Air Solutions KK2 User manual

KK2 instruction manual - Issue 1.0
Use and Instruction Manual
Issue 1.0
RECOVERY, RECYCLING AND
RECHARGING STATION

Index
1. Introduction 3
1.1 Instructions 3
1.2 Safety regulations 3
2. Outfit 1
2.1 Standard outfit 1
2.2 Quick coupling with safety hand wheel 1
3. Use 1
3.1 Preparing for use 1
3.2 Control panel description 2
4. Functions of the recharging unit 3
4.1 Brief working cycle description. 3
4.1.1 Manual cycle 3
4.1.2 Automatic mode (no access to the database) 4
4.1.3 Automatic mode (with access to the database) 5
4.1.4 Special Functions 5
4.1.5 Setup. 6
4.1.6 Info 6
4.2 Analytical description of the cycles 8
4.2.1 Manual cycle 8
4.2.2 Automatic cycle 11
4.2.3 Automatic cycle (database) 12
4.3 Settings 12
4.3.1 Date/time setting 12
4.3.2 Internal gas tank recharging. 12
4.3.3 Tare test 13
4.3.4 Language 13
4.3.5 Databank update 13
4.3.6 LCD settings 14
4.4 Remarks 14
4.4.1 Vehicles with only one connection. 14
4.6.2 Oil reservoir emptying and filling 14
5. SPECIAL FUNCTIONS 15
5.1 Printing 15
5.2 Flushing (with refrigerant) 15
5.3 Nitrogen test 16
5.4 A/C system pressures test 16
6. Service 17
6.1 Dryer filters and vacuum pump oil 17
6.1.2 Oil replacement of vacuum pump. 18
6.2 Warranty 19
6.3 Spare parts and accessories 19
6.4 Service reminder 20
6.5 Warranty sheet 21
7. Technical data 22
8. EC declaration of conformity 23
Cooling gas R 134 recharge and recovery unit 23
KK2 MANUAL 2

1. Introduction
1.1 Instructions
This manual has been drawn up in order to assist you in using our recharging unit for A/C systems at
best and to protect your security...
We advise you to read the instructions carefully and to strictly comply with the given information.
We shall decline any responsibility resulting from the improper use of the equipment and any violation
whatsoever will cancel the guarantee.
Never position the recharging unit in a horizontal way, this would give rise to oil discharge from the
vacuum pump.
1.2 Safety regulations
Our recharging station is built in a way to be used by professionals adequately prepared for the use
and after having read the following safety regulations and instructions;
-use the recharging unit with gloves and protective glasses,
-avoid to inhale the gas,
-avoid the contact with the skin,
-avoid the contact with the eyes,
-do not smoke whilst using the recharging unit,
-do not use the unit near flames or sources of heat,
-do not use the unit in humid and wet environments,
-use the unit in airy environments,
-only employ original spare parte and accessories,
-do not fill the stocking reservoir above 80%,
-turn off all cocks before connecting to the A/C system,
-use the recharging unit only for gas R134a,
-during maintenance operations disconnect the unit from the electrical system,
-avoid to disconnect the connecting tubes if not necessary,
-Maintenance operations have to be carried out by specialized and authorized personnel.
Only use oil, additives or dye substances included in our catalogues or approved by our
company. The non-observance of this rule, will
Whatsoever damage due to a wrong or improper use of the station will not be covered by
our warranty. Consumables like packings and seals hoses and couplings, fuses and
gauges and damages occurred during transport are not part of the warranty
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2. Outfit
2.1 Standard outfit
The standard outfit is always complete and of best quality:
n. 1 high pressure tube (red)
n. 1 low pressure tube (blue)
n. 1 Fitting for cylinder
n. 1 Quick coupling R134a high pressure (red).
n. 1 Quick coupling R134a low pressure (blue).
2.2 Quick coupling with safety hand wheel
The quick couplings have to be opened by screwing the hand wheels clockwise in order to avoid gas
dispersion into the environment (see figure 1)
It is recommended to empty the hoses and wait for some minutes before
disconnecting the quick couplings from the vehicle in order to avoid damages to
the seal rings of the connections
KK2 instruction manual - Issue 1.0
Fig. 1

3.2 Control panel description
Di
The control panel has been designed in a way that every operation to be carried out is easily intuitable
since all pressure gauges, buttons and cocks are coloured and equipped with symbols.
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9
8
12 10
11
2
1
3
4 5
6
7
1
3
Fig. 3

