ariazone 5001 FAHDF User manual

OPERATOR MANUAL
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ARIAZONE 5001 FAHDF
(R134a Data & Flush)
Automotive Air Conditioning Service Station
OPERATOR MANUAL

OPERATOR MANUAL
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Contents Page
1. Introduction ..............................................................................
2. SAFETY FIRST! Important Safety Information's ......................
3. Technical Features ..................................................................
4. Main Parts & Features .............................................................
5. Preparing the Machine for the First Use ..................................
6. Printer ......................................................................................
7. Refrigerant Cylinder Filling Procedure .....................................
8. Connecting to the A/C System .................................................
9. Individual (Manual) Function Selection Procedure ..................
9.1. Recovery & Recycling Mode .............................................
9.2. Evacuation Mode ..............................................................
9.3. Oil / UV Dye Injection Mode ..............................................
9.4. Refrigerant Charge Mode .................................................
10. Automatic Cycle Selection Procedure ....................................
11. Flushing the A/C system with refrigerant ..............................
12. Cylinder Air Purge ..................................................................
13. Service Procedure .................................................................
14. Unit Settings ...........................................................................
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1. Introduction_
Fully Automatic Air Conditioning Service Station is a user-friendly tool specifically designed for
the automotive air-conditioning technicians, to carry out the following functions:
-Testing air-conditioning system by comparing pressure readings on HP and LP
gauges,
-Recovery & Recycling the refrigerant from air-conditioning system and gauge
amount of refrigerant and oil (if any) recovered from air-conditioning system,
-Evacuate air-conditioning system,
-Electronically charge lubricating oil by weight into the air-conditioning system,
-Electronically charge UV Dye by volume into the air-conditioning system,
-Electronically charge refrigerant into the air-conditioning system by weight,
-Flushing (cleaning) the air-conditioning system with refrigerant.
The unit is suitable for servicing passenger and light
commercial vehicles air-conditioning systems
This is a microprocessor control system which provides electronically controlled functions, whilst
keeping the operator constantly informed and in full control.
This unit has been designed and build to be long lasting and with high level of reliability
including maximum safety for the operator. The operator needs only to be responsible for the
proper use and maintenance of the unit, in accordance with the instructions found in this
manual.
Important: This manual contains important information pertinent to operator safety,
and must accompany the unit, in the case of sale or transfer to another party.
Manufacturer reserves the right to modify this manual and the unit itself at any time without prior notice.
Environmental information
This product may contain substances that can be hazardous to the
environmental or to human health if it's not disposed of properly.
Electrical and electronic equipments should never be disposed of in the
usual municipal waste, but must be separately collected for their proper
treatment (recycling).
We also recommend that you adopt appropriate measures for
environmental protection: recycling of the internal and external
packaging of the product, including batteries (if any).
With your help it is possible to protect our planet and improve the
quality of life, by preventing potentially hazardous substances being
released in to our environment.

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2. Important Safety Information's_
This unit is extremely simple and reliable in selecting and performing all its functions. Therefore,
the user is not exposed to any risk, if the general safety guidelines reported below are followed,
in association with proper use and maintenance of the unit (improper use and maintenance will
reduce the safety of the unit).
This equipment is to be operated by accredited technician only! Users must have basic
knowledge of air-conditioning and refrigeration systems, including potential hazards associated
with the handling of refrigerants and systems under high pressure.
Read this user manual carefully before start up, connecting and operating the
unit. If you do not understand any section of this manual, please contact your
nearest distributor or manufacturer.
Handle refrigerant with care as serious injury may occur. Always wear appropriate
protective safety gloves.
The contact with refrigerant can cause blindness. Always wear appropriate
protective safety glasses.
-Avoid inhalation of the refrigerant. Use only in well ventilated work areas.
- The power cable may only be connected to a socket with nominal voltage stated
on the rating plate, located at the rear of the unit.
- RISK OF ELECTRICAL SHOCK. Power lead plug to be connected only to power
point with an earth.
- Never operate the equipment with a damaged power lead, replace it immediately.
Before removing any protective cover from unit, always unplug power lead from
power point.
- Use only pure R134a refrigerant with this equipment.
- The unit should not be operated with flammable refrigerants (HC of R1234yf).
- Position the unit on all four wheels, on a flat (horizontal) surface so that proper
operation of the scales is guaranteed.
-Do not expose the machine to direct artificial heat or rain.
- Do not tamper with or change safety control devices or their settings.
- When (if) transporting the unit, keep upright and if possible remove refrigerant
cylinder from platform.
- Do not cover ventilation openings on chassis cover when the unit is operating.
- Maintenance is to be carried out as per the manufacturer recommendation shown
in this manual. Only original parts are to be used for maintenance and repairs.
Maintenance of the unit must only be performed by an authorized technician.
- Only non aggressive substances to be used for cleaning of the unit.

