COOLIUS A30 BUS User manual

Original Operating Manual
Operating Manual
A30 BUS
A/C Service-Unit for refrigerant R134a
Doc.No.: 22102-V20177rev03.b

2COOLIUS A30 BUS
Introduction
Dear Customer,
Thank you for purchasing this product.
To ensure this condition and ensure safe operation, you must observe these operating instructions!
Read the entire operating instructions before using the machine for the rst time. Observe all operating
instructions and safety instructions!
All company names and product names are trademarks of their respective owners. All rights reserved.
If you have any questions, please contact the respective service partner of your country
See chapter 9 Con-
tact and support p. 3636.
This machine meets the requirements of valid EU directives.
2014/68/EU (PED)
2006/42/EU
2014/30/EU
2014/35/EU
The declaration of conformity can be obtained from: www.coolius-ac.com
WOW! Würth Online World GmbH
Via della Punta 6/2
48018 Faenza (RA)
Italy

3COOLIUS A30 BUS
Contents
1 Important notes on the operating instructions....................................................................................................... 5
The purpose of this operating manual is: ..................................................................................................... 5
Disclaimer ............................................................................................................................................................. 5
1.1 Important information about refrigerant ................................................................................................................... 6
Safety Classication and information about refrigerant:........................................................................... 6
1.2 Symbols ........................................................................................................................................................................... 7
1.3 Intended use .................................................................................................................................................................. 7
2 Important safety instructions ........................................................................................................................................ 7
2.1 Glossary of terms .......................................................................................................................................................... 7
2.2 General safety rules ..................................................................................................................................................... 8
2.3 Guidelines for handling refrigerants ......................................................................................................................... 8
2.4 Safety devices................................................................................................................................................................ 9
2.5 Not condensable gas discharge................................................................................................................................ 9
2.6 Ventilation Safety System ........................................................................................................................................... 9
2.7 The work environment ................................................................................................................................................. 9
3 Use of the machine ........................................................................................................................................................ 10
3.1 Unpacking and checking the components............................................................................................................ 10
3.2 Machine description.................................................................................................................................................... 10
3.3 Machine handling ........................................................................................................................................................ 12
3.4 On/O󰀨 and stopping ................................................................................................................................................... 12
4 Preparation for the use and settings........................................................................................................................ 12
4.1 Switch on the machine............................................................................................................................................... 12
Switch on the machine for the rst time...................................................................................................... 12
Unlocking the machine .................................................................................................................................... 13
4.2 Using the printer .......................................................................................................................................................... 14
4.3 Program selection ....................................................................................................................................................... 15
Overview of the menu contents..................................................................................................................... 15
4.4 Setting ............................................................................................................................................................................ 16
4.4.1 Machine set-up ..................................................................................................................................................... 16
4.4.2 Time-Date
............................................................................................................................................................. 17
4.4.3 Company data....................................................................................................................................................... 18
4.5 Maintenance messages............................................................................................................................................. 18
4.6 Error messages ........................................................................................................................................................... 19
4.7 Vessel charge............................................................................................................................................................... 19
5 Programs .......................................................................................................................................................................... 21
5.1 New oil bottle change ................................................................................................................................................ 21
5.2 Full service.................................................................................................................................................................... 23
5.3 A/C database .............................................................................................................................................................. 24
5.4 Open program ............................................................................................................................................................. 25
5.4.1 Recovery ................................................................................................................................................................ 25
5.4.2 Vacuum................................................................................................................................................................... 26
5.4.3 A/C system charge .............................................................................................................................................. 26
5.4.4 A/C pressure test ................................................................................................................................................. 26
5.5 A/C ushing (UNLOCK CODE required)............................................................................................................... 27
6 Maintenance
...................................................................................................................................................................... 28
6.1 Operation history ......................................................................................................................................................... 29
6.2 Next service .................................................................................................................................................................. 29

