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Operating
Manual
Automatic A/C Charging Station
For Refrigerant R-134a Systems Only!
Safety
Precautions
This equipment is intended for professional use only. The service technician should be familiar with proper servicing of air conditioning systems as well as the dangers and use of refrigerants and pressurized components before using the equipment.
▲
WARNING
▲
Always wear safety goggles when working with refrigerants. Contact with refrigerants can cause injury.
Connecting hoses to the wrong ports may cause personal injury or may damage the equip-
ment. Check the operating manual for your air conditioning system for the correct hookup.
Disconnect hoses with extreme caution! All hoses may contain liquid refrigerant under pressure.
Contact with refrigerant can cause injury. Wear proper, personal protective equipment, including safety goggles. Point the disconnected end of a hose away from you and anyone who is nearby.
Use only with refrigerant type R-134a! Cross-contamination with other refrigerant types will cause severe damage to the A/C system and to service tools and equipment. Do not mix refrigerant types through a system or in the same container!
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose
and throat. To remove R-134a from the A/C system, use service equipment certified to meet the requirements of SAE J2210 (R-134a recycling equipment). If accidental system discharge occurs, ventilate work area before resuming service.
HFC-134a service equipment or vehicle A/C systems should not be pressure tested or leak
tested with compressed air. Some mixtures of air/HFC-134a 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. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Improper use or connections may cause electrical shock hazards. Read and follow these instructions carefully and take all necessary precautions to avoid electrical shock hazards. Before energizing circuits, be sure that all associated devices are properly grounded. Unplug the station from the power source before removing the control box.
Limited
Warranty
This product is warranted to be free from defects in workmanship, materials, and components for a period of one year from date of purchase. All parts and service center labor required to repair defective products covered under the warranty will be at no charge. The following restrictions apply:
1. The limited warranty applies to the original purchaser only.
2. The warranty applies to the product in normal usage situations only, as described in the Operating Manual. The product must also be serviced and maintained as specified.
3. If the product fails, it will be repaired or replaced at the option of the manufacturer.
4. Transportation charges for warranty service will be reimbursed by the factory upon verification of the warranty claim and submission of a freight bill for normal ground service. Approval from Robinair must be obtained prior to shipping to either an authorized service center or the factory.
5. Warranty service claims are subject to factory inspection for product defect(s).
6. Robinair shall not be responsible for any additional costs associated with a product failure including, but not limited to, loss of work time, loss of refrigerant, and nonauthorized shipping and/or labor charges.
7. All warranty service claims must be made within the specified warranty period. Proofof-purchase date must be supplied to the manufacturer.
8. Use of Robinair charging equipment with non-authorized refrigerants will void our warranty. Authorized refrigerants are listed on the equipment or are available through our Technical Service Department.
This Limited Warranty does not apply if:
• The product, or product part, is broken by accident.
• The product is misused, tampered with, or modified.
• The product is used for recharging any substance other than the specified refrigerant type.
Introduction ................................................................................................................... 2
Set Up Instructions ....................................................................................................... 2
Preparing the Vacuum Pump .................................................................................. 2
Diagram of Vacuum Pump Components ................................................................. 2
Installing a Refrigerant Tank .................................................................................. 3
Diagram of Disposable Tank Installation ............................................................... 3
Diagram of Refillable Tank Installation ................................................................. 4
Removing an Empty Tank ........................................................................................ 4
Using the Heater Blanket ........................................................................................ 4
Operating Procedures ................................................................................................... 5
Summary Chart of Operating Procedures ............................................................... 5
To Attach Hoses to the System ................................................................................ 5
To Diagnose System Problems ................................................................................. 5
To Add Refrigerant to Partially Charged Systems ................................................. 5
To Recover Refrigerant ............................................................................................. 6
To Program Vacuum/Charging Cycle ...................................................................... 6
To Use Automatic Vacuum/Charging Cycle ............................................................ 6
To Check Final System Operation ........................................................................... 7
To Disconnect the System ........................................................................................ 7
Maintenance Instructions ............................................................................................. 7
Storing the Station .................................................................................................... 7
Maintaining the Vacuum Pump ............................................................................... 7
Checking the Scale Accuracy ................................................................................... 7
Calibrating the Scale ................................................................................................ 8
Using Manual Diagnostics ....................................................................................... 8
Additional Operating Guidelines ................................................................................. 9
How to Use the Controls ........................................................................................... 9
Diagram of Control Components ............................................................................. 9
Using the Keypad ...................................................................................................... 10
Diagram of Keypad ................................................................................................... 10
Using the Display Panel ........................................................................................... 10
Quick Reference Chart .............................................................................................. 11
Diagram of Display Panel ........................................................................................ 11
Replacement Parts List ................................................................................................. 12
Troubleshooting Tips ..................................................................................................... 13
Temperature/Pressure Relation Chart ........................................................................ 14
Conversion Chart .......................................................................................................... 14
Table of
Contents
Glossary of
Terms
A/C
System
Tank
Station
Air conditioning
The A/C system being serviced
The refrigerant supply tank
The automatic A/C charging station
U.S. Patent Nos.: 4,523,897; 5,005,375; 4,688,388 RE: 33,212
Other U.S. and Foreign Patents Pending
R-134a Smart Cart ® Automatic A/C Charging Station
1
2
Introduction
This automatic A/C charging station is designed with you in mind. It is accurate, easy to program, and simple to use.
