5 10 6 11 7 5. Dryer filter 6. Compressor 7. Vacuum pump 8. Distiller 9. Oil separator 10. Ventilated condenser 11. Refrigerant vessel ONLY AUTHORIZED SERVICE CENTRE PERSONNEL CAN REMOVE THE FRONT, REAR DOORS AND UPPER COVER ENGLISH 23 / 75 CAP. 5 - GENERAL DESCRIPTION
5.3 Right side view of CLIMA-8500 EVO 12 13 12. Hose LP 4,5m with quick coupler 13. Hose HP 4,5m with quick coupler DO NOT USE THE STATION WHEN (HP LP) CHARGE HOSES ARE DISCONNECTED CAP. 5 - GENERAL DESCRIPTION 24 / 75 ENGLISH
5.4 Left side view of CLIMA-8500 EVO 14 15 16 14. Main switch 15. Tool programming connector 16. Power cord 2,5 m with shuko plug ONLY USE THE SPECIFIC PROGRAMMING CABLE FOR CLIMA MACHINES (OPTIONAL) ENGLISH 25 / 75 CAP. 5 - GENERAL DESCRIPTION
5.5 TOP front view CLIMA-8500 EVO 19 20 21 18 17 22 17. Multifunction Keyboard 18. Graphic Display 19. LP D80 Gauge 20. Inner Refrigerant Bottle Gauge 21. HP D80 Gauge 22. Thermal Printer CAP. 5 - GENERAL DESCRIPTION 26 / 75 ENGLISH
5.6 User s interface The selection menu has a tree structure where different functions can be selected through a 6-key keypad. Details for the user are displayed on an alphanumerical LCD display having 4 lines of 20-digit each. The first line shows the menu title, while the lines below show the operations available for that menu: the selected function flashes. Key functions: Arrow keys : navigation within the menu Arrow Keys :parameters setting STOP key : if pressed once within the menu it cancels the operation; by holding it down for more than 1s the system exits the database and goes back to the initial page START key : if pressed once within the menu it confirms the operation; by holding it down for more than 1s from the first level of the menu the system goes back to the database ENGLISH 27 / 75 CAP. 5 - GENERAL DESCRIPTION
5.7 Accessories coming with the tool Besides accessories already mounted on the UNIT, the standard set of accessories includes Vessel fitting 1 Piece. It is used to recharge the internal vessel PAG oil bottle 2 Pieces Additional bottles for PAG oil having different viscosities Use manual 1 Piece The CDRom contains this manual in the pdf format. ISO46/100/150 pag oil stickers 1 Piece. To be applied on the side of the PAG oil bottles // // 5.8 Optional accessories You can ask your Reseller or sales partner for the other optional accessories available. CAP. 5 - GENERAL DESCRIPTION 28 / 75 ENGLISH
CAP. 6 - TECHNICAL FEATURES Vessels for R134a fluids R134a vessel capacity Maximum working pressure (PS) PED category (Dir.97/23/EC) Heating belt for R134a vessel Safety valve 20 l 20 bar II Standard Type New General Instruments D7/CS 20bar R 1/4 GAS (or equivalent) Calibration pressure 20 bar PED category (Dir.97/23/EC) IV Containers for oil and tracer Recovered PAG oil container capacity 250 ml New PAG oil container capacity 250 ml, with OIL CARE valve UV tracer container capacity 250 ml, with OIL CARE valve Pneumatic circuit Vacuum pump flow 6 m 3 /h Vacuum level 0,05 mbar Vacuum pump oil quantity 0,5 l Refrigerant recovery compressor cubic 14 cc capacity Safety pressure switch Standard Dryer filter 45 kg of recovered R134a Non condensable gases discharge Manual, with solenoid valve HP and LP valves Toggle-type Safety pressure switch Type Danfoss ACB-2UB506W 13/18bar 1/4SAE (or equivalent) Intervention pressure 18 bar PED category (Dir.97/23/EC) IV Pneumatic fittings HP and LP external hoses net length 4,5 m HP and LP pressure gauge Analog 80 mm, pulse-free, 1.6 class Vessel pressure gauge Analog, 40 mm, pulse free, 1.6 class User s interface Display Alphanumerical LCD 4x20 Keypad Membrane, 4 arrows, START and STOP Software updating Printer Functions RS232 (accessible from the outside via cable or ACU CLIMASolution accessory) 24 column thermal ENGLISH 29 / 75 CAP. 6 - TECHNICAL FEATURES
R134a recovery, exhausted oil recovery, Automatic and manual vacuum, recharge, oil and tracer injection Recycling mode Single or MULTIPASS Memory for customized cycles Up to 30 Recovered oil measurement Automatic weighing, 1 g res., 5 g acc. New oil automatic injection By means of automatic scale 1 g res., 5g acc. UV tracer automatic injection Timed Flushing With integrated solenoid valves Database electronic Autodata (refrigerant amount) System pressure test Visual (with HP and LP pressure gauges) Alarms Dryer filter replacement check Active Vacuum pump oil replacement check Active Full/empty vessel check Active Oils overflow control Active Oils underflow control Active Dimensions LxPxH 600x522x1145 mm Loadless weight 86 kg Power supply Frequency 50 Hz Voltage 230 V ~ Power 800 W Environmental conditions Working temperature 5-40 C Storage temperature and humidity 5-40 C, 10-90% R.H. (non condensing) Ambient pressure 75 kpa 106 kpa Max operating altitude 2000 m Pollution degree 2 Overvoltage category II Fuses Retarder fuses 250V T10A CAP. 6 - TECHNICAL FEATURES 30 / 75 ENGLISH
