Magneti Marelli Clima-Tech Plus User manual

Magneti Marelli Aftermarket Spółka z.o.o.
Plac Pod Lipami 5, 40-476 Katowice
Tel.: + 48 (032) 6036107, Faks: + 48 [phone]
e-mail: [email protected]
www.magnetimarelli-checkstar.pl
Clima-Tech Plus / Hd Evolution
User’s Manual
007950015110

1INTRODUCTION
Congratulations on your choice!
The equipment that you selected is a result of our industry experience and the choice of
this specific equipment is a guarantee of a long and efficient operation.
The device was designed and manufactured to guarantee continuous reliability and
assuring maximum safety for employees. Therefore, MAGNETI MARELLI (apart from
applying high safety indices) carefully selected the material and components. The device
was created under a management system, whereby by continuous inspections, from the
material incoming to the plant, through warehousing operation up to the application in the
service workshop, guarantees a product free from any defects.
The efficiency is guaranteed by strict inspections that the equipment undergoes.
Therefore, the only task of the user is to use and maintain the device correctly,
according to the indications in this manual. That is why, it is important to stress at
the beginning that:
• Before any use of the device you must read all parts of this manual.
• It is essential and an obligation of the user to use the device according to the manual
and in line with the intended use specified in this document. MAGNETI MARELLI is not
responsible for any use of this device that is not compliant with its intended purpose.
The purpose of this manual is to provide the user with all information necessary for using
the equipment.
The manual was prepared to help the personnel using the device. If you have any
questions or need technical assistance, please contact our Technical Support
Department.
Magneti Marelli Aftermarket Spółka z.o.o.
Plac Pod Lipami 5, 40-476 Katowice
Tel.: + 48 (032) 6036107, Faks: + 48 [phone]
e-mail: [email protected]
www.magnetimarelli-checkstar.pl

2WARRANTY CONDITIONS
This device consists of several assemblies installed inside the housing and accessible only
after the front and top covers (fixed with screws) are removed, and of several assemblies
installed outside and presented in the figure below.
3.1. Warranty period and duration
Magneti Marelli AfterMarket provides a warranty for “CLIMA-TECH TOP” cooling/air-
conditioning installation diagnostic and maintenance station for 12 months from the
purchase date as in the Magneti Marelli network sales document. Performing one or more
warranty interventions during the warranty period doe not impact the warranty expiry
period.
3.2. Repairs
The warranty covers repair or replacement, free of charge, of the components which,
according to an undisputable opinion of Magneti Marelli, show defects in material or
workmanship; the warranty does not cover the replacement of the whole device.
Warranty repairs are performed on the premises of Magneti Marelli Technical Support
service. Repairs at the customer’s premises are permitted only if performed or approved
by authorized Magneti Marelli service. Technical Support does not guarantee any
minimum repair time, however they are required to perform the repairs in possibly the
shortest time.
3.3. Obtaining warranty service
To avail of the warranty service, the customer must arrange a shipment of the device to
the Magneti Marelli Technical Service on reporting the failure. The device must be shipped
in appropriate packaging that protects it against possible damage in transport. Magneti
Marelli shall not be responsible for any possible damage in transport. The device sent to
warranty service shall be sent together with a copy of the proof of purchase. Return of the
repaired part shall be paid for by the recipient.
3.4. Warranty exclusions
The warranty does not cover damages caused by using the device in conditions which do
not comply with the manufacturer’s specifications. Other cases not covered with the
warranty include:
Damage in transport due to securing the item incorrectly
Incorrect use of the product
Atmospheric discharge, flood, fire
Incorrect installation or maintenance
Mechanical damage
Calibration performed by unauthorized service station
Repairs and/or changes performed by unauthorized service station
Damages caused by rough operation or humidity, dust, voltage variations or
conditions unforeseen in the technical specification
Usage in inappropriate environmental conditions
Display damage
Any other damages outside the direct responsibility of Magneti Marelli Sp. z o.o.
If a product sent for warranty repair which is not covered by the warranty scope, the client
shall be informed that the repair may be performed outside the warranty in which case
the client must cover the cost of repair. Also, unfounded warranty complaint shall result in
charging the costs of diagnostic activities.

