Zell AC1000 User manual

®
Haining Zell Automobile Testing and Inspection Equipments Co.
，
，，
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Ltd
Automobile Air-Con Service Solution
AC1000 Operation Manual

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Contents
1 About this operation manual ..........................................2
1.1 Zell hot-line .......................................................2
1.2 Explanation of symbols in this operation manual ..........................3
2 Scope of delivery ...................................................4
3 Safety..............................................................5
3.1 General safety instructions ..............................................5
3.2 Warnings on the Air-Con Ser ice Station ..................................6
3.3 Safety de ices ..................................................... 7
4 Proper use..........................................................7
5 verview of the Air-Con Service Station .................................8
6 First start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.1 Setting up and switch up ............................................... 11
6.2 Putting into the bottles for new oil ....................................12
6.3 Filling up the internal refrigerant container .................................12
7 peration .........................................................15
7.1 Reco ery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
7.2 Vacuum . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.3 Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.4 Oil injection .......................................................18
7.5 Recharge ..........................................................19
7.6 Auto ...........................................................20
7.7 Pressure up .......................................................21
7.8 Pressure down .....................................................21
7.9 Vacuum test .....................................................22
7.10 Record print . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
8. Service tasks .......................................................25
8.1 Inner tank refill . ................. ......... ........................... . . . . 25
8.2 Language select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8.3 Zero balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .25
8.4 acuum pump oil . . . . . . . . . . . ( . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
8.5 Changing the internal filter ............................................27
8.6 Hose compensation .................................................29
8.7 Pressure rise wait ...................................................29
8.8 Other ser ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.9 Cleaning and maintenance ............................................. . . 29
9. Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .30
9.1 Disposing of used fluids ..............................................30
9.2 Disposing of packaging material .......................................30
9.3 Scrapping old unit ..................................................30
10 Trouble shooting...................................................31
11 Technical data ......................................................32
12 Spare Part list .....................................................32

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1 About this operation manual
This operation manual describes the Zell Air-Con Ser ice Station
This manual is for those who ha e the required professional ability of
pro iding the maintenance ser ice on ehicle air conditioning system.
This manual contains all the instructions necessary for safe and effecti e
operating of the air Conditioning ser ice Station. Read this operation manual
carefully before putting the de ice into using for the first time.
Also note the following:
■ the operator should comply with the laws about the ser ice of ehicle air-
conditioning by local go ernment.
■ the operator should be familiar with basic technical information of ehicle
air- conditioning
■ Instructions from the refrigerant manufacturer
■ Instructions from the car manufacturer
■Any special instructions on ser icing ehicle air conditioning systems which
applied at your company
Keep this operation manual in the tool box of Air-Con Ser ice Station, so that
any information needed is always at your hand.
1.1 Zell hotline
If you need more information about the Air-Con Ser ice Station that is not
concerned in this manual, call the Zell Hotline: [phone] 1215

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1.2 For illustrating the symbols in this operation manual
Risk of damage to the machine or other material damage
Special information for using the de ice effecti ely
Format Meaning Example
KEY Symbols used on the de ice
Press
„B LD” Display messages „LANGUAGE”
■ Text
■ Text
List in any order
■ Pressure monitor
■ Pressure relief al es
1. Text
2. Text
3. Text
Actions to be carried out in the
order shown
1. Connect the de ice.
2. Switch on the de ice.
3. Press the selection button.
Text (1) Part number Use the keypad (7) to enter the
data.
Text (A) Part designations which refer to
the diagrams shown in the
section describing the work
Remo e the filter cartridge (E)
on the left side.

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2 Scope of delivery
The Air-Con Ser ice Station and its accessories are carefully checked
before shipping.
After deli ery, please check all the parts listed below are present
and undamaged.
If any part is missing or damaged, notify the company responsible
for transport immediately
AC1000
Air-Con Ser ice Station
Blue hose with coupling for LP connection and red hose with HP connection
Container for air conditioning compressor oil (PAG oil)
Container for used oil
Inner tank refill connector
Power cord
operation manual

