MSG MS111 User manual

2022.09.08
MS111
TEST BENCH FOR DIAGNOSTICS OF VEHICLE AIR
CONDITIONER COMPRESSORS
USER MANUAL
STANOWISKO DO DIAGNOSTYKI SPRĘŻAREK
KLIMATYZACJI SAMOCHODOWEJ
INSTRUKCJA OBSŁUGI
СТЕНД ДЛЯ ДИАГНОСТИКИ КОМПРЕССОРОВ
АВТОКОНДИЦИОНЕРОВ
РУКОВОДСТВО ПО ЭКСПЛУАТАЦИИ
UNIQUENESS
TRAINING
SERVICE
INNOVATION
WARRANTY
QUALITY

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CONTENTS
INTRODUCTION....................................................................................................................................................
4
1. PURPOSE...........................................................................................................................................................4
2. TECHNICAL CHARACTERISTICS.....................................................................................................................5
3. EQUIPMENT SET ..............................................................................................................................................6
4. TEST BENCH DESCRIPTION...........................................................................................................................7
5. APPROPRIATE USAGE...................................................................................................................................10
5.1. Safety regulations.............................................................................................................................. 11
5.2. Pre-starting procedures...................................................................................................................12
5.2.1. Equipment installation..................................................................................................................12
5.2.2. Test bench filling.............................................................................................................................12
5.2.3. Connection of cables to the test bench terminals.................................................................14
6. TEST BENCH MAINTENANCE........................................................................................................................14
6.1. Cleaning and care ..............................................................................................................................15
6.2. Condensate draining.........................................................................................................................15
6.3. Replacement of filters in the test bench hydraulic system....................................................16
6.4. Firmware update................................................................................................................................19
7. TROUBLESHOOTING GUIDE........................................................................................................................ 20
8. RECYCLING.....................................................................................................................................................22
CONTACTS...........................................................................................................................................................23

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INTRODUCTION
Thank you for choosing the product of MSG equipment.
The actual manual contains information on the test bench purpose, package contents, design,
technical characteristics, and safe operation rules.
Read carefully this manual before putting MS111 (hereinafter “the test bench”) into operation,
take special training at the equipment manufacturing facility if necessary.
As the test bench is being continuously improved, some changes made to the equipment design,
package set, or firmware may not be reflected in this user manual. The test bench firmware is
updateable, so its maintenance can be terminated without prior notice to users.
WARNING! The actual user manual does not contain information on how to diagnose
alternators with the test bench. Follow the link MS111 Operation Manual or scan the QR-code to
find this information.
1. PURPOSE
Test Bench MS111 is used for diagnostics of the piston, axial piston, rotor, and scroll compressors
if vehicle climate systems on R134a or R1234yf.
The Test Bench performs the following operations:
• Diagnostics of all types of 12/24V compressors of belt-driven vehicle air conditioners in both
automatic and manual modes;
• Check of electromagnetic clutches and control valves for short circuit, open circuit, and the
presence of a diode both in assembly with a compressor and separately from it;
• Post-maintenance run of compressors;
• Pre-sale checks of new compressors-analogs;
• Test report generation and printout (any external printer can be used).

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2. TECHNICAL CHARACTERSISTICS
Main
Supply voltage, V
400
Supply type
Three-phase
Drive power, kW
5.5
Dimensions (L x W x H), mm
900×570×1280
Weight, kg
183
Utilized refrigerant
R134a, R1234yf
Refrigerant filtration
Yes (1 µm2)
Amount of refrigerant in the system, g
R134a – 1100
R1234yf – 1050
Test bench filling
Stand-alone filling station
Type of filling fittings
Automotive HP and LP
Utilized oil
PAG46yf
Amount of oil in the system, g
200
Compressor testing
Rated voltage of the diagnosed units, V
12, 24
Drive speed, rpm
From 0 to 3000
Drive speed adjustment
Smooth / gradual
Drive type
Belt
V-belt / poly-V belt
Vacuum line of the unit
Yes
Refrigerant pumping out of the unit
Yes
Output parameters
HP, bar;
LP, bar;
Compr t, °С;
Evpr t, °С;
PWM %.

