Ecotechnics ECK 3900 UP Instruction Manual Download Page 108

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INSTRUCTIONS MANUAL

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R134a MAINTENANCE

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R134a MAINTENANCE

1423A2422 343

17:53 30/02/2014

35A085 852

17:43 31/01/2013

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Injected gas:
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R134a MAINTENANCE

Summary of Contents for ECK 3900 UP

Page 1: ......

Page 2: ...INSTRUCTIONS MANUAL 2...

Page 3: ...WITH R1234yf FLUIDS 12 PRINCIPLES OF OPERATION 15 SETUP 16 Release refrigerant scale 16 Lock refrigerant scale 16 THE MACHINE 17 PLASTIC COVER 17 CONTROL PANEL 17 FUNCTION SELECTOR KEYBOARD 19 DISPLAY...

Page 4: ...IAGNOSIS optional 64 STATIC DIAGNOSIS optional 69 EXPRESS SERVICE 71 SETUP 72 LANGUAGE 72 OPTIONS 73 VACUUM SETTINGS 74 N2 TEST SETTINGS 75 SETUP HEADER PRINT 76 INSERT OPERATOR NUMBER 77 COUNTERS 78...

Page 5: ...M 1 OIL TOP UP 112 M 2 OIL CHANGE 114 FILLING THE RECHARGEABLE COLLAPSIBLE NEW OIL CONTAINER 117 FILLING THE RECHARGEABLE COLLAPSIBLE UV CONTAINER 118 REPLACE THE NEW OIL CARTRIDGE 119 REPLACE THE NE...

Page 6: ...rating methods Approval of the operating methods and personnel was entrusted to a competent outside party for category III pressure equipment and any work on this equipment that involves the need to c...

Page 7: ...INSTRUCTIONS MANUAL 7 CONDITIONS OF WARRANTY Refer to CONDITIONS OF WARRANTY booklet supplied with the machine...

Page 8: ...1100 mm Width 640 mm Depth 680 mm Weight 90 kg Operating temperature 10 50 C Storage temperature 25 50 C Like any equipment with moving parts the machine inevitably produces noise The construction sys...

Page 9: ...rned to the dealer in case of purchase of a new machine Current legislation provides severe sanctions in the case of disposal of WEEE into the environment If improperly used or disposed of into the en...

Page 10: ...above floor level stray electrical currents and cathode corrosion check that the electrical distribution system conforms to the relevant legal provisions static electricity check the earth system for...

Page 11: ...m oils Exposure can irritate the eyes and airways WARNING The machine must be connected to a socket with effective ground WARNING This is a class A product In a domestic environment this product may c...

Page 12: ...e skin The use of goggles to avoid contact with the eyes is especially recommended since the refrigerant liquid or gas can cause freezing of the ocular fluids Moreover we strongly advise users to avoi...

Page 13: ...rimeter protection thereby also exposing other operators and people to risks of a residual nature 5 Remove or alter the safety signs such as pictograms warning signs and others on the machine 6 Use th...

Page 14: ...ally the machine seems good and it is still working the machine must be taken outdoor or in a very ventilated place No fire no smoke no workers no cars nearby this service station The service station...

Page 15: ...rging the A C system of humidity and deposits contained in the oil The machine is in fact equipped with a built in evaporator separator that removes oil and other impurities from the refrigerant fluid...

Page 16: ...3 has to be unscrewed until it full stops Connect the machine to the electrical supply and switch it on Check if the value of refrigerant scale is correct Lock refrigerant scale NOTE in the event tha...

Page 17: ...INSTRUCTIONS MANUAL 17 FIG 4 2 1 3 THE MACHINE PLASTIC COVER Refer to Fig 4 1 Front plastic cover 2 Rear plastic cover 3 Upper plastic cover Disassembly Screw off screws marked...

Page 18: ...8 FIG 5 BOTTLE REL EAS E BOT TLE SCA LE REL EAS E BOT TLE TOOLS Screw driver Box spann er n 10 4 2 1 5 3 CONTROL PANEL Refer to Fig 5 1 High pressure gauge 2 Low pressure gauge 3 Printer 4 5 Graphic c...

Page 19: ...play used for scrolling down through menu items used for scrolling up through menu items used for scrolling right through menu items used for scrolling left through menu items BACK Return back to prev...

