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TEXA ACKF01 Installation And User Manual

Flushing kit
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ENGLISH....................................................................5

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Summary of Contents for TEXA ACKF01

  • Page 1 ENGLISH..............5...

  • Page 3: Table Of Contents

    SUMMARY REVISION OF THE MANUAL..............5 INTRODUCTION..................6 1 SPECIFIC SAFETY RULES FOR USING THE ACKF01 FLUSHING KIT .........................7 1.1 Glossary....................7 1.2 General Rules..................7 1.3 Operator Safety..................7 1.4 Safety Devices..................7 2 INTRODUCTION TO CLEANING WITH A REFRIGERANT ....9 2.1 What the cleaning is................9 2.2 Why the Cleaning is Important..............9...
  • Page 4 10 POST-CLEANING RECOMMENDATIONS........66 11 MAINTENANCE................67 11.1 Replacing the Dryer Filter of the Cleaning Vessel.......67 11.2 Internal Cleaning of the Cleaning Vessel..........68 12 ENVIRONMENTAL INFORMATION..........69 13 LEGAL NOTICES................70...

  • Page 5: Revision Of The Manual

    ACKF01 FLUSHING KIT INSTALLATION AND USER MANUAL REVISION OF THE MANUAL This document is revision 01 of the ACKF01 flushing kit installation and user manual. Issue date: 22/06/2018...

  • Page 6: Introduction

    INTRODUCTION Dear Customer, We would like to thank you for choosing a TEXA product for your workshop. We are certain that you will get the greatest satisfaction from it and receive a great deal of help in your work. Please read through the instructions in this manual carefully and keep it for future reference.

  • Page 7: Specific Safety Rules For Using The Ackf01 Flushing Kit

    The personnel in charge of using the charging stations is required to follow the general safety rules and to use the ACKF01 FLUSHING KIT for its intended use only. Furthermore, they are required to carry out the maintenance as described in this manual.
  • Page 8 Do not tamper with the overpressure valve in any way. Never get close to the overpressure valve when it is open, as it could discharge pressurised refrigerant. The maintenance operations on the safety devices must be performed by authorised Assistance Services only.

  • Page 9: Introduction To Cleaning With A Refrigerant

    2 INTRODUCTION TO CLEANING WITH A REFRIGERANT 2.1 What the cleaning is The cleaning with a refrigerant is an operation that is performed in order to remove the solid contaminants and the traces of old lubricant from the A/C system's compressor. The use of liquid refrigerants avoids the risk of damaging the internal components with harsh detergents.

  • Page 10: When Must You Clean The A/C System

    After a first fault within the components (for example in the compressor), the system is to be considered as contaminated. If the system is not cleaned properly, the spare parts (reconditioned or new) will have the same fate. Regardless of the defect detected in the A/C system, when you carry out a proper cleaning, it will be as clean (on the inside) as it was originally and thus perfectly efficient.
  • Page 11 Metal The presence of metal particles is a sign that the compressor is particles worn. The presence of black particles is a sign of the beginning of an excessive wear of the rider bands on the pistons. Black particles The small black particles accumulate on the input of the orifice tube.

  • Page 12: Components That Are Sensitive To Contaminations

    2.5 Components that are Sensitive to Contaminations Tube with Fixed Orifice When working on an orifice tube, always remove the tube and inspect it. The input filter supplies the best indication regarding possible contamination in the A/C system. Do not try to clean it. Always replace it if there are traces of residues or contamination.
  • Page 13 Condensers and Evaporators These components sensitive constrictions caused contamination, particularly the Multipass type have very small and multiple openings in which the refrigerant flows. Condenser If some of these openings get clogged up, it is almost impossible to clean them and the only solution is to replace the entire Evaporator component.
  • Page 14 Compressors The A/C system contains oil that is transported by the refrigerant in order to lubricate the compressor (as in the two-stroke engines); this means that the compressors are affected by the quality and cleanliness of the lubricant. Contaminated does supply requested lubrication due to dirt particles that act as abrasive paper and damage the moving...

