WABCO WÜRTH COOLIUS A30 Product guide

Service book
A30
A/C Service-Unit for refrigerant R134a
Serial Number from AC000140 onwards
Doc.No.: ?????_Rev.04.00
Original Service Book

2COOLIUS A30

3COOLIUS A30
Contents
1 Flow diagram ..................................................................................................................................................................................4
1.1 Flow diagram - SPARE PARTS LIST...............................................................................................................................6
2 Electric diagram ............................................................................................................................................................................7
2.1 Electric diagram - SPARE PARTS LIST..........................................................................................................................8
3 Machine description....................................................................................................................................................................9
3.1 Machine - SPARE PARTS LIST...................................................................................................................................... 10
3.2 Manifold - SPARE PARTS LIST.......................................................................................................................................11
3.3 Other parts - SPARE PARTS LIST................................................................................................................................. 12
3.4 Accessories - SPARE PARTS LIST............................................................................................................................... 13
4 Maintenance................................................................................................................................................................................. 13
4.1 Filter and Vacuum pump oil replacement .................................................................................................................... 13
4.1.1 Replacingthelter........................................................................................................................................................ 13
4.1.2 Replacing the vacuum pump oil .............................................................................................................................. 14
4.2 Counter reset (UNLOCK CODE required) .................................................................................................................. 15
5 Calibration..................................................................................................................................................................................... 16
5.1 Refrigerant weight scale .................................................................................................................................................... 16
5.2 Used oil weight scale .......................................................................................................................................................... 17
5.3 Pressure transducer............................................................................................................................................................ 17
6 Mainboard test ............................................................................................................................................................................ 19
6.1 Analysis of the displayed values..................................................................................................................................... 20
6.2 Output test............................................................................................................................................................................... 21
6.3 Phase / Neutral wires pinout ............................................................................................................................................ 23
7 Other passwords ....................................................................................................................................................................... 24
Service Passwords ................................................................................................................................................... 24
Service Report Passwords .................................................................................................................................... 24
Operator Code (OPC) Managing Password.................................................................................................... 24
8 Contact and support.............................................................................................................................................................. 25
8.1 Service Portal COOLIUS-AC.COM .............................................................................................................................. 25

4COOLIUS A30
1 Flow diagram
SN FROM AC000140 TO AC000302 AND FROM AC000305 TO AC000311 INCLUDED:

5COOLIUS A30
SN AC000303 / AC000304 AND STARTING FROM AC000312 INCLUDED:

6COOLIUS A30
1.1 Flow diagram - SPARE PARTS LIST
N° DESCRIPTION CODE
01 HP SERVICE COUPLING (A30 R134a) 0605115006
02 LP SERVICE COUPLING (A30 R134a) 0605115001
03 HP GAUGE (R134a/R1234yf) 0710175085
04 LP GAUGE (R134a/R1234yf) 0710145085
05 5 m SERVICE HOSE HP (A30 R134a) 0603015050
06 5 m SERVICE HOSE LP (A30 R134a) 0603010050
07 MANIFOLD (A30 with SN FROM AC000140 TO AC000302 AND FROM
AC000305 TO AC000311 INCLUDED) 0512035009
MANIFOLD v2 (A30 with SN AC000303 / AC000304 AND STARTING
FROM AC000312 INCLUDED) 0510005336
08 ELECTRONIC PRESSURE TRANSDUCER 0712350007
09* CHECK VALVE - A/C CHARGE (1/4SAE FM) 0501014063
10 VACUUM PUMP for A30 0420024009
11 FLEXIBLE HOSE (from REFRIG.PUMP to MANIFOLD) 0603511015
12 CHARGE HOSE (from INT.VESSEL to REFRIG.PUMP) 0603035300
13 RECOVERY HOSE W/VALVE + ADD.CHECK VALVE 0613010401
14 FLEXIBLE HOSE (from DISTILLER to HEAT EXCHANGER) 0603120035
15 INTERNAL BY-PASS KIT for R134a 0612400070
20 COMPRESSOR for A30 0420230236
21 CAPILLARY 0602099420
23 OIL DISTILLER GROUP (A30 R134a) 0610035020
24 MAIN FILTER 0607350344
25 HIGH PRESSURE SWITCH 0703014019
26 HEAT EXCHANGER GROUP (WITH FAN) 0418172635
27 ELECTRIC VALVE GROUP “1A”
(LP / XP / RF / A1* / A2 / EO) 0500142050
28 COMPRESSOR COPPER PIPE 0602005020
29 CHECK VALVE - OIL DISTILLER (7/16UNF O-Ring MM) 0501071605
30 LIQUID RECEIVER 35L GROUP (A30 R134a) 0612001035
32 OVERPRESSURE VALVE 0503016045
33 SAFETY VALVE 0503144020
40 UV TRACER BOTTLE 250 ml 0819015257
41 NEW OIL BOTTLE 500 ml 0819015515
42 USED OIL BOTTLE 1000 ml 0819015103
50 REFRIGERANT PUMP 0416590035
REFRIGERANT PUMP SPARE PARTS 0406930907
51 INTERNAL VESSEL PRESSURE GAUGE 0710040250
(*) NOT PRESENT IN A30 WITH SN AC000303 / AC000304 AND STARTING FROM AC000312
INCLUDED.

