Zell AC1000-3G User manual

ZELL
®
ZELL MOBILE AIR-CON SERVICE SOLUTION
Mobile Air-Con Service Solution
AC1000-3 Service Manual

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Contents
1 About this service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.1 ZELL hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . 2
2 Safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3 Electronic diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1 Main power diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . . . . . . . . . . ..4
3.2 Main control board diagram . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. 4
4 Flow chart. . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Overall layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 5
4.2 eneral flow chart . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . ... . . . . . . . . . . . 6
4.3 Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................ . . . 6
4.4 Purge and drain oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . .. . . . . . . . .. . ... . . . .
4.6 PA oil injection . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................... . . . . . . . . . .8
4.7 Recharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . .8
4.8 Pressure Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . .9
4.9 Pressure Down . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. . . .. . . . . . .. . .. . . .. . . . . .10
5.1 Recovery .....................................................................10
5.2 Vacuum ........................................ . . . ..........................10
5.3 Recharge ................................................. ...................11
5.4 Output check table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6 Load cell check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . .. . . . . . . 12
Compressor Suction and Discharge Pressure Test . . . . . . . . . . . . . . . . . .. . .. . . .. . . . . . . . 13
8 Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .14
8.1 No display
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.2 Recovery not start
. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.3 Recovery endless
. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.4 Will Not Evacuate
. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.5 Will not charge
. . . . . . . . . . . ... . . . . ... . . . ... . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.6 Recharge low efficiency
............................................................14
9. Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
9.1 Disposing of used fluids
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9.2 Disposing of packaging material
...................................................15
9.3 Scrapping old unit
..............................................................15
10. Spare part list.................................................................16

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1 About this service manual
This service manual describes the service task of ZELL AC1000 Air-Con Service
Station
This manual is for those who perform repair and maintenance on AC1000 and have the
expertise required to do so.
This manual contains all the instructions necessary for safe and effective service
operation of the AC1000 Station. Read this service manual carefully before putting the
device into operation.
Also note the following:
■ The operator should be familiar with basic technical information of vehicle air-
conditioning
■ The operator should be familiar with basic technical information of electronic parts,
components and assembly.
■The operator should be well trained about how to use the AC1000.
■Any special instructions on servicing vehicle air conditioning systems which apply at
your company
Keep this service manual in the compartment of the Station been serviced, so that any
information you need is always at hand.
1.1 ZELL hotline
If you need more information on the Air-Con Service Station that is not contained in this
manual, call the ZELL Hotline: [phone]

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2 SAFETY WARNINGS
■ it’s extremely important to follow the instructions in this manual. Do NOT attach any hoses or
accessories until prompted by the unit. Improper setup and failure of the unit will result.
■ always wear protection and protective clothing when working with refrigerants. Refrigerant can cause
injury. Read and follow all warnings in the operator’s manual and this service manual before service the unit.
■Disconnect hoses and tubes with extreme caution as they may contain liquid refrigerant under pressure.
■Always disconnect the unit from the power source before making any repairs or replacements to the
components. Risk of electrical shock! Avoid the use of extension cords because the extension cords may
overheat. However, if you must be NO.14AW minimum and should not exceed more than 25 feet in length.
■Always depressurize the machine before servicing or replacing any components.
■Pressurized tanks contain liquid refrigerant. Overfilling of the tank may cause violent explosion and
possible injury or death. Do NOT recover refrigerants into a non-refillable storage container. Federal
regulations require refrigerants to be transported only in containers meeting DOT spec.4BW or DOT
spec.4BA.Or the relative EU refillable tank standards.
■Be sure that the refrigerant level in the tank does not exceed 80% of the tank volume. Failure to monitor
the level could result in excessive hydrostatic pressure, causing physical injury or death.
■If scale assembly and circuit are not calibrated, scale can overfill the tank, causing possible explosion
and/or vehicle overcharge.
■Use only ZELL Designated Replacement Components when servicing your equipment. Refer to the
operator’s manual or this service manual for correct replacement part number(s).
■When replacing component, make certain the new parts are connected exactly as your instruction sheet
directs you to do. If an instruction sheet was not included, connect the replacement part just like the original.
Mark or label wire and plumbing disconnections so replacing the new parts will confirm the previous
configuration.
■Use this unit only with R-134a OR R-12 refrigerant. The user must dedicate the unit to only one type of
refrigerant. Do NOT attempt to adapt the unit for another refrigerant. Do NOT mix refrigerant types through a
system or in the same container, mixing of refrigerants will cause sever damage to the unit and the vehicle air
conditioning system.
■Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may cause personal injury,
especially to the eyes, nose, throat and lungs. Use the unit in locations with mechanical ventilation that
provides at least four air change occurs, ventilate work area before resuming service.
■Keep hands away from moving parts. Such as a running fan.
■Do NOT use compressed air to pressure test or leak test the unit or vehicle A/C system. Some mixtures
of air and refrigerant have been shown to be combustible at elevated pressures. These mixtures are potentially
dangerous and may result in fire or explosion causing injury or property damage.
■Never use the parts, components and assembly as a un-designed purpose from the station.
This may cause extremely dangerous.

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3 Electronic diagram
3.1 Main power diagram
3.2 Main control board diagram

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Flow chart
4.1 Overall layout

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AC1000-3G BLOCK AND SOLENOID LAYOUT
SV9 SV6 SV4 SV5
SV8
SV7
SV2
SV3
SV1

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4.2 eneral flow chart
4.3 Recovery

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4.4Purge and drain oil
4.5 Vacuum

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4.6 PA oil injection
4.7 Recharge