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3. Technical Features_
Refrigerant
R134a
Electronic refrigerant scale
+/- 10 g resolution
Load cell
60kg with 150% overload capacity
LP and HP gauges
D 68 mm kl.1.0
Recovery cylinder
27kg
Recovery pump
FR11G, 275W
Recovery rate
up to 400 g/min (liquid state)
Vacuum pump
2 stage, 100 l/min (3.5cfm)
Vacuum
3 x 10-1 Pa
Dimensions
620 mm, 600mm, H-1120 mm
Weight
84 kg
Chassis
Sturdy all steel construction, powder coated
Supply voltage
220-240VAC - 50/60Hz
Power
700 W
Max. Currency
6.7A
Working conditions
0 to 45 oC ambient temperature, up to 100% humidity, 2000m
altitude
Noise level
< 70 dB (A)
Fuse
10 amp/250V (slow blow type)
Measuring instrument
I category (Not to be mixed with II, III, IV category)
Approvals
EN 61010-1 Electric safety, EN 55014-1 EMC-CE

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4. Main components location_
1. Low Pressure and High Pressure gauges - Two large analogue gauges display suction
and discharge pressures. The gauges are mounted on the front panel for easy viewing by the
operator. Pressures are displayed in Bar & PSI and temperatures in degrees Celsius.
2. LED & LCD Displays - LED numerical display and LCD display below inform the operator on
weight of refrigerant and oil currently in the unit vessels, remaining vacuum time, the amount of
refrigerant and oil being recovered or charged, data base of vehicles and unit set up...
3. LED group and membrane switches (keys) - Six LED indicates the mode and status of the
unit. These are used in conjunction with 6 membrane switches (keys) to select the unit
functions. Further, once the mode is in operation the pattern in which the Led’s flash, indicate
the activity of the system. These can be viewed from several metres away.
4. Hand Valves - The console hand manifold valves allows the operator to control the flow of
the refrigerant (if desired).
5. Discharge & Suction Service Hoses - A pair of 3m hoses are connected to the console,
which allows the operator to connect the system to the vehicle air-conditioning system service
ports for testing system pressures, recovering and recharging refrigerant, oil and/or UV dye.
6. Service Hose Quick Couplers - Service hose quick couplers allows the operator to connect
the unit to the vehicle air-conditioning system service ports, without exhausting the refrigerant in
to the environment.
7. Moisture Indicator - The moisture indicator is conveniently mounted below the console for
added protection to indicate the condition of refrigerant and filter change intervals. The following
colours correspond to the following moisture content: Green or Blue Dry, Yellow or Pink Wet.