CAP. 7 - INSTALLATION 7.1 EQUIPMENT INSTALLATION 7.1.1 Unpack CLIMA-8500 EVO Remove the unit from the pallet constituting the base of the packing by using appropriate means; do not lift the unit through the handles. The unit will be handled through the four castors; note that the two smaller castors are self-locking. RISK OF OVERTURNING ENGLISH 31 / 75 CAP. 7 - INSTALLATION
7.1.2 Preparation for use HANDLING: During handling, the minimum devices required for correct handling shall be ensured, as provided for by accident prevention provisions. POSITIONING: Position the unit in a room with proper ventilation and/or air change. The unit must be placed at a distance of at least 10 cm from any object that could obstruct internal ventilation and access to the on/off switch. Protect and do not use under conditions of rain and atmospheric events. Protect the unit against rain or excessive humidity to avoid irreparable damage of it. In addition, the equipment must never be directly exposed to the sunrays or to excessive dust. During use, securing the equipment by the brake is recommended. INSTALLATION: The installation shall be carried out by specialized personnel, strictly complying with the instructions contained in this manual. The use of the equipment in explosive atmosphere is forbidden. CONNECTIONS: this being an electric equipment connected to the mains supply, correct use of the ground pin, placed on the supply plug, is compulsory. If the ground pin is willingly not being used or in case of connection of the supply plug to a supply socket not provided with suitable grounding, this might damage the tool. These procedures are forbidden and put the operator s life at risk. Place the station such that the mains socket can be easily accessed by the operator. CAP. 7 - INSTALLATION 32 / 75 ENGLISH
7.2 IMPORTANT INFORMATION ON ELECTRIC STORAGE BATTERIES (Batteries, etc.) Even if the equipment does not use electric storage batteries (rechargeable or not), this general safety information is included as a battery is always present on the vehicle. DISASSEMBLY: Never try to disassemble the batteries container or to modify it. The container has safety and protective devices ensuring safe operations. By damaging these devices, there is the risk of heat emissions, smoke emission, fluids leak, batteries container explosion and fire. ELECTRICAL CONTACTS: Never allow the positive and negative terminals of the batteries container to be connected by metal parts. Never transport or deposit the batteries container together with metal objects (necklaces, hairpins, etc.) which might cause short circuit and allow for a large quantity of energy to flow through the metal, thus leading to the risk of container explosion, heat emission, smoke emission, as well as burning of the metal object connecting the two terminals. TEMPERATURE: never use nor leave the batteries container close to flames, stoves, or any other place exposed to high temperatures (80 C or higher). This might damage the batteries container seal, thus leading to risk of short circuit, container explosion and fire CLEANING: never damp the batteries container with soft water, nor salty water or other types of fluid. Water can damage the batteries container safety device, thus leading to the risk of heat emission, smoke emission, container explosion and fire. CONTAINER: Never use the batteries container the external part of which is extremely damaged or deformed. The use of such containers leads to the risk of heat emission, smoke emission, container explosion and fire. CHARGE: When charging rechargeable batteries, use exclusively the battery-charger provided with the equipment and recharge in premises with a temperature ranging between 10 C and 40 C. The use of a batterycharger different from the recommended one can lead to batteries overload. FLUID: In case the batteries fluid comes in contact with your eyes, do not rub them. Rinse with tap water and then see a doctor immediately. In case the fluid is not completely removed, this can seriously damage the eyes. REPLACEMENT: In case of batteries replacement, use batteries of the same type and shape of the replaced ones. Otherwise, this might damage the equipment and lead to the risk of heat emission, smoke emission, container explosion and fire. ENGLISH 33 / 75 CAP. 7 - INSTALLATION
7.3 DURING USE EQUIPMENT USE: The use of the equipment is clearly described in this manual: anything differing from what is explicitly stated is to be considered as IMPROPER USE. The manufacturer disclaims all responsibility for damage to objects, persons or to the machine itself resulting from accidents caused by non compliance with the equipment instructions. WORK STATION: The operator shall stand in front of the machine, in a comfortable position to reach the equipment controls and parts. 7.4 WHEN THE TOOL IS NOT USED SUPPLY VOLTAGE: Disable all the supply switches and power off when the equipment is not used for a long period of time. PROTECTION: If the equipment is not used for a long period of time, it is advisable cover it with a protective sheet. CAP. 7 - INSTALLATION 34 / 75 ENGLISH
