Denso KRISTAL User manual
Revision number: 4 Manual code: 4018123 Date: 07/02/2020
Read this User Manual carefully and before operating the RRR station.
ORIGINAL MANUAL LANGUAGE: ITALIAN
User Manual
User Manual KRISTAL
KRISTAL
Refrigerant Recovery, Recycling and Recharging
station for R1234yf vehicle A/C system.
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User Manual KRISTAL
· Read this manual carefully for safe and correct operation.
· Read the “Safety Rules” on page 11 of this manual before operating this RRR station.
· Store this manual in a safe place.
IMPORTANT!
The information, illustrations and specications contained in this manual are based on the most recent
information available at the time of publication. The manufacturer reserves the right to make changes
to the manual at any time without any obligation to notify people or organizations about these
changesorrevisions.Themanufacturer,DensoThermalSystemsS.p.A.,shallnotbeliableformistakesinthemanual,
accidental or resulting damage (including loss of prots) in relation to the supply,
performances or use of this material. Always operate cautiously and in compliance with the local
regulations on health, safety and the environment. Additional information on safety and health and
the product specications relating to refrigerants, lubricants and motor vehicles should be asked for
from their producers. No part of this manual may be reproduced or translated without the authorization
from Denso Thermal Systems S.p.A. in writing.
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User Manual KRISTAL
CHAPTER INDEX PAG.
1Introduction 9
2Technical specications 10
2.1 Operator workstation 10
3Safety 11
3.1 Safety warnings 11
3.2 Warnings relating to the work place 11
3.3 RRR station unintended use 12
3.4 Precautions for use 12
3.5 Personal Protective Equipment 13
3.6 RRR station safety precautions and protections 13
3.7 Residual risks 14
3.8 Safety warnings - Decals and symbols 15
3.9 Power supply 16
4Disposal 16
5Instructions for use 17
5.1 Handling and transport 17
5.2 Inner tank blocking and release 18
5.3 Frame 19
5.4 Main functions 24
6First use 25
6.1 Printer preparing 25
6.2 Releasing the inner tank 25
6.3 Switch the RRR station on 25
6.4 Inner tank lling 26
6.5 New Oil/UV Tracer level inspection 28
7Operating instructions 30
7.1 Service hoses management 30
7.2 Description of main menu 30
7.3 Automatic operation 31
7.4 Manual function: Recovery 38
7.5 Manual function: Vacuum 41
7.6 Manual function: Charging 43
7.7 Tank rell 44
7.8 Hoses discharge 45
7.9 Gas analysis (optional) 46
7.10 Management of data in SD card 48
8“Service” menu 49
8.1 Structure of “Service” menu 49
8.2 Settings 51
8.2.1 Set date/time 51
8.2.2 Customizing 52
8.2.2.1 Gas analyzer 52
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User Manual KRISTAL
CAPITOLO INDICE PAGINA
8.2.2.2 Touch sensibility 52
8.2.2.3 Working mode 53
8.2.2.4 Select language 54
8.2.2.5 Workshop Data 54
8.2.2.6 Operators 56
8.2.2.7 Operators PIN 56
8.2.3 LAN conguration 57
8.2.4 Import / Export 57
8.2.5 Printer test 57
8.2.6 Calibrations 58
8.3 HP LP values 58
8.4 Sensors values 59
8.5 Counters 60
8.5.1 Gas counters 60
8.5.2 Oil counter 62
8.5.3 Vacuum pump counters 62
8.5.4 Compressor counters 62
8.5.5 Filter counter 63
8.6 PC connection 63
8.7 Filter change 63
8.8 Oil tank change 64
8.9 Hoses ushing 66
9Routine maintenance 68
9.1 Gas dry lter replacement 68
9.2 Gas analyzer lter replacement (optional) 70
9.3 Vacuum pump oil replacement 71
9.4 Oil top-up in vacuum pump 73
9.5 Replacement of paper roll in printer 73
10 Troubleshooting 74
10.1 Fuse replacement 76
11 Spare parts 77
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User Manual KRISTAL
Denso Thermal Systems S.p.A. would like to thank you for selecting a product from our range and to encourage you to read
these instructions. They
contain any information required for correct operation of the RRR station you have purchased. Please read this manual
entirely and follow the instructions provided in it thoroughly. This User Manual should be stored in a place where it is not
subject to alterations. The information given in this manual may be changed without prior notice and/or without any additional
obligation in order to add modications and improvements to any shipped units. Reproduction or translation of any part of the
manual is prohibited without the owner’s authorization in writing. Denso Thermal Systems S.p.A. is responsible for manufactu-
ring defects throughout
the entire warranty term, which they will try to x in the shortest time possible.
