MAHLE RTI RHS900 User Manual

A’GRAMKOW A/S
Augustenborg Landevej 19 DK-6400 Sønderborg Denmark
A/S Reg. No. 17 12 31 Telephone: 45 74 12 36 36 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
C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.11 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
C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.11 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.
C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.11 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.
C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.11 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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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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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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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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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.
C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.11 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.
C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.11 RHS 900
Before use
Connection of service couplings
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C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.11 RHS 900
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Before use
C:\RHS Computer Files\Instructions\RHS\GB\642-40\0012B-01.doc 1997.09.11 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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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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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 1997.09.11 RHS 900
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