Page 20: ...t helps the user to perform a vacuum phase OIL UV INJECTION activates a menu that helps the user to perform a oil uv injection followed by a gas filling phase GAS FILLING activates a menu that helps t...

Page 21: ...e user set up a quick express recover vacuum leak test charge sequence SETUP activates the setup menu of the service station MAINTENANCE activates the maintenance menu of the service station DATA acti...

Page 22: ...ser Fan n Front swirling wheel o Manifold p Capsizable control panel q Power supply filter r Oil pump filling cap s Refrigerant bottle lock knob t Rear wheel u New oil container v Used oil container w...

Page 23: ...INSTRUCTIONS MANUAL 23 FIG 7 x h a f 4 3...

Page 24: ...INSTRUCTIONS MANUAL 24 FIG 8 k m p o n u w z l...

Page 25: ...INSTRUCTIONS MANUAL 25 FIG 9 q t s v i j...

Page 26: ...INSTRUCTIONS MANUAL 26 FIG 10 7 6 5 1 2 9 y c d e r...

Page 27: ...tion is automatically interrupted to cancel this alarm charge one or more A C systems before recovering any more refrigerant EMPTY BOTTLE ALARM Beeper advise when the quantity of refrigerant fluid con...

Page 28: ...change the filters This should be considered more as a prompt than an actual error Solution Verify the coupler valve is open Solution Verify the gas analyzer filters are not plugged with debris or oil...

Page 29: ...the connections and repeat the procedure Error 13 PRESSURE LEAKS A C system flushing error message displayed A C system flushing leaks occurred during the pressure test A C system is not tight Solutio...

Page 30: ...in the refrigerant bottle is 3 kg otherwise fill the inner refrigerant bottle Rarely it may happen that the temperature of the engine compartment of the vehicle is too high compared to that of the cha...

Page 31: ...ry operate the substitution as described in ORDINARY MAINTENANCE section o Check that the oil level in the used oil container is 200 cc if necessary empty it as described in ORDINARY MAINTENANCE secti...

Page 32: ...k that the vacuum pump oil level indicator ref 3 Fig 12 shows at least one half full If the level is lower add oil as explained in the MAINTENANCE section 3 MAX MIN FIG 12 TOOLS Funn el Disp osal cont...

Page 33: ...nnect coupling for high or low pressure connect only the relative hose From the MAIN MENU Select the AUTOMATIC PROCEDURE the following screen is displayed only if the hardware for hybrid vehicles is i...

Page 34: ...to type the volume of UV to be injected type 0 for no UV injection UV is disabled while servicing HYBRID VEHICLE Edit GAS FILLING data NOTE For most systems the quantity of fluid to be refilled is ind...

Page 35: ...press NO to skip it then the following screen will be displayed Type the plate of the car press OK to confirm BACK to return back NOTE the numerical keys include an alphabet that is used similar to te...

Page 36: ...e any non condensable gas Allowing the machine to fully complete the procedure will reduce the risk of return flows which may cause excessive non condensable gas to be recharged into the air condition...

Page 37: ...lume will be equal to that of the used oil discharged or to the volume set by the operator the quantity of UV set by the operator will be automatically reintegrated When completed the system will go o...

Page 38: ...is enabled on the machine then the following screen will be displayed Disconnect coupling from A C system Automatic procedure is now successfully completed Unscrew HP and LP coupling Without disconnec...

Page 39: ...etion due to pressure balance In this case close the high pressure tap leaving the low pressure side open and switch on the A C system NOTE The automatic procedure may be run even if the A C system is...

Page 40: ...d that BLUE must be connected to the low pressure side and RED to high pressure If the A C system is equipped with a single quick connect coupling for high or low pressure connect only the relative ho...

Page 41: ...achine to fully complete the procedure will reduce the risk of return flows which may cause excessive non condensable gas to be recharged into the air conditioning system If any residual refrigerant i...

Page 42: ...system end press OK to complete the RECOVERY RECYCLE PROCEDURE STANDARD RECOVERY From MANUAL PROCEDURE select STANDARD RECOVERY the machine will run a recovery phase as described by the previous HIGH...

