COMPUTERIZED UNIT FOR Nitrogen test Azoidro test ......external recovery system), nitrogen test,...

COMPUTERIZED UNIT FORNitrogen testAzoidro testRefrigerant recoveryVacuum and vacuum testRefrigerant charge

User’s manual
ENGLISH

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INDEX

Safety precautions................................................................................................................3Technical regulations...........................................................................................................3Layout drawing .....................................................................................................................4Hydraulic diagram ................................................................................................................6Electric diagram....................................................................................................................7Legend...................................................................................................................................81. Introduction to KOMPACT unit.....................................................................................9

1.1. Technical specifications ....................................................................................................................... 9

2. Components description and standard equipment ....................................................92.1. High vacuum pump .............................................................................................................................. 92.2. Refrigerant electronic scale.................................................................................................................. 92.3. Flexible hoses ...................................................................................................................................... 92.4. Lock-Valve quick couplers and connections ........................................................................................ 92.5. Built-in electronic vacuum gauge ....................................................................................................... 102.6. Built-in ambient temperature probe.................................................................................................... 102.7. Printer ................................................................................................................................................. 102.8. Micro-sd.............................................................................................................................................. 102.9. Control module ................................................................................................................................... 10

3. Preparing unit KOMPACT for use ..............................................................................123.1 Charging the unit with oil and checking the vacuum pump oil level................................................... 12

4. Using unit KOMPACT ..................................................................................................134.1 Refrigerant recovery........................................................................................................................... 134.2 N2 testing ........................................................................................................................................... 154.3 N2+H2 testing..................................................................................................................................... 174.4 Discharge ........................................................................................................................................... 184.5 Vacuum + Vacuum Test..................................................................................................................... 194.6 Refrigerant Charge............................................................................................................................. 204.7 Auto 1 (R+T+V+C).............................................................................................................................. 224.8 Auto 2 (T+V+C) .................................................................................................................................. 254.9 Disconnecting the unit from the system ............................................................................................. 264.10 Setting menu ...................................................................................................................................... 27

5. Service Procedures .....................................................................................................285.1. Calibration menu ................................................................................................................................ 285.1.1. Refrigerant scale calibration .......................................................................................................... 285.1.2. Pressure sensor calibration ........................................................................................................... 285.1.3. Digital vacuum gauge calibration ................................................................................................... 295.2. Zero pressure ..................................................................................................................................... 295.3. Zero scale........................................................................................................................................... 295.4. Periodic operations............................................................................................................................. 30

6. Accessories and spare parts......................................................................................306.1. Spare parts ......................................................................................................................................... 306.2. Accessories ........................................................................................................................................ 30

7. Dimensions and weight...............................................................................................31

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WARNING

Safety precautions

a) This equipment is designed for trained personnel only, who must know the refrigerationfundamentals, cooling systems, refrigerants and possible damage that pressurized equipmentmay cause.

b) Carefully read the instructions contained in this manual; strict observance of the proceduresdescribed is fundamental to the operator’s safety, the perfect state of the unit and constantperformances as declared.

c) During nitrogen discharge operations, make sure that the silencer (ref. 14) is mountedon the suitable connection on the unit.

d) Before performing any operation, make sure that the hoses used for connections have beenpreviously evacuated and that they do not contain non-condensable gases.

e) Avoid skin contact; the low boiling temperature of the refrigerant (about -30°C) can causefreezing.

f) Avoid breathing refrigerant vapours.g) It is recommended to wear suitable protections like safety glasses and gloves; contact with

refrigerant may cause blindness and other personal injuries.h) Do not operate near open flames and hot surfaces; the high temperatures decompose the

refrigerant releasing toxic and caustic substances which are hazardous for the operator andthe environment.

i) Always make sure that the unit is connected to a suitably protected mains supply providedwith an efficient earth connection.

j) Before performing maintenance operations or when the unit will not be used for a long periodof time, turn the unit off by turning the main switch to 0 and disconnect the power supply cord;absolutely follow the sequence of operations.

k) Operate the unit only in locations with suitable ventilation and a high number of air changes.l) Before disconnecting the unit, make sure that the cycle has been completed and that all

valves are closed in order to avoid release of refrigerant to the atmospherem) Never fill any tank with liquid refrigerant to more than 75% of its maximum capacity.n) During operations avoid release of refrigerant to the environment; this precaution is required

by international environmental standards and is essential to avoid difficult leak detection in arefrigerant polluted environment.

o) The equipment must always work under the operator’s controlp) Protect the unit from drippingq) Do not modify the calibration of safety valves and control systems.r) If you recover refrigerant from a cooling system equipped with a water evaporator and/or

condenser, it is necessary to drain water from the evaporator and/or condenser or to keep thecirculation pump running during the entire recovery operation in order to avoid frosting.

s) The unit is equipped with an independent ventilation system able to flux the inside airand it can be used with gases R32 and R1234yf. The operator must have attendedspecific training courses before using these gases.

