Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Denso KRISTAL
Summary of Contents for Denso KRISTAL
- Page 1 User Manual KRISTAL KRISTAL Refrigerant Recovery, Recycling and Recharging station for R1234yf vehicle A/C system. User Manual ORIGINAL MANUAL LANGUAGE: ITALIAN Read this User Manual carefully and before operating the RRR station. Revision number: Manual code: 4018123 Date: 07/02/2020...
- Page 2 The manufacturer reserves the right to make changes to the manual at any time without any obligation to notify people or organizations about these changes or revisions. The manufacturer, Denso Thermal Systems S.p.A., shall not be liable for mistakes in the manual, accidental...
-
Page 3: Table Of Contents
User Manual KRISTAL CHAPTER INDEX PAG. Introduction Technical specifications Operator workstation Safety Safety warnings Warnings relating to the work place RRR station unintended use Precautions for use Personal Protective Equipment RRR station safety precautions and protections Residual risks Safety warnings - Decals and symbols... - Page 4 User Manual KRISTAL CAPITOLO INDICE PAGINA 8.2.2.2 Touch sensibility 8.2.2.3 Working mode 8.2.2.4 Select language 8.2.2.5 Workshop Data 8.2.2.6 Operators 8.2.2.7 Operators PIN 8.2.3 LAN configuration 8.2.4 Import / Export 8.2.5 Printer test 8.2.6 Calibrations HP LP values Sensors values Counters 8.5.1...
- Page 5 User Manual KRISTAL Denso Thermal Systems S.p.A. would like to thank you for selecting a product from our range and to encourage you to read these instructions. They contain any information required for correct operation of the RRR station you have purchased. Please read this manual entirely and follow the instructions provided in it thoroughly.
- Page 6 User Manual KRISTAL ID LABEL DENSO Thermal Systems S.p.A. Frazione Masio, 24 10046 Poirino (TO)
- Page 7 User Manual KRISTAL DICHIARAZIONE DI CONFORMITA’ FARE RIFERIMENTO AL DOCUMENTO A CORREDO DEL MANUALE D’USO DECLARATION OF CONFORMITY REFER TO THE ATTACHED DOCUMENT OF THE USER MANUAL DÉCLARATION DE CONFORMITÉ CONSULTEZ LE DOCUMENT ATTACHÉ AU MANUEL D’UTILISATION DECLARACION DE CONFORMIDAD CONSULTE EL DOCUMENTO ADJUNTO AL MANUAL DEL USUARIO KONFORMITÄTSERKLÄRUNG...
- Page 8 SERVICE TECHNICIAN This term identifies any member of technical staff who has been trained and authorized by Denso Thermal Systems S.p.A. to carry out maintenance and service operations.
-
Page 9: Introduction
User Manual KRISTAL 1. INTRODUCTION The RRR station illustrated in this user and maintenance manual is an automatic multifunctional system with digital setting functions and a database, designed for first installation air conditioning systems on vehicles to fulfil operations such as gas recovery, waste oil drain, vacuum creation, leak testing and gas recharge under the control of a microprocessor with electronic precision scales. -
Page 10: Technical Specifications
User Manual KRISTAL 2. TECHNICAL SPECIFICATIONS For easier understanding, technical specifications have been divided by model. Stazione per il recupero, il riciclo e la ricarica del Nome gas refrigerante Modello KRISTAL Refrigerante applicabile R1234yf Tensione alimentazione 220V / 240V Frequenza alimentazione... -
Page 11: Safety
User Manual KRISTAL 3. SAFETY 3.1 SAFETY WARNINGS The RRR station must not be operated by staff who are not qualified or have not read, understood and learned the information contained in the manual with which the RRR station is supplied, and who have not received suitable training at courses organized by the manufacturer. -
Page 12: Rrr Station Unintended Use
User Manual KRISTAL 3.3 RRR STATION UNINTENDED USE Below is a list of UNINTENDED USES of the RRR station which may cause hazardous conditions: use of the RRR station for other purposes than those for which it was designed and manufactured, as specified in the section “Scope”;... -
Page 13: Personal Protective Equipment
User Manual KRISTAL Warning!!! Live parts: Power outlet ON/OFF buttons If the work cycle is disrupted for any reason whatsoever (e.g. no power supply), the operation should be restarted from the beginning. The outer vessel used for the recharge should be type-approved for pressures of at least 35 bar and it is provided with a safety valve (it must be compliant with the requirements laid down in pressure vessel standards). -
Page 14: Residual Risks