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8. Vacuum Pump Oil Level - Oil level must be checked when the pump is running, the oil level
should be even with the horizontal line on the vacuum pump sight glass. Under filling with oil will
result in poor vacuum performance. Overfilling can result in oil blowing out from the vacuum
pump exhaust.
9. Recovered Oil Drain Reservoir - Plastic vessel of 250ml is mounted on the right rear of the
unit to electronically gauge the amount of oil recovered from the air-conditioning system, if any.
10. Oil Storage Reservoir - Plastic vessel of 250ml is mounted on the left rear of the unit to
electronically inject the recovered amount of oil back in to air conditioning system, or to select
the desired amount of oil to be injected.
11. UV DYE Storage Reservoir - Plastic vessel of 250ml is mounted on the lower left rear of
the unit (below the Oil Reservoir) to electronically inject UV Dye in to air- conditioning system.
12. Refrigerant Cylinder - 27kg capacity cylinder is used to store the recovered/recycled
refrigerant. The cylinder is secured with strap to the platform.
13. Cylinder Non-Condensable Indicator - A large pressure gauge is mounted on the back
upper left side of the unit to indicate to the technician of any non-condensable (air) built up in
the storage cylinder.
14. USB port – Connection with PC
15. Cylinder Vapour Hose (Blue) - Connecting the cylinder vapour valve (blue) with the unit
16. Cylinder Liquid Hose (Red) with Ball Valve - Connecting the cylinder liquid valve (red)
with the unit
17. Brass Adapter – For connection of the suction service hose (5) to a storage refrigerant
cylinder valve.
18. Power Lead with Fuse - 10A
19. Main Power Switch
20. Printer - After completion of every operation the unit will print a report
21. Cylinder Air Purge Ball Valve - To purge the non-condensable gases (air) from the
cylinder (12) and bring back the pressure to the recommended chart values.
22. Flushing port – ¼” SAE male adapter with Schrade valve.

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5. Preparing the Machine for the First Use_
Perform the following steps to prepare the unit before the first use.
1. Remove the shrink wrap and styrofoam insert behind the cylinder (12) (see figure 1).
2. Check to ensure that all of the accessory
components are with the unit:
- Cylinder (12)
- Adapter (17)
- Cylinder vapour hose (blue) (15)
- Cylinder liquid hose (red) with ball valve (16)
- Service hoses with quick couplers (5)
- User's manual
- Cylinder strap
3. Check that the cylinder (12) is already placed on the platform and properly secured with the
strap provided. Unscrew two securing M6 bolts situated on each side of the platform base
app. 3-4 mm and LOCK the locking nut, making sure that there is 3mm clearance between the
end of the safety bolt and the base of the machine.

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4. Check the vacuum pump oil level (8).
The oil level should be even with the horizontal
line on the vacuum pump sight glass when the
pump is running.
5. Power up the unit on a main switch (19).
The unit will perform a lamp test, whereby all
LED displays are illuminated. This will enable
the operator to determine if any display
segments have failed.
After the sequence has been completed, the
displays will indicate: FILT - REMAINING
WORKING HOURS XX Hr.
This is the number of hours left before
equipment servicing is required.
6. In next sequence the unit is on "Stand by"
and the LCD display is showing:
- The amount of refrigerant in the cylinder (12),
- The quantity of new oil in the vessel (10).
- The quantity of oil in recovered oil vessel (9)
- The time is displayed
If the cylinder is delivered empty, display should
indicate approximately 0.00kg of refrigerant in
the cylinder (cylinder empty).

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7. Mode Selection.
To select a mode of operation, press either the
"UP" or "DOWN" arrow keys until the LED
indicator is beside the desired function.
Press 'START' key which will cause the unit to
enter the selected mode. Any mode that has
been selected can be exited by pressing the
'STOP' key.
Note, that if a valid key was depressed, the unit
will beep. If an inappropriate selection has been
made, i.e. attempting to select a mode whilst
another mode is in operation, the unit will ignore
the pressed key and will not beep.
8. Check if both cylinder (12) valves and liquid hose (16) ball valve are open.
9. Attach the service hoses (5) on the unit. Carefully tight (with fingers only) knurled nut on
console bellow hand wheels (blue-left, red-right). Hook up quick couplers (6) to parking brass
adapter (pull back bottom knurled section with fingers and carefully press the coupler into the
proper adapter).
10. Fill the plastic oil vessels (10) with new oil (minimum 50ml) and plastic vessel (11) with UV
Dye (minimum 50ml). The display in Stand by mode will show the amount of the oil filled in new
oil injector.