7COOLIUS A30
2 Electric diagram

8COOLIUS A30
2.1 Electric diagram - SPARE PARTS LIST
N° DESCRIPTION CODE
01 MAIN SWITCH 0404230022
03 MAIN FAN 120mm 0408080025
04 HEAT EXCHANGER GROUP (WITH FAN) 0418172635
05 COMPRESSOR A30 0420230236
06 VACUUM PUMP A30 0420024009
8a ELECTRIC VALVE GROUP “1A”
(LP / XP / RF / A1* / A2 / EO) 0500142050
PISTON FOR “1A” ELECTRIC VALVE
(LP / XP / RF / A1* / A2 / EO) 0500142150
8b ELECTRIC VALVE GROUP “1B”
(NO / UV / VP) 0500142075
PISTON FOR “1B” ELECTRIC VALVE
(NO / UV / VP) 0500142175
10 HIGH PRESSURE SWITCH 0703014019
50 REFRIGERANT PUMP 0416590035
REFRIGERANT PUMP SPARE PARTS 0406930907
(*) NOT PRESENT IN A30 WITH SN AC000303 / AC000304 AND STARTING FROM AC000312
INCLUDED.

9COOLIUS A30
3 Machine description

10 COOLIUS A30
3.1 Machine - SPARE PARTS LIST
N° DESCRIPTION CODE
01 HP SERVICE COUPLING (A30 R134a) 0605115006
02 LP SERVICE COUPLING (A30 R134a) 0605115001
03 HP GAUGE (R134a/R1234yf) 0710175085
04 LP GAUGE (R134a/R1234yf) 0710145085
05 5 m SERVICE HOSE HP (A30 R134a) 0603015050
06 5 m SERVICE HOSE LP (A30 R134a) 0603010050
07 PRINTER KIT 0413002025
08 TOP COVER (PLASTIC) 0800700600
09 STICKER “WABCOWÜRTH” 0807005035
STICKER “WOW!” NOT AVAILABLE
10 A30 STICKER 0807005030
11 REAR WHEEL D260 (PNEUMATIC) 0206001261
12 FRONT WHEEL WITH BRAKE D100 0206001100
13 MAIN FAN 120mm 0408080025
14 MAIN SWITCH 0404230022
15 INTERNAL VESSEL PRESSURE GAUGE 0710040250
17 UV TRACER BOTTLE 250 ml 0819015257
18 NEW OIL BOTTLE 500 ml 0819015515
19 USED OIL BOTTLE 1000 ml 0819015103

11COOLIUS A30
3.2 Manifold - SPARE PARTS LIST
SN FROM AC000140 TO AC000302 AND FROM AC000305 TO AC000311 INCLUDED:
A30 WITH SN AC000303 / AC000304 AND STARTING FROM AC000312 INCLUDED:
N° DESCRIPTION CODE
01 MANIFOLD (A30 with SN FROM AC000140 TO AC000302 AND FROM
AC000305 TO AC000311 INCLUDED)0512035009
02 MANIFOLD v2 (A30 with SN AC000303 / AC000304 AND STARTING
FROM AC000312 INCLUDED)0510005336

