A’GRAMKOW A/S Telephone: Telefax: Telex: Bank: Augustenborg Landevej 19 DK-6400 Sønderborg Denmark INSTRUCTIONS A/S Reg. No. 17 12 31 45 74 12 36 36 45 74 43 36 46 5 23 18 Unibank No. 22 37 RHS 900 Recovery, Recycling, Evacuation and Charging Station RHS 900 C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 0.1 - Contents 1. Application 2. Safety precautions 3. Components 4. Before use - Service couplings - Flow control - function and programming 5. Operating RHS 900 - Test - Recovery/recycling - Evacuation - Oil charging - Refrigerant charging - Automatic process - Charging of Leakdetector dye 6. Maintenance 7. Flow control, programming 8. Specifications 9. Service set 10. Accessories 11. Trouble shooting 12. Pos. no. location - Mechanical diagram - Electrical diagram 13.
- 1.1 - Application Your new RHS 900 station represents the latest in equipment for servicing air conditioning units (A/C units). The station is designed for refrigerants R12 and R134a. It can, and must, only be used for one of these refrigerants. RHS 900 is a test, recovery/recycling-(draining/cleaning), evacuation, oil/refrigerant charging station and is thus able to perform a total process cycle in servicing A/C units for the automobile industry.
- 1.2 - Application We reserve the right to make constructional and design changes and accept no responsibility for printing errors. RHS 900 complies with European standards on “Safety and health” and is GSapproved. See appendixes, "Declaration of Conformity" and TÜV Certificat. C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 2.1 - Safety precautions 1. Always wear protective goggles and gloves when working with refrigerant. 2. Do not allow refrigerant to come into contact with the skin or eyes. 3. Before disconnecting RHS 900 from the A/C unit, make sure that the process is completed so that refrigerant does not escape to the atmosphere. 4. RHS 900 is for use only in dry indoor surroundings. 5. Disconnect the electrical supply before performing maintenance on RHS 900. 6.
- 3.1 - Components 1) Oil charging: Oil charging switch. 2) Oil tank 3) Parking sockets: The high and low-pressure valves can be parked here. 4) Measuring beaker: For drained oil. 5) 6) Oil draining valve: For draining oil received from the A/C unit. Connection: Low-pressure, hose connection for the low-pressure side of the A/C unit. C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 3.2 - Components 7) Connection: High-pressure, hose connection for the high-pressure side of the A/C unit. 8) High and low-pressure valves. 9) Low-pressure gauge: Indicates the pressure on the low-pressure side in the test function. 10) High-pressure gauge: Indicates the pressure on the high-pressure side in the test function. 11) Connection: For leak detector dye, or alternative type off oil. 12) Levelindication: Showing the actual level in the internal cylinder.
- 3.3 - Components 14) Charging cylinder full - lamp (yellow): lights up when the charging cylinder is full and stops the process. 15) Compressor lamp (green): remains on for as long as the A/C unit is subject to pressure, i.e. when vacuum reaches -0.2 bar the lamp goes out. 16) Flow control: Display and keyboard. 17) Oil charging lamp (green): lights up when the evacuation process is complete, and indicates oil charging. Oil charging is activated by the switch (pos. 1).
- 3.4 - Components 22) Low-pressure gauge 23) Automatic process switch/lamp (green): cuts in the automatic process and lights up when the connection is made. 24) Evacuation switch/lamp (green): cuts in the evacuation process and lights up when the connection is made. After completed evacuation, a vacuum test is carried out automatically. The vacuum lamps light up to indicate “OK” or “Fault”. 25) Evacuation timer: Evacuation time can be set between 0 and 60 minutes.
- 4.1 - Before use Check the following: - whether the station has been damaged in transit - if so, contact supplier immediately; - oil level in vacuum pump: it must not be below the centre of the sight glass. If the level is too low, see section MAINTENANCE for vacuum oil replenishment instructions; - whether the mains supply is as stated on the station nameplate; - whether the refrigerant in the A/C unit is as stated on the station nameplate. Preparation: - Connect mains plug to mains supply.
