TEXA KONFORT 744 User manual
KONFORT 744
Recharging ang Maintenance
Technical manual
www.elektropartner.com
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SUMMARY
REVISION OF THE MANUAL..................................................................7
INTRODUCTION......................................................................................8
1 GENERAL SAFETY REGULATIONS.................................................9
1.1 Glossary.................................................................................................9
1.2 Operator Safety Regulations..................................................................9
1.2.1 General Safety Regulations........................................................................9
1.2.2 Risk of Asphyxiation...................................................................................9
1.2.3 Risk of Impact and Crushing.......................................................................9
1.2.4 Hazards Caused by Moving Parts............................................................10
1.2.5 Risk of Burning or Scalding......................................................................10
1.2.6 Fire and Explosion Hazard.......................................................................11
1.2.7 Noise Hazard............................................................................................11
1.2.8 High Voltage Hazard.................................................................................11
1.2.9 Poisoning Hazard.....................................................................................12
1.3 General User and Maintenance Warnings...........................................12
2 KONFORT 744 USER SAFETY........................................................13
2.1 Glossary...............................................................................................13
2.2 General Rules......................................................................................13
2.3 Operator Safety....................................................................................14
2.4 Device Safety.......................................................................................14
2.5 Workplace Safety.................................................................................15
2.6 Guidelines for the handling the refrigerants and user safety................15
2.7 Safety Devices.....................................................................................16
3 NORMATIVE INFORMATION...........................................................17
4 OPERATION OF THE TOOL'S RADIO DEVICES............................18
5 KONFORT 744 RECHARGING STATIONS.....................................19
6 DESCRIPTION..................................................................................21
6.1 Front view.............................................................................................21
6.1.1 Top panel..................................................................................................22
6.2 Right Side View....................................................................................22
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6.3 Rear view.............................................................................................23
6.3.1 Containers................................................................................................24
6.4 Left Side View......................................................................................24
7 INSTALLATION.................................................................................25
7.1 Unwrapping the Device........................................................................25
8 SETTING UP BEFORE USING........................................................26
8.1 Scale Locking/unlocking.......................................................................26
8.2 Refrigerant tank housing......................................................................26
8.3 Moving the Device................................................................................32
8.4 Positioning............................................................................................32
8.5 Connection to the Power Mains...........................................................33
8.6 Entering the SD CARD.........................................................................33
8.7 How to Load the Paper into the Printer................................................33
8.8 How to Fill the Bottles...........................................................................34
8.9 Language Setup...................................................................................34
9 START-UP........................................................................................37
9.1 Switching on.........................................................................................37
9.2 Activation..............................................................................................37
10 User Instructions.............................................................................38
10.1 How to Connect to the Vehicle Air Conditioning System....................38
10.2 Visual Warnings.................................................................................38
10.3 Audible Warnings...............................................................................38
10.4 CO2 alarm..........................................................................................38
10.5 How to Use the Software ...................................................................39
10.6 Printer.................................................................................................40
11 STOP..............................................................................................42
11.1 Normal Stop.......................................................................................42
11.2 Emergency Stop.................................................................................42
11.3 Stopping the Equipment for Long Periods..........................................42
12 UPDATING......................................................................................43
13 MAINTENANCE AND CLEANING..................................................44
13.1 Ordinary Maintenance........................................................................44
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13.1.1 How to Replace the Vaccum Pump Oil...................................................45
13.1.2 Replacing the Paper in the Printer..........................................................45
13.2 Periodical Checks...............................................................................45
14 DISPOSAL......................................................................................47
14.1 How to Dispose of the Device............................................................47
14.2 How to Dispose of the Recycled Materials.........................................47
15 TECHNICAL FEATURES................................................................48
16 LEGAL NOTICES............................................................................50
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KONFORT 744 RECHARGING AND MAINTENANCE
STATIONS TECHNICAL MANUAL
REVISION OF THE MANUAL
This document is review 01 of the technical manual for the KONFORT 744
charging stations.
Issue date: 01/09/2016
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INTRODUCTION
Dear Customer,
We would like to thank you for choosing a TEXA product for your workshop.
We are certain that you will get the greatest satisfaction from it and receive a
great deal of help in your work.
