BrainBee multigas 8500 Service Manual
Below you will find brief information for MULTIGAS 8500. This service manual provides technicians with essential information on the MULTIGAS 8500, including installation, maintenance, and troubleshooting procedures. It covers key aspects like safety precautions, initial setup, component replacement, and calibration. This manual is an indispensable resource for maintaining and servicing the MULTIGAS 8500.
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MULTIGAS 8500
Equipment for recharge of air conditioning systems of vehicles with refrigerant gas R-134a/R-1234yf.
Service Manual
Ver. 1.0
MULTIGAS 8500
CAP. 1 - CONTENTS
Unpacking MULTIGAS 8500 ...........................................................................8
Programming through ACU device ................................................................ 10
EC declaration of conformity and Use and maintenance manual......................12
First tank filling (including weight and pressure check) ....................................12
Setting working parameters and garage data.................................................16
“LONG LIFE PUMP” SPECIAL FUNCTION - VACUUM PUMP OIL CHANGE ......................18
6.4
WEAR CHECK OF THE RED AND BLUE CHARGE HOSES AND THE HP RED AND LP BLUE
ECO LOCK® QUICK COUPLERS...................................................................22
6.5
REFRIGERANT GAS SCALE CHECK WITH SAMPLE WEIGHT AND CALIBRATION, IF NEEDED,
6.6
NEW OIL SCALE CHECK WITH SAMPLE WEIGHT AND CALIBRATION, IF NEEDED, (SERVICE
6.7
EXHAUSTED OIL SCALE CHECK WITH SAMPLE WEIGHT AND CALIBRATION, IF NEEDED,
WEAR AND TIGHTNESS CHECK OF THE MANIFOLD SOLENOID VALVE PISTONS ...........24
6.9
WEAR CHECK OF THE OR2-106 4.42X2.62
NBR O-RING OF THE PRESSURE SENSOR
6.10
PRESENCE AND WEAR CHECK OF THE OR2212 53,7 X 1,78 NBR O-RINGS OF THE OIL
ENGLISH 2 / 78 CAP. 1 - CONTENTS
MULTIGAS 8500
CLIMA 8501 SERVICE KIT FOR STATIONS WITH GAS R134A...........................................27
7.2
CLIMA GAS R-1234YF / R-134A SERVICE KIT FOR STATIONS WITH GAS R134A AND
GAS TYPE SWITCHING FROM R134 TO R1234YF ..........................................................34
NEW DATABASE PURCHASE AND ACTIVATION.............................................................44
EXTRAORDINARY MAINTENANCE LIST....................................................................68
Replacement of components connected to refrigerant circuit............................69
Replacement of logic electronic board with display .........................................69
Replacement of electronic power board .........................................................71
ENGLISH 3 / 78 CAP. 1 - CONTENTS
MULTIGAS 8500
2.1
CAP. 2 - INTRODUCTION
GENERAL INFORMATION
Careful attention was paid in the collection and checking of the documentation contained in this manual; despite this, this publication could contain small technical errors or typos.
No responsibility shall be attributed to BRAIN BEE or to other persons or companies involved in the creation, production and distribution of the product due to damage following use of the present documentation.
BRAIN BEE reserves the right to improve or change its instruments at any time and without any notice.
It is possible for this manual to contain references or information regarding BRAIN BEE services or products not yet on the market. Said references or information may not in any way mean that BRAIN BEE intends to place said products or services on the market.
This publication may not be reproduced nor distributed, wholly or partially, without previous written authorisation by BRAIN BEE (Law 22 April 1941 no. 663 and following updates). Requests of other copies of the present manual or further information must be addressed to an authorised distributor or to a BRAIN BEE sales representative or to the email address [email protected]
All technical and sales documentation may also be found on the website: http://www.brainbee.com
BRAIN BEE is a registered trademark property of BRAIN BEE s.p.a., v. Quasimodo 4/a -
43126 Parma, Italy. Other names of products and companies mentioned in these pages may be registered trademarks of their respective owners.
Any references to programs on use license or other BRAIN BEE products or services contained in this publication do not mean that only said programs and/or products and/or services may be used. In replacement to those supplied by BRAIN BEE equally functional products, programs or services may be used that do not imply violation of
BRAIN BEE intellectual property rights or other rights. It is the user's responsibility to evaluate and verify the possibility to use other programs and/or products and/or services, except for those expressly indicated by BRAIN BEE .
BRAIN BEE may have patents or pending patent applications relative to what is being treated in the present publication. The supply of this publication does not imply concession of any license on them.
2.2
SUMMARY
The present manual is intended for the assistance technician and is aimed at outlining clearly and coherently the use and function principles and supplying a basic guide to carry out assistance and maintenance operations on the service station for air conditioning systems for vehicles with R-134a refrigerant gas.
The manual chapters describe the functional units of MULTIGAS 8500 under the aspects of structure, operation, disassembly and assistance.
To access the service menu reserved to maintenance activities, the technician operating on the device must know the password communicated by Brain Bee to the Assistance Centres.
________________________________________
ENGLISH 4 / 78 CAP. 2 - INTRODUCTION
MULTIGAS 8500
CAP. 3 - SAFETY CONDITIONS
3.1
IMPORTANT SAFETY INFORMATION
In installation, maintenance and technical assistance operations it is necessary to respect the fundamental staff and workplace safety regulations.
Carefully respect all the indications included in this manual, in the device use manual and in the use manuals of any other equipment employed.
In particular the operator must view all the safety prescriptions described in the use manual.
All the operations described in this manual must be carried out by trained staff, equipped with adequate individual protection devices.
To move heavy loads or to handle the equipment and its components always use gloves and clothing that may guarantee adequate protection also against accidental contact with the refrigerant.
To use instruments such as springs, drills, saws etc. and to protect oneself against accidental contact with the refrigerant, always use protection goggles.
Smoking and using open flames is forbidden.
To manually lift loads (weights), limits are foreseen by the enforced regulations of own country, carefully respect the limits, above which appropriate lifting means must be used.
Before accessing to execute operations within the equipment, always disconnect the power supply and use tools with insulated handles.
ENVIRONMENTAL PRECAUTIONS 3.2
Any service operation on the equipment must be carried out being careful not to disperse
R134a gas into the environment, in order to prevent the greenhouse effect and the subsequent global warming of the planet. The release of refrigerant gas R134a into the atmosphere is forbidden by laws that were enacted within the framework of the Kyoto protocol.
For information only, we will mention in particular, for the European Union, Regulation (EC.) no. 842/2006 on certain fluorinated greenhouse gases (regulation on F-gases).
The waste coming from the service activities must be placed in collection centres foreseen by the enforced laws, they must not be dispersed in the environment and they must not be disposed of with urban waste.
ENGLISH 5 / 78 CAP. 3 - SAFETY CONDITIONS
MULTIGAS 8500
4.1
CAP. 4 - LAYOUT AND USE OF THE MANUAL
USE OF THE MANUAL
The present service manual must be used together with the use and maintenance manual of the equipment, it must be kept by the
Authorised Assistance Centre or by the Distributor of Brain Bee products and made available to own assistance staff.
• The content of this manual has been drawn up in compliance with the guide lines of the UNI standard 10893:2000.
• Diffusion, modification or use of this manual for own aims is forbidden.
• The manual uses symbols which call the reader’s attention to specific points to facilitate its use.
• It includes all technical, operating, shutdown, maintenance, spare parts and safety information.
• In case of doubts on the correct interpretation of the instructions, please contact our technical service to obtain the required clarifications.
Operations which are potentially hazardous for the operator are highlighted with this symbol.
Such operations can cause serious injury.
Operations requiring special attention are highlighted with this symbol.
Such operations shall be carried out correctly to avoid causing damage to objects or to the surrounding environment. This symbol also highlights information to which special attention must be paid.
Operations which require careful reading of the manual’s instructions are highlighted with this symbol.
4.2
SYMBOLS
This paragraph describes the safety-related symbols that might be present on the external part of the equipment.
4.2.1
Safety
ALTERNATING CURRENT
SAFETY GROUNDING
CONSULT THE INSTRUCTIONS MANUAL
CAUTION! ELECTROCUTION HAZARD
CAUTION !: DO NOT TRY REMOVING THE COVER
(this operation can be carried out exclusively by qualified technicians)
4.2.2
Marking
CE CONFORMITY MARK
ENGLISH 6 / 78 CAP. 4 - LAYOUT AND USE OF THE MANUAL
MULTIGAS 8500
5.1
CAP. 5 - INSTALLATION
EQUIPMENT INSTALLATION
The order of the following listed steps is the one advised even if the same could be carried out in a different order.
AT DISTRIBUTOR SITE (INTERNET CONNECTION REQUIRED)
It is advised to lift the carton, connect electricity and switch on the equipment.
1° Contrast adjustment (if needed) and Language selection.
(after this step, the device can already be used to show the software potentials without use of the gas).
2° Check the software version and reprogram the equipment if needed
3° Registration of the equipment and data of the end customer on the website www.brainbee.com (distributor reserved area).
Registration may also be postponed to after initial checking and it will be proposed again when the database is selected, or every time the equipment is switched on. Without registration, the automatic cycles and the database will not be enabled.
4° Pack the equipment for final transport to the end customer.
AT END CUSTOMER’S SITE
5° Unpack, position the equipment and execute the electrical connections. Unscrew the scale locking screw and check that the empty containers of new and exhausted oil and tracer have been inserted. The altitude compensation procedure shall be executed in case of installation in a location above 500m a.s.l. (this is aimed at improving the station performance, which can be affected by atmospheric pressure that changes in relation to altitude). Every time the station is moved to an altitude other than the one at which the sensor was calibrated or the initial check was carried out, a new calibration at the altitude of destination is required.
Enter the menu:
Service, using the password “XHIGH”
Altitude – enable the function [when pressure is reset or calibrated, the station will require setting the altitude range (with 500m intervals) where the station is located].
6° Carry out the first tank filling (including weights and pressure checks) as proposed by the software according to the following points:
• Check gas scale zero
• Check oil scales zero
• Relative pressure zero setting according to local atmospheric pressure
• Internal tank filling (with value of at least 3 Kg, 2 Kg minimum)
Initial checking, if passed, enables use of the equipment with gas.
Checking may be interrupted at each of its points, if not completed it will be proposed again at every following CLIMA machine switch on or in case one attempts to carry out the recharge operation.
If the check is not passed, it may be necessary to proceed to equipment scales or electronic pressure gauge calibration; for said operation described as follows, the appropriate Brain
Bee SERVICE KIT is required.
7° New oil and tracer containers filling, the use of Brain Bee WARRANTY LINE consumables is recommended.
8° Delivery and illustration of the warranty conditions, of the EC declaration of conformity and use and maintenance manual to the end customer.