4COOLIUS A30 BUS
6.3 Counter reset (UNLOCK CODE required)............................................................................................................ 29
6.4 Filter replacement ....................................................................................................................................................... 30
6.5 Vacuum pump oil replacement ................................................................................................................................ 31
6.6 Report............................................................................................................................................................................. 32
6.7 Scale reset ................................................................................................................................................................... 32
6.7.1 Refrigerant Weight scale.................................................................................................................................... 32
6.7.2 Waste oil Weight scale ....................................................................................................................................... 33
7 Technical features............................................................................................................................................................ 34
8 Disposal............................................................................................................................................................................... 35
8.1 Storage for long periods ............................................................................................................................................ 35
8.2 Disposal of used uids............................................................................................................................................... 35
8.3 Disposial of packaging material............................................................................................................................... 35
8.4 Scrapping the old unit ................................................................................................................................................ 35
9 Contact and support...................................................................................................................................................... 36
9.1 Service Portal COOLIUS-AC.COM ...................................................................................................................... 36

5COOLIUS A30 BUS
1 Important notes on the operating instructions
COOLIUS A30 BUS (the machine) has been designed and built to ensure long lasting, high-level operating
reliability with maximum safety for user.
This operating manual is part of the machine.
Read carefully before use.
• The user is responsible for the proper use of the machine in accordance with the instructions found in
this operating manual.
• The manufacturer cannot be held responsible for damage to persons, animals and/or objects due to
improper use di󰀨erent to that illustrated in this instruction manual.
• The manufacturer reserves the right to make technical and aesthetic alterations to the machine without
prior notication.
The purpose of this operating manual is:
• To supply the user with all the information needed to use the unit starting from purchase on through to
the disposal of this same machine.
• To ensure maximum support for the personnel assigned to the use and the maintenance of the ma-
chine.
For any special information or requests for technical assistance or spare parts, please contact the Service
partner of your country.
Disclaimer
This manual was created with great care. However, if you notice any omissions or inaccuracies,
please inform the service partner of your country in writing.
The manufacturer shall not be liable for technical or typographical errors and reserves the right at
any time without prior notice to the product and the instruction manuals make.
The illustrations in this document may di󰀨er from the machine actually supplied with this manual.

6COOLIUS A30 BUS
1.1 Important information about refrigerant
Note: All the information here is current as of the date of printing of this manual.
Warning! The machine is designed exclusively for R134a. The design meets all the guidelines of
the European standard EN 378:2010
Safety Classication and information about refrigerant:
The refrigerant is classied in Table E.1 (Refrigerants designation) of Annex E (Normative) of the European
standard EN 378-1:2008 + A1: 2010 (E) (EN 378-1:2011)
The refrigerant can assume di󰀨erent names depending on the manufacturer!
For more information relating to the refrigerant refer to the SAFETY DATA SHEET according to
Regulation (EC) No. 1907/2006 (MSDS).
The SAFETY DATA SHEET (MSDS) must be delivered to the operator (s) employee (s) using the
machine!

7COOLIUS A30 BUS
1.2 Symbols
This safety alert symbol indicate that this message involves personal safety. Works danger,
warning and caution indicate degree of hazard. Death, personal injury and/or property damage
may occur unless instructions are followed carefully.
Do not operate this machine if you have not read and understood the following safety items.
Read this entire Operating Manual.
1.3 Intended use
The machine is designed solely for use in automobile air-conditioning system maintenance.
Caution! Risk of injury due to improper use.
This machine is intended for use by Qualied personnel only. Such users must have a knowl-
edge of the basics of refrigeration, refrigeration system, refrigerants and the potential hazards
that unit under high pressure can cause.
2 Important safety instructions
The user should follow the “general safety rules”, and use the machine according to the “intended use” and
the instructions of this operating manual.
Therefore, the user is not exposed to any risk if the general safety rules reported below are followed with
proper use and maintenance of the machine.
2.1 Glossary of terms
• Machine: The machine relative to this operating manual.
• Refrigerant: Fluid reported on the identication label.
• A/C system: Air-conditioning system in the vehicle.
• External container: New Refrigerant used to ll the internal container.
• Internal container: Refrigerant storage tank.
• Process: Execution of an individual function (Ex. Recovery).
• Cycle: Execution of more processes.
• Recovery: The recovery of refrigerant in any condition and its storage in a container outside the A/C
system, without necessarily undergoing analysis or treatment of any kind.
• Recycling: A reduction of the contaminating substances in used refrigerants through oil separation, the
recovery of incondensable and their single or multiple passages through elements that enable a reduc-
tion in humidity, acidity and gasses.
• Disposal: Recovery of refrigerant to store it for subsequent distribution or disposal.
• Vacuum: Phase in which air and moisture are evacuated from an A/C system solely by means of a
vacuum pump.
• Oil charge: Introduction of oil inside an A/C system for the purpose of maintaining the amount of oil
specied by the manufacturer.
• UV tracer charge: Introduction of UV tracer inside an A/C system in order to detect possible leaks by
means of a UV lamp.
• Refrigerant charge: Phase during which refrigerant is introduced into an A/C system in the amount
specied by the manufacturer.