Before using the station, read and understand all instructions and warnings in this operating manual.
The 220V 50Hz models have some operating exceptions, which are noted in this operating manual.
In addition, all measurements are metric and the manifold is equipped with kPa/ bar gauges showing temperature in degrees Celsius.
Before operating the 220V 50Hz model, plug the short power cord from the upper control box into the outlet on the lower power box. Plug the main power cord into a 220V 50Hz power source that is free of transients and electrical noise.
Set Up
Instructions
To set up the station for operation, you need to prepare the vacuum pump and install the refrigerant tank.
PREPARING THE VACUUM PUMP
The VacuMaster ® vacuum pump is shipped without oil in the reservoir.
Before starting the station, you must fill the pump with oil and remove the exhaust plug from the end of the pump’s handle.
Note: The Iso-Valve TM isolation valve on the side of the pump must remain open
(the position shown in the illustration) for the station to operate.
CAUTION!
Do not attempt to run the vacuum pump when the manifold gauge set shows pressure readings above 5 psi.
In the vacuum mode, positive pressure will:
• High pressure — not allow the vacuum solenoids to open.
• Low pressure — blow oil out of the pump handle when the vacuum solenoids do open.
Running the vacuum pump with positive pressure locks high pressure between the two solenoids and prevents operation of the pump.
Follow these procedures to prepare the vacuum pump for use with the charging station.
1. Remove and discard the exhaust plug from the end of the pump’s handle.
2. Remove and retain the black plug on the oil fill port.
3. Pour vacuum pump oil into the oil fill port until oil appears in the sight glass on the reservoir. The approximate oil capacity of the pump is 13 ounces (384 milliliters).
4. Close both the high side and low side valves on the station’s manifold.
OIL FILL PORT
EXHAUST PLUG
SIGHT
GLASS
ISO-VALVEˇ
Diagram of Vacuum Pump Components
OIL
DRAIN
VALVE
© 1991 Robinair Division, SPX Corporation
5. Plug the station into the proper voltage outlet, and turn on the MAIN
POWER switch.
6. Simultaneously press the ENTER and zero keys on the keypad to access the manual diagnostic mode.
7. Press “1” on the keypad to start the pump.
8. While the pump is running, add enough vacuum pump oil so that the oil level is even with the line on the reservoir’s sight glass.
9. Press “1” or the RESET CYCLE key on the keypad to stop the pump.
10. Replace the black plug on the oil fill port.
IMPORTANT!
For maximum performance, change the vacuum pump oil frequently (approximately after every four hours of running time). We recommend using our Premium High Vacuum
Pump Oil; it is specifically blended to maintain maximum viscosity at normal running temperatures and to improve cold weather starts (see the “Replacement Parts List”).
Read and follow the detailed instructions in the Vacu-Master ® Vacuum Pump
Operating Manual. You do not need to return the warranty registration card contained in the Vacu-Master ® Vacuum
Pump Operating Manual — return only the warranty registration card attached to the station to validate your warranty.