Please read through the instructions in this manual carefully and keep it for
future reference.
Reading and understanding the following manual will help you to avoid damage
or personal injury caused by improper use of the product to which it refers.
TEXA S.p.A reserves the right to make any changes deemed necessary to
improve the manual for any technical or marketing requirement; the company
may do so at any time without prior notice.
This product is intended for use by technicians specialized in the automotive
field only. Reading and understanding the information in this manual cannot
replace adequate specialized training in this field.
The sole purpose of the manual is to illustrate the operation of the product sold.
It is not intended to offer technical training of any kind and technicians will
therefore carry out any interventions under their own responsibility and will be
accountable for any damage or personal injury caused by negligence,
carelessness, or inexperience, regardless of the fact that a TEXA S.p.A. tool
has been used based on the information within this manual.
Any additions to this manual, useful in describing the new versions of the
program and new functions associated to it, may be sent to you through our
TEXA technical bulletin service.
This manual should be considered an integral part of the product to which it
refers. In the case it is resold the original buyer is therefore required to forward
the manual to the new owner.
Reproduction, whole or in part, of this manual in any form whatsoever without
written authorization from the producer is strictly forbidden.
The original manual was written in Italian, every other language is a translation
of the original manual.
© copyright and database rights 2016. The material contained in this
document is protected by copyright and database rights. All rights reserved
according to law and international agreements.
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1 GENERAL SAFETY REGULATIONS
1.1 Glossary
•Operator: qualified individual, in charge of using the device/tool.
•Machine/device/tool: the product purchased.
•Workplace: the place where the operator must carry out her/his work.
1.2 Operator Safety Regulations
1.2.1 General Safety Regulations
•Theoperatormustbecompletelyclear-headedandsoberwhenusingthedevice;
taking drugs or alcohol before or when operating the device is strictly forbidden.
•The operator must not smoke during device operation.
•The operator must carefully read all the information and instructions in the
technical documents provided with the device.
•The operator must follow all the instructions provided in the technical documents.
•The operator must always watch over the device during the various operating
phases.
•The operator must make sure she/he is working in environment which is suitable
for the operations that must be carried out.
•The operator must report any faults or potentially hazardous situation in
connection with the workplace or the device.
•The operator must carefully follow the safety regulations required for the
workplace in which she/he is working and required by the operations she/he has
been asked to carry out.
1.2.2 Risk of Asphyxiation
Exhaust gas from internal combustion engines, whether they may be
petrol or diesel, are hazardous to your health and can cause serious
harm to your body.
Safety Precautions:
•The workplace must be equipped with an adeguate ventilation and air extraction
system and must be in compliance with standards according to current national
laws.
•Always activate the air extraction system when working in closed environments.
1.2.3 Risk of Impact and Crushing
The vehicles which are undergoing A/C system recharging operations
and the devices, must be properly blocked using the specific
mechanical brakes/blocks, while being service.
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Safety Precautions:
•Always make sure that the vehicle is in neutral gear (or that it is set in parking
position in case of a vehicle equipped with automatic transmission).
•Always activate the hand brake or parking brake on the vehicle.
•Always block the wheels on the vehicle with the specific mechanical blocks.
•Make sure the device is stable, on a flat surface and the wheels are locked with
the specific brakes.
1.2.4 Hazards Caused by Moving Parts
Vehicle engines include parts that move, both while running and not
running (eg: the cooling fan is controlled by a thermal switch in
connection with the coolant temperature and become activated even
when the vehicle is off), that can injure the operator.
Safety Precautions:
•Keep hands away from moving parts.
•Disconnect the engine cooling fan each time the engine you are working on is
still hot. This will avoid the fan from becoming activated unexpectedly even when
the engine is off.
•Do not wear ties, loose clothes, wrist jewellery or watches when working on a
vehicle.
•Keep connection cables, probes and similar devices away from the moving parts
of the engine.
1.2.5 Risk of Burning or Scalding
The parts that are exposed to high temperatures in engines that are
moving or have just stopped could burn the operator.
Remember that catalytic mufflers reach very high temperatures, able
to cause serious burns or even start fires.
