Wow Coolius 4000 Bus User manual

Automatic A/C-Service Unit
1
Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
Automatic A/C
Automatic A/CAutomatic A/C
Automatic A/C-
--
-Service Unit
Service UnitService Unit
Service Unit
Coolius 4000 Bus
Coolius 4000 BusCoolius 4000 Bus
Coolius 4000 Bus
Art.
Art.Art.
Art.-
--
-No.
No. No.
No. 0900700605
09007006050900700605
0900700605
Instruction manual
Instruction manualInstruction manual
Instruction manual
WOW! GmbH Künzelsau reserves the right to discontinue, or change at any time specifications or designs
without notice and without incurring obligations according to her policy of always improving her products.

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
CONTENTS
Layout drawing .......................................................................................................................5
Electric scheme ......................................................................................................................9
Legend...................................................................................................................................10
1. Introduction to Coolius 40000 BUS recovery unit ......................................................12
1.1 Technical specifications................................................................................................................... 12
2. Components description and standard equipment....................................................12
2.1 High vacuum pump ......................................................................................................................... 12
2.2 Refrigerant charging pump.............................................................................................................. 12
2.3 Refrigerant bottle............................................................................................................................. 12
2.4 Distiller - separator.......................................................................................................................... 13
2.5 Compressor .................................................................................................................................... 13
2.6 Filters.............................................................................................................................................. 13
2.7 Flexible hoses................................................................................................................................. 13
2.8 Quick coupler valves....................................................................................................................... 13
2.9 Printer............................................................................................................................................. 13
2.10 Temperature probe ......................................................................................................................... 13
2.11 Control module................................................................................................................................ 13
2.12 Functions programming................................................................................................................... 13
2.13 Functions that can be performed..................................................................................................... 14
3. Control panel..................................................................................................................15
3.1 Description of the control keys......................................................................................................... 15
4. Preparing the unit Coolius 4000 BUS for operation..................................................16
4.1 Checking the vacuum pump oil level................................................................................................ 16
4.2 Unlocking the scale......................................................................................................................... 16
4.3 "Zero" scale check .......................................................................................................................... 17
4.4 Filling refrigerant into the bottle ....................................................................................................... 17
4.4.1 Filling refrigerant into the internal bottle by means of recovery from the service bottle...................... 17
4.4.2 Emptying the internal bottle............................................................................................................. 19
5. Recovery ........................................................................................................................20
5.1 Preparing the vehicle for refrigerant recovery from the A/C system.................................................. 20
5.2 Refrigerant recovery for R= all......................................................................................................... 20
5.3 Refrigerant recovery for R<>00.00................................................................................................... 21
6. Draining of the oil extracted from the A/C system......................................................22
7. Evacuating and checking the A/C system for tightness ............................................22
8. Refilling oil into the A/C system...................................................................................23
8.1 Warning .......................................................................................................................................... 23
8.2 Warning .......................................................................................................................................... 23
8.3 Oil refilling procedure in the A/C system.......................................................................................... 23
8.4 Suggested oil quantities for refilling the vehicle air conditioner......................................................... 24
8.5 Warning .......................................................................................................................................... 24
8.6 UV refilling procedure in the A/C system.......................................................................................... 24
9. Charging refrigerant into the A/C system................................................................25
9.1 Warning .......................................................................................................................................... 25
9.2 A/C system refrigerant charging procedure...................................................................................... 25
10. Checking the A/C system operating pressures.......................................................25
11. FLUSHING automatic function..................................................................................26
12. FIRE&GO automatic function....................................................................................26
13. AUTO function............................................................................................................27
14. Operations before disconnecting the unit from the A/C system ...........................27

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
15. Routine maintenance.................................................................................................28
15.1 Material for routine maintenance ..................................................................................................... 28
15.2 Periodic operations ......................................................................................................................... 28
15.3 Changing the vacuum pump oil ....................................................................................................... 28
15.4 Replacing the filter driers................................................................................................................. 29
16. Accessories and spare parts ....................................................................................30
17. Dimensions and weight.............................................................................................30

