Zell AC1800 Operation Manual
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Zell AC1800 Operation Manual

Automobile air-con service station
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AC1800 Operation Manual

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  • Page 1 Automobile Air-Con Service Station AC1800 Operation Manual...

  • Page 2: Table Of Contents

    Contents 1 About this operation manual.....................2 of symbols in this operation manual............1.1 Explanation 2 Scope of delivery........................Safety............................5 3.1 General safety instructions......................3.2 Warnings on the Air-Con Service Station..................3.3 Safety devices..........................4 Proper use..........................5 Overview of the Air-Con Service Station................9 6 First start up.........................

  • Page 3: About This Operation Manual

    1 About this operation manual This operation manual describes the ZELL Air-Con Service Station This manual is for those who have the required professional ability of providing the maintenance service on vehicle air conditioning system. This manual contains all the instructions necessary for safe and effective operating of the air Conditioning service Station.
  • Page 4 For illustrating the symbols in this operation manual Format Meaning Example Symbols used on the device button Press „BOLD” „LANGUAGE” Display messages ■ ■Pressure monitor Text List in any order ■Pressure relief valves ■ Text 1. Text Actions to be carried out in the 1.

  • Page 5: Scope Of Delivery

    After delivery, please check all the parts listed below are present and undamaged. If any part is missing or damaged, notify the company responsible for transport immediately AC1800 Air-Con Service Station Blue hose with coupling for LP connection and red hose with HP connection 2 Containers for new oil...

  • Page 6: Safety

    → Wear personal safety equipment (goggles and gloves) and avoid touching refrigerant, as this can cause chilblains to your body. → Use only ZELL approved storage cylinder,part NO.5150998 with this refrigerant recovery unit. → Only use genuine R1234yf refrigerant .If other refrigerants are mixed in, it can damage the Air-Con Service Station and the vehicle air condition system.
  • Page 7 gas . Although the gas is non-toxic, it displaces the oxygen you needed. → This equipment should NOT be used in the vicinity of spilled or open containers of gasoline. → To reduce the risk of fire.connect only to a circuit provide with 20 amperes maximum branch circuit over current protection in accordance with the National Electric Code,ANSI/NFPA 70.

  • Page 8: Warnings On The Air-Con Service Station

    3.2 Warnings on the Air-Con Service Station Be careful Observe the operation manual. Protect the device against rain Wear gloves when handling refrigerants. Wear goggles when handling refrigerants. Horizontal holding the station Caution for fire 3.3 Safety devices Pressure monitor: switch the compressor off if the normal ■...

  • Page 9: Proper Use

    ZELL assumes no liability for damage resulting from the following: Use for purposes more than those described in this operation manual. ■ Modification to the Air-Con Service Station without the permission of ZELL ■ Damage to the device resulting from external influences.

  • Page 10: Overview Of The Air-Con Service Station

    Overview of the Air-Con Service Station Used oil bottle Pressure gauge for working tank...
  • Page 11 USER COMMUNICATION INTERFACE: Recovery button : to recover the A/C refrigerant into the inside working tank,also it used for a number and character input. Vacuum button : to extract Non-condensable gases from A/C system,also it used for a number and character input. New oil button : to inject new oil into vehicle A/C system.also it used for a number and character input.
  • Page 12 Auto button: one press operation for all steps automatically. also it used for a number and character input. Weigh Scale Verification: check scale weight accuracy. also it used for a number and character input. Record print button: Car plate input and Print receipt (printer is an option item), also it used for a number and character input.
  • Page 13 Info: Example 1, when input the workshop info. If the desired character is on below page, Press for “1”input,like wise, for “8”input,and so on. Press On this page you can select whatever number you want. Page down...
  • Page 14 page up or page down, check the If the desired character is not on the page,press character showing on the LCD, For example, if you want you input “D” press ,and press for“C”,and so on.
  • Page 16 Example 2, when input the gas amount in Recharge function. Each press of the adjust button, the gas amount is showed below: All the other adjustment like in OIL INJECT,VACUUM, is the same conception.

  • Page 17: First Start Up

    1 First start-up 1.1 Setting up and switching on 110v 60Hz Power supply must be firmly grounded. If not,it will cause the weight scale a incorrect operation;it also may cause an injury to operators from an electric shock. 1. Place Air-Con Service Station to the workplace and lock the front casters.
  • Page 18 When at standby mode keep pressing...
  • Page 19 6.2 Installing in the bottle for new oil Unscrew the refrigerant oil bottle, put about 150 ml new oil in and screw it back to the device. 6.3 Filling up the working tank When the Air-Con Service Station is started for the first time, the internal refrigerant container is suggested be filled gas with at least 6 kg from an external refrigerant cylinder.
  • Page 20 ONE IS THE VAPOR PORT OF THE SOURCE TANK Only LIQUID refrigerant is recommended. ■ For other type of source tank, be sure that Only Liquid port should be connected to the refill adapter. BLUE ONE IS THE LIQUID PORT OF THE SOURCE TANK On standby mode,put the refill connector to the refrigerant bottle and fix it,then join the LP adapter with the low pressure hose(blue) to the connector, open the adapter, open the bottle valve and up side down it.press...
  • Page 21 3. use the button to input the gas amount that you want to refill into the working tank,then press button Tip:The filling will stop automatically when the quantity of refrigerant is desired,the LCD will show...
  • Page 22 4. Close the refrigerant bottle valve and disconnect the LP adapter，press to confirm. The LCD will show 5. press to confirm. And start hose cleaning operation to collect the gas reminded in hose !
  • Page 23 you should recover the refrigerant. If you do not recover the Note 1 : refrigerant inside the hose, it will cause refrigerant leakage when you release connections, as this can cause frosty. you can not select the recovery operation to instead of this one, Note 2 : or it will speed up the usage of filter driers.
  • Page 24 7. Press to confirm,disconnect the LP adapter from the external refrigerant bottle. And the program will come back to the standby mode.

