MasterCool 69789-220 Instruction Manual

RECOVERY/RECYCLE/RECHARGE

Operating Instructions

69789-220

INSTRUCTIONS MANUAL

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INSTRUCTIONS MANUAL

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INDEX

INDEX .................................................................................................................................3

INTRODUCTION.................................................................................................................5

CARE OF THE MANUAL...........................................................................................................5

CONDITIONS OF WARRANTY...........................................................................................6

GENERAL INFORMATION .................................................................................................6

END-OF-LIFE......................................................................................................................7

BATTERY DISPOSAL ...............................................................................................................7

SAFETY RULES..................................................................................................................7

PRECAUTIONS FOR HANDLING AND USE OF REFRIGERANT FLUIDS .............................7

PRINCIPLES OF OPERATION...........................................................................................8

SETUP ................................................................................................................................8

THE MACHINE....................................................................................................................9

BASIC COMPONENTS .............................................................................................................9

CONTROLS AND CONTROL SYSTEM....................................................................................9

FUNCTION SELECTOR KEYBOARD.......................................................................................9

ALARMS....................................................................................................................................9

PRELIMINARY OPERATIONS..........................................................................................10

PURGING NON-CONDENSABLE GASES .............................................................................10

AUTOMATIC PROCEDURE..............................................................................................11

Edit VACUUM data:.................................................................................................................11

Edit OIL data:...........................................................................................................................12

Edit TRACER data:..................................................................................................................12

Edit FILLING data:...................................................................................................................12

ASSISTED PROCEDURE.................................................................................................15

RECOVERY AND RECYCLING..............................................................................................15

EMPTYING PIPES 16

VACUUM .................................................................................................................................16

NEW OIL REINTEGRATION...................................................................................................17

TRACER REINTEGRATION....................................................................................................17

CHARGING THE A/C SYSTEM...............................................................................................17

STATIC DIAGNOSIS (optional)...............................................................................................20

DATA.................................................................................................................................21

CONFIGURATION ............................................................................................................22

LANGUAGE.............................................................................................................................22

UNIT OF MEASURE................................................................................................................22

WEIGHT 23
PRESSURE 23
TEMPERATURE 23

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OPTIONS.................................................................................................................................23

DATE AND TIME .....................................................................................................................24

CONFIGURATION OF SETTING UP AND PRINTING............................................................24

ENTER OPERATOR N............................................................................................................ 25

SERVICES.........................................................................................................................26

REFRIGERANT MANAGEMENT.............................................................................................26

PASSWORD............................................................................................................................26

COUNTERS.............................................................................................................................27

MAINTENANCE.................................................................................................................28

FILLING THE MACHINE BOTTLE..........................................................................................28

SERVICE AND CHANGE FILTERS ALARM ...........................................................................29

QUICK GUIDE .........................................................................................................................30

CALIBRATION...................................................................................................................31

CALIBRATING THE BOTTLE SCALE .....................................................................................31

BOTTLE DATA.........................................................................................................................32

CALIBRATING THE OIL SCALE .............................................................................................33

VACUUM PUMP......................................................................................................................34

M.1) Oil top-up 34
M.2) Oil change 34

FILLING THE NEW OIL CONTAINER

(if installed)

........................................................................35

FILLING THE TRACER CONTAINER

(if installed)

.........................................................................35

REPLACING THE COLLAPSIBLE NEW OIL / TRACER CARTRIDGE

(if installed)

.......................35

INSERTING THE CARTRIDGE 35
REMOVING THE CARTRIDGE 35

EMPTYING THE USED OIL CONTAINER ..............................................................................36

REPLACING THE PRINTER PAPER ......................................................................................36

CUSTOMIZING THE DBA (DATABASE ADVANCED)......................................................37

DATA ENTRY ..........................................................................................................................37

USE..........................................................................................................................................37

DELETION...............................................................................................................................37

CONTRAST.......................................................................................................................38

INSTALLING THE USB VIRTUAL COM DRIVE................................................................38

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INTRODUCTION

This machine is a pressure unit as can be seen in the CE declaration of conformity and
Data plate. The equipment supplied conforms to the Essential Safety Requirements
according to Annexure I of Directive 97/23/CE (PED). Any work involving repairs,
modifications, and/or changing pressurised components or parts make safe use of the
equipment very risky. Any tasks done must be authorised by the Manufacturer.

This manual contains important information pertinent to operator
safety. Read this manual through before beginning operation of the
machine.

The manufacturer reserves the right to modify this manual and the machine itself with no prior
notice. We therefore recommend checking any updates. This manual must accompany the
machine in case of sale or other transfer.

Any repair, modification, or changing of components not formally agreed with and authorised
by the manufacturer poses a risk of the conformity to Directive 97/23/CE being nullified and
makes this pressure equipment a significant risk. If not authorised in writing the Manufacturer
considers the tasks indicated above to be tampering with the machine, which nullifies the initial
declaration of conformity issued, and so they do not accept any direct responsibility.

Braze welding of parts that contribute to the pressure strength of the equipment and the parts
directed attached to it was done by adequately qualified personnel, using adequate operating
methods. Approval of the operating methods and personnel was entrusted to a competent
outside party for category II pressure equipment, and any work on this equipment that involves
the need to carry out braze welding must comply with the requirements laid down in ann. 1 of
Directive 97/23/CE, or the Manufacturer must be contacted for the relevant information.

− The pressure equipment has been inspected and tested, complete with the safety
accessories identified by the manufacturer as being of a direct discharge type with
calibrated air pressure. Testing and inspection of the accessories is not necessary prior
to starting up.

− The pressure equipment must be subjected to routine inspections and checks when
operating, according to the relevant regulations and legal norms.

For the unit in question, it is hereby declared that a competent Authorised Body carried out
their part of the final check according to ann. I of point 3.2.3 of Directive 97/23/CE as well as
checking safety accessories and control devices in conformity to comma d) of art 5 of
Ministerial Decree 329 of 01/12/2004.