Technical regulations

a) The unit is equipped with an independent ventilation system able to flux the inside airand it can be used with gases R32 and R1234yf. The operator must have attendedspecific training courses before using these gases. The ventilation system startsautomatically when the unit is plugged in.

b) According to the type of gas that the operator is using, it is important to value the dimensions ofthe volume of the room in which we operate. Such value must be compared with the quantityof gas contained in the stocking cylinder and/or inside the system.

c) In order to remove possible refrigerant pockets inside the system, we suggest to use tubepiercing valves, as for example model W341 part number 05004004. Perform solderingoperations only when it is sure at 100% that there is no gas inside the circuit and after havingperformed a good vacuum process (especially with R600a and R290).

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Layout drawing

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Hydraulic diagram

Figure 1 Hydraulic diagram

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Electric diagram

Figure 2 Electric diagram for KOMPACT without printer

Figure 3 Electric diagram for KOMPACT with printer

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Legend

EV1 Solenoid valve – nitrogen discharge line /recovery line

10 Vacuum pump oil sight glass

EV4 Solenoid valve - vacuum pump suction line 11 Vacuum pump oil drain plugEV13 Solenoid valve - refrigerant charging line 12 Discharge / Recovery connectionEV19 Solenoid valve - oil/additive charging line 13 Complete frameEV20 Solenoid valve - digital vacuum gauge 14 Silencer for N2 dischargeCV1 Check valve - refrigerant charging line 15 Handle

CV2 Check valve - nitrogen charging line 16 Power cableTR15 Pressure sensor 0 ÷ 50 bar 17 Bearing for bottle without tubeVA18 Digital vacuum sensor 18 RG180 (Adapter 5/16”SAE f - 1/4”SAE m)CEL1 Load cell 35 Kg (refrigerant) 68 Main power switch1 Vacuum pump connecting hose PRT Printer (optional)2 Vacuum gauge connecting hose PWR Transformer3 Refrigerant charging hose CPU Control module4 Central connection for system T1 Connecting hose to the system5 Connection for nitrogen or azoidro (95%nitrogen

+ 5% hydrogen) bottleT2 Connecting hose to the bottle with valve

6 Vacuum pump V1 Lock valve 1/4” SAE7 Scale pan V2 Lock valve 5/16” SAE8 Fan9 Vacuum pump oil filler plug

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1. Introduction to KOMPACT unit

KOMPACT unit enables the quick and efficient recovery of refrigerant from the system (by means of anexternal recovery system), nitrogen test, azoidro mixture test, system’s evacuation, check for tightnesswith a precision electronic vacuum gauge, the subsequent charge with refrigerant and the systemdiagnosis.Thanks to its microprocessor, KOMPACT unit permits the control of all the functions by means of 1electronic scale which controls the refrigerant charge.

1.1. TECHNICAL SPECIFICATIONS

Model KOMPACTRefrigerants all halogenated refrigerantsElectronic scale capacity 35 kgMax working pressure 50 barPower supply 230/1/50Absorption 0.7-1.2 APower input 150-270 WStorage temperature -10 ÷ + 50 °CAmbient working temperature +10 ÷ + 50 °CProtection degree IP20Noise level < 70dB (A)Class of precision 1% F.S.

2. Components description and standard equipment

2.1. HIGH VACUUM PUMP

Essential component for extracting from the A/C system the residues of technical gases used forpressing, ambient air and vapour contained in it as well as water possibly formed through vapourcondensation.The high vacuum pump the unit is equipped with is rotary vane type, dual stage, lubricated by oilinjection.KOMPACT is available with a vacuum pump with swept volume of either 46 l/min or 90 l/min.