9° Optional accessories presentation
10° Working parameters and garage data (end customer) setting
ENGLISH 7 / 78 CAP. 5 - INSTALLATION
5.1.1
Unpacking MULTIGAS 8500
RISK OF OVERTURNING - CRUSHING -
BUMPING
MULTIGAS 8500
Position the pallet on a level surface, remove the carton after eliminating the straps that bind it. Free the equipment from the pallet by cutting the straps that block it. Remove the unit from the base pallet of the package by using suitable means. Once on the ground, the unit is handled on the four wheels; the two smaller wheels have brakes.
5.1.2
Scale unlocking
Under the machine there is a bolt locked by a wing nut, which locks the scale during transport, once the equipment is delivered to the client the lock must be removed to make the scale operational.
Stabilise the equipment with the brakes of the front wheels.
Insert hand under the equipment from the front side, unscrew the wing nut, when the bolt is free to move, unscrew it for 4 turns and then lock it in that position by locking the wing nut.
ENGLISH 8 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
5.1.3
Connections
In proximity of where the machine must be used, there should be a schuko type current socket available protected by a differential switch. The nominal current voltage and absorbed power data are indicated on the unit identification tag positioned near the ON switch. Connect the equipment through the supplied cable.
Connections to the
A/C system
Connection to the power mains – power cable
L=4.5 m
The equipment includes connecting pipes of a 4.5 m length that when not in use must be kept in the appropriate pipe winder with the taps positioned on the false couplers and closed. Further views of the equipment and technical characteristics are reported in the user manual.
5.1.4
Contrast and language setting
When switched on for the first time, the station will propose the contrast and language adjustments, which must be performed by means of the left and right arrow keys and saving by means of the START key .
For subsequent modifications to the contrast or to the language, the settings page can be accessed by switching on the station and keeping the
“beep” sound. button pressed until you hear the
After the beep sound, adjust the contract using the left and right keys and saving by means of the START key .
5.1.5
Programming
The equipment already includes multi-language application software, it is however advised to check that the version installed is updated compared to what is available on the website www.brainbee.com.
PROGRAMMING the CLIMA station with the last version available on the website
• of the CLIMA station management software and of the vehicles database (the license for the specific version starts upon registration). www.brainbee.com at the time of installation guarantees the installation of the latest versions:
5.1.5.1
Programming through serial cable
The following items are required for programming:
• Windows PC with a COM serial port or USB-Serial adaptor
• programming cable included in the BRAIN BEE CLIMA SERVICE KIT
• CLIMA UPDATE software (execute download and set up)
ENGLISH 9 / 78 CAP. 5 - INSTALLATION
• MULTIGAS 8500 application software (execute download and unzip)
MULTIGAS 8500
The version number is only indicative; refer to the one indicated on the website
The equipment programming procedure includes the following steps:
• double click on the .cli software icon
• press the “Program (F3)” button then switch on the equipment
5.1.5.2
Programming through ACU device
With the ACU device (contained in the CLIMA SOLUTION product) it is possible to update the CLIMA machines software without a serial cable. By following the instructions contained in the CLIMA SOLUTION product, install the CLIMA SOLUTION program on a Windows PC connected to the internet.
If on the website www.brainbee.com a new version is available, this will be transferred to the
PC automatically.
Connect ACU to the PC to transfer the new version of the software onto the ACU mobile device.
To update the clima station, connect the ACU to the serial port, and switch on the equipment again, it will be updated to the latest version.
5.1.6
Registration
To start the warranty period and to activate the automatic cycles it is necessary to carry out
REGISTRATION, which implies:
• access to the distributor reserved area on the website www.brainbee.com
• selecting the icon “ACTIVATION AND MANAGEMENT OF DEVICES”
• selecting the icon “ACTIVATE/UPDATE DEVICE”
• entry of the equipment serial number
• waiting for the activation code which will have to be entered into the equipment.
See pictures below.
ENGLISH 10 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
ENGLISH 11 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
Until the activation code is entered into the equipment, it will always be requested.
5.1.7
EC declaration of conformity and Use and maintenance manual
Deliver the EC Declaration of conformity document attached to the equipment to the client, it will have to be carefully kept by the end customer.
Deliver and illustrate the use and maintenance manual attached to the equipment which will have to be carefully kept by the end customer and made available to the operators.
5.1.8
First tank filling (including weight and pressure check)
To proceed with first filling of the equipment inner tank, execute the following actions in sequence by following the display guided procedure and the illustrations on the summary sheet provided with the equipment:
ALTITUDE COMPENSATION
The altitude compensation procedure shall be executed in case of installation in a location above 500m a.s.l. (this is aimed at improving the station performance, which can be affected by atmospheric pressure that changes in relation to altitude). Every time the station is moved to an altitude other than the one at which the sensor was calibrated or the initial check was carried out, a new calibration at the altitude of destination is required.
Enter the menu:
Service, using the password “XHIGH”
Altitude – enable the function [when pressure is reset or calibrated, the station will require setting the altitude range (with 500m intervals) where the station is located].
ENGLISH 12 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
• Gas weight check (check of scale zero deviation after transport and tare weight reset)
• Oils weight check (check of scales zero deviation after transport and tare weight reset)
• Pressure check (Reset of relative pressure in relation to the local atmospheric pressure; a tank recharge coupler, supplied with the equipment, must be used)
• First tank filling (it requires a refrigerant gas tank with specific coupler for the tank recharge supplied with the equipment)
It is possible to interrupt the initial check and print a report with the equipment printer in which the checking status is reported.
5.1.8.1
First tank filling
CAREFULLY ABIDE BY THE FOLLOWING
INSTRUCTIONS TO AVOID DANGER TO
PERSONS, THE DISCHARGE OF
REFRIGERANT IN THE ATMOSPHERE
Let us consider as first filling the one carried out during the initial check with internal tank of the equipment free of refrigerant gas and containing air.
Set the quantity of gas to fill (at least 3 kg; 2 kg minimum) and follow the guided procedure shown on the display.
Check that the equipment hoses are not connected and positioned in the hose winder. Start the procedure that initially foresees the creation of vacuum in the internal tank.
Only when the message appears to connect the recharge tank, connect the HP quick coupler
(red colour), of the unit to an external R134a refrigerant gas tank using the supplied adaptor.
Open the coupler by turning the knob clockwise. Open the valve on the external tank.
There are two types of source tanks: with plunger and without plunger.
Tanks with plunger shall remain upright to be able to transfer liquid refrigerant; for this type of tanks connect to the L (liquid) coupler.
Tanks without plunger have only one valve, so they must be turned upside down to transfer the liquid refrigerant.
ENGLISH
The HP gauge shows the pressure level into the external tank.
After some minutes the unit will automatically end the function.
At the end the weight of the charged refrigerant will be displayed.
5.1.9
Containers filling
5.1.9.1
New oil container filling
The new oil container is on the left, looking at the equipment from the front.
To fill it, it has to be extracted from its housing by means of the quick coupler on the top of the container; slightly press downward the coupler ring nut to extract it.
13 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
Fill the bottle by paying special attention to the “oil care” valve.
This valve is made of a silicon polymer membrane; it compensates pressure variations within the bottle and stops humid air infeed, thus preserving the new oil inside.
After filling, close the container and place it back in its seat.
5.1.9.2
Tracer container filling
The tracer is a substance made up of a yellow-green coloured fluorescent pigment, which means that, when lit by an ultraviolet lamp, it becomes fluorescent and thus visible.
The tracer can therefore be used to detect small leaks inside the vehicle A/C system.
The tracer container is on the right, looking at the equipment from the front.
To fill it, it has to be extracted from its housing by means of the quick coupler on the top of the container; slightly press downward the coupler ring nut to extract it.
Fill the bottle by paying special attention to the “ oil care ” valve.
This valve is made of a silicon polymer membrane; it compensates pressure variations within the bottle and stops humid air infeed, thus preserving the new oil inside. After filling, close the container and place it back in its seat.
ENGLISH 14 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
5.1.10
Optional accessories presentation
The MULTIGAS 8500 station may be equipped with additional accessories such as:
1) the kit for washing the system components (Flushing kit) and
2) the leak searching kit (UV kit) with the tracer and the UV lamp
3) the leak test kit (Nitrogen leak test kit) and
4) the kit to carry out service on hybrid cars (Hybrid pro kit).
FLUSHING KIT UV KIT
NITROGEN LEAK TEST KIT HYBRID PRO KIT
To avoid contaminations that may result from the use of a single container for new oil, it is advisable to propose the purchase of additional containers so that different oils of different type and density can be kept ready for use.
ENGLISH 15 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
5.1.11
Setting working parameters and garage data
From the SETUP menu it is possible to select parameters and activations before starting cycles:
HYBRID FUNCTION
• by selecting this entry, one may change the type of Oil to inject into the A/C system
Attention: the HYBRID KIT PRO (optional accessory) is required in order to run this function
ECO LOCK®
• by selecting this entry, you can enable the ECO LOCK® function (the ECO LOCK® quick coupler must be present on the car).
PRESSURES ZERO
• by selecting this entry, one may carry out calibration of the atmospheric pressure.
RECHARGE MODE
• by selecting this entry, one may decide whether to enable use of the Quick Mode or Zero
Tolerance recharge method
RECOV. GAS AND OIL PRINTING
• by selecting this entry, you can choose whether you want to enable displaying and printing of the recovered gas quantity.
VESSEL HEATING
• by selecting this entry, one may decide whether to enable use of the heating band during the vacuum phase.
MULTIPASS
• by selecting this entry, one may decide whether or not to enable the multipass function, which enables an additional recycling, within the station itself, started automatically when it is switched on but not in use. This function ensures a higher level of purity of the recycled refrigerant to the advantage of the service quality.
PRESSURE CHECK
• by selecting this entry, one can enable or disable the pressure check.
DISPLAY CONTRAST
• by selecting this entry, you can change the display contrast level.
HOSES LENGTH
• by selecting this entry, it will be possible to change the length of the charge hoses.
UNIT OF MEASURE
• selecting this entry, you can modify the pressure unit of measurement (switching from Bar to
PSI)
CLOCK ADJUSTMENT
• by selecting this entry, date and time of the station may be changed.
GARAGE DATA
• by selecting this entry, one can enter the garage data to be printed on the end of cycle report.
ENGLISH 16 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
LANGUAGE
• by selecting this entry, any language present in the database may be set. In case you choose a language with unintelligible characters, hold down the button in the starting screenpage and you will directly return to the language setting menu.
RIGHT-HAND / LEFT-HAND DRIVE
• It allows setting the database for operations on A/C systems of vehicles with right-hand or left-hand drive and return the exact value of gas and oil to be injected.
STARTUP SCREEN
• By selecting this entry, you can decide whether the startup screen of the unit will be the database page or the main menu page.