List of the critical components in terms of PED safety DIR 97/23/CE
Condenser, dehydrator filters, distributor, refrigerant storage bottle, airtight compressor, safety

pressure switch, pressure transducers, and safety valves.

CARE OF THE MANUAL

This manual must be kept for the entire life of the machine and protected against humidity and
excessive heat. Take care not to damage this manual in any way during consultation.

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CONDITIONS OF 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 considered same by the Manufacturer.

Reference to the machine serial number must be included in any requests for spare parts. If
the serial number is not available, contact the manufacturer immediately with valid proof of
purchase (invoice or other valid fiscal document). 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. The manufacturer guarantees the perfect suitability of the
materials used for packing, in terms both of composition and mechanical strength/resistance.

The guarantee does not cover breakdowns attributable to damage suffered during shipping or
warehousing or caused by the use of accessories not meeting manufacturer’s specifications, or
to tampering with or repair of the product by unauthorized personnel. It is of utmost importance
that the crates containing the machine be carefully inspected, upon delivery, in the presence of
the shipping agent. We recommend performing inspection with extreme care, since damages
to the crates due to shocks or dropping are not always immediately visible thanks to the shock­absorbing capacity of today’s composite packing materials. The apparent integrity of the
packing materials does not exclude possible damage to the goods, despite the due care taken
by the manufacturer in packing them.

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. A 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. 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. This warranty replaces and excludes any other warranty or guarantee that the seller is
required to provide under law or contract and defines all the customer’s rights in regard of faults
and defects and/or scarce quality in the products as purchased.

The warranty will expire automatically at the end of the twelve-month period or whenever even
one of the following occurs: failure to perform maintenance or erroneous 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.

GENERAL INFORMATION

Machine identification information is printed on the data plate on the rear of the machine (see
Figures 1 and 2). Overall machine dimensions:

Height: 1030 mm Width: 570 mm
Depth: 630 mm Weight: 70 kg

Operating temperature 10/40°C Storage temperature -25/49°C
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 not in excess of 70 dB (A).

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END-OF-LIFE

The symbol on the right indicates that in accordance with Directive 2002/96/EC the
machine may not be disposed of as ordinary municipal waste but must be
delivered to a specialized center for separation and disposal of WEEE (Waste
Electrical and Electronic Equipment) or be returned to the dealer in case of
purchase of a new machine. Current legislation provides severe sanctions in the
case of disposal of WEEE into the environment. If improperly used or disposed of
into the environment, electrical and electronic equipment can release substances dangerous
for the environment and for human health.

BATTERY DISPOSAL

The machine uses an electronics card containing a Nickel-metal hydride (NiMH) battery (ref.:
bt, see Fig.12). When discharged, it must be removed by expert personnel trained in machine
demolition.

SAFETY RULES

The machine is designed for use in recovering the R134a refrigerant fluid used in the air­conditioning (A/C) systems of motor vehicles. The MACHINE is designed to be used by
qualified personnel only; moreover, it can be used correctly only if the operator has read this
manual and is aware of the basic safety information contained herein, including the following.
Wear protective gloves and goggles. Do not expose the machine to direct sunlight or rain. Use
only in well-ventilated work areas. Before performing any operation, check the vehicle use and
maintenance manual for the type of refrigerant fluid used by the A/C system. Do not smoke in
proximity to the machine while it is in operation.

Do not use the machine in proximity to sources of heat, open flames, or sparks. Check
whenever the engine is turned off that the ignition key is turned to the full OFF position. Always
close all the valves on the machine before connecting it to the A/C system of the vehicle.
Connect only the machine hose supplied with the RED quick-connect coupling to the high­pressure branch of the A/C system. Connect only the machine hose supplied with the BLUE
quick-connect coupling to the low-pressure branch of the A/C system. Keep the connection
hoses away from moving parts and rotating elements such as cooling fans, alternators, etc.
Keep the connection hoses away from hot objects and elements such as engine exhaust
pipes, radiators, etc. Fill the A/C system only with the quantity of refrigerant recommended by
the manufacturer. Never exceed said quantity. Check the oil levels at the beginning of each
operation. Always top up with the correct quantity of oil. Before connecting the machine to the
electrical supply, check that voltage and frequency match the values shown into the CE label.

Never fill the bottle to more than 80% of maximum capacity in order to leave an
expansion chamber for absorbing any pressure increases.

Never touch the valves on the refrigerant bottle installed on-board the machine. Dispose of the
oil extracted from the A/C system and from the vacuum pump in suitable containers for used
oils. Replace the filters punctually at the prescribed replacement times. Use only filters
recommended by the manufacturer. Take care never to use the vacuum pump oil in the A/C
system, or vice-versa. Failure to observe any of the above safety precautions will invalidate all
forms of warranty on the machine.

PRECAUTIONS FOR HANDLING AND USE OF REFRIGERANT FLUIDS

Refrigerant fluids expand to the gaseous state in standard environmental conditions. In order
that they may be shipped and used they must be compressed into suitable bottles. We
therefore recommend observing all the general precautions applicable to handling of
pressurized containers. In the case of R134a in particular, we suggest the following special
precautions. Avoid inhaling highly concentrated vapors even for short periods of time, since
such vapors can cause loss of consciousness or death. R134a is not flammable, but if the

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vapor is exposed to open flames or incandescent surfaces it may undergo thermal
decomposition and form acid substances. The acrid and pungent odor of these products of
decomposition is sufficient to signal their presence. We therefore recommend avoiding use of
R134a near open flames and incandescent elements. There exists no evidence of risks
deriving from transdermal absorption of R134a Nevertheless, due to the low boiling point of the
liquid, it is advisable to wear protective garments such as to ensure that no jets of liquid or gas
can come into contact with the skin. The use of goggles to avoid contact with the eyes is
especially recommended, since the refrigerant liquid or gas can cause freezing of the ocular
fluids. Moreover, we strongly advise users to avoid dispersing the R134a refrigerant fluid
utilized in the machine since it is a substance that contributes to raising the temperature of the
planet, with a global warming potential(GWP) of 1300.