1 – High pressure gauge: For the inspection and diagnosis of the A/C system.
2 – Low pressure gauge: For the inspection and diagnosis of the A/C system and for
the control of the vacuum.
3 - Tank pressure gauge: to check the pressure inside the stocking gas reservoir
4 - High pressure valve Connects the recharging unit to the A/C system.
5 - Low pressure valve: Connects the recharging unit to the A/C system.
6 - High pressure coupling Connects the cross-connection to the A/C system.
7 - Low pressure coupling Connects the cross-connection to the A/C system.
8 - Bias lighted display: Shows the operations of the unit on two lines.
9 - Button UP: Shows the operation of the unit and sets the time and the
quantity of gas and oil.
10 – Button DOWN: Shows the operation of the unit and sets the time and the
quantity of gas and oil.
11 – Button ENTER: Confirms the set operations.
12 – Button CANCEL interrupts any operation
13 – Serial port Used for yearly database updating
4. Functions of the recharging unit
4.1 Brief working cycle description.
When switched on, the unit displays the Database and allows the choice of a vehicle model to carry
out the working cycle (both in manual and in full automatic mode) with the help of the stored data
The choice of the vehicle is made by selecting PRODUCER – MODEL – YEAR OF CONSTRUCTION.
The database includes information regarding: A/C SYSTEM TYPE , OIL TYPE AND OVERALL
QUANTITY in the system compressor and sets the working cycle data according to the GAS
QUANTITY of the A/C system and the suggested vacuum and vacuum test times.
By pressing the button © it is instead possible to select the other functions of the unit:
- MANUAL OPERATION: allows to carry out working cycles, both in automatic mode (without access
to the database) and in manual mode i.e. one step after the other
- SPECIAL FUNCTOINS: allows carrying out some additional functions such as a nitrogen pressure
test or a flushing cycle (with refrigerant)
- SETUP: allows to configure the unit and to update the database
- INFO: offers different information such as the number of carried out working cycles, the overall
quantity of recovered gas and the installed software version.
4.1.1 Manual cycle
With the help of the button ©, select MANUAL. With buttons it is possible to select
the following working cycles:
Description of the working cycle Symbol
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Gas recovery, oil separation and drain.
Vacuum
Vacuum test
Oil injection
Dye injection
Gas recharging
The working cycle includes following phases:
Phase 1:Gas recovery from A/C system, gas residuals control and recovery, oil separation and oil
drain
Phase 2:Vacuum and vacuum test of the A/C system (the time is set by the operator).
Phase 3:Oil injection (by means of a solenoid valve)
Phase 4: Injection of the set dye quantity (by means of a solenoid valve).
Phase 5: Automatic gas recharging in the A/C system
With the use of the buttons choose ENTER and the desired working phase and press
↵
ENTER in order to modify the values. With buttons modify the values, if necessary.
By pressing ENTER once, the working cycle will start- By pressing the button © , instead, the data
are stored without starting the working cycle immediately.
4.1.2 Automatic mode (no access to the database)
At the beginning, the last recalled car model is displayed. In order to work in automatic mode without
the use of the database, press © to go back to the function choice and select “MANUAL”. The
different working phase’s data are shown on the display
By selecting the icon with the help of the buttons and confirming with
↵
ENTER all working phases are carried out in automatic mode (according to the values shown on
display), i.e.
Description of the working cycle Symbol
KK2 MANUAL 4

Gas recovery, oil separation and drain.
Vacuum
Vacuum test
Oil injection
Dye injection
Gas recharging
In case it is necessary to change one or more of the shown values, proceed as follows:
- select the working PHASE to be modified by means of the buttons , confirm with
“ENTER”, modify the values by means of the buttons , store the data by pressing ©, To
start the automatic cycle, select and press
↵
ENTER.
4.1.3 Automatic mode (with access to the database)
At the beginning, the last recalled car model is displayed. In order to work in automatic mode with the
use of the database select the desired vehicle model by means of , press
↵
ENTER to
reach the following menu, up to the final vehicle choice
Once the right vehicle has been se3ected, it is possible to start the full automatic mode by selecting
and pressing ENTER.
If, instead, it is necessary to modify one or more of the displayed values, proceed as described above
(see par. 4.1.2).
4.1.4 Special Functions
The special functions include:
a) The printing out of the working cycle data (optional)
b) The flushing cycle (with refrigerant) (optional)
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c) The nitrogen pressure test (optional)
d) The working pressure test with pressure transducer for the Low Pressure side and
temperature probe (optional).
NOTE: for the use of the above special functions, the unit has to be ordered with additional
devices
4.1.5 Setup.
By selecting “setup” the following functions can be carried out:
Internal gas bottle recharging
Test of the electronic load cell
Language selection on display
Database updating
LCD display setting (this is carried out by the producer)
4.1.6 Info
By selecting the following statistic information are displayed:
a) Recharging station model
b) Software version
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