7.5 CLEANING DISMANTLING AND DISPOSAL CLEANING: the power supply unit cleaning can be performed even by unskilled personnel provided they have been previously informed about the main controls to cut the power supply unit from the mains. When the outer surfaces need to be cleaned, avoid using detergents containing alcohol, ammonia or gasoline; only use neutral detergents with slightly moistened soft cloths. DISMANTLING AND DISPOSAL: The product was designed and assembled with high quality materials and components that may be recycled and reused. If one product displays a symbol showing a bin with wheels barred by an X, this means that the product meets the requirements of the Community Directive 2002/96/CE. For the disposal no particular devices are needed since the power supply unit is not made with noxious materials. The disposal shall have to be carried out by complying with the local regulations for the disposal of waste: do not throw the product into the ordinary domestic waste but bring it to the special collection centres present over the territory according to what is provided for by the current regulations in force. An adequate disposal of the products helps preventing environmental pollution as well as possible damage to health. At the end of the equipment working life the following operations shall be carried out: Ask the service department to recover the whole gas in the unit circuit, by making sure that the gas storage internal tank is completely emptied. COOLANT AND LUBRICANTS: The coolants recovered from the systems that cannot be used again must be delivered to the gas suppliers for their necessary disposal. The lubricants taken from the systems must be delivered to the exhausted oil collecting centres ENGLISH 35 / 75 CAP. 7 - INSTALLATION
CAP. 8 - COMMISSIONING 8.1 Connections The unit has to be taken near the car A/C system and positioned on a horizontal surface to ensure the correct operation. CLIMA-8500 EVO is delivered by BrainBee with a Factory software and shall hence be programmed by the reseller. The unit has to be connected to the electric mains following instructions on the identification plate of the unit applied next to the main switch, mainly as to applicable voltage and power. Connections to the A/C system Power mains connection CAUTION: Leave the quick coupler valves closed when the station is not working and at the end of the operations. CAP. 8 - COMMISSIONING 36 / 75 ENGLISH
8.2 Recharge of the internal vessel IT IS PROHIBITED TO CARRY OUT INTERVENTIONS OTHER THAN THOSE INDICATED IN THIS CHAPTER. CLIMA-8500 EVO comes with the storage vessel empty and fixed by a locking screw protecting the scale against shocks during transport. Slacken the screw of few mm and leave it into its housing; the screw has to be screwed (manually, without using any tool) in case of transport. Never transport the station with full vessel. 1 ENGLISH 37 / 75 CAP. 8 - COMMISSIONING
8.3 Oil Charge Cells Zero Check Before starting the operations, check that the oil weight values correspond to those in the following table: New oil empty bottle weight Exhausted oil empty bottle weight 0 ± 10 g 0 ± 10 g The oil scales zero check is simply performed by entering the SETUP menu and selecting NEW OIL SCALE ZERO or EXHAUSTED OIL SCALE ZERO. Read the values on the scales with no oil on them and zero set the reading; this zero setting does in no way alter the scales adjustment, but can be useful to eliminate any possible negative deviations. IN CASE THE VALUES DEVIATE FROM THOSE SHOWN IN THE TABLE APPLY TO THE AFTER- SALES SERVICE DEPARTMENT FOR CHARGE CELLS RE-ADJUSTMENT CAP. 8 - COMMISSIONING 38 / 75 ENGLISH
8.4 New oil bottle filling The new oil bottle is on the left looking at the unit from the front side. To fill it, it has to be extracted from its housing by means of the quick coupler on the top of the bottle; slightly press downward the coupler ring nut to extract it. Fill the bottle by paying special attention to the oil care valve. This valve is made of a silicon polymer membrane; it compensates pressure variations within the bottle and stops humid air infeed inside thus preserving the new oil inside. At the end of the filling, close the bottle and take it back to its housing. ENGLISH 39 / 75 CAP. 8 - COMMISSIONING
8.5 Tracer bottle filling The tracer is made of a fluorescent yellow-green pigment: if lighted by a UV lamp it becomes fluorescent and hence visible. It is used to detect small leaks inside the car A/C system. The tracer bottle is on the right looking at the unit from the front side. To fill it, it has to be extracted from its housing by means of the quick coupler on the top of the bottle; slightly press downward the coupler ring nut to extract it. Fill the bottle by paying special attention to the oil care valve. This valve is made of a silicon polymer membrane; it compensates pressure variations within the bottle and stops humid air infeed inside thus preserving the new oil inside. At the end of the filling, close the bottle and take it back to its housing. CAP. 8 - COMMISSIONING 40 / 75 ENGLISH