Page 43: ...nding of machine model NOTE use the VACUUM SETTING to change the duration of the LEACK CHECK NOTE if selected VACUUM TIME is lower 15 minutes the following popup warning will be displayed Press YES to...

Page 44: ...larm Detection of micro leaks is not guaranteed At the end of the preset vacuum time the machine will sound and alarm and the following screen will be displayed Close and disconnect HP and LP coupling...

Page 45: ...type 0 for no UV injection can never be more than 10 ml UV is disabled while servicing HYBRID VEHICLE Edit GAS FILLING data NOTE For most systems the quantity of fluid to be refilled is indicated on a...

Page 46: ...car press OK to confirm BACK to return back NOTE the numerical keys include an alphabet that is used similar to text messaging for example press 2 once to display A twice to display B three time for...

Page 47: ...YES to continue The machine will recover the residual refrigerant into the service hoses then the following screen will be displayed Are you sure that you have unscrewed the coupling without removing...

Page 48: ...uccessfully completed NOTE Rarely charging may not run to completion due to pressure balance In this case close the high pressure tap leaving the low pressure side open and switch on the A C system R1...

Page 49: ...e of refrigerant into the GAS FILLING field NOTE if gas filling is lower than 100 grams the following popup warning will be displayed Gas filling lower than 100 grams is not allowed press OK then digi...

Page 50: ...preset quantity of refrigerant Then the following screen will be displayed Unscrew HP and LP coupling without disconnect from A C system end press OK to continue Inset vehicle Plate number R134a MANU...

Page 51: ...enabled on the machine then the following screen will be displayed Disconnect coupling from A C system Procedure is now successfully completed NOTE Rarely charging may not run to completion due to pre...

Page 52: ...e respective fitting on the machine the press OK to continue After checking connection leaks the following screen will be displayed Flushing hoses lasts few minutes then the machine will sound and ala...

Page 53: ...TIONS MANUAL 53 Disconnect coupling then press OK to return to the MAIN MENU FLUSHING HOSES is now successfully completed END OF PLUSHING HOSES Disconnect coupling then press OK R134a DEVICES FLUSHING...

Page 54: ...ANUAL PROCEDURE select DEVICES Then select NITROGEN TEST the following screen will be displayed Select a test or press BACK to return to DEVICES menu NITROGEN TEST N2 MIXTURE TEST N2 H2 CHOOSE THE TYP...

Page 55: ...be displayed Connect nitrogen bottle and press OK Regulate pressure reducer between 8 and 12 bar and press OK The nitrogen will be injected into the A C system the test will start as soon as the press...

Page 56: ...splayed Disconnect coupling then press OK the following screen will be displayed Unscrew and disconnect HP and LP coupling from A C system end press OK to complete the N2 TEST WARNING Connect nitrogen...

Page 57: ...continue the following screen will be displayed Connect mixture N2 H2 bottle and press OK Regulate pressure reducer between 8 and 12 bar and press OK Connect and open HP and LP coupling to A C system...

Page 58: ...alarm and the following screen will be displayed Disconnect coupling then press OK the following screen will be displayed R134a DEVICES N2 H2 TEST N2 H2 INJECTION N2 H2 pressure x x bar rel Check for...

Page 59: ...INSTRUCTIONS MANUAL 59 Unscrew and disconnect HP and LP coupling from A C system end press OK to complete the MIXTURE TEST N2 H2 WARNING Connect mixture supply only to the quick connect coupling...

Page 60: ...value then press OK to continue the following screen will be displayed Connect the flushing kit as described previously then press OK to begin the flushing operation The machine will proceed automatic...

Page 61: ...MANUAL 61 NOTE for additional information about PRINCIPAL COMPONENTS ASSEMBLY OF THE FLUSHING KIT CONNECTION TO THE SYSTEM and FLUSHING KIT MAINTENANCE please refer to A C SYSTEM FLUSHING INSTRUCTIONS...

Page 62: ...onal From the MANUAL PROCEDURE select DEVICES Then select GAS ANALYZER if gas analyzer is installed The machine will test the purity of the refrigerant gas in the A C system refer to Gas analyzer inst...

