RECOVERY/RECYCLE/RECHARGE Operating Instructions
CONTENTS SAFETY SUMMARY 4 SAFETY INFORMATION 4 ELECTRICAL SHOCK HAZARDS 4 MOTION HAZARDS 4 FUME HAZARDS 4 HEAT/FREEZING HAZARDS 5 EXPLOSION/FLAME HAZARDS 5 ADDITIONAL SAFETY INFORMATION 5 INTRODUCTION 5 CERTIFICATION 6 ABOUT THIS MANUAL 6 ABOUT YOUR RECOVERY/RECYCLE AIR CONDITIONING SERVICE CENTER 6 WARRANTY 6 GENERAL INFORMATION 6 PRINCIPLES OF OPERATION 7 SETUP 7 THE MACHINE 8 BASIC COMPONENTS 8 CONTROLS AND CONTROL SYSTEM 9 FUNCTION SELECTOR KEYBOARD 9 ALARMS 9 P
DATA 20 PASSWORD PROTECTION 20 21 CUSTOMIZING THE DBA (DATABASE ADVANCED) 21 DATA ENTRY 22 USE 22 DELETION 22 DATABASE UPGRADE 22 CONVERSION CHART ENGLISH SYSTEM FLUSHING 22 3
SAFETY SUMMARY The following safety information is provided as guidelines to help you operate your new system under the safest possible conditions. Any equipment that uses chemicals can be potentially dangerous to use when safety or safe handling instructions are not known or not followed. The following safety instructions are to provide the user with the information necessary for safe use and operation. Please read and retain these instructions for the continued safe use of your service system.
• Avoid breathing A/C refrigerant and lubricant vapor mist. Exposure may irritate eyes, nose, and throat. To remove R134a from the A/C system, use service equipment certified to meet the requirements of SAE J2788--R134a recycling equipment. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. • Stop the recycling process if you develop momentary eye, nose, or throat irritation as this indicates inadequate ventilation.
CERTIFICATION All technicians opening the refrigeration circuit in automotive air conditioning systems must now be certified in refrigerant recovery and recycling procedures to be in compliance with Section 609 of the Clean Air Act Amendments of 1990. For information on certification call MACS Worldwide at (215) 631-7020. ABOUT THIS MANUAL This manual includes a SAFETY SUMMARY, MACHINE PREPARATION FOR USE, OPERATION procedures, and MAINTENANCE instructions, for your Air Conditioning Service Center.
ENGLISH ������ ������ PRINCIPLES OF OPERATION In a single series of operations, the machine permits recovering and recycling refrigerant with no risk of release into the environment, and also permits purging the A/C system of humidity and deposits contained in the oil. The machine is equipped with a built-in evaporator/separator that removes oil and other impurities from the refrigerant recovered from the A/C system and collects them in a container for that purpose.
THE MACHINE BASIC COMPONENTS (Refer to Figures 5, 6, 7 and 8.) A) Control Console B) Service Valves C) High & Low Service Ports G) Vacuum Pump H) Wheels I) Main Switch M) Used Oil Bottle N) Drier Filters O) Tank D) New Oil Bottle E) Sight Glass F) Serial Port J) Socket for Electrical K) Fuse Holder Supply Plug P) Tank Heater L) Electronic Scale � � � � � � FIG. 5 FIG. 6 � � � � � � � � � FIG. 7 8 FIG.
CONTROLS AND CONTROL SYSTEM Refer to Figure 9. A2) Low pressure gauge A3) Keyboard A4) LCD: 4 lines, 20 characters �� ENGLISH A1) High pressure gauge �� �� �� FIG. 9 FUNCTION SELECTOR KEYBOARD STOP: Press to interrupt the operation being performed -- recovery - oil discharge - vacuum/oil charging - charging. Press START to resume operation from the point of interruption. Pressing STOP during an alarm state, error state, or end-of-operation state silences the audible alarm.
beeper will sound and the LCD will display ENTER FILTER CODE. There will also be 10 dots along the bottom of the screen. To deactivate the alarm, the filters will need to be replaced (see page 16, Replacing the dryer filters.) NOTE: It is good practice to change the Vacuum pump oil when the filters are being changed. (see page 15 & 16, Vacuum Pump) INSUFFICIENT REFRIGERANT ALARM: Beeper and the LCD advise when the charging quantity set exceeds the amount of refrigerant available.
