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Section 3 

- Repair Procedures Component Service and Repair 

Instructions 
 
 

1. PC Board/ LCD Replacement 
 
2. Scale Replacement 
 
3. Compressor Replacement 
 
4. Solenoid Replacement 
 
5. Pressure Transducer Replacement 
 
6. Gauge Replacement 
 
7. DC Power Supplies Replacement 
 
8. High Pressure Switch Replacement 
 
9. Fan Replacement 
 
10. Refrigerant Identifier Replacement / Maintenance 
 
11. HI and LO Manifold Block Replacement 
 
12. LO or HI Manifold PCB Replacement 
 
13. Relay PCB Replacement 
 
14. Pressure Transducer PCB Replacement 
 
15. Printer Replacement 
 
16. Wheel Service and Replacement 
 
17. Vacuum Pump Replacement 
 

Summary of Contents for FX1234

Page 1: ...1 FX Series Service Manual Models FX134 FX1234 FX3030 CPS AUTOMOTIVE RECOVER RECYCLE RECHARGE ...

Page 2: ...Avoid breathing refrigerant vapors and lubricant vapor or mist Breathing high concentration levels may cause heart arrhythmia loss of consciousness or even cause suffocation and death Caution all hoses may contain liquid refrigerant under pressure Contact with refrigerant may cause frostbite or other related injuries Wear proper personal protective equipment such as safety goggles and gloves When ...

Page 3: ... FX3030 series uses the integrated scale for tanks overfill protection The information on Maximum Refrigerant and Empty Tank weights must be accurately inputted or the overfill protection will not function correctly See Warnings and Dangers of overfilling a tank CPS Models Voltage Hz FX134 FX1234 FX3030 115 50 60 FX134E FX1234E FX3030E 220 240 50 60 FX134J FX1234J FX3030J 100 50 60 CPS Tank Max Re...

Page 4: ...problems and how to resolve them Section 3 contains instructions on how to repair various components used in the FX134 FX1234 FX3030Series Section 4 contains additional Electrical and Plumbing Schematics of the FX134 FX1234 FX3030Series This section also contains the FX134 FX1234 FX3030Series parts list SUMMARY OF OPERATION The following information will help illustrate the flow path of the FX134 ...

Page 5: ...or The REGULATOR reduces the pressure down to 80 psig where it flows into a DOA Chamber where oil is separated from refrigerant if liquid is present the liquid refrigerant is boiled off by the heat exchanger in DOA Chamber After leaving the DOA Chamber the vapor refrigerant enters the COMPRESSOR suction where it is compressed to a high pressure gas This completes the first step in the recycling pr...

Page 6: ...shuts off The air purge valve HS1 will open to pressurize DOA Chamber then HS1 will close The compressor will come on to lower pressure in DOA for oil draining Once pressure level is achieved then HV3 opens allowing excess oil to drain from DOA Chamber for 30 seconds ...

Page 7: ...the LO and HI Manifold The gasses will then pass through their respective open LO and HI valves LV1 and LV2 The combined HI and LO gasses then flows through the open EVACUATION valve LV3 and then into the VACUUM PUMP The VACUUM PUMP exhausts the evacuated gasses to the atmosphere IMPORTANT if either the LO or HI manifold gauges read more than 5 psig the unit will not start the evacuation mode but ...

Page 8: ...rough the FILTER DRIER F2 the liquid refrigerant will then pass through the open CHARGING SOLENOID VALVE LS1 The liquid refrigerant will then pass through the open Low Manifold valve LV2 and onward through the Low service hose After the required amount of refrigerant is charged the control PCB de energizes charging solenoid valve LS1 The LCD display charge complete and ask if you want to go to Car...

Page 9: ...should be in a deep vacuum before proceeding After using the keypad to program the desired charge the liquid refrigerant from the storage tank will pass through the FILTER DRIER F2 This completes the third and final procedure of the recycling process Once through the FILTER DRIER F2 the liquid refrigerant will then pass through the open CHARGING SOLENOID VALVE LS1 The liquid refrigerant will then ...