WARRANTY
The term of the warranty is 12 months from the purchase date. The warranty only entitles the user to the replacement of
defective parts. The warranty is voided if equipment is not operated according to its intended use, if it is tampered with by
unauthorized people or in cases where non-conforming components or procedures are used.
Warranty terms (please read)
1. Warranty details
Denso agrees to repair free-of-charge any defects that may be identied within the warranty term, which have occurred during
normal use in compliance with the precautions laid down in this user manual.
2. Procedure for repairs under warranty
To ask for repairs under warranty following a malfunction during the warranty term, contact the dealer from which the equip-
ment was purchased and give him the purchase document. If this document is not submitted, repairs under warranty may not
be granted.
3. Cases outside the warranty
Even if they are identied during the warranty term, the following defects are not included in the warranty:
(I) defects due to equipment operation in special environments (e.g. potentially explosive environments);
(II) defects resulting from failure to comply with the danger, warning and caution signs and other indications provided in the
user manual of the product in question;
(III) defects resulting from checks, handling, disassembly, etc. which have not been performed by our company or by an
authorized service center;
(IV) defects occurring with the purchased model. These include defects due to environmental factors relating to ageing (paint
dissipation, etc.) or wear linked to equipment use;
(V) defects caused by pets/animals;
(VI) defects resulting from accidents such as re, explosions, etc. lightning, earthquakes,
eruptions, ooding and tsunami, and other types of natural disasters or destruction due to riots, etc.;
(VII) defects originating from problems connected to the electricity supply;
(VIII) defects resulting from use of electricity other than that specied;
(IX) defects originating from use of different spare parts from those specied by Denso Thermal Systems S.p.A.;
(X) defects due to events caused by malfunctioning of other products than this device;
(XI) defects due to electromagnetic disturbance.
4. Denso srl shall not be liable for the resulting costs.
(I) Denso Thermal Systems S.p.A. shall not be liable for additional costs connected to a product defect such as lost working
hours, refrigerant leaks,
refrigerant contamination and unauthorized shipment and/or labor costs.
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User Manual KRISTAL
ID LABEL
DENSO Thermal Systems S.p.A.
Frazione Masio, 24
10046 Poirino (TO)
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User Manual KRISTAL
DICHIARAZIONE DI CONFORMITA’
FARE RIFERIMENTO AL DOCUMENTO A CORREDO DEL MANUALE D’USO
DECLARATION OF CONFORMITY
REFER TO THE ATTACHED DOCUMENT OF THE USER MANUAL
DÉCLARATION DE CONFORMITÉ
CONSULTEZ LE DOCUMENT ATTACHÉ AU MANUEL D’UTILISATION
DECLARACION DE CONFORMIDAD
CONSULTE EL DOCUMENTO ADJUNTO AL MANUAL DEL USUARIO
KONFORMITÄTSERKLÄRUNG
VERWEIS AUF DAS DOKUMENT, DAS DEM HANDBUCH ANGEBOTEN IST
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User Manual KRISTAL
SYMBOLS
Below is a short description of the symbols used in this manual.
DANGER: This symbol draws attention to situations or problems which may
undermine the operators’ safety as they result in accidents or the risk of
death.
WARNING: This symbol draws attention to situations and problems
connected to the machine efciency which do not undermine the
operators’ safety.
PROHIBITION: The operations specied by this symbol should not be per-
formed as they would jeopardize the level of machine efciency.
IDENTIFICATION OF OPERATORS
Operators are classied by levels depending on their specic skills. So, it is important to keep in mind that, for
the sake of individual safety and compliance with the existing regulations, each operator must only perform
the tasks for which he is qualied. For easier identication of the operators’ levels, we have used terminology
in this user manual that species the min. qualication required to carry out the described operation.
Below are the operators’ qualication levels to operate the machine.