PRINCIPLES OF OPERATION

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

- Loosen the nut [2].

- Completely loosen the screw [1].

- Keep the screw [1], the nut [2], and the knurled washer [4] for possible future use.

NOTE: in the event that the equipment has to be transported, the refrigerant bottle scale should
be locked in place as follows:

- Procure two size 10 wrenches.

- Tighten the nut [2] almost completely onto the screw [1].

- Insert the knurled washer [4] onto the screw [1].

- Turn the screw [1] just a few times on the threaded bush [6].

- Switch the machine on.

- Tighten the screw [1] until the display signals ZERO availability.

- Tighten the nut [2] forcefully (using the second wrench to block the screw [1]).

- Check that the screw [1] is actually locked, if necessary repeat the locking operation
from the beginning.

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THE MACHINE

BASIC COMPONENTS

Refer to Figures 5, 6, 7 and 8.
a) Control consoles b) Taps
h) Wheels l) High/Low Pressure threaded connectors
m) Used oil tank n) New oil collapsible container*
bi) Oil scale d) Bottle
e) Drying filters o) Electronic scale
r) Heating resistance ps) Serial port
i) Main switch j) Socket for electrical supply plug
k) Fuse c) Moisture indicator
f) Vacuum pump u) USB port
w) collapsible tracer cartridge* z) tracer container*
v) purge valve s) new oil container*
* if installed

CONTROLS AND CONTROL SYSTEM

Refer to Figure 9.

A1) High pressure gauge A2) Low pressure gauge
A3) Keyboard A4) Bottle pressure gauge
A5) LCD: 4 lines, 20 characters A6) Printer*

FUNCTION SELECTOR KEYBOARD

STOP: Press to interrupt the operation being performed in the case of the principal functions:
recovery - oil discharge - vacuum/oil reintegration - charging). Press START to resume
operation from the point of interruption. Pressing STOP during an alarm state, error state, or
end-of-operation silences the audible alarm.

RESET: Press to interrupt the operation being performed. The procedure may be restarted
from the beginning.

ENTER: Press to confirm the procedure or operation flashing on the LCD.

↓: Press to move downward from one procedure or operation to another within a menu.
↑: Press to move upward from one procedure or operation to another within a menu.

START: Press to launch the procedure or operation shown on the display.

ALARMS

HIGH PRESSURE ALARM: Beeper and led advise when the pressure of the fluid in the circuit
reaches 20 bar. The recovery operation is automatically interrupted.

FULL BOTTLE ALARM: Beeper and led advise when the bottle is filled to more than 80% of
maximum capacity; that is, 18 kg. The RECOVERY operation is automatically interrupted (to
cancel this alarm, charge one or more A/C systems before recovering any more refrigerant).

EMPTY BOTTLE ALARM: Beeper and led advise when the quantity of refrigerant fluid
contained in the bottle is low.

SERVICE ALARM: Beeper and led advise whenever the total recovered refrigerant amounts to
100 kg. To deactivate the alarm, replace the filters and the vacuum pump oil. A code for
canceling the alarm is supplied with the spare filters.

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INSUFFICIENT GAS ALARM: Beeper and LED advise when the charging quantity set
exceeds the difference between availability and bottle minimum.

PRELIMINARY OPERATIONS

Check that the main switch (i) is set to O. Check that all the MACHINE taps are closed.
Connect the MACHINE to the electrical supply and switch on. Check that the vacuum pump oil
level indicator shows at least one-half full. If the level is lower, add oil as explained in the
MAINTENANCE section. Check that in the new oil container (n) there are at least 100 cc of the
oil recommended by the manufacturer of the vehicle A/C system. Check that the oil level in
tank (m) is < 200 cc. Check on the MACHINE display that there are at roughly 3 kg of
refrigerant in the bottle. Should this not be the case, fill the on-board MACHINE bottle from an
external bottle of appropriate refrigerant following the procedure described in the ROUTINE
MAINTENANCE section.

PURGING NON-CONDENSABLE GASES

Before every use, check if there is air in the bottle: select the DATA MENU and read the bottle
temperature. Compare the bottle pressure with the values given in the table; pull the ring of the
safety valve until the bottle pressure reading corresponds to the values given in the table.

Example: Bottle Temperature = 20°C. The bottle pressure must be brought to 5.2 bars.

T

(°C) P (bar) T (°C) P (bar) T (°C) P (bar) T (°C) P (bar)T (°C) P (bar)T (°C) P (bar)T (°C) P (bar)T (°C) P (bar) T (°C) P (bar)

10 3.6 15 4.4 20 5.2 25 6.1 30 7.2 35 8.3 40 9.6 45 11 50 12.6

10.5 3.7 15.5 4.4 20.5 5.3 25.5 6.2 30.5 7.3 35.5 8.4 40.5 9.7 45.5 11.2 50.5 12.8
11 3.8 16 4.5 21 5.4 26 6.3 31 7.4 36 8.6 41 9.9 46 11.3 51 12.9

11.5 3.8 16.5 4.6 21.5 5.5 26.5 6.4 31.5 7.5 36.5 8.7 41.5 10 46.5 11.5 51.5 13.1
12 3.9 17 4.7 22 5.6 27 6.5 32 7.6 37 8.8 42 10.2 47 11.6 52 13.3

12.5 4 17.5 4.8 22.5 5.6 27.5 6.6 32.5 7.7 37.5 8.9 42.5 10.3 47.5 11.8 52.5 13.4
13 4.1 18 4.9 23 5.7 28 6.7 33 7.8 38 9.1 43 10.4 48 12 53 13.6

13.5 4.1 18.5 4.9 23.5 5.8 28.5 6.8 33.5 8 38.5 9.2 43.5 10.6 48.5 12.1 53.5 13.8
14 4.2 19 5 24 5.9 29 6.9 34 8.1 39 9.3 44 10.7 49 12.3 54 14

14.5 4.3 19.5 5.1 24.5 6 29.5 7.1 34.5 8.2 39.5 9.5 44.5 10.9 49.5 12.4 54.5 14.2

QUICK GUIDE

The first time the machine is used, a quick startup guide appears: the operator is guided
through the steps described at the start of the PRELIMINARY OPERATIONS section.

