Zell AC1800 User manual

®
Automobile Air-Con Service Station
AC1800 Operation Manual

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contents
1 About this operation manual......................................................................................................2
1.1 Zell hot-line.............................................................................................................................2
2 For illustrating the symbols in this operation manual ................................................................3
2.1 Scope of delivery....................................................................................................................4
3 Safety......................................................................................................................................... 5
3.1 General safety instructions.....................................................................................................5
3.2 Warnings on the Air-Con Service Station...............................................................................7
3.3 Safety devices ........................................................................................................................7
4 Proper use.................................................................................................................................8
5 Overview of the Air-Con Service Station...................................................................................9
5.1 USER COMMUNICATION INTERFACE:.............................................................................10
6 First start-up.............................................................................................................................12
6.1 Setting up and switching on..................................................................................................12
6.2 Installing in the bottle for new oil ..........................................................................................13
6.3 Filling up the working tank....................................................................................................13
7 Operation.................................................................................................................................18
7.1 Recovery...............................................................................................................................20
7.2 Vacuum and Vacuum Test...................................................................................................24
7.3 Oil injection...........................................................................................................................27
7.4 UV injection...........................................................................................................................29
7.5 Recharge..............................................................................................................................32
7.6 FULLY AUTO........................................................................................................................36
7.7 Weigh Scale verification .......................................................................................................39
7.8 RECORD PRINT ..................................................................................................................42
7.9 Weight Scale and Pressure Sensor Zero.............................................................................43
7.10 SD Card data editing ..........................................................................................................48
8 Service tasks ...........................................................................................................................49
8.1 Inner tank refill......................................................................................................................49
8.2 Language select ...................................................................................................................49
8.3 Weight Unit...........................................................................................................................50
8.4 Other service ........................................................................................................................50
9. Disposal..................................................................................................................................51
9.1 Disposing of used fluids........................................................................................................51
9.2 Disposing of packaging material ..........................................................................................51
10 Trouble shooting....................................................................................................................52
11 Technical data .......................................................................................................................53
12 Spare part list.........................................................................................................................53

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1 About this operation manual
This operation manual describes the Zell Air-Con Service Station
This manual is for those who have the required professional ability of
providing the maintenance service on vehicle air conditioning system.
This manual contains all the instructions necessary for safe and effective
operating of the air Conditioning service Station. Read this operation manual
carefully before putting the device into using for the first time.
Also note the following:
■the operator should comply with the laws about the service of vehicle air-
conditioning by local government.
■the operator should be familiar with basic technical information of vehicle
air- conditioning
■Instructions from the refrigerant manufacturer
■Instructions from the car manufacturer
■Any special instructions on servicing vehicle air conditioning systems which
applied at your company
Keep this operation manual in the tool box ofAir-Con Service Station, so that
any information needed is always at your hand.
1.1 Zell hot-line
If you need more information about the Air-Con Service Station that is not
concerned in this manual, call the Zell Hot-line:

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2 For illustrating the symbols in this
Risk of damage to the machine or other material damage
Special information for using the device effectively
Format
Meaning
Example
KEY
Symbols used on the device
Press
„BOLD”
Display messages
„LANGUAGE”
■ Text
■ Text
List in any order
■Pressure monitor
■Pressure relief valves
1. Text
2. Text
3. Text
Actions to be carried out in the
order shown
1. Connect the device.
2. Switch on the device.
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
Remove the filter cartridge (E)
on the left side.

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2.1 Scope of delivery
The Air-Con Service Station and its accessories are carefully checked
before shipping.
After delivery, 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
AC1800
Air-Con Service Station
Blue hose with coupling for LP connection and red hose with HP connection
2 Containers for new 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 Service Station for the first time
Please note the following:
■the operator should comply with the laws about the service of vehicle air-
conditioning by the local government.
■the operator should be familiar with technical information of vehicle air-
conditioning
■Information form the refrigerant manufacturer
■Any special instructions on servicing vehicle air conditioning systems
which applied at your company
And also please pay attention to these massages:
→Risk of injury, This equipment should only be operated by certified
personnel.
→Only use the device for its intended purpose. To reduce the risk if injury,
care should be taken when moving this equipment.
→For indoor use only.
→Wear personal safety equipment (goggles and gloves) and avoid
touching refrigerant, as this can cause chilblains to your body.
→Use only Zell approved storage cylinder, part NO.5150998 with this
refrigerant recovery unit.
→Only use genuine R134a refrigerant .If other refrigerants are mixed in,
it can damage the Air-Con Service Station and the vehicle air condition
system.
→The Equipment has mistake inside or a wrong operation of the
equipment will cause a possible contamination of refrigerant in equipment
and it’s cylinder. Contaminated R134-a DO NOT USE, MUST BE
REPROCESSED.
→Only use correct type refrigerator oil (refrigerant oil) used with the
R134a.If other oil are mixed in, it can damage the vehicle air condition
system.
→This equipment should be used in locations with mechanical ventilation
that provides at least four air changes per hour or the equipment should be

