MAHLE AIR-NEX 9380 User manual

MAHLE
AIR-NEX 9380/9480
EN
Service
Manual
A/C Service Equipment

en
2
|AIR-NEX 9380/9480|
Contents
1 General instructions ................................... 3
1.1 General notes ............................................ 3
1.2 General instructions ................................... 3
1.3 Manufacturer identification ......................... 3
1.4 Environmental precautions ......................... 3
2 Safety conditions ....................................... 3
2.1 ersonal safety information ........................ 3
2.1.1 Definitions ......................................................... 3
2.1.2 ersonal safety information .............................. 3
2.2 Important information on service equipment
safety ................................................................. 5
2.3 Safety devices ........................................... 5
3 Layout of the manual ................................. 5
3.1 Use of the manual ...................................... 5
3.2 Symbols .................................................... 6
3.2.1 Safety ............................................................... 6
3.3 Glossary .................................................... 6
3.4 Guidelines for the handling of refrigerant ..... 6
3.4.1 recautions for refrigerant storage ................... 6
3.4.2 Conditions of refrigerant and system ............... 7
3.4.3 Recycling capacity ........................................... 7
4 roduct description ................................... 7
4.1 Application ................................................ 7
4.2 Scope of delivery ....................................... 7
4.3 Description of the unit ................................ 7
4.4 User interface ............................................ 8
4.4.1 Main menu ........................................................ 9
4.5 ECO LOCK® quick couplers ....................... 9
5 Technical features .................................... 10
6 Installation ................................................. 11
6.1 Equipment installation .............................. 11
6.1.1 Unpacking ...................................................... 11
7 Commissioning ......................................... 11
7.1 Connections ............................................ 11
7.1.1 ositioning and connection ............................ 11
7.2 Software update ...................................... 12
7.3 Initial verification ...................................... 12
7.4 New AG and OE oil bottles filling .......... 12
7.5 UV dye bottle filling .................................. 13
8 Setup .......................................................... 14
9 Service Menu ............................................ 15
9.1 Manual activations and analogue channel
view ............................................................... 15
9.2 ressures calibration (service kit) .............. 15
9.3 OOB ressures calibration (service kit) ...... 16
9.4 Gas weight calibration .............................. 16
9.5 Oil weight calibration ................................ 17
9.6 Spare parts & consumables ...................... 17
10 Equipment and simulator ........................... 17
11 Refrigerant fluid circuit ............................ 17
11.1 Refrigerant fluid circuit ............................. 17
11.2 Operational cycles ................................... 17
11.3 Receiving tank (refrigerant cylinder) .......... 17
11.4 Manifold charts ....................................... 18
11.5 Suction circuit components ...................... 19
12 Non -permanent junction .............................. 19
13 Electrical connections ............................. 19
14 Maintenance ............................................. 20
14.1 Maintenance interval ............................... 20
14.2 Hoses emptying ..................................... 21
14.3 Air purge ................................................ 21
14.4 Vessel filling ........................................... 21
14.5 ressures zero ....................................... 21
14.6 Self leak test .......................................... 21
14.7 LONG LIFE UM ................................. 21
14.8 ump oil change .................................... 22
14.9 Dryer filter change ................................. 22
14.10 Replacement of Active Oil rotection
Cartridge .............................................................. 22
14.11 Maintenance of printer ........................... 23
14.12 eriodic checks ..................................... 24
14.13 Refrigerant type change (only for AIR-NEX
9380) .............................................................. 25
14.14 Air purge ................................................. 25
14.15 Counters ................................................ 25
14.16 Replacing white sample filter (Refrigerant
identification unit ).................................................... 25
15 Replacement interventions ........................... 26
15.1 Extraordinary maintenance list ................. 26
15.2 Extraordinary maintenance ...................... 26
15.2.1 Replacement of component connected
to refrigerant circuit ....................................................... 26
15.2.2 Replacement of logic electronic board with
display .................................................................... 27
15.2.3 Replacement of electronic power board .. 27
16 Spare and wearing parts .............................. 28
16.1 Refrigerant identification unit .................... 28
A ENDIX 1 – REFRIGERANT FLUID CIRCUIT AIR-NEX
9380/9480 .......................................................... 29
A ENDIX 2 – REFRIGERANT FLUID CIRCUIT AIR-
NEX 9380/9480 O ERATIONAL CYCLES ........ 30
A ENDIX 3 – AIR-NEX 9380/9480 - ELECTRICAL
CONNECTION – LOGIC ELECTRONIC BOARD
........................................................................... 34
A ENDIX 4 – AIR-NEX 9380/9480 - ELECTRICAL
CONNECTION – OWER ELECTRONIC
BOARD AND OWER SU LY ....................... 35
A ENDIX 6 – TROUBLE SHOOTING .......................... 37
A ENDIX 7 – FAILURE LIST AIR-NEX 9380/9480 ....... 38

| AIR-NEX 9380/9480 | 3 en
©MAHLE
1 General instructions
1.1 General notes
All rights reserved.
This manual may not be reproduced, in part or entirely,
either in printed or digital form.
It may be printed out solely for use by the user and
operators of the equipment to which it refers.
MAHLE and resources used for the drawing up of this
manual will not be held responsible for the incorrect use of
the manual while they guarantee that information in the
manual have been duly checked.
The product can be subject to changes and improvements.
MAHLE reserves the right to change without notice the
information contained in the manual.
1.2 General instructions
ressure equipment undergoes checks before
commissioning and periodical checks during operation, in
compliance with rules and law provisions in force in the
country where the tool is used.
The operator is responsible for operating the equipment in
conformity with local legislation.
Only for model AIR-NEX 9380.
The equipment is designed for recovering and recycling
R1234yf/R134a refrigerant fluid from automotive A/C
system.
The equipment is intended to be used by automotive
and similar repair and service workshops.
The switch between the two refrigerant types, from
R134a to R1234yf, can only be performed by a
technician of an Authorised MAHLE Centre.
This equipment is intended solely for use by professionally
trained operators familiar with the basics of refrigeration,
refrigeration systems, refrigerants and the hazards
associated with pressurised equipment.
Careful reading of the present manual by the owners, the
users and the operators is required for a correct and safe
use of the tool.
The user shall not be entitled to open the product since
maintenance operations are reserved to the authorised
service centre.
1.3 Manufacturer identification
The AIR-NEX equipment is manufactured by:
MAHLE Aftermarket Italy S.p.A.
via Quasimodo 4/a, Italy
hone: [phone]
1.4 Environmental precautions
Any service operation with the equipment must be carried
out being careful not to disperse fluorinated gases (R134a)
into the environment, in order to prevent the greenhouse
effect and the subsequent global warming of the planet. The
release of refrigerant gas R134a into the atmosphere is
forbidden by laws that were enacted within the framework of the
Kyoto protocol.
For information only, we will mention in particular, for the European
Union, REGULATION (EU) No 517/2014 OF THE EURO EAN
ARLIAMENT AND OF THE COUNCIL of 16 April 2014 on
fluorinated greenhouse gases and repealing Regulation (EC) No
842/2006.
The waste coming from the service activities must be placed in
collection centres foreseen by the enforced laws, they must not be
dispersed in the environment and they must not be disposed of with
urban waste.
2 Safety conditions
2.1 Personal safety information
2.1.1 Definitions
DANGEROUS AREAS:
Any area within or close to the equipment implying risk for the safety
and health of exposed persons.
EX OSED ERSON:
Any person completely or partially standing in a dangerous area.
O ERATOR:
The person/s charged with operating the machine for its intended
purpose.
CLASSIFICATION OF O ERATORS
The operator can be classified according to two main categories,
which, in some cases, refer to one single person:
•The operator charged with the equipment operation has the
duty to:
oStart up and monitor the machine's automatic cycle;
oCarry out simple setting operations;
oRemove the causes of equipment stop not implying
breakings of members but simple operating anomalies.
•Maintenance technician a technician trained by an authorised
MAHLE centre, capable of working on the machine’s
mechanical and electrical components with its guards open to
make adjustments and to service and repair it.
USER
Body or person legally responsible for the equipment.
2.1.2 Personal safety information
The A/C service station is particularly simple and reliable due to its
adjustments and functions. When used correctly it presents no
hazard for the operator, provided he observes the following general
safety instructions and that the service station is regularly serviced
(incorrect maintenance/use compromise the equipment's safety).
Before operating the service station for the first time, read these
instructions carefully. If any part of the instructions is unclear,
contact your reseller or MAHLE.
This service station may be used by only one equipment operator,
familiar with A/C and refrigeration systems and the hazards
associated with refrigerants and high pressure equipment.