- unclamp the gas bottle scale - press ENTER

- cheek the vacuum pump oil level - press ENTER

- fill the new oil container - press ENTER

- install the tracer cartridge - press ENTER

- assemble the hoses - press ENTER

- connect the quick-connect couplings - press ENTER

- press START to run the vacuum cycle for 1 minute

- fill the on-board bottle (see the instruction manual) - press ENTER

- press START to print the guide - press STOP to exit

Follow the instructions displayed. At the end of the procedure, press START to print a
summary report of the guided procedure. Press STOP to exit.

NOTE: If the guided procedure is not completed, it will be displayed again the next time the
machine is switched on.

NOTE: to display the QUICK GUIDE at any time, select from the menu of the same name
under SETUP.

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AUTOMATIC PROCEDURE

In the automatic mode, all the operations are performed automatically: recovery and recycling,
oil discharge, vacuum, new oil reintegration, and charging. The values for the quantity of gas
recovered, quantity of oil recovered, vacuum time, quantity of oil reintegrated, and quantity of
gas charged into the system are automatically printed at the end of each single operation.

Connect the hoses to the A/C system with the quick-connect couplings bearing in mind that
BLUE must be connected to the low-pressure side and RED to high pressure. If the A/C
system is equipped with a single quick-connect coupling for high or low pressure, connect only
the relative hose.

Check that the high- and low-pressure taps are closed. Start the vehicle for about 5 to 10
minutes. Switch off the vehicle engine.

The machine is equipped with a 4-line LCD display, maximum 20 characters per line. On the
menus the selected line flashes; in this manual it is enclosed in quotation marks.

Select AUTOMATIC PROCEDURE and press the ENTER key.
The following message appears:

Press ENTER to continue – the following screen opens:

Key in the vehicle’s licence plate using the ↓↑ arrows to move around the licence plate
number. Then press "ENTER" to confirm.

NOTE: The numerical keys include an alphabet similar to that for text messages, for example:
press “2” once to display “A”, twice to display “B”, three times for "C" and four time for "2".

The following screen is displayed:

NOTES:

xy Default values extrapolated from a previous automatic procedure.

To edit the data proceed as follows:

Edit VACUUM data:

Use the arrows ↓↑ to select VACUUM and key in the new value (using keys 0 to 9).

VACUUM xy min
OIL xy ml
TRACER xy ml
REFILLING xy g
START to continue

Enter licence plate

............

Press ENTER

WARNING
USING PAG OIL OR TRACER
IN HYBRID VEHICLES CAN
DAMAGE THE COMPRESSOR
USE SPECIFIC OIL WITH A
SEPARATE DEVICE
Press ENTER

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Edit OIL data:

Use the arrows ↓↑ to select OIL, press ENTER, the following screen will be displayed:

1) Press ENTER and select AUTOMATIC OIL.
NOTE: Once the Vacuum operation has been completed the system automatically tops up
the same quantity of oil as that extracted during Recovery.

2) Select the second line using ↓, the use keys 0 to 9 to key in the volume of oil that must
automatically be refilled after the Vacuum. Finally press "ENTER" to confirm.

Edit TRACER data:

Use the arrows ↓↑ to select TRACER and press ENTER. The following screen is displayed:

1) Press ENTER to select NO and therefore skip tracer injection.

2) Select the second line using ↓, the use keys 0 to 9 to key in the volume of TRACER that
must automatically be refilled after the Vacuum. Finally press "ENTER" to confirm.

Edit FILLING data:

Use the arrows ↓↑ to select FILLING and press ENTER. The following screen is displayed:

1) Use keys 0 to 9 to enter the quantity (in grams) of refrigerant to be charged into the A/C
system and press ENTER.
NOTE: For most systems the quantity of fluid to be refilled is indicated on a plate that is in
the vehicle’s engine compartment. If this quantity is not known, look for it in the relavant
manuals.

2) If installed, you can use DATABASE BASIC (DBB): Use the arrows ↓↑ to select the second
line and press ENTER. The following screen is displayed:

Use the relevant “table” to read off the code for the vehicle. Use the numerical keypad to
key in the code. Once the setting has been completed, press ENTER to confirm. If you
wish to install DATABASE BASIC (DBB) contact the machine dealer.

3) If installed, you can use DATABASE ADVANCED (DBA): Use the arrow ↓ to select the
second line and press ENTER. The following screen is displayed:

ENTER CODE
VEHICLE MODEL

...

press ENTER to exit

AUTOMATIC PROCEDURE
FILLING <xxxg>
DATABASE

AUTOMATIC PROCEDURE
TRACER <NO>
TRACER xx ml

AUTOMATIC PROCEDURE
OIL <AUTO.>
OIL xx ml

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Use the arrow keys (↓↑) to move to the brand of vehicle you are servicing, press ENTER to
confirm, and the display will show the models for that type (for example, if you have chosen
FORD):

Use the arrow keys (↓↑) to go to the model required, and press ENTER to confirm. If you
wish to install DATABASE ADVANCED (DBA) contact the machine dealer.

Once you have checked that the data displayed is correct, you can push START to run the
AUTOMATIC PROCEDURE.

The following screen is displayed:

Open high and low pressure on the machine and press the START button. At this stage the
refrigerant recovery / recycle phase begins, marked by the message “Recovery Recycle”.
During this phase the system displays the grams of refrigerant recovered.

When recovery is complete the machine stops and discharges and automatically displays the
spent oil extracted by the A/C system during recovery. The oil discharge operation lasts 4
minutes. If during this phase some pockets of refrigerant are still inside the A/C system the
pressure increases and the machine automatically starts recovering refrigerant again.