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Additional features
Test results printout
Available
Firmware update
Available
Diagnostics results storage
Available
Connection of external devices
2 x USB 2.0
Internet connection
Ethernet, Wi-Fi (802.11 a/b/g/ac)
3. EQUIPMENT SET
Test Bench set includes:
Item name
Number of
pcs
Test Bench MSG MS111
1
MS122 – Adapter for connecting compressors with 24V clutch
1
Set of two quick-disconnect hoses
1
MS0101 – polypropylene filter element
2
MS0102 – filter element of electromagnetic valve
2
Set of fittings to connect the compressor to the test bench
1
Clamping plates
3
MS0103 – rubber ring gasket O-02289 for sealing of interlocking parts of filter
case 4
Set of cables for connection to the electromagnetic clutch and valve
1
Test Bench door key
1
Wi-Fi module
1
Power socket 400V
1
User Manual (card with QR code)
1

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4. TEST BENCH DESCRIPTION
The test bench consists of the following major components (Fig.1): test bench housing - 1; door for
access to the power compartment - 2; mounting face - 3; control panel - 4; door for access to the
service compartment - 5; swivel wheels with a brake - 6.
Figure 1 – Major components of the Test Bench
All diagnostic procedures with the tested unit are performed on the mounting face. The mounting
face contains:
1 – Compressor drive belts: V-belt and Poly-V belt.
2 – Compressor fixing chain.
3 – Dust cover. The diagnostic procedure is suspended when the cover is opened.
4 – Compressor temperature sensor.
5 – Connecting fitting for low-pressure hose.
6 – Connecting fitting for high-pressure hose.
7 – Compressor control valve connection terminals. Adherence to polarity is not necessary.
8 – Compressor electromagnetic clutch connection terminals. Adherence to polarity is not
necessary.
6
1
5
2
4
3

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Figure 2 – Mounting face of the Test Bench
Control panel (Fig.3) includes the following elements:
Figure 3 – Control panel of the Test Bench
1 – LP valve: low-pressure hose control.
2 – Start button “OFF/ON”: Test Bench power on/off. Button “OFF/ON” cannot be activated when
button “EMERGENCY STOP” is pressed.
3 – Touch screen: diagnostic data display and test bench control.
4 – Button “EMERGENCY STOP”: emergency shutdown.
5 – HP valve: high-pressure hose control.
1
8
2
7
4 5 6
3
5
1
4
2
3

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The back panel of the test bench (Fig.4) is equipped with a LAN port to connect the Test Bench to
the Ethernet and two USB ports to connect the Wi-Fi adapter (included in the equipment set) and
external printer.
Figure 4 –Back panel of the Test Bench
The routine maintenance of the Test Bench is
essential for trouble-free enduring operation of the
equipment. A service compartment of the bench
(Fig.5) includes:
1 – Vacuum pump.
2 – Condensate tank.
3 – Electromagnetic valve filters.
4 – Main filter of the test bench hydraulic system.
5 – LP and HP filling fittings.
6 – Compressor for refrigerant pumping.
Figure 5 – Service compartment of
the Test Bench
1
2

