Zell AC1000-3G User manual

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

1
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

5
Flow chart
4.1 Overall layout

6
AC1000-3G BLOCK AND SOLENOID LAYOUT
SV9 SV6 SV4 SV5
SV8
SV7
SV2
SV3
SV1

7
4.2 eneral flow chart
4.3 Recovery

8
4.4Purge and drain oil
4.5 Vacuum

9
4.6 PA oil injection
4.7 Recharge

10
4.8 Pressure up
4.9 Pressure down

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5 Function check
5.1 Recovery
5.1.1 The working tank must have at least 2.5Kg of refrigerant in it to perform this test.
5.1.2 Plug in the cord to 220V 50HZ power supply, Turn ON the main power switch.
220V 50Hz Power supply must be firmly grounded
5.1.3 Confirm that the HP, LP quick coupler and hoses are well fixed to the units. And all
tank hoses are properly attached to the working tank.
5.1.4 Press Function button, and enter Other Service Item, use password 9227. Enter
the M. control valve interface. Long press the RECOVERY button, check the output of the
main control board is CN2,CN4,CN8. That means the SV8/compressor, SV4/SV6, SV1/fan
are working. Or please check the circuit connection.
5.1.5 After check the output, If the station is not OK, Pressurize the high and low side
hoses with refrigerant by function recharge, long press the key CHARGE button.
5.1.6 Start the recovery by long pressing the “R” button for at least 30 seconds. Suction
will begin and the LP gauge will be pulled into -0.2bar vacuum at least. Or please check if
the flow routine blocked, The solenoid valve and the compressor are in health working state.
5.2 Vacuum
5.2.1 Confirm that the HP, LP quick coupler and hoses are well fixed to the units. And all
tank hoses are properly attached to the working tank.
5.2.2 Press Function button, and enter Other Service Item, use password 9227. Enter
the M. control valve interface. Long press the VACUUM button, check the output of the
main control board is CN3,CN8. That means the SV1/fan, SV5/vacuum pump are working.
Or please check the circuit connection.
5.2.3 Start the vacuum by long pressing the VACUUM button for at least 20 seconds.
Suction will begin and the LP gauge will be pulled into -0.85bar vacuum at least. Or please
check if the flow routine blocked, the solenoid valve and the compressor are in health
working state.

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5.3 Recharge
5.3.1 Confirm that the HP, LP quick coupler and hoses are well fixed to the units. And all
tank hoses are properly attached to the working tank.
5.3.2 Press Function button, and enter Other Service Item, use password 9227. Enter
the M. control valve interface. Long press the RECHARGE button, check the output of
the main control board is CN5, CN8. That means the SV1/fan, SV2 are working. Or please
check the circuit connection.
5.3.3 Pressurize the high and low side hoses with refrigerant by function recharge, long
press the key CHARGE button for at least 20 seconds. Check if the tank gauge pressure is
same as the LP gauge. If not, Or please check if the flow routine blocked, the solenoid
valves are in health working state.
5.4 Output check table
Long Press Key
In
M. Control Valve
Main control board output Load
RECOVERY CN2, CN4, CN8. SV8/compressor, SV4/SV6, SV1/fan
VACUUM CN3,CN8 SV1/fan, SV5/vacuum pump
RECHAR E CN5, CN8. SV1/fan, SV2
PA OIL CN7, CN8. SV1/fan, SV3
PUR E CN4, CN6, CN9. SV4/SV6, SV7, SV9
HINT CN4, CN5, CN6, CN8 SV4/SV6, SV2, SV7, SV1/FAN
Other key NULL NULL

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6 Load cell check
6.1.1 Press Function button, and enter Other Service Item, use password 7278. Enter
the Data Info interface. There displays the raw data and the convert data, The Raw data is
the original data from the load cell, the convert data is the manual handled data.
To check if the scale is ok or not, remove the tank on the load cell plate. Confirm that
there is nothing on it.
Then check the raw data and the convert data. Normally the data is as below,
Raw data: 2500---2550
Convert data -15 ---15
6.1.2 If the raw data is incorrect or both data are incorrect, please check the installation
of the load cell; confirm that there is nothing interferential. If problem not resolved, change
load cell or main control board.
6.1.3 If the raw data is ok but the convert dada is no good. That means the scale needs
to be calibrated.
6.1.4 Prepare a sample weight of 10 kg. Press Function button, and enter Other
Service Item, use password 5814. Enter the Cal.-scale interface. Please follow the LCD
display to calibrated the scale.