INSTALLING A REFRIGERANT TANK
Follow these steps to install a refrigerant tank on the charging station.
▲
WARNING
!
▲
Always wear safety goggles when working with refrigerants.
Read and follow all warnings at the beginning of this manual before operating the unit.
Connecting hoses to the wrong ports may cause personal injury or may damage the equipment.
Read and follow all warnings at the beginning of this manual before operating the unit.
Use only with refrigerant type R-134a!
Cross-contamination with other refrigerant types will cause severe damage to the station and to tools and equipment.
Do not mix refrigerant types through a system or in the same container!
1. Attach the station’s yellow charging hose to a full refrigerant tank, as follows:
•Disposable tanks — Connect the yellow hose, open the tank’s valve, and place the inverted tank (with its valve down) on the scale platform.
Be sure to center the tank over the stud welding point. Use only tanks designed for use with R-134a, including Acme threads on the fittings.
Set Up
Instructions
(Continued)
Dual Purpose
Hold-Down
Bracket
Bulk Refrigerant Tank
(Not Included)
Yellow Hose To
Refrigerant
Solenoid
Ball
Valve
Tank
Valve Handle
Diagram of Disposable Tank Installation
R-134a Smart Cart ® Automatic A/C Charging Station
3
4
Set Up
Instructions
•Refillable tanks — Leave the tank upright, attach the yellow charging hose to the blue LIQUID valve on the tank, and open the blue valve.
2. Open the ball valve on the yellow charging hose (the open position runs parallel to the hose).
Note: Use a maximum tank size of 50 pounds (23 kilograms) with this charging station.
3. Fasten the tank securely with the tank hold-down bracket. Place the heater blanket around the center of the tank, and fasten it securely (see
“Using the Heater Blanket”).
4. Secure the retaining strap around the tank.
Note: Adjust the strap so that it comes in contact with the tank, but is not tight
around the tank .
5. If the tank was changed after pressing the HOLD key to interrupt the cycle, press the CONT key or RESET
CYCLE key, depending on the operation you require next.
REMOVING AN EMPTY TANK
Follow these steps to remove an empty refrigerant tank from the charging station.
1. If the station is operating, press the
HOLD key. You do not need to turn off the MAIN POWER switch.
▲
WARNING
!
▲
Disconnect hoses with extreme caution!
All hoses may contain liquid refrigerant under pressure.
Read and follow all warnings at the beginning of this manual before operating the unit.
2. Disconnect the hose from the tank.
3. Release the retaining strap buckle.
4. Loosen the wing nut on the holddown bracket and remove the empty tank from the platform.
USING THE HEATER BLANKET
A heater blanket speeds the transfer of refrigerant and assures a complete charge by raising the pressure within the refrigerant tank.
1. Wrap the heater blanket around the refrigerant tank, secure it with the
Velcro
®
strap, and plug its power cord into the heater outlet on the bottom of the control box (right receptacle).
2. Turn on the MAIN POWER switch on the front of the station.
The heater blanket is on whenever the station’s MAIN POWER switch is on, eliminating the need for manual control.
You can extend the life of the heater blanket by unplugging the heater when it’s not being used or turning off the
MAIN POWER switch.
Blue LIQUID Valve
Ball Valve
Yellow
Hose To
Refrigerant
Solenoid
Bulk
Refrigerant
Tank
(Not Included)
Platform
Mount
Ring
Diagram of Refillable Tank Installation
© 1991 Robinair Division, SPX Corporation
Before operating the 220V 50Hz model, plug the short power cord from the upper control box into the outlet on the lower power box. Plug the main power cord into a 220V 50Hz power source that is free from transients and electrical noise.
The chart below summarizes the steps in each of the following sections.
TO ATTACH HOSES TO THE SYSTEM
1. Be sure all valves on the manifold are closed.
▲
WARNING
!
▲
Connecting hoses to the wrong ports may cause personal injury or may damage the equipment.
Check your A/C system operating manual for the correct hook-up.
Use only with refrigerant type R-134a!
Cross-contamination with other refrigerant types will cause severe damage to the station and to tools and equipment.
Do not mix refrigerant types through a system or in the same container!