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5. APPROPRIATE USAGE
1. Use the test bench as intended only (read Section 1).
WARNING! The Test Bench operates on refrigerants either R134a or R1234yf. It is strongly
recommended not to use other refrigerants. Oil PAG46yf must be used for thesystems on R1234yf
and R134a.
2. Turning off the bench should be done through the interface of the service program by pressing
the "Turn off the bench" button.
3. Use the button «EMERGENCY STOP» only if necessary to stop the diagnostic process in an
emergency.
4. The accuracy of the compressor test depends on the amount of refrigerant in the test bench.
Observe standard filling rate.
5. The refrigerant leak occurs every time after the replacement of a tested unit. Refrigerant
deficiency in the system leads to inaccurate test results and may cause damage to the tested unit.
Evacuate refrigerant from the system at the end of the working day and fill it in before you start.
6. In case compressor sealing gaskets lost their airtightness, air can enter the system during
refrigerant pumping. Air in the system may cause diagnostics inaccuracy and damage to the tested
unit.
Refill the system after the message “Too much air in the system” appears on the screen.
7. Automatic test mode is intended for the initial assessment of compressor performance and
cannot be used for detection of such latent faults as, for example, sporadic sticking of a control
valve and some others.
If any malfunction is detected during automatic testing, proceed with a manual test for accurate
diagnostics of a unit.
8. During compressor diagnostics, wear particles normally retained by the test bench filters, can
penetrate the system. These filters require periodic replacement. The test bench will signal the
necessity for filter replacement.
Do not test compressors with obvious symptoms of malfunction. For example, the oil in a
compressor is black and has metal shavings in it.
9. The use of inappropriate computer hardware or firmware will cause cancellation of the warranty
(even if the computer facilities or programs were removed or deleted shortly after). Only the MSG
Equipment original firmware can be used with this equipment.
10. To prevent the damage and the failure of the bench, do not make any modifications in the
bench in your discretion. Any modifications can be effected by the official manufacturer only.
Should the bench have defects contact the manufacturer or a dealer.
11. In case of failures in the operation of the bench, stop further operation and contact the
manufacturer or sales representative.

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The manufacturer is not responsible for any damage or injury to human health resulting from
non-compliance with the requirements of this user manual.
5.1. Safety regulations
1. The Test Bench should only be used by the persons qualified to operate the test benches of
certain types who received a special training in the equipment safety operation.
2. Before the unit dismounting from the test bench, the refrigerant should be evacuated.
3. Before starting any maintenance work on the bench, disconnect it from the electrical network.
4. The workplace should be clean, well-lit and spacious.
5. The use of the faulty or unearthed Test Bench is strictly prohibited.
6. The compressor mounting and/or dismounting should be conducted carefully to prevent its
fall.
7. The unit with the running drive may not be left on the test bench unattended.
8. It is strictly forbidden to open the door of the power compartment (n. 2, Fig.1) when the test
bench is connected to 400V power supply.
9. Avoid body contact with the refrigerant, it may lead to a frostbite (R134a boiling point is -26°С,
R1234yf boiling point is -30°С).
10. It is strongly recommended to use protective gloves and glasses.
11. Any refrigerant is a colorless and odorless gas which is heavier than air. Entering the
atmosphere, it can cause asphyxiation or heart rhythm disorders. That is why, the Test Bench
should be used in well-ventilated premises only. The available exhaust units in the room must be
switched on.
12. Refrigerant R-1234yf is a highly flammable gas. Take extra care when working with this
refrigerant.
13. Open flame sources are allowed nowhere near the test bench operating area. Smoking near
the Test Bench is prohibited. A regular fire-extinguishing appliance is a must.
14. If the protective caps of the filling fittings cannot be easily unscrewed, there is a risk of injury
due to the valves poor tightness.

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5.2. Preparation of the Test Bench for use
5.2.1. Placement location and installation
The bench is delivered packed. Release the bench from the packaging materials, remove the
protective film from the display (if available). After unpacking, it is necessary to make sure that
the bench is intact and does not have any damage. If damage is detected before the bench is
activated, contact the manufacturer or the sales representative.
The bench has to be placed on the level floor, with the pivot wheels fixed from rotating (min. two
wheels) by the activating of the brake mechanism.
The bench ensures the operation at the temperature from +18°C up to +38°C and relative air
humidity from 10% up to 75%.
When installing the bench, keep the minimum space gap 0.5 m from the rear bench side - for a
proper air circulation.
Considering that the Test Bench components are exposed to heating during operation, the
working room should be well-ventilated. To ensure a free circulation of air, it is necessary to
provide the airspace of no less than 0.5m behind the back panel of the bench and 0.3m on either
side of it. Don’t block the air flow behind the Test Bench.
5.2.2. Refilling of the Test Bench
The Test Bench is delivered to a customer charged with refrigerant R134a for 10-15% and with a
full charge of oil. To ensure the Test Bench performance, it is necessary to fill the hydraulic system
up to the standard level. The required amount of the refrigerant is specified in the chart “Technical
characteristics” (Item 2 of the Manual).
WARNING! Refilling of the Test Bench directly from a container with the refrigerant is strictly
prohibited as it can lead to emergency situations.
WARNING! Use specialized equipment for evacuation and purification of the refrigerant R134a
and system refilling. Observe the instructions set out in the corresponding User Manual.