MACHINE OPERATOR
This term identies any operator qualied to operate the station in normal working conditions, using the
on-board controls and with all the safety devices enabled.
SKILLED TECHNICIAN
This term identies any member of staff who has been trained to work with the specied uid and, generally,
to carry out routine, preventative and non-preventative maintenance, including cleaning, uid level
inspections, adjustments, etc.
SERVICE TECHNICIAN
This term identies any member of technical staff who has been trained and authorized by Denso Thermal
Systems S.p.A. to carry
out maintenance and service operations.
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User Manual KRISTAL
1. INTRODUCTION
The RRR station illustrated in this user and maintenance manual is an automatic multifunctional system
with digital setting functions and a database, designed for rst installation air conditioning systems on
vehicles to full operations such as gas recovery, waste oil drain, vacuum creation, leak testing and gas
recharge under the control of a microprocessor with electronic precision scales. The RRR station was
designed for specic use with the refrigerant specied in the ID label, and it features electronic
management functions to control the entire process by means of a microprocessor.
The table below shows the main components and their functions.
Components and their functions
Electronic scales: No.1 scale to weigh the amount of refrigerant gas in the gas bottle and to manage
the RECOVERY and RECHARGE cycles with a 1g precision; No.3 scales to weigh the amount of New Oil,
the UV Tracer and the Waste Oil with a 1g precision.
Refrigerant gas recovery compressor, 10cc.
Recovery lter (n.1) anti-acid and dehydrating, high capacity lter, quick to replace.
Gas distillation unit at intake, featuring automatic and separate adjustment of the refrigerant and the
oil ows coming from the A/C system, including the oil drain from the system.
Oil separator, installed immediately after the compressor featuring automatic return after the recovery
cycle.
Gas bottle to recover the refrigerant gas, provided with a safety valve.
Vacuum pump capable of creating a high level of vacuum.
Dashboard featuring digital controls.
High contrast multi language display for use in environments with poor or excessive lighting
Analog adjustable pressure gauges, 80mm, class 1.0, featuring pulse-free movement for A/C system.
Hoses: No. 2 LP e HP da 2,5m ad alta afdabilità con valvole ad innesto rapido e ad apertura manuale
(ad avvitamento) No. 2t high reliability LP and HP hoses, 2.5m in length, with quick coupling valves and
manual opening function (screw-on).
Oil bottles: No. 2 250ml bellows and rechargeable containers for New Oil and UV Tracer; No.1 250ml
graduated container for waste oil.
The RRR station is supplied with 2.5m long hoses for connection to the A/C system. If this
hoses length is not enough for operational and functional purposes, 6m long hoses may
be purchased from our sales outlet.
The RRR station is supplied with a vessel for oil rell and a vessel for oil drain. If
different types of oil are required during operation, various vessels should be purchased,
one for each oil in use.
Under no circumstances should different types of oil be blended. Always check the types
of oil to be used in the different A/C systems (they vary according to the compressor type
tted), which are identied in the product data sheets.
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2. TECHNICAL SPECIFICATIONS
For easier understanding, technical specications have been divided by model.
Nome Stazione per il recupero, il riciclo e la ricarica del
gas refrigerante
Modello KRISTAL
Refrigerante applicabile R1234yf
Tensione alimentazione 220V / 240V
Frequenza alimentazione 50Hz / 60Hz
Corrente massima assorbita 6,5A
Potenza massima assorbita 1400W
Temperatura massima di esercizio 50°C
Temperatura minima di esercizio 5°C
Pressione massima del circuito
pneumatico 20Bar
Capacità bombola refrigerante 9,5 Litri
Peso netto 90Kg
Peso a pieno carico 100Kg
Dimensioni di ingombro
(Altezza x Larghezza x Profondità) 1116cmm x 530mm x 600mm
Capacità di recupero del sistema 370 g/min
Portata pompa vuoto 70 l/min
Vuoto nale 0.1mBar
Diametro attacco Alta Pressione HP
(sul veicolo 17mm
Diametro attacco Alta Pressione HP
(sul veicolo) 11mm
Please refer to the ID label on the RRR station for the mains power value.
The value of the noise pressure measured is below 70dBA, so no special arrangements are envisaged for
the operator, even in conditions of continual use.
Pursuant to the existing regulations on safety and health at work, the employer must, in any case, assess
the level of workers’ exposure to noise.