User Manual KRISTAL In the event of an EMERGENCY press the OFF button (see arrow) located in the front panel of the RRR station in order to cut off the power supply immediately. Always connect the high and low pressure piping (red and blue) to the supplied parts and do not use it for other purposes than those specified. -
Page 15: Safety Warnings - Decals And Symbols
User Manual KRISTAL 3.8 SAFETY WARNINGS - DECALS AND SYMBOLS Below is a list of decals and symbols affixed on the RRR station with their position. Please refer to the relevant section in this manual for the corresponding meaning. Position... -
Page 16: Power Supply
KRISTAL 3.9 POWER SUPPLY Power must be supplied to the RRR station as instructed by Denso that is not responsible for the connection, in any case. The RRR station is only safe when the power supply system upstream the RRR station is compliant with the safety rules. -
Page 17: Instructions For Use
User Manual KRISTAL 5. INSTRUCTIONS FOR USE 5.1 HANDLING AND TRANSPORT Before moving the RRR station, check its level of stability and the support surface to ensure it is horizontal. Check for bumps, holes or materials which may obstruct the path travelled by the RRR station. -
Page 18: Inner Tank Blocking And Release
User Manual KRISTAL 5.2 INNER TANK BLOCKING AND RELEASE The inner tank block is one of the safety devices featured in the RRR station that is designed to protect the electronic scale against shocks during handling and/or transport operations. This precision mechanical system blocks the inner tank when the load is lifted from the scale. -
Page 19: Frame
User Manual KRISTAL 5.3 FRAME Front and rear view LAN connection Analogue pressure gauges Control keypad Power cable connection HP High Pressure Service Hose LP Low Pressure Service Hose Service Connection Air out flow Pivoting wheels with lock Waste Oil... - Page 20 User Manual KRISTAL LH side view Printer Refrigerant Dryer Filter cover Refrigerant Analyser Filter (optional) Refrigerant Dryer Filter Air out flow...
- Page 21 User Manual KRISTAL RH side view UV Tracer bottle Flushing ports for Hoses cleaning New Oil container New Oil bottle change Sight glass for oil inspection in vacuum pump...
- Page 22 User Manual KRISTAL Pressure gauges and control panel Low pressure gauge High pressure gauge Cycle in progress indicators Switch Emergency button Pulsante SD card reader Keypad...
- Page 23 User Manual KRISTAL LCD Display Ciclo in corso (3) Barra di pressione Condotto HP (2) Barra di pressione Condotto LP (2) Pressione Pressione Condotto HP Condotto LP Temperatura Temperatura refrigerante Condotto HP (1) refrigerante Condotto LP (1) Pressione sistema Dati inerenti al...
-
Page 24: Main Functions
User Manual KRISTAL 5.4 MAIN FUNCTIONS The functions featured in the main menu of this RRR station are as follows: • Automatic operation: This is the automatic cycle for refrigerant gas recovery, waste oil drain, gas recycling, vacuum creation, leak testing, refill of New Oil/UV Tracer and refrigerant gas. -
Page 25: First Use
User Manual KRISTAL 6. FIRST USE 6.1 PRINTER PREPARING Open the printer cover. Fit the paper roll following the direction as shown in picture. Failure to fit the paper roll in the correct direction is likely to cause paper jams. -
Page 26: Inner Tank Filling
User Manual KRISTAL Switch on the RRR station. The IP address of the RRR station appears on the display. After viewing the IP address, the Home page is displayed. *The setup procedure of the IP address may vary according to the RRR station model. - Page 27 User Manual KRISTAL Selection: Main Menu “5. Tank refill” External two-valve tank: open the valve marked with the “drop” symbol indicating the refrigerant outflow in liquid state. External one-valve tank: turn the external tank upside down after opening the valve mar- ked with the “drop”...
-
Page 28: New Oil/Uv Tracer Level Inspection
Do not unscrew and/or screw the caps of the New Oil and UV Tracer bottles without having first removed them from their seats. Use of other types of New Oil/UV Tracer from those recommended by Denso Ther- mal Systems S.p.A. is not allowed The New Oil and the UV Tracer bottles are not interchangeable;... - Page 29 User Manual KRISTAL New Oil bottle: Fit the female quick plug of the New Oil bottle into the male quick coupling located on the left; the New Oil container housing. Gently push the New Oil bottle forward to fit it into its seat.