  • Page 25: Operation

    6 Operation When the automobile air-conditioning is serviced, the engine and the air-conditioning must be switched off. 7.1 Recovery Recovery operation is the process that the Air-Con Service Station sucks the refrigerant from the vehicle A/C system, purity it and storage the gas into the working tank.
  • Page 26 2. Check the HP and LP gauges. If the showed pressure is zero or about, it means that no refrigerant is in the air-conditioning system, you can select other functions directly. If there exist pressure inside, press button,the LCD show Note: At this time you can specially keep pressing button for recovery.
  • Page 27 The recovery is only through the low side service port, and the operation will stop if the keep pressed button is released. And the gas quantity can not be measured in the process. Press to confirm,the device will start the recovery and recycling process.it will show the below information fter first phase of recovery, you need to spend some minutes, just waiting for more refrigerant evaporating into vapor, if the pressure inside the A/C raised,...
  • Page 28 5. When the recovery process is over, it will discharge used refrigerant oil automatically. 6. For about 30-50 seconds , The oil draining process would be finished.

  • Page 29: Vacuum And Vacuum Test

    Press button to stop the alarm buzzer,or press button to print,then the recovery process finished! 7.2 Vacuum and Vacuum Test Vacuum operation is the process that the Air-Con Service Station evacuate the vehicle A/C system into a vacuum state. The small quantity gases are exhausted outside.
  • Page 30 1. Press button, the device comes to vacuum mode. Note: at the time you can keep pressing button for a manual vacuum. If you do so, whatever the pressure is, the gas would be exhausted outside. careful for this operation, the introduced pressure is less than 0.5 bar, or when the gases rush out, the vacuum pump oil would spray.
  • Page 31 2. Use to set the vacuum time and test time, press confirm 3. Press , It comes from the vacuum and to the test automatically. The device will show the below information after expiry of the test time. If testing passed ,you will see If testing not passed ,you will see...
  • Page 32 Whatever the result,you can choose to press the button to print or press to confirm and come back to the standby mode. In fully auto mode,If the result is OK, the operation can go ahead, but if failed, the operation stop and will return to standby interface. Note: if the A/C system is not opened to air, the suggested vacuum time is 5-10 minutes.

  • Page 33: Oil Injection

    7.3 Oil injection This operation is to make up of new refrigerant oil into vehicle A/C system though the Air-Con Service Station. it must be a vacuum state that the new oil could be added into the A/C system. 1. Check the new oil bottle, make sure that the refrigerant oil is more than 50ml inside.
  • Page 34 2. Use to adjust the oil quantity, then press Or keep pressing button, the new refrigerant oil would be sucked into the A/C system. Watch the scale of the PAG bottle, when the oil is added with the desired quantity, stopped the operation. 3.

  • Page 35: Uv Injection

    4. Press the button to print or press to confirm and come back to the standby mode. 7.4 UV injection This operation is to make up of UV oil into vehicle A/C system though the Air-Con Service Station. it must be a vacuum state that the UV could be added into the A/C system.
  • Page 36 Press button. more than 50ml...
  • Page 37 2. Use to adjust the oil quantity, then press Or keep pressing button, the UV oil would be sucked into the A/C system. Watch the scale of the UV bottle, when the UV oil is added with the desired quantity, stopped the operation. 3.
  • Page 38 4. Press the button to print or press to confirm and come back to the standby mode.

  • Page 39: Recharge

    7.5 Recharge This operation is to fill with the refrigerant into the vehicle A/C system though the Air-Con Service Station. the quantity is measured by load cell and it must be a vacuum state that the gas could be added into the A/C system. Usually, if the tank pressure is over than 6 bar, the recharge will be done quickly, or it need some special solution to resolve it.
  • Page 40 If the machine is available for charge,you can press to adjust the refrigerant quantity that you could check the amount on the vehicle,or you can press button to use the database. When all are ready,press to confirm. 2. press button, it will recharge the air-conditioning with the refrigerant.
  • Page 41 The process will be stopped automatically when the set quantity of refrigerant is completely filled into the A/C system .press button to print or press to confirm,and you will see...
  • Page 42 This tip is to tell you take off the quick couples from the A/C system and screw back the valve caps to the service port. And empty the service hoses by recovery operation. The device is then ready for further use. 3.
  • Page 43 the hose-cleaning operation will finished automatically and come back to the standby mode. Note1: some time the recharge maybe not finished in time, and the bellow information displayed: This is because tank pressure is not enough for the operation. Please go on the process by starting the automobile engine and A/C, CLOSE AND TAKE OFF THE HP ADAPTER FROM THE AC , only let the Low side to suck the gas into A/C system, it will automatically stop if the set gas quantity is finished.