| AIR-NEX 9380/9480 | 4en
WORK LACE: The station can work with both R134a and
R1234yf (the two refrigerants cannot be stored within the
station at the same time).
Refrigerant R1234yf is defined as flammable refrigerant.
Nonetheless, although refrigerant R134a is not defined as
flammable, mixtures of air or oxygen with R134a may
become flammable under very particular conditions.
The equipment must be operated outdoor or in a well-
ventilated location (at least 1 air change per hour). The
workshop has to be equipped with ventilation systems
able to ensure air change in every environment area or
carry out periodical ventilation by opening the areas.
Use the equipment away from heat sources or hot
surfaces. The equipment must not be used in explosion risk
environments (potentially explosive atmospheres). Before
using it, put the equipment on a levelled plane and secure
position, blocking it with suitable wheel stops.
Do not expose the tool to direct sunrays, heat sources, rain
and jets of water. Do not smoke near the equipment and
during operations (keep at a distance of at least 1 m).
The work area must be monitored by the operator while the
equipment is operating.
ATTENTION: R134a and/or R1234yf refrigerant
fumes/gases are heavier than air and can gather on the floor
or inside cavities/holes and cause choke by reducing the
oxygen available for breathing.
At high temperatures, the refrigerant breaks down releasing
toxic and aggressive substances, harmful for the operator
and the environment. Avoid inhaling the system coolants
and oils. Exposure can irritate eyes and the respiratory tract.
ELECTRICAL CONNECTION: Connect the power cord
solely to a mains supply which conforms to the ratings on
the machine's nameplate (mounted on its side). Make sure
the mains socket is grounded.
Maximum impedance allowed in the point of connection to
the mains shall comply with standard EN 61000-3-11.
Starting currents can cause short voltage drops, which may
affect other equipments under unfavourable conditions. If
impedance in the point of connection to the mains is not
compliant, this may lead to interference so please consult
the electrical power network operator before connecting the
equipment.
Never use the service station with a defective power cord or
a different one from that supplied with the machine. If
damaged, immediately have it replaced with an original
spare part or equivalent by a MAHLE centre. Before
opening the service station, extract completely the supply
cable from the plug, or you can get an electric shock.
Do not tamper with or bypass the safety equipment and
settings.
Do not leave the machine powered up when not in use; shut
off the power supply before leaving the equipment unused
for a long time. Do not forget that the tool (pressure tool) must
always be protected.
REFRIGERANTS AND LUBRICANTS - ERSONAL SAFETY
EQUI MENT AND RECAUTIONS: The refrigerants and the
pressure cylinders have to be handled with care, otherwise there will
be possible health risks.
The operator must wear safety glasses, gloves and protective
clothing suitable to the work. Contact with the refrigerant can cause
blindness (eyes) and other physical damages (freezing) to the
operator. Avoid contact with the skin; the refrigerant's low boiling
point (approx. –26 °C for R134a and approx. -30 °C for R1234yf) can
cause freezing burns.
Further information about safety can be obtained from the safety
sheets of lubricant and refrigerant producers.
Do not inhale refrigerant or oil vapour. Keep away from the vent
valves and ventilation coupling, especially when non-condensable
gas is being vented.
Never direct the quick couplings (taps) towards your face or other
persons or animals.
OTHER ROHIBITIONS AND USE LIMITATIONS: Only use pure
R134a or R1234yf refrigerants, refrain from using on vehicles
containing other types of refrigerants or mixtures of the two
refrigerants or other refrigerants. Mixture with other types of
refrigerant produces serious damage to the conditioning and cooling
systems. Mixed refrigerants have to be disposed of according to
the current regulations. Never use AIR-NEX equipment with
systems containing compressed air; mixtures of R134a or R1234yf
with air or oxygen may be potentially flammable.
Do not modify calibration of safety devices. Do not remove seals of
safety valves and of control systems. Do not use external tanks or
other storage containers that are not type-approved or without
safety valves.
Make sure the equipment's aeration and ventilation ports are not
obstructed or covered while the equipment is operating.
HOSE CONNECTIONS: Hoses may contain pressurised refrigerant.
Before changing the service couplers, check the respective
pressures in the hoses (pressure gauge).
Before connection to a car A/C system, to an external tank/cylinder,
check that the quick couplers are closed (unscrewed H and L
valves).
Scrupulously follow the instructions on the equipment's display.

©MAHLE
QUICK COU LERS CLOSING/O ENING:
MAINTENANCE/GENERAL CLEANING:
The equipment
has to be serviced at the intervals indicated by the
equipment itself.
The service station maintenance
has to be performed
according to the procedures described in this manual and
to the current safety regulations.
Use only MAHLE original parts.
When the equipment requires the drier filter and the vacuum
pump oil to be changed, you have to be careful in the
replacement.
A/C service station maintenance can be carried out
exclusively by a trained operator or by a service man of a
MAHLE certified seller.
Do not use chemical agents for the service station cleaning
as they could attack the material or the surface.
STO FOR LONG ERIOD:
Store the equipment in a safe
place, disconnected from the mains, away from excessive
temperatures, humidity and the risk of damaging impact.
Contact the Technical Service to run a safety shutdown of
the equipment, and if
scrapping the unit, to drain and
recycle the R134a or R1234yf refrigerant as required by
local legislation.
To resume operation, repeat the installation (there is no
need to register the unit anew on the website) and run the
commissioning trials and regula
r operational checks as
required by local legislation.
2.2
Important information on service
equipment safety
When using the equipment, the following operations are not
allowed as they might cause, under certain circumstances,
danger for persons and cause
permanent damage to the
equipment itself.
-
Do not remove or make unreadable labels,
signs and/or dangers signs placed on the
equipment and in the area nearby.
-
Do not disable the unit's safety equipment.
-
The electrical system to which the service
equipment is connected must be configured as
provided by local legislation.
Closing (detach from
the vehicle):
counter clockwise
Opening (connect to
the vehicle):
clockwise
| AIR
-
The equipment
has to be serviced at the intervals indicated by the
has to be performed
according to the procedures described in this manual and
When the equipment requires the drier filter and the vacuum
pump oil to be changed, you have to be careful in the
A/C service station maintenance can be carried out
exclusively by a trained operator or by a service man of a
Do not use chemical agents for the service station cleaning
Store the equipment in a safe
place, disconnected from the mains, away from excessive
temperatures, humidity and the risk of damaging impact.
Contact the Technical Service to run a safety shutdown of
scrapping the unit, to drain and
recycle the R134a or R1234yf refrigerant as required by
To resume operation, repeat the installation (there is no
need to register the unit anew on the website) and run the
r operational checks as
Important information on service
When using the equipment, the following operations are not
allowed as they might cause, under certain circumstances,
permanent damage to the
Do not remove or make unreadable labels,
signs and/or dangers signs placed on the
Do not disable the unit's safety equipment.
The electrical system to which the service
equipment is connected must be configured as
-
Only operators or qualified staff instructed or
certified for the
equipment
open the equipment
. The equipment
parts which can cause electrocution: shut off
power to the equipment before
servicing/repairing it.
2.3 Safety devices
The A/C service station
is equipped with the following safety
devices:
SAFETY RESSURE SWITCH
in case of excessive pressure.
SAFETY VALVE:
The safety valve opens when the
pressure inside the system reaches a level higher than the
fixed limits.
MAIN SWITCH:
Switches the equipment off by
interrupting the power supply. It is advisable to pull the
power cord plug out of the mains socket in any case
before starting maintenance work.
ANY TAM ERING WITH THE ABOVE
SAFETY DEVICES IS ROHIBITED.
Failure to observe any of the above safety instructions voids the
equipment's warranty.
3
Layout of the manual
3.1 Use of the manual