2.2. REFRIGERANT ELECTRONIC SCALE

Max weight capacity 35 kg Resolution ± 2 g Precision 1% F.S. Scale pan dimensions 230x230 mm

2.3. FLEXIBLE HOSES

The unit is equipped with 2 flexible hoses:- 1 blue hose for the connection to the system (T1)- 1 yellow hose with valve for the connection to the refrigerant bottle (T2)Their flexibility assures easy connection in any situation; they withstand the system operatingpressures and maintain their passage section even when operating in vacuum.KOMPACT is equipped with adapters to be able to connect to the different types of systems.

2.4. LOCK-VALVE QUICK COUPLERS AND CONNECTIONS

The unit is equipped with 2 Lock-Valve quick couplers:- 1 with 1/4” SAE connection (V1)- 1 with 5/16” SAE connection (V2)Furthermore, the unit is equipped with the following connections:- 1 adapter RG180 (adapter 5/16”SAE f – 1/4”SAE m) (17)- 1 bearing for bottle without tube (18)

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2.5. BUILT-IN ELECTRONIC VACUUM GAUGE

The unit is equipped with a high precision electronic vacuum gauge. It allows to measure vacuum andcheck the system’s tightness during the vacuum test. The measuring range is 1 ÷ 350 Pa.

2.6. BUILT-IN AMBIENT TEMPERATURE PROBE

The unit is equipped with one ambient temperature probe (built in the main board) for reading theambient temperature inside the unit.

2.7. PRINTER

The printer (optional) allows to print on thermic type paper with a chart size of 57mm width a reportticket with the values programmed by the operator and performed by the unit.

2.8. MICRO-SD

The unit is equipped with an interface with micro-SD card. Inside you can find the following:- Firmware of the unit (files containing languages, parameters, etc..)- User’s manual- WLGraph (interface software for the download of the recorded data). For the use of the

programme, we suggest to refer to the guide on line after having installed it).

2.9. CONTROL MODULE

Access to the functions:- Test N2 (nitrogen)- Test N2+H2 (azoidro mixture)- Refrigerant recovery- Discharge N2 / N2+H2

Test N2Test N2+H2RecoveryDischarge

VacuumVacuum test

Refrigerant charge

Access to MenuExit key (Back)

Auto 1Auto 2Start / Stop key

Arrow UPZero-Scale

Arrow DOWNZero Pressure

Micro-sd cardconnector

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Access to the Vacuum + Vacuum Test function

Access to the Oil charge/ Refrigerant charge function

Standby – Access to the Menu for the modification of the unit’s settings parametersDuring a function setting – Back to the previous screen

Standby – Access to the Automatic functions (Auto 1 - Auto 2)During a function – Start and end of the functionDuring a function under way – if pressed for more than 3 seconds, stops thefunction for emergency

Shift through the various ranges and modify the numerical valuesStandby – if pressed for more than 3 seconds, it performs the scale reset procedure(Tara)

Shift through the various ranges and modify the numerical valuesStandby – if pressed for more than 3 seconds, it performs the pressure sensor resetprocedure (atmospheric zero)

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3. Preparing unit KOMPACT for use

IIMMPPOORRTTAANNTT!! TThhee ssyynnooppttiicc ssttiicckkeerr ddooeess nnoott eexxeemmpptt tthhee ooppeerraattoorr ffrroomm ccaarreeffuullllyy rreeaaddiinngg tthhiissuusseerr’’ss mmaannuuaall aanndd ffrroomm ssttrriiccttllyy oobbsseerrvviinngg tthhee iilllluussttrraatteedd pprroocceedduurreess..

IIMMPPOORRTTAANNTT WWhheenn tthhee uunniitt iiss ssttaarrtteedd,, tthhee vveennttiillaattiioonn ssyysstteemm wwiillll ssttaarrtt aauuttoommaattiiccaallllyy.. TThheessyysstteemm iiss ssuuiittaabbllee ffoorr rreemmoovviinngg tthhee rreessiidduuaall ggaasseess iinnssiiddee tthhee wwoorrkkiinngg aarreeaa..

3.1 CHARGING THE UNIT WITH OIL AND CHECKING THE VACUUM PUMP OIL LEVEL

IIMMPPOORRTTAANNTT!! NNeevveerr uussee tthhee vvaaccuuuumm ppuummpp wwiitthhoouutt ffiilllliinngg ooiill iinnttoo iitt bbeeccaauussee iitt wwiillll ddaammaaggee tthheeppuummpp.. AAllwwaayyss cchheecckk tthhaatt tthheerree iiss eennoouugghh ooiill iinnssiiddee tthhee ppuummpp bbeeffoorree uussee..