VACUUM XX MIN 0→1→0→7→ENTER→ NOTE: When working with A/C systems with a single high-pressure (RED) coupling, set the charging quantity 3 oz. (.19 lb or 85g) more than the required quantity, since in this case it will be impossible to recover the residual refrigerant from the hoses after charging. NOTE: In most cases, the quantity of refrigerant being charged into the A/C system is given on a data plate inside the engine compartment of the vehicle.
At this point, 69788 will pause and give the operator an opportunity to inject oil. If oil is needed, open the NEW oil valve and add the needed quantity. When completed, close the NEW oil valve and press START to go on to charging the quantity of refrigerant set previously. If no oil is to be injected, then press START. NOTE: It’s very important to remember to CLOSE the new oil valve before pressing the START button.
phase, you may go on to refrigerant fluid charging. NOTE: Using PAG oil or tracer in hybrid vehicles may damage the compressor. Use only suitable oil with a separate oil injection device. ENGLISH ��������� ������������������� FIG. 10 CHARGING THE A/C SYSTEM Press the UP or DOWN arrow to select the ASSISTED PROCEDURE and then press ENTER when the “Assisted Procedure” message flashes on the LCD. Press the down arrow to select REF CHARGING.
coupling, open only the relative valve on the machine). NOTE: Charging may not run to completion due to pressure balance between the internal tank and the A/C system. If this occurs, close the valve on the high pressure quick connect coupling (leaving the low-pressure side open), turn on the vehicle and switch on the A/C system. The unit is equipped with a tank heater to limit this occurrence.
Press START again: TANK LB ACP xx PSI TP xx PSI The machine will now fill the machine tank with the preset quantity ±1.1lb (≈500g). When the quantity minus 1.1lb (≈500g) is reached, the machine will stop and display: TANK ENGLISH 0 CHARGING CHARGING Close external tank and Press Start Close the tank valve and press START. The machine will stop automatically after having recovered the residual refrigerant from the hoses. Close the high pressure valve. Disconnect the external tank.
CHECKING OIL LEVEL The oil level in the sight glass should be between the max and min line (Fig 11-4.) If oil level falls below the MIN line add oil per oil fill instructions. OIL CHANGE The vacuum pump oil must be replaced: 1) Every 120 working hours, or 2) When the filter/dryers are replaced, or 3) At the beginning or end of every season, or 4) Whenever the oil changes color due to absorption of moisture. Before beginning the oil change procedure, obtain an empty 16 oz.
FILLING THE NEW OIL CONTAINER It is good practice to fill the oil container whenever the oil level falls below 3.4 oz (100 cc) in order to guarantee that there will be sufficient oil for � topping off during successive operations. Always refer to the information provided by the A/C system manufacturer for oil specifications (oil is not supplied.) � Lift the quick-connect coupling near the top of the container and remove the container complete with cap.
Press START: the machine will begin to discharge the air and the pressure value on the screen will gradually decrees. Press STOP when the pressure is approximately 5 to 10 PSI higher than what the P/T chart say’s it should be for the temperature showing on the screen. For example, if Tp is 140 PSI and the T is 80 degree F. The P/T chart say’s that the pressure at 80˚F should be 86.8 PSI. That means that there is approximately 53 PSI of NCG.
CALIBRATION
TEMPERATURE Select TEMPERATURE: WEIGHT oz(lb) PRESSURE psi TEMPERATURE ˚F EXIT Press ENTER to change from °C to °F or from °F to °C. WEIGHT oz(lb) PRESSURE psi TEMPERATURE ˚F EXIT Select another parameter or EXIT to go to the previous screen. DATA This menu shows all the data read by the machine. Switch the machine on.
AUTOMATIC ASSISTED PROCEDURE Ref PROCEDURE MENU> avail X,XX lb Select NEXT MENU: CALIBRATION ENGLISH PREVIOUS MENU Select SERVICES: COUNTERS Select PASSWORD: .... Put in your own 4 digit password and press enter. SYSTEM FLUSHING (OPTIONAL) See instructions provided with the flushing kit CUSTOMIZING THE DBA (DATABASE ADVANCED) Select ASSISTED PROCEDURE.
HIJK MNOP ???? ???? DATA ENTRY To enter customized data, press START. The following screen will be displayed: MODEL NAME: ...................... MODEL QUANTITY: XXXX Type in the vehicle model on the keyboard; press ENTER to confirm. Use the down arrow key to move the cursor to the next character. Type in the corresponding refrigerant quantity; press ENTER to confirm. NOTE: Refrigerant quantity is in grams.
ENGLISH 23
If you have difficulty with a procedure please call Mastercool’s Technical Service at 973-252-9119 24 69788-INST-0811
