Mastercool 69788 User Manual

RECOVERY/RECYCLE/RECHARGE

Operating Instructions

CONTENTS

SAFETY SUMMARY 4

SAFETY INFORMATION 4

ELECTRICAL SHOCK HAZARDS 4
MOTION HAZARDS 4
FUME HAZARDS 4
HEAT/FREEZING HAZARDS 5
EXPLOSION/FLAME HAZARDS 5
ADDITIONAL SAFETY INFORMATION 5

INTRODUCTION 5

CERTIFICATION 6

ABOUT THIS MANUAL 6

ABOUT YOUR RECOVERY/RECYCLE AIR CONDITIONING SERVICE CENTER 6

WARRANTY 6

GENERAL INFORMATION 6

PRINCIPLES OF OPERATION 7

SETUP 7

THE MACHINE 8

BASIC COMPONENTS 8
CONTROLS AND CONTROL SYSTEM 9
FUNCTION SELECTOR KEYBOARD 9
ALARMS 9

PRELIMINARY OPERATIONS 10

AUTOMATIC PROCEDURE 10

ASSISTED PROCEDURE 12
RECOVERY AND RECYCLING 12

VACUUM 12
ADDING NEW OIL 12
CHARGING THE A/C SYSTEM 13

ROUTINE MAINTENANCE 14
FILLING THE MACHINE TANK 14

VACUUM PUMP 15
Oil Fill 15
Checking Oil Level 16
Oil Change 16
REPLACING THE DRYER FILTERS 16
FILLING THE NEW OIL CONTAINER 17
EMPTYING THE USED OIL CONTAINER 17
CHECKING THE SCALE RESPONSE 17
PURGING NON-CONDENSABLE GASES 17

SETTINGS 18

LANGUAGE 18

UNITS OF MEASUREMENT 18

WEIGHT 19
PRESSURE 19
TEMPERATURE 20

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DATA 20
PASSWORD PROTECTION 20

SYSTEM FLUSHING 21

CUSTOMIZING THE DBA (DATABASE ADVANCED) 21
DATA ENTRY 22

USE 22
DELETION 22
DATABASE UPGRADE 22

CONVERSION CHART 22

ENGLISH

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SAFETY SUMMARY

The following safety information is provided as guidelines to help you operate your new system under the safest possible conditions. Any equipment
that uses chemicals can be potentially dangerous to use when safety or safe handling instructions are not known or not followed. The following
safety instructions are to provide the user with the information necessary for safe use and operation. Please read and retain these instructions for
the continued safe use of your service system.

SAFETY INFORMATION

Every craftsman respects the tools with which they work. They know that the tools represent years of constantly improved designs and
developments. The true craftsman also knows that tools are dangerous if misused or abused. To reduce risk of discomfort, illness, or even death,
read, understand, and follow the following safety instructions. In addition, make certain that anyone else that uses this equipment understands and
follows these safety instructions as well.

READ ALL SAFETY INFORMATION CAREFULLY before attempting to install, operate, or service this equipment. Failure to comply with these
instructions could result in personal injury and/or property damage.

RETAIN THE FOLLOWING SAFETY INFORMATION FOR FUTURE REFERENCE.

Published standards on safety are available and are listed at the end of this section under ADDITIONAL SAFETY INFORMATION.

The National Electrical Code, Occupational Safety and Health Act regulations, local industrial codes and local inspection requirements also provide a
basis for equipment installation, use, and service.

The following safety alert symbols identify important safety messages in this manual.

When you see one of the symbols shown here, be alert to the possibility of personal injury and carefully read the message that follows.

Never fill the tank to more than 80% of maximum capacity as this will not leave an expansion chamber for absorbing any pressure increases.

ELECTRICAL SHOCK HAZARDS

• To reduce the risk of electric shock, unplug the power supply cord from the outlet before attempting any maintenance or cleaning. Turning off
controls will not reduce this risk.

• Do not operate the machine with a damaged cord or plug — replace the cord or plug immediately. To reduce the risk of damage to electric plug
and cord, disconnect the power cord by pulling on the plug rather than the cord.

An extension cord should not be used unless absolutely necessary. Use of an improper extension cord could result in a risk of fire, electric shock
and component damage. If extension cord must be used, make sure:
a. That pins on plug of extension cord are the same number, size, and shape as those on plug on recycler.
b. That extension cord is properly wired and in good electrical condition; and
c. That the wire size is large enough for the length of cord as specified below:

Length of cord in feet: 25 50 100 150

AWG size of cord: 16 12 10 8

MOTION HAZARDS

• Engine parts that are in motion and unexpected movement of a vehicle can injure or kill. When working near moving engine parts, wear snug fit
clothing and keep hands and fingers away from moving parts. Keep hoses and tools clear of moving parts. Always stay clear of moving engine
parts. Hoses and tools can be thrown through the air if not kept clear of moving engine parts.

• The unexpected movement of a vehicle can injure or kill. When working on vehicles always set the parking brake or block the wheels.