-
Page 30: Operating Instructions
User Manual KRISTAL 7. OPERATING INSTRUCTIONS 7.1 SERVICE HOSES MANAGEMENT How to CONNECT the service hoses: Pull up the lock ring and push the quick coupler on the service port corresponding to the A/C system. Open the valve of the quick coupler by turning it clockwise. -
Page 31: Automatic Operation
User Manual KRISTAL 7.3 AUTOMATIC mode The RRR station runs the following cycles in automatic mode: • recovery and recycling of refrigerant gas • drainage of recovered waste oil, if any • pressure checking • vacuum and leak testing under vacuum conditions •... - Page 32 User Manual KRISTAL Selection: Main Menu “1. Automatic” “1. Database” “1. OEM DB” Select the vehicle brand from the available menus until you find and confirm the desired vehicle. At the end of the selection, the display shows all the selected parameters.
- Page 33 User Manual KRISTAL Select either 1, 2 or 3 in the menu to set the connection type based on the A/C system configuration: 1 -> high pressure (HP) service hose only; 2 -> low pressure (LP) service hose only; 3 -> both HP and LP service hoses.
- Page 34 User Manual KRISTAL Then proceed with the replacement of the New Oil bottle; the RRR station activates an acoustic signal in order to inform the operator that the container has been replaced. If necessary, read the instructions in section “6.5 New Oil, UV Tracer and Waste Oil level inspection” on page 28 for installation and/or removal of the New Oil bottle.
- Page 35 User Manual KRISTAL Selection: Main Menu “1. Automatic” “2. Manual” Set the desired amount of refrigerant gas, New Oil and UV Tracer. Press “ENTER” to continue. Select either 1, 2 or 3 from the menu to set the connection type based on the A/C system configuration: 1 ->...
- Page 36 User Manual KRISTAL At the end of the refrigerant charging cycle, proceed as instructed below to complete the optimal recharge according to the selections in items 7 or 16: HP connection (high pressure service hose only) Start the engine and switch on the A/C system in the vehicle Press “ENTER”...
- Page 37 User Manual KRISTAL The display shows the screen where the pressure test is enabled using the analogue LP pressure gauge. The RRR station waits for the operator to evaluate the working pressure (LP) in the A/C system for the necessary time.
-
Page 38: Manual Function: Recovery
User Manual KRISTAL 7.4 Manual mode: RECOVERY During this cycle the RRR station recovers refrigerant gas from the vehicle A/C system. The refrigerant is filtered, dried and separated from oil, after which it is stored in the inner tank while waste oil, if any, is transferred to the relevant bottle. - Page 39 User Manual KRISTAL As soon as the printer screen appears: press “ENTER” to print. After report printing is completed, the display offers the possibility to print the report once again. The report may be printed for as many times as required Press “EXIT”...
- Page 40 User Manual KRISTAL The refrigerant gas recovery starts as soon as the internal pressures have been tested. After the desired amount of refrigerant gas has been recovered, the cycle ends and the display shows the final report. Press “ENTER” to continue.
-
Page 41: Manual Function: Vacuum
User Manual KRISTAL 7.5 Manual mode: VACUUM During this cycle the RRR station extracts humidity from the A/C system using a pump capable of achieving a high level of vacuum. Before this cycle is started, a check must be made that no refrigerant gas has been left in the A/C system. - Page 42 User Manual KRISTAL Once the pre-set vacuum time has elapsed, the RRR station runs a leak test in the A/C system that has been evacuated for a time of 5 minutes. At the end of the cycle the total time and the variation in pressure measured in the A/C system are displayed.
-
Page 43: Manual Function: Charging
User Manual KRISTAL 7.6 Manual mode: CAR CHARGING During this cycle the RRR station refills refrigerant gas, New Oil and UV Tracer into the vehicle A/C system. New Oil and/or UV Tracer should be filled before the refrigerant gas. This cycle is completed automatically as soon as the initial amount set points are achieved. -
Page 44: Tank Refill
User Manual KRISTAL At the end of the cycle the RRR station always checks for non-condensable gases in the inner tank. If such gases are identified, the RRR station starts a function to restore optimized conditions. The display shows the message “Air purge”. -
Page 45: Hoses Discharge
User Manual KRISTAL 7.8 HOSES DISCHARGE This function should be run at the end of each pressure testing in the A/C system as well. The RRR station automatically restores the amount of refrigerant gas in the HP and LP service hoses to the vehicle A/C system (gas previously used for pressure testing). -
Page 46: Gas Analysis (Optional)
User Manual KRISTAL 7.9 GAS ANALYSIS (optional) This function should be run before to recovery the refrigerant gas from an A/C system or an external tank in order to analyse its purity. The optional analyzer is integrated into the RRR station and it’s able to detect R1234yf, R134a, R22 refrigerant gases, hydrocarbons and other contaminants with great precision. - Page 47 RRR station. If necessary, follow the instructions as described in section “9.2 Gas analyzer filter replacement” on page 70. The gas analyzer can be installed at any time. Please, contact Denso dealer to purchase the optional kit.