8COOLIUS A30 BUS
• Flushing: at the purpose to clean the A/C system or components, liquid refrigerant is ushed through it,
in order to do so a special device and adapters are needed.
2.2 General safety rules
• This machine is intended for use by QUALIFIED PERSONNEL only. Such users must have a knowl-
edge of the basics of refrigeration, refrigeration system, refrigerants and the potential hazards that unit
under high pressure can cause.
• It’s essential to supervise the machine at all times.
• DO NOT modify the safety devices
• DO NOT use external tanks or other storage tanks that have not been type-approved or that lack safety
valves.
• DO NOT use the machine near open ames and hot surfaces. At high temperatures, the refrigerant de-
composes, releasing toxic and chemical substances that are hazardous for users and the environment.
• It’s essential to use only the refrigerant indicated on the identication label. Mixtures with other types of
refrigerant will seriously damage the cooling and refrigeration system, as well as the machine.
• Gloves and Goggles should be worn - contact with the refrigerant can cause blindness and other physi-
cal injury to the user.
• Avoid inhalation of vapours from the refrigerants and contact of the refrigerant with skin.
• Do not switch on the machine unless the machine is going to be used immediately. Cut o󰀨 the electrical
power supply prior to long intervals in which the machine will not be used.
• Attention: Ensure that all valves are closed before making connections between the machine and an
A/C system or an external tank.
• Attention: Ensure that the process has been completed and that all valves are closed before discon-
necting the machine.
• Attention: All of the exible hoses may contain refrigerant under high pressure.
• Attention: The machine and A/C system in vehicles containing refrigerant should not be tested with
compressed air. Some mixtures of air and refrigerant have proven to be combustible at high pressure
levels. These mixtures are potentially hazardous and there is a risk of re and explosions that can
cause damage to property and personal injury.
Additional medical and safety information can be obtained from the manufacturers of the oils and refrig-
erants.
2.3 Guidelines for handling refrigerants
Precautions for Refrigerant Storage
The refrigerant to be removed from a system must be handled carefully in order to prevent or minimise the
possibilities of di󰀨erent refrigerants mixing.
The tank used for storing refrigerants must be assigned to specic refrigerants to avoid di󰀨erent refrigerants
mixing
Recycling of refrigerants
The recycling machine’s lter system should be replaced regularly in order to maintain the e󰀩ciency of the
recycling machine

9COOLIUS A30 BUS
General Notions
Before re-introducing refrigerant into the system, the system itself must be evacuated and cleaned.
In order to be sure that the system is free of contaminating agents before introducing the refrigerant, all the
procedures described in this instruction manual must be followed.
Clean and maintain the machine regularly, especially when highly contaminated refrigerant is used: it
is extremely important that contamination from the previous operation is not transferred to subsequent
operations.
2.4 Safety devices
The machine is equipped with the safety devices required from the European Directives:
• Electric safety switch
• Safety valve
Caution! Danger of injury due to manipulation.
DO NOT MODIFY THE SAFETY DEVICES.
2.5 Not condensable gas discharge
A not condensable gas discharge valve is installed to allow these gasses to be released.
The not condensable gas discharge valve could generate noises.
Warning! Risk of injury from escaping gases under high pressure..
Make sure that you never come in contact with the drain valve!
2.6 Ventilation Safety System
The machine is equipped with a ventilation security system which allows the use in high temperature
environments.
It is forbidden to obstruct the inlet grid of the fan.
2.7 The work environment
• The machine must be used in open environments or in places equipped with good ventilation (at least 4
changes of air per hour).
• The unit has been designed for use at a maximum altitude of 1000 m above sea level, within a tempera-
ture range of +10 and +49°C and with a maximum humidity of 50% at +40°C.
• Operate in su󰀩ciently lit conditions.