FUME HAZARDS

• FUMES, GASES, AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS, AND DEATH! To reduce the risk of discomfort, illness, or death, read,
understand, and follow the following safety instructions. In addition, make certain that anyone that uses the equipment understands and follows
these safety instructions as well.

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• Avoid breathing A/C refrigerant and lubricant vapor mist. Exposure may irritate eyes, nose, and throat. To remove R134a from the A/C system,
use service equipment certified to meet the requirements of SAE J2788--R134a recycling equipment. Additional health and safety information
may be obtained from refrigerant and lubricant manufacturers.

• Always perform vehicle service in a properly ventilated area. Never run an engine without proper ventilation for its exhaust.

• Stop the recycling process if you develop momentary eye, nose, or throat irritation as this indicates inadequate ventilation. Stop work and take
necessary steps to improve ventilation in the work area.

HEAT/FREEZING HAZARDS

• When under pressure, refrigerants become liquid. When accidentally released from the liquid state they evaporate and become gaseous. As they
evaporate, they can freeze tissue very rapidly. When these gases are breathed in, the lungs can be seriously damaged. If sufficient
quantities are taken into the lungs, death can result. If you believe you have exposed your lungs to released refrigerant, seek immediate medical
assistance.

• Refrigerants can cause frostbite and severe burns to exposed skin. Refrigerants are under pressure and can be forcibly sprayed in all directions if
carelessly handled. Avoid contact with refrigerants and always wear protective gloves and make certain other exposed skin is properly covered.

• Refrigerants can also severely injure or cause permanent blindness to unprotected eyes. Refrigerants are under pressure and can be forcibly
sprayed in all directions if carelessly handled. Avoid contact with refrigerants and always wear safety goggles.

ENGLISH

EXPLOSION/FLAME HAZARDS

• Never recover anything other than the approved refrigerants as specified on the machine. Alternate refrigerants may contain flammables such as
butane or propane and can explode or cause a fire. Recovering alternate refrigerants will also void the warranty on your machine.

• For general safety reasons, at the end of the working day or in between services (when services do not immediately follow), see to it that all valves
on hoses and the machine are closed.

ADDITIONAL SAFETY INFORMATION

For additional information concerning safety, refer to the following standards.
ANSI Standard Z87.1 — SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION - obtainable from the American National
Standards Institute, 11 West 42nd St., New York, NY 10036, Telephone [phone], Fax [phone] - www.ansi.org

CAUTION: This equipment should be used in locations with mechanical ventilation that provides at least four air changes per hour or the
equipment should be located at least 18 inches (457 mm) above the floor,” or the equivalent.

CAUTION: Do not pressure test or leak test R134a service equipment and/or vehicle air conditioning systems with compressed air. Some
mixtures of air and R134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or
property damage. Additional health and safety information may be obtained from refrigerant manufacturers.

ATTENTION: Technicians using this equipment must be certified under EPA Section 609 (Environmental Protection Agency).

WARNING: There is the possibility of refrigerant contamination in the refrigerant container or the mobile A/C system being serviced or
refrigerant container. Before recycling use proper equipment such as a refrigerant identifier, if necessary.

NOTE: Use only new refrigerant oil to replace the amount removed during the recycling process. Used oil should be discarded per
applicable federal, state, and local requirements.

The manufacturer shall not be responsible for any additional costs associated with a product failure including, but not limited to, loss of
work time, loss of refrigerant, cross contamination of refrigerant, and unauthorized shipping and/or labor charges.

IMPORTANT: R134a systems have special fittings (per SAE specifications) to avoid cross-contamination with R12 systems. DO NOT adapt
your unit for a different refrigerant — system failure will result.

PERIODICALLY INSPECT AND MAINTAIN REFRIGERANT HOSES AND SEALS TO ENSURE THAT HOSES AND SEALS PREVENT THE ADDITION OF
EXCESS AIR, DUE TO LEAKS, DURING THE RECOVERY PROCESS, WHICH WOULD INCREASE THE NCG LEVEL IN THE RECOVERED REFRIGERANT.

INTRODUCTION

This machine is ETL Laboratories approved, in compliance with SAE J2788. We are dedicated to solving the issues surrounding the safe
containment and proper management of refrigerants. Your new machine incorporates the latest technology and state of the art features to aid you
in servicing R134a air conditioning and refrigeration systems.

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CERTIFICATION

All technicians opening the refrigeration circuit in automotive air conditioning systems must now be certified in refrigerant recovery and recycling
procedures to be in compliance with Section 609 of the Clean Air Act Amendments of 1990. For information on certification call MACS Worldwide at
[phone].

ABOUT THIS MANUAL

This manual includes a SAFETY SUMMARY, MACHINE PREPARATION FOR USE, OPERATION procedures, and MAINTENANCE instructions, for your
Air Conditioning Service Center. Anyone intending to use the machine should become familiar with ALL the information included in this manual
(especially the SAFETY SUMMARY) before attempting to use it.