2. Attach the red high side hose’s coupler to the high side of the A/C system.
3. Attach the blue low side hose’s coupler to the low side of the A/C system.
Note: The manifold is ported so that the gauges indicate pressure whether or not the valves are open.
TO DIAGNOSE SYSTEM PROBLEMS
1. Start the A/C system and watch the gauge pressures (refer to the manufacturer’s specifications for proper operating pressures).
2. Perform any other visual and diagnostic inspections recommended by the manufacturer.
3. If the A/C system is operating properly, disconnect the hose couplers from the A/C system. To recharge or make necessary repairs, see the appropriate sections that follow.
TO ADD REFRIGERANT TO PARTIALLY
CHARGED SYSTEMS
1. In the program mode, press ADD .2
lbs. REFRIG. The messages “AUTO-
MATIC” and “REFRIGERANT” appear on the display.
2. Open the low side valve. The station dispenses .2 pounds (.1 kilograms) of refrigerant, then displays the message “CPL.” Close the low side valve.
3. Monitor the A/C system operating pressures. Correct any low charge indications by pressing RESET
CYCLE; repeat Step 1 as necessary.
Note: There are other A/C system problems which cause symptoms similar to a low refrigerant charge — refer to your operator’s manual or a reliable A/C troubleshooting chart. If adding one pound of refrigerant does not correct the low charge symptoms, you may need to recover and/or recharge refrigerant, as described next.
Operating
Procedures
SUMMARY
1.
Attach hoses to the A/C system.
2.
Start the A/C system and compare operating pressures to manufacturer’s specifications.
3.
Add a partial charge, if necessary.
4.
Discharge the A/C system, if required.
5.
Program the vacuum/recharge cycles.
6.
Start the A/C system and perform final operating check.
7.
Disconnect the hoses from the A/C system.
Summary Chart of Operating Procedures
R-134a Smart Cart ® Automatic A/C Charging Station
5
6
Operating
Procedures
TO RECOVER REFRIGERANT
IMPORTANT!
Use a recovery unit. Do
not vent refrigerant to the atmosphere.
1. Be sure the A/C system is turned off, then connect the yellow hose from the manifold’s center port to your recovery unit’s inlet port.
2. Open the manifold’s red high side valve, blue low side valve, and center valve, and start the recovery unit.
Follow the recovery unit’s instructions to recover refrigerant.
TO PROGRAM VACUUM/
CHARGING CYCLE
Vacuum is programmed in minutes and refrigerant is programmed by weight. If no quantity for any particular category is required, enter zeros.
1. If the message “PROGRAM” is not displayed, press RESET CYCLE.
2. The message “VACUUM” should appear on the display. If it does not, press the REVIEW PROGRAM key repeatedly until it does.
Note: Follow the A/C system manufacturer’s recommendations for the proper vacuum and refrigerant requirements.
3. Press the appropriate number keys until the desired vacuum time appears on the display. Enter vacuum time in whole minutes.
For example, to program 20 minutes, press two and zero — the display shows “20.00.” Press ENTER and the display flashes once indicating the programmed data is accepted.
4. Press the REVIEW PROGRAM key.
The message “REFRIGERANT” appears on the display. Enter the amount of refrigerant to be recharged to hundredths of a pound.
For example, to program 2 3 /
4
pounds, press two, seven, five and ENTER.
The display shows “2.75” and flashes once, indicating the programmed data is accepted. To program 2 1 /
2 pounds, press two, five, zero and
ENTER — be sure to add the last zero.
Note: Use the convenient conversion chart on the back cover of this manual if you need help converting ounces to hundredths of a pound.
TO USE AUTOMATIC VACUUM/
CHARGING CYCLE
IMPORTANT!
Before starting the vacuum pump, be sure that all A/C system pressure is discharged.
1. Close the SYSTEM DISCHARGE valve, and open the appropriate high side and/or low side valves on the station.
2. Press the START key on the keypad.
The display shows the message
“AUTOMATIC” followed by the message “VACUUM.”
3. After a slight delay the vacuum pump starts. The display shows the amount of time programmed and begins a countdown to zero.
4. At the end of the automatic vacuum cycle, the display shows the message
“HOLD.” Close the high and low side valves and make sure the A/C system holds a vacuum (if it doesn’t, perform any necessary repairs). Then open the high and low side valves, and press CONT to continue charging.