3DEVICE DESCRIPTION
3.1 INTENDED PURPOSE
CLIMA-TECH TOP is a fully automatic device designed for automotive air-conditioning
installation maintenance.
Recovery, recycling, emptying, oil injection, UV additive injection, installation charging
and washing are the functions which can be performed by CLIMA-TECH TOP in a
completely safe way and with maximum efficiency, exceptional in other similar
equipment.
The device was not designed for disposal! (see Glossary section)
3.2 Description and layout of components
This device consists of several assemblies installed inside the housing and accessible only
after the front and top covers (fixed with screws) are removed, and of several assemblies
installed outside and presented in the figure below.
46
45
04
43
47
19
20
21
07
08
03
02
01
10
11
06
05
60

NO.
CODE |
DESCRIPTION
1
logic board
2
MEMORY CARD (OPTION)
3
LOW PRESSURE VALVE
4
HIGH PRESSURE VALVE
5
BLUE HOSE 3000
6
RED HOSE 3000
7
LP QUICK CONNECTOR
8
HP QUICK CONNECTOR
10
D80 HP PRESSURE GAUGE
11
D80 LP PRESSURE GAUGE
12
PRESSURE SENSOR –1/20 BAR
13
KPL DISTILLER
14
OIL SEPARATOR
15
FILTER
16
COMPRESSOR
17
VACUUM PUMP
18
WEIGHT 60 kg
19
OIL INJECTION RESERVOIR
20
USED OIL RESERVOIR
21
UV CONTRAST RESERVOIR
22
EXPANSION VALVE
25
RUBBER HOSE
26
RUBBER HOSE
27
CONDENSER FAN
28
HP SAFETY DEVICE
29
MECHANICAL FILTER
31
M/F CHECK VALVE
32
CHECK VALVE
33
NON-CONDENSED GASSES VALVE
34
INTERNAL RESERVOIR
42
TWO-STAGE SWITCH
43
PANEL
44
CONTROL PANEL
45
LOWER PANEL
46
REAR WHEEL
47
WHEEL WITH A BRAKE
50
VALVE SET
53
Safety valve
60
PRESSURE GAUGE IN INTERNAL CYLINDER

DOWN
Decrease/enter parameters
UP
Increase/enter parameters
ENTER
Confirm function or menu
STOP/BACK
Select or exit menu
S LED
Power supply
STOP/BACK
LED
F
A LED
Recycling phase indication.
B LED
Emptying phase indication.
C LED
Oil injection indication.
D LED
UV additive injection indication.
E LED
Installation charging indication.
ALPHA NUMERIC DISPLAY
16 x 2
Up
ENTER
Down
A LED
B LED
C LED
D LED
STOP/BACK
STOP/BACK LED
ENTER LED
E LED
2

3.3 Technical specifications
3.3.1 Main specifications
Refrigerant: R134a
Refrigerant electronic scales: Accuracy +/- 10 g
Electronic vacuum meter: class 1.0
Low pressure / high pressure gauge: class 1.6
PLUS EVOLUTION Internal reservoir capacity: 12.4 l
HD EVOLUTION Internal reservoir capacity: 27.2 l
Maximum volume of R134a medium: 10 kg
Maximum volume of R134a medium: HD version: 25 kg
Pump capacity: 6 m3/h 3.5 CFM –100 l/min
Pump capacity: HD version: 13 m3/h 3.5 CFM - 226 l/min
Final vacuum: 5 Pa –0.05 mbar
Filtration unit: 2 filters in series
DIMENSIONS: 1222x629x628 mm
Weight: 90 kg
Weight - HD version: 105 kg
3.3.2 Energy consumption
Supply voltage : 230 V 50/60 Hz
Power: 770 W
3.3.3 Power: Noise level
Device noise level was measured in reference to the operator’s location (at the front).
Measured parameters: 53.5 dB (A)
Microphone distance above ground: 1.40 m
Microphone distance from the device: 1.00 m
3.3.4 Technical specifications of measuring instruments used
Technical specifications of measuring instruments used
(in accordance with the recommendations of IEC 651 Group1).
Precision integrating phonometer B.&.K.
Condenser dielectric-bias microphone.

