MAHLE ACX2180H, ArcticPRO ACX2250, ACX2150, ArcticPRO ACX2280 Operation Manual
MAHLE ACX2180H
en 2 | ACX2180H |
| ACX2180H | 3
en
Contents
1
Symbols use
1.1
In the documentation ................................. 4
1.1.1
Warning notices- Structure and
meaning 4
1.1.2 Symbols in this documentation
1.2
On the product ............................................ 4
2
Important notes .............................. 4
2.1
User group
2.2
Agreement
2.3
Obligation of contractor
2.4
Safety regulations
2.4.1 ACX2180H
2.5
Safety devices ............................................ 8
2.6
Proper disposal ........................................... 8
2.7
Recycled material disposal ....................... 8
2.8
Packaging disposal .................................... 8
2.9
Disposal of combo filter ............................. 8
2.10
Technical Data ............................................ 8
2.11
Glossary....................................................... 8
3
Product description ....................... 9
3.1
Application
3.2
Scope of delivery
4
Description of unit ....................... 10
5
Input Selection ............................. 12
5.1
Selection and function key ...................... 12
5.2
Display screen .......................................... 13
5.3
Main Menu Options .................................. 13
5.4
Unit Features ............................................ 13
5.4.1
EcoLOCK ® couplers (optional) ........ 13
5.4.2 Locking caster brakes
5.4.3 Power supply cable and switch
5.5
Functional description
6
Equipment installation ................ 15
6.1
Unpacking ACX2180H
7
Commissioning ............................ 16
7.1
Connections and positioning
7.2
First start-up verification
7.3
Setup
............................................ 4
................................................. 4
................................................. 4
......................... 5
................................... 6
............................................. 6
.................................................. 9
..................................... 9
....................... 13
.......................... 14
......................... 15
..................... 16
......................................................... 17
......... 4
...... 13
.............. 16
7.4
Internal Bottle Fill
8
A/C service preparation .............. 18
8.1
Preliminary preparation
8.2
Non-condensable gas discharge
8.3
Charge Modes
8.3.1 Quick Modes
8.3.2 Zero tolerance mode
9
A/C system service ...................... 19
9.1
Automatic cycle setup ............................. 19
9.2
Manual cycle setup .................................. 19
9.3
Recovery process .................................... 20
9.4
Vacuum process ...................................... 20
9.5
Charge process ........................................ 20
9.6
Flushing after changing type of Oil .. 21
9.7
Vehicle Pressure Check
9.8
Unit of measure
9.9
9.10
10
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
Clock
Setting language .................................... 21
Maintenance ................................. 22
Maintenance interval
Filling internal refrigerant cylinder
Self test
Pressure zero
Counters
Long life pump test
Vacuum pump oil change
Replace filter dryer
Printer maintenance (optional)
Adjustment ................................. 21
.................................................... 23
................................................... 23
10.10 Periodic checks
11
Spare parts ................................... 26
12
Maintenance ................................. 27
12.1
Vacuum pump oil change ....................... 27
12.2
Filter dryer change ................................... 29
12.3
Refrigerant load cell calibration check .. 32
12.4
Other checks/maintenance/repairs ....... 33
12.5
Notes .......................................................... 35
.................................. 17
....................... 18
....... 18
......................................... 18
......................................... 18
......................... 18
.................. 21
................................... 21
............................ 22
.... 22
......................................... 23
............................... 23
.................... 24
................................. 24
.......... 25
...................................... 25
en 4 | ACX2180H |
Warning
symbol
KEYWORD - Nature and source of hazard!
Consequences of hazard in the event of failure
to observe action and information given.
Hazard prevention action information.
Key word
Probability of
occurrence
Severity of danger
if instructions not
observed
impending
Death or severe injury
impending
Death or severe injury
Possible
Minor injury
Symbol
Designation
Explanation
Warns about possible property
damage
Practical hints and other useful
information.
1.
2.
Instruction consisting of several
steps.
Instruction consisting of one step.
An instruction produces a visible
intermediate result.
There is a visible final result on
completion of the instruction.
1
Symbols use
1.1
In the documentation
1.1.1
Warning notices- Structure and meaning
Warning notices warn of dangers to the user or people in
the vicinity. Warning notices also indicate the
consequences of the hazard as well as preventive action.
Warning notices have the following structure
The key word indicates the likelihood of occurrence and the
severity of the hazard in the event of non-observance:
:
1.1.2
Symbols in this documentation
1.2
On the product
Observe all warning notices on products and ensure
they remain legible.
2
Important notes
Before start up, connecting and
operating MAHLE products it is
absolutely essential that the Original
instructions/owner’s manual and, in
particular, the safety instructions are studied carefully.
