MAHLE RTI RHS700 User Manual

A’GRAMKOW A/S

Augustenborg Landevej 19
DK-6400 Sønderborg
Denmark

A/S Reg. No. 17 12 31
Telephone: [phone]
Telefax: 45 74 43 36 46
Telex: 5 23 18
Bank: Den Danske Bank, No. 32 27

INSTRUCTIONS RHS 700

Recovery, Recycling, Evacuation

and Charging Station

RHS 700

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RHS 700

Contents RHS 700

1. Application

2. Safety precautions

3. Components

4. Before use

5. Test

6. Recovery/recycling

7. Evacuation

8. Charging

9. Maintenance

10. Trouble shooting

11. Service set

12. Accessories/spare parts

13. Specifications

14. Pos. no. location

15. Appendix

- 0.1 -

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RHS 700

- 1.1 -

Application

Your new RHS 700 station represents the latest in equipment for servicing air­conditioning 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 700 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.

The recycling process is designed to follow SAE-standards J1989 and J2099 on
recycled refrigerant for A/C units.

Process operations - from test to charging - are performed by operating four
different process switches and two shut-off valves. This reduces the risk of error
operation to a minimum.

Constant monitoring ensures that the automatic process sequence does occur
correctly. Safety devices are built into the station to stop operation and indicate
faults in processes, e.g. excessively high pressure, overcharging of charging
cylinder.

During the recycling process a small quantity of oil is drained from the A/C unit.
On completion of the recovery process this quantity can be drained into a
measuring beaker. The same quantity of new oil must be filled into the A/C unit.
Refer to the A/C unit instructions and use only the type of oil specified.

The filter driers have a very high capacity (200 kg) and are easy to replace during
servicing.

A system built into the station ensures that non-condensable gases are automa­tically blown off and that the discharge of refrigerant to the atmosphere is kept to
a minimum.

Before using RHS 700, read these instructions carefully to ensure that the pro­cesses are performed correctly.

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RHS 700

- 1.2 -

Application

We reserve the right to make constructional and design changes and accept no
responsibility for printing errors.

RHS 700 complies with European standards on “Safety and health” and is GS­tested.

See appendixes, "Declaration of Conformity" and TÜV test report.

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RHS 700

- 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 700 from the A/C unit, make sure that the
process is completed so that refrigerant does not escape to the atmos­phere.

4. RHS 700 is for use only in dry indoor surroundings.

5. Disconnect the electrical supply before performing maintenance on RHS

700.

6. To reduce the risk of fire, avoid using an extension cord. If, however, an
extension cord is necessary, it must have a minimum cross-sectional area
of 2.5 mm2.

7. In the event of fire, remove any external refrigerant cylinders.

8. When oil which accompanies the refrigerant drained from the A/C unit is
tapped from the suction accumulator into the measuring beaker supplied,
ensure that it is handled according to existing national legislation. A
suitable container can be obtained from the refrigerant supplier.

9. Always brake the two front wheels of the station when parking.

10. Most national legislation forbids the station being used for the charging
of cylinders which are intended for transference to a third party.

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RHS 700

- 3.1 -

Components

1. Main switch

2. Operation time indicator

3. Low-pressure valve

4. Pressure gauge - low pressure

5. High-pressure valve

6. Pressure gauge - high pressure

7. Charging switch

8. Charging quantity indicator

9. Evacuation switch

10. Cylinder full - lamp

11. Vacuum check

12. Recovery/recycling switch

13. Vacuum gauge

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RHS 700

- 3.2 -

Components

14. High-pressure side

15. Oil beaker - 250 ml

16. High-pressure hose - red

17. Oil charging

18. Sightglass

19. Low-pressure side

20. Low-pressure hose - blue

21. Service coupling - high pressure

22. Service coupling - low pressure

23. Oil drain valve

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RHS 700

- 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.

- Connect the red and blue hoses to their stubs on the rear of the station. Blue

hose to low-pressure side, red hose to high-pressure side. (See the next two
pages.)