4Safety
The advanced technology adopted on design and production of CLIMA-TECH PLUS/HD
EVOLUTION makes this unit extremely simple and reliable performing of all operations.
The user is therefore not exposed to any risk provided that the general safety rules
indicated below are followed and that the unit is properly used and maintained.
4.1 Safety rules
The device described in this manual is to be used only by qualified employees, who are
required to know the basics of refrigeration industry, cooling systems and refrigerants
and have knowledge concerning possible damages that may be caused by
pressurized equipment.
Users are requested to carefully read this manual to assure proper and reliable use of
the device .
use only refrigerant marked as R134a. Mixing the refrigerant with other refrigerating
media may result in serious damage to the air-conditioning and refrigerating
installations and to the service hardware.
It is recommended that appropriate personal protective equipment, such as goggles
and gloves is used as the contact with the refrigerant may result in bodily damage and
even loosing one’s sight.
Avoid skin contact as low boiling point (approx -30oC) may cause frostbite.
Avoid inhaling refrigerant vapors.
Before connecting the unit to the air-conditioning installation or external tank, check if
all valves are closed.
Before disconnecting the unit check if all operations were finished and if all valves al
closed to avoid spilling the refrigerant.
Do not re0callibrate safety valves and control systems.
Do not use external tanks or any other reservoirs without certification or uncertified
safety valves.
Do not leave the unit powered if you do not plan to use it another time. If the unit will
not be used for a longer period of time, disconnect the power supply.
All flexible parts (hoses) may contain pressurized refrigerant:
Be extremely careful when disconnecting hoses and tubes
Service equipment and vehicle air-conditioning systems using R134a refrigerant should
not be checked using compressed air. Certain R134a-air mixes turn out to be
inflammable in high pressure conditions. Such mixes may be dangerous and may
create potential fire and explosion risk causing injuries to people and damages to
property. For more information on hazards, refer to lubricants and refrigerants
manufacturers.

4.2 Refrigerants handling instruction
4.2.1 Glossary
• Refrigerant: cold-generating liquid to be only used in the device (e.g. R134a).
• A/C system: air-conditioning system in a vehicle.
• Device: CLIMA TECH EVOLUTION used for pumping out, cleaning and charging A/C
system.
• External tank: tank not designed to be refilled with a fresh refrigerant (e.g. R 134a), which
is used for filling the internal tank.
• Internal tank: tank designed specifically for storage of the refrigerant.
• Phase: performing a specific operation.
• Cycle: sequential performance of individual phases.
• Emptying: emptying an a/c system and storage of the removed refrigerant in the
external tank, without analyzing it or any other processing.
• Recycling: removal of contamination present in the refrigerant by separation of oil and
non-condensing substances and single or multiple filtration through a special device which
reduces humidity, acids and particles.
• Removal: phase in which a refrigerant is sucked-off from the A/C system and gathered in
the internal tank and then disposed of.
• Vacuum phase: a phase in which condensing substances and moisture are removed
from an A/C system using only the vacuum pump.
• Oil injection: refilling oil in A/C system to restore the oil quantity recommended by the
manufacturer.
• Filling: pouring in an A/C system the refrigerant in the quantity recommended by the
manufacturer.
• Washing: A/C system cleaning phase completed to remove any possible contamination.
• Non-condensing gasses: air removed from A/C system or tanks which is not gathered as
a result of refrigerant evaporation.