Page 63: ...INSTRUCTIONS MANUAL 63 SANITIZER optional From the MANUAL PROCEDURE select DEVICES Then select SANITIZER to perform a PURIFICATION refer to Sanitizer instruction manual MANU040 IGN R134a DEVICES...

Page 64: ...e assembly including a relief valve Orifice tube system with constant running compressor a system making use of a capillary valve orifice tube and a variable displacement compressor For additional inf...

Page 65: ...finished the following screen will be displayed Press OK prints the options or BACK to exit R134a DEVICES DYNAMIC DIAGNOSIS Connect and open HP and LP coupling to A C system press OK R134a DEVICES DYN...

Page 66: ...below to reintegrate the quantity of refrigerant present in the A C system hoses Turn of the A C system and the vehicle s engine then press OK Unscrew HP coupling without disconnect from the A C syst...

Page 67: ...ill check if the Schrader valve of the coupling are tightened then the following screen will be displayed R134a DEVICES DYNAMIC DIAGNOSIS Turn of the A C system and vehicle s engine then press OK R134...

Page 68: ...M DIAGNOSTICS Wind speed ca 0 km h A C fan set to second speed A C temperature control set to maximum cold External ambient temperature from 21 C to 38 C Engine at 1500 RPM for two minutes Do not expo...

Page 69: ...s The following screen will be displayed Type in in order the minimum value of low pressure the maximum and minimum value of high pressure of the A C system and the temperature of the air at the outle...

Page 70: ...been checked out and or repaired in order to determine whether or not the repair has solved the system problem Retest after each DIAGNOSIS has been verified and or the trouble repaired OPTIMUM CONDIT...

Page 71: ...CLE is selected UV is disabled NOTE VACUUM TIME and LEACK CHECK have fixed value not modifiable Use arrows to scroll through menu items then use the keypad to modify procedure parameters press OK to b...

Page 72: ...NOTE current language is indicated by black background Select a language then press OK to confirm LANGUAGE VACUUM SETTINGS N2 TEST SETTING SETUP HEADER PRINT INSERT OPERATOR NUMBER COUNTERS Deutsch Fr...

Page 73: ...displayed Type the enabler code retrieved within the option kit and press OK to enable the option If the enabler code is not available call the Service Center NOTE EXPRESS SERVICE doesn t need the ena...

Page 74: ...VACUUM SETTINGS default setting is displayed Each value can be modified within the values shown in parentheses NOTE press INFO to restore default values Vacuum time 25 min Time of check 2 min Vacuum r...

Page 75: ...g is displayed Each value can be modified within the values shown in parentheses NOTE press INFO to restore default values Waiting time 2 min Leaks threshold 500mbar Leaks threshold N2 test Waiting Ti...

Page 76: ...telephone n and e mail From the SETUP select SETUP HEADER PRINT Use the keypad to modify the 4 lines then press BACK to return to SETUP menu NOTE the numerical keys include an alphabet that is used s...

Page 77: ...It is possible to enter an alphanumeric code of 10 symbols to indicate the habilitation nr of the operator This number will be indicated in all printouts Use the keypad to modify operator number then...

Page 78: ...with the bottle refilling function From the SETUP MENU select COUNTERS the following screen is displayed This screen displays the total values for gas recovered service alarm COUNTERS total vacuum tim...

Page 79: ...hange date and time press OK to confirm or press BACK to return to SETUP menu without saving the changes For example to insert the date January 21st 2013 use ARROW to select the day then type 21 using...

Page 80: ...select CONTAINER press OK to confirm NOTE this operation is to use different containers for example if instead of a UV you want to use a HYBRID UV use ARROW to select UV CONTAINER the press ARROW to s...

Page 81: ...elect the MAINTENANCE the following screen will be displayed CALIBRATION BOTTLE FILLING CHANGE DRIER FILTER A C PRESSURE CHECK AIR PURGE MANUAL SERVICE ARCHIVE EMPTYING HOSES R134a MAINTENANCE AUTOMAT...

Page 82: ...med with maximum attention and care In particular always observe the following precautions Always place the weights at the center of the scale plate Never exert pressure on the oil scale Always recove...

Page 83: ...eating coil ref 2 Fig 14 from the bottle do not touch or disconnect the wires of the resistance coil Close the red tap of the bottle ref 7 Fig 15 and blue tap of the bottle ref 8 Fig 15 Close the tap...