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6. Printer_
The printer is equipped with two keys and green led:
>> Paper feed
II on line / off line
The green led shows the state of the printer:
Led constantly ON - Printer in line
Led blinking - Printer not in line or no paper
Led off - Press II. If the problem persists, contact
authorized distributor or manufacturer.
Printer roll specifications,
Paper width: 57-58mm
Max paper thickness: 80 µ
Printing report:
After completion of every operation the unit will print
a report as per list on the right --->

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7. Refrigerant Cylinder Filling Procedure (Refrigerant Transfer)_
The cylinder (12) may be filled with refrigerant by the following procedures.
Connect the suction (blue) service hose (5) to storage cylinder liquid valve by using the
refrigerant cylinder adapter (provided from refrigerant supplier), open liquid valve on storage
cylinder, open service hose quick coupling (5) and console blue hand valve (4)...
Press "UP" key once to select the RECOVERY /
TRANSFER function and press "START". By using
“DOWN” key select TRANSFER (REFRIGERANT)
and press “START”.
Now, select from two options:
- TOTAL TRANSFER (all refrigerant) or,
- PARTIAL TRANSFER (set the amount of
refrigerant to be transferred).
Press "START" key and unit will automatically transfer refrigerant from storage cylinder to the
unit cylinder (12).
When the selected amount of refrigerant is transferred, close the storage cylinder valve and
allow the unit to recover the refrigerant from the service hose (5). Once the function is
completed the unit will display symbol "DONE" and the amount of refrigerant transferred will be
displayed in kg or lb on main display (2).
Important: Always keep a minimum of 2 kg in the cylinder (12).

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8. Connecting to the A/C system_
Use the service hose (5) quick-connect couplers to connect the hoses to the A/C system service
ports, bearing in mind that BLUE must be connected to the low-pressure (suction) side and
RED to high pressure (discharge) side.
If the system is equipped with a single service port, connect only the relative hose.
Winding the quick coupler hand wheel clockwise will allow the refrigerant to flow through the
hoses. Turning hand wheel in opposite direction, the flow will be closed. If there is any
refrigerant in the air-conditioning system, the pressure gauges will indicate a pressure rise.
Important: Console manifold hand valves (4) need to stay closed, NOT to allow
refrigerant to enter into the unit until the required function has been selected.
The unit gauges (suction & discharge) are important and useful instruments. The operator
should have basic understanding between gauge reading and air-conditioning system operation
in order to correctly diagnose any possible system malfunction.
Set the transmission in neutral -
park, start engine and turn the air
conditioning on. Allow pressure
gauge needles to stabilize and
record the pressure readings.
Gauges reading may show
particular problem or associate to a
possible problems.

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9. Individual (Manual) Function Selection Procedures_
With this procedure, all functions:
-Refrigerant recovery & recycling,
-A/C System Evacuation,
-New Oil and/or UV Dye Injection and
-Refrigerant Charge)
can be performed individually (step by step).
The values for the quantity of refrigerant recovered, quantity of the oil recovered, vacuum time,
quantity of oil injected and quantity of refrigerant charged into the a/c system are automatically
printed at the end of each single operation.

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9.1. Recovery & Recycling Mode_
The purpose of the Recovery & Recycling
mode is to recover refrigerant from the air
conditioning system, which will condense,
purify and store the liquid refrigerant in the
storage cylinder ready for re-use.
To initiate the Recovery mode, press the 'UP'
key once, followed by 'START' on the console.
Display will show:
1. TOTAL RECOVERY to recover the whole amount of the refrigerant from the A/C system or
storage cylinder.
2. PARTIAL RECOVERY to select desired quantity of refrigerant to be recovered from the a/c
system or storage cylinder.
After the quantity selection is made, press "START" key.
Important: Open the hand manifold valves (4) on the console to allow the flow of the
refrigerant from the a/c system before making the above selection (valves on the unit
storage cylinder (12) and ball valve on the cylinder liquid hose (16) must be open also).
During the recovery process, the 'Recovery' mode LED indicator will blink and the display (2)
will indicate the amount of refrigerant being recovered.
In normal operation the above condition will be maintained until a vacuum of -0.4 bar is reached
at either the discharge or suction ports. When this occurs, the machine will beep once, and the
unit will enter in Recovery "PAUSE" mode. In this mode, the unit will shut down the Recovery
function and pause for 180 seconds, in which during this time the recovery mode enunciator will
be ON constantly. The display (2) will indicate "PAUSE". During this function, the unit is
monitoring whether the air-conditioning system pressure is increasing, due to any refrigerant
that may be left in the a/c system. If the pressure increases above zero, the machine will re-start
the recovery function automatically and recover the remaining refrigerant.
If at the end of Recovery process a sufficient vacuum of -0.4 Bar has been maintained, the unit
will stop, and the display (2) will indicate 'DONE' and the amount of refrigerant recovered will be
displayed in kg (or lb) depending on the operator’s selection.
Press 'STOP' on the console, the unit will display "busy" for 5 seconds. The value of the quantity
of refrigerant recovered will be automatically printed.