10 COOLIUS A30 BUS
3 Use of the machine
3.1 Unpacking and checking the components
Remove the machine packaging and ensure that the following parts are present:
• EC/PED documentation
3.2 Machine description
Control panel
1. Display
2. START button / LED
3. STOP button / LED
4. Information button (i)
5. Cancel button (X)
6. COOLIUS SELECT with ENTER button / LED
7. Right button / LED
8. Left button / LED
g. 001 Control panel
1
2
3
5
87
4
6

11COOLIUS A30 BUS
The machine
1 LP pressure indicator
2 HP pressure indicator
3 Printer
5 Front cover
6 Rear wheel
7 Front wheel with brake
8 Vacuum pump air grid
9 Main switch
10 Internal vessel pressure
gauge
11 Storage box for accesso-
ries
12 Container for absorbed oil
500 ml
13 Container for UV leakage
additive 250 ml
14 Container for new oil
500 ml
15 LP quick coupling
16 HP quick coupling
17 LP hose
18 HP hose
19 By-pass
1 2
5
7
6
3
g. 004 View Front
8
9
11
g. 005 View back
g. 006 View left
15
16
18
17
13 14
g. 007 View right
10
12
19

12 COOLIUS A30 BUS
3.3 Machine handling
In spite of the fact that the heaviest components have been assembled on the base in order to lower the
centre of gravity, it has not been possible to eliminate the risk of overturning completely.
The machine is moved on the four wheels.
On rough ground, the machine must be moved by tilting it and balancing the weight on the two rear wheels.
3.4 On/O󰀨 and stopping
start-up: Move the main switch to the ON position (I)
Stopping: Move the main switch to the OFF position (O)
Attention! Damage to the machine.
Do not switch o the machine by unplugging the mains plug!
4 Preparation for the use and settings
4.1 Switch on the machine
Press the Power Switch (I) to turn on the Machine.
The ventilation security system starts.
Switch on the machine for the rst time
Select the display language
Turn COOLIUS SELECT to select the language, then conrm
by ENTER.
After selecting the language, you have two possibilities to
work with the machine.
1. Demo-Mode
You can now activate the machine or work in demo mode.
NOTE: All functions will be full working except for the „Time-
Date“ menu, that is not available.
1. Press STOP to use the machine in DEMO MODE. (The
machine start-up and skip the activation procedure).
• The display shows the number of days before the
activation will be necessary to use the machine.
2. Press START to go to Stand-by mode.
Select:
Language 03

“START” to activate
the machine.
www.coolius-ac.com
Machine is working
now in DEMO MODE!
Day(s) left 7

13COOLIUS A30 BUS
2. Machine activation
1. Press START to activate the machine.
NOTE: After 7 days, starting from the rst switch on, the
display will show only this print screen at the start-up.
2. To perform the activation, go to website
www.coolius-ac.com or call the hotline
[phone] and request the UNLOCK CODE related to the Serial Number written on the display
(in this case, the Serial Number is AA000000).
3. Press START to continue with activation.
4. Press STOP to skip the activation procedure and start-up the machine in DEMO MODE.
NOTE: STOP key is available only if there is at least one day left for DEMO MODE, otherwise the activation is
compulsory and only the START key is available.
Unlocking the machine
The following procedure requires the knowledge of the UNLOCK CODE.
1. By the COOLIUS SELECT enter the UNLOCK CODE.
Once done, conrm by START.
• If the UNLOCK CODE is wrong, repeat the procedure
just described.
• If the UNLOCK CODE is correct, press START to
conrm. The machine is activated and shows the
Stand-by mode.
The machine is now activated and displays the standby
mode.
Get UNLOCK CODE
register: AA000000
www.coolius-ac.com
_
V
34567890 ABCDEFGHIJK
COOLIUS
01-01-2017 10:20:30