Acid in the vehicle batteries is another potential hazard.
Safety Precautions:
•Protect your face, hands, and feet by using suitable protection.
•Avoid contact with hot surfaces, such as spark plugs, exhaust pipes, radiators
and connections within the cooling system.
•Make sure there are no oil stains, rags, paper or other inflammable material near
the muffler.
•Avoid splashing electrolyte on skin, eyes and clothes, as it is a corrosive and
highly toxic compound.
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1.2.6 Fire and Explosion Hazard
The following are potential fires and/or explosion hazards:
•The types of fuel used by the vehicle and the vapours released by these
fuels.
•The refrigerants used by the A/C system.
•The acid in the vehicle batteries.
Safety Precautions:
•Let the engine cool.
•Do NOT smoke near the vehicle.
•Do NOT expose the vehicle to open flames.
•Make sure that the electrical connections are all well insulated.
•Collect any fuel that might have spilled.
•Collect any refrigerant that might have spilled.
•Make sure you are always working in an environment equipped with a good
ventilation and air extraction system.
•Always activate the air extraction system when working in closed environments.
•Cover the openings of the batteries with a wet cloth in order to stifle the explosive
gases before proceeding in testing or recharging.
•Avoid causing sparks when connecting cables to the battery.
1.2.7 Noise Hazard
Loud noises that may occur within the workplace, especially during
service operations may damage the operator's hearing.
Safety Precautions:
•Protect your ears with suitable protective ear wear.
1.2.8 High Voltage Hazard
The voltage supply from the mains that powers the devices in the
workplace and the voltage within the vehicle starter system is a
potential shock hazard to the operator.
Safety Precautions:
•Make sure the electrical system in the workplace is compliant to current national
standards.
•Make sure the device being used is connected to ground.
•Cut off the power supply voltage before connecting or disconnecting cables.
•Do NOT touch the high voltage cables when the engine is on.
•Operate in conditions of insulation from ground. 11
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•Work with dry hands only.
•Keep conductive liquids away from the engine while working.
•Never leave tools on the battery in order to avoid accidental contacts.
1.2.9 Poisoning Hazard
The hoses used to extract the refrigerants can release toxic gases,
dangerous to the operator if exposed to temperatures higher than 250
°C or in case of a fire.
Safety Precautions:
•Contact a doctor immediately should you inhale these gases.
•Use neoprene or PVC gloves when eliminating combustion deposits.
1.3 General User and Maintenance Warnings
When using the device or carrying out scheduled maintenance (eg. fuse
replacement) on the device, carefully follow the information provided below.
•Do not remove or damage the labels/tags and the warnings on the device; do
NOT in any case make them illegible.
•Do not remove, or block, any safety devices the device is equipped with.
•Only use original spare parts or spare parts approved by the manufacturer.
•Contact your retailer for any non-scheduled maintenance.
•Periodically check the electrical connections of the device, making sure they are
in good condition and replacing any damaged cables.
•Check parts that are subject to wear periodically and replace if necessary.
•Do not open or disassemble the device.
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2 KONFORT 744 USER SAFETY
Technology used for the design and testing of the recharging stations
KONFORT 744 make them simple, reliable and safe.
Personnel in charge of using the recharging stations is required to follow the
general safety regulations, use the KONFORT 744 recharging stations for their
intended use only and carry out the maintenance as described in this manual.
TEXA S.p.A. declines any responsibility deriving from an improper use of this
product that is not within its destination of use or an appropriate workspace or
that does not meet the safety regulations and the procedure described here
within.
2.1 Glossary
•Equipment: any KONFORT 744 charging station (the charging station does not
include the external refrigerant tank).
•External tank: new R744 (carbon dioxide, CO2) tank.
•Cycle: automatic execution of the single phases.
•Operating phase: a single operation carried out by the equipment (ex. Charge).
•UV tracer injection: the introduction of UV tracer into the A/C system in order to
check for leaks.
•Oil injection: the introduction of oil into the A/C system in order to restore the
correct quantity recommended by the manufacturer.
•Operator: qualified individual, in charge of servicing air conditioning systems
using the KONFORT 744 recharging station.