4.2.2 Refrigerant storage precautions
Do not allow mixing various types of refrigerants removed from A/C systems.
CLIMA TECH EVOLUTION is designed to support only R134a.
To avoid mixing various refrigerants, it is recommended to store them in separate cylinders.
Cylinders may not contain oil or other contaminants and the refrigerant they contain must
be clearly indicated.
4.2.3 Conditions for further usability of refrigerant
Knowing the origin and the age of the A/C system is very important for deciding about
further usability of refrigerant. A/C system repairs and maintenance greatly impact the
refrigerant quality.
If the system was not emptied correctly or not properly cleaned, the refrigerant and oil
may be highly contaminated. If you do nit know the history of the A/C system, recycle the
removed refrigerant in at least one cycle before it is reintroduced in the system.
If the operator is not certain how much contaminated the refrigerant is, it may be
checked using a special acidity and water content measurement set.
4.2.4 Recycling remarks
Replace the recycling system filter set regularly (see “Messages” section), to assure correct
operation of the device.
Refrigerant recycling should be carried out even if all parameters indicate that it is not
necessary.
4.2.5 General information
Before the refrigerant is introduced in the system, make sure the system was cleaned and
emptied.
All recommendations specified in this manual must be complied with to assure that the
system is not contaminated before filling it with the refrigerant.
Regularly clean and maintain the device if it is frequently in contact with contaminants; it
is important that the contamination remaining after the last interference in the system is
not transferred to the new refrigerant
4.3 Safety devices
CLIMA TECH EVOLUTION is equipped with the following safety devices:
• Pressure sensor: switches off the compressor if excessive pressure builds up.
• Pressure relief valves
• Main switch: allows to disconnect the power supply if it is necessary to interfere in the
device.

It is forbidden to introduce any design changes in the above safety devices.
.
4.4 Operational environment
• The device may only be operated in open or well-ventilated areas (minimum 4 air
exchanges per hour).
• The device is adapted to use in the following climate conditions:
height up to 1000 m a.s.l., ambient temperature between +5°C and +40°C, humidity of up
to 50% at +40°C.
• The device shall be operated in a place with sufficient lighting (average workshop
lighting value shall be 500-750-1000 lx).
• Do not operate the device near open fire or hot surfaces. At high temperatures
refrigerant dissolves and releases dangerous, aggressive substances, which are hazardous
to health of the operator and the environment.
• Do not inhale the refrigerant and lubricating oil because they cause irritation of eyes and
respiratory tracts.

5Use
5.1 Unpacking
Remove the device from the packaging and make sure all equipment is included:
operation manual
memory card
2 R134a ball valves
power supply cable
5.2 Storage
Remove the device from the base.
The device is fitted with 4 wheels; both front wheels are equipped with brakes.
If placed on an uneven surface, CLIMA TECH EVOLUTION may be inclined and moved on
rear wheels only.
The device is designed in such a way that the heaviest components are located in its
bottom part which assures low center of gravity.
Nevertheless, there is a risk that inclined device may fall down.
5.3 Preparation for operation
As soon as CLIMA TECH EVOLUTION is placed next to the A/C system to be maintained,
place it with four wheels on a level surface to ensure proper operation of the scales.
.
Then, plug the device plug into the socket of the installation complying with the
parameters specified on the rating plate, next to the main switch of the device. Pay
special attention to the voltage, frequency and the power.
.

5.4 Start-up
Place the device with empty oil tanks on a level surface.
Connect
the
device
to the
power
network,
set the
main
switch
(42) into
ON (l)
During the first start-up, select the language version from among the available ones. The
default language is Italian
SELECT LANGUAGE
Polski
Press UP–DOWN to select the desired language version. Confirm by pressing ENTER
Vacuum in process
XX
The device performs vacuum phase.
calibration ok!
Press ENTER to confirm.
Display shows the installed software version, date and time for a couple of
seconds
CLIMA TECH EVO
SW xx xx xx xx
Then the display shows available resources (stand-by).
Refrigerant
g xxx
5.5 Switching off
To stop the operation of the device, turn the main switch (42) into off position (0).
Until the device is stopped under no circumstances disconnect the plug from the socket.
5.6 Filling the internal tank
WARNING! FOLLOW THE INDICATIONS BELOW TO AVOID EMISSION OF THE
REFRIGERANT TO THE ATMOSPHERE!
42
Do not remove
or insert the memory
card when the device
is on.
At the first startup,
the device checks if
there is new software
on the card and may
install it on the logic
board.