2.1 OPERATOR WORKSTATION
The RRR station is not provided with a real operator workstation as no constant operator supervision is not
required: the operator is only expected to manage the controls and to monitor/check the station whenever
an alarm triggers or a malfunction occurs.
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User Manual KRISTAL
3. SAFETY
3.1 SAFETY WARNINGS
The RRR station must not be operated by staff who are not qualied or have not read,
understood and learned the information contained in the manual with which the RRR station is
supplied, and who have not received suitable training at courses organized by the manufacturer.
We recommend that the RRR station be operated by mature and responsible adults. Special
attention should be paid that the control device is not operated by children.
When needed, our Service Dept. should be your only reference contact (especially for repairs or
component replacement).
The RRR station is tted with an internal pressurized bottle. Be cautious!!! Adhere to the
regulations in place in the country of use concerning nal testing, periodic checking and the
expiry date of the utilized bottle so that it can be used on a continuous basis over time.
The refrigerant type for which the RRR station was designed is specied in the ID label. Always
comply with the existing regulations on health and safety at work. Have safety data sheets at
hand and always adhere to the instructions therein. Do not leave the machine unattended in the
work place, even if it is operating in automatic mode. This user manual contains essential safety
rules in order for the operator to use the RRR station correctly. Wear safety goggles and gloves.
DO NOT dump the refrigerant in the atmosphere and follow the instructions provided in
section 4 “Disposal”.
Install the connection pipes (A/C system) and the feed pipes in such position that they DO
NOT represent an obstacle or ARE NOT subject to damage.
DO NOT use aggressive detergents to clean the RRR station. More specically, it is strictly
prohibited to use ammable uids or detergents
DO NOT place any object on the RRR station and do not use it as a support surface or to carry
objects.
DO NOT allow unskilled operators to carry out repair works as this may alter the level of safety of
the RRR station.
DO NOT unplug the high pressure (HP) and low pressure (LP) service hoses.
3.2 WARNINGS RELATING TO THE WORK PLACE
We recommend that the RRR station be operated by mature and responsible adults. Special
attention should be paid that the control device is not operated by children.
DO NOT go close to the RRR station with naked ames or any other object which may cause
overheating (resulting in the risk of re). Do not operate the RRR station in rooms where a risk of
explosion or re exists.
DO NOT smoke in the room where work processes are performed.
We recommend using the RRR station in rooms with a proper level of lighting.
DO NOT go close to the RRR station with naked ames or any other object which may cause
overheating of the recharge circuit (resulting in the risk of re).
Work should always be carried out in a properly ventilated place. Perform work with and store the
RRR station in a dry place, away from the elements (generally, not in harsh environmental
conditions), and do not use the station in rooms where there is a hazard of explosive or
potentially explosive areas (ATEX)
Operate and store the RRR station in a dry place sheltered against the elements.
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3.3 RRR STATION UNINTENDED USE
Below is a list of UNINTENDED USES of the RRR station which may cause hazardous conditions:
use of the RRR station for other purposes than those for which it was designed and
manufactured, as specied in the section “Scope”;
use of the RRR station with a different bottle from the one in the standard supply;
use of oils for the A/C systems other than those specied by the vehicle and/or A/C system
manufacturer;
use of different oil bottles from those in the standard supply.
In addition to the above, we recommend using the RRR station in rooms with a proper level of lighting.
Any other use that has not been specied in the section above is not allowed. Notably, it is
prohibited:
– to allow RRR station operation by staff who are not qualied or have not read, understood and learned
the information contained in the manual with which the RRR station is supplied, and who have not received
suitable training at courses organized by the manufacturer. We recommend that the RRR station be operated
by mature and responsible adults; special attention should be paid that the control device is not operated by
children;
– to operate the RRR station if one or more than one safety device has been tampered with or disabled;
– to operate the RRR station in rooms where there is a risk of re or explosion;
– to use other refrigerants than those specied in the ID label;
– to use the station to drain uids and/or ll other liquids; to use other uids than
refrigerant gas R-1234yf. More specically, it is prohibited to use ammable uids;
– to place objects on the RRR station;
– to install the connection pipes (A/C system) and the feed pipes in such position that
they represent an obstacle or are subject to damage;
– to use (pressure) vessels that are not suitable with the station in terms of material type and existing
pressure level;
– to go close to the RRR station with naked ames or any other object which may cause overheating of the
recharge circuit (resulting in the risk of re); to operate the RRR station in rooms where a risk of explosion
or re exists;
– to smoke in the room where work processes are performed;
– to expose the station to rain and direct sunlight;
– to use ammable uids or solvents for cleaning;
– to make unauthorized conversions and modications to the RRR station;
– to operate the station when it is not in perfect operating conditions;
– to dump the refrigerant in the environment.
