Table Of Contents - MAHLE ACX380 Service Manual

2 | ACX380/480
en
|
Contents
1 General instructions ....................................... 3
1.1 General notes .......................................... 3
1.2 General instructions ................................ 3
1.3 Manufacturer identification...................... 3
1.4 Environmental precautions ...................... 3
2 Safety conditions ........................................... 3
2.1 Personal safety information ..................... 3
2.1.1 Definitions ......................................................... 3
2.1.2 Personal safety information .............................. 3
2.2 Important information on service
equipment safety .................................................... 5
2.3 Safety devices ......................................... 5
3 Layout of the manual ...................................... 5
3.1 Use of the manual ................................... 5
3.2 Symbols................................................... 6
3.2.1 Safety ............................................................... 6
3.3 Glossary .................................................. 6
3.4 Guidelines for the handling of refrigerant 6
3.4.1 Precautions for refrigerant storage ................... 6
3.4.2 Conditions of refrigerant and system ............... 7
3.4.3 Recycling capacity ........................................... 7
4 Product description ........................................ 7
4.1 Application .............................................. 7
4.2 Scope of delivery ..................................... 7
4.3 Description of the unit ............................. 7
4.4 User interface .......................................... 8
4.4.1 Main menu ........................................................ 9
4.5 E³ CONNECT quick couplers .................. 9
5 Technical features ........................................ 10
6 Installation.................................................... 11
6.1 Equipment installation ........................... 11
6.1.1 Unpacking ...................................................... 11
7 Commissioning............................................. 11
7.1 Connections .......................................... 11
7.1.1 Positioning and connection ............................ 11
7.2 Software update .................................... 12
7.3 Initial verification .................................... 12
7.4 New PAG and POE oil bottles filling ...... 12
7.5 UV dye bottle filling ............................... 13
8 Setup ........................................................... 14
9 Service Menu ............................................ 15
9.1 Manual activations and analogue channel
view ............................................................... 15
9.2 Pressures calibration (service kit) .............. 15
9.3 OOB Pressures calibration (service kit) ...... 16
9.4 Gas weight calibration .............................. 16
9.5 Calibration check ..................................... 17
9.6 Oil weight calibration ................................ 17
9.7 Compressor and vacuum pump test ......... 17
9.8 Spare parts & consumables ...................... 17
10 Equipment and simulator ........................... 17
11 Refrigerant fluid circuit ............................ 17
11.1 Refrigerant fluid circuit ............................. 17
11.2 Operational cycles ................................... 18
11.3 Receiving tank (refrigerant cylinder) .......... 18
11.4 Manifold charts ....................................... 18
11.5 NITROGEN TEST and FORMING GAS
LEAK TEST - MANIFOLD ..................................... 20
11.6 Suction circuit components...................... 21
12 Non-permanent junction .............................. 21
13 Electrical connections ............................. 21
14 Maintenance ............................................. 22
14.1 Maintenance interval ............................... 22
14.2 Hoses emptying ..................................... 23
14.3 Air purge ................................................ 23
14.4 Vessel filling ........................................... 23
14.5 Pressures zero ....................................... 23
14.6 Self leak test .......................................... 23
14.7 E³ PUMP ................................................ 23
14.8 Pump oil change .................................... 24
14.9 Dryer filter change ................................. 24
14.10 Replacement of Active Oil Protection
Cartridge .............................................................. 25
14.11 Calibration check ................................... 25
14.12 Maintenance of printer ........................... 25
14.13 Periodic checks ..................................... 26
14.14 Refrigerant type change (only for ACX 380)
.............................................................. 27
14.15 Air purge................................................. 27
14.16 Counters ................................................ 27
14.17 Replacing white sample filter (Refrigerant
identification unit).................................................... 27
15 Replacement interventions ........................... 28
15.1 Extraordinary maintenance list ................. 28
15.2 Extraordinary maintenance ...................... 28
15.2.1 Replacement of component connected
to refrigerant circuit ....................................................... 28
15.2.2 Replacement of logic electronic board with
display .................................................................... 29
15.2.3 Replacement of electronic power board .. 29
16 Spare and wearing parts .............................. 30
16.1 Refrigerant identification unit .................... 30
APPENDIX 1 - REFRIGERANT FLUID CIRCUIT
ACX380/480 ....................................................... 31
APPENDIX 2 - REFRIGERANT FLUID CIRCUIT
ACX380/480 OPERATIONAL CYCLES ............ 32
APPENDIX 3 - ACX380/480 - ELECTRICAL
CONNECTION - LOGIC ELECTRONIC BOARD
........................................................................... 36
APPENDIX 4 - ACX380/480 - ELECTRICAL
CONNECTION - POWER ELECTRONIC
BOARD AND POWER SUPPLY ....................... 37
APPENDIX 5 - ACX380/480 - ELECTRICAL
CONNECTION - STATUS AND WARNING
INDICATOR LIGHT ELECTRONIC BOARD ........ 39
APPENDIX 6 - TROUBLE SHOOTING .......................... 40
APPENDIX 7 - FAILURE LIST ACX380/480 .................. 41