This manual is an integral part of the equipment and
must be kept in the equipment's immediate vicinity by
the purchaser
•
This manual shall accompany the equipment in case this is
passed on to a new user.
•
The content of this manual has been drawn up in
compliance with the guide lines of the UNI standard
10893:2000.
•
Diffusion, modification or use of this manual for own aims is
forbidden.
•
The manual uses symbols which call the reader's attention
to specific points to facilitate its use.
•
It includes all technical, operating, shutdown, maintenance,
spare parts and safety information.
•
In case of doubts on the correct interpretation
instructions, please contact our technical service to obtain
the required clarifications.
Operations which are potentially hazardous for the
operator are highlighted with this symbol.
Such operations can cause serious injury.
Operations
requiring special attention are highlighted with
this symbol.
Such operations shall be carried out correctly to avoid
causing damage to objects or to the surrounding
environment. This symbol also highlights information to
which special attention must be pa
-
NEX 9380/9480 | 5 en
Only operators or qualified staff instructed or
equipment
maintenance can
. The equipment
contains
parts which can cause electrocution: shut off
power to the equipment before
is equipped with the following safety
SAFETY RESSURE SWITCH
: It stops the compressor
The safety valve opens when the
pressure inside the system reaches a level higher than the
Switches the equipment off by
interrupting the power supply. It is advisable to pull the
power cord plug out of the mains socket in any case
before starting maintenance work.
ANY TAM ERING WITH THE ABOVE
-
MENTIONED
SAFETY DEVICES IS ROHIBITED.
Failure to observe any of the above safety instructions voids the
Layout of the manual
This manual is an integral part of the equipment and
must be kept in the equipment's immediate vicinity by
This manual shall accompany the equipment in case this is
The content of this manual has been drawn up in
compliance with the guide lines of the UNI standard
Diffusion, modification or use of this manual for own aims is
The manual uses symbols which call the reader's attention
to specific points to facilitate its use.
It includes all technical, operating, shutdown, maintenance,
spare parts and safety information.
In case of doubts on the correct interpretation
of the
instructions, please contact our technical service to obtain
Operations which are potentially hazardous for the
operator are highlighted with this symbol.
Such operations can cause serious injury.
requiring special attention are highlighted with
Such operations shall be carried out correctly to avoid
causing damage to objects or to the surrounding
environment. This symbol also highlights information to
which special attention must be pa
id.


Operations which require careful reading of the manual's
instructions are highlighted with this symbol.
3.2 Symbols
This paragraph describes the safety symbols which may be
posted on the service equipment.
3.2.1 Safety
ALTERNATING
CURRENT
SAFETY GROUNDING
CONSULT THE
INSTRUCTIONS
MANUAL
ATTENTION!
ELECTROCUTION
HAZARD
CAUTION !: DO NOT
REMOVE THE COVER
(maintenance
technicians only)
USE ROTECTIVE
GLOVES
WEAR ROTECTIVE
GOGGLES
USE ANTI
-
SMASH
SAFETY SHOES
3.3 Glossary
To make the reading of this manual easier, we have
prepared the list of the most important technical terms used
in the manual.
Refrigerant:
Refrigerant fluid used in
advanced motor vehicle A/C systems.
The following refrigerant fluids
may be used:
•R-1234yf CH2CFCF3 2,3,3,3-
Tetrafluoropropene.
•R-134a C2H2F4 - 1,1,1,2-
Tetrafluoroethane
A/C system: air conditioning system.
Equipment: A/C service station for
recovering, recycling, draining and
charging the A/C system.
External tank: Refrigerant bottle used to
fill the internal tank.
Internal cylinder: cylinder for refrigerant
storage.
hase: erformance of a single function.
| AIR-
NEX 9380/9480
Operations which require careful reading of the manual's
instructions are highlighted with this symbol.
This paragraph describes the safety symbols which may be
To make the reading of this manual easier, we have
prepared the list of the most important technical terms used
Cycle:
Sequence of steps.
Recovery: Extraction of ref
rigerant from
the vehicle.
Recycling:
Cleaning of refrigerant,
includes: separating out oils, removal of
non-
condensable gas and
single/multiple pass through filters to
reduce humidity, acidity and particulate
content of the fluid.
Disposal: disposal of
refrigerant for
storage followed by
destruction/scrapping by an authorised
waste management centre.
Vacuum cycle:
Draining out of a motor
vehicle A/C system and separation out of
condensed matter and humidity, using
only the vacuum pump.
Oil charge:
Charge of oil into an A/C
system to ensure the correct charge as
specified by the vehicle's manufacturer.
Charge:
filling of refrigerant into the A/C
system in the amount specified by the
manufacturer.
System flushing:
Cleaning phase for the
removal of p
ossible polluting substances
from the A/C system or parts of it.
Non condensable gas:
Refrigerant
stored in gaseous phase, including air
and nitrogen.
3.4
Guidelines for the handling of refrigerant
3.4.1
Precautions for refrigerant storage
The refrigerant remov
ed from the A/C system must be handled with
care to prevent or minimise the risk of mixing with other refrigerants.
This machine is suitable for treating R134a or R1234yf
refrigerants, individually (not simultaneously).
The external cylinders used to store
the refrigerants must be clearly
marked to prevent mixing different refrigerants.
Cylinders shall be free from oil or other contaminants and clearly
marked so as to identify the refrigerant contained.
ATTENTION:
when handling, using and storing
R-1234yf
refrigerant and dealing with emergency
situations, MAKE SURE
to refer to the product’s safety
sheet.
GET THE SAFETY SHEET FROM YOUR REFRIGERANT
SU LIER AND FOLLOW ITS INSTRUCTIONS.
REFRIGERANT R1234YF IS DEFINED AS FLAMMABLE
REFRIGERANT.
NEX 9380/9480
|6en
rigerant from
Cleaning of refrigerant,
includes: separating out oils, removal of
condensable gas and
single/multiple pass through filters to
reduce humidity, acidity and particulate
refrigerant for
storage followed by
destruction/scrapping by an authorised
Draining out of a motor
vehicle A/C system and separation out of
condensed matter and humidity, using
Charge of oil into an A/C
system to ensure the correct charge as
filling of refrigerant into the A/C
system in the amount specified by the
Cleaning phase for the
ossible polluting substances
Refrigerant
stored in gaseous phase, including air
Guidelines for the handling of refrigerant
Precautions for refrigerant storage
ed from the A/C system must be handled with
care to prevent or minimise the risk of mixing with other refrigerants.
This machine is suitable for treating R134a or R1234yf
refrigerants, individually (not simultaneously).
the refrigerants must be clearly
marked to prevent mixing different refrigerants.
Cylinders shall be free from oil or other contaminants and clearly
marked so as to identify the refrigerant contained.
when handling, using and storing
R
-
134a
or
refrigerant and dealing with emergency
to refer to the product’s safety
GET THE SAFETY SHEET FROM YOUR REFRIGERANT
SU LIER AND FOLLOW ITS INSTRUCTIONS.
REFRIGERANT R1234YF IS DEFINED AS FLAMMABLE

