User manual for Automatic A/C
Contents
1. DE x ui ce i p 0000000000C Mk DI N A LN N 20 4 60000 L Hydraulic diagram LO o ok OO Electric diagram 7 Ry6 3 Ry REI SI gt C Ds 17 7 bord di 147 6 19 X e X 20 X i N 67 FUI IE 10A RIT O 18V FU3 0 24 RIT O FU2 10A RIT Legend 1 Solenoid valve2. oil discharge line 43 Distiller separator 2 Solenoid valve recovery line 45 Oil separator 3 Printer 47 Handle support 4 Solenoid valve vacuum line 48 Oil discharge bottle 6 Vacuum pump 50 Oil charging bottle 7 Compressor 51 Plastic cover 8 Motor fan 52 HP flexible hose 9 Compressor starting capacitor 53 LP flexible hose 10 Vacuum pump oil filler plug 54 Supply cable 11 Vacuum pump sight glass 55 HP quick coupler 12 Vacuum pump oil drain plug 56 LP quick coupler 13 Solenoid valve refrigerant charging line 57 Manual discharge valve on the distiller 15 Pressure transducer 60 Control Board 17 Safety pressure switch 63 Electric feeder 19 Solenoid valve Oil charging line 64 Frame 20 Solenoid valve oil return to compressor line 65 Bottle service connection 21 Liquid valve on the bottle 66 Service connection for compressor evacuation 22 Refrigerant charge capillary tube 67 Main power switch with socket 23 Vapor valve on the bottle 68 LP Pressure gauge 24 Service valve on refrigerant bottle 69 HP pressure gauge 25 Manual valve LOW 71 Vibration damping feet 26 Manual valve HIGH 73 Load cell 5 kg oil charge 27 Capillary hose connecting HIGH valve to HP 74 Heater belt with thermostat on the bottle gauge 28 Capillary hose connecting LOW valve to LP 75 Load cell 5 kg oil discharge gauge 29 Oil discharge capillary tube 78 Spring for heater belt 30 Distiller bottle connecting capillary hos
3. User manual for Automatic A C Service Unit Coolius 1000 2108 ENG MANUAL COOLIUS 1000 V 1 1 24 05 2013 Identification Manufactory WIGAM Loc Spedale 10 b 52018 Castel San Niccold Arezzo Italy Tel 39 0575 5011 Fax 439 0575 501200 info wigam it Distributed W rth Online World GmbH Schliffenstr Falkhof 74653 K nzelsau Product Automatic A C Service Unit Typ WOW Coolius 1000 Product No 0900 764 981 Directives 2006 42 EEC Machines directive 2004 108 EEC Directive on elctromagnetic compatibility 2006 95 EEC Directive on low voltage IEC 34 11 EN 60034 General standards on single phase electric rotative machines IEC 335 1 Safety on electrical devices in domestic application W rth Online World GmbH K nzelsau reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations according to her policy of always improving her products Index Identifieathon ette eee esee ente een Pec Peste ete rete e rete rede Praed bec eee ene UERR 1 Fey eju Ko To VIT no BASE MERAS PRP nr nn nn nn se DD DLL 3 Hydraulic diagram ettet ete nee tea ee n aa aae 0 e e ea TED e e TR RN 0 ea 5 Bleeiriediagramen sese Meet A Rei ERR Re Me e tt 6 EI a m 7 Safety precdulions TT OR OR nee 8 1 Introduction to recovery unit COOLIUS 1000 RN 9 1 1 TECHNICAL SPECIFICATIONS nn eee
4. Connect the 53 hose to the refrigerant bottle 11 3 Open the LOW valve ref 25 and close the HIGH valve ref 26 4 Press the Vacuum key on the control module 5 Set a vacuum time of 5 minutes by means of the UP DOWN arrows V a c u um T i me 5 Press the START key to start the function Once the vacuum cycle is completed slowly open the valve on the bottle containing refrigerant Press the Recovery key Set the refrigerant quantity to recover we suggest a quantity of 3 000 kg by means of the UP DOWN arrows v R 13 4 a 3 0 0 0 k g Press the START key to start the function Wait until the recovery cycle is completed A sound signal will let the user know that the cycle is over Close the valve on the bottle containing refrigerant Start a recovery cycle with ALL set Wait for the end of the cycle Disconnect the hose of the bottle Re place the valve ref 55 on the hose end IMPORTANT Perform a vacuum cycle for 2 minutes 12 3 Using COOLIUS 1000 unit 3 1 Refrigerant recovery WARNING During recovery regulate the LOW and HIGH valves on the control panel so that the input pressure never rises over 5 bar Turn on the engine with closed hood Turn the air conditioner on and have it run for some minutes Open the hood and set the air conditioner fan to maximum speed Have the vehicle engine run slowly 800 1200 revolutions min for a few minutes RB Turn the vehicle engine off and have the air conditioner fan