•Refrigerant: R744 (carbon dioxide, CO2) coolant.
•Refilling: refrigerant charging phase; charges the A/C system with the quantity
of refrigerant recommended by the manufacturer.
•Discharge: discharge of the refrigerant inside the A/C system.
•A/C system: air conditioning or climate control system.
•Vacuuming: the evacuation of incondensable gases and humidity from within
the A/C system exclusively through a vacuum pump.
2.2 General Rules
•The operator must have basic knowledge of refrigeration, of the refrigeration
system,ofrefrigerantsandofthepotentialhazardsthatequipmentunderextreme
pressure can cause.
•The operator must have fully read and understood the information and the
instructions described in the technical documentation provided with the device.
•The equipment must be used only by personnel properly trained by TEXA S.p.A.
or through courses that are specifically approved by TEXA S.p.A.
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2.3 Operator Safety
The use of refrigerants may cause serious risks for your health.
Detailed medical and safety information can be obtained from the
manufacturers of the lubricants and refrigerants.
SUFFOCATION
Inhaling large amounts of R744 (carbon dioxide, CO2) refrigerant may be
harmful due to its low content of oxygen.
During the discharge, the R744 (carbon dioxide, CO2) refrigerant of the A/C
system is released directly into the air, constantly checking the degree of
concentration of carbon dioxide (CO2) in the working area thanks to a specific
sensor.
Through both visible and audible indications, the equipment warns that an
excessivelevel ofconcentration ofcarbon dioxide(CO2) hasbeen reachedand
automatically interrupts the activity in progress.
The discharge of the refrigerant resumes normally once the alarm has ceased,
when the level of carbon dioxide (CO2) has returned to normal.
Safety Precautions:
•Use the equipment in well-ventilated environments only.
•Avoid inhaling the refrigerant; use appropriate safety devices when required.
•If the equipment, through the specific alarm, warns that there is high level of
concentration of carbon dioxide (CO2), move away from it and aerate the
workspace for the time needed in order to bring the level of concentration of
carbon dioxide (C02) back within the safety level.
FREEZING AND FREEZE BURNS
Giventheirlowcondensationtemperature,physicalcontactwiththerefrigerants
may cause freeze burns.
Safety Measures:
•Wear adequate safety glasses and gloves, that prevent direct contact with the
refrigerants.
•Make sure the refrigerant tank's valve is closed before moving it.
•Make sure the service pipes are not under pressure before disconnecting them.
BLINDNESS
Direct contact of the refrigerant with eyes may cause blindness.
Safety measures:
•Wear protective goggles!
2.4 Device Safety
•Use R744 (carbon dioxide, CO2) refrigerant only.
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•Make sure you use the correct refrigerant for the vehicle you are working on.
•Connect the hoses correctly by following the colours indicated: Blue hose - LP
connection, red hose - HP connection.
•Make sure all the valves are closed before connecting the device to the A/C
system or to an external cylinder.
•It is absolutely forbidden to modify the calibration of the safety valves and the
control systems.
•Do not smoke near the device or during the operating phases.
•Do not use the equipment near open flames, sparks, hot surfaces: the refrigerant
decomposes at high temperatures, letting off toxic chemical substances that may
cause fires or explosions.
•Do not expose the device to direct sunlight, rain and bad weather conditions.
•Disconnect the hoses with extreme caution; they may contain refrigerant under
high pressure.
•Do not leave the device connected to the power supply if you do not intend to use
it immediately.
•To move the equipment use the specific handles only and balance the station on
its wheels.
•If storing the device for a long period of time, disconnect it from the power mains
and put it in a safe place, where it is not exposed to outside weather conditions.
2.5 Workplace Safety
The device is designed to work at a maximum altitude of 1000 m above sea
level, with an operating temperature between 10°C and 50 °C and a maximum
humidity of 50% at 50 °C.
Safety measures:
•Never, under any circumstance, use the device in an environment where there is
risk of an explosion.
•Only use the device in open or well-ventilated environments (at least 4 air
changes per hour).
•Make sure the workplace is well-lit (average operating illuminance, for mechanic
workshops and assembly on work benches for precision work, is 500-750-1000
lux).
