Zell AC2000 User manual

ZELL AC2000 Automobile Air-Con Service
Solution with Printer & Heat Belt
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 Service Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Safety devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
4 Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5 Overview 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 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....15
7.1 Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..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 vacuum pump oil . . . . . . . . . . . … . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
8.5 Changing the internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.6 Hose compensation . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .29
8.7 Pressure rise wait . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .29
8.8 Other service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 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 of Air-Con Service Station, so that
any information needed is always at your hand.
1.1 Zell hotline
If you need more information about the Air-Con Service Station that is not
concerned in this manual, call Interequip Pty Ltd 18000EQUIP (1800037847)

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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 device effectively
2 Scope of delivery
The Air-Con Service Station and its accessories are carefully checked
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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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
3 Safety
3.1 General safety instructions
AC2000
Air-Con Service 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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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:
→Only use the device for its intended purpose.
→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.
→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 vehicle air
condition system.
→Wear personal safety equipment (goggles and gloves) and avoid 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 Service Station.
→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.
→Only used approved refrigerant bottles with safety valves to refill the
Air-Con Service Station.
→Drain the service hoses before you release connections.
→Do not operate the Air-Con Service Station in areas where there is a risk of
explosions (for example battery charging rooms or spraying booths).
→Always use the main switch of theAir-Con Service Station for switching it on
and off. Do not leave the device unattended when it is switch on.

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→Before you shut down the Air-Con Service 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 Service
Station or into the vehicle air-conditioning system. A mixture of compressed air
and refrigerant can be flammable or explosive.
3.2 Warnings on theAir-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

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protect lines or vessels from bursting if the pressure continues to rise despite
the action of the pressure monitor.
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 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 Service Station without the permission of Zell
■Damage to the device resulting from external influences.
■Incorrect operation
5 Overview of the Air-Con Service Station

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USER COMMUNICATION INTERFACE:
POWER SWITCH
Tank Pressure Gauge
High pressure gauge
Low pressure gauge
Printer
New oil
Drain oil

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Recovery key : to recover 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 service operation.