1. Unscrew the oil filler plug situated on top of the pump (ref.9)2. Slowly fill the oil into the pump until the level reaches half of the sight glass (ref.10)3. Screw on the oil filler plug again (ref.9)

Each time the unit is used, it is necessary to check that the level of oil is at the half of the sightglass.Before checking the oil level, the unit must be placed on a level surface and its power supplymust be turned off.

WARNING! Do not pollute environment with oil; it is a special waste and must be disposed ofaccording ttoo tthhee rreegguullaattiioonnss iinn ffoorrccee

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4. Using unit KOMPACT

4.1 REFRIGERANT RECOVERY

1. Perform the connection to the system by means of the hose supplied with the unit (see belowfigure). In case you need to connect to both LOW and HIGH connections of the system, use amanifold.

2. Turn the handwheel of the V1 or V2 lockvalve to enable the connection between the system andthe unit.

3. Turn the 68 switch to position I.

4. Press the key.

5. Shift downwards by means of the key until you select “Recovery” from the menu. Confirm

with

6. The unit sets the recovery function on ALL by default: in this way, the unit recovers all therefrigerant there is inside the system. In case you want to recover a definite quantity of

refrigerant, modify the value by means of the or keys, until the quantity you want torecover appears on the display.

T e s t N 2T e s t N 2 + H 2

R e c o v e r yD i s c h a r g e

R 1 3 4 a A L L

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7. Confirm with .8. The display will advise that you have to connect a recovery system.

9. Connect the recovery system (EasyRec120 code 13001015 or EasyRec120R100 code

13001016) as shown in figure. Confirm with10. The display will advise that you have to connect the recovery bottle.

11. Connect the bottle previously evacuated by means of the T2 service hose. Press the keyto proceed.

12. The display will advise that you can start the recovery system.

13. Start the recovery system according to the user’s manual of the recovery system you are using.It is recommended to use the recovery system with a disarmed pressure switch. Unit KOMPACTwill inform the operator when it is necessary to turn off the recovery system.

14. The recovery process will stop automatically, when a pressure of -0.2 bar inside the system isreached. A message will appear on the display and a beep will be heard. This means that theoperator can turn off the recovery system (according to its user’s manual).

15. Confirm with .16. A recap screen will appear on the display with the total quantity of recovered refrigerant.

Besides, a report of the recovery performed will be printed (if the printer is installed).

17. Press the key to leave.18. If no other operation needs to be done, turn the 68 switch to position 0 to turn off the unit.

C o n n e c tr e c o v e r y u n i t

S u i t a b l e b o t t l ef o r r e c o v e r y

S t a r tr e c o v e r y u n i t

T u r n o f fr e c o v e r y u n i t

R 1 3 4 a 3 . 1 5 0 k g

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4.2 N2 TESTING

WWAARRNNIINNGG!! TThhee uunniitt iiss ssuuiittaabbllee ttoo bbee ccoonnnneecctteedd ttoo aa 11 lliittrree nniittrrooggeenn ccyylliinnddeerr iinn iittss ssttaannddaarrddvveerrssiioonn.. FFoorr tthhee ccoonnnneeccttiioonn ttoo aa bbiiggggeerr ccyylliinnddeerr,, iitt iiss nneecceessssaarryy ttoo uussee aa pprreessssuurree rreegguullaattoorr((ccooddee 1100000022001177))..

WWAARRNNIINNGG MMaakkee ssuurree tthhaatt tthhee ssiilleenncceerr rreeff.. 1144 iiss mmoouunntteedd oonn tthhee ccoonnnneeccttiioonn rreeff.. 1122 oonn tthhee rreeaarrooff tthhee uunniitt,, ttoo lliimmiitt tthhee nniittrrooggeenn eemmiissssiioonn..


2. Insert the BN2/1-TPED 1 litre nitrogen cylinder into its dedicated place or connect the biggercylinder through a pressure regulator (code 10002017 AZ200-50)



5. Press the key

6. Select “N2 test” by means of the key

T e s t N 2T e s t N 2 + H 2

P 1 5 b a rT i m e 1 0 ‘

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Suggested pressure values:

Refrigerant type Pressure range (MPa) Test duration (‘) Systems up to 5kW

R134a 1,5 - 2,7 30R1234yf 1,5 - 2,7 30R404A 2,8 - 3,2 30R407C 2,8 - 3,2 30R507 2,8 - 3,2 30R22 2,8 - 3,2 30R410 4,0 - 4,2 30R32 4,0 - 4,2 30R12 1,4 - 1,6 30R502 2,6 - 3,0 30

WWAARRNNIINNGG!! TThhee aabboovvee aarree ssuuggggeesstteedd vvaalluueess;; ccoonnssiiddeerr tthhee tteesstt ppaarraammeetteerrss ssuupppplliieedd bbyy tthheessyysstteemm’’ss mmaannuuffaaccttuurreerr aannyywwaayy..