Note: Consult your A/C system service guide for the proper charging procedure.
5. During the charging cycle, the message “REFRIGERANT” appears on the display. The display shows the programmed amount of refrigerant, counts down to zero as the charging process proceeds, and indicates the end of the charging process by showing the message “CPL.”
6. If the refrigerant transfer is too slow, the station emits an audible signal, the display countdown stops, and the message “CHECK REFRIGERANT” appears on the display. Press the
HOLD key and close the high side valve, but leave the low side valve open. Start the A/C system, and press the CONT key to pull the remainder of the charge into the low side of the
A/C system.
© 1991 Robinair Division, SPX Corporation
If the signal continues and the display does not count down, press the HOLD key and replace the tank as described in “Installing a Refrigerant Tank.” Press the CONT key to complete the automatic cycle, or press RESET to access the program mode.
7. When the automatic cycle is completed, the station beeps once, and the message “CPL” appears on the display, followed by the “HOLD” message. Press any key to access the program mode.
TO CHECK FINAL SYSTEM OPERATION
Before disconnecting the A/C system from the station, you should check that it is operating properly.
CAUTION!
Before starting the A/C system, be sure both valves on the station’s manifold are closed.
1. Run the A/C system until the gauge readings stabilize.
2. Compare the gauge pressure readings to the system manufacturer’s specifications.
3. Check the cool air vent discharge temperature to be sure that the system cooling is acceptable.
TO DISCONNECT THE SYSTEM
1. Turn off the A/C system.
▲
WARNING
▲
Disconnect hoses with extreme caution!
All hoses may contain liquid refrigerant under pressure.
Read and follow all warnings at the beginning of this manual before operating the unit.
2. Disconnect the blue and red hose couplers from the A/C system.
3. Replace the caps on all fittings. Store the hoses on the cart, and store the couplers by connecting them to the coupler rack.
Operating
Procedures
Follow these instructions to properly maintain your automatic A/C charging station. Be sure to wipe up any spills immediately and keep the station clean.
STORING THE STATION
1. Turn off the MAIN POWER switch, and unplug the station.
2. Store the hoses on the cart, and store the couplers by connecting them to the coupler rack.
3. Close all valves when the station is not in use.
MAINTAINING THE VACUUM PUMP
1. Check the vacuum pump oil daily, and add oil as necessary. The proper level is at the midpoint of the sight glass when the vacuum pump is running and the A/C system is under vacuum.
Note: Use only our Premium High
Vacuum Pump Oil (see “Replacement
Parts List”).
2. For maximum efficiency and longer pump life, change the vacuum pump oil frequently (approximately after every four hours of running time).
Read and follow the detailed instructions in the vacuum pump operating manual to change oil.
CHECKING THE SCALE ACCURACY
You should routinely check the accuracy of the scale platform and calibrate the scale, if necessary, to assure that the unit charges accurately.
1. While in the PROGRAM mode, simultaneously press the ENTER and zero keys on the keypad to clear the display.
2. Press the “6” key on the keypad to display the approximate scale platform weight.
3. Remove the tank from the scale platform. The empty platform weight displayed should range from + two pounds. If it does not, contact the factory.
Maintenance
Instructions
R-134a Smart Cart ® Automatic A/C Charging Station
7
Maintenance
Instructions
CALIBRATING THE SCALE
You should also routinely calibrate the scale, if necessary, to assure that the compressor shuts off when the tank is full. You can automatically calibrate the scale through the keypad.
▲
WARNING
▲
Proper operation of the scale is essential to safety features built into the station. If you have any questions about scale accuracy, call the factory.
1. Press ENTER and the zero key on the keypad to access the diagnostic mode, then press 8-7-8-7. The display will show “A1.”
Note: If you press any other key before the 8-7-8-7 sequence, you cannot enter the automatic calibration routine.
2. Be sure the scale is empty of all weight (e.g. tank). Press “0” and then press ENTER on the keypad. The display shows “0.00” and then changes to the message “A2.”
3. Place a known weight (between 10 and 80 pounds) in the center of the scale platform. Enter that weight on the display using the keypad, then press ENTER. The display returns to the VACUUM mode.