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3 Safety
3.1 General safety instructions
Read this operation manual carefully before starting up the
Air-Con Ser ice Station for the first time
Please note the following:
■ the operator should comply with the laws about the ser ice of ehicle air-
conditioning by the local go ernment.
■ the operator should be familiar with technical information of ehicle air-
conditioning
■ Information form the refrigerant manufacturer
■ Any special instructions on ser icing ehicle air conditioning systems
which applied at your company
And also please pay attention to these massages:
→ Only use the de ice for its intended purpose.
→ Only use genuine R134a refrigerant .If other refrigerants are mixed in, it
can damage the Air-Con Ser ice Station and the ehicle air condition
system.
→ Only use the performance of POLYOL ester type refrigerator oil (PAG oil)
used with the R134a.If other oil are mixed in, it can damage the ehicle air
condition system.
→ Wear personal safety equipment (goggles and glo es) and a oid
touching refrigerant, as this can cause chilblains to your body.
→ Do not inhale refrigerant gas . Although the gas is non-toxic, it displaces
the oxygen you needed.
→ Do not make modifications to the Air-Con Ser ice Station.
→ Each time before you start up the de ice or add gas to the Air-Con
Ser ice Station, first check whether the de ice is undamaged and
components are not lost.
→ Do not start up the Air-Con Ser ice Station if it is damaged.
→ Only used appro ed refrigerant bottles with safety al es to refill the
Air-Con Ser ice Station.
→ Drain the ser ice hoses before you release connections.

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→ Do not operate the Air-Con Ser ice Station in areas where there is a risk
of explosions (for example battery charging rooms or spraying booths).
→ Always use the main switch of the Air-Con Ser ice Station for switching
it on and off. Do not lea e the de ice unattended when it is switch on.
→ Before you shut down the Air-Con Ser ice Station, make sure that the
selected program has ended. Otherwise refrigerant can leak.
→ Do not pump compressed air into the refrigerant lines of Air-Con Ser ice
Station or into the ehicle air-conditioning system. A mixture of compressed
air and refrigerant can be flammable or explosi e.
3.2 Warnings on the Air-Con Ser ice Station
Be careful
Obser e the operation manual.
Protect the de ice against rain
Wear glo es when handling refrigerants.
Wear goggles when handling refrigerants.
Horizontal holding the station
Caution for fire

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3.3 Safety de ices
■ Pressure monitor: switch the compressor off if the normal
operation pressure is exceeded.
■ Tank with pressure relief function: additional safety mechanism releaser
to protect lines or essels from bursting if the pressure continues to rise
despite the action of the pressure monitor.
4 Proper use
The Air-Con Ser ice Station is intended for performing maintenance on ehicle
air-conditioning systems. The de ice is designed for commercial use.
The Air-Con Ser ice Station may be operated by persons who ha e the required
professional ability for ser icing air-conditioning systems.
This Air-Con Ser ice Station may only be used to ser ice ehicle
air-conditioning systems in which R134a refrigerant is used.
Zell International assumes no liability for damage resulting from the following:
■ Use for purposes more than those described in this operation manual.
■ Modification to the Air-Con Ser ice Station without the permission of Zell
■ Damage to the de ice resulting from external influences.
■ Incorrect operation

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5 verview of the Air-Con Service Station
（1）used oil bottle （2）new oil bottle
（3）power switch(double fuses embedded) （4）pressure gauge for HIGH and LOW
（5）keypad （6）HP and LP hoses
（7）pressure gauge for working tank （8）working tank
（9）heating belt (optional item) （10）printer(optional item)
（11）window for oil sight glass of acuum pump
（7）
(bac )
（5）
（4）
（9）
（6）（8）
（1）
（2）
(bac )
（10）（3）
(11)

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USER COMMUNICATION INTERFACE:
Reco ery key : to reco er the A/C refrigerant into the working tank
Vacuum key : to extract gases from A/C system
Purge key : to release non-condensable gases from working tank
Recharge key : to refill refrigerant into A/C system.
New oil key : to inject new oil into A/C system.
Function key : it allows to start the other ser ice operation.
Auto key: one press operation for all steps automatically

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Pressure up key: to add gas to A/C system.
Pressure down key: to remo e gas from A/C system
Vacuum test key: Vacuum test for detecting leakage
Record print key: Record the pre ious 3 operations and to
print recept (printer is an option item)
Select keys: to shift the ser ice items or edit the number inputted.
Start key : it allows to start the operation step.
Stop key : it allows to cancel the operation step.
Hint key : Help information for operations

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6 First start-up
6.1 Setting up and switching on
220V or 110v ower supply must be firmly grounded
1. Dri e the Air-Con Ser ice Station to the workplace and lock the front
wheels.
Before operation the de ice must be on a le el, flat surface so that
measurement can be made correctly.
2. Plug in the Air-Con Ser ice Station to the power mains.
3. Switch it on, the Air-Con Ser ice Station comes to standby mode:
“Refrige rant **.** KG” describes the quantit y of re frige rant hold in
wo rk in g ta nk .
No te 1: The highlight "H" on the lower right LCD corner is the prompt that means you can
long press key to get the help information about the current operation.
No te 2: if the LC D sh ow be llo w:
ZE LL
AIR CON SERVI CE STATIO N
Re f rig e rant ** .** KG
H
ERROR! CODE:E00
ELECTRONIC SCALE FAULT
** .**
ZERO BALANCE PLEASE!