7. Set the value of the testing pressure (range 2 ÷ 49 bar) by means of the arrows or .

8. Confirm with .

9. Set the value of the testing time (range 1 ÷ 9999 minutes) by means of the arrows or .

10. Confirm with .11. The function will start automatically and the system will be brought to the value set for the test.12. The pressurization phase will be followed by a stabilization phase during which the pressure

value of the system will settle (about 2 minutes). After stabilization, the real testing phase willstart.

13. The nitrogen pressure value at the start of the test will be indicated on the first line; this value isthe reference the unit considers to detect the leak.

14. The pressure value read in real time inside the system in alternation with the remaining testingtime (hh:mm:ss) will be indicated on the second line.

15. In case you need to stop the test before completion, it is possible to do so by pressing the

key.16. Otherwise, the test will end automatically with positive or negative result. In both cases, the

display will show the value of pressure at the start of the test and the value of pressure at theend of the test. Furthermore, a report of the test performed will be printed (if the printer isinstalled).

17. At the end of the test, if the result is positive, the unit will ask the operator to perform the

automatic discharge of nitrogen. Press the key to proceed with the discharge of thesystem.

18. If there is a leakage, discharge will not be performed. The operator must locate the leak in thesystem by means of suitable items (for instance spray leak detector GAS CONTROL code09001080).

19. Discharge of nitrogen from the system must be performed manually (see chapter 3.4).

S t a r t 1 5 b a rP 1 5 b a r

P . S t a r t 1 5 . 0 b a rP . 1 5 . 0 b a r

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20. If no other operations need to be done, turn the 68 switch to position 0 in order to turn off theunit.

IMPORTANT! At the end of each N2 testing, the result of the test is saved on the micro-SD card. Thefile is created in the following way: AAMMGG_X where:

o AA Year of the testingo MM Month of the testingo GG Day of the testingo X Daily increment: A/B/C…

Files created in this way are useable with the WLGraph software, which is inside the micro-SD card.

4.3 N2+H2 TESTING

WWAARRNNIINNGG!! TThhee uunniitt iiss ssuuiittaabbllee ttoo bbee ccoonnnneecctteedd ttoo aa 11 lliittrree nniittrrooggeenn ccyylliinnddeerr..

WWAARRNNIINNGG!! MMaakkee ssuurree tthhaatt tthhee ssiilleenncceerr rreeff.. 1144 iiss mmoouunntteedd oonn tthhee ccoonnnneeccttiioonn rreeff.. 1122 oonn tthheerreeaarr ooff tthhee uunniitt,, ttoo lliimmiitt tthhee nniittrrooggeenn eemmiissssiioonn


2. Insert the AZOIDRO 1 litre cylinder into its dedicated place.



5. Press the key

6. Select “Test N2+H2” by moving downwards by means of the key or key

T e s t N 2T e s t N 2 + H 2

P 1 5 b a rT i m e 1 0 ‘

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7. Set the value of the testing pressure (range 2 ÷ 49 bar) by means of the arrows or .The test with azoidro mixture must be performed at a pressure of 5 bar.

8. Confirm with .


10. Confirm with .11. The function will start automatically and the system will be brought to the value set for the test.12. After the pressurization phase, the testing phase will start.13. The countdown will appear on the display and the operator will have to search for possible leaks

by means of the electronic leak detector FINDER (code 09001090).

14. In case you need to stop the test before completion, it is possible to do so by pressing thekey.

15. Otherwise, the test will stop when the countdown is over.

16. At the end of the test, the unit will ask the operator to perform the automatic discharge of

nitrogen. Press the key to proceed with the discharge of the system.17. If no other operations need to be done, turn the 68 switch to position 0 in order to turn off the

unit.