After the operations described in the previous section, connect HP quick connector (red)
of the device to the external tank using a supplied adapter.
Open the coupling by twisting the valve clockwise.
Open the valve on the external tank.
There are two different tanks available: with and without suction pipe.
tanks with suction pipe must be positioned straight to let the liquid refrigerant flow. These
tanks must be connected to L (liquid) coupling.
tanks without suction pipe have only one valve and therefore must be put with their top
down to let the liquid refrigerant flow.
TANKS
Tank with a float Tank without a float
Open HP valve on the main panel
If the device is in stand-by, press ENTER
Registration no. □
Other Menu ■
Press UP–DOWN to select Other menu. Confirm by pressing ENTER.
Cylinder filling ■
Servicing □
Push UP–DOWN to select cylinder filling. Confirm by pressing ENTER
Printing □
Diagnostics □
Printing and Diagnostics are available only if memory card and/or printer is installed
.
Connect high pressure hose
to the external cylinder
. Confirm by pressing ENTER
Open cylinder valve

Confirm by pressing ENTER.
Input desired refrigerant quantity
g XXXXX
Push UP–DOWN to select quantity. Confirm by pressing ENTER
Recovery in process
Quantity of recovered refrigerant
g XXXXX
Filling of external tank finished
Confirm by pressing ENTER.
Close cylinder valve
Follow the on-screen instructions. Confirm by pressing ENTER
Wait!Refrigerant recovery from tubes
Process finished
Confirm by pressing ENTER
The maximum
quantity of R134a
refrigerant to be gathered
in the internal tank is
25 kg. Please, note that
after the message “Qty
reached, close internal
cylinder valve” appears,
the device can recover
up to 1 kg or more of the
refrigerant.

5.7 Cylinder bleeding
Non-liquefied gasses draining valve (33) is calibrated at 12.8 bar for the standard version
and for 16.8 bar for HD version; the valve was installed to allow gradual removal of non-
liquefied gasses from the external tank.
The valve is automatically energized by the system each time there is non-liquefied gas in
the tank and their pressure is greater than the calibration pressure.
The purpose of the non-liquefied gasses draining valve (33) is to allow gradual removal of
non-liquefied gasses present inside the internal tank if their pressure exceeds the
calibration pressure for 33 non-liquefied gasses draining valve.
.
33 NON-LIQUEFIED
GASSES DRAINING
VALVE

6MESSAGES
6.1 Error messages
WARNING! Maximum pressure
in the internal cylinder
Maximum pressure was reached in the internal tank. Wait approx. 30 minutes before
restarting the refrigerant recovery function. If this does not eliminate the problem, contact
Magneti Marelli technical support.
WARNING! Internal cylinder
is full
Maximum permitted quantity of refrigerant in the internal cylinder was reached. This value
cannot be exceeded in any circumstances.
WARNING! Pressure in
the A/C system
Appears at the beginning of the vacuum phase, if pressure is detected in the A/C system.
The device starts the recovery phase.
A/C-not tight! Continue?
mB XXX
Vehicle A/C system is not tight. This message appears if the station detects a pressure
growth in the system during vacuum leak test. Repair the A/C system.
Select ENTER to continue. Select STOP/RETURN to return to standby mode
Insufficient vacuum.
Continue?
mB XXX
This message appears after 10 minutes of vacuum build-up if the pressure in the A/C
system is not lower than 100 mBar.
Select ENTER to continue with the vacuum phase. Select STOP/RETURN to return to standby
mode
WARNING!
Insufficient vacuum
Excessive pressure during pressure check before oil or contrast injection. This phase is only
run in systems in which vacuum was achieved.
Select ENTER to continue. Select STOP/RETURN to return to standby mode
Insufficient refrigerant quantity!
Add refrigerant!
Too little refrigerant in the internal tank. Select ENTER to go to the phase of refrigerant filling
from the external cylinder. Select STOP/RETURN to go to the next step.
External cylinder empty
or valve is closed!
Please check!