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
WARNING
Safety precautions
a) This equipment is designed for trained personnel only, who must know the
refrigeration fundamentals, cooling systems, refrigerants and
possible damage that pressurized equipment may cause.
b) Carefully read the instructions contained in this manual; strict
observance of the procedures described is fundamental to the operator’s
safety, the perfect state of the unit and constant performances as
declared.
c) Do not operate the unit with different refrigerant than the one it has
been designed for.
d) Before performing any operation, make sure that the hoses used for
connections have been previously evacuated and that they do not
contain non-condensable gases.
e) Avoid skin contact; the low boiling temperature of the refrigerant (about -30°C)
can cause freezing.
f) Avoid breathing refrigerant vapours.
g) It is recommended to wear suitable protections like safety glasses and
gloves; contact with refrigerant may cause blindness and other personal
injuries.
h) Do not operate near open flames and hot surfaces; the high temperatures
decompose the refrigerant releasing toxic and caustic substances which
are hazardous for the operator and the environment.
i) Always make sure that the unit is connected to a suitably protected mains
supply provided with an efficient earth connection.
j) Before performing maintenance operations or when the unit will not be used
for a long period of time, turn the unit off by turning the main switch to 0
and disconnect the power supply cord; absolutely follow the
sequence of operations.
k) Operate the unit only in locations with suitable ventilation and a high
number of air changes.
l) Before disconnecting the unit, make sure that the cycle has been
completed and that all valves are closed in order to avoid release of
refrigerant to the atmosphere.
m) Never fill any tank with liquid refrigerant to more than 75% of its maximum
capacity.
n) During operations avoid release of refrigerant to the environment; this
precaution is required by international environmental standards and is essential to avoid
difficult leak detection in a refrigerant polluted environment.
o) The equipment must always work under the operator’s control.
p) Protect the unit from dripping.
q) Do not modify the calibration of safety valves and control systems.
r) If you recover refrigerant from a cooling system equipped with a water
evaporator and/or condenser, it is necessary to drain water from the
evaporator and/or condenser or to keep the circulation pump running
during the entire recovery operation in order to avoid frosting.

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
Layout drawing

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
Hydraulic diagram

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
Electric scheme

Automatic A/C-Service Unit
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Letzte Änderung: 24.06.2009 / Art.Nr.: 2059ENG
Legend
1
-
EV1
Solenoid valve on oil draining line
60
Electronic card on control panel
2
-
EV2
Solenoid
valve on recovery line
61
Paper for printer
3
-
EV3
Solenoid valve on UV charging line
62
Black plastic basin
4
-
EV4
Solenoid valve on vacuum pump suction line
64
Electronic card power with cables
5
Condenser
65
Right panel
6
Vacuum pump
66
Left panel
7
Recovery compressor
67
Main p
ower switch
8
Fan
68
-
M1
Low pressure gauge
10
-
EV10
Solenoid valve on vacuum test line
69
-
M2
High pressure gauge
12
Warning light
71
-
PRT
Printer
13
-
EV13
Solenoid valve on refrigerant charging line
72
-
MC
M
emory card
15
Pressure / vacuum switch
74
–
CEL3
OIL injection load cell - 5kg
17
Safety switch
75
–
CEL2
OIL drain load cell
-
5kg
18
Vacuum switch
76
-
R14
Heater on the refrigerant bottle
19
-
EV19
Solenoid valve on oil charging line
77
–
CEL4
UV injection load cell - 5kg
20
-
EV20
Solenoid valve on oil return line to compressor
78
-
S2
Refrigerant bottle service connection
21
Refrigerant charge hose
-
Pump liquid suction
79
-
VS1
Safety valve
–
non condensable gases
22
–
EV22
Solenoid valve on recovery line (2° line)
80
–
CEL1
Load cell - 100kg
23
Valve on the refrigerant bottle
81
-
CV5
Check valve on oil charging line
24
Bottle service valve
82
-
CV1
Check valve on suction line
25
Connecting hose between bottle assembly and
bottle
83
-
C
V3
Check valve on refrigerant charging
line
27
Bottle pressure gauge
84
-
CV6
Check valve on UV charging line
30
Electrical box
85
-
S1
Compressor service connection
31
Refrigerant bottle
86
-
CV4
Check valve on oil draining line
34
UV injection capillary tube
87
-
R5
Heater on the distiller
35
Oil injection capillary tube
88
-
CV2
Check valve on compressor discharge
line
39
Bottle pressure gauge capillary tube
89 (1
-
2)
Oil discharge capillary tube
40
Vacuum tube
90
-
F2
Filter drier
41
Compressor suction side hose
91
-
EV24
Solenoid valve – LOW line
42
Distiller - filters hose (1° line)
92
-
EV25
Solenoid valve – HIGH line
43
Distiller – separator hose (1° line)
93
LP gauge connection capillary tube
44
Double nut
94
HP gauge connection capillary tube
45
Compressor lubricant distiller
95
-
F1
Filter drier
48
Oil drain bottle
96
Safety valve connection capillary tube
49
UV dosimeter
97
Safety valve – non condensable gases
50
Oil dosimeter
100
Valve on the refrigerant bottle in
charging line
51
Heater switch
101
-
CV2
1
Check valve on compressor suction
line (2° line)
52
High pressure service hose
102
Distiller
–
separator
(2° line)
53
Low pressure service hose
103
–
F21
Filter drier
(2° line)
54
Main power cable
104
–
F22
Filter drier (2° line)
55
High pressure connection valve
105
–
S11
Compressor service connection (2°
line)
56
Low pressure connection valve
106
–
EV40
Solenoid valve on oil return line to
compressor (2° line)
58
Temperature probe
107
Recovery compressor (2° line)