| AIR-NEX 9380/9480 | 7 en
©MAHLE
3.4.2 Conditions of refrigerant and system
The condition of the refrigerant is critical to the operation of
the vehicle's A/C system. Running repairs properly following
failure or damage safeguards the quality of the refrigerant
itself (particulates, acids and water).
3.4.3 Recycling capacity
The service equipment's filtering systems must be replaced
regularly (see maintenance messages) to ensure effective
recycling.
4 Product description
4.1 Application
A/C service station is suitable for vehicle with A/C systems
using R134a or R1234yf.
The following functions can be implemented:
•Refrigerant recovery and recharging.
•Vacuum generation.
•Flushing.
4.2 Scope of delivery
Description
Service hose (high pressure)
Service hose (low pressure)
Quick-release coupling (high pressure)
Quick-release coupling (low pressure)
New AG oil bottle
Used oil bottle
UV dye bottle
UV dye hybrid bottle
New OE oil bottle
Original instructions
Adapter for external bottle
connection
Funnel
4.3 Description of the unit
Fig.1: Left-Front view
1 Rear Handle
2 Tool Tray
3 Status light
4 Low ressure Gauge
5 High ressure Gauge
6 Front Cover
7 Locking Caster
8 Rear Wheel
9 New & Used Oil Bottles
10 rinter
11 Touch screen
DO NOT USE THE UNIT UNLESS THE CHARGING
HOSES (H – L ) ARE CORRECTLY CONNECTED
Fig. 2: Rear view (detail)
1 Fan
2 Vents
3 ower cord connector and ower switch
4 H &L quick couplers and hoses
1
4
2
3

| AIR-NEX 9380/9480 | 8en
Fig. 3: Right-front view (detail)
1 High-pressure gauge
2 Low-pressure gauge
3 Display with Touch screen and USB port
The pressure gauges (Fig. 3, os. 1, 2) of the display and
operating unit are used to monitor the pressure during the
individual vehicle A/C service phases. The status of the
various service phases during maintenance is displayed
on the touch screen (Fig. 3, os. 3).
The menu selection and the necessary entries are made
on the touch screen (Fig. 3, os. 3). MAHLE provides a
USB stick for ACX station to activate an additional
database (e.g. Agri&Work machinery). The USB stick can
be inserted in the USB type A port on touch screen frame
(Fig. 3, os. 3).
4.4 User interface
All settings, controls and service functions are available on
the touch screen display. It also displays the service
equipment’s status, the progress of A/C system service and
any alarms and warning/error messages.
The touch screen is the basic operator interface and can be
operated with the fingers. When a button is pressed, a beep
sounds.
The following icons are available on the display:
Icon
Description
Device
connected via
WiFi
The residual
refrigerant weight
(in kg and with
visual bar)
to enable/disable
the bar by
vertically swiping
your finger from
top to bottom
Remote
connection “RE
SOLVE” active
Icon to send
email via WiFi
Icon to print
report via the unit
printer
Icon
Description
Icon to print via
WiFi on a
network printer
document in the
print queue
Icon to start cycle
Recovered
refrigerant
amount
Amount of
refrigerant to be
injected
Recovered oil
amount
Amount of oil to
be injected
Amount of UV
dye injected
Vacuum time
Vacuum test time
Function or cycle
disabled
Function or cycle
enabled
Icon to update
list
low light intensity
high light
intensity
To select a function in the menu press the text name of the function,
the selection occurs when the finger is released.
If there are functions that need more space on the screen page, for
example: the additional functions or maintenance list, to display the
different entries, it is necessary to horizontally swipe on the display,
or in case of setup it is possible to display the different entries by
moving the scroll bar on the display with the finger.
Lift the finger when you are on the desired position.
1
2
3

| AIR-NEX 9380/9480 | 9 en
©MAHLE
Horizontal swipe gesture on
touch screen
If you need to enter free text or identify a set of data, a
keypad automatically appears (for example, for entering
workshop data or at the end of the service cycle).
4.4.1 Main menu
The Main menu of the graphical user interface allows to
select the following functions:
•Vehicle selection
•OneClick
•Cycles
•Additional Functions
•Maintenance
•Setup
•Secured Service (not available for user; reserved
only for customer service personnel)
Each function will be described in the next chapters.
4.5 ECO LOCK® quick couplers
ECO LOCK® is the INTELLIGENT COU LER, that with the
suitable automated procedure in the software enables to:
•reduce the non condensable gas formation inside
the cylinder ;
•avoid refrigerant dispersion in the air during
disconnection (puff effect);
•check possible SCHRADER valve leaks before
disconnection.

| AIR-NEX 9380/9480 | 10 en
5 Technical features
Cylinders for R134a or R1234yf fluids
Gas type for AIR
-
NEX 9380
R134a
Convertible to R1234yf
(with optional kit)
Gas type for AIR
-
NEX 9480
R1234yf
R134a or R1234yf
cylinder capacity
20 l
Maximum
operating
pressure ( S)
20 bar
ED category
(Dir.2014/68/EU)
III
Weight of
refrigerant content
Scale
Safety valve
Type
AIRTEK
-
VS14N T20HNBR ED4
20bar R 1/4 N T
Calibration
pressure
20 bar
ED category
(Dir.2014/68/EU)
IV
Containers for oil and detection dye
Recovered AG
oil container
250 ml
New AG oil
container
250 ml
UV Dye container
250 ml
New OE oil
container
250 ml
neumatic circuit
Vacuum pump
flow rate
100 l/min double stage
Vacuum
level
0.02 mbar
Vacuum pump oil
life
60h
–
extensible to max
1000 h with LONG LIFE
UM procedure
Refrigerant
recovery
compressor cubic
capacity
14 cc
Drier filter
Every 150Kg of refrigerant
recovered
Non condensable
gas discharge
Automatic, with
solenoid
valve
H and L taps
Automatic
Safety pressure switch
Type
13/18bar 1/4SAE
Trip pressure
18 bar
ED category
(Dir.2014/68/EU)
IV
neumatic fittings
Net length of
external H and
L hoses
4.5 m
H and L
pressure gauges
Analog 80 mm
, pulse
-
free,
1.0 class
Display
Touch screen
7” TFT colours
Keypad
Touch screen
Software updating
Via Wi
-
Fi
rinter
via Nexusprint software or
via thermal printer
Functions and features
Recovered oil
measurement
Automatic weighing, 1 g
res., 5 g acc.
New oil automatic
charge
With automatic scale, 1 g
res., 5g acc.
UV dye automatic
charge
Timed
Electric
compressor
function
With integrated flushing
function
Flushing
Flushing available with
external accessory (option)
Database
Complete
electronic (cars
and industrial vehicles only)
AC erformance
Test
Manual and automatic
Recovered oil
measurement
Automatic weighing, 1 g
res., 5 g acc.
Sound level
< 70 dB (A)
Battery type for
internal Real time
clock
Lithium CR
-
2032 3V
180mAh 3g.
Overall dimensions
WxDxH
700 x 750 x 1100 mm
Loadless weight
about 85 kg
ower supply
Frequency
50 Hz
Voltage
230 V ~
ower
800 W
rotection
Thermal
Installation
category
II
Environmental conditions
Operating
temperature
10
-
50°C
Humidity
10
-
90%
R.H. (non
condensing)
Ambient pressure
75 k a until 106 k a

©MAHLE
6 Installation
6.1 Equipment installation
6.1.1 Unpacking
Warning –
Risk of personal injury! Incorrect
handling could cause equipment to overturn.
RISK OF OVERTURNING
The manufacturer
disclaims all responsibility for damage
to objects and/or persons resulting from the equipment
being wrongly removed from the pallet, or from the
operation being made by unsuitable personnel, with
improper means/protections and without complying with
the e
xisting laws on manual handling of loads and with
the operations described in this manual.
Remove the metal
staples for wood
and open the
carton box
Remove the cap
and carton box
Cut the plastic straps that connect unit
to the pallet
Remove the packaging of the unit.