2.6 Guidelines for the handling the refrigerants and user safety
The equipment has been designed and built to operate with R744 (carbon
dioxide, CO2) refrigerant only.
Safety measures:
•Do not transport the equipment with the external tank installed.
•The cylinders must be perfectly clean and clearly labelled in order to identify the
refrigerant contained within.
•Use tanks with pickup pumps only. 15
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•Do not use external tanks or other storage systems that have not been approved
and/or that are not equipped with safety valves.
•Consult the safety sheet of this refrigerant in order to store it correctly.
•Store the refrigerant tanks in well-ventilated environments and away from
sunlight.
•Before switching off the equipment, using the specific pressure gauges, make
sure the service pipes are not under pressure and eventually depressurise them
through the specific software function.
2.7 Safety Devices
The KONFORT 744 recharging stations are equipped with the following safety
features:
•Emergency button: it allows you to cut off the power supply from the mains in
case of emergency or in order to carry out maintenance operations.
•Rupture discs: rupture discs are membranes that are calibrated to open at 200
bar ± 10% needed to protect the equipment's hydraulic circuit areas. When one
or more rupture discs intervene, the equipment can no longer be used until the
discs are replaced by authorised and qualified personnel.
Tampering with the above mentioned safety devices of any kind is strictly
forbidden.
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3 NORMATIVE INFORMATION
Simplified EU Declaration of Conformity
The manufacturer, TEXA S.p.A., declares that the type of
KONFORT 744 equipment complies with the following directives:
•PED 2014/68/EU
•Machinery directive 2006/42/EC
•Low voltage directive 2014/35/EU
•RED 2014/53/UE
•RoHS 2011/65/EU
The complete text of the EU declaration of conformity is available at
the following Internet address: http://www.texa.it/download.
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4 OPERATION OF THE TOOL'S RADIO DEVICES
Wireless connection with Bluetooth, WiFi and HSUPA technology
Wireless connectivity through Bluetooth, WiFi and HSUPA is a technology that
supplies a standard, reliable method for exchanging information between
different devices using radio waves. Many other products besides those built
by TEXA use this technology, such as mobile phones, portable devices,
Computers, printers, cameras, Pocket PCs etc.
The Bluetooth, WiFi and HSUPA interfaces search for compatible electronic
devices based on the radio signals they emit and establish a connection. TEXA
tools only select and prompt compatible TEXA devices. This does not exclude
the presence of other sources of communication or disturbance.
THE EFFICIENCY AND QUALITY OF BLUETOOTH, WiFi AND HSUPA
COMMUNICATION MAY BE AFFECTED BY THE PRESENCE OF RADIO
DISTURBANCE. THE COMMUNICATION PROTOCOL IS DESIGNED TO
MANAGE THESE TYPES OF ERRORS; HOWEVER, IN SUCH CASES
COMMUNICATION MAY BE DIFFICULT AND CONNECTION MAY REQUIRE
SEVERAL ATTEMPTS.
SHOULD THE WIRELESS CONNECTION ENCOUNTER SERIOUS
PROBLEMS AND COMPROMISE REGULAR COMMUNICATION, THE
SOURCEOFTHEENVIRONMENTALELECTROMAGNETICDISTURBANCE
MUST BE IDENTIFIED AND ITS INTENSITY REDUCED.
Position the tool so that the radio devices it is equipped with can work properly.
In particular, do not cover it with any shielding or metallic materials in general.
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5 KONFORT 744 RECHARGING STATIONS
The KONFORT 744 charging stations are intended for the maintenance of A/C
systems that use carbon dioxide as refrigerant.
The KONFORT 744 stations are high performance devices capable of carrying
out the following operations in complete safety: system discharge, vacuum, oil
injection, UV dye injection, system charge and leak checks on A/C systems.
The KONFORT 744 stations are provided with an SD CARD containing the
dedicated software.
TheSD CARD allowsyoutoautomatically storethedataof eachservicecarried
out.
The software update can be performed through the SD CARD.
The FORMING GAS KIT for leak detection is available.
The FORMING GAS KIT, once connected to the equipment, allows you to test
the A/C system under pressure in order to be able to detect possible leaks
through a specific software function.
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