3.4 PRECAUTIONS FOR USE
Special care should be paid to possible refrigerant uid ejections as:
- contact with the eyes may cause serious harm to sight;
- contact with the body skin (considering the very low boiling temperature) may cause burns.
If refrigerant gas is ejected and it contacts the operator’s eyes or skin, the affected part should
be rinsed with plenty of fresh water and medical staff should immediately be contacted.
The RRR station was designed for specic use with refrigerant gas R1234yf.
The type of refrigerant gas (R1234yf) for which the RRR station was designed is specied in the relevant ID
label.
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Warning!!! Live parts:
Power outlet ON/OFF buttons
If the work cycle is disrupted for any reason whatsoever (e.g. no power supply), the operation
should be restarted from the beginning.
The outer vessel used for the recharge should be type-approved for pressures of at
least 35 bar and it is provided with a safety valve (it must be compliant with the
requirements laid down in pressure vessel standards).
During operation check that the level in the oil vessels is correct: make sure that it is not too
high because this may result in cycle disruption.
Do not ll these vessels with substances other than those specied.
3.5 PERSONAL PROTECTIVE EQUIPMENT
The table below lists the personal protective equipment that operators should be wearing for
correct use of the RRR station. The rst column shows the symbol afxed on the machine
with a description of its meaning.
Wear safety goggles. Contact with the eyes may cause serious injuries.
Wear safety gloves: contact with the skin (considering the very low boiling temperature) may
cause cold burns.
3.6 RRR STATION SAFETY PRECAUTIONS AND PROTECTIONS
The RRR station is intended for operation by one operator at a time. Other people, if any,
are recommended to stay at a safe distance from the station both during work cycles and
adjustment and maintenance.
After the RRR station is switched on, wait at least ve minutes before starting any
operation.
The inner tank in the RRR station containing the refrigerant gas MUST NEVER be
lled 80% above its total capacity in order to prevent falls in performances.
During operation check that the level in the oil bottles is correct: make sure that it is not
too high as this may result in brisk falls in performance.
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User Manual KRISTAL
In the event of an EMERGENCY press the OFF button (see arrow) located in the front panel of
the RRR station in order to cut off the power supply immediately.
Always connect the high and low pressure piping (red and blue) to the supplied parts
and do not use it for other purposes than those specied.
During operation check the level in the waste oil bottle: the oil must not ow out.
3.7 RESIDUAL RISKS
Fluid spillage due to breakage of pressure parts
Special care should be paid to possible refrigerant uid ejections as:
• contact with the eyes may cause serious harm to sight.
• contact with the body skin (considering the very low boiling temperature) may
cause burns.
If the refrigerant is ejected and comes into contact with the operator’s eyes or skin,
the affected part should be rinsed with plenty of fresh water and medical staff should
be immediately contacted.
Where this label is afxed, attention should be paid as it indicates the risk of
electrocution.
More specically, attention should be paid to live parts that are indicated by
the lightning symbol on a yellow background.
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3.8 SAFETY WARNINGS - DECALS AND SYMBOLS
Below is a list of decals and symbols afxed on the RRR station with their position.
Please refer to the relevant section in this manual for the corresponding meaning.
Position Decal Description
Control panel
Safety goggles should be worn to protect
the operator’s safety and health in the
event of a refrigerant leak.
Safety gloves should be worn to protect the
operator’s safety and health in the event of
a refrigerant leak.
Refer to the vehicle manual for the type of
refrigerant uid before operating this re-
charging station.
Operate and store this recharging unit in a
dry location, away from wind, rain or direct
sunlight
Back Inner tank block
Blocked: block lever all the way in.
Unblocked: block lever pulled.