4. To re-enter the diagnostics mode and verify the calibration, simultaneously press ENTER and the zero key on the keypad. Then press “6.” The display shows the known weight on the scale platform.
5. Remove the known weight, and the display returns to “0.00.”
USING MANUAL DIAGNOSTICS
The station has internal and manual diagnostic modes. The internal or selfdiagnostic mode checks for entries or pressures outside of normal limits and for certain electrical conditions. The manual diagnostic mode allows you to check major components for proper operation.
The station’s safety features include a check valve which prevents high side pressure from entering the refrigerant tank. Also, any operating problems resulting in an error message on the display prevent operation until the problem is corrected.
▲
WARNING
▲
Be sure to discharge any system pressure before performing any manual diagnostics.
1. If the message “PROGRAM” is not displayed, press the RESET CYCLE key.
2. Simultaneously press the ENTER and zero keys. The display should be blank except for the decimal point.
3. Press the following keys to perform these functions:
Press “1” — The VACUUM display segment comes on, the vacuum solenoid opens, and the pump starts.
Press “1” again to turn off.
Press “3” — The REFRIGERANT display segment comes on and the solenoid opens. This is a momentary contact switch which turns off when released. Close the high and low side valves to perform this test.
Press “5” — All display segments light up. Press “5” again to turn off.
Press “6” — The display shows the approximate weight on the scale. See
“Checking the Scale Accuracy” for diagnostic procedures.
4. Press the RESET CYCLE key to return to the program mode.
© 1991 Robinair Division, SPX Corporation
8
HOW TO USE THE CONTROLS
The charging station has various components that control its operating functions.
CAUTION!
Do not operate the station until you have filled the vacuum pump with oil and removed the exhaust plug from the pump’s handle, as outlined in
“Preparing the Vacuum Pump.”
1.
SYSTEM DISCHARGE
Valve — Lets you depressurize the A/C system.
Connect to a refrigerant recovery unit — do not vent refrigerant to the atmosphere.
2.
LOW
Side Valve — When closed, isolates the low side of the A/C system from the station controls.
Note: The manifold is ported so that the gauges indicate pressure whether or not the valves are open.
3.
LOW
Side Compound Gauge — When connected to the low side of an A/C system, indicates the system’s low side pressure.
4.
HIGH
Side Valve — When closed, isolates the high side of the A/C system from the station controls.
5.
HIGH
Side Pressure Gauge — When connected to the high side of an A/C system, indicates the system’s high side pressure.
6. Display — Shows the time programmed for vacuum, the weight of refrigerant programmed for charging, the control status, and the cycle of operation. Detailed instructions for programming the display follow the next section.
7. Keypad — Accomplishes specific operating functions, as described in the next section.
8.
MAIN POWER
Switch — Supplies electrical power to the control panel.
9.
ACCESSORY
Outlet — Provides an electrical outlet for accessory equipment, such as a thermistor vacuum gauge. This outlet is energized when the station is plugged in, and it is located on the side of the control box.
Note: There is no accessory outlet on the
220V 50Hz model.
10.
HEATER
Outlet — Provides an electrical outlet for the refrigerant tank’s heater blanket. This outlet is controlled by the MAIN POWER switch and is energized when the power is on.
11.
PUMP
Outlet — Provides an electrical outlet for the vacuum pump. This outlet is controlled by the logic board.
Diagram of Control Components
Additional
Operating
Guidelines
R-134a Smart Cart ® Automatic A/C Charging Station
9
10
Additional
Operating
Guidelines
USING THE KEYPAD
The charging station also has a unique keypad for data entry. It uses only six keys for sequence control, and the LCD display indicates the operating mode.
CAUTION!
Do not operate the station until you have filled the vacuum pump with oil and removed the exhaust plug from the pump’s handle, as outlined in
“Preparing the Vacuum Pump.”
START
— Press to begin the automatic cycle after the charging station is programmed.
CONT
— Press to resume (or continue) operations after pressing the HOLD key
(described below).
HOLD
— Press to interrupt the automatic cycle.
REVIEW PROGRAM
— Press to review the existing programmed data.
ENTER
— Press to enter program data into the computer’s memory.