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Thi s means the weigh ting sys tem is out of work, need to be
ca libr ated. press and come to ZERO BALANCE item.Mo re de t ail
inf orm ation ,pleas e re fer to 8. 3
6.2 Putting in the bottle for new oil
Unscrew the PAG oil bottle, put about 150 ml new oil in and screw it back to the
de ice.
6.3 Filling up the working tank
When the Air-Con Ser ice Station is started for the first time, the internal
refrigerant container must be filled with at least 6 kg from an external
refrigerant cylinder.
Also note the instructions on the refrigerant bottle.
The current refrigerant quantity is shown in the standby mode.
There are three different types of external refrigerant bottle a ailable:
■ Refrigerant bottles without a rising pipe: These refrigerant bottles ha e
one connection. When filling the Air-Con Ser ice Station, the connection
port must be at the bottom (turn the bottle upside down). As Pic 1
■ Refrigerant bottles with rising pipe: These refrigerant bottles ha e one
connection. When filling the Air-Con Ser ice Station, the connection port
must be on the top (place the bottle upright). As Pic 2
■ Refrigerant bottles with rising pipe: These refrigerant bottles ha e two
connections. To refill the Air-Con Ser ice Station, use the connection
marked with L (= liquid). When filling the Air-Con Ser ice Station, the
connection must be on the top (place the bottle upright). As Pic 3

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1. On standby mode, put the refill connector to the refrigerant bottle and fix it,
then join the LP adapter with the low pressure hose(blue) to the connector,
as Pic 4
Pic 4

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open the adapter, open the bottle al e and up side down it.press
key, use the or key to select the item you want (highlight field is
acti ated), select “INTERNAL TANK REFILL”
2. Press to confirm. Follow the instructions on the display.
3. Press to confirm. The quantity of refrigerant in the inner tank is shown.
4. The filling will stop automatically when the quantity of refrigerant is 9 KG
5. Close the refrigerant bottle al e, press to confirm. Press key
to start reco ery operation!
No te : you should reco er the refrigerant. If you do not recycle the
refrigerant inside the hose, it will cause refrigerant leakage when you
release connections, as this can cause frosty.
6. Disconnect the LP adapter from the external refrigerant bottle. The
de ice now is ready for operation.
FUNCTION
1．INNER TANK REFILL
2．LANGUAGE SELECT
3．ZERO BALANCE
INNER TANK REFILL
CONNECT THE LP HOSE TO
THE SOURCE TANK,OPEN THE
VALVE UP_SIDE DOWN IT .
REFILL
RUNNING **：**
RECOVERED *****G
Press ESC to exit
INNER TANK REFILL
FINISHED!
PRESS OK TO CONFIRM

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7 peration
When the automobile air-conditioning is ser iced, the engine and the
air-conditioning must be switched off.
7.1 Reco ery
Reco ery operation is the process that the Air-Con Ser ice Station
sucks the refrigerant from the ehicle A/C system, purity it and storage the gas
into the working tank. The equipment could automatically detect the gas is
enough or not for the operation.
1. Unscrew the caps of the ser ice port on ehicle and put on the LP/HP
adapters of the Air-Con Ser ice Station and open them.
2.Check the high and low pressure gauges. If the pointer is zero or
about, it means that no refrigerant is in the air-conditioning system, you can
select other functions directly. If there exist pressure inside, press
key, the de ice will start the reco ery and recycling process.
Note: The highli ght "R" on the lower right corner is the prompt that means you can
specially long press key for reco ery. The reco ery is only through the low
side ser ice port, and the operation will stop if the long pressed key is released. And the gas
quantity can not be measured in the process.
3. When the reco ery process is o er, it will discharge used PAG oil
automatically.
RECOVERY
FILTER DRIER **KG
TANK SPACE **KG
Press ESC to stop.
R
RECOVERY
FINISHED!
RECOVERED **:**KG
DRAINING OIL。。。。。

