AC Service Machine
INSTALLATION GUIDE
United States
17779 Main Street Suite C
Irvine, CA 92614 USA
Tel: +1(949) 333-3800
Fax: +1(949) 333-3804
United Arab Emirates
P.O. Box 121971 Saif Zone A2-032
Sharjah, UAE
Tel: +971 (06) 552 98 60
Fax: +971 (06) 552 98 61
Egypt
9A Al-Mothalath
End of Mostafa El-Nahas Street
Nasr City, Cairo 11528 Egypt
Tel: +2019 550 0001
Fax: +2022 472 4346
Model
ACM1LSF
www.TexasEquipment.net
Contents
1 About this operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.1 Kernel hotline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.2 Explanation
2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1 General safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Warnings on the Air-Con Service Station
3.3 Safety devices
4 Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5 Overview of the Air-Con Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 First start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Setting up and sw it ch u p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.2 Putting in the containers for oil
6.3 Filling up the internal refrigerant container
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.1 Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
7.2 Vacuum
7.3 Purge
7.4 Oil injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.5 Recharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .16
8. Service tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.1 Inner tank refill . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.2 Language select
8.3 Zero balance
8.4 vacuum pump oil
8.5 Changing the internal filter
8.6 Hose compensation
8.7 Pressure rise wait
8.8 Other service
8.9 Cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9. Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
9.1 Disposing of used fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.2 Disposing of packaging material
9.3 Scrapping old unit
10 T rouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11 Technical dat a . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
12 Spare Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .24
of symbols in this operating manual . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2
1 About this operating manual
This operating manual des cr i bes t he Kernel Air-Con Service Station
This manual is for those who perform maintenance on vehicle air
conditioning system and have the expertise required to do so.
This manual contains all the instructions necessary for safe and effective
operation of the air Conditioning service Station. Read this operating
manual carefully before putting the device into operation for the first time.
Also note the following:
■ The operator should comply w ith the law s about th e s erv ice of v ehi cle air conditioning by the local goverment
■ The operator shoul d be familiar with basic techni cal i n formatio n o f vehicle
air- conditioning
■ Instructions from the r efrigerant manufacturer
■ Instructions from the car manufacturer
■Any special instructions on servicing vehicle air conditioning systems
which apply at your company
Keep this operating manual in the compartment of Air-Con Service Station,
so that any information you need is always at hand.
1.1 Kernel hotline
If you need more information on the Air-Con Service Station that is not
contained in this manual, call the
Kernel Hotline:
3
Format
Meaning
Example
1.2 Explanation of symbols in this operating manual
KEY
„BOLD”
■ Text
Designations used on the
device
Display messages
List in any order
■ Text
1. Text
2. Text
3. Text
Text (1) Part numbers Use the keypad (7) to enter the
Actions to be carried out in the
order shown
Press
„LANGUAGE”
■Pressure monitor
■Pressure relief valves
1. Connect the device.
2. Switch on the device.
3. Press the selection button.
data.
Text (A) Part designations which refer to
the diagrams shown in the
section describing the work
Remove the filter cartridge (E)
on the left side.
Risk of damage to the machine or other material damage
Special information on using the device effectively
4
2 Scope of delivery
The Air-Con Service Station and its accessories are carefully checked
before shipping.
After delivery, check that all the parts listed below are present
and undamaged
If any part is missing or damaged, notify the company responsible
for transport immediately
K11
AirCon Service Station
Service hoses with coupling for HP/LP connection
Container for air condit ioning compressor oil (PAG oil)
Container for used oil
Operating manual
Power cord
5
3 Safety
3.1 General safety instructions
Read this operating manual carefully before starting up the
Air-Con Service Station for the first time
Also note the following:
■ The operator should comply with the laws about the service of vehicle
air- conditioning by the local goverment
■ The operator should be fami liar with technical information of vehicle airconditioning
■ Information form the re fri g er ant ma nu f actur er
■ Any special instructions on servicing vehicle air conditioning systems
which apply at your company
Only use the device for its intended purpose.