Page 10: ...system should be in a deep vacuum before proceeding After using the keypad to program the desired charge the liquid refrigerant from the storage tank will pass through the FILTER DRIER F2 This completes the third and final procedure of the recycling process Once through the FILTER DRIER F2 the liquid refrigerant will then pass through the open CHARGING SOLENOID VALVE LS1 The liquid refrigerant wil...

Page 11: ...will flow through the open HI Side service hose and pass through the open Hi Side valve LV1 then through the open RECOVER valve LV4 and then into a Constant Pressure Regulator The REGULATOR reduces the pressure down to 80 psig where it flows into a DOA Chamber where liquid refrigerant is boiled off by heat exchanger in DOA chamber and oil separated from refrigerant After leaving the DOA Chamber th...

Page 12: ...he storage tank have had enough time to stabilize Once it is determine Air Purge can take place the unit will open the charging solenoid valve LS1 to the Pressure transducer PT The PT compares this pressure to the actual saturated pressures stored in the PCB microprocessor If Air Purge is required the Air Purge solenoid pressure ...

Page 13: ...s according to J2743 Refrigerant sample will pass through SC2 low side service hose The refrigerant sample will then pass through low side manifold valve LV2 and LS2 solenoid valve allow sample into identifier Once refrigerant has been sampled and passes The recovery unit will operate as instructed below ...

Page 14: ...14 FX3030 PUMP DOWN ...

Page 15: ...15 Hose Flush High Voltage Compressor ...

Page 16: ...pen and allow low side running pressure to be seen at the PT 1 pressure transducer The hi side pressure will be seen at PT 2 pressure transducer which is common to hi side service hose The screen will then display digital manifold and operating pressures on hi and low side of A C system ...

Page 17: ...imply inserted to the SD reader on the back of control panel and turn on unit The unit will beep three times at the start of installation and then single beeps as it loads program The unit will beep three times at the end if down load No password is needed Do not remove SD card unit main screen Do Not Connect to Car comes up c The USB is used from the update date screen On the home screen push the...

Page 18: ... indicated in picture and remove front panel Note Check for screws on side cover over lapping top panel outer edge at very top on control panel Remove screws if unit has them c Removing the front access panel gives access to the lower section of the unit where the DOA Fan Condenser Evaporator Regulator Compressor Vacuum Pump Power Supply PCB s Pressure Transducer PCB and Relay PCB are contained ...

Page 19: ...ews on both sides as shown below c Then remove screws from side covers over lapping top panel edge if unit came with screws d Then gently pull side cover back to clear top panel edge when lifting top panel straight up The top panel is engaged by to plastic placement pins on back side of control panel Remove plastic engagement screws from both sides ...

Page 20: ...on and allow main screen to come up Select the gears icon at the bottom of screen Then select the wrenches icon on next screen Then select the scale icon on next screen Then select the scale icon with plus sigh on scale on next screen Enter password ABBA1216 to allow full calibration Follow instruction on screen to complete calibration Replace tank and tank strap around tank Don t forget to plug h...

Page 21: ... following is how to adjust the tank settings on the FX134A FX1234 FX3030 Series PCB a Turn unit on and proceed to main menu and select the gears icon on bottom of screen b On next screen select the gears icon on the left side of screen c Then select tank icon on next screen Then select red circle icon on next screen and enter password ABBA1216 d The first screen you will enter tank weight This is...

Page 22: ...een select the wrenches icon on the right side of screen c Then select scale icon on screen d Then select scale icon with check mark above it e Then place 1 lb weight that is supplied with FX unit on top of tank Leave tank on scale f Select green check mark if 1 lb is displayed and continue back to main menu g Select red circle if 1lb is not displayed and select Tare icon on screen and follow inst...

Page 23: ...se the service couplers or ball valve on the end of the service hoses are removed or open to atmosphere Then remove the Plastic Plug on the gauge lens And finally use a small flat tip screwdriver to turn the pressure gauge adjustment screw located on the face of the gauge until the gauge pointer reads 0 psig Mpa kPa bar Repeat this adjustment for both gauges Once done re install the Plastic Plugs ...