- 4.2 - Before use Connection of service couplings C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 4.3 - Before use C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 4.4 - Before use Flow control - function and programming The Flow Control system - the “FC” - monitors and controls the different processes of RHS 900. FC can be programmed by the operator. Variables can be altered when process switch TEST is selected (see Section 7 for further information). C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 4.5 - Before use The functions of the various processes are described below. TEST: - Operation time Oilchange Maintenance time (for filter replacement) Variable programming. RECYCLING:- - Display is showing processcycle and indicating the elapsed time. EVACUATION: - Display is showing processcycle and indicating the elapsed time. PRESSURERIZING: - Indicates that pressure is being built up for 2 min. , and that the charging process will follow automatically.
- 5.1 - Operating RHS 900 Test - Open valves on service couplings. - Activate test switch. - Station mains switch ON (pos. 27). - The station now performs a test function. Connect the automobile A/C unit. The high and low-pressure gauges now indicate whether the A/C unit needs maintenance work. - Perform a condition diagnosis in accordance with the A/C unit supplier instructions. C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 5.2 - Operating RHS 900 Test - FLOW CONTROL function in TEST process: On pressing the clock-key the display shows how much time remains before servicing is necessary. FLOW CONTROL SERVICE TIME = 25 F1 F2 RESET PAUSE START 0.0 634-130041A-00 On pressing the clock-key and “F1” simultaneously the display shows for how long the unit has been in operation. FLOW CONTROL OPERATION TIME=125 1 F2 RESE PAUSE START 0. 634-130042A- C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.
- 5.3 - Operating RHS 900 Recovery/recycling - Press process switch (pos. 12) RECOVERY. - Open valves on service couplings (pos. 8). - The compressor starts and the RECOVERY lamp (pos. 15) lights up. - The recovery process now proceeds automatically until the A/C unit is empty. - The recovery process is finished when the RECOVERY lamp goes out. Wait 5-8 minutes to ensure that the unit is completely empty. - When the A/C unit is empty, the quantity of oil drained from the unit must be measured.
- 5.4 - Operating RHS 900 - The recovery and recycling time can be read from the FLOW CONTROL display. - If the A/C unit requires oil charging, the process sequence must be EVACUATION, OIL CHARGING and REFRIGERANT CHARGING. If oil replenishment is not necessary, AUTOMATIC PROCESS (page 5.8) can be selected. Evacuation - Set the evacuation time on the timer (pos. 25). - Press process switch (pos. 24) EVACUATION. - If overpressure remains in the A/C unit, the vacuum pump will not start.
- 5.5 - Operating RHS 900 Oil charging IMPORTANT! When the A/C unit has been charged with refrigerant, oil charging is not possible. Oil charging must always be performed before refrigerant charging. Oil charging is only possible after evacuation is complete and only when the lamp VACUUM OK (pos. 18) lights up. Proceed as follows: - Check to make sure that there is sufficient oil in the oil tank or replenish the tank as described below.
- 5.6 - Operating RHS 900 Refrigerant charging - Before the charging process, check the quantity of refrigerant necessary for the A/C unit concerned. This information can be found on a nameplate in the vehicle engine compartment. - Press process switch (pos. 20) REFRIGERANT CHARGING. - If PAUSE is indicated, push the RESET /0.0 button and following the STARt-button to accept it. - Key in the charging quantity required: - The value of each numeral can be changed with the arrow-up key.
- 5.7 - Operating RHS 900 - The charging process must be cut in with the START key. - The charging process can be monitored on the display. - If the process has to be stopped for a short period, press the PAUSE key. - When the process is to be cut in again, press the START key. - If the entire process is to be annulled, first press the PAUSE key and then the RESET key. Now press the START key to confirm the annulment. C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 5.8 - Operating RHS 900 For further information on trouble shooting and GAS, BLOCK-ALARM etc., see Section 7. - It is now possible to check whether the A/C unit has been charged with the correct quantity of refrigerant. To do this, start the unit and then read off high and low pressure from the appropriate unit pressure gauges. The correct pressures are given in the A/C unit supplier instructions. - When charging is complete, wait 30 seconds before disconnecting quickcoupling hoses from the A/C unit.