Only use R134a refrigerant .If other refrigerants are mixed in, it can
damage the Air-Con Service Station and the vehicle air condition system.
Only use the performance of a POLYOL ester type refrigerator oil used
with the R134a(PAG oil).If other oil are mixed in, it can damage the
vehicle air condition system
Wear personal safety equipment (goggles and gloves) and avoid
touching refrigerant, as this can cause frost bite.
Do not inhale refrigerant vapour. Although the vapour is non-toxic, it
displaces the oxygen you need to frostbi t e.
Do not make modifications to the Air-Con Service Station.
Each time you start up the device or top up the Air-Con Service Station,
first check whether the device and all the service hoses are undamaged
and that all valves are closed.
Do not start up the Air-Con Service Station if it is damaged.
Only used approved refrigerant bottles with safety valves to refill the
Air-Con Service Station.
Drain the service hoses before you release connections.
6
Do not operate the Air-Con Service Station in areas where there is a risk
of explosions (for example battery charging rooms or spraying booths).
Always use the main switch lf the Air-Con Service Station to switch it on
and off. Do not leave the device unattended when it is switch on.
Before you shut down the Air-Con Service Station, make sure that the
selected program has ended and that all valves are shut. Otherwise
refrigerant can leak.
Do not pump compressed air in the refrigerant lines of Air-Con Service
Station or the vehicle air-conditioning system. A mixture of compressed
air and refrigerant can be flammable or explosive.
3.2 Warnings on the Air-Con Service Station
Be careful
Observe the operating manual.
Protect the device against rain
Wear gloves when handling refrigerants.
Wear goggles when handling refrigerants.
Horizontal hold
Care for fire
7
3.3 Safety devices
■ Pressure monitor: switch the compressor off if the normal
operating pressure is exceeded.
■ Tank with pressure relief function: additional safety mechanism to
protect lines or vessels from bursting if the pressure continues to rise
despite the action of the pressure monitor.
4 Proper use
The Air-Con Service Station is intended for performing maintenance on vehicle
air-conditioning systems. The device is designed for commercial use.
The Air-Con Service Station may be operated by persons who have the
expertise required for servicing air-conditioni ng systems.
This Air-Con Service Station may only be used to service vehicle
air-conditioning systems in which R134a refrigerant is used.
Kernel International assumes no liability for damage resulting from the
following:
■ Use for purposes other than those describ ed i n the operating manual.
■ Alterations to the Air-Con Service Station made without the explicit
permission of Kernel international.
■ Damage to the device resulting from external influences.
■ Incorrect operation
8
5 Overview of the Air-Con Service Station
(3)
(1)
(2)
(4)
(5)
(8)
(6)
(9)
(7)
`
(1) Pressure gauge for HP (6) New oil bottle
(2) Pressure gauge for LP (7) Used oil bottle
(3)LCD display (8) power
(4)Pressure gauge for Tank (9) service hose
(5) Keypad
9
USER COMMUNICATION INTERFACE:
Recovery key : to suct the A/C refrigerant into the inner cylinder
Vacuum key : to extract gases from A/C system
Purge key : to release gases from inner cylinder
Recharge key : to refill refrigerant in to A/C system.
Pag oil key : to inject new oil into A/C system.
Function key : it allows to start the other service operation and
use the Air-Con Service Station’s database.
Selection keys: to select the service items or adjust the number
inputted.
Start key : it allows to start the execution of any working operation.
Stop key : it allows to return to the original menu or stop the
execution of any working operation.
Information key : Decide and prompt Some functions and operations
10
6 First start-up
6.1 Setting up and switching on
Power sup pl y must be firmly grounded
1. Drive the Air-Con Service Station to the workplace and lock the f r ont
wheels.
During operation the device must be on a level, flat s urface so that
measurement can be made correctly.
2.
Connect the Air-Con Service Station to the mains.