DEFAULT SETUP
• By selecting this entry, you can restore the unit default settings.
REPORT SAVING MODE
• by selecting this entry, you can save the reports of the performed charges (automatic cycles or
Reg. 842/2006).
DATABASE ACTIVATION
• by selecting this entry, you will receive the “database activation request code” to be provided to your distributor in order to be able to buy the database update and subsequently receive the “database activation code”.
GAS TYPE
• by selecting this entry, you can learn the type of gas the unit is set for, to change the type of gas, please contact an Authorised Brain Bee Service Centre.
Brain Bee reserves the right to add new parameters to make the equipment increasingly versatile and adaptable to market’s needs.
ENGLISH 17 / 78 CAP. 5 - INSTALLATION
MULTIGAS 8500
6.1
CAP. 6 - MAINTENANCE
EQUIPMENT MAINTENANCE
The interventions foreseen for periodical and preventive maintenance are listed as follows:
• “LONG LIFE PUMP” special function and VACUUM PUMP OIL change
• DRYER FILTER replacement (every 45 kg of recovered gas)
• Wear check of the RED and BLUE CHARGE HOSES (4.5 m) and the HP RED and LP BLUE
QUICK COUPLERS
• Refrigerant gas scale check with sample weight and calibration, if needed, (SERVICE KIT)
• New oil scale check with sample weight and calibration, if needed, (SERVICE KIT)
• Exhausted oil scale check with sample weight and calibration, if needed, (SERVICE KIT)
• Wear and tightness check of the manifold solenoid valve pistons
• Wear check of the OR2-106 4.42x2.62 NBR O-RING of the pressure sensor present on the
MANIFOLD
• Presence and wear check of the OR2212 53,7x1,78 NBR O-RINGS of the oil and tracer containers
6.2
“LONG LIFE PUMP” SPECIAL FUNCTION - VACUUM PUMP
OIL CHANGE
The tool is equipped with a special function named LONG LIFE PUMP that enables to optimize the use of vacuum pump oil, avoiding the replacement every 60 hours of operation.
LONG LIFE PUMP is a Brain Bee patented special function allowing to extend up to 1000 hours the life of the pump oil used in the station.
LONG LIFE PUMP function performance is suggested at the end of 60-hour operation intervals of the vacuum pump and can be manually activated in the MAINTENANCE menu.
ENGLISH
LONG LIFE PUMP procedure has to be started only after checking and, if necessary, topping up the pump oil level and lasts 1 hour: during this time the tool cannot be used.
During the procedure the oil is automatically purified from the gaseous polluting residues absorbed during the emptying operations of vehicles air conditioning systems.
At the end of the procedure, the vacuum pump performance check is carried out and a result is shown to the operator.
In case of negative result you have to replace the vacuum pump oil.
After 1000 hours of vacuum pump operation since the last oil change, LONG LIFE PUMP procedure cannot be activated anymore and you have to replace the oil according to the following described modes.
Required equipment:
1 Medium-sized cross-tip screwdriver
1 Medium size flathead screwdriver
1 Hex key (10 mm)
For replacement, comply with the instructions outlined below:
Unplug the unit from power mains.
Remove the screws that fix the front door of the unit and remove it.
18 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
Place a container under the pump oil drain hole. Open the upper plug and then the lower plug to drain the exhausted oil contained within the vacuum pump.
UPPER PLUG
SIGHT GLASS
LOWER PLUG
Once the pump is emptied, rescrew the bottom plug.
Fill the pump with new oil via the filler cap; use a funnel if necessary. Bring new oil level halfway through the sight glass.
Once the pump is filled, close the top plug.
Once oil has been replaced, switch on the unit and from the MAINTENANCE menu select
PUMP OIL REPLACEMENT: press the “RESET” key to set the counter to zero.
6.2.1
Vacuum pump oil specifications
Performance and good operation of the vacuum pumps largely depend on the type of oil being used.
Oil ensures lubrication of mechanical moving parts, tightness and vacuum level, as well as low noise levels.
Unsuitable oil may jeopardize the pump performance, or it may cause breaking of inner mechanisms.
For this reason, using oil provided by Brain Bee, or a type of oil having the characteristics indicated below, is of the utmost importance.
ENGLISH 19 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
These types of oil must ensure:
• high viscosity index, which minimizes viscosity variations when temperature changes. This means, in cold conditions, promptness and sensitivity of control and, at the same, time, in warm conditions, stability of operation.
• Remarkable wear-prevention properties, ensuring a long life of moving parts.
• Excellent defoaming power, which limits noise level, irregular operation, impossibility of reaching the final pressure.
• Great chemical stability, ensuring oil can be used for longer periods without causing formation of oxidization products, such as mud and sludge.
• Strong rust preventive properties, which ensure effective protection of metal surface against corrosion caused by the action of humidity present in the pumped fluid.
IMPORTANT
The described oils for vacuum are of mineral origin and, as such, are fuels. If during normal use, the vacuum pump shall suck up mixtures containing oxygen above 21% or pure oxygen, this would lead to oil oxidation and thus to a loss of lubricating properties, with significant damage to the pump itself.
Physical and chemical properties
Physical status: Liquid
Appearance: Crystal clear (visual)
Odour: Typical pH in aqueous solution (conc.): Not applicable
Solubility in water: Insoluble
Density at 15°C kg/l: 0.890 (ASTM D1298)
Kinematic viscosity at 40°CcSt: 68 (ASTM D445)
Flammability point (COC)°C 220: ( A STM D92)
Pour point °C: -9 (ASTM D97)
6.3
DRYER FILTER CHANGE
The dryer filter shall be replaced once 45 kg of refrigerant fluid have been dehydrated, because the filter depletes its capacity of retaining the moisture present in the refrigerant.
To replace the dryer filter, from the MAINTENANCE menu select DRYER FILTER REPLACEMENT: press “RESET” to set the counter to zero and to start the filter replacement procedure.
Now you can replace the filter.
Required equipment:
• 1 Medium-sized cross-tip screwdriver
• 1 regular or torque Hex wrench (24 mm)
• 1 Hex key (17 mm)
ENGLISH 20 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
For replacement, comply with the instructions outlined below:
1.
disconnect the HP and LP hoses from other systems/circuits or vehicles and close the quick couplers
2.
the unit turns on and empties the hoses.
3.
Confirm to have already worn the personal protective equipment (PPE) and follow the safety regulations in force.
DANGER OF CONTACT WITH R134a REFRIGERANT and motor vehicle A/C system oil
4.
Before opening the doors of the equipment, turn off the switch and disconnect the machine from the mains.
DANGEROUS VOLTAGE HAZARD
5.
Remove the screws that fix the rear door of the unit.
6.
Unscrew the 2 connection nuts of the filter by means of the Allen wrenches.
7.
Remove the straps that wind up the filter
DRYER FILTER
NUTS
8.
Install the new filter paying attention to the position of gaskets and to the direction of the arrow indicating the fluid flowing direction.
9.
Screw the two connection nuts of the filter.
10.
Close the equipment before reconnecting it to the mains.
ENGLISH 21 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
6.4
WEAR CHECK OF THE RED AND BLUE CHARGE HOSES AND
THE HP RED AND LP BLUE QUICK COUPLERS
Check that the entire length of the piping does not present:
• abrasions, cracks, cuts, irreversible folds, deformations, twists.
Check that the contact points between the piping and the joints with quick couplers and with the equipment do not present:
• abrasions, cracks, cuts, irreversible folds, deformations, twists.
Check that the quick couplers do not present:
• abrasions, excessive plays, cracks, deformations.
TESTS of the piping and quick couplers tightness with leak tests under vacuum and under pressure conditions.
• Connect the hoses through quick couplers to the false joints on the wall of MULTIGAS 8500 and open the taps/valves;
• Launch the “Leak test” function inside the Maintenance Menu, check that the test is passed successfully.
• From the Service menu - “Manual activation”, activate valves “R” and “I”, check that the hoses are pressurized (at least 5 bar) and check that the pressure does not drop in a time slot equal to 30 minutes and that gas leaks do not occur.
In case the station is equipped with the ECO LOCK® quick couplers, you shall check that the ECO
LOCK® function is enabled within the “SETTINGS” menu – “ECO LOCK” submenu.
In case the previous couplers are replaced with the ECO LOCK® quick couplers, you shall enable the ECO LOCK® function within the “SETTINGS” menu – “ECO LOCK” submenu.
6.4.1
ECO LOCK® QUICK COUPLERS
ECO LOCK® is the INTELLIGENT COUPLER, Brain Bee patented, that with the suitable automated procedure in the software enables to:
1.
reduce the formation of non condensable gas inside the vessel ;
2.
avoid refrigerant dispersion in the air during disconnection ( puff effect);
3.
check possible SCHRADER valve leaks before disconnection.
The ECO LOCK® quick couplers accomplish ground-breaking functions, for which they are conceived, only if the ECO LOCK® function is enabled within the “SETTINGS” menu – “ECO
LOCK” submenu of the specific equipment.
ENGLISH 22 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
6.5
REFRIGERANT GAS SCALE CHECK WITH SAMPLE WEIGHT
AND CALIBRATION, IF NEEDED, (SERVICE KIT)
Place a sample weight on the tank and check that the changes in weight are adequately detected by the machine scale.
Place the clamp that is part of the service kit under the tank
Position a 10 kg sample weight on the clamp and check that the weight increases by
10 kg +/- 50 g, in case of errors in excess execute calibration. a new
Note: to verify that the item 4. sample weight support bracket doesn’t touch any component; in case of contact, use a reference weight of 5 kg.
6.6
NEW OIL SCALE CHECK WITH SAMPLE WEIGHT AND
CALIBRATION, IF NEEDED, (SERVICE KIT)
Place a sample weight in the new oil bottle (part of the service kit) and check that the changes to the weight are adequately detected by the machine scale. In case of errors greater than ± 10 g execute a new oil weights calibration.
6.7
EXHAUSTED OIL SCALE CHECK WITH SAMPLE WEIGHT AND
CALIBRATION, IF NEEDED, (SERVICE KIT)
Place a sample weight in the exhausted oil bottle (part of the service kit) and check that the changes to the weight are adequately detected by the machine scale. In case of errors greater than ± 10 g execute a new oil weights calibration.
ENGLISH 23 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
6.8
WEAR AND TIGHTNESS CHECK OF THE MANIFOLD
SOLENOID VALVE PISTONS
1.
Apply the 2 pipes in the supports on the side of the machine and close the taps counter clockwise.
2.
Switch off the machine, remove the power supply cable and open the cover and the front panel.
3.
Close central tap (liquid side) of the tank with service kit key (about 7 clockwise turns)
4.