-
Page 48: Management Of Data In Sd Card
User Manual KRISTAL 7.10 MANAGEMENT OF DATA IN SD CARD The RRR station is supplied with an SD card where the following information is stored: 1. the results of all the cycles performed by the RRR station; 2. data pertaining to the Customized Database;... -
Page 49: Service Menu
User Manual KRISTAL 8. SERVICE MENU 8.1 STRUCTURE OF SERVICE MENU Service menu Setup menu Function PAG. 1. Settings The Service menu is designed to edit the base 2. HP LP values setup parameters of the RRR station, to read the 3. - Page 50 User Manual KRISTAL PC connection It is designed to connect the RRR station to a PC or laptop for a remote use; only with optional software. Filter change It is designed to start the automatic procedure for periodic replacement of the refrigerant gas dryer filter.
-
Page 51: Settings
User Manual KRISTAL 8.2 SETTINGS The following basic setup parameters are edited in the Setting menu. 8.2.1 Set date/time The default value is the central European time (UTC +1). This function is for use by operators, skilled technicians and service technicians. -
Page 52: Customizing
User Manual KRISTAL 8.2.2 Customizing 8.2.2.1 GAS ANALYZER This screen is used to either enable or disable the refrigerant gas analysis function The instructions in this section are addressed to skilled technicians and service technicians only. Selection: Main Menu “8. Service “1. -
Page 53: Working Mode
User Manual KRISTAL 8.2.2.3 WORKING MODE The operating mode of the RRR station can be selected among three different levels, depending on the work requirements. The instructions in this section are addressed to skilled technicians and service technicians only. Selection: Main Menu “8. -
Page 54: Select Language
User Manual KRISTAL ADVANCED mode: This mode is used to match all refrigerant gas in and out movements to/from the RRR station with the cycles performed by the various operators included in the list (max. 20 opera- tors). In this case, the counters relating to the selected operator are increased. - Page 55 User Manual KRISTAL Select “1. New” and enter the name of the company using the alphanumeric keypad. Example: · “C” is displayed when key “1” is pressed three times. · “T” is displayed when key “8” is pressed one time.
-
Page 56: Operators
User Manual KRISTAL 8.2.2.6 OPERATORS This screen is used to record operators who normally run the station in “Advanced” and “PIN Protected” modes. The instructions in this section are addressed to skilled technicians and service technicians only. Selection: Main Menu ”8. -
Page 57: Lan Configuration
User Manual KRISTAL 8.2.3 LAN network configuration This screen is used to set up the LAN connection to the user’s network using a non-crossover network cable or a WIFI connection. Depending on the type of network, select either “Manual” or “DHCP” for the correct configuration. -
Page 58: Calibrations
User Manual KRISTAL 8.2.6 Calibrations This screen is used to calibrate each sensor in two different ways: · full calibration (Hard), by service technicians only; · zero calibration (Soft), by skilled technicians and service technicians.. Selection: Main Menu “8. Service “1. -
Page 59: Sensors Values
User Manual KRISTAL 8.4 SENSORS VALUES This screen is used to check the actual values measured by all sensors. This function is for use by operators, skilled technicians and service technicians. Selection: Main Menu “8. Service “3. Sensors values” The screen showing the measurements taken by each sensor is displayed as follows. -
Page 60: Counters
User Manual KRISTAL 8.5 COUNTERS This screen is used to view the totalizers and the counters of each individual operator (if the recharging station is set for Advanced or Pin Protected mode) relating to: • amount of refrigerant gas and oils moving in and out;... - Page 61 User Manual KRISTAL After checking the counters, data may be printed or exported. Follow the procedure below to either print or export data. Press “EXIT” to go back to the Counters menu. Press “ENTER” to view the Print screen. Press “ENTER” one more time to print the report of gas counters.