Page 24: ...art when the compressor relay light on the Relay PCB is energized F Vacuum Pump will not start when the Evacuation relay light on the Relay PCB is energized G Unit will not Charge no pressure on Manifold gauges H Unit will not Charge pressure on Manifold gauges I Charging is very slow J Charging Inaccuracies Over and Under Charging K High Pressure Limit Cutout L Tank Full Limit M Vacuum Pump start...

Page 25: ...supply If no inlet power check wire connections If inlet power is measured then check the output voltage 12VDC of AC DC power supply If no outlet power replace AC DC power supply B Circuit breaker trips when plugging the unit into power source Possible Cause Short circuit exists Solution Take an OHM meter and check L1 and L2 of the IEC inlet to the IEC ground If continuity exists trace back to whe...

Page 26: ...d Solution Check the compressor power leads to see if voltage exists Unit should be turn on If the unit goes into auto air purge after the air purge the compressor is to run Check the Relay PCB for the compressor relay to be energized If voltage is present the problem can be narrowed down to the overload compressor motor windings compressor start relay and capacitor If voltage does not exist on th...

Page 27: ... closed Solution Make sure the service coupler valve is open Possible Cause The service couplers are not depressing the ac system s service valve core Solution Make sure the Coupler core depressor is functioning correctly Possible Cause The Liquid and Vapor hoses are switched on the storage tank would charge but become static Solution Correct the hose configuration I Charging is very slow Possible...

Page 28: ...essure Limit Cutout LCD message HIGH PRESS LIMIT Possible Cause Tank Vapor valve and or the Vapor Hose valve are closed causing the High Pressure to build up on the compressor discharge Once the pressure goes above 450 PSIG the HP switch will activate Solution Open Tank Vapor and Vapor Hose valve to relieve the high pressure restriction Re start unit Possible Cause High amounts of non condensable ...

Page 29: ...se Service Hose or Service Couplers have developed a leak Solution Replace the defective part N Compressor is running continuously when the compressor relay light on the Relay PCB is energized Possible Cause PT is out of calibration Solution Recalibration the PT by turning unit off and then back on Possible Cause Oil Injection Valve is not closed Solution Make sure Oil Injection Valve is closed An...

Page 30: ... Replacement 6 Gauge Replacement 7 DC Power Supplies Replacement 8 High Pressure Switch Replacement 9 Fan Replacement 10 Refrigerant Identifier Replacement Maintenance 11 HI and LO Manifold Block Replacement 12 LO or HI Manifold PCB Replacement 13 Relay PCB Replacement 14 Pressure Transducer PCB Replacement 15 Printer Replacement 16 Wheel Service and Replacement 17 Vacuum Pump Replacement ...

Page 31: ...4A FX1234 FX3030 Keep the PC Board free from static electricity Static electricity can damage the microprocessor a Service Access See Section 1 parts 2 3 b Remove all wire connection from Main PCB c Remove four screws on PCB LCD mounting bracket d Remove four outside screws on PCB to separate LCD and Main PCB Remove four mounting screws two on each each side Remove all four screws located in corne...

Page 32: ...nd disconnect tank hoses from purge block Then remove tank from scale platform and place to the side l Remove two platform screws and set platform to the side Be sure to gather up spacer for reinstallation of platform m Remove black scale patch cord and the four screws on scale base to remove scale assembly Unplug heater blanket Remove thumb screw both sides Remove tank strap Remove both platform ...

Page 33: ...ear proper personal protective equipment such as safety goggles and gloves When disconnecting any hose please use extreme caution Danger Always assume that high pressure refrigerant exists in the Compressor Failure to do so may result in bodily injury a Service Access See Section 1 part 2 b Disconnect power connector on compressor c Remove suction and discharge compressor hoses d Remove the four m...

Page 34: ...0 Series a Service Access See Section 1 part 2 3 b Check resistance by unplugging coil from lo side block PCB and ohm coil out Reading on coil should be between 18 to 22 Ohms c Locate proper solenoid valve and remove 9 16 nut from top of coil d Remove coil and washer from plunger stem e Remove Plunger stem with screw driver Charge solenoid on left Air purge solenoid on right Remove 9 16 coil nut L...