Reconnect the power supply cable, turn on the machine (do not to touch terminals or printed circuit boards)
5.
Open the service menu
6.
Select manual activations
7.
In manual activations activate OUT R, OUT I, OUT A, C, wait for the LP gauge to show a pressure of at least – 0.3 bar,
8.
Switch off the machine and remove the power supply network cable
9.
Close the other tap (gas side) of the tank with service kit key (about 7 clockwise turns)
10.
Close the tap along the connecting pipe towards the capacitor
11.
Dismantle the solenoid valve reel block with a wrench or 14mm spark plug wrench (No.1 in the following figure)
12.
With the 24 spark plug wrench (No.2 in the following figure) using the screwdriver as handle, the valve sleeve can be removed
13.
Evaluate whether the rubber is visibly ruined and swollen (the presence of a circular trace is normal, but there must not be swells and grooves different from the circular one)
14.
Blow the piston air channels with compressed air
15.
Blow inside the sleeve and the manifold seat where the valve is screwed
16.
Blow the seat of the valve on the aluminium base of the MANIFOLD
17.
Do not use chemical products or cloths and brushes
18.
In case of deteriorated gasket, it is preferable to replace the entire piston
19.
Reassemble the solenoid valve by first mounting the piston and subsequently the block of the electrical reel.
20.
Once the solenoid valve mounting is complete, reopen the taps/valves of the tank
21.
Close panel and cover, reconnect the power supply cable and turn on the machine again.
TEST UNDER PRESSURE
From the Service Menu “Manual activations”, in relation to the replaced valve, open (activate) or keep closed the solenoid valves represented in the chart reported as follows.
Ensure that the tank pressure reaches the valve being serviced.
Check that the valve in question does not present refrigerant leaks through the identification of leaks or pressure drops (over 200 mbar).
ENGLISH 24 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
TEST IN VACUUM
Launch the function inside the Maintenance Menu “Leak test”, check that the test is passed successfully.
SERVICE MENU - Manual activations
6.9
WEAR CHECK OF THE OR2-106 4.42X2.62 NBR O-RING OF
THE PRESSURE SENSOR PRESENT ON THE MANIFOLD
1.
Apply the 2 pipes in the supports on the side of the machine and close the taps counter clockwise.
2.
Switch off the machine, remove the power supply cable and open the cover and the front panel.
3.
Close central tap (liquid side) of the tank with service kit key (about 7 clockwise turns)
4.
Reconnect the power supply cable, turn on the machine (do not to touch terminals or printed circuit boards)
5.
Open the service menu
6.
Select manual activations
7.
In manual activations activate OUT R, OUT I, OUT A, C, wait for the LP gauge to show a pressure of at least – 0.3 bar,
8.
Switch off the machine and remove the power supply network cable
9.
Close the other tap (gas side) of the tank with service kit key (about 7 clockwise turns)
10.
Close the tap along the connecting pipe towards the capacitor
11.
Cut the straps if necessary and disconnect the sensor cable.
12.
Insert the cable in the key, position the key on the sensor and unscrew it by using the screwdriver as handle.
13.
Clean the seat of the pressure sensor using compressed air and keeping the bronze filter still with a screwdriver.
14.
Check the conditions of the bronze filter, and replace it in case of impurities.
15.
Check the conditions of the O-Ring inside the manifold cavity and in case of wear or deformation replace with a new one.
16.
Remount the sensor in its seat.
ENGLISH 25 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
17.
Once the solenoid valve mounting is complete, reopen the taps/valves of the tank
18.
Close panel and cover, reconnect the power supply cable and turn on the machine again.
TEST UNDER PRESSURE
From the Service Menu “Manual activations”, in relation to the replaced valve, open (activate) or keep closed the solenoid valves represented in the chart reported as follows.
Ensure that the tank pressure reaches the sensor being serviced.
Check that the sensor in question does not present refrigerant leaks through the identification of leaks or pressure drops.
TEST IN VACUUM
Launch the function inside the Maintenance Menu “Leak test”, check that the test is passed successfully.
6.10
PRESENCE AND WEAR CHECK OF THE OR2212 53,7x1,78
NBR O-RINGS OF THE OIL AND TRACER CONTAINERS
Check the presence of the O-RING, which acts as sign of the oil level on new, exhausted and tracer oil containers. In case of signs of deterioration replace them with new ones.
In case of problems when inserting the connector on the machine joint, replace the bottle.
ENGLISH 26 / 78 CAP. 6 - MAINTENANCE
MULTIGAS 8500
CAP. 7 - CALIBRATION
7.1
CLIMA 8501 SERVICE KIT FOR STATIONS WITH GAS R134A
The service kit is made up of a series of equipment identified as follows, necessary for the programming, calibration and maintenance activities of the CLIMA line equipment.
1.
Service Kit Case
2.
24 mm spark plug to disassemble pressure sensors
3.
Distance bracket for tank lifting
4.
Sample weight support bracket
5.
7 mm box end wrench for opening / closure of tank taps
6.
303 g sample weight for new oil scale calibration
7.
293 g sample weight for exhausted oil scale calibration
8.
Gauge for Unit pressure sensors calibration
9.
DB9 M/F pin to pin serial cable
NOTE: with the above kit service you need to have the upgrading kit, code: 1010350138XX
1. Quick coupler for oils scale calibration for CLIMA SUPER 9000 (to be connected to the sample weight no. 6. or no. 7.).
9. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-1234yf (2 pcs).
12. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-134A.
14. Adaptor for sample weight support bracket for CLIMA SUPER 9000.
15. Fitting for equipment internal flushing for R-134a quick couplers.
16. Fitting for equipment internal flushing for R-1234yf quick couplers.
ENGLISH 27 / 78 CAP. 7 - CALIBRATION
MULTIGAS 8500
Only for CLIMA SUPER 9000; CLIMA-1234-H; CLIMA-1234-HO; for gas weight calibration, use the following 322 g reference weight, assembled as per following instructions:
FUNCTION
PROGRAMMING
ZERO PRESSURE
ITEM
9. DB9 M/F pin to pin serial cable
9. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-1234yf (2 pcs).
12. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-134A.
PRESSURE CALIBRATION
NEW & EXHAUST OIL
WEIGHT CALIBRATION
9. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-1234yf (2 pcs).
12. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-134A.
8. Gauge for Unit pressure sensors calibration.
GAS WEIGHT CALIBRATION 3. Distance bracket for tank lifting
4. Sample weight support bracket
SOLENOID VALVE
DISASSEMBLY
INTERNAL VESSEL MANUAL
VALVE CLOSING
6. 303 g sample weight for new oil scale calibration.
7. 293 g sample weight for exhausted oil scale calibration.
2. 24 mm spark plug to disassemble pressure sensors
5. 7 mm box end wrench for opening/closure of tank taps
INTERNAL VESSEL GAS
RECHARGE
INTERNAL GAS FLUSHING
INTERNAL VESSEL GAS
EMPTYING
9. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-1234yf (2 pcs).
12. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-134A.
15. Fitting for equipment internal flushing for R-134a quick couplers.
16. Fitting for equipment internal flushing for R-1234yf quick couplers.
15. Fitting for equipment internal flushing for R-134a quick couplers.
16. Fitting for equipment internal flushing for R-1234yf quick couplers.
ENGLISH 28 / 78 CAP. 7 - CALIBRATION
MULTIGAS 8500
7.2
CLIMA GAS R-1234YF / R-134A SERVICE KIT FOR STATIONS
WITH GAS R134A AND R1234YF
This is another type of service kit suitable to execute programming, calibration and maintenance activities on MULTIGAS 8500 equipment.
1.
Quick coupler for oils scale calibration for CLIMA SUPER 9000 (to be connected to sample weight no. 2 or no. 3).
2.
293 g sample weight for exhausted oil scale calibration.
3.
303 g sample weight for tracer scale calibration.
4.
Sample weight support bracket.
5.
Distance bracket for tank lifting.
6.
User manual CD-ROM.
7.
Service Kit Case.
8.
24 mm spark plug to disassemble pressure sensors
9.
Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-1234yf (2 pcs).
10.
DB9 M/F pin to pin serial cable
11.
Gauge for Unit pressure sensors calibration.
12.
Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-134A.
13.
7 mm box end wrench for opening / closure of tank taps
14.
Adaptor for sample weight support bracket for CLIMA SUPER 9000
15.
Fitting for equipment internal flushing for R-134a quick couplers
16.
Fitting for equipment internal flushing for R-1234yf quick couplers
NOTE:
The sample weight support bracket (4) is suitable for the MULTIGAS 8500; this model does not require the bracket adaptor (14).
ENGLISH 29 / 78 CAP. 7 - CALIBRATION
MULTIGAS 8500
Only for CLIMA SUPER 9000; CLIMA-1234-H; CLIMA-1234-HO; for gas weight calibration, use the following 322 g reference weight, assembled as per following instructions:
FUNCTION
PROGRAMMING
ZERO PRESSURE
ITEM
10. DB9 M/F pin to pin serial cable
9. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-1234yf (2 pcs).
12. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-134A.
PRESSURE CALIBRATION
NEW & EXHAUST OIL
WEIGHT CALIBRATION
GAS WEIGHT CALIBRATION 5. Distance bracket for tank lifting
4. Sample weight support bracket
SOLENOID VALVE
DISASSEMBLY
INTERNAL VESSEL MANUAL
VALVE CLOSING
8. 24 mm spark plug to disassemble pressure sensors
13. 7 mm box end wrench for opening/closure of tank taps
INTERNAL VESSEL GAS
RECHARGE
9. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-1234yf (2 pcs).
12. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-134A.
11. Gauge for Unit pressure sensors calibration.
3. 303 g sample weight for new oil scale calibration.
2. 293 g sample weight for exhausted oil scale calibration.
INTERNAL GAS FLUSHING
9. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-1234yf (2 pcs).
12. Coupler for the recharge of inner tank and for pressure sensors calibration operations, for gas R-134A.
15. Fitting for equipment internal flushing for R-134a quick couplers.
16. Fitting for equipment internal flushing for R-1234yf quick couplers.
INTERNAL VESSEL GAS
EMPTYING
15. Fitting for equipment internal flushing for R-134a quick couplers.
16. Fitting for equipment internal flushing for R-1234yf quick couplers.
ENGLISH 30 / 78 CAP. 7 - CALIBRATION
MULTIGAS 8500
7.3
PRESSURE CALIBRATION (SERVICE KIT)
From the SERVICE menu, password “BRN”, select the PRESSURE CALIBRATION menu by means of the keys and press .
Disconnect the LP and HP quick couplers from any A/C system and press .
Wait for the message asking to connect the tank coupler, included in the clima station accessories kit; when the next message is displayed, screw HP so that air gets into the HP hose.