14 COOLIUS A30 BUS
4.2 Using the printer
The machine has a built-in roll-up printer which can be
used to print the vehicle data and the results of the main-
tenance work.
• Paper width: W 58 mm
• Diameter: D 40 mm
• Paper feed 1
Before a process:
Turn COOLIUS SELECT to select the character then conrm by
ENTER.
Max 20 characters (plate, chassis, etc...).
At the end of a process:
Press START key for printing.
Press STOP key to end.
1
g. 008 roll-up printer
CAR DATA:_
V
567890 ABCDEFGHIJKLM
Press “START“ to
print Service report

15COOLIUS A30 BUS
4.3 Program selection
Press ikey to check the refrigerant available.
Press ikey to come back in stand-by mode.
Press ENTER to select a menu item.
.
Turn COOLIUS SELECT to select the required program.
The symbol shows the current position of the cursor.
The number of symbols shows the number of available
menu points of this level.
Overview of the menu contents
1. OTHER SELECTIONS
• SERVICE
• A/C PRESSURE TEST
• A/C FLUSHING
• NEW OIL BOTTL.CHANGE
• MACHINE SET-UP
• TIME-DATE
• COMPANY DATA
• SCALE RESET
• MAINTENANCE
2. A/C DATABASE
3. FULL SERVICE
4. OPEN PROGRAM
5. VESSEL CHARGE
Available quantity:
Refrigerant g. /////
01-01-2017 10:20:30
Full Service


16 COOLIUS A30 BUS
4.4 Setting
4.4.1 Machine set-up
The procedure allows to set the machine.
Turn COOLIUS SELECT to select. Press ENTER to conrm.
Recovery data:
• 1The data are reported on the ticket (refrigerant
quantity and oil).
• 0The data are not reported.
Turn COOLIUS SELECT to select 1or 0.
Press ENTER to conrm.
Refrigerant residual check:
The default value is applied in:
A/C DATABASE and FULL SERVICE
Turn COOLIUS SELECT to set. Press ENTER to conrm.
The next menu item is displayed.
Leak test:
The default value is applied in:
A/C DATABASE and FULL SERVICE
Turn COOLIUS SELECT to set. Press ENTER to conrm.
The next menu item is displayed.
Fresh oil:
The default value is applied in:
A/C DATABASE and FULL SERVICE
Turn COOLIUS SELECT to set. Press ENTER to conrm.
The next menu item is displayed.
UV Dye:
The default value is applied in:
A/C DATABASE and FULL SERVICE
Turn COOLIUS SELECT to set the value. Press ENTER key to
conrm.
NOTE: Set 0 to bypass the process
The next menu item is displayed.
Print recovery
data?
1
Residual refrigerant
check
min. 5
Leak test min. 4
PAG Oil ml. 10
UV Dye ml. 6

17COOLIUS A30 BUS
Hoses length
Press ENTER key:
Turn COOLIUS SELECT to set the service hoses length, then
conrm by ENTER.
Language:
Turn COOLIUS SELECT to select the language, then conrm
by ENTER.
The next menu item is displayed.
Unlock Code:
These eight digits are necessary to obtain the UNLOCK
CODE for the counter reset. Request the new UNLOCK
CODE on the website www.coolius-ac.com or by phone call
to the hotline [phone].
1 Printer built in.
0 Printer o󰀨 line or not installed.
Turn COOLIUS SELECT to select 1 or 0.
Press ENTER to conrm, then press STOP key to exit.
4.4.2 Time-Date
Turn COOLIUS SELECT to select.
Press ENTER to conrm.
Turn COOLIUS SELECT to modify the blinking value.
Press ENTER to conrm. The next value blinks.
When the data is right press START key to conrm.
Hoses length
Set the HP hose
length (red hose)
cm. 500
Language 03
UNLOCK CODE:
BB111111
Serial Number:
AA000000
Optional
Printer 1
Time: 10:20:30
Date: 01/01/17