Remove the equipment from the pallet (operators are
required)

Keep the pallet, carton and scratch protection film for use
when returning the unit. The unit
rolls on wheels; the two
front wheels can be locked.
A/C service station is supplied with the internal refrigerant
tank empty. This prevents problems in shipping
the unit
| AIR
-
Risk of personal injury! Incorrect
disclaims all responsibility for damage
to objects and/or persons resulting from the equipment
being wrongly removed from the pallet, or from the
operation being made by unsuitable personnel, with
improper means/protections and without complying with
xisting laws on manual handling of loads and with
Remove the equipment from the pallet (operators are
Keep the pallet, carton and scratch protection film for use
rolls on wheels; the two
A/C service station is supplied with the internal refrigerant
the unit
.
REFRIGERANT SCALE SCREW RELEASE
The unit is transported, with the scale blocked by a locking screw to
avoid damaging the load cell.
The scale locking screw is placed on
the equipment bottom side (see the box shown above) and is
formed by a bolt.
For commissioning, unscrew the screw.
7 Commissioning
7.1 Connections
The unit has to be positioned on a horizontal surface to ensure the
correct operation.
The unit has to be connected to the electric mains following
instructions on the identification plate of the unit applied next to the
main switch, mainly as to applicable voltage and power.
The A/C service stations
are designed for
Follow the information on the rating plate.
7.1.1
Positioning and connection
HANDLING:
During handling, the minimum devices required
for correct handling shall be ensured, as provided for by
accident prevention provisions.
OSITIONING:
lace
the unit in a stable place. The location
must be well ventilated, with a good rate of change of air.
The unit must be located at least 10 cm from any potential
obstacles to its internal ventilation.
rain and excessive humidity as t
hey can irreparably damage
it.
In addition, the equipment must never be directly exposed
to the sunrays or to excessive dust.
INSTALLATION:
the unit must be installed by a specialized
technician in scrupulous observance of in accordance with
electrical engineering principles. The use of the equipment in
explosive atmosphere is forbidden.
CONNECTIONS:
since the unit is connected to the main
power supply, it must be properly grounded with its power
plug GND pin. Failure to ground the unit can damage it and
constitutes a risk of fatal injury to the operator. osition the
unit so that the power plug is easy for the operator to
access.
-
NEX 9380/9480 | 11 en
REFRIGERANT SCALE SCREW RELEASE
The unit is transported, with the scale blocked by a locking screw to
The scale locking screw is placed on
the equipment bottom side (see the box shown above) and is
For commissioning, unscrew the screw.
The unit has to be positioned on a horizontal surface to ensure the
The unit has to be connected to the electric mains following
instructions on the identification plate of the unit applied next to the
main switch, mainly as to applicable voltage and power.
are designed for
230VAC, 50Hz.
Follow the information on the rating plate.
Positioning and connection
During handling, the minimum devices required
for correct handling shall be ensured, as provided for by
the unit in a stable place. The location
must be well ventilated, with a good rate of change of air.
The unit must be located at least 10 cm from any potential
obstacles to its internal ventilation.
Keep the unit away from
hey can irreparably damage
In addition, the equipment must never be directly exposed
to the sunrays or to excessive dust.
the unit must be installed by a specialized
technician in scrupulous observance of in accordance with
electrical engineering principles. The use of the equipment in
explosive atmosphere is forbidden.
since the unit is connected to the main
power supply, it must be properly grounded with its power
plug GND pin. Failure to ground the unit can damage it and
constitutes a risk of fatal injury to the operator. osition the
unit so that the power plug is easy for the operator to

Fig. 4: Rear view (detail)
1 ower cord connector and ower switch
2 H &L vehicle connector/couplers and hoses
ATTENTION:
Leave the quick coupling taps closed
when the unit is not in use and at the end of vehicle
service operations.
7.2 Software update
It is possible to check for software updates via Wi-
Fi and
download them inside the
•Main Menu
oSetup
Updates Check
7.3 Initial verification
Execute the following actions in sequence by following the
display guided procedure and the illustrations
on the screen
of the equipment:
•Gas weight verification
•Oil weight verification
•First vessel filling
It is possible to interrupt the initial verification, the station
will propose at next powering to continue.
The equipment cannot operate until all the ste
ps of the
initial verification have been completed.
CAREFULLY ABIDE BY THE
FOLLOWING INSTRUCTIONS TO
AVOID DANGER TO ERSONS, THE
DISCHARGE OF REFRIGERANT IN
THE ATMOS HERE
Let us consider as first filling the one carried out during the
initial check with internal tank of the equipment free of
refrigerant and containing air.
2
1
| AIR-
NEX 9380/9480
Leave the quick coupling taps closed
when the unit is not in use and at the end of vehicle
Fi and
Execute the following actions in sequence by following the
on the screen
It is possible to interrupt the initial verification, the station
ps of the
Let us consider as first filling the one carried out during the
initial check with internal tank of the equipment free of
Set the quantity of refrigerant to fill (at least 3 kg) and follow the
guided procedure shown on the display.
Check that the equipment hoses are not connected and pos
in the hose winder. Start the procedure that initially implies the
creation of vacuum in the internal tank. This phase will take 15
minutes and will act on the whole equipment.
Only when the message appears asking to connect the charge tank,
conne
ct the L quick coupler (colour blue) of the unit to an external
refrigerant tank using the supplied adaptor.
When the message occurs open the coupler by turning the knob
clockwise. Open the valve on the external tank.
Just right before reaching the planne
d quantity of refrigerant, the
unit will stop and ask the user to close the external refrigerant tank.
Then, the device will continue the recovery from the hoses and ends
when these are empty. Hence, it is necessary to open the L quick
coupler and disconn
ect it from the external tank.
Thanks to the ECO LOCK® function, the refrigerant
between the cylinder fitting and the hose quick
of the process -
will not be released in the environment.
There may be two types of sour
ce tanks: with plunger and without
plunger.
Tanks with plunger
shall remain upright to be able to transfer liquid
refrigerant; for this type of tanks connect to the L (liquid) coupler.
Tanks without plunger
have only one valve, so they must be turned
upsid
e down to transfer the liquid refrigerant.
The L
gauge indicates the pressure inside the external tank.
After some minutes the unit will automatically end the function.
At the end the weight of the charged refrigerant will be displayed.
7.4 New PAG and
POE oil bottles filling
To fill the new oil bottles (Fig.1 os. 9) they have to be extracted
from their housing by means of the quick coupler on the top of the
bottle; slightly press downward the coupler ring nut to extract it.
Fill the
bottle by paying special attention to the “oil care” system.
•
During the oil suction phase, before entering the bottle air is
made dry as it passes through a path of special desiccant”
material.
•
The air inside the bottle is therefore completely dry”
NEX 9380/9480
|12 en
Set the quantity of refrigerant to fill (at least 3 kg) and follow the
Check that the equipment hoses are not connected and pos
itioned
in the hose winder. Start the procedure that initially implies the
creation of vacuum in the internal tank. This phase will take 15
minutes and will act on the whole equipment.
Only when the message appears asking to connect the charge tank,
ct the L quick coupler (colour blue) of the unit to an external
refrigerant tank using the supplied adaptor.
When the message occurs open the coupler by turning the knob
clockwise. Open the valve on the external tank.
d quantity of refrigerant, the
unit will stop and ask the user to close the external refrigerant tank.
Then, the device will continue the recovery from the hoses and ends
when these are empty. Hence, it is necessary to open the L quick
-
ect it from the external tank.
Thanks to the ECO LOCK® function, the refrigerant
- usually kept
between the cylinder fitting and the hose quick
-coupler until the end
will not be released in the environment.
ce tanks: with plunger and without
shall remain upright to be able to transfer liquid
refrigerant; for this type of tanks connect to the L (liquid) coupler.
have only one valve, so they must be turned
e down to transfer the liquid refrigerant.
gauge indicates the pressure inside the external tank.
After some minutes the unit will automatically end the function.
At the end the weight of the charged refrigerant will be displayed.
POE oil bottles filling
To fill the new oil bottles (Fig.1 os. 9) they have to be extracted
from their housing by means of the quick coupler on the top of the
bottle; slightly press downward the coupler ring nut to extract it.
bottle by paying special attention to the “oil care” system.
During the oil suction phase, before entering the bottle air is
made dry as it passes through a path of special desiccant”
The air inside the bottle is therefore completely dry”