RESET CYCLE
— Press to access program mode.
ADD .2 LB. REFRIG.
— Press to partially charge the A/C system.
Diagram of Keypad
USING THE DISPLAY PANEL
The charging station also displays various messages on the display panel.
CAUTION!
Do not operate the station until you have filled the vacuum pump with oil and removed the exhaust plug from the pump’s handle, as outlined in
“Preparing the Vacuum Pump.”
Segment A
— Indicates in which mode the station is operating:
PROGRAM
— The station is in the programming mode, which allows you to program vacuum time and refrigerant weight or to review the existing program.
HOLD
— The evacuation process is complete and the vacuum pump is off, or no refrigerant is being charged; also HOLD is used while changing a refrigerant tank or to interrupt the vacuum/charging cycles.
AUTOMATIC
— Either the vacuum or refrigerant charging cycle is in process.
Segment B
— Indicates the station is either evacuating the A/C system or charging refrigerant or the station is ready to be programmed for one of these two functions:
VACUUM
• With PROGRAM, indicates the station is ready to be programmed for evacuation.
• With AUTOMATIC, indicates the vacuum pump is running; the number displayed counts down in seconds, showing the amount of time remaining for evacuation.
• With HOLD, indicates the vacuum cycle is complete (if the display shows
“0.00”), or if you pressed the HOLD key to interrupt the vacuum cycle, indicates the remaining time the pump runs when you press the
CONT key.
© 1991 Robinair Division, SPX Corporation
VACUUM
VACUUM
VACUUM
REFRIGERANT
REFRIGERANT
REFRIGERANT
Segment B Messages
+ PROGRAM
+ AUTOMATIC
+ HOLD
+ PROGRAM
+ AUTOMATIC
+ HOLD
= Program station for vacuum
= Vacuum pump is running
= Evacuation complete or interrupted vacuum cycle
= Program station for charge
= Station is charging A/C system
= Interrupted charging cycle
Quick Reference Chart
REFRIGERANT (POUNDS)
• With PROGRAM, indicates the station is ready to be programmed for the amount of refrigerant to be charged into the A/C system; on the keypad enter the charge in pounds (or kilograms, depending on the model you have).
• With AUTOMATIC, indicates the station is charging refrigerant into the A/C system; the number shown on the display counts down, showing the remaining amount of refrigerant to be dispensed.
• With HOLD, indicates the HOLD key was pressed to interrupt the charging cycle; the number shown on the display is the amount of refrigerant remaining to be charged into the system. To continue charging, press
CONT.
Use the quick reference chart above to interpret Segment B messages.
Segment C
— Shows a number or a coded error message on the display that indicates the station’s operating status or any specific problems.
NUMBER
Indicates the vacuum time in minutes or the refrigerant weight in pounds (or kilograms, depending on the model you have).
MESSAGE CODES
• CPL — Indicates the refrigerant charging cycle is complete.
• ERR5 — Indicates an overloaded or broken scale.
Segment D
— Indicates the transfer of refrigerant is slow or has stopped.
• If the disposable tank is empty or
the refillable tank is low , replace the tank following the instructions in
“Installing a Refrigerant Tank.” A small amount of refrigerant always remains in a refillable tank.
• If there is adequate refrigerant in
the tank , you need to pull the remainder of the programmed charge into the low side of the A/C system, as outlined in Step 7 of “To Use
Automatic Vacuum/Charging Cycles.”
Additional
Operating
Guidelines
Diagram of Display Panel
R-134a Smart Cart ® Automatic A/C Charging Station
11
Replacement
Parts List
The following is a list of replacement parts you may need to service or maintain your automatic charging station.
Because of ongoing product improvements, we reserve the right to change design, specifications, or materials without notice.
Our Premium High Vacuum Pump Oil is also available in handy quart containers or in convenient gallon containers:
Quart (shipped 12 quarts per case) 13203
Gallon (shipped 4 gallons per case) 13204
This oil has been specifically blended to maintain maximum viscosity and to improve cold weather starts.