Turn the HP quick coupler clockwise to open it and press
Wait for the message to connect the reference gauge contained in the service kit.
Close the HP quick coupler by rotating it counter clockwise and connect it to the gauge present in the SERVICE KIT, open the HP quick coupler by rotating it clockwise and press .
SAFETY NOTE:
ATTENTION NOT TO POINT THE GAUGE TOWARDS ONESELF OR OTHER PEOPLE UNTIL ONE
HAS THE ABSOLUTE CERTAINTY THAT THE CONNECTION WITH THE QUICK COUPLER IS
SAFE.
OPEN THE TAP OF THE QUICK COUPLER BY POINTING THE GAUGE TOWARDS THE
GROUND, ALWAYS KEEP THE GAUGE TOWARDS THE GROUND EXCEPT WHEN THE GUIDED
PROCEDURE REQUIRES ENTERING THE VALUE DISPLAYED ON THE SAMPLE GAUGE.
Measure the pressure reached by the SERVICE KIT gauge and, by means of the keys it on the Unit and press .
, set
Subsequently the equipment will execute the vacuum, at the end of which one will be asked to check that the gauge reaches -1 bar, when requested by the guided procedure press confirm calibration. to
ENGLISH 31 / 78 CAP. 7 - CALIBRATION
MULTIGAS 8500
7.4
GAS WEIGHT CALIBRATION (SERVICE KIT)
From the SERVICE menu, password “BRN”, select the GAS WEIGHT CALIBRATION menu by means of the keys and press .
Unscrew the tank, lift it and insert below it the spacer bracket in order to keep it detached from the load cell. Press to acquire the loadless cell signal.
Remove the spacer bracket and re-screw the tank to the load cell, insert the weight holder clamp without the sample weight.
Press to acquire the signal of the cell with tank and bracket.
Rest a sample weight of at least 10 kg on the weight holder bracket and press : you will be asked to enter the value of the weight that has just been put onto the bracket
Press the keys to set the value of the sample weight and press of the cell with tank, bracket and sample weight. to acquire the signal
Subsequently remove the sample weight and the weight holder clamp and press .
When required by the guided procedure, press to confirm the calibration.
Note: verify that the sample weight support bracket (item no. 4) doesn’t touch any component; in case of contact, use a reference weight of 5 kg.
ENGLISH 32 / 78 CAP. 7 - CALIBRATION
MULTIGAS 8500
7.5
OIL WEIGHT CALIBRATION (SERVICE KIT)
From the SERVICE menu, password “BRN”, select the OIL WEIGHT CALIBRATION menu.
Remove the new oil and exhausted oil containers from the equipment and press the signals of the two loadless oil cells. to acquire
Insert the 303 g sample weight in the new oil attachment and, by means of the arrow keys, set its value.
Press to acquire the signal of the load cell with the sample weight.
Insert the 293 g sample weight in the exhausted oil attachment and, by means of the arrow keys, set its value on the equipment. Press weight. to acquire the signal of the load cell with the sample
Remove the oil sample weights and insert the empty new oil and exhausted oil containers and press .
When required by the guided procedure, press to confirm the calibration.
ENGLISH 33 / 78 CAP. 7 - CALIBRATION
MULTIGAS 8500
CAP. 8 - GAS TYPE SWITCHING
8.1
GAS TYPE SWITCHING FROM R134 TO R1234YF
When the MULTIGAS 8500 station leaves the factory, it is ready for the gas R134a and can be transformed, by applying the specific kit ( MULTIGAS 134 TO 1234 KIT cod. 1010350131XX ) to be ready to receive gas R1234yf. Here below we will briefly outline the procedure that shall be followed by a technician of Brain Bee authorized service centre in order to transform the equipment.
MULTIGAS 134 TO 1234 KIT cod. 1010350131XX
WHEN THE PROCEDURE SHOULD BE APPLIED
When the installation of the MULTIGAS 134 TO 1234 KIT cod. 1010350131XX is required in order to change the type of gas in the station.
If gas type change is done on a MULTIGAS 8500 station containing gas R134a.
[ If gas type change is done on a MULTIGAS 8500 station that has never contained gas R134a, all you have to do is install the transformation kit following the instructions supplied with it, without replacing the dryer filter as it is not contaminated by gas R134a. The gas type setting in the software shall be done before the initial check “First vessel filling (weights and pressure check included)” then proceed with cleaning.
]
STAFF REQUIREMENTS
Expert staff, specifically trained for execution of service operations on live equipment, and containing refrigerant fluids.
Staff shall be aware of the contents of the use and maintenance manual of the equipment and of gas R134a and R1234yf safety data sheets of refrigerants fluids used. Any other qualification required by local national laws/provisions in force.
ENGLISH 34 / 78 CAP. 8 - GAS TYPE SWITCHING
MULTIGAS 8500
CHECK-LIST
1.
A/C station inner flushing
2.
A/C station emptying
3.
Installation of transformation kit
4.
A/C station cleaning cycle
5.
Gas type setting and vessel charging
EQUIPMENT REQUIRED
• Brain Bee A/C recovery station or equivalent station for R134.
• Screwdrivers and wrenches set
MATERIALS/SPARE PARTS
• MULTIGAS 134 TO 1234 KIT cod. 1010350131XX
• R134 MALE HP -> R134 MALE LP COUPLER cod. 14123560010100
PROTECTION EQUIPMENT
• Insulating gloves for refrigerant fluids
• Total protection goggles
• Operate in compliance with the local national laws/provisions in force.
WORKPLACE
• Non-closed premise with adequate air change rate.
• Flat and even floor
• Operate in compliance with the local national laws/provisions in force.
SAFETY NOTE: These instructions do no replace the use and maintenance manual of the station, the prescriptions of which shall be strictly complied with.
SAFETY NOTE: Never point the hoses of the machine, which may contain gas, towards yourself or other people.
1) A/C station inner flushing a) Lock the machine wheels to prevent any movement b) Connect the HP and LP charge hoses together, using the R134 MALE HP -> R134 MALE
LP COUPLER cod. 14123560010100 c) Open the taps of the HP and LP quick couplers d) Turn on the station o Enter the “Service” menu, password “BRN” o Enter the Manual Activations section o Activate, in sequence, the R - A valves and the compressor C o Flush the circuit for 10 minutes e) Drain the exhausted oil o Deactivate the R valve and wait for HP and LP pressure (check on pressure gauge) to reach between +300 & +400mbar o Turn off compressor C o Activate oil drain valve S o Keep it active until all residual oil has been drained. o Deactivate oil drain valve S f) Complete hoses emptying o Turn on compressor C again o Wait for HP and LP pressure (check on pressure gauge) to reach -300mbar and complete hoses emptying.
ENGLISH 35 / 78 CAP. 8 - GAS TYPE SWITCHING
MULTIGAS 8500 o Turn off compressor C g) Close the taps of the LP and HP quick couplers and disconnect the adapter.
2) Total emptying of GAS R134a from the station a) Connection between MULTIGAS 8500 and station for gas R134a recovery o Connect the LP coupler of the MULTIGAS 8500 station to the HP coupler of the recovery station, using the R134 MALE HP -> R134 MALE LP COUPLER
14123560010100 o Open HP and LP taps. b) Activation of MULTIGAS 8500 station solenoid valves o Turn on the MULTIGAS 8500 station o Enter the “Service” menu, password “BRN” o Enter the Manual Activations section and activate, in sequence, the R-A-I valves c) Start of recovery cycle of the station for gas R134a recovery o Start a recovery cycle on the station used for emptying o Wait for recovery to be completed. o Close the HP and LP taps and disconnect the recovery station. o Switch off MULTIGAS 8500 station and station for gas R134a recovery.
3) Installation of transformation kit a) Switch off the recharge station MULTIGAS 8500 and remove the power supply cable to avoid any electric hazard. b) MULTIGAS 134 TO 1234 KIT main components preparation: o quick couplers for R1234yf o HP and LP false couplers o Dryer filter
ENGLISH 36 / 78 CAP. 8 - GAS TYPE SWITCHING
o vacuum pump output hose o not condensable gas valve output hose o safety valve output hose o fan with rpm control system
MULTIGAS 8500 o 220 V cable o External R-1234yf refrigerant gas bottle fittings and seals
ENGLISH 37 / 78 CAP. 8 - GAS TYPE SWITCHING
MULTIGAS 8500 c) Replacement of fan o Remove the old fan of the station and substitute it with the new one inside the kit. o Disconnect the 220V cable (brown and blue) from the switch, from the power board and from the fan. fan: remove 220 V cable power board switch o Disconnect the ground cable (yellow and green) from the fan and from the other connector of equipment case.
ENGLISH 38 / 78 CAP. 8 - GAS TYPE SWITCHING
o Connect the new 220 V cable from the switch to the power board
MULTIGAS 8500 switch power board
ENGLISH 39 / 78 CAP. 8 - GAS TYPE SWITCHING
MULTIGAS 8500
Logic board
“exhaust oil” o Assemble and connect the new fan and the cable with electronic circuit
Logic board
“pwr prn” printer fan
Take the pre-assembled fan with metal base with hoses fittings
Using the plastic rivets (previously disassembled) assemble the fan onto the case of equipment
AIR FLOW DIRECTION
(from inside to outside)
ATTENTION –VERIFY THAT THE AIR FLOW DIRECTION IS
DIRECTED TO THE OUTSIDE OF EQUIPMENT CASE
ENGLISH 40 / 78 CAP. 8 - GAS TYPE SWITCHING
MULTIGAS 8500 o Assemble the black box to the case of equipment using the cable ties d) Fix the hoses on the fan fittings and connect them to the components below
Vacuum pump
Non condensable gas valve
Safety valve
AIR FLOW
DIRECTION
Fix the vacuum pump hose using the cable ties
Fix the vacuum pump hose using cable ties
Not condensable gas valve Safety valve
ENGLISH 41 / 78 CAP. 8 - GAS TYPE SWITCHING
MULTIGAS 8500 e) Disassemble the old fittings and assemble the new ones for R-1234yf quick couplers to the case of the equipment f) Change the old dryer filter as described on service manual and assemble the new one
(only if the equipment worked with R134a refrigerant) g) Connect the R1234yf HP & LP quick couplers to the HP & LP hoses of equipment h) Assemble the conductive plastic belt (to discharge the electrostatic charges) to the case of equipment with bolt
ENGLISH 42 / 78 CAP. 8 - GAS TYPE SWITCHING
MULTIGAS 8500
4) A/C station cleaning cycle a) Disconnect the hoses of the machine from any other system b) Turn on the recharge station o Enter the “Service” menu, password “BRN” o Make sure the vessel pressure is Z 0 bar o Enter “Manual Activations” o Start the cleaning cycle, activating valves “A”-“I”-“R”-“V” c) Make sure the gauges pressure reaches -1Bar o Wait at least 2 hours d) Turn on compressor C o Wait 30 minutes e) Deactivate valves “A”-“I”-“R”-“V” and the compressor C
5) Change of station gas type and vessel charging a) Turn on the recharge station o Make sure the station firmware is updated. If needed, update using CLIMA
Solution o Enter the “Setup” menu, o Enter the menu “GAS type” o Select R1234 as gas type o Save changes using the password “NGAS” b) Charge the inner vessel of the MULTIGAS 8500 station with gas R1234yf as outlined in the station user manual (at least 3 kg).