By doing so you can eliminate any uncertainties in
handling MAHLE products and thus associated safety
risks upfront; something which is in the interests of your
own safety and will ultimately help avoid damage to the
device. When a MAHLE product is handed over to
another person, not only the Original instructions but
also the safety instructions and information on its
designated use must be handed over to the person.
2.1
User group
The product may be used by skilled and instructed
personnel only. Personnel scheduled to be trained,
familiarized, and instructed or to take part in a general
training course may only work with the product under the
supervision of an experienced person. All work conducted
on pressurized equipment may be performed by persons
with sufficient knowledge and experience in the field of
refrigeration, cooling systems and coolants and, also be
aware of the risks involved in the use of pressurized
devices
2.2
Agreement
By using the product you agree to the following regulations:
Copyright
Software and data are the property of MAHLE or its
suppliers and protected against copying by copyright
laws, international
regulations. Copying or sell
part thereof is impermissible and
event of any infringements MAHLE reserves the right to
proceed with criminal prosecution and to claim for
damages.
agreements and other national legal
ing of data and software or any
punishable; in the
Wear protective goggles.
Wear protective gloves.
| ACX2180H | 5
en
Liability
All data in this program is based—where possible—on
manufacturer and importer details. MAHLE does not accept
liability for the correctness and completeness of software and
data; liability for damage caused by faulty software and data is
ruled out. Whatever the event, MAHLE liability is restricted to
the amount for which the customer actually pays for the
product. The disclaimer of liability does not apply to damages
caused by intent or gross negligence on the part of MAHLE.
Warranty
Any use of non-approved hardware and software will result in
a modification to our product and thus to exclusion of any
liability and warranty, even if the hardware or software has in
the meantime been removed or deleted.
No changes may be made to our products. Our products may
only be used in combination with original accessories and
original service parts. Failing to do so, will render null and void
all warranty claims.
This product may only be operated using MAHLE approved
operating systems. If the product is operated using an operating
system other than the approved one, then our warranty
obligation
null and void. Furthermore, we will not be held liable for
damage and consequential damage incurred through the use
of a non-approved
pursuant to our supply conditions will be rendered
operating system.
2.3
Obligation of contractor
The contractor is obliged to ensure that all measures
geared
towards the prevention of accidents, industrial
diseases, labor- related health risks are taken and
measures towards making the workplace fit for people
to work in are carried out.
Basic rules
The contractor is bound to ensure that all electrical
equipment and operating material is set up, modified
and maintained by skilled electricians only or under
the guidance and supervision of a skilled electrician in
accordance with electrical engineering principles.
Furthermore, the contractor must ensure that all
electrical equip
operated in keeping with electrical engineering
principles.
If a piece of electrical equipment or operating
material is found to be defective, i.e. It does not or no
longer complies with electrical engineering principles,
the contractor must ensure that the fault is rectified
immediately and, in the event that imminent danger
exists, also ensure that the electrical equipment or
the electrical operating material is not used.
Tests (taking Germany as an example)
The contractor must ensure that all electrical systems and
equipment are tested by a qualified electrician or under the
guidance of a qualified electrician to ensure they are in proper
working order:
— Before starting for the first time.
— After modifications or repairs before starting
— At given intervals. Set intervals such as to ensure that
ment and operating material is
faults that can be expected to occur are determined in
good time.
The test is to take the electrical engineering principles
relating hereto into account.
Upon request of the free trade association, a test manual is
to be maintained into which specific entries are made.
en 6 | ACX2180H |
Avoid all skin contact with the refrigerant. The low
boiling point of the refrigerant (approx. -30° C) can
lead to frostbite. Should refrigerant come into contact
with the skin, remove any moistened clothing
immediately and rinse the area of skin affected with
generous amounts of water.
Never inhale refrigerant, dye and oil vapors. The
vapors can irritate the eyes, nose and respiratory
system. If liquid refrigerant or UV dye comes into
contact with the eyes, rinse them thoroughly with
water for 15 minutes. Then obtain medical attention
even if no pain is felt
Never use compressed air with R134a. Certain
mixtures of air and R134a are highly flammable.
Such mixtures are a potential hazard and may lead
to fire or explosions and thus cause damage or
injury.
If high-voltage components or high-voltage wires are
handled incorrectly, there is a risk of fatal injury from
high voltage and the possible transmission of current
through the body.
2.4
Safety regulations
2.4.1
MAHLE product.
ACX2180H
Always carefully study and follow all the safety regulations before using the
Avoid all skin contact with the UV dye. Should UV dye
come into contact with the skin, remove any moistened
clothing immediately and rinse the area affected with
generous amounts of water.
R134a is not to be mixed with other refrigerants. The
mixing of refrigerants could damage the vehicle air
conditioning system.
De-energizing is only to be performed by a qualified
electrician, a qualified electrician for specific tasks (hybrid) or
a power systems engineer.