18 COOLIUS A30 BUS
4.4.3 Company data
Turn COOLIUS SELECT to select.
Press ENTER to conrm.
5 lines are available:
1_________ Company name (Workshop)
2_________ Address (road, etc..)
3_________ City
4_________ Phone
5_________ FAX
The above setting is an example only.
NOTE: The ve lines are reported on the service report.
Procedure:
• Turn COOLIUS SELECT to select the character.
Press ENTER to conrm.
The character is reported on the rst line (left).
• If required, press Xkey to delete.
• It is possible to move in the line by LEFT / RIGHT
• Turn COOLIUS SELECT to select the next character.
Press ENTER to conrm.
The character is reported on the rst line.
• Press START key to conrm the setting.
The display shows the following line.
• Press STOP when the 5 lines are set.
4.5 Maintenance messages
At the start-up is possible to see the following messages:
Notice: “MAINTENANCE WILL EXPIRE SOON!” or “MAINTENANCE EXPIRED”
The message MAINTENANCE WILL EXPIRE SOON! can be skipped.
Press STOP to continue with the start-up of the machine.
1. At the message MAINTENANCE EXPIRED!
UNLOCK CODE REQUIRED press the STOP key, then
the display shows..
2. Write down the code shown at the end of the sec-
ond line and use it to get the UNLOCK CODE on the
website www.coolius-ac.com or by hotline phone call
[phone].
3. Press STOP to continue with the start-up of the machine.
NOTE:
See chapter 6.3 Counter reset (UNLOCK CODE required) p. 29 to reset the maintenance counter.
1_________
V
567890 ABCDEFGHIJKLM
Maintenance expired!
UNLOCK CODE required
Get UNLOCK CODE
register: BB111111
www.coolius-ac.com

19COOLIUS A30 BUS
4.6 Error messages
No Error message Description
A1 ERROR! Weight scale Scale blocked or faulty (see 6.7 on p. 32)
C1 ERROR! Recovery Recovery process anomaly or compressor faulty
ERROR! Overpressure in recovery process!
High pressure switch activated. Wait 20/30 min.
If the message appears again, please contact
SERVICE CENTER.
Vessel full! Please wait! Maximum refrigerant quantity allowed! Reduce
the refrigerant quantity in the internal vessel.
Leakage!
„START“ to mb. ///
If after a few minutes the minimum value is not
reached.
Possible causes: defective A/C system, etc….
Insu󰀩cient vacuum for oil/UV charge!
START to by-pass
The vacuum value is not enough to guarantee the
process.
Possible causes: defective A/C system, air in the
bottles, etc…
Press START to by-pass the process and go to
charge process.
Insu󰀩cient refrigerant.
Charge the vessel.
The refrigerant quantity is below the minimum
quantity required.
Perform “Vessel charge”.
WARNING!
Empty waste
oil bottle!
The unit detects that is necessary to empty the
bottle.
WARNING!
PLS install waste
oil bottle!
The unit detects that the bottle is not installed.
4.7 Vessel charge
The equipment may not contain enough refrigerant to run. The available quantity could be negative
(Es: -500 g.) It will be necessary to add new refrigerant into the internal vessel before the use (at least 3 or 4
Kg).
1. Turn COOLIUS SELECT to select VESSEL CHARGE. Press ENTER to conrm.
NOTE: The message is shown before processes.
2. Connect the LP (BLUE) or the HP (RED) hose to a new
tank of refrigerant. If available, open the liquid tank valve
(RED).
Otherwise turn the tank up-side-down.
WARNING!
Verify Oil/UV
quantity in the
bottles.
Connect LP or HP
hose to ext. tank.
Open the valve
liquid side.

20 COOLIUS A30 BUS
3. Turn COOLIUS SELECT to set the value.
• Minimum: 800 g.
• Maximum: the value shown by the display.
4. Press ENTER to conrm..
5. Press START key to conrm
Message: If the equipment senses a pressure
lower than the minimum value for the process.
Process STARTS
Message: If the equipment senses a lower
pressure than the minimum value for the process.
• Replace the external bottle, then press START key to
conrm.
• Press STOP key to complete the process.
Process completed.
6. Close the tank valve and disconnect the red hose from
the tank.
7. Press START key to conrm.
Press STOP key to end.
Set the quantity.
g./////
Confirm by “START”
Check:
Ext. Bottle empty or
tank valve closed.
Vessel charge in
process.
Pressure mb.
Refrigerant g./////
Vessel charge end.
Close the external
tank valve.
Refrigerant recovery
from the
service hoses
Vessel charge end.
g./////