- Make sure that the shut-off valves on hoses and pos. 5 are closed.

- Connect high and low-pressure hoses to their respective sides (using the

service couplings) on the A/C unit. (See the next two pages.)

- RHS 700 is now ready for operation.

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RHS 700

- 4.2 -

Before use

Connection of service couplings

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RHS 700

- 4.3 -

Before use

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RHS 700

- 5.1 -

Test

The test function must be performed to check the station.

1. Close both valves on the control panel (pos. 1-2).

2. Connect the high and low-pressure hoses to the A/C unit and open the service

couplings.

3. Switch on the A/C unit and read the pressures on the high and low-pressure

gauges (pos. 3/4). The correct pressures are given in the A/C unit manual.

4. Perform a condition diagnosis in accordance with the supplier’s instructions.

See appendix “Example of trouble shooting in an A/C unit”.

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RHS 700

- 6.1 -

Recovery/recycling

When an A/C unit is to be repaired or serviced, the RECOVERY/RECYCLING
process must be used in order to drain refrigerant from the A/C unit.

1. Make sure that all valves are closed, then connect high and low-pressure hoses

to the A/C unit and open the service couplings.

1. Switch on the main switch and the RECOVERY/RECYCLING

process switch

2. Open valves 1 and 2. Provided there is pressure/refrigerant in the A/C unit, it

will be automatically emptied by RHS 700. The green lamp in the RE-
COVERY/RECYCLING process switch remains on until the process is
complete.

3. When the green lamp goes out for the first time, wait 5 minutes to ensure that

the A/C unit is completely empty.

1. As soon as the charging cylinder becomes full during the RECOVERY/RE-

CYCLING process, RHS 700 stops and the yellow CYLINDER
FULL lamp lights up. The charging cylinder must then be emptied

into an A/C unit or a refrigerant cylinder before the process can be continued.
See description in the section CHARGING.

2. During the RECOVERY/RECYCLING process, oil might be drained from

the A/C unit. This oil can be tapped from oil drain valve (23) into the
accompanying measuring beaker. The A/C unit must be replenished with a
corresponding amount of oil. Follow the supplier’s instructions and use only
the specified oil type.

3. The internal cylinder is charged by connecting the service hose between

refrigerant cylinder and low-pressure stub (blue). Open the gas valve on the
refrigerant cylinder (charge only on the gas phase). Follow the instructions,
points 1, 2 and 3, until the required amount of refrigerant in the internal
cylinder has been reached. Close the gas valve on the cylinder again. When the
green RECOVERY/RECYCLING lamp goes out the process has been
completed. Close valves 1 and 2 and disconnect service hose.

Note:

Sometimes it can be an advantage to recover from the low-pressure side only, for
then no oil is drained from the A/C unit. However, if this method is used make
sure that valve 2 is kept closed.

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RHS 700

- 7.1 -

Evacuation

After servicing the A/C unit, air and/or moisture must be evacuated. Air and/or
moisture in the A/C unit will impair system operation.

1. Set the main switch on I and switch on the EVACUATION process switch

(if the pressure exceeds 0.2 barg, the evacuation process cannot be started). If
the pressure does exceed 0.2 barg, a short recovery process should be
performed.

2. Before connecting the service couplings to the A/C unit, read the vacuum

gauge. This reading is the max. level attainable.

3. Now open the service couplings on the hoses. An evacuation can be performed

if thought necessary.

4. A vacuum check must now be made. Switch on the VACUUM CHECK

process switch and at the same time watch the vacuum gauge! If the pressure
rises continuously the system either leaks or contains moisture.

5. When the evacuation process is complete, the A/C unit can be replenished with

the amount of oil which might have been taken out during the recovery
process. Open the valve, pos. 17, on the oil container on the right-hand side
and read off the required amount of oil on the scale.

Note:

If the pressure rises slightly and then restabilises, it means that the A/C unit is
adjusting itself to the ambient temperature.