R134a is colorless, with weak characteristic smell and
heavier than air. It may flow into repair pits. Should
refrigerant escape, Provide for sufficient ventilation
(particularly in repair pits) and leave the workshop.
Never swallow UV dye. Should it be swallowed inadvertently,
never attempt to induce vomiting. Drink generous amounts of
water and obtain medical attention.
Before connecting the ACX2180H to a vehicle air conditioning
system or an external refrigerant bottle, make sure the quickrelease couplings are not leaking. Only ever use external
refrigerant bottles provided with safety valves and certified
in line with applicable standards.
Before switching off the ACX2180H, make sure all charging
and drainage operations have been completed. This
prevents damage to the unit and reduces the risk of
refrigerant escaping into the environment.
Work on vehicles with high-voltage components is only ever
to be performed in a safe de-energized condition by persons
with the minimum qualification “Trained to perform electrical
work”.
Even after deactivating a high-voltage vehicle electrical
sys
tem, the high-voltage battery may still be live.
Operating condition cannot be established from any running
noise, as the electric machine is silent when stationary.
In gear positions "P" and "N" the engine or electric motor
may start spontaneously depending on the charge of the
high-voltage battery.
Never open or damage high-voltage batteries.
On vehicles that have been in an accident , never touch high-
voltage components or exposed high-voltage wires before
deactivating the high-voltage vehicle electrical system.
The ACX2180H must be constantly monitored when in
opera
tion. Never leave the ACX2180H unattended when in
operation. Vehicle A/C service using the ACX2180H must be
prepared and implemented such that the vehicle air
conditioning syst em
example by removing the radiator or engine).
circuit does not have to be opened (for
Refrigerant extracted from a vehicle air conditioning system
may be contaminated with moisture, lubricant, dirt and traces of
other gases.
If the refrigerant has been contaminated by being
mixed with other gases, remove the contaminated
refrigerant and add fresh R134a before using the
ACX2180H for A/C service.
R134a is not to be used in areas in which there is a
danger of explosion. Fire, open flames and smoking
are prohibited.
The ACX2180H unit should not be exposed to
excess moisture or be operated in wet areas
Position the ACX2180H on all four wheels on a flat,
vibration- proof surface so that proper operation of the
scales is guaranteed
Vehicle A/C service using the ACX2180H must be prepared
and implemented such that the vehicle air conditioning
system circuit does not have to be opened (for example by
removing the radiator or engine).
The ACX2180H can be secured in position by locking
the caster brake.
| ACX2180H | 7
en
Parameters
Rated voltage
110 VAC ± 10%
Rated frequency
50/60Hz
Rated current
10A
Rated tripping current
30mA
Tripping switch
C
The ACX2180H must always be transported in its operating
position. Never lay the ACX2180H on its side, as oil could
then escape from the vacuum pump or the built in compres
could be damaged.
for protecting the ACX2180H against damage resulting from
natural catastrophes.
There are no additional safety systems
sor
We recommend calibrating the scales at least once per year.
Contact customer service for calibration of the scales.
The ACX2180H must be subjected to regular maintenance by
service personnel or authorized agents to ensure the safety of
the unit.
Disconnect power before performing any maintenance or
service to unit.
Never perform any maintenance work which is not expressly
recommended in this manual. Contact customer service if
components have to be replaced other than in the course of
maintenance work.
The ACX2180H must be connected to a properly grounded
electrical connection.
If there is damage to the ACX2180H, terminate usage
imme
diately and contact customer service.
The service hoses and service quick-release couplings must be
regularly checked for wear and replaced if damaged.
The ACX2180H must be operated in an environment
corresponding to the directive BGR 157 with respect to the
exchange of air.
Observe local laws or directives as to ensure the safety of the
pressurized device.
Follow the pertinent legal regulations or directives to ensure
safe handling of pressurized devices.
For safety reasons it is advisable to use a residual current
operated circuit breaker (rccb) with the following
specifications:
Never remove any components from inside the ACX2180H
except for maintenance or repair purposes.
Avoid using an extension cord with the unit. If necessary,
use a good condition (three wire grounded, #14AWG or
larger) extension cord of the shortest possible length. In
addition, the current drawn by all devices connected to the
wall socket must not exceed 15A total.
en 8 | ACX2180H |
Description
Function
Pressure
switch
Switches the compressor off in the normal operating
pressure is exceeded
Safety valve
The safety valve opens if the design pressure is exceeded
Circuit
Breaker
Interrupts the power supply if overcurrent is applied to the
ACX2180H
Vents
The ACX2180H is provided with vents in the housing to
ensure the exchange of air even when switched off.
Description
Specification
R134a tank capacity
12L
Service pressure
400PSI
Maximum content
22lbs.