5. Axial type and high flow rate Refrigerant bottle Capacity of 10 kg with liquid and vapour connections Distiller Separator High heat exchange distillation chamber with automatic flow control Bottle for discharged oil Capacity of 200 grams of oil on load cell Bottle for oil charge Capacity of 200 grams of oil on load cell Control module Fast access keys to the functions 1 2 Control module Recovery function Vacuum function Menu function gt Recovery m Vacuum m Charge i Menu Exit Auto Auto ES Start Stop A Up Down Exit key Oil Charge Refrigerant charge function UP arrow DOWN arrow Auto function Start Stop key Access to the Refrigerant Recovery function Access to the Vacuum function Access to the oil refrigerant charging function Standby Access to the menu for the modification of the unit s settings parameters During a function setting Back to the previous screen Standby Access to the automatic function During a function Start and end of the function When pressed singularly enables to shift through the various ranges and modify the numerical values When pressed at the same time Start of the Flushing function 10 2 Preparing unit COOLIUS 1000 for use 2 1 Checking the vacuum pump oil level Before checking the oil level the unit must be placed on a level surface and its power supply must be turned off The user must check that the vacu
6. e Contrast By pressing the START key it is possible to modify the value of the display contrast e Data exportation By pressing the START key it is possible to export the services performed by the unit into the SD card from inside memory to SD Card The unit creates a txt file to import into your own PC In case the message ERROR CODE 08 appears re start the unit and try again the exportation procedure To cancel all the data saved in the memory card follow the procedure explained at Service e Workshop data By pressing the START key it is possible to modify the 6 lines available on the report to write some information about your own workshop Once the information have been written they will be printed on each report 18 4 Accessories and spare parts Part number Description 14015013 XH412 anti acid filter direr 12002003 oil for vacuum pump 14020014001 G19020 kit of gaskets for Y4 SAE hoses 10pcs 14020015001 G19030 kit of gaskets for 3 8 SAE hoses 10pcs 14025079 Printer update kit 5 Dimensions and weight K wow u O od N Net weight with empty refrigerant bottle 50 kg WOW reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations according to her policy of always improving her prod
7. the A C system which needs a maintenance 2 Open the LOW ref 25 and HIGH ref 26 valves according to how the connection on the system was made 3 Press the Auto key A IMPORTANT Before the cycle starts the unit will check the available volume inside the bottle In case the total weight on the scale exceeds 6 600kg COOLIUS 1000 unit will display the following alarm signal Check bottle weight 15 The operator will be asked to select the type of charge whether it will be effected through a single hose blue or red or whether it will be effected through both hoses This enables the unit to calculate the correct value of the pre charge when it is set 2 hos e s L H A 1 h o se v Confirm with START and then the screen for setting Vacuum will appear V a c u um T i m e 3 0 Modify the vacuum time by means of the UP DOWN arrows and confirm with START A IMPORTANT The function of refrigerant recovery will be performed in case refrigerant is detected in the A C system when connecting the unit to it Now the screen for setting the oil UV quantity appears O i I S AME O i I M a x 1 5 0 g The units sets SAME by default During the oil injection phase the same guantity of oil that has been recovered during recovery will be re injected into the system The units checks the maximum quantity that can be charged and indicates it on the second line of the display In case you would like to set a different quantity than SAME you