- 5.9 - Operating RHS 900 - If, however, vacuum rises above -0.8 bar the yellow lamp indicates VACUUM FAULT (pos. 19) and no refrigerant is charged. - If in any case refrigerant is to be charged, refrigerant charging can be started by activating the CHARGING switch. - Before the actual charging process starts, the display will be indicating “ PRESS. RIZING” in 2 minutes, where pressure is build up.
- 6.1 - Maintenance 29) 30) 31) 32) 33) 34) 35) Acid filter. Filter drier. Charging stub. Charging stub. Oil level vacuum pump. Oil draining plug. Nut. C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 6.2 - Maintenance To observe the warranty on RHS 900, all components used for maintenance must be identical to those in the service set, see Section 9 To ensure problem-free operation of RHS 900, the station must be maintained in accordance with the following: The power supply to the station must be switched off. For each 25 operating hours: The vakuumpump oil in time absorbs moisture, which in the end gives bad vacuum level. Therefore the oil must be changed frequiently.
- 6.3 - Maintenance C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 6.4 - Maintenance The condenser surface must be kept clean: - Remove the rear panel of the station (4 screws). - Clean the condenser with compressed air and perhaps a soft brush. Be careful not to bend the fins since this would reduce the air flow and impair condenser capacity. - Replace rear panel. Check the oil level in the vacuum pump: - Oil level check: Start the evacuation process and allow it to run for a few minutes.
- 6.5 - Maintenance For each 75 operating hours: Replace acid filter (pos. 28) - Remove front panel (4 screws). - Replace filter by loosening the two 3/8" flare nuts and fit new filter. Use only new filters fitted with protective caps on connections and make sure the filter is oriented correctly (arrow pointing downwards). Replace filter drier (pos. 29) - Remove filter by first loosening end unions. Slowly loosen nuts (pos. 35) and take out filter. - Draw insulation off filter drier.
- 7.1 - Flow control - programming The following programming is possible: 1) 2) Display text language Contrast/illumination of display background The following variables for the charging process can be programmed: 1) The additional quantity of refrigerant to be charged to compensate for the quantity in the hoses.
- 7.2 - Flow control - programming Changing the language: C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 7.3 - Flow control - programming Changing contrast/illumination of display background. C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 7.4 - Flow control - programming Compensation for refrigerant still in the charging hoses during charging. An extra stroke corresponds to approx. 5 g. The factory setting is 25 g corresponding to the maintenance hose supplied with the station, and an ambient temp. Of 20 oC. Resetting of Gasalarm/Block Alarm C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 7.5 - Flow control - programming C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 7.6 - Flow control - programming If the gas alarm cannot be turned into OFF position the charging cylinder is probably full. Shift to Process draining/recycling and connect refrigerant bottle. If the block alarm cannot be turned into OFF position the valve on high pressure hose is closed or the hose is blocked. Check hose gaskets or contact the supplier. C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
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- 8.3 - Specifications Service and maintenance Acid filter: Replaceable, 3/8" SAE Oil filter: 0.
- 9.1 - Service set Quantity Description Code no. 1 Acid filter 069-2910127 1 Filter drier 069-7480044 2 Gasket for filter drier 065-7751920 0.25 l Compressor oil - mineral 290-0001250 0.25 l Oil for vacuum pump 290-0001272 To order complete service set - state code no. (see nameplate). C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 10.1 - Accessories Qty Description Code no.
- 11.1 - Trouble shooting Test process Problem Fault Remedy Pressure gauge shows no 1. and 2. Valve not opened pressure 1. Open high and low-pressure valves on service couplings 2. No refrigerant in A/C unit Pressure gauge shows 1. A/C unit defective the same reading all the time 2. A/C unit not cut in 2. Repair A/C unit. 1. Empty A/C unit and repair 2. Cut in A/C unit Recovery process: Problem Fault Recovery process does 1. RHS 900 not cut in not start - green recovery lamp does not light up 2.