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Refilling of the hydraulic system with the refrigerant should be performed as follows:
1. Open the door of the service compartment (n.5, Fig.1) with a special key (included in the
equipment set).
2. There are two fittings for refilling of the test bench hydraulic system: «Service LP» and «Service
HP» (n.5, Fig.5).
3. Connect the filling station lines to the test bench fittings. High-pressure and low-pressure
valves (n.1,5, Fig. 3) located on the control panel (Fig.3) should be in the closed position (OFF).
4. Pump the refrigerant out of the hydraulic system.
WARNING! It is necessary to control the amount of oil released together with the refrigerant
since the same amount of it should be added when refilling.
5. Dehydrate the system to remove the air and moisture residues. To do this, take the filling station
off into the air pumping mode. Stop pumping on reaching the pressure of -0.9 Bar.
6. Upon the vacuuming procedure completion, non-condensable impurities must be removed
from the filling station in the following manner:
6.1. Disconnect the filling station line from the Test Bench.
6.2. Remove the non-condensed impurities through a special valve (Fig.6) as prescribed in the
corresponding Manual for the filling station.
Figure 6 – Discharge valve of the filling station
7. Connect the lines of the filling station to the Test Bench. Fill the bench with the necessary
amount of the refrigerant and oil.

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8. Upon completion, disconnect the filling station lines. Place protective caps on the fittings for
better tightness. Close the door of the service compartment with a special key.
WARNING! In cases when R1234yf must be used in the Test Bench, the evacuation of R134a
from the system is required. The evacuation time should be extended for 10 min from the rated
time. To fill the bench with refrigerant R1234yf, follow the procedure described in User Manual
for the filling station and the information specified above.
5.2.3. Connection of the cables tothe Test Bench
terminals
To perform the diagnostics and control of the compressor electromagnetic clutch or valve,
connect either Adapter MS122 or the appropriate cables to the test bench terminals as shown in
the connection diagram (Fig.7). Adherence to the electric polarity is not necessary.
Figure 7 – Connection of the cables (Adapter MS122)
to the test bench terminals «Clutch» and «Valve»
6. TEST BENCH MAINTENANCE
The bench is designed for a long period of operation, but for the maximum period of reliable
operation of the bench it is necessary to perform the following works:
• Daily, at the beginning of the working day to fill the bench with coolant and pump it out at the
end of the working day. It is necessary to control the amount of oil in the bench system.
•If the message "Condensate tank full" appears, empty it. The procedure is described in section
6.2.

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• If you see the message «Replace filter» you need to replace the filter 4 fig. 5. The replacement
procedure is described in section 6.3.
• When you see the message «Too much air in the system» you should take the following steps:
1) Refill the refrigerant bench (see sect. 5.2.2).
2) Make sure that the requirements for the placement and installation of the bench are met, see
section 5.2.1.
Error «Too much air in the system» most often appears in cases:
- improper filling of the bench, insufficient or excessive amount of refrigerant;
- refrigerant leakage;
- air entering the system, when diagnosing not hermetic compressors;
- high indoor air temperature.
6.1. Cleaning and Care
Clean the test bench surface with neutral detergents using soft tissues or wiping cloth. Use special
fiber tissue and spray to clean the display. The use of abrasives or solvents may cause failure or
damage to the test bench.
6.2. Condensate draining
Drain the condensate from the tank as follows:
1. Disconnect the bench from the power supply.
2. Open the door of the service compartment (n.5 Fig.1) with a special key (included in the
equipment set).
3. Unscrew the tank cap (n.3, Fig.8).
4. Disconnect the condensate level sensor (n.2 Fig.8).
5. Remove the tank from the test bench by pushing it upward.
6. Empty the tank.
7. Reinstall the tank, reconnect the sensor, put the tank cap on and screw it up.