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3.9 POWER SUPPLY
Power must be supplied to the RRR station as instructed by Denso that is not responsible for
the connection, in any case. The RRR station is only safe when the power supply system
upstream the RRR station is compliant with the safety rules.
Having said this, for correct operation:
• connection to the line should be made using the plug provided in the RRR station an adaptor too may
be added - after checking that the line voltage matches the voltage requirements specied in the ID label
afxed on the RRR station.
• in the event of breakage contact our Service Dept. only.
If extensions are required, check that the cross-section of the cable is proportional to its
length and the cable is installed in such position that it is not subject to any type of
damage (do not place in transit area and in wet areas).
If the station switches off following a power failure, wait a few seconds (normally approx.
10) before switching the station on again in order to allow for correct resetting of the
electronic parts.
Check that the point of connection to the electricity source provides for all protections and
meets all the requirements specied in the existing provisions (earthing and residual
current device).
If the power plug needs replacement, consult our Service Dept. and refrain from
replacing it on your own unless authorized to do so in writing by our competent
department. Failure to adhere to the above shall relieve Denso Thermal Systems S.p.A.
from claims for
damage to property or harm to people caused by the power supply.
4. DISPOSAL
Scrap the machine in compliance with the regulations existing in the
country where it is used. In other words:
1. separate components according to their type (e.g. plastics, hazardous
uids, metal, etc.). Notably, WEEE (waste electrical and electronic
equipment) must not be disposed of as urban waste, but must be collected
separately;
2. the waste collection systems used, either public or private, must be
those envisaged by the local legislation;
3. the station contains refrigerant uids: improper use or incorrect disposal
may have negative effects on human health and the environment, and it is
sanctioned by law. Address specialized companies for these operations.
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5. INSTRUCTIONS FOR USE
5.1 HANDLING AND TRANSPORT
Before moving the RRR station, check its level of stability and the support
surface to ensure it is horizontal.
Check for bumps, holes or materials which may obstruct the path travelled by the
RRR station.
Before moving the RRR station, check for residual packaging materials or
movable materials on the station.
We recommend the following during RRR station handling and transport:
• lock the inner tank (see section titled “Inner tank locking and release”);
• place all supplied accessories in such way that they are prevented from falling or getting
damaged;
• move the station grabbing the supplied handles;
• move the station slowly and pay attention that it remains stable;
• keep at a suitable distance;
• pay special attention to your work place: avoid kerbs, steps or other obstacles.
• If the unit is not hauled carefully, the adjustments which have already been made may go
out of calibration.
• Lift the RRR station with lifting equipment and place it on a pallet: lock the front wheels and
secure them to the pallet using clamps.
• Drain the refrigerant from the RRR station completely.
The station can be pushed
manually by the operator as its
base is supplied with wheels and
casters. Move the station on at
sur- faces only.
When moving the station, the
operator should check that all
casters/ wheels are in contact with
the ground and no part of the
station is lifted.
To lift the station remotely, the
operator should use lifting
equipment with a suitable lifting
capacity to the station weight (see
technical specications) and a
pallet as support base.
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5.2 INNER TANK BLOCKING AND RELEASE
The inner tank block is one of the safety devices featured in the RRR station that is designed to protect the
electronic scale against shocks during handling and/or transport operations. This precision mechanical
system blocks the inner tank when the load is lifted from the scale.
If the mechanism is blocked, the electronics prevents all operations, and a message appears on the screen
reading “Unblock internal tank”. This message also appears whenever the block is engaged accidentally du-
ring station operation: it causes the ongoing operation to be immediately stopped.
Tank block engaged (for handling, transport and
unloading)
Push the lever to block the inner tank.
Tank block disengaged (for operation)
Pull the lever to unblock the inner tank.
• Do not turn the block lever.
• Do not block the inner tank during operation of the
recharging
station, as this will cause all ongoing
operations to be stopped
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5.3 FRAME
Front and rear view
Analogue pressure gauges
Control keypad
Pivoting wheels with lock
Power cable connection
HP High Pressure
Service Hose
Air out ow
Inner tank block/release lever
LP Low Pressure
Service Hose
LAN connection
Service
Connection
Waste Oil
Bottle
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User Manual KRISTAL
LH side view
Printer
Air out ow
Refrigerant Dryer Filter
cover
Refrigerant Analyser Filter
(optional)
Refrigerant Dryer Filter
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