Method to weigh gas content
Load cell
Recovered oil container
250ml
Vacuum pump
2CFM dual stage
Vacuum pump oil quantity
250ml
Compressor capacity
0.87cu in/14cc
Dryer filter
90kg recovered R134a
Non-condensable gas purge
Automatic via solenoid valve
HP and LP taps
Automatic
Display
7 inch capacitive touch screen
Software updating
USB type A or USB type B direct
connect to PC
Printer (optional)
Thermal, 24 columns
All functions
Automatic and manual
Recycling mode
Single pass
Memory for customized cycles
100 records
Flushing
With integrated solenoid valves
System pressure diagnostics
Manual and automatic
Dryer filter replacement alarm
Active
Vacuum pump oil replacement
alarm
Active
Full/empty tank check alarm
Active
Full oil container check alarm
Visual
Empty oil container alarm
Visual
Dimension H x W x D
119 x 74 x 74 cm
Dry weight
98kg
Power supply frequency
60Hz
Voltage
120VAC, 1 phase
Total max load
7.5A
Overcurrent protection
12A (circuit breaker)
Operating temperature
50 - 122°F
Humidity
10 90%RH (non-condensing)
Storage temperature and
humidity
-13 to 50°F
10 - 90%RH (non-condensing)
Max operating altitude
6562 ft.
Pollution degree
2
Water degree
0
Certifications
SAE J2788
UL 1963
CAN/CSA STD C22.2NO. 120 – M91
2.5
Safety devices
2.6
Proper disposal
At the end of its service life, this equipment must be
disposed of as follows:
— Contact the service center to have the refrigerant in
the unit recovered and recycled.
— Consign the unit to an authorized collection
center according to local legislation.
2.7
Recycled material disposal
— Return the refrigerant recovered from the
unit to the refrigerant supplier for proper
disposal or recycling.
— Lubricants extracted from the vehicle's
A/C system must be returned to an official
oil collection center
2.8
Packaging disposal
Electronic and electrical A/C service
equipment must never be disposed of with
domestic waste, but recycled appropriately.
— The packaging must be disposed of in
conformity with local legislation.
— This contributes to protecting the
environment
2.9
Disposal of combo filter
— Dispose of the filter via official collection
points or in accordance with the local
regulations. This contributes to protecting
the environment
2.10
Technical Data
2.11
Glossary
Recovery phase: The refrigerant is extracted from the vehicle
air conditioning system, cleaned and routed into the internal
bottle of the ACX2180H. The refrigerant oil collected in the
process is drained into the used oil bottle at the ACX2180H.
Vacuum phase: A vacuum is generated in the vehicle air con-
ditioning system. Measurement of the drop in pressure begins as
soon as the vacuum has been generated.
Charging phase: A certain quantity of refrigerant is added to the
vehicle air conditioning system.
Description of unit |
ACX2180H | 9 en
m
Description
Service hose (high pressure)
Service hose (low pressure)
Quick-release coupling (high pressure)
Quick-release coupling (low pressure)
Used oil bottle
Original instructions
Adapter (external bottle) - US Acme 1/2
Calibration check weight
3
Product description
3.1
Application
ACX2180H is suitable for vehicles with a conventional engine
as well as for hybrid and electric vehicles. ACX2180H features
all the functions required for vehicle A/C service.
The following functions can be implemented:
Refrigerant recovery and recha rging.
Vacuum generation.
Flushing.
The ACX2180H can only be operated with R134a. The
ACX2180H is not to be used for service work on vehicles
with air conditioning systems employing refrigerants other
than R134a, as this will cause damage. Prior to A/C service
check the type of refrigerant used in the vehicle air
condition
3.2
Scope of delivery
ing system.
en
10
| ACX2180H | Description of unit
Fig. 3 Front left view
1.
Vacuum pump oil level sight glass
Fig. 1: Front Left View
1.
Rear Handle
2.
Tool Tray
3.
Status indicator light
4.
LCD display
5.
Low Pressure Gauge
6.
High Pressure Gauge
7.
Front Cover
8.
Locking Caster
9.
Rear Wheel
10.
Printer (optional)
11.
Used oil bottle
Fig. 2: Rear View
1.
Service Hoses
2.
Fan
3.
Vent
4.
Hose Storage
Figure A: Rear Connection View
1.
High Side Parking Coupler
2.
Low Side Parking Coupler
3.
Refrigerant Identifier (Optional)
4.
Power Switch with circuit breaker
5.
Power Cord socket
4
4
Description of unit
Description of unit |
ACX2180H | 11 en
Fig. 4: Internal components
1.
Accumulator/Oil separator
2.
Combo filter
3.
Compressor
4.
Vacuum pump
5.
Refrigerant tank
6.
HS compressor oil separator
7.
Manifold
Loading...