CAP. 9 - MENU STRUCTURE I AUTOMATIC CYCLES MANUAL CYCLES SETUP MAINTENANCE Data bank Recovery Hybrid Function Leak Test Last Cycle Vacuum New Oil Oil density Weight Zero Pump Pump Oil Oil Replacement User Defined Oil Injection Tracer Injection Gas Injection R134a recharge mode Recovery Oil Weight Zero Pressure test at the end of recharge Oil Density Filter Replacement Vessel heating Counters Vessel heating Flushing Recharge Mode Vessel Filling Pressure Check Recovery Gas Enable Air Purge Multipass Hoses Empting Vessel Heating Multipass Enable Pressure Check Enable Display Contrast Hoses Lenght Unit of Measure Clock Adjustment Garage Data Language Right\Left Hand Driver Startup Screen Default Setup ENGLISH 41 / 75 CAP. 9 - MENU STRUCTURE
Keys are used for horizontal navigation between menus. Within each menu, keys are used for navigation in submenus. Upon switch on the UNIT enters the main menu of AUTOMATIC CYCLES. CAP. 9 - MENU STRUCTURE 42 / 75 ENGLISH
CAP. 10 - SETUP Entering the SETUP menu it will be possible to set different parameters and enable various options before starting the cycles: HYBRID FUNCTION selecting this entry you can change the type of Oil to be injected within the A/C system NEW OIL WEIGHT ZERO to cancel any negative deviation. RECOV.OIL WEIGHT ZERO to cancel any negative deviation. OIL DENSITY to choose between grams or volume (g/ml) as unit of measurement. RECHARGE METHOD ENGLISH 43 / 75 CAP. 10 - SETUP
to choose between Quick Mode or Zero Tolerance as recharge mode RECOVERED GAS ENABLING selecting this entry, you can choose whether you want to enable displaying and printing of the recovered gas quantity. VESSEL HEATING BELT to enable or disable the use of the heating belt during the vacuum phase. MULTIPASS ENABLE to enable or disable this function allowing for an additional recycling inside the station which starts automatically when the station is On but not in use. This function ensures a higher level of purity of the recycled refrigerant to the advantage of the service quality. PRESSURE CHECK to enable or disable the pressure check. HOSES LENGTH selecting this entry you can modify the charge hoses length. UNIT OF MEASUREMENT selecting this entry, you can modify the pressure unit of measurement (switching from Bar to Pascal) CLOCK ADJUSTMENT to modify date and time. GARAGE DATA to enter the garage data to be printed on the end of cycle report. LANGUAGE selecting this entry you can choose a language among those included in the database. In case you choose a language with unintelligible characters, hold down the button in the starting screen-page and you will directly return to the language setting menu. RIGHT-HAND / LEFT-HAND DRIVE selecting this entry, you can set the drive side of the vehicle to be recharged within the databank. STARTUP SCREEN selecting this entry, you can decide whether the startup screen of the unit will be the databank page or the main menu page. DEFAULT SETTINGS selecting this entry, you can restore the unit default settings. CAP. 10 - SETUP 44 / 75 ENGLISH
CAP. 11 - A/C SYSTEM RECHARGE 11.1 Preliminary operations The recovery and recharge operations have be carried out after the car /AC system has run for some time; however, an excessively hot A/C system has to be avoided since the next recharge phase could be adversely affected by high pressures. The recharge station has to be ON. No special pre-arrangement is required: connecting hoses have to be attached by identifying their position. Then connect HP and LP quick couplers (or the single coupler, depending on the type of system). After quick couplers connection the knob has to be screwed. Details necessary for the performance of the charge/recovery/vacuum cycle are the amount of refrigerant and of oil. These data are often found on the engine compartment plate or on the technical manuals of the garage. As to oil quantity technical manuals of cars, systems as well as available details in general indicate the total quantity of oil in the system. Indeed the amount of oil to be recharged is that extracted during the refrigerant recovery phase which is very small. 11.2 Non condensable Gases Discharge The non condensable gases discharge solenoid valve shall have to be enabled if air is present into the vessel and can be activated from the keypad in the maintenance menu. The air presence into the vessel can be detected only after the machine has been at rest for a certain period (as for instance during the morning). Read the pressure measurement shown on the vessel gauge to check the air presence and check if the vessel pressure value on the LP gauge ( C) scale corresponds to the temperature marked on the scale: if it proves to be significantly higher than ambient temperature, then some air is likely to be inside the vessel. ENGLISH 45 / 75 CAP. 11 - A/C SYSTEM RECHARGE