At the end of the oil discharge phase the machine automatically moves on to the vacuum
operation for the preset time. Operator will then be prompted to check the VACUUM HOLD.
Once the vacuum phase has finished the oil top-up starts again automatically on the basis of
the volume of oil discharged or the volume entered by the operator. If installed, the tracer is
refilled automatically according to the quantity entered by the operator. At the end the system
automatically moves on to filling the quantity set.

NOTE: In rare cases the filling operation may not be completed due to the pressure balance. In
this case shut high pressure (leaving the low pressure open) and start the A/C system. Once
the filling operation has been completed the machine displays the message:

Close the high and low pressure taps.

Press START to continue:

Start the vehicle’s engine and the A/C system and wait at least 3 min:

Start the engine and A/C
System to check pressures
Press START

End filling
Close HP and LP
Press START to continue

press RESET

Open high and low
pressure, then Press START

<COUGAR>
ESCORT
ESCORT D
FIESTA

<ALFA ROMEO>
AUDI
BMW
CHRYSLER/JEEP

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At this stage the system is running normally and the high and low pressures can be checked by
reading them off the relevant pressure gauges. Press STOP to exit.

Only disconnect the high pressure rapid coupling (if necessary switch off the engine) and press
START:

Start the A/C system, open the high and low pressure taps and make the A/C system suction
the refrigerant left in the pipes. Press START to continue:

Wait until the high and low pressures balance out, after about 1 min disconnect the machine’s
low pressure rapid coupling on the vehicle’s A/C system and switch off the engine.

Press STOP to complete the procedure.
Turn the main switch (I) to the 0 position.
NB – The automatic procedure can be run even if the A/C system is empty. In this case the

machine begins the vacuum operation immediately. In the case of an A/C system with a single
high pressure rapid coupling set the filling quantity at +100 g (quantity that can remain in the
high pressure pipe because in this case it is not possible to suction up the refrigerant left in the
pipes).

NOTE: If STOP is pressed during recovery, the following screen will be displayed:

When START is pressed the procedure resumes, whereas when STOP or RESET is pressed
you go back to the MAIN MENU.

Wait for HP and LP to
Balance and close the
rapid couplings
STOP per completare

Open HP and LP taps
Start A/C system
Press START to continue

Disconnect HP coupling
Press START to empty the
pipes

CHECK PRESSURES

STOP to exit

Procedure paused.
START to continue
STOP to abort procedure

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ASSISTED PROCEDURE

In the assisted procedure mode, all the operations can be performed singly to the exception of
the recovery/recycling phase, which is automatically followed by used oil discharge. The values
for the quantity of gas recovered, quantity of oil recovered, vacuum time, quantity of oil
reintegrated, and quantity of gas charged into the system are automatically printed at the end
of each single operation.

From the MAIN MENU:

Select ASSISTED PROCEDURE and press the ENTER key.
The following screen is displayed:

NOTES:

* Only if the hardware is installed in the machine.
xy Default values extrapolated from a previous procedure.

RECOVERY AND RECYCLING

Press ENTER to confirm RECOVERY / RECYCLE. The following screen is displayed:

Press ENTER to confirm RECOVERY / RECYCLE. The following screen is displayed:

Key in the vehicle’s licence plate using the ↓↑ arrows to move around the licence plate
number. Then press "ENTER" to confirm.

NOTE: The numerical keys include an alphabet similar to that for text messages, for example:
press “2” once to display “A”, twice to display “B”, three times for "C" and four time for "2".

The following screen is displayed:

Enter licence plate

............

Premere ENTER

<RECOVERY / RECYCLE>
PIPE EMPTYING

RECOVERY / RECYCLE
VACUUM xy min
OIL xy ml
TRACER xy ml
FILLING xy g
SYSTEM FLUSHING*
STATIC DIAGNOSIS*
CHANGE OIL TYPE

AUTOMATIC PROCEDURE
<ASSISTED PROCEDURE>
DATA AND CONFIGURATION
MAINTENANCE xx.x kg

INSTRUCTIONS MANUAL

-16-

Open the high and low pressure taps on the machine and press START to start the refrigerant
recovery/recycle phase. During this phase the display shows the quantity of refrigerant
recovered, expressed in grams.

When recovery is complete the machine stops and discharges and automatically displays the
spent oil extracted by the A/C system during recovery. The oil discharge operation lasts 4 min.
If during this phase some pockets of refrigerant are still inside the A/C system the pressure
increases and the machine automatically starts recovering refrigerant again.

NOTICE: if during recovery STOP is pressed, the following message appears:

When START is pressed the procedure resumes, whereas when STOP or RESET is pressed
you go back to the MAIN MENU.

EMPTYING PIPES

In the RECOVERY AND RECYCLE MENU select EMPTY PIPES and press ENTER to
confirm.

The following screen is displayed:

Open high and low pressure on the machine and press the START button.

VACUUM

Use the quick-connect couplings to connect the hoses to the A/C system, bearing in mind that
BLUE must be connected to the low pressure side and RED to high pressure. If the system is
equipped with a single quick-connect coupling for high or low pressure, connect only the
relative hose. Select the assisted procedure by pressing ENTER when “Assisted Procedure”
flashes on the LCD. Select the vacuum operation by pressing ENTER when the message
“Vacuum xx min.” flashes on the LCD. Set the vacuum time only if different from that previously
used. Press ENTER to confirm. Open the high- and low-pressure taps of the machine and
press START. Operator will then be prompted to check the VACUUM HOLD.

Open high and low
pressure then
Press START

RECOVERY / RECYCLE
<PIPE EMPTYING>

Procedure in standby
START to continue
STOP to exit
Procedure

Open high and low
pressure then
Press START

INSTRUCTIONS MANUAL

-17-

NEW OIL REINTEGRATION

This operation can be carried out ONLY following a vacuum operation and before charging.
Select the assisted procedure by pressing ENTER when the “ASSISTED PROCEDURE”
message flashes on the LCD.