3. To switch it on, the Air-Con Service Station switches to standby mode:
“Refrigerant **.** KG” describes the quantity of refrigerant hold in inner
tank
KERNEL
AIRCON SERVICE STATION
Refrigerant **.** KG
6.2 Putting in the containers for oil
Unscrew the PAG oil bottle, put about 150ml new oil into the bottle and
screw it back to the device.
11
6.3 Filling up the internal refrigerant container
When the Air-Con Service Station is started for the first time, the internal
refrigerant container must be filled with at least 6000g from an external
refrigerant bottle.
Also note the instructions on the refrigerant bottle.
The current refrigerant quantity are shown in the standby mode.
There are three different types of external refrigerant bottle available:
■ Refrigerant bottles without a rising pipe: These refrigerant bottles have
one connection. When filling the Air-Con Service Station the
connection piece must be on the bottom (turn the bottle upside down).
■ Refrigerant bottles with rising pipe: These refrigerant bottles have one
connection. When filling the Air-Con Service Station the connection
piece must be on the bottom (place bottle upright)
■ Refrigerant bottles with rising pipe: These refrigerant bottles have two
connections. To top up the Air-Con Service Station, use the connection
marked with L (= liquid ). When fillin g the Air-Con Service Station, the
connection must be at the top (place the bottle upright).
1. In standby mode, press key, use the or key to
activate the fields you want (dark fields are activated), select “INTERNAL
TANK REFILL”
1． INNER TANK REFIL L
FUNCTION
12
THE LP HOSE TO
2. Press to confirm. Follow the instructions in the display.
INNER TANK REFILL
CONNECT
THE SOURCE TANK,OPEN THE
VAL VE U P_S IDE DOWN IT .
3. Press
to confirm. The quantity of refriger ant in the internal
container is shown.
REFILL
RUNNING **：**
RECOVERED *****G
4. The filling will stop automatic when the quantity of refrigerant is 7KG
INNER TANK REFILL
FINISHED!
PRESS ST A RT TO CONFI RM
5. Close the valve, press to confirm. Press key,
start to recov er y operation! the device will recover the refrigerant in the
hose. If you do not recycle the refrigerant in the hose, it will be cause
refrigerant leakage when you release connections, as this can cause
frostbite.
6. Disconnect the service hoses from the external refrigerant bot tl e .
.The device now is ready for operation.
13
7 Operation
When the air-conditioning is serviced, the engine and the air-conditioning
must be switched off.
7.1 Recovery
1. First fit the connections of the Air-Con Service Station to the vehicle air
conditioning system and open them.
2. Check for the high and low pressure gauges. If the pressure is equal to
zero or lower, it shows that no refrigerant leaves in the air-conditioning
system, you can select other selections directly. If the pressure is higher
than zero, press key, the device will start to recover recycling
operation.
RECOVERY
RUNNING **：**
RECOVERED **:**KG
3. When the device recovery process is over, it will discharge used PAG oil
automatically.
RECOVERY
FINISHED!
RECOVERED **:**KG
14
4. About 5 seconds later, oil draining finished.
5. Press key to stop the buzzer, then recovery process finished!
RECOVERY FINISHED!
PRESS STAR TO CONFIRM!
7.2 Vacuum
1. After recovery you had better to wait for about 1minute, if the A/C system
raise continue to recov ery, if the A/C system press ure didn’t rises above zer o,
press key, the device enter vacuum process.
VACUUM
DEFAULT **： **
2. Use or to set the vacuum time (suggest10 minutes).
3. Press , the device will start vacuum operation.
VACUUM
RUNNING **： **
3.The device will be finished automatically after expiry of the vacuum time，
press return to the standby mode.
15
VACUUM FINISHED
PRESS START TO CONFIRM!
4. wait about five minutes .and check the low pressure gauge indicator, if
the pressure is raising, you need confirm whether the air-conditioning’s
leakage. I f leak ag e, you should repair it. If not, continue the next pro cess.