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9.1.1. Recovered Oil Drain
After completing the recovery function, the unit will automatically drain the recovered oil (if any)
into recovered oil vessel (9) to electronically calculate amount of oil that has been recovered.
The value of the recovered oil will be automatically printed.
9.1.2. Conditions that will stop the recovery mode
The above sequence assumes that neither the stop button was pressed, or that no undesirable
condition occurred. The following conditions will cause the unit to halt the recovery function.
1. If hand m-fold valves (4) on the console are CLOSED. “NO REF” will be displayed.
2. Air conditioning system empty. If the A/C system pressure is not above atmospheric
pressure, the recovery function will not be activated. “NO REF” will be displayed.
3. Refrigerant cylinder (12) full. To protect the storage cylinder from being overfilled, the unit will
not allow the operator to recover refrigerant once it has reached 80% of its capacity. “CYL
FULL” will be displayed.
4. High Pressure. If the operating pressure of the unit exceeds 25 bar (340 PSI), the unit will
stop and display 'HiGH - PRES'. The following can cause the above:
Cylinder (12) valves not open.
Restricted cylinder hose (16). Check the ball valve.
Excessive high ambient temperatures.
Excessive air in refrigerant cylinder (12).
Faulty pressure control
In all the above circumstances, press the 'STOP' key to return to the machines initial mode.
If the above conditions are ok and the ‘H-PRES’ display keeps on appearing, contact your local
distributor or manufacturer for further advice.
5. Recovered oil vessel (9) full.

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9.2. Evacuation Mode_
In the evacuation mode the air and moisture in
the air conditioning system is removed and
exhausted to the atmosphere. The evacuation
mode runs for a predetermined time selected
by the operator.
To initiate evacuation mode, press the 'UP' key
twice, followed by the 'START' key. Select the
desired evacuation duration by pressing the 'UP'
key to increase or ‘DOWN’ key to decrease time
duration. Once the desired time has been
selected, press the 'START' key and the function
will commence.
The evacuation time can be set from one minute
to eight hours. At any time the evacuation time
can be paused or cancelled by pressing the
“STOP” button once to pause, or twice to cancel
the function.
Important:
During evacuation mode the manifold hand valves (4) on the console must be open.
The unit has a unique function that if the evacuation function is selected and there is residual
refrigerant in the air conditioning system, greater then 0.5 Bar (10 PSI), the unit will detect this
condition, whereby it will beep six times to warn the operator. After this warning the unit will
automatically recover the residual refrigerant, once it has recovered the entire refrigerant it will
start the selected evacuation function automatically.
Leak Test - If the vacuum of min -0.85 Bar is not reached after first 90sec, the unit will beep
and display TEST FOR LEAK, indicating for possible leak in the a/c system or bad connection
of the service hoses.
In Normal operation after completion of evacuation function, next 3 minutes the unit will test if
there is leak in the a/c system. Depends if the a/c system is leaking or not, the display will show
OK or FAILED.
After completion of evacuation function, the unit will automatically print the report.