Page 84: ...34a bottle or 5800 g for 12l R1234yf bottle then press OK to confirm Tare Press BACK to exit to CALIBRATION MENU Switch off the machine and disconnect it from mains supply Replace the bottle ref 6 Fig...

Page 85: ...can vary from a few grams depending on the positioning of the bottle and the tubing connected to it but it is not always possible or easy empty it The value of the tare does not compromise the correct...

Page 86: ...the empty container in place and ensure that the amount is 0 ml otherwise modify the value of the tare use keys 0 through 9 to type in the value of the tare usually approximately 150g then press OK to...

Page 87: ...ce the empty container in place and ensure that the amount is 0 ml otherwise modify the value of the tare use keys 0 through 9 to type in the value of the tare usually approximately 150g then press OK...

Page 88: ...ottle valve ref 7 Fig 17 then press OK Make sure that HP and LP couplings are disconnected from A C system or else then press OK to continue Automatic BP calibration can be done only after a PA C cali...

Page 89: ...OK return exit Switch off the machine and disconnect it from the electrical supply R134a BOTTLE PRESSURE PB AUTOMATIC CALIBRATION Calibration running Please wait PB AUTOMATIC CALIBRATION R134a BOTTLE...

Page 90: ...0 2 bar Press NO to run a quick emptying hoses press YES to continue the following message is displayed After few minutes the following message will be displayed YES NO R134a A C PRESSURE PA C AUTOMA...

Page 91: ...S MANUAL 91 A C PRESSURE calibration successfully completed Press OK return exit Switch off the machine and disconnect it from the electrical supply R134a A C PRESSURE End of PA C AUTOMATIC CALIBRATIO...

Page 92: ...from A C system or else then press OK to continue After few minutes the following message will be displayed R134a EVAPORATOR PRESSURE Evaporator pressure AUTOMATIC CALIBRATION Press OK Automatic Evap...

Page 93: ...AL 93 EVAPORATOR PRESSURE calibration successfully completed Press OK return exit Switch off the machine and disconnect it from the electrical supply R134a EVAPORATOR PRESSURE End of PB AUTOMATIC CALI...

Page 94: ...ead on the external thermometer If necessary use ARROW to select SET button of bottle temperature then use keys 0 through 9 to type in the value read on the external thermometer then press OK to confi...

Page 95: ...ure transducer Pa c Pev Pb bottle load cell new oil load cell used oil load cell You can restore the factory calibration From CALIBRATION select RESTORE CALIBRATION the following screen is displayed P...

Page 96: ...he refrigerant into the service hoses then the machine will sound and alarm and the following screen will be displayed Press OK to return to the MAINTENANCE MENU EMPTYING HOSES is now successfully com...

Page 97: ...creen will be displayed Use the keypad to insert the amount of refrigerant then press OK to continue The BOTTLE FILLING will start the machine will now fill the machine bottle with the preset quantity...

Page 98: ...external bottle and press OK Bottle filling procedure successfully completed Switch the machine off NOTE if the external bottle is not supplied with a liquid side coupling upend it to recover liquid r...

Page 99: ...couplings of the new filter using an electronic leak tester 4 From MAINTENANCE select CHANGE DRYER FILTER the following warning message is visualized An accidental leakage of refrigerant may cause se...

Page 100: ...able call the Service Center 9 Remove the dryer filter use the special wrench ref Fig 18 10 press OK to continue Remove the drier filter Use the special wrench and press OK Unscrew Recovering gas from...

Page 101: ...r use the special wrench ref Fig 19 13 and press OK 14 Press OK to continue with vacuum check Continue with vacuum and check for leaks Press OK Verify that both o rings are correctly placed into their...

Page 102: ...filter tightening and press OK to restart the pressure check 18 If no leaks are detected the following screen will be displayed 19 Then After few minutes Check leaks with vacuum R134a MAINTENANCE CHAN...

Page 103: ...TRUCTIONS MANUAL 103 20 Press OK to return to the MAINTENANCE MENU DRYER FILTER CHANGE is now successfully completed R134a MAINTENANCE CHANGE DRYER FILTER CHANGE DRIER FILTER OPERATION COMPLETED Press...