7.3 Oil injection
1. Check the new oil bottle, make sure that the PAG oil leaves more than
50ml.Press key to enter oil injection process.
OIL INJECTION
PLEASE LONG_PRESS O
2. All ready, long press key until the new oil decreased to the right
value .Press key back to the standby mode, continue t he next
process.
7.4 Recharge
1. Press key to enter recharge process.
RECHARGE
DEFAULT ****G
PRESS F KEY TO USE
DATABASE!
16
2. Press or key to enter the refrigerant filling quantity. Either
use the value shown on the filling quantities sticker in the vehicle and
enter it using the keypad and the cursor keys, or press key
use the Air-Con Service Station’s database.
3. All ready, press to confirm, the device will start to recharge
the air-conditioning.
RUNNING **:**
THERE ****g LEFT!
RECHARGE
4. The process will be finished when the quantity is decreased to
zero .Press to go to standby mode.
RECHARGE FINISHED!
PRESS ST A RT TO CONFI RM!
5. Screw the valve caps of the air-conditioning system back on the
connections. And empty the service hoses by recovery operation. The
device is then ready for further use.
17
7.5 Purge
The purge is designed to purge mixed gases such as ai r pr esent in the inner tank.
It is harmful for the system when the pressur e in the tank exceed. The unit must
purge when it is turned on.
1. In stand by mode, press
2. Press
of refrigerant in t he tank.
3.
Check the tank pressure gauge. If the pressure is no higher than display
key, the display will show the temperature and the relative pressure
PLEASE LONG_PRESS P KEY
Hints:
THE TEMP IS **.*℃
REFRIERANT PURSSURE
key to enter purge mode
PURGE
value, it means that no mixed gases in the tank, you can return to the standby
mode and select the other operations directly. If the pressure is higher than
display value, long-press key, the device will start to release the
gases, until the tank pressure come to the relative valve.
18
8 Service tasks
Other service are included this items as:
“1.INNER TANK REFILL
2.LANGUAGE SELECT
3.ZERO BALANCE
4.VACUUM PUMP OIL
5.FILTER DRIVER
6.HOSE COMPENSATION
7.PRESSURE RISE WAIT
8.OTHER SERVICE.”
If you want come to these items , please pre ss key and use
or to select and enter it.
8.1 Inner tank refill
Refer to 6.3
8.2 Language select
You can select Chinese or English accordi ng to custom.
8.3 Zero balance
In order to make sure the refrigerant quantities correctly , the zero point of the
scales must be checked regular ly and reset if necessary.
Resetting is necessary:
■ If the quantity deviates by more than 10g from the target value
■ If the Air-Con Service Station has been shaken, for example during
transport on bumpy roads
■ Every four to six weeks
19
PRESS OK WHEN
1. In standby mode, press key ,to use the or key to
select “ZERO BALANCE”
ZERO BALANCE
2. Unscrew the tank and remove it from the scale plate. Make sure that there
is nothing on, press key .
Once you have set the zero point, the standby mode appears again.
3. place back the tank on the scale plate and screw it.
8.4 vacuum pump oil
Switch off the Air-Con Service Station and unplug it from the power supply
before opening the housing.
Before changing the oil, let the vacuum pump run for about 10 minutes (manuall y
using the menu).
(A)
(B)
1. Take off the front cover. Place a vessel with capacity of at least 1/2 litre
under the Air-Con Service Station. The used oil in the vacuum pump
would flow through the outlet in the base of the device.
(C)
20
2. Unscrew the oil filler plug (A).
3. To drain the oil, unscrew the oil drain plug (C).
4. Once the oil has been completely drained from the pump housing, screw
the oil drain plug (C) back in.
5. Feed up new oil into the vacuum pump , until the oil level is at the middle
of the sigh t glass (B) and screw the oil filler plug (A) back.