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RHS 700

- 8.1 -

Charging

The required quantity of refrigerant can be seen in the vehicle manual or on the
nameplate under the vehicle bonnet.

1. Close valve 1 and open valve 2 . Then connect high and low-pressure

hoses, keeping both hose valves closed. (When charging R12 systems, do not
connect the high-pressure hose at this point).

2. Set the main switch on I and switch on the CHARGE process switch

The high-pressure hose will now contain refrigerant.

3. To ensure that the correct quantity of refrigerant is used, the red pointer on the

charging quantity indicator must now be set to determine the level at which the
black pointer indicates that the required quantity of refrigerant has been
charged (i.e. the level to which the charging cylinder is to be emptied).

Note: The charging quantity indicator will first indicate the level 2 minutes after

starting the station.

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RHS 700

- 8.2 -

Charging

4. Open the high-pressure valve on the red hose (on R12 systems simply close the

hose) and observe the charging quantity on the charging quantity indicator.
When the black pointer has reached the red pointer, the charging process must
be stopped with the process switch.

5. It is now possible to check the function of the A/C unit by closing valves 1 and

2 and opening both hose valves.

6. After completion of the A/C unit test process, close the red high-pressure hose

valve and open valves and while the A/C unit is in operation. This
empties refrigerant from the high-pressure hose and ensures the accuracy of the
refrigerant quantity charged. Now close the service valve on the blue hose. (On
R12 systems simply remove the hose.)

7. After charging, hoses will contain a small quantity of refrigerant. To recover

this refrigerant, first close hose valves and then switch over to RECOVERY
for a short time.

8. Connect the service hose between refrigerant cylinder and high-pressure stub

(red) to empty/recharge the internal cylinder. Emptying must be as described in
point 4 and recharging as described in the RECOVERY process. Open valve
and the valve on the refrigerant cylinder. The refrigerant cylinder must only be
filled to not more than 80% of its maximum volume. After emptying/re­charging of the required refrigerant quantity, close the valves again. Open
valves and (low-pressure stub closed) and switch on the process
switch for RECOVERY/RECYCLING to empty the hose.

Note:

It is often a problem to charge the whole charging quantity from the high-pressure
side only. If this is the case, a two-sided charge is possible by opening valve .

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RHS 700

- 9.1 -

Maintenance

3) Suction accumulator

5) Acid filter / filter drier

6) Check valve

9) Check valve

8) Filter drier

18) Charging cylinder

M1) Compressor
M2) Condenser
M3) Vacuum pump
SP4) Pressure control

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RHS 700

- 9.2 -

Maintenance

To observe the warranty on RHS 700, all components used for maintenance must
be identical to those in the service set, see Section 9.

To ensure problem-free operation of RHS 700, 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:

A large amount of the moisture evacuated from the A/C unit accumulates in the
vacuum oil and therefore it can be advantageous to change the oil from time to
time. The reason moisture accumulates in the vacuum oil is that the vacuum pump
does not create the required vacuum!

Changing vacuum pump oil:

- Hold an oil beaker under the oil drain screw (pos. 34) and loosen the screw.

Allow the old oil to drain into the beaker.

- Remove the oil filling cap (pos. 32).

Retighten the oil drain screw and fill with new oil through the oil filling stub (pos.

32) until the level reaches the centre of the sight glass (pos. 33).

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RHS 700

- 9.3 -

Maintenance

The condenser cooling surface must be kept clean:

- Remove the rear panel of the station (4 screws).

- Clean the cooling surface 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:

- If the oil level is below the centre of the sight glass, replenish as follows:

- Remove cap (pos. 32) to replenish vacuum pump.

- Replenish (slowly) with vacuum oil to the correct level.

- Replace cap.

For each 75 operating hours:

Replacement of filter drier (pos. 5)

- Remove front panel (6 screws).

- Remove filter by loosening the pressure control (two 3/8” flare nuts), and

then fit the replacement filter. Always use a new filter fitted with protective
caps on the connectors.

Replacement of filter drier (pos. 8)

- Remove rear panel (6 screws).