11.3 Zero Tolerance Mode CLIMA-8500 EVO can apply two different refrigerant recharge modes; the first one is called Quick mode and features the opening of the recharge valve by injecting gas through the HP port. By the Quick Mode part of the refrigerant remains into the hoses and is compensated by software calculation. Whenever the recharge is not completed the UNIT shifts automatically to the Zero Tolerance mode. The Zero Tolerance function is the second recharge procedure, an alternative to the Quick Mode. It features a more accurate recharge and guarantees a successful recharge (it however requires a longer time and the operator s intervention). If the car A/C system is equipped with both couplers or with LP coupler only, there are two slightly different working modes; in any case if only the HP coupler is available the Zero Tolerance mode is not applicable. With both HP and LP couplers available the Zero Tolerance features the injection of the selected refrigerant amount into the system through the HP hose; then refrigerant remained into the HP hose is sucked by the car system engine and compressor running through LP (after disconnecting and closing the HP coupler). In case the LP coupler only is available the station charges the system with 50% of the selected amount with car compressor off and waits for 10 minutes before recalling the operator. This wait time quite rare since most of cars are equipped with HP coupler too allows the refrigerant injected near the compressor that is LP side to evaporate to prevent any damage to the compressor during the admission of liquid phase refrigerant. Then, after car and A/C system switch ON recharge continues through timed injection of refrigerant through hose LP, such injections start exclusively if the LP pressure is lower than 3 bar. CAP. 11 - A/C SYSTEM RECHARGE 46 / 75 ENGLISH
CAP. 12 - AUTOMATIC CYCLES 12.1 Preliminary operations Connect the LP HP couplers or the single coupler to the car system. Open couplers (or the single coupler) rotating knobs clockwise. LP HP pressure gauges (or the single pressure gauge) indicate pressure inside the system. 12.2 Database Brain Bee offers customers purchasing a CLIMA-8500 EVO the possibility of enhancing potentials of the UNIT through the database. This database stores data on the A/C system of most cars; it hence allows acceleration of system recharge operations by exploiting data supplied by the database. Upon tool switch On the menu of the database storing vehicles divided by maker, model, and type of A/C system is displayed. The selected car flashed, press to change selection and to confirm selection. Press to go back to the previous field. After selecting the type of A/C system the main page is shown with the following preset values: Amount of refrigerant to be charged into the system PAG oil amount to be injected into the system Option for the injection of tracer The reserve of refrigerant in the internal vessel of the UNIT is also displayed. ENGLISH 47 / 75 CAP. 12 - AUTOMATIC CYCLES
The value of each selected field (flashing) can be either increased or decreased pressing. Through entered. the selected value is confirmed and the next field is By pressing the previous field is entered. At the end of the setup the message START starts flashing: press to start the automatic cycle. NOTE: to quit the database and enter directly the main menu hold down for more than 1 s key. To enter the database again from the recharge main menu hold down for more than 1 s key. CAP. 12 - AUTOMATIC CYCLES 48 / 75 ENGLISH
12.3 Last recharge cycle The AUTOMATIC CYCLES main page with values preset like in the previous recharge cycle can be accessed directly: from the database menu hold down for more than 1s key. The value of each selected field (flashing) can be either increased or decreased pressing. Through entered. the selected value is confirmed and the next field is By pressing the previous field is entered. At the end of the setup the message START starts flashing: press to start the automatic cycle. ENGLISH 49 / 75 CAP. 12 - AUTOMATIC CYCLES
12.4 Previously saved recharge cycle The AUTOMATIC CYCLES main page with values preset like in the previously saved recharges can be accessed directly (up to 10 automatic cycles can be accessed): from the database menu hold down for more than 1s key to go to the main menu of automatic cycles. From the main menu press to select the AUTOMATIC CYCLE. Press to confirm. Through keys select the previously saved cycle and confirm by : the main menu page with the preset values of the previously saved recharge is displayed: The value of each selected field (flashing) can be either increased or decreased pressing. Through entered. the selected value is confirmed and the next field is By pressing the previous field is entered. At the end of the setup press to start the automatic cycle. CAP. 12 - AUTOMATIC CYCLES 50 / 75 ENGLISH