Page 104: ...OK Turn off A C system and the vehicle s engine then press OK Unscrew HP coupling without disconnect it then press OK Connect and open HP and LP coupling to A C system Press OK Turn on A C system and...

Page 105: ...isplayed Disconnect coupling from A C system press OK to return to the MAINTENANCE MENU A C PRESSURES CHECK is now successfully completed Turn off engine and A C system unscrew LP coupling without dis...

Page 106: ...e In this case press OK the machine will begin discharging the air Press STOP to pause the Air Purging process NOTE If there isn t air into the bottle the following message is displayed AIR PURGE NOT...

Page 107: ...lowing screen will be displayed Use the keypad to insert plate number to search then press OK A list will be displayed select service for detailed info Press OK to print the report of the service or p...

Page 108: ...lect service for detailed info Press OK logo to print the report of the service or press BACK to return to previous menu SEARCH BY DATE DAY MONTH R134a MAINTENANCE Plate Time Date R134a MAINTENANCE 14...

Page 109: ...press OK to save to copy a TXT file with all the operations into the Pendrive The following screen will be displayed for few seconds Extraction is now completed the machine will return to the previou...

Page 110: ...newer one already filled then press OK to begin oil drain procedure the following screen will be displayed After some minutes at the end of the operation the following screen will be displayed R134a...

Page 111: ...elect VACUUM PUMP OIL CHANGE the following screen will be displayed Type the code retrieved on the new oil bottle and press OK to delete the alarm If the filter code is not available call the Service...

Page 112: ...for information concerning the correct type of oil M 1 OIL TOP UP This operation must be performed when the level of the oil falls to less than half on the indicator ref 3 Fig 20 NOTE in order to cor...

Page 113: ...ren ch n 5 8 1 The oil must be added through the hole in which the oil cap was lodged by using a proper funnel ref 5 Fig 21 Add oil a little at a time waiting for the level to rise before each success...

Page 114: ...e oil must also be replaced whenever it changes color due to absorption of humidity Before beginning the oil change procedure procure a container of at least 500 cc capacity in which to collect the us...

Page 115: ...8 Disp osal conta iner 9 Alle n wren ch n 5 8 2 4 FIG 26 TOOLS 10 Funn el 11 Disp osal 2 4 Unscrew the drain cap ref 2 Fig 25 Allow all the oil to run out into a disposal container ref 4 Fig 25 with h...

Page 116: ...wren ch n 5 8 5 FIG 28 TOOLS Funn el Disp osal conta iner Allen wren ch n 5 8 1 6 Pour in new oil through the filling hole using a proper funnel ref 5 Fig 27 until the level rises to the midpoint on t...

Page 117: ...ntainer OIL container ref j Fig 29 2 Remove the container from its lodging 3 Hold the container and unscrew the cap ref 2 Fig 30 Fill the container Fig 31 with the correct quantity about 250 260ml of...

Page 118: ...the UV container out of its lodging ref l Fig 32 3 Unscrew the cap ref 2 Fig 33 and fill the container Fig 34 with the required quantity of UV for compressors 4 Screw the cap ref 2 Fig 33 back into t...

Page 119: ...cturer Always refer to the information provided by the A C system manufacturer Procedure 1 Press quick connection button ref 1 Fig 35 to disconnect the oil cartridge OIL cartridge ref j Fig 35 2 Remov...

Page 120: ...e warranty Procedure 1 Press quick connection button ref 1 Fig 36 to disconnect the UV cartridge 2 Lift the UV cartridge out of its lodging ref l Fig 36 3 Insert the male fitting of the new UV cartrid...

Page 121: ...ssure on the scale 3 Unscrew the cap ref 2 Fig 38 while holding the container empty the used oil into a suitable container for used oils Fig 39 4 Screw the cap back into the container 5 Replace the co...

Page 122: ...2 3 FIG 40 REPLACING THE PRINTER PAPER Open the print cover ref 3 Fig 40 ad replace the paper roll with a new one Use only heat sensitive paper of the type described below Paper width 58 mm Maximum pa...

Page 123: ...ed quantity of OIL in the USED OIL container Ambient temperature ambient temperature near the service station Bottle temperature refrigerant storage bottle temperature Bottle pressure refrigerant stor...

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