The following message will be displayed:

Press ENTER to continue.
Select the OIL by pressing ENTER when “OIL XX CC” flashes on the LCD. Set the volume of

new oil to be reintegrated, in cc. Press ENTER to confirm. Open the high- and low-pressure
taps (if the A/C system is equipped with a single quick-connect coupling for high or low
pressure, open only the relative tap) of the machine and press START.

TRACER REINTEGRATION

This operation can be carried out only following a vacuum procedure and before charging.
Select the assisted procedure when the “ASSISTED PROCEDURE" message flashes on the
LCD, and press ENTER. Select “TRACER” and set the volume of tracer to be reintegrated, in
cc. Press ENTER to confirm.

The following message will be displayed:

Press ENTER to continue.
Open the high- and low-pressure taps (in the case of an A/C system with only one pressure

coupling—high or low—open only the relative tap) on the machine and press START.

NOTE: To enable the TOP UP TRACER function, use the OPTIONS MENU.

CHARGING THE A/C SYSTEM

Select the ASSISTED PROCEDURE by pressing ENTER when the “Assisted Procedure”
message flashes on the LCD. Select charging by pressing ENTER when “CHARGING XXXX
G” flashes on the LCD. The following screen is displayed:

1) Use keys 0 to 9 to enter the quantity (in grams) of refrigerant to be charged into
the A/C system and press ENTER.
NOTE: For most systems the quantity of fluid to be refilled is indicated on a plate

ASSISTED PROCEDURE
CHARGING <xxxg>
DATABASE

ATTENTION
USING PAG OIL OR TRACER IN
HYBRID VEHICLES MAY DAMAGE
THE COMPRESSOR.
USE ONLY SUITABLE OIL WITH A
SEPARATE DEVICE.

ATTENTION
USING PAG OIL OR TRACER IN
HYBRID VEHICLES MAY DAMAGE
THE COMPRESSOR.
USE ONLY SUITABLE OIL WITH A
SEPARATE DEVICE.

INSTRUCTIONS MANUAL

-18-

that is in the vehicle’s engine compartment. If this quantity is not known, look for
it in the relavant manuals.

2) If installed, you can use DATABASE BASIC (DBB): Use the arrow ↓ to select
the second line and press ENTER. The following screen is displayed:

Use the relevant “table” to read off the code for the vehicle. Use the numerical
keypad to key in the code. Once the setting has been completed, press ENTER
to confirm. If you wish to install DATABASE BASIC (DBB) contact the machine
dealer.

3) If installed, you can use DATABASE ADVANCED (DBA): Use the arrow ↓ to
select the second line and press ENTER. The following screen is displayed:

Use the arrow keys (↓↑) to move to the brand of vehicle you are servicing, press
ENTER to confirm, and the display will show the models for that type (for
example, if you have chosen FORD):

Use the arrow keys (↓↑) to go to the model required, and press ENTER to
confirm. If you wish to install DATABASE ADVANCED (DBA) contact the
machine dealer.

The following screen is displayed:

Key in the vehicle’s licence plate using the ↓↑ arrows to move around the licence plate
number. Then press "ENTER" to confirm.

NOTE: The numerical keys include an alphabet similar to that for text messages, for example:
press “2” once to display “A”, twice to display “B”, three times for "C" and four time for "2".

The following screen is displayed:

Open the machine hig-pressure tap and press START (if it is an A/C apparatus with only low or
high pressure couplings, open only the relevant tap on the machine) . NOTICE: In some cases
the refilling operation may not conclude successfully because of the pressure balance; in this

REFILLING
Gas xyz g

Press START

Enter licence plate

............

Press ENTER

<COUGAR>
ESCORT
ESCORT D
FIESTA

<ALFA ROMEO>
AUDI
BMW
CHRYSLER/JEEP

ENTER CODE
VEHICLE MODEL
... Press ENTER and exit

INSTRUCTIONS MANUAL

-19-

case, close the high-pressure tap (leave the low pressure open), and turn the A/C apparatus
on.

Once the filling operation has been completed the machine displays the message:

Close the high and low pressure taps. Press START to continue:

Start the vehicle’s engine and the A/C system and wait at least 3 min:

At this stage the system is running normally and the high and low pressures can be checked by
reading them off the relevant pressure gauges. Press STOP to exit.

Only disconnect the high pressure rapid coupling (if necessary switch off the engine) and press
START:

Start the A/C system, open the high and low pressure taps and make the A/C system suction
the refrigerant left in the pipes. Press START to continue:

Wait until the high and low pressures balance out, after about 1 min disconnect the machine’s
low pressure rapid coupling on the vehicle’s A/C system and switch off the engine.

Press STOP to complete the procedure.

N.B. - When working with A/C systems with a single high-pressure coupling, set the charging
quantity ate about 100g in excess of the required quantity, since in this case it will be
impossible to recover the residual refrigerant from the hoses.

Wait for HP and LP to
balance and close rapid
couplings
STOP to complete

Open HP and LP pipes
Start A/C system
Press START to continue

Disconnect HP couplings
Press START to empty
pipes

CHECK PRESSURES

STOP to exit

Start the engine and the
A/C system to check
pressures
Press START

End charging
Close HP and LP
Press START to continue

Press RESET

INSTRUCTIONS MANUAL

-20-

STATIC DIAGNOSIS (optional)

See instructions [MANUSTA001.0]

INSTRUCTIONS MANUAL

-21-

DATA

This menu shows all the data read by the machine. Switch on the machine. From the MAIN
MENU:

Select DATA & CONFIGURATION. The following screen is displayed:

Press ENTER to open the DATA MENU:

- Gas available: quantity of refrigerant available in the storage bottle.

- Oil: quantity of oil in all the oil containers.

- Temperature: temperature of the refrigerant storage bottle.

- Pac: pressure in the external air conditioner system.