CAP. 13 - MANUAL CYCLES 13.1 Preliminary operations Connect the LP HP couplers or the single coupler to the car system. Open couplers (or the single coupler) rotating knobs clockwise. LP HP pressure gauges (or the single pressure gauge) indicate pressure inside the system. Open LP and HP valves on the control board or the single valve according to the selected A/C system From the main menu use keys CYCLES. until selection of MANUAL Through keys select the desired phase and press 13.2 Recovery Phase In the MANUAL CYCLES menu, position on RECOVERY through the keys,then push to start the phase. In case of problems or errors during this phase, a message will be displayed, identifying the type of error. It is possible to interrupt the phase in progress at any time, by pushing. At the end of the process the display will show the quantity of recovered oil, together with a message stating that the phase is over. ENGLISH 51 / 75 CAP. 13 - MANUAL CYCLES
13.3 System vacuum phase In the MANUAL CYCLES menu, position on VACUUM through the keys,then push to start the phase. By means of the keys, you can set the vacuum time and the test time, then push. In case of problems or errors during this phase a message identifying the type of problem is displayed. At any moment, by pressing, the current phase can be interrupted. At the end of the vacuum phase the display shows the vacuum level reached. CAP. 13 - MANUAL CYCLES 52 / 75 ENGLISH
13.4 Oil Injection Phase Connect the HP LP couplers (or the single coupler) to the vehicle system. Open the coupler/s by turning the knobs clockwise. The LP HP gauges (or the single gauge) must not indicate the presence of pressure into the system. On the contrary, execute a recovery/recycle function. THIS PHASE MUST ONLY BE EXECUTED ON A/C SYSTEMS UNDER NEGATIVE PRESSURE (THAT IS AFTER PULLING A VACUUM IN THE SYSTEM). In the MANUAL CYCLES menu, position on OIL INJECTION through the keys, then push to start the phase. Push to set the quantity of PAG oil that you need to inject and push to confirm. Select the type of A/C system on to which the new oil injection is to be performed by pushing. Push to confirm the entered values and start the phase. In case of problems or errors during this phase, a message will be displayed, identifying the type of error. It is possible to interrupt the phase in progress at any time, by pushing. ENGLISH 53 / 75 CAP. 13 - MANUAL CYCLES
13.5 Tracer injection phase The LP HP pressure gauges (or the single pressure gauge) must not indicate pressure inside the system. Otherwise carry out a recovery/recycling function. THIS PHASE HAS TO BE CARRIED OUT EXCLUSIVELY ON A/C SYSTEM UNDER VACUUM (AFTER A SYSTEM VACUUM HAS BEEN PULLED). In the MANUAL CYCLES menu, position on TRACER INJECTION through the keys, then push to start the phase. Select the type of A/C system on to which tracer injection is to be performed by pushing. Push to confirm the entered values and start the phase. In case of problems or errors during this phase a message identifying the type of problem is displayed. At any moment, by pressing, the current phase can be interrupted. 13.6 Refrigerant injection phase In the MANUAL CYCLES menu, position on REFRIGERANT INJECTION through the keys, then push to start the phase. Push to set the quantity of refrigerant that you need to inject and push to confirm. CAP. 13 - MANUAL CYCLES 54 / 75 ENGLISH
Select the type of A/C system on to which the refrigerant injection is to be performed by pushing. Push to confirm the entered values and start the phase. In case of problem during the recovery phase the last line of the display shows a specific message. Press to interrupt at any moment the recovery phase. In case injection of refrigerant is not completed after the preset recharge time has elapsed detach the high pressure (HP) coupler and start the car A/C system. ENGLISH 55 / 75 CAP. 13 - MANUAL CYCLES
13.7 Flushing Phase It is advisable to perform the system washing phase (Flushing) after a certain number of recharging cycles or after replacing any components or parts of the A/C system of a vehicle. The system washing (Flushing) consists in purifying the vehicle cooling system through several R134a gas flushes, by recovering it each time, so that the impurities can be filtered little by little through the additional dryer filter. Thanks to its specific design, CLIMA-8500 EVO can automatically manage the flushing process so that the process becomes fully automatic. In order to carry out the washing, the operator has to separately buy a specific kit; this kit is a necessary tool because in every A/C system there are parts that shall not have to undergo the washing, such as the flow-restriction valve and the internal compressor, that could otherwise be damaged by it. Once that you have installed the flushing kit, in the MANUAL CYCLES menu position on FLUSHING through the keys then push to start the phase. You can set the flushing time by pushing. Push to confirm the entered values and start the phase. In case of problems or errors during this phase, a message will be displayed, identifying the type of error. It is possible to interrupt the phase in progress at any time, by pushing. CAP. 13 - MANUAL CYCLES 56 / 75 ENGLISH