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7 Compressor Suction and Discharge Pressure Test
7.1 eneral Spec. of compressor
7.1.1 Disconnect all fittings from the compressor. Cap the Suction port. Install a LP
gauge on the process port. Install a HP gauge on the discharge port. Start the compressor
and monitor the gauge readings the discharge pressure should build to 17 bar in HP gauge.
And the compressor should pull a -0.85 bar vacuum in LP gauge.
Shut off the compressor. The LP gauge and HP gauge values should hold for 30
seconds to one minute. If not, proceed to step-7.3, then repeat test. If no improvement,
replace the compressor.
7.1.2 If the compressor has weak suction or discharge, check the oil level and add oil if
necessary. If the oil level is okay or oil was added with no improvement, replace the
compressor

15
8 Trouble shooting
8.1 No display
Check for proper power source, check circuit breaker and electrical connectors for
damage or corrosion.(Refer to compressor specifications on wiring diagram if needed.
if not receiving power, check the continuity of the wring between solenoid and circuit
board-repair as needed.
If the wiring is correct and no power is being applied to the solenoid, replace the main
control board.
8.2 Recovery not start
Check for relative load are correct voltage received.
Check for the SW2 is in work.
8.3 Recovery endless
Check for the SW2 is in work.
Check for the Suction and Discharge performance of compressor
Check for the block on flow chart
8.4 Will Not Evacuate
Check for power switch is closed on the Vacuum pump.
Check for relative load are correct voltage received.
8.5 Will not charge
Check for relative load are correct voltage received.
Check for if the refrigerant is enough
8.6 Recharge low efficiency
Check for the tank pressure is above 6 bars. If the pressure is less than 6 bar (the
environment temperature is lower than 27℃) the recharge maybe can’t be finished in the
course of nature. The process could be done by start the engine and power on the A/C, the
rest R134a could be sucked into the A/C system of the car, and the AC1000 will stop the
process automatically if the right quantity refrigerant is recharged. Please also refer to the
HINT information on the AC1000 LCD

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9 Disposal
9.1 Disposing of used fluids
Used oil is hazardous waste. Do not mix used oil with other fluids.
Keep used oil in suitable containers prior to disposal.
9.2 Disposing of packaging material
■The cardboard packaging material should be disposed of with other waste paper.
■Plastic packaging material should be added to other recyclable waste.
9.3 Scrapping the old unit
■If you wish to scrap the Air-Con Service Station, first completely drain it of all liquids
and dispose of them in an environmentally responsible manner.
■Take the old device to your nearest recycling centre .

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10. Spare part list
NO.
Parts Specification
1
Hermetic R134a compressor COM013
2
Vacuum pump PUM101
3
Filter drier DRY080
4
Vacuum pump oil POL250
5
Solenoid valve (sv1.6) SOL002
6
Solenoid valve (sv3) SOL003
7
Low pressure gauge AL080
8
High pressure gauge AH080
9
Tank pressure gauge AT040
10
Service hose for low pressure side(blue) HSB250
11
Service hose for high pressure side(red) HSR250
12
Service coupling for low pressure QAL030
13
Service coupling for high pressure QAH030
14
Load cell LDC030
15
Key pad KPD011
16
Main board MCB011
17
R134a Tank TAK145
18
Low pressure switch LSW005
19
High pressure switch HSW018
20
Drain oil switch SSW026
21
Power switch PSW001
22
Oil bottle PEB250
23
Vapor hose (blue) HSB030
24
Liquid hose(red) HSR030

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8. High pressure
gauge
11.Service hose for
high pressure
10.Service hose for low
pressure
12.Service coupling
for low pressure
13.Service coupling for
high pressure
1. Hermetic compressor
7. Low pressure
gauge
2. Vacuum pump
3.Filter drier
23.
Vapor
hose
4.Fan
24.Liquid hose 6. Solenoid valve
(SV6)
17.Tank
20.Drain oil switch
19.High pressure
switch
18.Low pressure
switch

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ZELL, Always Solution
END
Add: No.2,XIN CAN MINLIAN INDUSTRY DEVELOPMENT ROAD
HAININ DIN QIAO ZHEJIAN PROVINCE
Tel: [phone] 1215
Fax: [phone] 6636
E-mail: [e-mail]