ENGLISH 43 / 78 CAP. 8 - GAS TYPE SWITCHING
MULTIGAS 8500
9.1
CAP. 9 - UPDATE
SOFTWARE UPDATE
To update the equipment and the related database it is necessary to proceed to a new programming of the equipment as described in point 5.1.5 “programming” with the serial cable available in the Service Kit or through the ACU device (Automatic Clima Update).
9.2
NEW DATABASE PURCHASE AND ACTIVATION
In order to purchase and activate a new version of the database (included in the A/C station after the software update), REGISTRATION is required, implying the following steps:
• access to the distributor reserved area on the website www.brainbee.com
• selecting the icon “ACTIVATION AND MANAGEMENT OF DEVICES”
• selecting the serial number of the active A/C station from the list (if needed, start the search procedure through the icon
• entry of the equipment serial number
)
• waiting for the activation code which will have to be entered into the equipment.
See pictures below.
ENGLISH 44 / 78 CAP. 9 - UPDATE
Select the serial number by clicking on it, or
MULTIGAS 8500
Start the search procedure through the icon and enter the serial number you searched for.
ENGLISH 45 / 78 CAP. 9 - UPDATE
MULTIGAS 8500
Select update device
ENGLISH 46 / 78 CAP. 9 - UPDATE
MULTIGAS 8500
Enter the database update activation code, which is shown on the A/C station display when you try to access data of a new model present in the databank/database.
The confirmation code shown on the website page to avoid counterfeiting.
Enter the “DATABASE ACTIVATION REQUEST CODE” displayed on the equipment screen when attempting to access the vehicles added in the new version of the database.
Tick on the box to confirm the order.
ENGLISH 47 / 78 CAP. 9 - UPDATE
MULTIGAS 8500
Before confirming, check that the e-mail is correct, otherwise contact Brain Bee sales department.
After confirmation you will receive an e-mail (order confirmation) which enables to obtain the code to be entered into the CLIMA equipment to activate the new database version.
Until the activation code is entered into the equipment, it will always be requested.
ENGLISH 48 / 78 CAP. 9 - UPDATE
MULTIGAS 8500
CAP. 10 - EQUIPMENT AND SIMULATORS
The following equipment is required
• CLIMA GAS R-1234YF / R-134A SERVICE KIT FOR STATIONS WITH GAS R134A AND
R1234YF
• ACU - AUTOMATIC CLIMA UPDATER
Software (available on the website http://www.brainbee.it), reserved area
• Clima Update Software
• Multigas 8500 Software
ENGLISH 49 / 78 CAP. 10 - EQUIPMENT AND SIMULATORS
23
11.1
CAP. 11 - REFRIGERANT FLUID CIRCUIT
REFRIGERANT FLUID CIRCUIT
The chart of the refrigerant fluid circuit of MULTIGAS 8500 is reported as follows.
16
42
4
18
Vessel gauge
MULTIGAS 8500
5 33
28
43 40
19
17
7
6
20
41
8
29
1
9 10
15
11
21 27
12
34 37
35
36
22
14
24
32
31
30
26
13
2 3
25
38
39
1
2
3
4
5
6
7-8
9-10
11-12
13
14
15
16
17
ENGLISH
Vacuum pump
Compressor
Capacitor fan
Refrigerant charge solenoid valve
New oil injection solenoid valve
Tracer injection solenoid valve
Interception HP-LP solenoid valves pair
Vacuum solenoid valves pair
Refrigerant absorption solenoid valves pair
Exhausted oil discharge solenoid valve
Non condensable gases vent solenoid valve
Compressor delivery high pressure safety pressure switch
HP branch pressure gauge
LP branch pressure gauge
50 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
MULTIGAS 8500
37
38
39
40
33
34
35
36
41
42
43
29
30
31
32
25
26
27
28
18
19
20
21
22
23
24
Internal refrigerant vessel pressure gauge
New and exhaust oil scale
Absolute pressure sensor -1 …+35 bar
Automatic mechanical expansion valve
Heat exchanger
Mechanical no return valve
Mechanical no return valve
Heating belt
Accumulation receiver safety valve (20 bar)
Expansion valve protection mechanical filter
HP vehicle quick coupler (SAEJ639)
LP vehicle quick coupler (SAEJ639)
Interception manual valve for internal vessel liquid phase
Interception manual valve for internal vessel vapour phase
Interception manual valve
Exhausted oil container
Dryer filter
Compressor oil restore separator receiver
Exhausted oil distiller double chamber receiver
Compressor oil restore capillary circuit
Refrigerant accumulation receiver
Refrigerant scale
New oil container
Tracer container
Mechanical no return valve
Mechanical no return valve
The circuit is made up of 3 main parts:
• the refrigerant fluid tank equipped with four couplers, o recovered refrigerant inlet, o liquid refrigerant outlet for recharge, o outlet towards non-condensable gases discharge valve, o safety valve.
• The manifold, joint aluminium block, equipped with channelling on which the valves and other devices are mounted, o inlet from fluid tank, o new oil container inlet, o tracer container inlet, o hose with HP gauge towards the vehicle, o hose with LP gauge towards the vehicle, o outlet towards vacuum pump o outlet towards refrigerant recovery group
• the refrigerant recovery group, which through its own components enables the following operations, expansion of the gas recovered from the vehicle, evaporation with exhausted oil separation, refrigerant dehydration, compression, condensation. o recovered refrigerant inlet, o exhausted oil outlet, o liquid refrigerant outlet towards the tank, o safety pressure switch.
ENGLISH 51 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
MULTIGAS 8500
11.2
OPERATIONAL CYCLES
The equipment enables, with a single series of operations, to recover and recycle the refrigerant fluids without dispersions in the environment, also removing humidity and various deposits contained in the oil from the A/C system. In fact, inside the equipment there is an evaporator/separator through which oil and other impurities are removed from the refrigerant fluid recovered from the A/C system, then collected in a suitable container. The fluid is then filtered and re-injected, perfectly recycled, inside the tank in the equipment. Through the equipment it is also possible to carry out some A/C system functioning and capacity tests.
ENGLISH 52 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
RECOVERY
MULTIGAS 8500
ENGLISH 53 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
VACUUM
MULTIGAS 8500
ENGLISH 54 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
OIL/TRACER INJECTION
MULTIGAS 8500
ENGLISH 55 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
RECHARGE
MULTIGAS 8500
ENGLISH 56 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
NON-CONDENSABLE GASES DISCHARGE
MULTIGAS 8500
ENGLISH 57 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
MULTIGAS 8500
11.3
RECEIVING TANK
The tank is the component which determines the category of the entire equipment according to the PED directive.
The PED “Pressure Equipment Directive” 97/23/EC defines and regulates all those parts that are subject to pressure, with a specific ratio between their pressure and volume.
Safety against the risk due to pressure of the refrigerant fluid inside the receiving tank is ensured by the safety valve installed during manufacturing. In case of replacement, use of new and original spare parts not contaminated with other substances is recommended as well as requesting the relative declaration of conformity proving the effective test of the components in the beginning.
The assistance centre assumes responsibility for workmanlike assembly and for checking before new commissioning according to the prescriptions provided for by the regulations in force in the country of use; in particular, the assistance centre will have to guarantee that the assembly will ensure perfect tightness and that safety components are installed appropriately so as to ensure operation is not jeopardized.
VESSEL 20l
Category III (Dir. 97/23/EC)
SAFETY VALVE 20 bar R 1/4 GAS
Category IV (Dir. 97/23/EC)
Notes regarding operator safety:
Attention: presence of dangerous 230 VAC voltage near the tank, disconnect the equipment from the mains before each maintenance intervention.
Attention: presence of refrigerant fluid under pressure, in case of disassembly of the tank or of its components, make sure the tank is empty and closed, the connecting pipe between tank and manifold is empty and the connecting pipe between tank and pneumatic group is empty.
Emptying with the aid of a second CLIMA line equipment is recommended. Do not disperse gas into the environment.
ENGLISH 58 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
MULTIGAS 8500
11.4
MANIFOLD CHART
The manifold chart, where the identification letters of the sectioning valves are highlighted, is reported as follows:
• V = vacuum;
• A = recovery;
• I = interception (HP side and LP side separation);
• L = new oil
• T = tracer
• R = refrigerant
The valves (V,A,I) which must control the gas flow in both directions must necessarily be double since the single valve is not able to guarantee bidirectional closure.
Notes regarding operator safety:
Attention: presence of dangerous 230 VAC voltage on the solenoid valve terminals and near the manifold; disconnect the equipment from the mains before each maintenance intervention.
Attention: presence of refrigerant fluid under pressure, in case of disassembly of manifold or its components ensure that the tank is closed, the connection pipe between the tank and the manifold is empty, the LP and HP connectors are disconnected from any system and closed, that a pipe emptying operation has been made, and the manifold has been completely emptied (for further details see CHAP.14)
ENGLISH 59 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
Tracer New oil
MULTIGAS 8500
Vacuum Recovery
Vacuum Recovery
Interception
HP/LP
Tracer New oil Vessel pressure gauge
ENGLISH 60 / 78
Recharge
CAP. 11 - REFRIGERANT FLUID CIRCUIT
MULTIGAS 8500
11.5
SUCTION UNIT CHART
The suction unit is a group made up of various pressurised equipments interconnected through brazed piping, which according to the PED directive fall under article 3 paragraph 3.
A routine maintenance operation is the replacement of the dryer filter, the procedure of which is outlined in the user manual.
Safety against the risk due to pressure of the refrigerant fluid inside the suction unit is ensured by a safety gauge installed during manufacturing.
In case of replacement of the pressure switch or the unit, use of new and original spare parts not contaminated by other substances is recommended as well as requesting the declaration of conformity proving the effective test of the components in the beginning.
The assistance centre assumes responsibility for workmanlike assembly and for checking before new commissioning according to the prescriptions provided for by the regulations in force in the country of use; in particular, the assistance centre will have to guarantee that the assembly will ensure a perfect tightness and that the safety components are installed appropriately so as to ensure operation is not jeopardized.
