MAHLE RTI RHS900 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: Unibank No. 22 37

INSTRUCTIONS RHS 900

Recovery, Recycling, Evacuation

and Charging Station

RHS 900

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RHS 900

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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. Appendixes

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RHS 900

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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.

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

The six processes - from test to charging - are performed by operating six
different process switches. This reduces the risk of error operation to a minimum.
After each evacuation, RHS 900 automatically performs a vacuum test and
indicates whether or not there is any leakage in the A/C unit. In addition, the
station incorporates an automatic process which ensures that subsequent processes
are performed fully automatically and in the correct sequence: evacuation,
vacuum test and refrigerant charging.

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 drier has a very high capacity (300 kg) and is 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 900, read these instructions carefully to ensure that the pro­cesses are performed correctly.

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RHS 900

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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.

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RHS 900

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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. 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 mm

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.

2

.

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RHS 900

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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) Oil draining valve: For draining oil received from the A/C unit.

6) Connection: Low-pressure, hose connection for the low-pressure side of the

A/C unit.

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RHS 900

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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.

13) Quickcharge: For quick refilling of internal cylinder.

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RHS 900

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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).

18) Vacuum OK - lamp (white): indicates that no leakage was found

during vacuum test.

19) Vacuum defect - lamp (yellow): indicates that the vacuum has risen

to more than -0.8 bar during the vacuum test.

20) Refrigerant charging switch/lamp (green): cuts in the refrigeration

charging process and lights up when the connection is made.

21) High-pressure gauge

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RHS 900

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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.

26) Reset/test switch/lamp (green): cuts in the test process and lights

up when the connection is made.

27) Mains switch/lamp (white): on/off switch for mains supply to

station; lights up when the connection is made.

28) Recovery switch/lamp (green): cuts in the recovery process and

lights up when the connection is made.

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RHS 900

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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 side 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 900 is now ready for operation.

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RHS 900

Before use

Connection of service couplings

- 4.2 -

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RHS 900

- 4.3 -

Before use

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RHS 900

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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).

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RHS 900

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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.

CHARGING: - Monitoring/control of charging process

- Data storage

- Fault indication

- PAUSE (charging process cuts off)

Note: Operation and display texts for the various processes are described in the
operating instructions.

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RHS 900

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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.

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RHS 900