12 COOLIUS A30
1A ELECTRIC VALVE GROUP “1A”
(LP / XP / RF / A1* / A2 / EO) 0500142050
PISTON FOR “1A” ELECTRIC VALVE
(LP / XP / RF / A1* / A2 / EO) 0500142150
1B ELECTRIC VALVE GROUP “1B”
(NO / UV / VP) 0500142075
PISTON FOR “1B” ELECTRIC VALVE
(NO / UV / VP) 0500142175
(*) NOT PRESENT IN A30 WITH SN AC000303 / AC000304 AND STARTING FROM AC000312
INCLUDED.
3.3 Other parts - SPARE PARTS LIST
N° DESCRIPTION CODE
INTERNAL SUPPORT BUSHING for 4/6 TUBE 0102107704
BRASS OGIVE for 2/4 TUBE 0102137404
INTERNAL SUPPORT BUSHING for 2/4 TUBE 0104999105
O-RING 4,48x1,78 for 1/4 COPPER PIPE 0106178448
O-RING 14,00x1,78 for A30 VACUUM PUMP 0106178140
RILSAN PA11 SR HL NEUTRAL PIPE 6/8 0107106008
RILSAN PA11 NEUTRAL PIPE 4/6 0107004006
RILSAN GREEN PIPE 2/4 0107202004
RILSAN PA11 BLUE PIPE 2/4 0107402004
RILSAN BLUE PIPE 6/8 0107406008
RILSAN PA11 RED PIPE 2/4 0107502004
YELLOW PU PIPE 4/6 0107834006
BLUE PU PIPE 4/6 0107844006
CRISTAL PIPE 4/6 0107904006
USB PROTECTION CAP 0400009009
MAINBOARD “A” (PWR) for A30
(SN STARTING FROM AC000140 INCLUDED) 0402012014
MAINBOARD “A” (PWR) for A30 - PROTECTED
(SN STARTING FROM AC000140 INCLUDED) 0402035017
MAINBOARD “B” (DISPLAY) - EUROPEAN VERSION 0402014005
MAINBOARD “B” (DISPLAY) - CYRILLIC VERSION 0402014007
PRINTER PAPER ROLL 0403005840
POWER CORD (CEE7) 0405270005
CONTROL KNOB (COOLIUS SELECT) 0411210009
LOAD CELL 200KG (SN STARTING FROM AC000140 INCLUDED) 0714110205
LOAD CELL 15KG 0714211019
RED / BLUE RINGS FOR GAUGES 0800101168
KEYBOARD A30 (POLYESTER PANEL) 0805045041
MAINTENANCE KIT (DRIER+VACUUM PUMP OIL+GASKETS) 7500100010

13COOLIUS A30
3.4 Accessories - SPARE PARTS LIST
N° DESCRIPTION CODE
SERVICE HOSES EXTENSION KIT - ADDITIONAL 3 m (R134a) 2501003134
4 Maintenance
4.1 Filter and Vacuum pump oil replacement
4.1.1 Replacing the lter
NOTE: Always use goggles and gloves!
Contact with the refrigerant can cause blindness and other physical injury to
the user!
1. Beforedismountingthelter,performarecoveryprocessinordertoreducethepressureintheinternal
circuit!
IMPORTANT: Disconnect the plug from the supply!
2. Usea38mmwrenchtounscrewthelter.
NOTE: Dispose according to local regulations.
3. Lubricate and place correctly the new O-rings.
4. Assemblethenewlter.

14 COOLIUS A30
4.1.2 Replacing the vacuum pump oil
NOTE: Always use goggles and gloves!
Contact with the refrigerant can cause blindness and other physical injury to
the user!
IMPORTANT: Disconnect the plug from the supply!
1. Open the front cover (3x large head Phillips screws).
2. Unscrew the oil discharge screw Cand wait for the oil to drain.
Thenretthedischargescrew C.
NOTE: Dispose according to local regulations.
3. Unscrewthemu󰀪er A.
4. Fill with new oil.
The correct oil level of the pump is around half sight glass.
5. Retthemu󰀪er A.
6. Reassemble the front cover.
NOTE: Thepicturecouldshowadi󰀨erenttypeofvacuum
pump.
A Mu󰀪er
BSight glass to indicate the oil level
CDischarge screw
g.002 Vacuum pump
C
A
B

15COOLIUS A30
4.2 Counter reset (UNLOCK CODE required)
Change lter and vacuum pump oil before resetting maintenance!
NOTE: Only genuine spare parts or their equivalent The use of replacement parts which are not
of equivalent quality may damage the machine!
Go to website www.coolius-ac.com or call the hotline [phone] to get the UNLOCK CODE for
maintenance counter reset.
1. Press START to continue.
2. Use the COOLIUS SELECT to enter the maintenance
UNLOCK CODE obtained from www.coolius-ac.com.
Whendone,conrmbySTART.
• If the UNLOCK CODE is wrong, repeat the step 2.
• If the UNLOCK CODE is right, go to step 3.
3. Press X(CANCEL)keytoconrm.
4. Press again X(CANCEL) keytoconrmandresetthe
counter.
Maintenance reset successfully completed.
Get UNLOCK CODE
register:
BB111111
www.coolius-ac.com
A*******
A
34567890 BCDEFGHIJK
Counter reset.
Confirm by “X”
min. ///
Counter reset.
Confirm again!

16 COOLIUS A30
5 Calibration
1. Select SERVICE and type password: 311299
The display shows:
2. Turn COOLIUS SELECT to select among:
• Refrigerant weight scale
• Used oil weight scale
• Pressure transducer
3. Press ENTERtoconrmtheselection.
5.1 Refrigerant weight scale
The display shows:
1. Dismount the top cover (4 screws), then unload the scale by using the screws for transport locking.
2. Press ENTERkeytoconrmthesafetypositionandwait.
The display shows:
3. Load the scale by using the screws for transport locking.
Wait a few seconds then press ENTERkeytoconrmtheworkingposition.
The display shows:
4. Place a known sample weight (minimum 2 kg, suggested
5 kg) on the centre of the scale bracket.
Wait a few seconds then press ENTERkeytoconrm
and wait!
The display shows:
5. Turn COOLIUS SELECT to set the weight value.
Press STARTtoconrm.
Calibration completed.
Select:
Refrig. weight scale
Unload weight scale
(safety position)
Load weight scale
(working position)
Place the sample
weight on the scale.
Set the sample
weight value.
g.