SUCTION UNIT Art. 3.3 (Dir. 97/23/EC)
EXPANSION VALVE
DISTILLER
NET FILTER
SAFETY PRESSURE
SWITCH
DRYER FILTER
SETTLER
FAN AND
RADIATOR
EXHAUSTED OIL
DISCHARGE SOLENOID
VALVE
PRESSURE SWITCH 13/18bar 1/4SAE Category IV (Dir. 97/23/EC)
ENGLISH 61 / 78 CAP. 11 - REFRIGERANT FLUID CIRCUIT
MULTIGAS 8500
CAP. 12 - NON-PERMANENT JUNCTIONS
Here below some instructions on the use of Loctite® 577 on the thread of some non-permanent junctions in the pneumatic circuit of the CLIMA stations.
The product polymerizes when air is absent and when in contact with metal; its aim is preventing slackening caused by impacts and vibrations. Yet, after application and fixing onto the junction/thread, you must tighten and then wait several hours, in relation to the type of coupling between metals, before the product can get its maximum performance in terms of hold/resistance.
For one’s own and other people’s safety, the operator/user of the Loctite® 577 product must consider that it must be employed in well-ventilated premises and that protecting eyes and hands with suitable PPE (personal protective equipment) is required. For compulsory safety provisions to be followed when using the product, the user shall refer to the safety data sheet of Loctite® 577 manufacturer.
For further details on the product characteristics/performance and application instructions, please refer to the technical data sheet of Loctite® 577 manufacturer.
Points of insertion of Loctite® 577 onto the whole thread (on all Brain Bee A/C stations, unless otherwise specified):
Receiver (refrigerant gas storage inner tank):
• Safety valve;
• Non-condensing gas solenoid valve EV input coupler;
(Solenoid valves assembly) manifold:
• Pressure sensors only for models by the WIKA manufacturer
Vacuum pump:
• Inlet coupler only for models by the VALUE manufacturer;
Containers for oils/tracer:
• Couplers for connection to the load cells or the frame.
Point of insertion of Loctite® 577 only in one spot with anti-rotation purpose:
HP and LP bulkhead connector:
• connection side to 16ACME charge hoses.
ENGLISH 62 / 78 CAP. 12 - NON-PERMANENT JUNCTIONS
MULTIGAS 8500
CAP. 13 - ELECTRICAL CONNECTIONS
Here below the electric connection diagram of the MULTIGAS 8500 station, with connections between the main components and the printed circuit boards included in the equipment.
ENGLISH 63 / 78 CAP. 13 - ELECTRICAL CONNECTIONS
MULTIGAS 8500
Detail of the connectors connecting to the load cells (gas, new and exhausted oil) and the pressure sensor.
Connections between power board and actuators on the manifold.
ENGLISH 64 / 78 CAP. 13 - ELECTRICAL CONNECTIONS
MULTIGAS 8500
CAP. 14 - SPARE PARTS
The necessary components for ordinary and extraordinary maintenance are made available.
Routine maintenance includes the replacement of components subject to wear, such as thermal paper of the printer, or to use, such as: charge pipes, quick couplers and piping and solenoid valve gaskets.
Extraordinary maintenance includes the replacement of other components such as, for example: the load cells, the vacuum pump, the pressure sensors, the printer, the keyboard, the gauges, the safety valve and the suction unit.
On www.brainbee.com spare parts website, the complete list is available with codes to order them.
Enter the reserved area with your dealer username and the Password received from the Brain Bee
Sales Department.
ENGLISH 65 / 78 CAP. 14 - SPARE PARTS
MULTIGAS 8500
ENGLISH 66 / 78 CAP. 14 - SPARE PARTS
Enter the “Spare parts management” area
MULTIGAS 8500
Select the area of the CLIMA/air conditioning product line and model.
Download the document of the chosen model.
For the correct display of the spare parts you need to have Acrobat Reader and the appropriate
NetSpares Plugin available for installation after download.
In case the page display is not complete, use the zoom of your internet browser (example
Explorer).
Once the equipment has been selected from the appropriate list, a .pdf file will open and the
Net-Spares functions will be available among the Acrobat Reader tools. It is advisable to view the user manual, accessible through the key .
ENGLISH 67 / 78 CAP. 14 - SPARE PARTS
MULTIGAS 8500
15.1
CAP. 15 - REPLACEMENT INTERVENTIONS
EXTRAORDINARY MAINTENANCE LIST
SERVICE OPERATION DESCRIPTION
Vacuum pump replacement
Vacuum pump oil replacement
Replacement of PNEUMATIC SUCTION UNIT, which includes
Mechanical expansion valve
Distiller receiver
Compressor
Compressor oil restore separator receiver
Heat exchangers
Cleaning and/or replacement of refrigerant charge solenoid valve
Cleaning and/or replacement of new oil injection solenoid valve
Cleaning and/or replacement of tracer injection solenoid valve
Cleaning and/or replacement of HP-LP on-off solenoid valves pair
Cleaning and/or replacement of vacuum solenoid valves pair
Cleaning and/or replacement of exhausted oil discharge solenoid valve
Cleaning and/or replacement of non-condensable gas discharge solenoid valve of accumulation receiver
Replacement of LP branch pressure sensor
New and exhausted oil scale replacement
Replacement of accumulation receiver safety valve (20 bar)
Replacement of HP vehicle quick coupler
Replacement of LP vehicle quick coupler
Dryer filter replacement
Replacement of refrigerant accumulation receiver
Refrigerant scale replacement
Replacement of HP branch pressure gauge
Replacement of LP branch pressure gauge
Replacement of logic electronic board with display
Replacement of electronic power board
ENGLISH 68 / 78 CAP. 15 - REPLACEMENT INTERVENTIONS
MULTIGAS 8500
15.2
EXTRAORDINARY MAINTENANCE
15.2.1
Replacement of components connected to refrigerant circuit
The equipment contains parts subject to directive PED Pressure Equipment Directive 97/23/EC.
The components (pressurised equipment) constituting/connected to the refrigerant fluid circuit through permanent junctions, such as sealing or brazing, can in no way be disassembled, replaced, changed or handled.
Before each check and/or replacement intervention of components inside the machine it is recommended to firstly carry out the following operations:
Apply the 2 pipes in the supports on the side of the machine and close the taps counter clockwise.
1.
Switch off the machine, remove the power supply cable and open the cover and the front panel.
2.
Close central tap (liquid side) of the tank with service kit key (about 7 clockwise turns)
3.
Reconnect the power supply cable, turn on the machine (do not touch terminals or printed circuit boards)
4.
Open the service menu
5.
Select manual activations
6.
In manual activations activate OUT R, OUT I, OUT A, C, wait for the LP gauge to show a pressure of at least - 0.4 bar,
7.
Switch off the machine and remove the power supply network cable
In case of replacement of pipes equipped with o-rings, use Loctite® 577 thread locker and replace the internal o-ring.
In case of replacement of pipes without o-ring, insert the lubricated copper washer.
It is recommended to not disperse the refrigerant in the atmosphere.
If it is necessary to provide for emptying of the internal tank, you have to carry out refrigerant recovery with a second machine, after having interconnected the equipment with the HP pipe and having placed the machine to empty with the open tank and open OUT R valve.
Alternatively, it is possible to disconnect the inlet to the tank on the gas side by connecting the pipe to an external tank to fill and by activating OUT R, OUT I, OUT A, C until obtaining a tank pressure of about -0.4 bar,
15.2.2
Replacement of logic electronic board with display
After having excluded any problem regarding software, power supply, fuses on the switch block, connection cables, faults in the power board, running out of the clock battery, faults in the micro
SD card, faults in the sensors, replacement is required in case of:
• Impossibility to correctly complete card programming.
• Incorrect display operation
• Block in the acquisition and display of the analogue signals not caused by faults in the sensors or by a miscalibration.
• Incorrect activation of command relays.
• Wrong indications of the internal clock not due to lack of adjustment or running out of battery.
• Evident damage to board components and circuits.
For the replacement of the board it is recommended to position the new board alongside the one to be replaced. Disconnect and reconnect the cables in sequence one by one:
ENGLISH 69 / 78 CAP. 15 - REPLACEMENT INTERVENTIONS
MULTIGAS 8500
• Gas scale load cell (J1 W. TANK)
• New oil load cell (J2 W. NEW OIL)
• Exhausted oil load cell (J4 W. EXAUST OIL)
• LP pressure sensor (J8 P. LP)
• Printer serial communication (J16 RS232 PRN)
• Power board connection (J3 I/O INTERFACE)
• Printer power supply (J17 PWR PRN)
• Programming serial connector (J18 RS232 PRG)
• Keypad connector (J15)
• Insert a CR2032 battery on the new board.
In case less than 5 years have passed since the machine manufacturing date (see technical data label) it is possible to reuse the battery present on the replaced board.
• Reprogram the machine with the updated software. o Before starting programming through the CLIMAUPDATE programming software
(available in the reserved area of the website www.brainbee.com), the type/model of the CLIMA station (Machine Type) shall be set on the printed circuit board received as spare part.
Connect the CLIMA station to the PC via the serial cable included in the service kit (ref. chap. 7.1), start the CLIMAUPDATE software and press the “tools” icon; right after that, switch on the CLIMA station.
Enter the same “BRN” password to access the service menu reserved to maintenance activities on the device which is communicated by Brain Bee to the Assistance Centres.
ENGLISH 70 / 78 CAP. 15 - REPLACEMENT INTERVENTIONS
Select the machine type in the pull-down menu
MULTIGAS 8500
Reprogram the machine with the updated software (ref. Chap. 5.1.5.1)
• Select the language
• Carry out gas scale calibration
• Carry out new and exhausted oil scale calibration
• Carry out pressure calibration
• Enter the machine registration code (it can be obtained through Brain Bee service website in the service area by selecting “Clima Registration” “Registration Status” and selecting the machine serial number on which you are operating.
• Carry out the machine setup as in paragraph 5.1.11.
15.2.3
Replacement of electronic power board
After having excluded any problem regarding power supply, fuses on the switch block, connection cables, faults in the logic board, faults in the controlled actuators, replacement is required in case of:
• Incorrect functioning of the power supply unit section.
Incorrect activation of the command relays or the actuators connected to them. •
• Evident damage to board components and circuits.
For the replacement of the board it is recommended to position the new board alongside the one to be replaced. Disconnect and reconnect the cables in sequence one by one:
• FST7 OUT A
• FST2 OUT R
• FST3 OUT L
• FST4 OUT T
• FST5 OUT S
• FST6 OUT H (leave the contact on the edge of the board empty)
• FST8 OUT I
• FST9 OUT N
• FST10 OUT V
• FST11 OUT V
• FST14 PROTECT (pressure switch)
• FST13 OUT C
• FST1 LINE IN
• FST16 GROUND
• J1 I/O INTERFACE (Interface cable with logic board)
ENGLISH 71 / 78 CAP. 15 - REPLACEMENT INTERVENTIONS
MULTIGAS 8500
CAP. 16 - TROUBLE SHOOTING
MALFUNCTION
1. If the “SD card not present” message is shown during switch on and/or during software update just downloaded from the web.