8. a refrigerant polluted environment The equipment must always work under the operator s control Protect the unit from dripping Do not modify the calibration of safety valves and control systems If you recover refrigerant from a cooling system equipped with a water evaporator and or condenser it is necessary to drain water from the evaporator and or condenser or to keep the circulation pump running during the entire recovery operation in order to avoid frosting 1 Introduction to recovery unit COOLIUS 1000 COOLIUS 1000 unit permits quick and efficient recovery of refrigerant from the A C system refrigerant recycling system evacuation check for tightness additive or lubricant injection the subsequent charge with refrigerant and measurement of the operating pressures 1 1 TECHNICAL SPECIFICATIONS Model seat tt tt lt t COOLIUS 1000 Refrigerant xc ie b bbb ENNA R134a Maximum storage capacity pp 10 kg Maximum recovery rate pp 0 3 kg min Power ej PS 230 1 50 Power imul Storage temperature RN Working temperature pp Degree of protection Noise level RE Refrigerant max charge 1 2 UNIT S COMPONENTS Component Feature Compressor 6 cc recovery rate 0 3 kg min Vacuum pump Rotary vane type and single stage 100 l min Filter direr Dehydrating capacity of 75 PPM of water Flexible hoses L 3 meters with quick couplers Fan
9. been previously evacuated and that they do not contain non condensable gases Avoid skin contact the low boiling temperature of the refrigerant about 30 C can cause freezing Avoid breathing refrigerant vapours It is recommended to wear suitable protections like safety glasses and gloves contact with refrigerant may cause blindness and other personal injuries Do not operate near open flames and hot surfaces the high temperatures decompose the refrigerant releasing toxic and caustic substances which are hazardous for the operator and the environment Always make sure that the unit is connected to a suitably protected mains supply provided with an efficient earth connection Before performing maintenance operations or when the unit will not be used for a long period of time turn the unit off by turning the main switch to 0 and disconnect the power supply cord absolutely follow the sequence of operations Operate the unit only in locations with suitable ventilation and a high number of air changes Before disconnecting the unit make sure that the cycle has been completed and that all valves are closed in order to avoid release of refrigerant to the atmosphere Never fill any tank with liquid refrigerant to more than 75 of its maximum capacity During operations avoid release of refrigerant to the environment this precaution is required by international environmental standards and is essential to avoid difficult leak detection in
10. can modify it the quantity by means of the UP DOWN arrows and confirm with START Suggested quantities for refilling the A C system with oil According to the type of A C system component you have replaced you need to fill in the lubricant quantity indicated below even if no oil has been extracted during recovery Evaporator 50cc Condenser 30cc Filter 10cc Pipes 10cc In any case the operator must follow the instructions of the A C system manvfacturer 4 Press START and the screen for setting the refrigerant quantity will appear R 113 4 a Oo 3 00 kg A a t a b a s e v 5 If you press START on the first line the refrigerant quantity can be set manually by means of the UP DOWN arrows and confirming with START R 1 3 4 a 0 3 0 0 M a x 41 6 6 5 k g k g 6 Otherwise on the second line you can gain access to the database and choose between Standard Database containing the main cars on the market and Personal Database created by the user D b St a n d a r d D b Per sona l 16 7 After having set the refrigerant quantity either by means of the manual menu or by means of the database menu you will have the START screen cycle start where the settings will be summarized on the second line S t lalrit S t a r t 8 Press START to start the function 9 When the function is completed a beep will let the operator know that the cycle is over and the display will show the information on the cycle just perfo