Page 35: ...Manifold block PCB if servicing PT2 see section 3 12 for instruction e Remove brass packing nut If silicone is present then you will have to turn nut and wire harness together to remove sensor assembly f Remove nut and spring washer from defected assembly for reinstall on new pressure transducer g Check for o ring damage on center post of manifold block where pressure transducer is seated oil the ...

Page 36: ...t mist Exposure may irritate eyes nose throat and skin Please read the manufacturers Material Safety Data Sheet for further safety information on refrigerants and lubricants Danger Always assume that high pressure refrigerant exists Failure to do so may result in bodily injury Disconnect power supply to the FX134A FX1234 FX3030 Series a Run the RECOVER operation to remove residual refrigerant from...

Page 37: ...ccess See Section 1 part 2 b Locate both power supplies in vacuum pump compartment of unit c Disconnect wires from selected power supply d Using a pair of needle nose pliers Compress the nylon stand off one at a time to release PCB from standoffs 15 watt power supply front one The 65 watt power supply is the back on To remove PCB from stand offs Squeeze stand off from flat side using a pair of nee...

Page 38: ...lease use extreme caution Caution avoid breathing refrigerant vapors and or lubricant mist Exposure may irritate eyes nose throat and skin Please read the manufacturers Material Safety Data Sheet for further safety information on refrigerants and lubricants Danger Always assume that high pressure refrigerant exists Failure to do so may result in bodily injury Disconnect power supply to the FX134A ...

Page 39: ...sconnect power supply to the FX1234 FX3030 series Danger Only a qualified service technician should service this equipment An Electrical Shock hazard is present which could lead to severe injury or even death Danger Avoid breathing refrigerant vapors and lubricant vapor or mist Breathing high concentration levels may cause heart arrhythmia loss of consciousness or even cause suffocation Caution al...

Page 40: ...r PVC and power connector from back of identifier to replace unit e To replace brass orifice pull clear PVC out of the cabinet until brass orifice is present Using wrenches undo each end and replace brass body only f To replace oxygen sensor Remove plastic plug on back of identifier Then pull out the wire harness and unplug connector and unscrew sensor with screw driver g Replace filter on identif...

Page 41: ... gloves When disconnecting any hose please use extreme caution Caution avoid breathing refrigerant vapors and or lubricant mist Exposure may irritate eyes nose throat and skin Please read the manufacturers Material Safety Data Sheet for further safety information on refrigerants and lubricants Danger Always assume that high pressure refrigerant exists Failure to do so may result in bodily injury a...

Page 42: ...ipment An Electrical Shock hazard is present which could lead to severe injury or even death a Service Access Please see Section 1 part 2 3 b Locate lo or hi manifold block c Disconnect wire connections d Remove four mounting screws behind Mylar cover and remove PCB Remove four mounting screws from PCB Remove four mounting screws from PCB Lo Block PCB Hi Block PCB ...

Page 43: ...which could lead to severe injury or even death a Service Access Please see Section 1 part 2 3 b Locate Relay PCB in vacuum pump compartment c Disconnect wires and remove PCB using needle nose pliers on standoffs Relay PCB location Relay PCB To remove PCB from stand offs Squeeze stand off from flat side using a pair of needle nose pliers to depress little clip and slide PCB corner off of stand off...

Page 44: ... equipment An Electrical Shock hazard is present which could lead to severe injury or even death a Place brake on caster to prevent unit from rolling b Place a block of wood under unit to prop up wheel c Remove screw and washer from end of axel d Slide wheel off and replace with new wheel Remove screw and washer from end of axle Then slide wheel off of axle ...

Page 45: ... even death Disconnect power supply to the FX134A FX1234 FX3030 series a Service Access Please see Section 1 part 2 3 b Locate vacuum pump on bottom shelve c Disconnect power plug and remove vacuum pump hose d Remove mounting nuts and Oil refill cap to remove vacuum pump from shelve Unplug Power connection Remove oil fill cap Remove all four mounting nuts in each corner Remove vacuum hose ...

Page 46: ...erials 1 FX134A FX1234 FX3030 Series Refrigeration Schematic 2 FX134A FX1234 FX3030 Series Electrical Schematic 3 LO Manifold PCB Light Code 4 HI Manifold PCB Light Code 5 Relay PCB Light Code 6 Main PCB Light Code 7 Parts List ...