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Figure 8 – Removal of the condensate tank
1 – tank; 2 – connector of the condensate level sensor; 3 – tank cap
6.3. Replacement of filters in the hydraulic system of the
Test Bench
Observe the actual diagram and Chart 1 for replacement of the filters:
• each message «Replace filter» should be followed by replacement of the right filter element
MS0101 (Fig.9);
• every other replacement of the right filter element MS0101 should be followed by replacement
of the left filter element MS0101;
• every forth replacement of the left filter element MS0101 should be followed by replacement of
both filter elements MS0102 (Fig.13);
Chart 1. Frequency of filter replacements in the Test Bench.
Right MS0101 + + + + + + + + ...
Left MS0101 + + + + ...
Two filters
MS0102
+ ...

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Figure 9 – Direction of filter cover rotation during filter replacement MS0101
WARNING! Since the compression oil is hygroscopic and absorbs moisture from the air, filter
elements MS0101 and MS0102 should be reinstalled as quickly as possible.
The procedure of filter MS0101 (n.4, Fig.5, Fig.9-11) replacement is as follows:
1. Put both valves (HP and LP) in “OFF” position and disconnect the bench from the power supply.
2. Open the service compartment door (n.5, Fig.1) with a special key (included in the equipment
set).
3. Pump the refrigerant out using a special service station for air conditioners.
5. Level the inside pressure of the Test Bench with the atmospheric pressure by pressing the valve
of the filling port. Even a slight pressure difference will make it much more difficult to unscrew
the filter cup.
6. Turn the filter cover (n.1, Fig.10) counter-clockwise (Fig.9) with either a hook wrench or a socket
wrench until the filter bowl is free.
7. Check the condition of O-rings (n.3, Fig.10) and replace if necessary.
8. Replace the filter element MS0101 (n.2 Fig. 10).
9. Reinstall the filter cover and screw it clockwise until tight (see Fig.9).
10. Close the door of the test bench service compartment (n.5 Fig.1).
11. Refill the Test bench with the refrigerant (Item 5.2.2).
SCREW IN
UNSCREW
UNSCREW
SCREW IN
LEFT FILTER
RIGHT FILTER

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Figure 10 – Refrigerant filter structure:
1 – filter cover; 2 – filter element MS0101; 3 – O-rings
Figure 11 – Filter element MS0101
Figure 12 – Filter element MS0102

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It is recommended to replace filter elements MS0102 of electromagnetic valves together with
filter elements MS0101.
Figure 13 – Direction of the cover rotation when replacing filter MS0102
6.4. Firmware update
Being connected to the Internet, with every switching on, the test bench checks for software
updates. In case the bench finds the software update at company server, you’ll be offered to
install the update or disregard it. To start updating, press OK, to decline – SKIP.
WARNING! It’s forbidden to switch off the bench supply to stop the updating.
UNSCREW
SCREW IN
UNSCREW
SCREW IN

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7. TROUBLESHOOTING GUIDE
Below are the potential faults and recovery methods:
Failure symptom Potential cause Troubleshooting tips
1. Test Bench doesn’t
start up.
No connection to the power
supply
Restore the supply voltage
Button «EMERGENCY STOP» is
pressed Turn off the emergency button
Faulty power supply unit Contact the dealer
2. Touch screen doesn’t
respond the operator’s
touch.
Touch screen is damaged Contact the dealer
3. Operating system
doesn’t load.
Operating system failure Contact the dealer
4. Diagnostic program
doesn’t launch.
Operating system failure Contact the dealer
5. Compressor drive
doesn’t start.
Opened protective cover or
opened service compartment
door; full condensate tank
Shut down the protective
cover, close the service
compartment door, drain the
condensate.
The cable short circuit or motor
winding short circuit to the
ground Eliminate short circuit
Low power supply
Make sure that no high- power
consumers with high starting
currents are nearby the Test
Bench