Gas avail. xxxxx g
Oil xxxx cc
Temperature xx.x °C

Pac xx bar

<DATA>
CONFIGURATION SERVICES

AUTOMATIC PROCEDURE
ASSISTED PROCEDURE
<DATA & CONFIGURATION>
MAINTENANCE xx.xkg

INSTRUCTIONS MANUAL

-22-

CONFIGURATION

This menu is used to edit the machine’s settings. From the MAIN MENU:

Select DATA & CONFIGURATION. The following screen is displayed:

Select CONFIGURATION and press ENTER.

LANGUAGE

From the CONFIGURATION MENU:

Select LANGUAGE

NOTE : current language is indicated by the sign “<-“
Use the ARROW keys to scroll available languages, confirm your selection pressing ENTER,

the machin will reset and in a few seconds the MAIN MENU in the chosen language will
appear.

UNIT OF MEASURE

From the CONFIGURATION MENU:

Select UNIT OF MEASURE:

LANGUAGE
UNIT OF MEASURE
OPTIONS
SET DATE & TIME
SET PRINT HEAD.
ENTER OPERATOR NR.

ENGLISH
ITALIANO
FRANCAIS <­ESPANOL

LANGUAGE
UNIT OF MEASURE
OPTIONS
SET DATE & TIME
SET PRINT HEAD.
ENTER OPERATOR NR.

DATA
<CONFIGURATION>
SERVICES

AUTOMATIC PROCEDURE
ASSISTED PROCEDURE
<DATA & CONFIGURATION>
MANUTENZIONE xx.xKg

INSTRUCTIONS MANUAL

-23-

WEIGHT

Select WEIGHT:

press ENTER to swtich from g(Kg) to oz(lb) or from oz(lb) to g(kg).

Press STOP to exit.

PRESSURE

Select PRESSURE:

press ENTER to switch from bar to psi or from psi to bar.

Press STOP to exit.

TEMPERATURE

Select TEMPERATURE:

press ENTER to switch from °C to °F or from °F to °C.

Press STOP to exit.

OPTIONS

From the CONFIGURATION MENU:

WEIGHT g (Kg)
PRESSURE bar
TEMPERATURE °C

WEIGHT g (Kg)
PRESSURE bar
TEMPERATURE °C

WEIGHT g (Kg)
PRESSURE bar
TEMPERATURE °C

WEIGHT g (Kg)
<PRESSURE> bar
TEMPERATURE °C

WEIGHT g (Kg)
PRESSURE bar
TEMPERATURE °C

WEIGHT g (Kg)
PRESSURE bar
TEMPERATURE °C

WEIGHT g (Kg)
PRESSURE bar
TEMPERATURE °C

INSTRUCTIONS MANUAL

-24-

Select OPTIONS and the following screen is displayed:

Call the technical service for the code. Once you have entered the code, press ENTER:

Select the option required and press ENTER to switch from “on” to “off” and vice versa.
Press "STOP" to go back to the PREVIOUS MENU.

DATE AND TIME

The machine keeps date and time settings even if it is not used for around one year.
From the CONFIGURATION MENU:

Select DATE AND TIME and the following screen is displayed:

Press START to change date and time

CONFIGURATION OF SETTING UP AND PRINTING

The printout can be personalised by entering 4 lines containing the workshop’s details (e.g.
Name, address, telephone n° and e-mail).

From the CONFIGURATION MENU:

Select CONF. SET & PRINT and the following screen is displayed:

LANGUAGE
UNIT OF MEASURE
OPTIONS
SET DATE & TIME
SET PRINT HEAD.
ENTER OPERATOR NR.

hh:mm:ss – gg/mm/aa

ENTER TO CONFIRM
START TO CHANGE

LANGUAGE
UNIT OF MEASURE
OPTIONS
SET DATE & TIME
SET PRINT HEAD.
ENTER OPERATOR NR.

ENABLE TRACER on

........

LANGUAGE
UNIT OF MEASURE
OPTIONS
SET DATE & TIME
SET PRINT HEAD.
ENTER OPERATOR NR.

INSTRUCTIONS MANUAL

-25-

Key in the printing set up the ↓↑ arrows to move within the line. Then press ENTER to confirm
and go to the next lines.

NOTE: The numerical keys include an alphabet similar to that for text messages, for example:
press “2” once to display “A”, twice to display “B”, three times for "C" and four time for "2 ".

ENTER OPERATOR N

From the CONFIGURATION MENU:

Select ENTER OPERATOR N and the following screen is displayed:

It is possible to enter an alphanumeric code of 10 symbols to indicate the habilitation nr of the
operator. This number will be indicated in all printouts.

LEAK CHECK

It is possible to edit the intervals between leak checks on the A/C system.
From the CONFIGURATION MENU:

Select LEAK CHECK and the following screen is displayed:

Key in the time before the leak check and then press ENTER to exit.
NOTE: A period of less than 10 minutes cannot be set.

LEAK CHECK
Time before
Leak check: xx min

LANGUAGE
UNIT OF MEASURE
OPTIONS
SET DATE & TIME
CONF. PRINT HEAD.
ENTER OPERATOR NR.
CHECK LEAKS
NITROGEN LEAK THRESHOLD

ENTER OPERATOR N°

........

LANGUAGE
UNIT OF MEASURE
OPTIONS
SET DATE & TIME
CONF. PRINT HEAD.
ENTER OPERATOR NR.

CONF. PRINT HEAD.
1:

. . . . . . . . . . . . .

INSTRUCTIONS MANUAL

-26-

SERVICES

This menu makes it possible to manage some auxiliary services. From the MAIN MENU:

Select DATA & CONFIGURATION. The following screen is displayed:

Select SERVICES and press ENTER.

NOTE: The SERVICES MENU is only available to authorised technicians

REFRIGERANT MANAGEMENT

The machine keeps track of the operations done on refrigerant fluid: recovery, system refilling,
inner bottle filling. For any operation, a record is made with date, time, type of operation,
quantities involved, operator nr., inner bottle refrigerant fluid availability. The machine can keep
up to 100 records. From the 90th operation on, a message appears indicating how many
operations can be done..