  • Page 45: Fully Auto

    7.6 FULLY AUTO The automatic operation is including recovery, oil drain, vacuum and vacuum test, oil injection, and recharging, all steps are in one press. Before operation, you must confirm that the new refrigerant oil and the UV are enough, or it has risk that the air would be sucked into the vehicle A/C system.
  • Page 46 This display indicates that the machine is diagnosing itself whether it is available for automatic.If it is ok ,will show you 3. press button, it will work automatically. Note:If the vacuum test result is OK, the operation can go ahead, but if failed, the operation stop and will return to standby mode.
  • Page 47 After all the steps finished,it will give you all the data for confirming,you can take off the quick couples from the A/C system and screw back the valve caps to the service port. And empty the service hoses by hose-cleaning operation. The device is then ready for further use.
  • Page 48 the hose-cleaning operation will finished automatically and come back to the standby mode.

  • Page 49: Weight Scale Verification

    7.7 Weigh Scale verification This operation is for checking the output of the weigh sensor . If it does not work correctly, an additional calibration is needed. You need something with a known weight .for example prepare a 200 g standard sample weight.
  • Page 50 It will show a 0 as default , then put the sample weight on the tank. It shows 200 , it means the sensor is working well. If the total error is out of 7 gram, an additional calibration is needed. 3.

  • Page 51: Record Print

    7.8 RECORD PRINT Total reception view: Head of reception Content of reception end of reception...
  • Page 52 1.Press button,the LCD show This for input the car plate and one normal press button to print out the head of the reception. Use password 1013 to edit workshop info. Max 15 characters in all for the name. one keep pressing to print out the end of reception.

  • Page 53: Weight Scale And Pressure Sensor Zero

    7.9 Weight Scale and Pressure Sensor Zero Weight Scale Zero In order to make sure the refrigerant quantities correctly, the zero point of the scales must be checked regularly filter change and reset if necessary. Resetting is necessary: If the quantity deviates by more than 10g from the target value ■...
  • Page 54 3. The device prompts you to remove the fix screw and lift the tank off from the scale plate. Make sure that there is NOTHING on the scale, press button . After finishing it, the LCD will come to the standby mode automatically. IMPORTANT: It should show -9.0kg, that means the work is properly...
  • Page 55 done. 9.0 kg is an empty tank’s weight. 4. place back the tank on the scale plate and fix the screw back.Please make sure that the tank is placed vertically without touching any wall.
  • Page 56 Pressure Sensor Zero In order to make sure the pressure measure work correctly, the zero point of the pressure sensor must be checked regularly and reset if necessary. Resetting is necessary: If the quantity deviates by more than 20mBar from the target value ■...
  • Page 57 1. then press to start “PRESSURE SENSOR ZERO” item. button 2. The device prompts you to remove the low adapter and make sure that the hose is well connected to ATM,then press button . After finishing it, the LCD will come to the standby mode automatically, put back the low adapter to the hose.

  • Page 59: Service Tasks

    8 Service tasks Other service are included this items as: INNER TANK REFILL 3. LANGUAGE SELECT 4. WEIGHT UNIT 4.OTHER SERVICE If you want come to these items , please press button and use button to select and enter it. 8.1 Inner tank refill Refer to 8.2 Language select...

  • Page 60: Weight Unit

    8.3 Weight Unit You can select grams or lbs . 8.4 Other service This operations are need the password , if you want to use this you can call the ZELL hot line to ask for the password.

  • Page 61: Disposal

    9. Disposal 9.1 Disposing of used fluids Used oil is hazardous waste. Do not mix used oil with other fluids. Keep used oil in suitable containers prior to disposal. Disposing of used fluids should comply the local government laws. 3.Disposing of used filter should comply the local government laws. 9.2 Disposing of packaging material ■...

  • Page 62: Trouble Shooting

    10 Trouble shooting Fault Cause Remedy This message is The display shows Press continue normal, during the „WARNING! other operations. If you recovery process. CODE :W16 make sure that there is no NOT ENOUGH PRESSURE refrigerant in A/C system . TO RECOVERY!.”...

  • Page 63: Technical Data

    1 Technical data Dimensions (width x height x depth) 550 mm x 1100 mm x 750 mm Weight 120 kg Power supply 110 V- 60 Hz Refrigerant R1234yf Vacuum pump 4.2 CFM Compressor 3/8 P tank capacity 13.6kg (30 lbs) Filter driers ability 80kg HP/LP gauges size...

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