  • Page 15: Description

    3 DESCRIPTION 3.1 Intended Use ACKF01 is an optional kit to install on the KONFORT charging stations Series 700R, in particular on the following models: • 710R • 720R • 760R • 760R BUS • 780R BI-GAS • 770S The ACKF01 FLUSHING KIT requires many components (which are provided with it) and the activation of the cleaning function by the software of the charging stations listed above.

  • Page 16: Contents Of The Kit

    3.2 Contents of the Kit The images that follow show the contents of the ACKF01 FLUSHING KIT. Item Description Quantity Part code Cleaning vessel 74350486 Universal adapter set for the cleaning 3134 Red service pipe for the cleaning: 3/8" x 3/8", 3000...
  • Page 17 Item Description Quantity Part code 6 x 16 mm assembly screws 417560616 Aluminium assembly rings 74350488 SAE 1/4" x 3/8" adapter 3900172 SAE 1/4" adapter for HP R134a 3900173 SAE 3/8" adapter for HP R134a 3900174 SAE 1/4" adapter for HP R1234yf 3906803 10 SAE 3/8"...

  • Page 18: Technical Features

    4 TECHNICAL FEATURES Model ACKF01 FLUSHING KIT Manufacturer TEXA S.p.A. Refrigerant R134a - R1234yf Maximum pressure 21 bar Filtering efficiency 50 micron Vessel capacity 6.2 litres Service pipe length 3000 mm...

  • Page 19: Installation

    5 INSTALLATION The procedure described below indicates the installation of the ACKF01 FLUSHING KIT on the KONFORT charging stations Series 700R. Turn off the charging station and disconnect the power cable from the mains before proceeding with the installation operations.
  • Page 20 6. Insert the aluminium rings into the specific holes in the metal plate on the cleaning vessel. 7. Move the cleaning vessel downwards until it settles around the aluminium rings. The vessel installed this way can be removed whenever it is not used.

  • Page 21: Preparing The Charging Station

    6 PREPARING THE CHARGING STATION Prepare the charging station following the instructions indicated below. Proceed as follows: Connect: 1 - Red service pipe for the cleaning (code 3900171) 2 - Cleaning vessel input (code 74350486) Connect: 3 - SAE 1/4" x 3/8" adapter (code 3900172) 4 - Red service pipe for the cleaning (code 3900171) Connect:...
  • Page 22 If using the Audi-Volkswagen adapter set, connect: 7b - Charging station's red service pipe 8b - SAE 3/8" adapter for HP R134a (code 3900174) The Audi-Volkswagen adapter set is not included in the flushing kit, it must be purchased from the VW group directly. Make sure the charging station's recovered oil bottle (DRAIN) is empty so the oil or UV additive do not overflow.

  • Page 23: Examples Of Adapters And Couplers For The Cleaning

    6.1 Examples of Adapters and Couplers for the Cleaning Following there are various examples of couplers that can be used to clean the A/C system. Select the appropriate coupler based on the configuration of the system involved (the universal cleaning adapter case, code 3134, contains approximately 60 different types of adapters).
  • Page 24 Example 5 1. Charging station's red service pipe 2. SAE 1/4" adapter for HP R134a (code 3900173) 3. Compressor bridge (code 42070096) Example 6 1. Universal adapter (code 42070098) 2. SAE 1/4" adapter for HP R134a (code 3900173) 3. Charging station's red service pipe Example 7 1.

  • Page 25: Preparing The A/C System

    7 PREPARING THE A/C SYSTEM Based on the system's configuration, you must remove some components and install specific bridges and adapters. Below is the description of the operations that must be carried out base on the type of system. The following are the operations that must be carried out that are common to all system types: 1.

  • Page 26: Systems With The "Block" Type Expansion Valve

    7.1 Systems with the "Block" Type Expansion Valve Components that must be Removed Legend Components that must be Removed 1. Compressor 2. Condenser • Compressor 3. Dryer filter • Dryer filter 4. "Block" type expansion valve • "Block" type expansion valve 5.
  • Page 27 Bridges / Adapters that must be Installed Bridges / Adapters that must be Legend Installed 1. Universal adapter 2. Condenser • Universal adapter (x2) 3. Universal adapter • Bridge for the compressor 4. Bridge for the "block" type expansion • Bridge "block"...