POSSIBLE CAUSE
SD card absent or not mounted well.
POSSIBLE SOLUTION
1. Insert or check SD card insertion.
2. Reprogram the recharge station.
2. Slow or not possible refrigerant injection.
3. During the recovery phase there is an evident refrigerant leak from the exhausted oil container.
The leak test is negative.
4. Difficulty in the recovery and recharge phase
Closed refrigerant tank.
Seal gaskets, broken or deformed, are obstructing the pipes.
5. During the automatic cycle it is not possible to inject and recover the oil.
Joints seal gaskets cut for excessive tightening (they cause clogging of pipes and operational block of the machine, with different consequences based on the position of the gasket - in any case it is always related to clogging of a pipe or dirt in the solenoid valves).
Dirt inside the Oil discharge solenoid valve.
Oil loading cell out of calibration or defective.
1. Localisation of the defects of the rubber components or dirt residue and replacement or cleaning.
2.Carry out emptying of the gas as described in chap.13.2.1
3. If yellow pipes are present, check and, if needed, replace the seal gaskets placed inside the pipe which connects the solenoid valves group to the tank.
1. Cleaning of the solenoid valve
OUT – S.
2. Check of the gasket efficiency.
3. calibrate pressure sensor
1. Open the tank valve by unscrewing it counter clockwise.
2.Carry out emptying of the gas as described in chap.13.2.1
3. Reset the normal seal conditions of the HP-LP taps gaskets and the
HP-LP couplers, both internal and external.
4. If yellow pipes are present, check and, if needed, replace the seal gaskets placed inside the pipe which connects the solenoid valves group to the tank.
1. Calibration of the exhausted and new oil scales.
2. Replace if needed.
6. Vacuum pump emits disturbing vibrations
7. After the vacuum phase the leak test has a negative result.
Defective vacuum pump
This may occur when the vacuum time is too short,
4-5 minutes.
Vacuum pump replacement
When a vacuum time less than 20 minutes is set, the following message appears:
“Less than 20 minutes of vacuum do not guarantee the execution of a correct procedure. Continue?”.
ENGLISH 72 / 78 CAP. 16 - TROUBLE SHOOTING
Further unscrew the locking screw of the cell, ensuring that it is not in contact with the cell during use.
Substitution of logic electronic board.
MULTIGAS 8500
The solution is keeping to the 20 minutes vacuum time.
8. The gas scale appears blocked on a certain value.
9. ADC converter malfunctioning – equipment error/not functioning.
10. HP pressure gauge with same pressure of internal vessel gauge.
11. Hoses emptying not completed with system under pressure
12. Hoses emptying not completed.
With pressure at 0 bar
(empty circuit)
13. Initial verification not correctly carried out.
14. Power cut-off by pressure switch.
Loading cell locking screw not sufficiently unscrewed.
ADC failures.
Dirty inside OUT “R” solenoid valve
Failure of OUT “R” solenoid valve
Manifold defects
Compressor fault
Pressure sensor not calibrated
Close refrigerant internal vessel,
Menu Service – Manual Activation open OUT “R” OUT “I” OUT “A”
OUT “C” (compressor), close all valves once a pressure of 0 bar is reached.
Solutions could be in order: o Clean OUT “R” o Substitution of OUT “R” o Substitution of manifold
First of all, check for leaks from
OUT “R”. o Replace the compressor
First of all, check for leaks from
OUT “R”. o Calibrate the pressure sensor
Mistake during procedure. o Check valve before internal vessel blocked o Manual valve before internal vessel closed o o
Repeat pressure sensor calibration.
Substitute hose of check valve
Open manual valve
ENGLISH 73 / 78 CAP. 16 - TROUBLE SHOOTING
MULTIGAS 8500
17.1
CAP. 17 - DIAGNOSTICS
FAILURES LIST
Please find below the list of message and alarm codes that could be detected by the MULTIGAS
8500 software. If there are alarms, it is advisable to apply to your supplier or service Partner.
Notice/Warning messages are coded with Wxxx code on the title of the window.
CODE MESSAGE When it occurs Possible situations Actions
W008 REPLACE VACUUM
PUMP OIL
W009
W025
REPLACE DRYER
FILTER
REFRIGERANT
QUANTITY TOO
HIGH
When required after long life pump procedure
When the filter capacity is finished
During the programming of the inner tank charge amount
Vacuum pump oil with contamination the filter capacity is finished
Amount required greater than that available in internal tank
Change vacuum pump oil
Change filter with new one
Decrease the set quantity.
W026 RECHARGE VESSEL
EMPTY OR
DISCONNECTED
W029
W032
VESSEL NEARLY
FULL
NO PRESSURE -
VEHICLE WITHOUT
REFRIGERANT OR
DISCONNECTED
During the tank filling phase
During the refrigerant recovery or hoses emptying phase.
During the refrigerant recovery phase
Recharging tank empty or hoses/taps clogged/closed
The tank is close to its maximum capacity.
Check tank, hoses, taps.
Decrease quantity of gas by filling (injecting) an external tank rated for R134a (with safety valve)
Check connections and leaks in A/C system
ENGLISH 74 / 78 CAP. 17 - DIAGNOSTICS
MULTIGAS 8500
CODE MESSAGE
W036 FURTHER OIL
INJECTION NOT
POSSIBLE
W044 VESSEL EMPTY
W045
W047
LP VERY LOW
When it occurs
During oil injection phase
During flushing or multipass phase
During flushing phase
POSSIBLE LEAKAGE During the refrigerant recovery phase
Possible situations
Insufficient vacuum level
Gas level is too low for the procedure to be completed
LP hose disconnected, flushing couplings not properly hooked up or leak in circuit being flushed.
Vehicle A/C system (LP side) may have leaks
Actions
Increase the vacuum phase time, check the
A/C system tightness.
Fill the internal tank with gas
Reconnect LP and/or couplers and search for and eliminate any leak.
--
ENGLISH 75 / 78 CAP. 17 - DIAGNOSTICS
MULTIGAS 8500
Alarm messages are coded Axxx in the window title bar.
Alarms immediately terminate the procedure and prevent its resumption.
CODE MESSAGE Possible causes
A000 EEPROM NOT
WORKING
When it can occur
In case of faults in the
Eeprom memory
Eeprom damaged
Actions
Change the logic electronic board
A001 EEPROM DATA
CORRUPT
Eeprom damaged
Change the logic electronic board
A002 PRESSURE SAFETY
SWITCH
ACTIVATED
In case of faults in the
Eeprom memory
High pressure is over 18 bar
A003
A004
ADC NOT
WORKING
FAN NOT
WORKING
After turning on the equipment
Only during
R-1234yf use
High pressure
(due to pressure on vessel or circuit to vessel closed) on refrigerant circuit between equipment’s compressor and internal vessel.
ADC fault
Fan not working properly (stopped or fan’s rpm not adequate)
Verify
If internal vessel pressure level is over 18 bar, wait for pressure reduction disconnect equipment from the mains, use safety protection, open equipment and make sure the valves between compressor and internal vessel are open
Replacement of logic electronic board.
A032 CIRCUIT STILL
UNDER PRESSURE
During vacuum, vessel filling or leak test phase in vacuum
The vehicle A/C system is pressurized
Stop use of the equipment
1.
check fan connections and
2.
if necessary, change fan and related cables with a new one
3.
change logic electronic board with new one.
Recover the refrigerant gas from the vehicle before starting another vacuum phase.
ENGLISH 76 / 78 CAP. 17 - DIAGNOSTICS
MULTIGAS 8500
CODE MESSAGE
A033 CIRCUIT LEAKAGE During vacuum, vessel recharge or
A034 VACUUM LEVEL
TOO LOW leak test phase
During tracer injection and oil injection phase
A035 VESSEL EMPTY
When it can occur
A036
A037
VESSEL
REFRIGERANT
QUANTITY TOO
LOW
FURTHER
REFRIGERANT
INJECTION NOT
POSSIBLE
During the gas injection and flushing phase
During the gas injection and flushing phase
During gas injection phase
A038 CIRCUIT LEAKAGE
OR
DISCONNECTED
During flushing phase
Possible causes
Leakage in the circuit or in the vehicle fittings.
Vehicle A/C system is pressurised notwithstanding the vacuum phase
Refrigerant gas is too low for the procedure to be completed
Gas amount in internal tank less than required
Hoses not hooked up to
A/C system; tap closed; vacuum not sufficient; presence of pressure in the circuit
Leakages or obstructions in the circuit to be flushed
A039 FURTHER OIL
INJECTION NOT
POSSIBLE
During oil injection phase
Insufficient vacuum level
Actions
Identify the leak position in the vehicle or connected system and have it repaired by trained and qualified staff according to local legislation.
Identify the leak position in the vehicle or connected system and have it repaired by trained and qualified staff according to local legislation.
Fill the internal tank
Fill the internal tank
Caution: before proceeding, empty out the hoses.
Repeat the recovery procedure and increase the vacuum phase duration.
Enable the heating belt.
Check the connection to the A/C system or identify the leak in the circuit and have it repaired by trained and qualified staff according to local legislation.
Increase vacuum phase duration.
ENGLISH 77 / 78 CAP. 17 - DIAGNOSTICS
CODE
A043
A047
A048
MESSAGE
VESSEL FULL
LP LEAKAGE
HP LEAKAGE
A049 LP AND/OR HP
LEAKAGE
MULTIGAS 8500
When it can occur
During the gas recovery and hoses emptying phase
During the gas recovery and hoses emptying phase
During the gas recovery and hoses emptying phase
During the gas recovery and hoses emptying phase
Possible causes
Internal tank full, maximum capacity level reached
At the end of the gas injection, in the ECO LOCK quick coupler disconnection phase during the vehicle fittings leak test
At the end of the gas injection, in the ECO LOCK quick coupler disconnection phase during the vehicle fittings leak test
At the end of the gas injection, in the ECO LOCK quick coupler disconnection phase during the vehicle fittings leak test
Actions
Decrease quantity of gas by filling (injecting) an external tank rated for
R134a (with safety valve)
Empty the vehicle (follow the procedure guided by the displayed messages)
Empty the vehicle (follow the procedure guided by the displayed messages)
Empty the vehicle (follow the procedure guided by the displayed messages)
ENGLISH 78 / 78 CAP. 17 - DIAGNOSTICS
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Key features
- R-134a & R-1234yf refrigerant compatible
- Comprehensive maintenance section
- Detailed calibration procedures
- Troubleshooting guide
- Safety information
- Installation instructions