From the SERVICES MENU:

Select REFRIGERANT MANAGEMENT and the following screen is displayed:

Select DELETE and press ENTER to delete all the records from the memory.
Select PRINT and press ENTER to print the last 25 operations in the memory.
NOTE: If the machine is connected to a personal computer by means of a USB cable, the

GESTREF.TXT file can be downloaded that contains all the operations in the memory.

PASSWORD

From the SERVICES MENU:

Select PASSWORD and the following screen is displayed:

REFRIGERATION MANAGEMENT
PASSWORD
COUNTERS

REFRIGERATION MANAGEMENT
DELETE
PRINT

REFRIGERANT MANAGEMENT
PASSWORD
COUNTERS

DATA
CONFIGURATION
<SERVICES>

AUTOMATIC PROCEDURE
ASSISTED PROCEDURE
<DATA & CONFIGURATION>
MAINTENANCE xx.xkg

INSTRUCTIONS MANUAL

-27-

A four-digit password can be entered to block the machine use. Once the password is entered,
it is possible to proceed from the main menu only after entering the code.

Entering 0000 as a password, the block is eliminated.

COUNTERS

This is used to check total COUNTERS of:: recovered gas, service alarm meter, total vacuum
minutes, injected gas, gas recovered into the bottle with the bottle refilling function.

From the SERVICES MENU:

Select COUNTERS and the following screen is displayed:

Use ↓ to scroll the lines.
This screen displays the total values for: gas recovered, service alarm COUNTERS, total

vacuum time (minutes), gas injected, gas recovered in the internal bottle using the “Bottle
filling” function.

Pressing START, COUNTERS can be printed out with date and time.

Rec. gas 0.0 kg
Service 0.0Kg
Vacuum 0 min
Syst. Fill. 0.0 kg
Bott. fill. 0.0 Kg

REFRIGERATION MANAGEMENT
PASSWORD
COUNTERS

. . . .

INSTRUCTIONS MANUAL

-28-

MAINTENANCE

This menu is used for maintenance operations on the machine. From the MAIN MENU:

Select MAINTENANCE.

FILLING THE MACHINE BOTTLE

This operation must be performed whenever the available refrigerant fluid in the bottle is less
than 3 kg and must in any case be performed when the “empty bottle” alarm is displayed.
Procure a bottle of R134a gas and connect the liquid side coupling of the external bottle to the
high pressure hose (if the external bottle is not supplied with a liquid side coupling, upend it to
recover liquid refrigerant). Open the tap of the external bottle and the high-pressure tap of the
machine. If the external bottle is not supplied with a suction device, turn it upside down to
obtain a higher delivery rate.

From the MAINTENANCE MENU:

Select BOTTLE FILLING and the following screen is displayed:

Set the quantity of refrigerant to be transferred to the machine bottle (the quantity must be
between the limit values suggested by the machine) and press START to confirm:*

Press START:

Press START:

The machine will now fill the machine bottle with the preset quantity ± 500g. When the quantity
minus 500 grams is reached, the machine will stop and display:

BOTTLE FILLING
MANUAL AIR PURGING
SERVICE ALARM
CALIBRATION

AUTOMATIC PROCEDURE
ASSISTED PROCEDURE
DATA & CONFIGURATION
<MAINTENANCE> xx.x kg

FILLING BOTTLE
0 g

Open external
bottle tap, open
HP tap, and
press START.

Use the HP hose to
connect external
bottle and
press START.

INSTRUCTIONS MANUAL

-29-

Close the bottle tap and press START. The machine will stop automatically after having
recovered the residual refrigerant from the hoses. Close the high-pressure tap. Disconnect the
external bottle. Switch the machine off.

MANUAL AIR PURGING

From the MAINTENANCE MENU:

Select MANUAL AIR PURGING and the following screen is displayed:

If the pressure xx.x bar flashes, this means that there is air in the bottle. If this happens press
START. The machine starts to purge the air making the bottle pressure drop. As soon as the
pressure returns within the parameters, the machine stops purging.

Press STOP to go back to the PREVIOUS MENU.
NOTE: Each time the bottle pressure reaches 18 bar the machine automatically discharges

non-condensable gas until the pressure drops to 16 bar.

SERVICE AND CHANGE FILTERS ALARM

Replace the filters whenever the machine gives the service alarm during the first ten seconds
of operation. Before performing any operation, check that the replacement filters are the same
type as those installed on the machine. Then proceed as described below (refer to Fig. 11):

1) Disconnect the machine from the electrical supply

2) Wear protective gloves and glasses

3) Remove the rear plastic cover from the machine.

4) Remove the used filter and install new one, respecting the direction of the arrow.

IMPORTANT: Filter replacement must be performed as quickly as possible in order
to avoid possible contamination by moisture in the ambient air.

NOTE: If possible, use an electronic leak tester to check the seal on the couplings of the
new filter.

5) Replace the rear plastic cover on the machine.

6) Reconnect the machine to the electrical supply and switch on.

7) Select MAINTENANCE, and enter SERVICE ALARM.

8) Key in the filter code to cancel the alarm. If the filter code is not available, call the
Service Center.

9) Recover about 500g of gas to charge the machine circuit.

10) Switch the machine off.

11) Disconnect the machine from the electrical supply.

AIR PURGE
Press: xx.x bar
START to purge
STOP to exit

BOTTLE FILLING
MANUAL AIR PURGING
SERVICE ALARM
CALIBRATION

FILLING BOTTLE
Close external
bottle tap
Press Start

INSTRUCTIONS MANUAL

-30-

QUICK GUIDE

This resets the guide. Turn on the machine. Main Menu: Select MAINTENANCE. Use the
arrow to select "Quick setup" press ENTER to start the Quick Start Guide (see self-titled
paragraph in the chapter GETTING STARTED)