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9.3. Oil & UV dye Injection Mode_
The purpose of this function is to batch a
user-defined quantity of refrigerant oil or
UV dye from the oil reservoir (10) to the
vehicle air-conditioning system.
Important: The unit requires that the air
conditioning system has previously been
evacuated to a maximum vacuum before this
function can be carried out.
Make sure you have sufficient refrigerant oil and UV dye in the vessels (10 & 11) and select the
Oil/UV Dye Injection mode by pressing the 'UP’ or ‘DOWN' keys, followed by the 'START' key.
Now the display will shows the following:
Select the desired amount of refrigerant oil ('UP' key to increase or ‘DOWN’ key to decrease the
volume). With "> key go to UV DYE and again with "UP & DOWN" keys select the desired
number of UV Dye doses (1 dose ~ 8ml). Once the desired amount has been selected open
hand manifold valve (4) on the console and press the 'START' key.
Important:
During evacuation mode red HP hand valve (4) on the console must be open.
After completion of oil injection, the unit will automatically print the report of the oil injected into
the A/C system.
9.3.1. Conditions that will stop oil injection
The unit will not inject oil if the following conditions exist:
- Insufficient vacuum.
- Hand manifold valves (4) not opened on console.
- No oil in the reservoir (10).

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9.4. Refrigerant Charge Mode_
The purpose of the refrigerant charge mode
is to batch a user-defined weight amount of
refrigerant into the air-conditioning system.
Important: Before start refrigerant
charge A/C system MUST be
properly evacuated and leak tested.
To initiate charging mode, press the 'UP' key
four times, followed by the 'START' key. The
display will shows the following
Select the desired charging mode MANUAL or FROM DATABASE and set the amount of
refrigerant to be charged into the a/c system (with 'UP' key to increase or ‘DOWN’ key to
decrease in manual mode, or by selecting the vehicle make and model from database). The
smallest increment of refrigerant charge weight is 0.01 kg.
Holding the 'UP' or 'DOWN' keys for longer than two second will cause the increments of weight
change to increase or decrease rapidly.
Important: Once the refrigerant charge weight has been set, press the 'START' key and
open appropriate hand manifold valve depending on whether you are charging with the
engine running or engine stationary (if the A/C system is OFF or ON).
Once the present refrigerant weight has been charged, the charge function will automatically
stop and the display will indicate 'DONE'. The operator can return the machine to its initial state
by pressing 'STOP' key on the console.
After completion of refrigerant charge, the unit will automatically print the report of the amount of
refrigerant charged into the A/C system.
9.4.1. Conditions that will stop refrigerant charging
- If there is little or no refrigerant in cylinder (12). The operator will not be able to select the
desired amount of refrigerant required.
- If the cylinder (12) valve is closed.
- If the hand manifold valve (4) is closed.
- If the A/C system service port Schrader valve is not depressed

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10. Automatic Cycle Procedure_
In the Automatic cycle mode, all the
operations (Refrigerant Recovering
and Recycling, Recovered Oil Drain,
Evacuation, New Oil and/or UV Dye
Injection and Refrigerant Charging)
are performed automatically one after
the other in ONE CYCLE.
Quantity of the refrigerant recovered,
recovered oil, vacuum time, oil injected
and refrigerant charged into the A/C
system are printed at the end of each
single operation.
To initiate the Automatic cycle mode, press the 'DOWN' key
once, followed by 'START' on the console.
Press "START" button to confirm the Recovery function.
By pressing the 'UP' key to increase or 'DOWN' key to
decrease select the desired Evacuation Time Duration.
Once the desired time has been selected, press 'START' key.
Oil/UV Dye injection selection. The operator can choose between:
-AUTOMATIC selection. The unit determines the quantity of oil extracted during the recovery
process and will inject the same quantity back in the a/c system. Only desired quantity of UV
dye can be selected.
-MANUAL selection. With 'UP' key (to increase) or "DOWN" key (to decrease) select the
amount of refrigerant oil and/or UV dye to be injected into the a/c system (above the amount of
extracted oil). Press ">" key to change UV Dye selection.
Once the desired amount has been selected, press the 'START' key.