- Remove filter by loosening the union nuts and the solenoid valve (pos. 36)

at the filter end. Loosen the nuts slowly and take out the filter.

- Fit a new filter in the station, making sure to retighten the union nuts.

- Refit pressure control and solenoid valve.

On replacing filter driers a small quantity of refrigerant escapes - therefore
follow the appropriate safety precautions.

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RHS 700

- 10.1 -

Trouble shooting

Test process

Problem Fault Remedy

Pressure gauge shows no
pressure

Pressure gauge shows
the same reading all the
time

Recovery process:

Problem Fault Remedy

Recovery process does
not start - green recovery
lamp does not light up

Recovery process does
not stop

Recovery process runs
only for a short period

1. + 2. Valve not opened

3. No refrigerant in A/C unit

1. A/C unit defective

2. A/C unit not cut in

1. RHS 700 not cut in

2. Valves not opened

3. No refrigerant in A/C unit

4. System pressure is 16 bar

5. Internal cylinder full

6. Internal component fault

1. Oil drain valve not closed

2. A/C unit leakage

3. Internal component fault

1. Valves on service couplings not opened

2. System pressure is 16 bar

3. Internal cylinder full

4. Internal component fault

1. Open high and low-pressure valves on service
couplings

2. Open valves on service couplings

3. Repair A/C unit

1. Empty A/C unit and repair

2. Cut in A/C unit

1. Cut in RHS 700

2. Open high and low-pressure valves on
service couplings

3. Repair A/C unit

4. Contact RHS 700 supplier

5. Empty cylinder

6. Contact RHS 700 supplier

1. Close valve

2. Contact RHS 700 supplier

3. Contact RHS 700 supplier

1. Open valves

2. Blow off non-condensable gases

3. Empty cylinder

4. Contact RHS 700 supplier

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RHS 700

- 10.2 -

Trouble shooting

Evacuation process:

Problem Fault Remedy

Vacuum pump does not
run

Vacuum pump runs but
does not build up enough
vacuum

Charging process:

Problem Fault Remedy

No refrigerant flow 1. High-pressure valve on service coupling

1. RHS 700 not cut in

2. Overpressure in A/C unit

3. Internal component fault

1. Service couplings not fitted correctly

2. A/C unit defective/leaking

3. Internal component fault

not opened

2. Internal component fault

3. Charging cylinder empty

4. A/C unit not evacuated

5. Heating element defective

6. Thermal protector defective

1. Cut in RHS 700

2. Cut in recovery process

3. Contact RHS 700 supplier

1. Fit service couplings correctly

2. Repair A/C unit

3. Contact RHS 700 supplier

1. Open valve

2. Contact RHS 700 supplier!

3. Connect a refrigerant cylinder and use the
recovery process

4. Recover the A/C unit again and then
evacuate it

5. Contact the RHS 700 supplier

6. Contact the RHS 700 supplier

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RHS 700

- 11.1 -

Service set no. 645-010003A (RHS 700 unit)

Quantity Description Code no.

1

1

0.25 l

0.25 l

Filter drier - short

Filter drier - long

Compressor oil - mineral

Oil for vacuum pump

069-7480069

069-7480077

290-0001250

290-0001272

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- 12.1 -

Accessories / Spare parts

Qty Description Code no.

Spare
parts:

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Accessories:

1

1

1

Operating instructions

Service coupling, high pressure (R134a)

Service coupling, low pressure (R134a)

Service coupling (R12)

Service coupling (R12)

Service hose, blue (R134a) = 72"

Service hose, red (R134a) = 72"

Service hose, yellow (R134a) = 36”

Service hose, blue (R12) = 180 cm

Service hose, red (R12) = 180 cm

Service hose, yellow (R12) = 90 cm

Gasket for R134a hose - white

O-ring for R134a hose, Ø 14.5 mm

Gasket for R12 hose

Oil beaker

Oil charging (R134a)