- 11.2 - Trouble shooting Evacuation process: Problem Fault Vacuum pump does not 1. RHS 900 not cut in run 2. Overpressure in A/C unit 3. Internal component fault Vacuum pump runs but 1. Service couplings not fitted correctly does not build up enough vacuum 2. A/C unit defective/leaking 3. Internal component fault Remedy 1. Cut in RHS 900 2. Cut in recovery process 3. Contact RHS 900 supplier 1. Fit service couplings correctly 2. Repair A/C unit 3.
- 12.1 - Pos. no. location Mecanical diagram 642-120001A-01 C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 12.2 - Pos. no. location Electrical diagram: 642-120002A-01 C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 12.3 - Pos. no. location 2) 3) 5) 6) 8) 9) Check valve Suction accumulator Acid filter Check valve Oil filter Filter drier 10) 11) 17) M1) M2) M3) Check valve Check valve Check valve Compressor Condenser/Fan Vacuum pump C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
- 13.1 - Appendixes Example of trouble shooting in an A/C unit: Conditions: 1. Ambient temperature 30-35°C (86-95°F) 2. Motor speed 2000 rpm 3. A/C unit temperature setting Maximum Under the above conditions the pressure values for an intact A/C unit will be as follows during the TEST process: High pressure 15 bar Low pressure 2 bar Follow the TEST process as in Section 5: - Connect service couplings to A/C unit. - Close high and low-pressure valves on RHS 500.
- 13.2 - Appendixes Test - 1: High pressure Low pressure Fault/Problem Unsatisfactory refrigeration 8 - 9 bar Approx. 0.8 bar Symptom Conditioned air not cold Possible cause Leakage in A/C unit Remedy Locate leak and repair Air bubbles in sight glass Insufficient refrigerant in A/C unit Replenish with refrigerant Test - 2: High pressure Low presure Fault/Problem Unsatisfactory refrigeration Approx. 20 bar Approx. 2.
- 13.3 - Appendixes High pressure Low pressure Approx. 7 - 15 bar Approx. 1.5 bar Fault/Problem Periodic disturbances in A/C unit Symptom Varying pressure on high and low-pressure sides Possible cause Moisture in A/C unit causes ice formation on expansion valve resulting in reduced output, ore filter drier saturated. Remedy Empty A/C unit, evacuate and recharge. After the recovery process, replace filter drier. If necessary, remove expansion valve, clean it and refit or replace as necessary.
- 13.4 - Appendixes Test - 5: High pressure Low pressure Fault/Problem Unacceptable refrigeration Approx. 19 - 20 bar Approx. 2.5 bar Symptom Ice or moisture on hoses on low pressure/suction side of A/C unit Possible cause Expansion valve defective or sensor placed incorrectly. Expansion valve opens too much. Remedy Check expansion valve sensor placing. Replace expansion valve.
- 13.5 - Appendixes Pressure vessel declaration We confirm herewith that the condition of the pressure vessel in this unit conforms to regulations laid down by the appropriate authorities: Suction accumulator, pos. 3: Manufacturer: A'GRAMKOW A/S Augustenborg Landevej 19 DK-6400 Sønderborg Denmark Type: 642-010017A Permissible working pressure: PS = 25 bar Permissible working temperature: -40/70°C Volume: V = 1.53 litres Oil separator, pos. 8: Manufacturer: AC & R Components Chatham, Ill.
- 13.6 - Appendixes Filter drier, pos. 9: Manufacturer: RTI Technologies Inc. Type: 026-80044-00 Permissible working pressure: PS = 31.05 bar Permissible working temperature: 10/120°C Volume: V = 0.83 litres Charging cylinder, pos. 13 Manufacturer: Henry Valve (UK) Type: 642-100027B Permissible working pressure: PS = 25 bar Permissible working temperature: -20/120°C Volume: V =7.0 litres C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.