11. e 79 Safety valve 31 Complete refrigerant bottle 80 Load cell 100 kg refrigerant 32 Front wheel with brake 81 Check valve oil charging line 33 Rear wheel 200 82 Check valve recovery line 35 Oil injection capillary tube 83 Check valve refrigerant charging line 36 Capillary tube for safety valve 84 Check valve compressor delivery line second 37 Manifold valves assembly connecting hose 86 Check valve oil discharge line 38 Valves assembly Distiller connecting hose 88 Check valve compressor delivery line first 40 Vacuum pump hose 89 Oil discharge capillary tube solenoid valve bottle Al Compressor suction hose 90 Hose for oil return to compressor 42 Distiller filter connecting hose 95 Filter drier 96 Heater on oil separator of compressor Safety precautions This equipment is designed for trained personnel only who must know the refrigeration fundamentals cooling systems refrigerants and possible damage that pressurized equipment may cause Carefully read the instructions contained in this manual strict observance of the procedures described is fundamental to the operator s safety the perfect state of the unit and constant performances as declared The unit must always work under the operator s direct supervision Do not operate the unit with different refrigerant than the one it has been designed for Before performing any operation make sure that the hoses used for connections have
12. nding evaporation temperature on the 68 pressure gauge Read the pressure and its corresponding condensing temperature on the 69 pressure gauge 17 g Compare the values with the ones suggested by the cooling system manufacturer 3 7 Disconnecting the unit from the A C system 1 Disconnect the 52 hose from the A C system with the A C system compressor working 2 Make sure that the 53 hose is connected to the A C system 3 Open the LOW ref 25 and HIGH ref 26 valves in order to have all the liquid refrigerant be sucked by the A C system 4 As soon as the pressures on the high and low pressure gauges are the same and do not exceed 2 3 bar disconnect the 53 hose from the A C system 5 Perform a recovery cycle to extract the remaining refrigerant from the hoses so that the unit is immediately ready for the next operation Turn the unit off power switch 67 in position 0 Close the LOW ref 25 and HIGH ref 26 valves Reposition 52 and 53 in their supports Carefully screw the protective caps on the A C system service valves SS 0 Using a leak detector check the A C system for leaks WARNING The introduction of tracer additives and the following use of a UV leak detector will make it easier to locate the point of the possible leak in the future B 3 8 Setting Menu If you press the MENU key in the standby screen you can gain access to the setting menu of the unit e Car plate By pressing the START key it is possible to
13. o ER Ee e oed 9 1 2 Control module ertet t tte e eerte e ey data de een eee ep ekki 10 2 Preparing unit COOLIUS 1000 for use pp 11 2 1 Checking the vacuum pump oil level eee 11 2 2 TURNING COOLIUS 1000 QN 5 5557 53 ERR ooo RR ERR ERR SR ea anna RR S RR a STIPER ceata i 11 2 3 ZERO SCALE CHECK esse ette iatale 11 2 4 Filling refrigerant into the internal bottle nemen nere 11 3 Using COOLIUS 1000 Un 13 3 1 Retnigerant recovery stets ta asta E met A EE CA S aa eee Leu iet E UE Uf 13 3 2 Vacuum Vacuum Test saias L L RA k RR eus 14 3 3 Oil Uv Refrigerant nana nana 14 3 4 Automatic cycle sit tat esse esse sense nee 15 3 5 i DOE ah ee Pe et een RAR CRC GENO USER ERA GUS GUN GEAR CRM GUS CURSA Le ie Le SRA Le GR ote Sie Pe ee cn 17 3 6 Checking A C system operating pressures ni i inna on lt lt o lt lt 17 3 7 Disconnecting the unit from the A C system nenea 18 3 8 ER 18 4 Accessories and spare parts in onen rest aera ae evan 19 5 Dimensi ns and weight 2 2322 2 2 eee eres eee e eret d aie ane ee els 19 wa 20 Layout drawing fou FEN EN NEN EN AN SONA EN