| AIR-NEX 9380/9480 | 13 en
©MAHLE
After filling, close the bottle and place it back in its seat.
7.5 UV dye bottle filling
The UV Dye is a substance made up of a yellow-green
coloured fluorescent pigment, which means that, when lit by
an ultraviolet lamp, it becomes fluorescent and thus visible.
The UV dye can therefore be used to detect leaks of a small
entity inside the auto vehicle A/C system.
To fill the UV dye bottle (Fig.1 os. 9) it has to be extracted
from its housing by means of the quick coupler on the top
of the bottle; slightly press downward the coupler ring nut
to extract it.
standard UV Dye UV Dye for Hybrid
Note UV Dye for Hybrid bottle – for use with electric
compressor A/C system
Fill the bottle by paying special attention to the “oil care”
system.
•During the oil suction phase, before entering the bottle
air is made dry as it passes through a path of special
desiccant” material.
•The air inside the bottle is therefore completely dry”
After filling, close the bottle and place it back in its seat.

| AIR-NEX 9380/9480 | 14 en
8 Setup
From the SETU menu it is possible to select parameters
and activations before starting cycle:
Wi-Fi
•by selecting this entry, the user may check and select
the Wi-Fi networks available and connect the station
via Wi-Fi.
RINT
•by selecting this entry, the user can select the print
options, such as:
 Start print queue;
 Delete print queue;
 How to print (instructions);
 rint test.
To print are available two printing modes are
available: using the printer of the station if
available or, for all models, via Wi-Fi using the
printer software named Nexus rint to be installed on C
with Windows 7 or later.
U DATE
•by selecting this entry, the user may check if software
updates are available and download them. Updates
Check starts with this icon
BRIGHTNESS
•by selecting this entry, the user can modify the
brightness of touchscreen display and Status Led.
MAINTENANCE COUNTERS
•by selecting this entry, the user may check the status of
station counters and consumables counters.
ACCOUNT
•by selecting this entry, the user can fill in the garage
data to be printed at the bottom of the cycle report.
LANGUAGE
•by selecting this entry, any language present in the
database may be set. In case you choose a language
with unintelligible characters: switch off the equipment,
press and hold the touch screen while switching on the
equipment, you will be directed to the language setting
menu.
RESOLVE
•by selecting this entry, the user can connect the station
to the server via Wi-Fi to allow remote control service
session by the dealer. The system will give an ID
number and a IN code to give to dealer.
SYSTEM INFORMATION
•selecting this entry, the user can check the station
data.
DATE AND TIME
•selecting this entry, the user can change and save the date and
time.
NOTIFICATIONS
•by selecting this entry, the user can check the notifications
received by reseller for A/C service station.
LICENSES
•by selecting this entry, the user can check the licenses enabled
on the station.
SETTINGS
•selecting this entry, the user can enable specific functions (e.g.
Refrigerant analysis).
CREDITS
•by selecting this entry, the user can read the terms of the
licenses of the software.
MAHLE reserves the right to add new parameters to make
the equipment increasingly versatile and adaptable to
market’s needs.

©MAHLE
9 Service Menu
To carry out
calibration the service kit (tooling set)
described at chapter 10 is required.
9.1
Manual activations and analogue
channel view
From the SECURED
SERVICE menu, (insert the password
“BRN”), select
MANUAL ACTIVATIONS and press START,
insert the password “BRN”, press
RETURN and then enter
OK.
This submenu allows controlling the actuators and displays
all measurements.
Fig. 15: Manual activations screen
As shown in the picture the activated actuators are
highlighted with green background colour
. If deactivated
the colour is red.
The corresponding chart can be found in the
A ENDIX
At the bottom you can select the following functions:
•neumatic schema
•
Screen rotation (useful if the front door is open)
•Close menu (red square)
Manual Activation
Key
(in bold the names
used in this manual)
Actuators of
the neumatic
Schema (see
A ENDIX 1)
ower Board
Output
(see
A ENDIX
OUT A
A1, A2
OUT A
OUT R
R1, R2
OUT R
OUT L
L1
OUT L1
OUT T
T1
OUT T1
OUT S
S
OUT S
OUT I
I
OUT I
OUT N
N
OUT N
OUT
V1
V1, V2, V
OUT V
OUT C
C
OUT C
OUT L2
L2
OUT L2
OUT H
H
OUT H
OUT T2
T2
OUT T2
OUT X
Not Used
OUT X
| AIR
-
calibration the service kit (tooling set)
Manual activations and analogue
SERVICE menu, (insert the password
MANUAL ACTIVATIONS and press START,
RETURN and then enter
This submenu allows controlling the actuators and displays
. If deactivated
A ENDIX
.
At the bottom you can select the following functions:
Screen rotation (useful if the front door is open)
ower Board
(see
A ENDIX
4)
9.2 Pressures
calibration (service kit)
From the SECURED
SERVICE menu, (insert the password “
select RESSURE CALIBRATION
and press START
messages, and enter OK to confirm.
Disconnect the L and H quick couplers from any A/C system and
press enter OK.
Wait
some minutes until the sentence “Emptying hoses” disappears.
Then the message asks to
connect to L hose the
adapter
(alone, not connected to the bottle)
station accessories kit; when the next message is displayed,.
Fig. 16: LP quick coupler opening
Turn the L
quick coupler clockwise to open it and press enter OK
so that air gets into the L hose
Wait for the message to connect the reference gauge contained in
the service kit
and, by rotating L counter clockwise, close and
remove the bottle fitting adapter.
WARNING:
BE SURE BEFORE TO CONFIRM, THAT BOTTLE FITTING
ADA TER HAS BEEN
REMOVED FROM L QUICK COU LER.
Connect to H coupler the reference
gauge present in the SERVICE
KIT, open the H
quick coupler by rotating it clockwise and press
enter OK.
WARNING:
ATTENTION NOT TO OINT THE
REFERENCE
ONESELF OR OTHER
EO LE UNTIL ONE HAS THE ABSOLUTE
CERTAINTY THAT THE
CONNECTION WITH THE QUICK COU LER
IS SAFE.
O EN THE TA OF THE QUICK COU LER BY OINTING THE
GAUGE TOWARDS THE GROUND, ALWAYS KEE THE GAUGE
TOWARDS THE GROUND EXCE T WHEN THE GUIDED
ROCEDURE REQUIRE
S ENTERING THE VALUE DIS LAYED ON
THE SAM LE GAUGE.
Fig. 17: Reference gauge connection
Fig. 18
:
-
NEX 9380/9480 | 15 en
calibration (service kit)
SERVICE menu, (insert the password “
BRN”),
and press START
, read the
Disconnect the L and H quick couplers from any A/C system and
some minutes until the sentence “Emptying hoses” disappears.
connect to L hose the
bottle fitting
(alone, not connected to the bottle)
, included in the ACX
station accessories kit; when the next message is displayed,.
quick coupler clockwise to open it and press enter OK
Wait for the message to connect the reference gauge contained in
and, by rotating L counter clockwise, close and
BE SURE BEFORE TO CONFIRM, THAT BOTTLE FITTING
REMOVED FROM L QUICK COU LER.
gauge present in the SERVICE
quick coupler by rotating it clockwise and press
REFERENCE
GAUGE TOWARDS
EO LE UNTIL ONE HAS THE ABSOLUTE
CONNECTION WITH THE QUICK COU LER
O EN THE TA OF THE QUICK COU LER BY OINTING THE
GAUGE TOWARDS THE GROUND, ALWAYS KEE THE GAUGE
TOWARDS THE GROUND EXCE T WHEN THE GUIDED
S ENTERING THE VALUE DIS LAYED ON
:
Reference gauge reading