This message appears in the initial phase of filling the internal cylinder from the external
cylinder, if the station detects no pressure or, while filling the internal cylinder, if the
pressure is too low to fill the internal tank to the required degree.
Maximum recirculation
time exceeded!
Continue?
Maximum anticipated recirculation/recovery time. Check the readings on the pressure
gauges –if they show a pressure, the station may be damaged (contact Magneti Marelli
technical representative), if they show no pressure, the vehicle A/C system or valve set
may be leaking.
Select ENTER to continue with the recirculation/recovery phase. Select STOP/RETURN to
return to standby mode
Filling time exceeded
Continue?
Close HP valve
Start the A/C system
Open LP valve
These messages appear during filling phase if the target refrigerant quantity was not filled
despite the maximum duration, if HP-LP A/C system is selected.
The remaining refrigerant will be sucked in to the system by the compressor. Follow the
indications on the display. Select ENTER to continue with the filling phase. Select
STOP/RETURN to return to standby mode
Filling time
exceeded
Continue?
This message appears during filling phase if the target refrigerant quantity was not filled
despite the maximum duration, if HP A/C system is selected.
Select ENTER to continue with the filling phase. Select STOP/RETURN to return to standby
mode
Filling time
exceeded
Continue?
Select ENTER to continue.
Start the A/C system
This message appears during filling phase if the target refrigerant quantity was not filled
despite the maximum duration, if LP A/C system is selected.
The remaining refrigerant will be sucked in to the system by the compressor. Follow the
indications on the display.
6.2 Functional messages
Replace the drying filter!
Continue?

Replace vacuum pump filter!
Continue?
This message appears after starting the station, once it has reached the scheduled
maintenance interval. After replacing the component, reset the counter.
See 11.4.2 Resetting counters
Pressure sensor auto-calibration?
This message appears after starting the station. Select ENTER to allow the station to perform
auto-calibration of the pressure sensor.
Start operation?
Select ENTER to start the planned process or cycle.
Process finished!
Select ENTER to go to standby mode.
A new database
version is
available.
This message appears one year after database memory card activation.
Select ENTER
Please contact
the distributor.
Select ENTER to go to standby mode. See Replacing memory card. Replacing the memory
card into a card with a new database will disable the message automatically.
Printer
does not work!
Printer is not available (printer led flashes). Possible reasons include open printer cover or
no paper.
Select ENTER to continue with the next phase. Select STOP/RETURN to return to standby
mode.
If there are no paper in the printer, lift the printer cover to secure the head.
Use only paper available in Magneti Marelli Aftermarket offer. This message is
accompanied with a warning sound.
Select ENTER to exit.
The message appears only
when optional printer is
installed

7DESCRIPTION OF OPERATION
In standby mode the device displays the quantity of refrigerant available.
7.1 Description of functions
The station remembers selected A/C system filling parameters, linking them to the
registration numbers entered in the database. When servicing vehicle with the same
registration number again, it is possible to restore the parameters selected previously
during maintenance.
The station may also operate in the following modes:
Automatic program:
A vehicle with previously saved settings may be selected or a desired refrigerant
quantity may be input. The program will automatically calculate the time
necessary to achieve vacuum for the specific quantity of refrigerant.
Manual program:
The user selects the phases to be performed for a specific vehicle.
After selecting of the programs, follow the instructions on the display.
7.1.1 Memory card functions (optional)
For installed memory card, in the automatic program, specific car model may be selected
from the database. Moreover, a diagnosis mode is available, which allows checking the
A/C system operating parameters, suggesting possible causes of failures.
7.2 Software functionality
Use UP and DOWN buttons to select the desired program.
Select ENTER to confirm.
Select STOP/BACK to stop the selected function and return to standby mode.
Select STOP/BACK to return to the previous screen in settings mode.
7.3 Editing
When entering vehicle registration numbers, the characters are selected successively as
follows:
UP button –selecting successive letters/characters according to the diagram below, in
clockwise direction
DOWN button - selecting successive letters/characters according to the diagram below, in
anti-clockwise direction
ENTER –go to the next character
STOP/BACK –return to the previous character
Hold ENTER button for 3 seconds to confirm entered chain of characters.