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located at least 18(457 mm) in above the floor. Do not inhale refrigerant
gas . Although the gas is non-toxic, it displaces the oxygen you needed.
→This equipment should NOT be used in the vicinity of spilled or open
containers of gasoline.
→To reduce the risk of fire. connect only to a circuit provide with 20
amperes maximum branch circuit over current protection in accordance
with the National Electric Code, ANSI/NFPA 70.
→Avoid the use of an extension cord because the extension cord may
overheat. However, if you must use an extension cord, the cord shall be
NO.14 AWG minimum.
→Each time before you start up the device or add gas to the Air-Con
Service Station, first check whether the device is undamaged and
components are not lost. Do not start up the Air-Con Service Station if it is
damaged.
→Always use the main switch of the Air-Con Service Station for
switching it on and off. Do not leave the device unattended when it is
switch on.
→Before you shut down the Air-Con Service Station, make sure that the
selected program has ended. Otherwise refrigerant can leak.
→Avoid breathing A/C refrigerant and lubricant vapor or mist, exposure
may irritate eyes, nose and throat. To remove refrigerant from the A/C
system, Use only equipment certified for the type of refrigerant being
removed to meet the requirements of SAE J2210(HFC-R134a recycling
equipment.) Additional health and safety information may be obtained from
refrigerant manufactures.
→Do not pressure test or leak teat equipment and/or vehicle air
conditioning system with compressed air. Some mixtures of air and
refrigerant have been shown to be combustible at elevated pressures.
these mixtures, if ignited, may cause injury or property damage. Additional
health and safety information may be obtained from refrigerant
manufacturers.
→Recover the service hoses before you release connections.
→Do not make any modifications to theAir-Con Service Station.

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3.2 Warnings on the Air-Con Service Station
Be careful
Observe the operation manual.
Protect the device against rain
Wear gloves when handling refrigerants.
Wear goggles when handling refrigerants.
Horizontal holding the station
Caution for fire
3.3 Safety devices
■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 vessels from bursting if the pressure continues to rise
despite the action of the pressure monitor.

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4 Proper use
The Air-Con Service Station is intended for performing maintenance on vehicle
air-conditioning systems. The device is designed for commercial use.
The Air-Con Service Station may be operated by persons who have the required
professional ability for servicing air-conditioning systems.
This Air-Con Service Station may only be used to service vehicle
air-conditioning systems in which R134a refrigerant is used.
Zell assumes no liability for damage resulting from the following:
■Use for purposes more than those described in this operation manual.
■Modification to theAir-Con Service Station without the permission of Zell
■Damage to the device resulting from external influences.
■Incorrect operation

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5 Overview of the Air-Con Service Station
（1）used oil bottle （2）new oil bottle
（3）uv oil bottle （4）pressure gauge for HIGH and LOW
（5）LCD （6）HP and LP hoses
（7）pressure gauge for working tank （8）working tank (30Lbs)
（9）heating belt (optional item) （10）printer
（11）front wheel （12）power switch
（13）near- wheel
（7）
(back)
（5）
（4）
（9）
（6）
（8）
（1）
（2）
(12)
（3）
(11)
（10）
(13)
(inside)

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5.1 USER COMMUNICATION INTERFACE:
Auto key: one press operation for all steps automatically
Recovery : to recover the A/C refrigerant into the working tank
Vacuum : to extract Non-condensable gases from A/C system
New oil : to inject new oil into vehicle A/C system.
UV : to inject UV into vehicle A/C system.
Recharge key : to refill refrigerant into vehicle A/C system.

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print : Record the operations and to print receipt.
OK : it allows to start the operation step.
Stop : it allows to cancel the operation step.
Home: come to the main interface.
Back: back to the previous interface.
next step: go to the next interface.
Menu: Access to functional interface.

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6 First start-up
6.1 Setting up and switching on
110-120V 60Hz or 220-240V 50Hz Power supply must be firmly
grounded. If not, it will cause the weight scale a incorrect
operation; it also may cause an injury to operators from an
electric shock.
Before operation the device must be on a level, flat surface so that
measurement can be made correctly
1. Place Air-Con Service Station to the workplace and lock the front
casters.
2. Plug in the Air-Con Service Station .
3. Switch on the Air-Con Service Station.it come to the standby mode:
“**.* Kg” describes the quantity of refrigerant in working tank.
Gas amount inside the tank
Rest Percent for pump
oil
Rest Percent for driers
Time
Room Temperature
Menu

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6.2 Installing in the bottle for new oil
Unscrew the refrigerant oil bottle, put about 150 ml new oil in and screw it back
to the device.
6.3 Filling up the working tank
When the Air-Con Service Station is started for the first time, the internal
refrigerant container is suggested be filled gas 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.
■ Refrigerant bottles without a rising pipe: These refrigerant bottles have
one connection. When filling the Air-Con Service Station, the connection
port must be at the bottom (turn the bottle upside down).

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RED ONE IS THE VAPOR PORT OF THE SOURCE TANK
Only LIQUID refrigerant is recommended.
■For other type of source tank, be sure that Only Liquid port should be
connected to the refill adapter.
BLUE ONE IS THE LIQUID PORT OF THE SOURCE TANK
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,
open the adapter, open the bottle valve and up side down it. Touch the tank 3
continuously , the LCD will show
2. Touch the number to input the gas amount that you want to refill into the
working tank. Then touch the to confirm, Follow the instructions
on the display.
Touch here

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Tip: The filling will stop automatically when the quantity of
refrigerant is desired, the LCD will show
3. Close the refrigerant bottle valve and disconnect the LP adapter，
4. press to confirm. And start hose cleaning operation to collect the
gas reminded in hose !

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Note1: you should recover the refrigerant. If you do not recover the
refrigerant inside the hose, it will cause refrigerant leakage when you
release connections, as this can cause frosty.
Note2: you can not select the recovery operation to instead of this one,
or it will speed up the usage of filter driers.
5.When the hose cleaning program finished, it will show and press to
come back to the standby mode.
Tip: If the gas amount that you inputted in the last step not
finished, but the refrigerant bottle is empty ,the LCD will show

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6. Press to confirm, disconnect the LP adapter from the external
refrigerant bottle. And the program will come back to the standby mode.

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7 Operation
When the automobile air-conditioning is serviced, the engine and the
air-conditioning must be switched off.
1.When you power on the machine, the LCD will stay at the standby mode.
2.press the , it will lets you input the license plate

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3.touch the plate, it will show you a keyboard to input
4.when you finished your input, touch the to the option menu.