Before operating this machine for the first time, perform all PREPARATION FOR USE instructions. If your new machine is not properly prepared to
perform a service, your service data could be erroneous. In order to properly perform a complete air conditioning service, follow all procedures in the
order presented. Please take the time to study this manual before operating the machine. Then keep this manual close at hand for future reference.
Please pay close attention to the SAFETY SUMMARY and all WARNINGS and CAUTIONS provided throughout this manual.

ABOUT YOUR AIR CONDITIONING RECOVERY/RECYCLE SERVICE CENTER

Your machine incorporates a highly accurate electronic scale for determining charging weights, etc. Other functions can also be performed with
the electronic scale as you will discover during the operating procedures. Either standard or metric units of measure can be selected. Your new
machine has been designed specifically to use R134a, to operate within the objectives of the Montreal Protocol.

WARRANTY

This product is warranted against any defect in materials and/or construction for a period of 1 (one) year from the date of delivery. The warranty
consists of free-of-charge replacement or repair of defective component parts or parts considered defective by the Manufacturer. Reference to the
machine serial number must be included in any requests for spare parts. This warranty does not cover defects arising from normal wear, incorrect
or improper installation, or phenomena not inherent to normal use and operation of the product.

NOTE: Regarding the above, the Manufacturer reminds the Customer that according to international and national laws and regulations in force the
goods are shipped at the sole risk of the latter and, unless otherwise specified in the confirmation of order phase, the goods are shipped uninsured.
The Manufacturer therefore declines any and all responsibility in merit of CLAIMS for damages due to shipping, loading and unloading, and
unpacking.

The product for which repair under guarantee is requested must be shipped to the manufacturer under the customer’s exclusive responsibility and
at the customer’s exclusive expense and risk. In order to avoid damage during shipping for repairs, the Manufacturer’s original packing must always
be used and scale must be locked prior to shipping, refer to Setup on page 7.

The manufacturer declines any and all responsibility for damage to vehicles on which recovery/recycling and recharging are performed if said
damage is the result of unskillful handling by the operator or of failure to observe the basic safety rules set forth in the instruction manual.

The warranty will expire automatically at the end of the twelve-month period or whenever one of the following occurs: failure to perform
maintenance; use of improper maintenance procedures; use of unsuitable lubricants and/or tracer fluids; inept or improper use; repairs performed
by unauthorized personnel and/or with non-original spare parts; damage caused by shocks, fires, or other accidental events.

To activate the warranty, mail the attached warranty card.

GENERAL INFORMATION

Machine identification information is printed on the data plate on the rear of the machine (see Figure 1). Overall machine dimensions:

Height:

Like any equipment with moving parts, the machine inevitably produces noise. The construction system, paneling, and special provisions adopted by
the Manufacturer are such that during work, the average noise level of the machine is less than 70 dB (A).
NOTE: The machine is intended for indoor use only.

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41.7 inch

Width:

19.7 inch

Depth:

20.5 inch

Weight:

200 lb

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PRINCIPLES OF OPERATION

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In a single series of operations, the machine permits recovering and recycling refrigerant with no risk of release into the environment, and also
permits purging the A/C system of humidity and deposits contained in the oil. The machine is equipped with a built-in evaporator/separator that
removes oil and other impurities from the refrigerant recovered from the A/C system and collects them in a container for that purpose. The fluid is
then filtered, recycled and returned to the tank installed in the machine. The machine also permits running certain operational and leak tests on the
A/C system.

SETUP

The machine is supplied fully assembled and tested. Referring to Figure 3, mount the hose with the BLUE quick-connect coupling on the male
threaded connector indicated by the BLUE LOW PRESSURE symbol and the hose with the RED quick-connect coupling on the male threaded
connector indicated by the RED HIGH PRESSURE symbol.

Referring to Figure 4, remove the protection under the refrigerant scale as follows (UNLOCK SCALE):

- Loosen the nut (Fig 4-2.)

- Loosen the screw (Fig. 4-1) two to four turns (do not remove from machine.)

- Tighten the nut (Fig. 4-2.)

NOTE: In the event that the equipment has to be transported; the refrigerant tank scale
MUST be locked in place as follows:

- Use two 10mm wrenches.

- Loosen the nut (Fig. 4-2.)

- Switch the machine on.

- Tighten the screw slowly (Fig. 4-1) until the display signals ZERO Ref. Available.

- Tighten the nut (Fig. 4-2) forcefully (using the second wrench to lock the screw (Fig. 4-1).

- Check that the screw (Fig. 4-1) is actually locked, if necessary repeat the locking
operation from the beginning.

FIG. 3

ENGLISH

FIG. 4

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THE MACHINE

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BASIC COMPONENTS (Refer to Figures 5, 6, 7 and 8.)

A) Control Console B) Service Valves

G) Vacuum Pump H) Wheels I) Main Switch

M) Used Oil Bottle N) Drier Filters O) Tank P) Tank Heater

C) High & Low Service
Ports

D) New Oil Bottle E) Sight Glass F) Serial Port

J) Socket for Electrical
Supply Plug

K) Fuse Holder L) Electronic Scale

FIG. 5 FIG. 6

FIG. 7 FIG. 8

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