13.8 Pressure Check In order to check the conditions of the A/C system of the vehicle, for instance in case no cool air comes out from the ventilating flaps, you can perform the pressure check. Connect the HP LP couplers (or the single coupler) to the vehicle system. Perform the following preliminary operations on the vehicle: Turn on the A/C system Set temperature at minimum level. Set fan speed at maximum level; close all the flaps except the central one and set air distribution to central position. Keep engine at accelerated idle at constant speed for at least 2 minutes. Check the pressure values within about 3-5 minutes. In the MANUAL CYCLES menu push to select PRESSURE CHECK, then push to confirm. Open the coupler/s by turning the knobs clockwise. After the refrigerant injection, a check of the pressure on HP and LP sides will be requested; make sure that both values on LP and HP gauges fall within the values shown on the display. PRESSURE VALUES CHANGE CONSIDERABLY WHEN AMBIENT TEMPERATURE CHANGES. SO BEAR THIS IN MIND WHEN PERFORMING THE PRESSURE CHECK. In case of problems or errors during this phase, a message will be displayed, identifying the type of error. It is possible to interrupt the phase in progress at any time, by pushing. ENGLISH 57 / 75 CAP. 13 - MANUAL CYCLES
13.9 Hoses Emptying To empty the charge hoses completely perform the HOSES EMPTYING phase. In the MANUAL CYCLES menu push to select HOSES EMPTYING (we refer to the external Blue and Red charge hoses), then push to confirm. In case of problems or errors during this phase, a message will be displayed, identifying the type of error. It is possible to interrupt the phase in progress at any time, by pushing. CAP. 13 - MANUAL CYCLES 58 / 75 ENGLISH
CAP. 14 - STORAGE IN CASE OF LONG STOPS The unit has to be stored in a safe place, protected against excessive temperatures, humidity and risk of impacts with other objects which might damage it. ENGLISH STOPS 59 / 75CAP. 14 - STORAGE IN CASE OF LONG
CAP. 15 - MAINTENANCE CLIMA-8500 EVO is a remarkably reliable unit, manufactured using the highest quality components, making use of the most advanced production techniques. Please contact an authorized technical service centre for all maintenance interventions and to purchase spare parts. The equipment includes parts subject to the PED Directive. The PED Pressure Equipment Directive 97/23/EC defines and regulates all those parts that are subject to pressure, with a specific ratio between their pressure and volume. Therefore, such parts cannot be disassembled or handled. Under the responsibility of the owner, the equipment and parts subject to the PED Directive shall be checked upon commissioning and at periodic intervals, in line with the provisions of national laws on this subject. The parts subject to the PED Directive are: VESSEL 20l Category II (Dir. 97/23/EC) CAP. 15 - MAINTENANCE 60 / 75 ENGLISH
SAFETY VALVE D7/C 20bar R 1/4 GAS Category IV (Dir. 97/23/EC) SUCTION UNIT Art. 3.3 (Dir. 97/23/EC) PRESSURE SWITCH ACB-2UB506W 13/18bar 1/4SAE Category IV (Dir. 97/23/EC) ENGLISH 61 / 75 CAP. 15 - MAINTENANCE
BEFORE CARRYING OUT ANY MAINTENANCE OPERATION, MAKE SURE THE EQUIPMENT HAS BEEN DISCONNECTED FROM THE MAINS. ANY INTERVENTION ON PARTS OF THE UNIT NOT EXPRESSLY OUTLINED IN THIS CHAPTER IS FORBIDDEN. 15.1 Leak test From the MAINTENANCE main service through keys select the LEAK TEST menu and press couplers. after connecting the quick In case of problems or errors during this phase, a message will be displayed, identifying the type of error. It is possible to interrupt the phase in progress at any time, by pushing. CAP. 15 - MAINTENANCE 62 / 75 ENGLISH
15.2 Replacement of vacuum pump oil The vacuum pump oil shall be replaced every 60 hours of operation. When vacuum pump oil needs to be replaced, the message will be shown on the display. Required equipment: n 1 Medium-sized cross-tip screwdriver n 1 Medium-sized flathead screwdriver n 1 Allen wrench (10 mm) For replacement, comply with the instructions outlined below: 1 Disconnect the unit from the mains. 2 remove the screws (6) fixing the front door of the unit and remove it. 3 Place a bowl underneath the machine, right under the pump oil drain hole. Open the upper plug and then the lower plug to drain the exhausted oil contained within the vacuum pump. UPPER PLUG SIGHT GLASS LOWER PLUG ENGLISH 63 / 75 CAP. 15 - MAINTENANCE
4 Once the pump has been emptied, screw the lower plug again. 5 Fill the pump with new oil through the upper opening, using a funnel if needed. Bring new oil level halfway through the sight glass. 6 Once the pump has been filled, close the upper plug. Once oil has been replaced, switch on the unit and from the MAINTENANCE menu select PUMP OIL REPLACEMENT: press the RESET key to set the counter to zero. CAP. 15 - MAINTENANCE 64 / 75 ENGLISH