  • Page 28: System With The Thermostatic Expansion Valve (Txv)

    7.2 System with the Thermostatic Expansion Valve (TXV) Components that must be Removed Legend Components that must be Removed 1. Compressor 2. Condenser • Compressor 3. Dryer filter • Dryer filter 4. Thermostatic expansion valve • Thermostatic expansion valve 5. Evaporator...
  • Page 29 Bridges / Adapters that must be Installed Bridges / Adapters that must be Legend Installed 1. Universal adapter 2. Condenser • Universal adapter (x2) 3. Universal adapter • Bridge for the compressor 4. Bridge for the thermostatic expansion • Bridge thermostatic valve expansion valve.

  • Page 30: System With An Orifice Tube

    7.3 System with an Orifice Tube Components that must be Removed Legend Components that must be Removed 1. Compressor 2. Condenser • Compressor 3. Dryer filter • Dryer filter 4. Orifice tube • Orifice tube 5. Evaporator...
  • Page 31 Bridges / Adapters that must be Installed Legend Bridges / Adapters that must be Installed 1. Universal adapter 2. Condenser • Universal adapter (x3) 3. Universal adapter • Bridge for the compressor 4. Evaporator • Bridge for the thermostatic expansion valve. 5.

  • Page 32: Konfort - A/C System Connection

    8 KONFORT - A/C SYSTEM CONNECTION 8.1 Cleaning of Systems with an Expansion Valve Cleaning on evaporator side In order to prevent contamination in the entire system due to particles from the damaged compressor, you must start cleaning towards the location of the compressor and proceed according to the regular direction of the A/C system flow.
  • Page 33 Legend Notes 1. Bridge for the compressor* 2. Condenser 3. Universal adapter** * Location of the compressor 4. Evaporator ** Location of the dryer filter 5. Bridge for the expansion valve 6. Cleaning vessel 7. Charging station Proceed as follows: 1.
  • Page 34 Backwashing on evaporator side To carry out the last cleaning step, reverse the couplers previously connected to the system. This way, backwashing towards the location of the dryer filter can be performed, proceeding in the opposite direction of the A/C system's regular flow.
  • Page 35 Legend Notes 1. Bridge for the compressor* 2. Condenser 3. Universal adapter** * Location of the compressor 4. Evaporator ** Location of the dryer filter 5. Bridge for the expansion valve 6. Cleaning vessel 7. Charging station Proceed as follows: 1.
  • Page 36 Cleaning on condenser side In order to prevent contamination in the entire system due to particles from the damaged compressor, start cleaning towards the location of the compressor and proceed in the opposite direction of the A/C system's regular flow. Legend Notes 1.
  • Page 37 Proceed as follows: 1. Connect the HP coupler of the charging station's red service pipe to the universal adapter installed in place of the dryer filter. 2. Connect the red service pipe for the cleaning (code 3900171) to the bridge installed in place of the compressor.
  • Page 38 Backwashing on condenser side To carry out the last cleaning step, reverse the couplers connected to the system. This way, backwashing towards the location of the dryer filter can be performed, proceeding in the opposite direction of the A/C system's regular flow. Legend Notes 1.
  • Page 39 Proceed as follows: 1. Connect the HP coupler of the charging station's red service pipe to the bridge installed in place of the compressor. 2. Connect the red service pipe for the cleaning (code 3900171) to the universal adapter installed in place of the dryer filter.