| AIR-NEX 9380/9480 | 16 en
Measure the pressure reached by the reference gauge and,
insert the value on the screen of ACX unit when required by
software and press enter OK.
Subsequently the equipment will execute the vacuum, at
the end of which one will be asked to check that the gauge
reaches -1 bar, when requested by the guided procedure
press enter OK to confirm calibration.
9.3 OOB Pressures calibration (service
kit)
This function is possible to do only before to carry out the
First Vessel Filling (before to fill refrigerant) if the station
showed problems on the pressure measures.
From the SECURED SERVICE menu, (insert the password
“BRN”), select OOB RESSURE CALIBRATION and press
START, read the messages, and enter OK to confirm.
Disconnect the L and H quick couplers from any A/C
system and press enter OK.
Then the message asks to connect to L hose the bottle
fitting adapter (alone, not connected to the bottle), included
in the ACX station accessories kit; when the next message
is displayed.
Fig. 16: LP quick coupler opening
Turn the L quick coupler clockwise to open it and press
enter OK so that air gets into the L hose.
Wait for the message to connect the reference gauge
contained in the service kit and, by rotating L counter
clockwise, close and remove the bottle fitting adapter.
WARNING:
BE SURE BEFORE TO CONFIRM, THAT BOTTLE FITTING
ADA TER HAS BEEN REMOVED FROM L QUICK
COU LER.
Subsequently the equipment will execute the vacuum, at
the end of which one will be asked to check that the gauge
reaches -1 bar, when requested by the guided procedure
press enter OK to confirm calibration.
9.4 Gas weight calibration
From the SECURED SERVICE menu, (insert the password “BRN”),
Select the “Gas Weight calibration” follow the instruction on the screen.
The reference weight need to be ≥ 4 kg max 22 kg (advised from 8 to
20 kg) to be placed on the arm connected above the load cell.
Fig. 14: cylinder
disconnected
Disconnect the vessel from
the scale.
Lift it and insert the spacer
under the vessel/cylinder
Fig. 15: cylinder re
-
connected with
arm
Re-connect the vessel/cylinder to
the scale. Insert the arm below the
vessel/cylinder.
Fig. 16: Reference weight on the arm
lace the reference weight on the top of the arm (i.e. 5 kg on
drawing above)

| AIR-NEX 9380/9480 | 17 en
©MAHLE
9.5 Oil weight calibration
From the SECURED SERVICE menu, (insert the password
“BRN”), select the OIL WEIGHT CALIBRATION.
Remove the exhausted oil container from the equipment
and press ”OK” to acquire the signal zero of the load cell.
•Insert a reference weight (200g – 400g) in the new
oil ( AG) fitting and set its value.
•Insert a reference weight (200g – 400g) in the new
oil ( OE) fitting and set its value.
•Insert a reference weight (200g – 400g) in the used
oil fitting and set its value.
•Insert a reference weight (200g – 400g) in the UV
Dye fitting set and set its value..
Fig. 19: Reference weight insertion
Remove the oil sample weights and insert the empty
containers and procede.
When required by the guided procedure, confirm the
calibration.
9.6 Spare parts & consumables
From the SECURED SERVICE menu, (insert the password
“BRN”), Select the “Spare parts & consumables”
In this menu is possible to watch the counters of spare parts
replaced and consumables used, managed by software (it is
not possible to reset the counters).
10 Equipment and simulator
The following equipment is required:
ACX SERVICE KIT
•Oil calibration reference weights
•ressure reference gauge
•fittings for L /H coupler
An iron ≥4 kg reference weight is necessary for “gas weight
calibration” (this is not included inside the ACX service kit).
11 Refrigerant fluid circuit
11.1 Refrigerant fluid circuit
For components and circuit layout ref. A ENDIX 1 -
REFRIGERANT FLUID CIRCUIT.
11.2 Operational cycles
For components and circuit layout ref. A ENDIX 2 –
O ERATIONAL CYCLES.
11.3 Receiving tank (refrigerant cylinder)
The tank is the component which determines the category
of the entire equipment according to the ED directive.
The ED “ ressure Equipment Directive” 2014/68/EU
defines and regulates all those parts that are subject to
pressure, with a specific ratio between their pressure and volume.
Safety against the risk due to pressure of the refrigerant fluid inside
the receiving tank is assigned to the safety valve installed during
manufacturing. In case of replacement, use of new and original
spare parts not contaminated with other substances is
recommended as well as requesting the relative declaration of
conformity proving the effective test of the components in the
beginning.
The assistance centre assumes responsibility for workmanlike
assembly and for checking before new commissioning according to
the prescriptions provided for by the regulations in force in the
country of use; in particular, the assistance centre will have to
guarantee that the assembly will ensure a perfect tightness and that
the safety components are installed appropriately so as to ensure
operation is not jeopardized.
VESSEL 20l
Category III (Dir. 2014/68/EU)
Fig. 20: Refrigerant internal bottle
SAFETY VALVE GAS AIRTEK - VS14N T20HNBR ED4
S 20 bar R 1/4 N T - Category IV (Dir. 2014/68/EU)