15.3 Dryer filter replacement The dryer filter shall be replaced once 45 kg of refrigerant fluid have been dehydrated, because the filter depletes its capacity of retaining the moisture present in the refrigerant. To replace the dryer filter, from the MAINTENANCE menu select DRYER FILTER REPLACEMENT: press RESET to set the counter to zero and to start the filter replacement procedure. Now you can replace the filter. Required equipment: n 1 Medium-sized cross-tip screwdriver n 1 Allen wrench (24 mm) For the replacement operation, comply with the instructions outlined below: 1 Disconnect the unit from the mains. 2 Remove the screws (6) fixing the front part of the unit. 3 Unscrew the 2 connection nuts of the filter by means of the Allen wrenches. 4 cut the two plastic straps wrapping the filter DRYER FILTER NUTS ENGLISH 65 / 75 CAP. 15 - MAINTENANCE
4 Install the new filter paying attention to the position of gaskets and to the direction of the arrow indicating the fluid flowing direction. 5 Screw the two connection nuts of the filter. 15.4 Counters In the COUNTERS menu, at any time, the vacuum pump and compressor hours of life can be displayed; besides, remaining time before replacement of vacuum pump oil and dryer filter can also be displayed. To access the COUNTERS menu, from the main menu enter the MAINTENANCE menu and press COUNTERS. Within the COUNTERS menu, you will find the following data: CAP. 15 - MAINTENANCE 66 / 75 ENGLISH
15.5 Storage Vessel Filling CAREFULLY COMPLY WITH THE FOLLOWING INSTRUCTIONS TO AVOID REFRIGERANT DISCHARGE INTO THE ATMOSPHERE After following the above described procedure, connect the HP quick coupler (red) of the unit to an external tank by using the adapter supplied with it. Open the coupler by turning the knob clockwise. Open the valve on the external tank. There are two types of source tanks: with plunger and without plunger. Tanks with plunger must stay upright to transfer the liquid refrigerant; for this type of tanks, connect with coupler L (liquid). Tanks without plunger have only one valve, so they must be turned upside down to transfer the liquid refrigerant. The HP gauge shows the pressure level into the external tank. Push to select the submenu VESSEL FILLING, then push to enter it. In the following screen page set the quantity of refrigerant you wish to charge. The field RESIDUAL shows the quantity of refrigerant being currently present in the vessel. Position the cursor into the field TO CHARGE that will suggest, by default, the maximum quantity of refrigerant to charge. ENGLISH 67 / 75 CAP. 15 - MAINTENANCE
Push to set the quantity of refrigerant you need to charge. Push to start the charging phase. Note that upon the signal of set limit weight reached, after the closing of the external tank valve, the unit still absorbs a little quantity of refrigerant. In case of problems during the internal vessel filling phase, a specific message will appear on the last line of the display. It is possible to interrupt the phase in progress at any time, by pushing. After some minutes the unit will automatically end the function. At the end the weight of the charged refrigerant will be displayed. CAP. 15 - MAINTENANCE 68 / 75 ENGLISH
15.6 Printer Maintenance To change the roll of paper follow instructions below: Open the printer lid as indicated in the picture Position the roll of paper inside the housing in the rotation direction indicated in the picture; ENGLISH 69 / 75 CAP. 15 - MAINTENANCE
Pull the paper out of the housing as indicated in the picture and close the lid ; The printer is ready for printing. CAP. 15 - MAINTENANCE 70 / 75 ENGLISH
15.7 Periodical checks The A/C service stations shall undergo periodical checks, as provided for by relevant national laws. Checks will be performed by competent authorities, in compliance with their procedures. Here below, some possible checks on components subject to the PED directive are outlined. According to national laws, checks might be extended to other components in order to verify the metrological characteristics of the integrated equipment or the presence of devices or accessories that are essential to its use. VESSEL 20l Category II (Dir. 97/23/EC) To check the refrigerant vessel date of manufacture, see the vessel plate Make sure no corrosion or leakage is present; under normal conditions of use, the vessel life is at least 20 years. ENGLISH 71 / 75 CAP. 15 - MAINTENANCE
SAFETY VALVE D7/C 20bar R 1/4 GAS Category IV (Dir. 97/23/EC) In case of intervention of the automatic safety valve, it is advisable to contact the technical service that will replace the valve. SUCTION UNIT Art. 3.3 (Dir. 97/23/EC) Make sure no corrosion and leakages are present. CAP. 15 - MAINTENANCE 72 / 75 ENGLISH
PRESSURE SWITCH ACB-2UB506W 13/18bar 1/4SAE Category IV (Dir. 97/23/EC) Check presence of the device with references indicated above, wholeness of connection cables and connector, and the correct connection to the equipment printed circuit board. HOSES Periodically check external charge hoses, red (HP) and blue (LP), to verify their perfect conditions and the lack of damages which could compromise their correct operation. OTHER CHECKS Make sure lubricants and filters have been replaced in line with the intervals required to ensure correct operation of the equipment. ENGLISH 73 / 75 CAP. 15 - MAINTENANCE