Tracer kit R12

Tracer kit R134a

645-400008A

290-7480095

290-7480096

290-4669016

066-7390234

634-140002A

634-140001A

634-140004A

080-4665015

080-4665017

080-4665002

087-7481010

087-7481341

066-7750950

146-7489012

642-040003A

634-040007A

643-040002A

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RHS 700

- 13.1 -

Specifications

General:

Supply voltage: See nameplate
Amperage: See nameplate
Power consumption: See nameplate
Starting current: See nameplate
Weight: 95 kg
Dimensions: 1030 x 670 x 800 mm

Test function:

High-pressure gauge: 0 to 34 bar
Low-pressure gauge: -1 to 8 bar

Recovery/recycling process:

Refrigerant: See nameplate
Oil level measurement: Drain at side of station, measuring beaker

supplied
Recycling capacity: 4 kg/h (3-5 vehicles/h)
Non-condensable gases: Automatic blow-off, temperature-compensated
Suction accumulator: 2.4 litres (approx. 2 kg)
Refrigerant charge: 4.0/4.2 kg R134a/R12
Filter drier: Replaceable (every 75 hours)
Charging pressure gauge: 0-4000 g

Evacuation process:

Suction capacity: Approx. 3 m3/h
Vacuum level: < 0.5 mbar absolute

Option:

Oil charging: Oil container = 250 ml

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RHS 700

- 13.2 -

Specifications

Operating panel:

Mains switch - white: Power supply cut in

Recovery switch - green: Recovery process in function

Evacuation switch - green: Evacuation process in function

Refrigerant charging switch - green: Refrigerant charging in process

Vacuum check lamp - green: Vacuum OK

Charging cylinder lamp - yellow: Cylinder full

Service and maintenance

Filter drier 1: Replaceable, 3/8" SAE

Filter drier 2: Replaceable, 3/8” SAE (capacity 50 hours or 200

kg refrigerant)

Vacuum pump oil level: Sight glass + charging stub

Safety equipment: Mechanical safety valve on charging cylinder

Overfilling protection on charging cylinder

Suction pressure regulator on compressor

High-pressure control on compressor

Code number of RHS 700: See nameplate

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RHS 700

Wiring diagram:

- 14.1 -

Pos. no. location

(645-120000A-03)

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RHS 700

- 14.2 -

Pos. no. location

Wiring diagram

M3: Vacuum pump
Y14: Solenoid valve
Y15: Solenoid valve
Y16: Solenoid valve
EH1: Heating element
EH2: Heating element
ST1: Thermostat
ST2: Thermal protector (manual reset)
ST3: Thermostat
ST4: Thermal protector (manual reset)
M1: Compressor
M2: Fan
Y9: Solenoid valve
Y21: Solenoid valve
SL2: Level switch
Y8: Solenoid valve
SP1: Pressure control
SP2: Pressure control
SP3: Pressure control
SP4: Pressure control
SP5: Pressure control

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RHS 700

Mechanical diagram

- 14.3 -

Pos. no. location

(645-120001A-00)

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RHS 700

- 14.4 -

Pos. no. location

3) Suction accumulator

5) Acid filter / filter drier

6) Check valve

9) Check valve

8) Filter drier

18) Charging cylinder
M1) Compressor
M2) Condenser
M3) Vacuum pump
SP4) Pressure control

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RHS 700

- 15.1 -

Appendixes

Example of trouble shooting on an A/C unit:

Conditions:

1. Ambient temperature 30-35°C (86-95°F)

2. Motor speed 2,000 rpm

3. A/C unit temperature setting Maximum

Under the above conditions an intact A/C unit will show the following
pressures in the TEST process:

High pressure 15 bar

Low pressure 2 bar

Follow the TEST process as shown in section 5:

- Connect service couplings to the A/C unit.

- Close the high and low-pressure valves on RHS 700

- Open the valves on the service couplings.

- Cut in the A/C unit.

- The station will now perform a test function.
Perform a condition diagnosis in accordance with the supplier’s instructions.

- When the test is completed, cut the A/C unit off again.