  • Page 40: Cleaning Of Systems With A Orifice Tube

    8.2 Cleaning of Systems with a Orifice Tube Cleaning on evaporator side In order to prevent contamination in the entire system due to particles from the damaged compressor, start cleaning towards the location of the accumulator, according to the regular direction of the A/C system flow.
  • Page 41 Legend Notes 1. Condenser 2. Universal adapter* * Location of the orifice tube 3. Universal adapter** 4. Evaporator ** Location of the accumulator 5. Cleaning vessel 6. Charging station Proceed as follows: 1. Connect the HP coupler of the charging station's red service pipe to the universal adapter installed in place of the orifice tube.
  • Page 42 Backwashing on evaporator side To carry out the last cleaning step, reverse the couplers connected to the system. This way, backwashing towards the location of the orifice tube can be performed, proceeding in the opposite direction of the A/C system's regular flow.
  • Page 43 Legend Notes 1. Condenser 2. Universal adapter* * Location of the orifice tube 3. Universal adapter** 4. Evaporator ** Location of the accumulator 5. Cleaning vessel 6. Charging station Proceed as follows: 1. Connect the HP coupler of the charging station's red service pipe to the universal adapter installed in place of the accumulator.
  • Page 44 Cleaning of the accumulator-compressor coupler In order to prevent contamination in the entire system due to particles from the damaged compressor, start cleaning towards the location of the compressor, according to the regular direction of the A/C system flow. Legend Notes...
  • Page 45 1. Condenser 2. Location of the orifice tube 3. Universal adapter* * Location of the accumulator 4. Evaporator ** Location of the compressor 5. Cleaning vessel 6. Charging station 7. Bridge for the compressor** Proceed as follows: 1. Connect the HP coupler of the charging station's red service pipe to the universal adapter installed in place of the accumulator.
  • Page 46 Backwashing of the accumulator-compressor coupler To carry out the last cleaning step, reverse the couplers connected to the system. This way, backwashing towards the location of the accumulator can be performed, proceeding in the opposite direction of the A/C system's regular flow.
  • Page 47 Legend Notes 1. Condenser 2. Location of the orifice tube 3. Universal adapter* * Location of the accumulator 4. Evaporator ** Location of the compressor 5. Cleaning vessel 6. Charging station 7. Bridge for the compressor** Proceed as follows: 1. Connect the HP coupler of the charging station's red service pipe to the bridge for the compressor installed in place of the compressor.
  • Page 48 Cleaning on condenser side In order to prevent contamination in the entire system due to particles from the damaged compressor, you must always start cleaning towards the compressor and proceed in the opposite direction of the A/C system's regular flow.
  • Page 49 Legend Notes 1. Charging station 2. Cleaning vessel 3. Universal adapter* * Location of the orifice tube 4. Condenser ** Location of the compressor 5. Evaporator 6. Location of the accumulator 7. Bridge for the compressor** Proceed as follows: 1. Connect the HP coupler of the charging station's red service pipe to the universal adapter installed in place of the orifice tube.
  • Page 50 Backwashing on condenser side To carry out the last cleaning step, reverse the couplers connected to the system. This way, backwashing towards the location of the orifice tube can be performed, according to the regular direction of the A/C system flow.
  • Page 51 Legend Notes 1. Charging station 2. Cleaning vessel 3. Universal adapter* * Location of the orifice tube 4. Condenser ** Location of the compressor 5. Evaporator 6. Location of the accumulator 7. Bridge for the compressor** Proceed as follows: 1. Connect the HP coupler of the charging station's red service pipe in place of the accumulator.