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4. After about 5 seconds , The oil draining process would be finished.
5. Press key to stop the alarm buzzer, then the reco ery process
finished!
Note: After first phase of reco ery, you need to spend some minutes, just waiting for more
refrigerant e aporate into gas, if the pressure inside the A/C raised, the equipment will go
on the reco ery process, or it will go to next step.
7.2 Vacuum
Vacuum operation is the process that the Air-Con Ser ice Station
e acuate the ehicle A/C system into a acuum state. The small quantity
gases are exhausted outside. In the process, the pressure inside the A/C
changes from the relative zero to absolute zero.
The equipment could automatically detect the pressure is suitable or not
for operation.
1. Press key, the de ice comes to acuum mode.
Note: at the lower right LCD corner there is a highlight "V", this also is a prompt that
means you can long press key for a manual acuum. If you do so, whate er
the pressure is, the gas would be exhausted outside. Be careful for this operation, the
introduced pressure is less than 0.5 bar, or when the gases rush out, the acuum pump oil
would spray.
VAC UU M
DE FA U LT ** ：**
Pr ess ESC to quit !
V
RECOVERY FINISHED!
PRESS OK TO CONFIRM!

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2. Use or to set the acuum time (suggest at least10 minutes).
3. Press , the de ice will start acuum operation.
4.The de ice will be finished automatically after expiry of the acuum time，
press return to the standby mode.
5. wait about fi e minutes and check the state changing from the LP gauge
indicator, if the pressure is raising, you need to confirm the
air-conditioning’s leakage. If leakage happens, you should repair it. If not,
continue the next process.
Note: if the A/C system is not opened to air, the suggested acuum time is
5-10 minutes. If it is, the minutes should be 20-30.
If there is an heating belt for the equipment, the suggested minutes is at
least 10 minutes. The heating belt only work during the acuum process.
7.3 Oil injection
This operation is to make up of new PAG oil into ehicle A/C system
though the Air-Con Ser ice Station. it must be a acuum state that the new oil
could be added into the A/C system.
1. Check the new oil bottle, make sure that the PAG oil is more than 50ml inside.
VAC UU M
RU N NI NG ** ：**
Pr ess
ES C
to
qui t!
VAC UU M FINI SHE D
PR ESS OK TO CONF I RM !

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2. Use or to adjust the oil quantity, then press OK, it will finish
automatically. Or long press key, the new PAG oil would be sucked
into the A/C system. Watch the scale of the PAG bottle, when the oil is added
with the desired quantity, stopped the operation.
3. Press key back to the standby mode, continue the next process.
7.4 Recharge
This operation is to fill with the refrigerant into the ehicle A/C system
though the Air-Con Ser ice Station. the quantity is measured by load cell and
it must be a acuum state that the gas could be added into the A/C system.
For this operation, the work tank should ha e at least 3 kg gas inside.
Usually, if the tank pressure is o er than 6 bar, the recharge will be done
quickly, or it need some special solution to resol e it.
1. Press key to come to recharge process.
Note: The highlight "G" at the lower right corner is the prompt that means you could
specially recharge the gas by long pressing ey. the charge only from the low
side port. And the gas quantity can not be measured.
RE CHAR GE
DE FA ULT *** * G
PR ESS F KEY TO USE
DATABAS E! G
OIL INJECTI ON
INJECTION 20 ML
PRESS OK TO START

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2. Press or key to adjust the refrigerant filling quantity. You
could check the amount on the ehicle, or press key to use the
database embedded.
3. When all are ready, press to start, it will recharge the air-conditioning
with the refrigerant.
4. The process will be stopped automatically when the set quantity of
refrigerant is completely filled into the A/C system .Press to back
to the standby mode.
5. Take off the quick couples from the A/C system and screw back the al e
caps to the ser ice port. And empty the ser ice hoses by reco ery
operation. The de ice is then ready for further use.
Note: some time the recharge maybe not finished in time, and the bellow
information displayed:
This is because tank pressure is not enough for the operation. Please go on
the operation by starting the automobile engine and A/C, let the Low side to suck
the gas into A/C system, it will automatically stop if the set gas quantity is finished.
RE CHAR GE
RU N NI N G **: * *
TH ERE ** * *g LEF T!
RE CHA RGE FINI S HED!
PRESS OK TO CONFIRM!
charging time exceed!
RUNNING... **:**
THERE g LEFT
H