-
Page 62: Oil Counter
User Manual KRISTAL 8.5.2 OIL counters This screen is used to view the total amounts of filled New Oil/UV Tracer in detail.. OilC: total amount of New Oil filled, OilC: 0Kg expressed in Kg (no resetting). UvC: 0Kg UvC: total amount of UV Tracer filled, OilR: 0Kg expressed in Kg (no resetting). -
Page 63: Filter Counter
User Manual KRISTAL 8.5.5 FILTER counter This screen is used to view the number of gas dryer filters replaced and the percentage usage of the installed gas dryer filter. Filter replacements: specifies the number of times the gas dryer filter was replaced. -
Page 64: Oil Tank Change
User Manual KRISTAL 8.8 OIL TANK CHANGE This function is designed to automatically clean the service hoses and the inner lines affected by the convey of the New Oil in order to avoid contamination due to the different characteristics of the lubricants. - Page 65 User Manual KRISTAL Open the Low and High Pressure quick couplings. Once all operations listed above are been performed, confirm with “ENTER”. Continue with the process only if the operations listed have been strictly carried out in according to the instructions on the screen.
-
Page 66: Hoses Flushing
User Manual KRISTAL 8.9 HOSES FLUSHING This function is designed to automatically clean the service hoses every time it will be necessary. This function should be periodically performed to ensure the cleaning of the service hoses and the inner lines... - Page 67 User Manual KRISTAL Continue with the process only if the operations listed have been strictly carried out in according to the instructions on the screen Once the internal conditions have been checked, the RRR station starts the process and automatically cleans the service hoses as expected.
-
Page 68: Routine Maintenance
Genuine parts only should be used, as specified by Denso. In addition to a new gas dryer filter, filter replacement requires that a serial number be entered in order to start the relevant procedure. If the entered serial number is invalid, the procedure will not continue. - Page 69 User Manual KRISTAL Undo the four screws shown in the figure and re- move the metal filter cover to access the refrigerant gas dryer filter. Undo the two locking screws and take out the waste refrigerant gas dryer filter. Do not use the O-rings if they are worn.
-
Page 70: Gas Analyzer Filter Replacement (Optional)
The instructions in this section are addressed to skilled technicians and service technicians only. • Genuine spare part only must be used, as specified by Denso. • The use of any other spare part from the one specified may cause irremediable damage. -
Page 71: Vacuum Pump Oil Replacement
The instructions in this section are addressed to skilled technicians and service technicians only. • Genuine oil only must be used, as specified by Denso. • The use of any other oil from the one specified may cause irremediable damage. - Page 72 User Manual KRISTAL Unscrew the fill plug as shown in the figure Fill with fresh oil until the oil level rises to half the sight glass. Screw the oil fill plug correctly and with caution. Fit the front cover back in place.
-
Page 73: Oil Top-Up In Vacuum Pump
User Manual KRISTAL 9.4 OIL TOP-UP IN VACUUM PUMP Follow the steps (1, 4 and 5) illustrated in the procedure in section 9.3 “Vacuum pump oil replacement” to top up the oil level. The instructions in this section are addressed to skilled technicians and service technicians only 9.5 REPLACEMENT OF PAPER ROLL IN PRINTER... -
Page 74: Troubleshooting
User Manual KRISTAL 10. TROUBLESHOOTING In the event of a malfunction the display shows the corresponding error messages according to the contemplated options. Refer to the table below for troubleshooting operations, where necessary. The error message disappears automatically as soon as the problem is resolved. - Page 75 User Manual KRISTAL...
-
Page 76: Fuse Replacement
User Manual KRISTAL 10.1 FUSE REPLACEMENT These instructions are addressed to operators, skilled technicians and service technicians. Fuse type: Glass, 250V, 8A T Disconnect the power cable. Take out the fuse holder, including the fuse. Remove the fuse. Fit a new fuse in the fuse holder. -
Page 77: Spare Parts
User Manual KRISTAL 11. SPARE PARTS Order spare parts from the same dealer you have purchased your RRR station from. Parts description Parts picture Parts No. LP service hose 4018553 HP service hose 4018554 LP quick coupling 4018628 HP quick coupling... - Page 78 Refrigerant gas analyzer filter 4017116 Waste oil bottle 4018952 New Oil bottle 4018821 UV Tracer bottle 4018820 CONTACTS Denso Thermal Systems S.p.A. Frazione Masio, 24 - 10046 Poirino (TO) Tel. +39 011/9417111 - Fax. +39 011/9417403 http://www.denso-ts.com – e-mail: info@denso-ts.it...