  • Page 52: Flushing

    9 FLUSHING The cleaning or flushing can be single or multiple: This type of flushing performs only one cleaning cycle. SINGLE The single flushing is recommended for small contaminations FLUSHING and/or for simply removing the oil / UV additive. This type of flushing runs three or more consecutive cleaning cycles.
  • Page 53 The cleaning vessel is equipped with a coupler that has a control window which allows you to monitor the progress of the cleaning and the conditions of the cleaning agent, the refrigerant. Through this window you may verify the nature of the contamination that is transported by the refrigerant.
  • Page 54 The cleaning can be completed: • by letting the function advance on its own until the end of the cleaning cycle (single flushing) or cycles (multiple flushing); • by monitoring the passage of the cleaning agent through the control window and interrupting the cleaning when the agent has a light colour (no contaminating elements) pressing The cleaning can be interrupted at any time by pressing...
  • Page 55 NOTE By pressing the button , all the data that identifies the charging station and the firmware version installed is displayed. Press to return to the main menu. Press until selecting Additional Functions. Press Press until selecting Flushing. Press...
  • Page 56 ONLY ON KONFORT 780R BI-GAS: Press until selecting the type of refrigerant that you wish to use for the cleaning Press Press until selecting the desired type of flushing. Press Enter the customer data using the alphanumeric keypad. Press...
  • Page 57 Enter the vehicle data using the alphanumeric keypad. Press The charging station requires you to run the Internal Konfort cleaning. Press Connect the LP (blue) and HP (red) couplers to the related LP and HP fittings on the side of the charging station.
  • Page 58 Open the valves on the couplers turning the handwheels clockwise. Press The internal cleaning is launched. The final phase of the internal cleaning is the automatic check of the recovered oil.
  • Page 59 Close the valves on the couplers by turning handwheels counter- clockwise. Press Connect the HP service pipe to the system that must be cleaned. Wait for the system pressure check to end.
  • Page 60 Connect the LP service pipe to the external tank. Press Wait for the system pressure check to end. The vacuum phase is launched. The predefined length of this phase is 5 minutes. This phase can be interrupted at any time by pressing to go on to the following phase.
  • Page 61 The leak test on the couplers is launched. The predefined length of this phase is 3 minutes. This phase can be interrupted at any time by pressing to go on to the following phase. If there are not any leaks the following message is displayed.
  • Page 62 If there are not any faults, the system is ready for the cleaning. The cleaning phase starts. The liquid refrigerant is loaded into the system, it flows through it and reaches the cleaning vessel filled with the impurities it removed. At the end of the cleaning phase, the system and/or the components are full of liquid refrigerant.
  • Page 63 After the pressure test, the charging station discharges liquid contamination (compressor oil, UV additive) into the waste oil bottle. contamination discharge marked by a countdown. The amount of liquid contamination is expressed in cc. If the charging station is equipped with a printer, a report related to the completed procedure is printed.

  • Page 64: Alarm Notifications

    Let it cool down for 30 minutes. Press If the problem persists, contact TEXA S.p.A. or an authorised retailer. message appears beginning or during the vacuum phase if pressure is detected inside the A/C system.
  • Page 65 The amount of refrigerant is not enough for the cleaning. Perform the Internal tank filling phase (refer charging station's technical manual). Check the A/C system.

  • Page 66: Post-Cleaning Recommendations

    10 POST-CLEANING RECOMMENDATIONS After cleaning a system, we recommend to proceed with some maintenance operations on the A/C system: • Replace all the system's O-rings. • Replace the dryer filter or the accumulator. • Discharge and replace the compressor oil. •...

  • Page 67: Maintenance

    11 MAINTENANCE Following are the maintenance operations that must be carried out on the components of the flushing kit. Refer to the charging station's technical manual for the maintenance operations related to the equipment. 11.1 Replacing the Dryer Filter of the Cleaning Vessel Replace the dryer filter of the cleaning vessel periodically.

  • Page 68: Internal Cleaning Of The Cleaning Vessel

    7. Reinstall the dryer filter (code 3906914) on the upstream coupler. 8. Reconnect the coupler downstream of the dryer filter using the right sized wrench. 11.2 Internal Cleaning of the Cleaning Vessel Clean the inside of the cleaning vessel periodically. Protect eyes and hands from solid particles that could be ejected during the cleaning.

  • Page 69: Environmental Information

    12 ENVIRONMENTAL INFORMATION For information regarding the disposal of this product please see the pamphlet supplied.

  • Page 70: Legal Notices

    13 LEGAL NOTICES TEXA S.p.A. Via 1 Maggio, 9 - 31050 Monastier di Treviso - ITALY Tax Code - Company Register of Treviso ID No. - VAT No.: 02413550266 Single-shareholder company subject to the direction and coordination activities of Opera Holding S.r.l.