14. r the test starts to check the possible presence of leaks in the A C system When the vacuum test is over or if there are leaks a sound signal will inform the user c u um 3 j V a 0 V a c u um s e s s OK 3 3 Oil Uv Refrigerant 1 Connect the hoses to the A C system which needs a maintenance 2 Open the LOW ref 25 and HIGH ref 26 valves according to how the connection on the system was made 3 Press the Charge key 4 The operator will be asked to select the type of charge whether it will be effected through a single hose blue or red or whether it will be effected through both hoses This enables the unit to calculate the correct value of the pre charge when it is set 2 hh os e s L H A 1 h o s e v 5 Confirm with START and then the screen for setting the oil UV quantity will appear O i I S AME O i I M a x 15 0 g 6 The units sets SAME by default During the oil injection phase the same quantity of oil that has been recovered during recovery will be re injected into the system 7 The units checks the maximum quantity that can be charged and indicates it on the second line of the display 8 In case you would like to set a different quantity than SAME you can modify it the quantity by means of the UP DOWN arrows and confirm with START 14 Suggested quantities for refilling the A C system with oil According to the type of A C system component you have replaced you need to fill in the lubricant q
15. rmed R 1 3 4 a 1 1 0 0 kg O i I O vu t 1 0 g V a c uu m 3 0 V ac uu m t est O K O i 1 0 g R13 4 a 0 7 0 0 k g 3 5 Flushing 1 Connect the hoses to the A C system which needs a maintenance 2 Open the LOW ref 25 and HIGH ref 26 valves according to how the connection on the system was made 3 Press the UP DOWN keys to enter the function menu V a c u um 1 0 FI u s hing cy c I e3 Set the vacuum time by means of the UP DOWN arrows and press the START key to confirm Set the number of cycles by means of the UP DOWN arrows and press the START key to start the function When the function is completed a sound signal will let the user know thot the cycle is over and the summary of the operation performed will be displayed A IMPOTRANT At the beginning of the cycle the unit checks the volume available inside the bottle In case the total weight on the scale is under 4 000 kg the unit will display the alarm message Check weight in the bottle In fact in order to perform the function it is necessary to have at least 4 000 kg of refrigerant inside the bottle 3 6 Checking A C system operating pressures 1 Make sure that the LOW ref 25 and HIGH ref 26 valves are closed and that the power switch ref 67 is on position O Connect the 53 hose to the cooling system low pressure side Connect the 52 hose to the cooling system high pressure side Start the compressor of the A C system Read the pressure and its correspo
16. run at maximum speed and start the recovery operations ps Connect the hoses to the A C system which needs a maintenance M Open the LOW ref 25 and HIGH ref 26 valves according to how the connection on the system was made 8 Press the Recovery key Recovery R13 4 a A 1 1 The unit sets the recovery function on ALL by default Press the START key to start the function During the recovery cycle the recovered refrigerant quantity appears on the display o In case of emergency it is possible to leave the function by keeping the STOP key pressed for more than 3 seconds During the cycle the unit performs the automatic oil discharge O i I di s ch ar ge Wait for the function to be completed the quantities of recovered refrigerant and oil will appear on the display O i WARNING Do not pollute environment with oil it is a special waste and must be disposed of according to the regulations in force 13 3 2 Vacuum Vacuum Test 1 Connect the hoses to the A C system which needs a maintenance 2 Open the LOW ref 25 and HIGH ref 26 valves according to how the connection on the system was made 3 Press the Vacuum key Set a vacuum time by means of the UP DOWN keys We suggest a vacuum time of at least 30 minutes Press the START key to start the function In case of emergency it is possible to leave the function by keeping the STOP key pressed for more than 3 seconds When the vacuum cycle is ove