11.4 Manifold charts
The manifold chart, where the identification letters of the
sectioning valves are highlighted, and
reported as follows:
•V = vacuum;
•A = refrigerant recovery;
•
I = interception (H side and L side separation);
•R = refrigerant recharge
•L1 = New oil injection AG
•L2 = New oil injection OE
•T1 = tracer UV dye injection 1 AG
•T2 = tracer UV dye injection 2 OE
The pressure sensors are highlighted, and reported as
follows:
•T = tank - pressure sensor
•L = Low ressure - pressure sensor
•H = High ressure - pressure sensor
The valves (V, A, R
) which must control the gas flow in both
directions must necessarily be double since the single valve
is not able to guarantee bidirectional closure.
Notes regarding operator safety:
Attention: presence of dangerous
230 VAC voltage on the
solenoid valve terminals and near the manifold; disconnect
the equipment from the mains before each maintenance
intervention.
Attention: presence of refrigerant fluid under pressure, in
case of disassembly of manifold or its compone
nts ensure
that the tank is closed, the connection pipe between the
tank and the manifold is empty, the L and H connectors
are disconnected from any system and closed, that a pipe
emptying operation has been made, and the manifold has
been completely emptied.
Fig. 21: Manifold components
NOTE: on the manifold drawing above the position of the
pressure sensors is reported only with a labels
and the
arrows.
PSLP
PSTP
PSHP
| AIR-
NEX 9380/9480
The manifold chart, where the identification letters of the
reported as follows:
I = interception (H side and L side separation);
The pressure sensors are highlighted, and reported as
) which must control the gas flow in both
directions must necessarily be double since the single valve
230 VAC voltage on the
solenoid valve terminals and near the manifold; disconnect
the equipment from the mains before each maintenance
Attention: presence of refrigerant fluid under pressure, in
nts ensure
that the tank is closed, the connection pipe between the
tank and the manifold is empty, the L and H connectors
are disconnected from any system and closed, that a pipe
emptying operation has been made, and the manifold has
NOTE: on the manifold drawing above the position of the
and the
Fig. 22: Manifold circuit
Fig. 23: Manifold valves
Fig. 24: Manifold
with pressure sensors installed.
V
A
I
V A I
T1
T1
A
V
PS
HP
PS
LP
One-
way
valve
V A I
T1
A
V
PS HP
PS LP
NEX 9380/9480
|18 en
with pressure sensors installed.
R
L1
V A I
L2
R
L1
R
PS
TP
way
valve
L2
L2
R
L1
R
PS TP
T2
T2

©MAHLE
11.5 Suction circuit components
The suction circuit is a group made up of various
pressurised equipment connected through hoses and/or
brazed piping.
A routine maintenance operation is the replacement of the
dryer filter, the procedure of which is outlined in the user
manual.
Safety against the risk due to pressure of the refrigerant
fluid inside the suction unit is ensured by a safety
pr
switch and a thermal fuse both
installed during
manufacturing.
In case of replacement of
one of these safety devices
new and original spare parts.
The assistance centre is responsible for workmanlike
assembly and for checking before new commissi
according to the prescriptions provided for by the
regulations in force in the country of use; in particular, the
assistance centre will have to guarantee that the
components ensure a perfect tightness and that the safety
components are installed app
ropriately so as to ensure
operation is not jeopardized.
Fig. 25: Suction circuit position
RESSURE SWITCH ACB-2UB949W o ACB-
2UB1145W
13/18bar 1/4SAE Category IV (Dir. 2014/68/EU)
Pressure Safety Switch
(on the red circle)
| AIR
-
The suction circuit is a group made up of various
pressurised equipment connected through hoses and/or
A routine maintenance operation is the replacement of the
dryer filter, the procedure of which is outlined in the user
Safety against the risk due to pressure of the refrigerant
pr
essure
installed during
one of these safety devices
use
The assistance centre is responsible for workmanlike
assembly and for checking before new commissi
oning
according to the prescriptions provided for by the
regulations in force in the country of use; in particular, the
assistance centre will have to guarantee that the
components ensure a perfect tightness and that the safety
ropriately so as to ensure
2UB1145W
12 Non -permanent
junction
Here below some instructions on the use of Loctite® 577 on the
thread of some non-
permanent junctions in the pneumatic circuit of
the ACX stations.
The product polymerizes when air is absent and when in contact
with metal ; its aim is preventing
slackening caused by impacts and
vibrations. Yet, after application and fixing onto the junction/thread,
you must tighten and then wait several hours, in relation to the type
of coupling between metals, before the product can get its
maximum performance in
terms of hold/resistance.
For one’s own and other people’s safety, the operator/user of the
Loctite® 577 product must consider that it must be employed in
well-
ventilated premises and that protecting eyes and hands with
suitable E (personal protective e
quipment) is required. For
compulsory safety provisions to be followed when using the
product, the user shall refer to the safety data sheet of Loctite® 577
manufacturer.
For further details on the product characteristics/performance and
application instru
ctions, please refer to the technical data sheet of
Loctite® 577 manufacturer.
Generally the points of insertion of Loctite® 577 only in one spot
with anti-
rotation purpose are on connection/fittings where there is
not an O-ring/seal, before to apply it c
lean well the surfaces.
13
Electrical connections
The electrical connections are described on the following
A ENDIX:
A ENDIX 3 – AIR-NEX 9380/9480 -
ELECTRICAL CONNECTION
LOGIC ELECTRONIC BOARD
A ENDIX 4 – AIR-NEX 9380/9480 -
ELECTRICAL CONNECTION
OWER ELECTRONIC BOARD AND OWER SU LY
A ENDIX 5 – AIR-NEX 9380/9480 -
ELECTRICAL CONNECTION
STATUS AND WARNING INDICATOR LIGHT ELECTRONIC BOARD
-
NEX 9380/9480 | 19 en
junction
Here below some instructions on the use of Loctite® 577 on the
permanent junctions in the pneumatic circuit of
The product polymerizes when air is absent and when in contact
slackening caused by impacts and
vibrations. Yet, after application and fixing onto the junction/thread,
you must tighten and then wait several hours, in relation to the type
of coupling between metals, before the product can get its
terms of hold/resistance.
For one’s own and other people’s safety, the operator/user of the
Loctite® 577 product must consider that it must be employed in
ventilated premises and that protecting eyes and hands with
quipment) is required. For
compulsory safety provisions to be followed when using the
product, the user shall refer to the safety data sheet of Loctite® 577
For further details on the product characteristics/performance and
ctions, please refer to the technical data sheet of
Generally the points of insertion of Loctite® 577 only in one spot
rotation purpose are on connection/fittings where there is
lean well the surfaces.
Electrical connections
The electrical connections are described on the following
ELECTRICAL CONNECTION
–
ELECTRICAL CONNECTION
–
OWER ELECTRONIC BOARD AND OWER SU LY
ELECTRICAL CONNECTION
–
STATUS AND WARNING INDICATOR LIGHT ELECTRONIC BOARD

| AIR-NEX 9380/9480 | 20 en
m
m
14 Maintenance
Please contact an authorized technical service
center for purchasing factory replacement parts.
14.1 Maintenance interval
Make sure AIR-NEX 9380/9480 is disconnected from
power before removing plastic housing.
Never perform any maintenance work which is not
expressly recommended in this Section.
Contact customer service if components have to be
replaced other than in the course of maintenance work.
To access MAINTENANCE from the MAIN MENU, press
and s croll to MAINTENANCE and then select.
Fig. 26: Maintenance screens
Only for model AIR-NEX 9380 – “REFRIGERANT TYPE CHANGE”
With this function allows the service assistance technician to change
the Refrigerant Type from R134a to R1234yf with the empting and
cleaning of the A/C service station and with use of a specific
transformation kit.
The operation is protected by password NGAS
Description eriod
Vacuum pump oil replacement
and
syst
em
leak
t
est
As required by software or max.
a
ft
er
1000
hours
of
service
Combo filter replacement and system
leak
t
est
After 150kg of
refrigerant
pr
ocessed
System leak test As required