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Appendixes

Test 1:

High pressure 8 - 9 bar
Low pressure Approx. 0.8 bar

Fault/problem Symptom Possible cause Remedy
Unsatisfactory
refrigeration output

Test 2:

High pressure Approx. 20 bar
Low pressure Approx. 2.5 bar

Fault/problem Symptom Possible cause Remedy
Unsatisfactory
refrigeration output

Virgin ventilation air

Air bubbles in sight
glass

Refrigerant over-

Leak in A/C unit

Insufficient refrigerant
in A/C unit

charged

Insufficient condenser
cooling

Fan not running

Reduced condenser
output because of oil
or dirt deposits

Insufficient oil in A/C
unit (compressor fric­tion)

Locate leak and repair

Replenish refrigerant

Clean the condenser

Repair fan

Clean the condenser

Replenish oil

If none of the above
steps remedy the fault,
check refrigerant
quantity in A/C unit,
empty, evacuate and
recharge unit

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Appendixes

Test 3:

High pressure Approx. 7 - 15 bar
Low pressure Approx. 1.5 bar

Fault/problem Symptom Possible cause Remedy
A/C unit runs irregu­larly

Test 4:

High pressure Approx. 6 bar
Low pressure Approx. -0.3 bar

Fault/problem Symptom Possible cause Remedy
A/C unit does not cool

- or cools only slightly

Varying pressures on
high and low-pressure
sides

Hoses ahead of or after
expansion valve or
filter drier covered
with moisture or ice

Moisture in A/C unit
causes ice on expan­sion valve and reduces
output.

Filter drier saturated

Because of moisture in
A/C unit, expansion
valve or filter drier
blocked by ice

Empty, evacuate and
recharge A/C unit.
After recovery process
replace filter drier. If
necessary, remove and
clean expansion valve.
Replace valve or fit
new valve.

Cut out A/C unit, wait
a few minutes and
empty it. Then eva­cuate and recharge
A/C unit.

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- 15.4 -

Appendixes

Test 5:

High pressure Approx. 19 - 20 bar
Low pressure Approx. 2.5 bar

Fault/problem Symptom Possible cause Remedy
Unacceptable cooling Ice or moisture on

hoses on high and low­pressure sides of A/C
unit

Test 6:

High pressure Approx. 7 - 10 bar
Low pressure Approx. 4 - 6 bar

Fault/problem Symptom Possible cause Remedy
A/C unit does not cool Pressure on low-pres-

sure side too high or
pressure on high-pres­sure side too low

Expansion valve
defective or sensor
placed incorrectly

Expansion valve opens
too much

Internal compressor
leakage

Check position of
expansion valve
sensor.

Replace expansion
valve.

Repair or replace com­pressor

C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.26
RHS 700

- 15.5 -

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. 4:

Manufacturer: Denaline S.R.L.
Via Segaluzza
11/B
Italy

Type: GRA.120.240.0

Permissible working pressure: PS = 23 bar

Permissible working temperature:

Volume: V = 2.4 litres

Filter drier, pos. 5:

Manufacturer: RTI Technologies Inc. (A’G subsidiary)
York, PA
USA

Type: 026-80069-00

Permissible working pressure: PS = 31.05 bar

Permissible working temperature:

Volume: V = 0.83 litres

-40/70°C

10/120°C

C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.26
RHS 700

- 15.6 -

Appendixes

Filter drier, pos. 8:

Manufacturer: RTI Technologies Inc. (A’G subsidiary)
York, PA
USA

Type: 026-80077-00

Permissible working pressure: PS = 31.05 bar

Permissible working temperature:

Volume: V = 0.83 litres

Charging cylinder, pos. 10

Manufacturer: A’GRAMKOW A/S
Augustenborg Landevej 19
DK-6400 Sønderborg
Denmark

Type: 645-010038A

Permissible working pressure: PS = 25 bar

Permissible working temperature:

Volume: V = 4.26 litres

10/120°C

10/70°C

C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.26
RHS 700