17. type the plate of the car on which you are making maintenance You can modify each single field by means of the UP DOWN arrows and move forward by means of the START key When the car plate number has been typed press the MENU key to leave e Language By pressing the START key it is possible to change the language of the unit Shift through the languages by means of the UP DOWN arrows and confirm with START e Unit of measurement By pressing the START key it is possible to modify the unit of measurement INTERNATIONAL or IMPERIAL Shift by means of the UP DOWN keys and confirm with START e Inner Database By pressing the START key it is possible to make your own database Shift onto the field you want to modify by means of the UP DOWN keys and confirm with START Modify each digit by means of the UP DOWN arrows and confirm with START Then type the value of the refrigerant charge by means of the UP DOWN arrows and confirm with START e Date and Hour By pressing the START key it is possible to set the date and hour Modify each value by means of the UP DOWN arrows and confirm with START e Calibration e Service By pressing the START key it is possible to make some service operations using several keys combinations With the following combination Recovery Down Charge Vacuum it is possible to cancel all the data saved on the SD Card With the following combination Vacuum Charge Down Up itis possible to reset all the scales
18. uantity indicated below even if no oil has been extracted during recovery Evaporator 50cc Condenser 30cc Filter 10cc Pipes 10cc In any case the operator must follow the instructions of the A C system manufacturer 9 Press START and the screen for setting the refrigerant quantity will appear R 113 4 a Oo 3 00 kg A t a base v 10 If you press START on the first line the refrigerant quantity can be set manually by means of the UP DOWN arrows and confirming with START R 13 A a 0 300 k og M a x 4 6 6 5 k g 11 Otherwise on the second line you can gain access to the database and choose between Standard Database containing the main cars on the market and Personal Database created by the user D b S t a n d ar d D b Pe ris o nal 12 After having set the refrigerant quantity either by means of the manual menu or by means of the database menu you will have the START screen cycle start where the settings will be summarized on the second line IS t a r t St a r t 13 Press START to start the function A IMPORTANT The refrigerant charge cycle is performed by steps in order to reach a high precision You may hear subsequent clicks inside the unit during this phase 14 When the function is completed a beep will let the operator know that the cycle is over and the display will show the information on the cycle just performed R 13 4a 0 300kg Oli I i n 5 g 3 4 Automatic cycle 1 Connect the hoses to
19. ucts 19 Support For more support please contact your local service partner www wuerth com Newer versions of this manual please go to our homepage www wow portal com 20 WOW Wirth Online World GmbH SchliffenstraBe Falkhof 74653 K nzelsau zx 49 0 7940 15 1770 Ex 49 0 7940 15 3299 info wow portal com http www wow portal com 2108 ENG MANUAL COOLIUS 1000 V 1 1 24 05 2013
20. um pump oil level covers half of the sight glass see drawing below N 2 2 TURNING COOLIUS 1000 ON 1 Connect the unit to the power supply 2 Place the power switch ref 67 in position 1 When turned on the unit will display the software version and the hardware version Wait a few seconds in order to see the standby screen By means of the UP DOWN arrows it is possible to shift to the second standby screen R 134 a 0 00 0k g 1 0 3 4 08 10 12 Standby screen 1 O i i n 0 g A O i o u t 0 Standby screen 2 2 3 ZERO SCALE CHECK 1 Make sure that the unit refrigerant bottle is empty 2 Wait at least 5 minutes so that the bottle scale assembly stabilizes before proceeding in case the values of scales are not equal to 0 perform the procedure by following the below steps otherwise go to section 2 4 3 Proceed to the unit initial reset before the first use 4 Press the MENU key 5 Select Service by means of the UP DOWN arrows 6 Confirm by pressing the START key 7 Press the following keys in succession Vacuum Charge Down Up 8 2 1 When coming back to the Standby screen all the scales will be placed on the value O 4 Filling refrigerant into the internal bottle Place the bottle containing refrigerant so that liquid refrigerant will come out bottle with tube upright bottle without tube upside down 2
Download Pdf Manuals
Related Search