Page 47: ...47 1 FX134A FX1234 FX3030 Series Refrigeration Schematic ...

Page 48: ...48 2 FX134A FX1234 FX3030 Series Electrical Schematic ...

Page 49: ...closed L2 Low service hose Green LED ball valve L1 Hi service hose Red LED ball valve closed L1 Hi service hose Green LED ball valve open Red LED L4 Motor energized L4 12VDC motor power supply Red LED L3 Motor energized L3 12VDC motor power supply Red LED L2 Motor energized Red LED L1 Motor energized L2 12VDC motor power supply L1 12VDC motor power supply Heater blanket input to relay PCB 12VDC Ch...

Page 50: ...gized when FILTER CHANGE is shown on LCD LV1 LV2 LV3 and LV4 Sensor Lights Red Green Red light will indicate CLOSED position Green light will indicate OPEN position 12VDC power supply connection Green patch cord connection HS1 Air purge solenoid valve 12 VDC Red LED energized HS1solinoid is on is on HV1 ball valve 12VDC Red LED energized HV1 motor is on HV2 ball valve 12VDC Red LED energized HV2 m...

Page 51: ... Air Purge is shown on LCD HV1 HV2 and HV3 Sensor Lights Red and Green Red light will indicate CLOSED position Green light will indicate OPEN position 12VDC power supply connector Red patch cord connector Red LED energized Compressor on Red LED energized Vacuum Pump on Red LED energized Fan on Red LED energized Heater Blanket on Aux Heater Blanket connection Hi Pressure Switch Compressor wire Powe...

Page 52: ...energize when charging Power switch led power Air Flow Switch connector 12VDC IN connector 12VDC out connector 12 VDC IN main wire harness 12VDC OUT main wire harness Printer power Printer communication cable Identifier power communication cables 5 pin 4 pin Blue patch cord connector Green patch cord connector Yellow patch cord connector Red patch cord connector USB connector SD Reader connector 5...

Page 53: ...hich MBV has failed E6 AMB THRM Ambient thermistor in the head is bad E7 TNK THRM Thermistor attached to the oil sep is bad E8 PT TRANS Pressure transducer is bad E9 WEAK BATT Should never appear E10 BAD FILTERTIME Filter code problems E11 DEFAULTS NOT SET What it says E12 BAD GRAPH MEM Problems with the graphics like Chinese and Russian E13 BAD PTR TO INFO MEM Major software corruption fatal erro...

Page 54: ...e rubber grommets 00004 Error 4 The unit is beyond the operating temperature range Solution Move the unit to an area where the ambient temperature is within the specified operating range 00005 Error 5 The refrigerant sampled has an excessively large amount of air or there was little or no sample flow due to a closed valve or plugged sample filter This is the code to prompt the user to change the b...

Page 55: ...WER SWITCH LIGHT WIRE HARNESS FA1234X18 FA1234 134AHOSE COMP DISCHARGE DOAIN HEAT EX FX3030X36 USB WIRE HARNESS FA1234X19 FA1234 134AHOSE ASSY DOA HEAT EX OUT TO HV1 TEE FX3030X37 IDENTIFIER WIRE HARNESS FA1234X2 FX134A COMPRESSOR ASSY 115 VAC sealed relay FX3030X38 SD CARN READER WIRE HARNESSES 4 PIN FA1234X21 FA1234 134A HOSE ASSY DOA PURGE TEE IN AUX FX3030X38B SD CARN READER WIRE HARNESSES 5 P...

Page 56: ...______________________________ ______________________________________________________________________________________________________ ______________________________________________________________________________________________________ ______________________________________________________________________________________________________ ____________________________________________________________...

Page 57: ... 30 40 Fax323 281 6583 Email infor cpsproducts be www cpsproducts be CPS Australia PTY Ltd 109 Welland Ave South Australia 5007 Telephone 61 8 8340 7055 Fax 61 8 8340 7033 Email sales cpsaustralia com au CPS ASIA 56A Kallang Rd 02 00 Singapore Rd 349329 Telephone 65 68461056 Fax 68461054 Email cpsasia sinnet sg www cpsproducts com Website www cpsproducts com ...

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