17COOLIUS A30
5.2 Used oil weight scale
The display shows:
1. Remove the used oil bottle.
Press ENTERkeytoconrmthatthescaleisunloaded
and wait!
The display shows:
2. Press ENTERkeytoconrmagainthatthescaleis
unloaded and wait!
The display shows:
3. Place a known sample weight (minimum 50 g) on the
waste oil scale bracket.
Wait a few seconds then press ENTERkeytoconrm
and wait!
The display shows:
4. Turn COOLIUS SELECT to set the weight value.
Press STARTtoconrm.
Calibration completed.
5.3 Pressure transducer
IMPORTANT: The quick coupler must be assembled on the service hoses and the gauges must
show 0 (zero) pressure!
1. Press START to begin the calibration of pressure trans-
ducer.
2. The vacuum pump starts and perform a short vacuum
phase.
After a few seconds, the displayed value (ADC points)
must be lower than 250.
Unload used oil
scale!
Confirm by “ENTER”
used oil scale
unloaded!
Place the sample
weight on the scale.
Set the sample
weight value.
g.
Confirm by “START”
Wait!
xx

18 COOLIUS A30
3. When the vacuum pump stops and the display shows:
Remove the LP service connector (low pressure side
quick coupling) from the BLUE service hose, then press
ENTERtoconrm.
Wait for screen change!
4. Turn COOLIUS SELECT to set the atmospheric pres-
sure (ex. 1010 mb)
When done, press STARTtoconrm.
5. Wait the end, then press STOP to exit.
Calibration completed.
Remove the LP
connector from the
service hose.
Set the atmospheric
pressure value (abs)
mb. 0

19COOLIUS A30
6 Mainboard test
IMPORTANT NOTE: Machine disconnected from any A/C system or refrigerant tank!
Check that both HP and LP gauges show zero pressure!
1. Select SERVICE and type password: 228482
The display shows:
(1) CONTROLLED OUTPUT
(2) REFRIGERANT SCALE Net compensated value.
(3) USED OIL SCALE Net compensated value.
(4) PRESSURE TRANSMITTER Absolute pressure compensated value.
(5) KEY ID. number
(6) TEMPERATURE Mainboard “A” (PWR) [tenths of °C].
(7) TEMPERATURE Mainboard “B” (Display) [tenths of °C].
(8) REFRIGERANT SCALE Analog to digital converter points.
(9) USED OIL SCALE Analog to digital converter points.
(10) PRESSURE TRANSMITTER Analog to digital converter points.
KEY IDENTIFICATION NUMBER
Thenumberidentiesthepressedkeyasdescribedbelow:
0 No key pressed
2 ENTER key (The ENTER key activates the output indicated on the display, read the instruc-
tions before use)
4 STOP key (Not visible)
8 START key
16 X(CANCEL) key
32 RIGHT key
64 i(INFO) key
128 LEFT key
CP 0 TA209 TB208
1240 8850000
21 4000
50 2890
2
3
4
56
7
8
9
10
1

20 COOLIUS A30
6.1 Analysis of the displayed values
NOTE: Machine with pressure transmitter and weight scales correctly calibrated.
Pressure transmitter
Remove the LP quick coupler, then the absolute pressure compensated value shall be around the absolute
atmospheric pressure -10 / -15 mb.
Blow compressed air into the LP service hose (blue):
The display has to show an increase of the absolute pressure value and of the ADC points.
Disconnect the pressure transmitter connector from the mainboard “A” (PWR).
The absolute pressure value shall be 1 and the pressure transmitter ADC point should be roughly 1.
Refrigerant weight scale
The display shows the net value (Total–Tare Weight Value)
The ADC point value is the total value.
Therstfournumbersshallbestable,thelastthreecanoat.
The values displayed are directly linked to the weight on the scale.
As a reference, consider that a calibrated scale with all the containers empty shall show roughly 8900000
points.Valuesthataresignicantlydi󰀨erentfromthereferenceindicateapossibleproblem.
To check quickly if the weighing system is working correctly it is enough to press on the load cell (scale
bracket): both the ADC points and the net value compensated shall increase.
Used oil weight scale
The display shows the net value (Total–Tare Weight Value)
The ADC point value is the total value.
The values displayed are directly linked to the weight on the scale.
Mainboard temperature
The temperature is shown in tenths of Celsius degrees (°C).
The displayed values are the temperatures of each sensor mounted on the two mainboards.