6. Put back the front cover and reconnect the power plug.
7. In function mode, to use the or key to select “VACUUM PUMP
OIL” , press to reset the count
8.5 Changing the internal filter
Switch off the device before opening it and pull out the mains plug.
1. Take off the front panel, Remove the filter cartridge on the left side and
replace it wi th a new one. When insert ing a new filter cartr i dg e, observe the
flow direction (FLOW arrow must point downwards).
2. conform that the new filter drier is well fixed.
3. Put the front panel back on and reconnect the power plug.
4. In function mode, to use the or key t o select “FILTER DRIER”
press key to reset the count
21
8.6 Hose compensation
You can service yourself by inputting a new quantity of refrigerant as a
compensation when the recharging occurs.
note: we strongly claim to use the default number of compensation
8.7 Pressure rise wait
Setting the waiti ng ti me that the refrigerant evaporate in the A/C system, dur i ng
the recovery operation phase.
8.8 Other service
This operations are need password , if you want to use this you can call the
hotline to ask for the password.
8.9 Cleaning and maintenance
■ Clean the exterior of the device with a damp cloth as required. If
necessary, use a little washing-up liquid. Do not use solvents or
scouring agents.
■ Regularly check the service hoses and adapters for damage. Do not
start up the Air-Con Service Station if it is damaged.
22
9. Disposal
9.1 Disposing of used fluids
Used oil is hazardous waste. Do not mix used oil with other fluids. Keep used oil in
suitable containers prior to dispos al.
9.2 Disposing of packaging material
■ The cardboard packaging material should be disposed of with other
waste paper.
■ Plastic packaging material should be added to other recyclable waste.
9.3 Scrapping the old unit
■ If you wish to scrap the Air-Con Service Station, first completely drain it
of all liquids and dispose of them in an environmentally responsible
manner.
■ Take the old device to your nearest recycling centre
23
ENOUGH.
RECOVERY START.”
10 Trouble shooting
Fault Cause Remedy
The display shows
„WARNING!
CODE :W16
NOT ENOUGH PRESSURE
TO RECOVERY!.”
This message is
normal, during the
recovery process.
Press to continue
other operations. If you
make sure that there is no
refrigerant in A/C system.
The display shows
„WARNING!
CODE:02
INNER TANK FILLED.”
The display shows
„WARNING!
CODE:W01
TANK PRESSURE IS TOO
HIGHT”
The display shows
„WARNING!
CODE:W08
REFRIGERANT IS NOT
”
The display shows
„WARNING!
CODE:W03
PRESSURE IN SYSTEM
The inner tank is full of
refrigerant.
This message is normal
during the recovery
process.
Message during the
recharge. The quantity
of refrigerant is less
than 2KG
Message during the
vacuum. It means that
there has refrigerant in
the A/C system.
Drain the internal
refrigerant container in the
proper manner.
Stop and wait for the tank
cooling down. And release
some gases if necessary.
Refill the refrigerant into the
internal tank.
Recovery the refrigerant
first.
24
11 Technical data
Dimensions (width x height x depth)
Weight
Power supply
Refrigerant
Vacuum pump
Compressor
Drier filter output
Filling cylinder accumulator capacity
LCD back-lit display
Manometers
Tank manometers
Scale resolution
Service hose
600 mm x 1150 mm x 700 mm
80 kg
220 V- 50 Hz
R134a
1L /MIN
3/8 P
150 kg
80 kg
192*64
80mm
40mm
1g
2.5m
12 Spare part list
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Service hose for high pressure side(red) 2.5m
Service hose for low pressure side(blue) 2.5m
Hermetic compressor QD-10
High pressure gauge 80mm
Low pressure gauge 80mm
Tank pressure gauge 40mm
Service coupling for low pressure QC-ML
Service coupling for high pressure QC-MH
Parts Specification
Vacuum pump VE115
Vacuum pump oil 330ml
Filter drier 302
Oil bottle 250ml
Solenoid valve SV1.6B
Liquid hose(red) 0.3m
Vapor hose (blue) 0.3m
25
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