Description
Handle (Red)
Handle (Blue)
Gauge, Blue Low Side Compound
Gauge, Red High Side Pressure
High Side Coupler
Low Side Coupler
Vacuum Pump
120” Blue Hose
120” Red Hose
60” Yellow Hose
9” Blue Hose
Tank Hose
Black Vacuum Hose
Main Power Switch
Scale Assembly
Tank Platform
Heater Blanket
Vacuum Solenoid Assembly
Refrigerant Solenoid
Main Board
Keypad
Check Valve
Tank Strap
Cover
Wheel & Nut
Transformer
High Vacuum Grease
RA19008
RA14967
10994
RA19020
RA19006
RA18761
RA18751
RA17112
RA19056
17495
RA10751
N/A
13033
115V 60 Hz
40448
40447
11741
11742
18191
18190
RA15427
62120
63120
37160
37059
37024
40586
RA40994
RA19008
RA14967
45605
RA19020
RA19006
RA19092
RA18751
RA17112
RA19056
17495
RA10751
RA19091
13033
220V 50 Hz
40448
40447
11726
11727
18191
18190
RA15428
62120
63120
37160
37059
37024
40586
RA40994
© 1991 Robinair Division, SPX Corporation
12
Symptom
No power when
POWER switch is on — no display showing
Vacuum pump does not start
Audible tone sounds and “CHECK REFRIG-
ERANT” message displays during refrigerant transfer
Cause
• Station unplugged
• No power at wall outlet
Cure
• Plug station into power source
• Locate problem with outlet or change outlets
• Vacuum pump unplugged • Plug pump into power source
• Vacuum time not entered • Program required vacuum time
• Defective vacuum pump • Remove and replace pump
• Faulty components • Call factory
• Transfer stopped or too slow
• Start A/C system and pull rest of refrigerant into system
(Step 6 in “To Use Automatic
Vacuum/Charge Cycle”)
• Tank safety strap too tight • Loosen the safety strap
• Refrigerant supply empty • Replace the refrigerant tank or call factory
Trouble-
Shooting
Tips
Refrigerant doesn’t flow or “REFRIGERANT” message doesn’t display
Vacuum pump runs, but low side gauge does not register an appropriate vacuum
ERR5
• Refrigerant supply empty • Replace the refrigerant tank
• Discharge valve open
• Low side valve closed
• Pump oil contaminated
• Hose gasket damaged
• Close discharge valve
• Open low side valve
• Flush and change pump oil
• Replace gasket or hose
• Charging line loose
• Manifold leaking
• Check connections
• Check connections
• Pump’s Iso-valve closed • Open Iso-valve
• Overloaded or broken scale
• Check tank weight, recalibrate if necessary, or call factory
R-134a Smart Cart ® Automatic A/C Charging Station
13
Temperature — Pressure Relation
R-134a Refrigerant
( o F)
100
105
110
115
120
125
130
135
140
80
85
90
95
60
65
70
75
40
45
50
55
20
25
30
35
-20
-15
-10
-5
10
15
0
5
PSI
R-34a
Note: Gauge pressures are approximations rounded to the nearest 1/20 PSI.
124.1
134.9
146.3
158.4
171.1
184.5
198.7
213.5
229.2
57.4
64.0
71.1
78.5
86.7
95.3
104.3
113.9
18.4
22.1
26.1
30.4
35.0
40.1
45.4
51.3
-1.8
0
2.0
4.1
6.5
9.1
12.0
15.1
Conversion Chart
Ounces to Hundredths of a Pound
Ounce
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
Pound
.56
.62
.69
.75
.81
.88
.94
1.00
.06
.12
.19
.25
.31
.38
.44
.50
☎
For assistance in servicing or using the
Automatic A/C Charging Station, call the toll-free Service Line, 800-822-5561, inside the continental U.S. In Canada, call 419-
485-5561, Ext. 300. In all other locations, contact your local distributor. To help us serve you better, please be prepared to provide the model number, serial number, and date of purchase.
To validate your warranty, you must complete the warranty card attached to your station and return it within ten days from date of purchase.
SP
x
ROBINAIR
Robinair Division
SPX Corporation
Robinair Way
Montpelier, OH 43543-0193 USA
Phone 419-485-5561
FAX 419-485-8300
111615 (Rev. 1/94) 34100/10324 Smart Cart Charging Station © 1993 Robinair Division, SPX Corporation Printed In USA
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