4.4 DISCHARGE

WWAARRNNIINNGG!! MMaakkee ssuurree tthhaatt tthhee ssiilleenncceerr rreeff.. 1144 iiss mmoouunntteedd oonn tthhee ccoonnnneeccttiioonn rreeff.. 1122 oonn tthheerreeaarr ooff tthhee uunniitt,, ttoo lliimmiitt tthhee nniittrrooggeenn eemmiissssiioonn

1. In case the N2 test has detected a leak, the system is kept under pressure to enable theoperator to perform the nitrogen discharge manually.

2. Press the key

T e s t N 2T e s t N 2 + H 2

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3. Shift downwards by means of the key until you select “Discharge” in the menu. Confirm

with

4. The display will advise the operator to start the discharge process.

5. Press to start the cycle.6. The process will stop automatically when a pressure of +0.1 bar is reached inside the system. A

message will appear on the display and a beep will be heard.

7. Press to leave (no report is printed in this operation, even if the printer is installed).8. If no other operations need to be done, turn the 68 switch to position 0 in order to turn off the

unit.

4.5 VACUUM + VACUUM TEST




4. Press the key

5. Set the vacuum time by means of the arrows or . In order to make an efficient serviceon the system, we suggest to set a vacuum time of at least 30 minutes.

R e c o v e r yD i s c h a r g e

V a c u u mT i m e 3 0 ‘

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IIMMPPOORRTTAANNTT!! FFoorr ssyysstteemmss wwiitthh rraatteedd oouuttppuutt bbeellooww 66 kkWW,, wwee ssuuggggeesstt ttoo ppeerrffoorrmm aa vvaaccuuuummccyyccllee ooff aatt lleeaasstt 3300--4455 mmiinnuutteess..

6. Press to start the function.7. During the initial phase, the numeric value of vacuum will blink on the display. The countdown

starts when vacuum inside the system reaches below 100 mbar absolute.

8. Once the countdown is completed (or if the key is pressed to exit), the vacuum test willstart. The display will show the vacuum inside the system.

9. The unit will show an alarm message if the vacuum value goes beyond the pre-set threshold of200 mbar absolute

10. In case the function stops with positive result, the display will show the vacuum time performedand the test result. A report of the test performed will be printed (if the unit is equipped with theprinter) confirming the maximum vacuum level reached.

IIMMPPOORRTTAANNTT!! IIff,, oonn tthhee rreeppoorrtt,, ““--------““ aappppeeaarrss ffoorr tthhee vvaaccuuuumm lleevveell,, iitt mmeeaannss tthhaatt tthhee vvaaccuuuummttiimmee ppeerrffoorrmmeedd wwaass ttoooo sshhoorrtt..

IMPORTANT! At the end of each N2 testing, the result of the test is saved on the micro-SD card. Thefile is created in the following way: AAMMGG_X where:

o AA Year of the testingo MM Month of the testingo GG Day of the testingo X Daily increment: A/B/C…

Files created in this way are useable with the WLGraph software, which is inside the micro-SD card.

4.6 REFRIGERANT CHARGE


V a c u u m 3 0 ‘V a c u u m t e s t O K

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4. Press the key5. On the display a message will appear to inform the operator to check the position of the bottle on

the scale and its connection to the system.In case you use a bottle with no tube, we suggest to use the connection ref. 17. Connect theconnection to the scale pan as shown in the below figure.

WWAARRNNIINNGG!! TThhee cchhaarrggiinngg ffuunnccttiioonn mmuusstt bbee ppeerrffoorrmmeedd wwiitthh aa ssyysstteemm wwhhiicchh hhaass bbeeeennpprreevviioouussllyy eevvaaccuuaatteedd..

6. Set the refrigerant quantity by means of the arrows or .

7. Press to confirm and start the function.

WWAARRNNIINNGG!! The refrigerant charge cycle is performed “by steps” in order to reach a highprecision.. You may hear subsequent “clicks” inside the unit during this phase..

8. When the function is completed, a beep will let the operator know that the cycle is over and thedisplay will show the information on the cycle just performed. A report of the charge performedwill be printed (if the unit is equipped with a printer).

9. If no other operations need to be done, turn the 68 switch to position 0 in order to turn off theunit.

R 1 3 4 a 0 , 3 0 0 k g

R 1 3 4 a 0 , 3 0 0 k g

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4.7 AUTO 1 (R+T+V+C)

The Auto 1 cycle includes the following functions:a. Refrigerant recoveryb. Test with nitrogen N2c. Vacuum + vacuum testd. Refrigerant charge

1. Perform the connection to the system by means of the hose supplied with the unit (see belowfigure). In case you need to connect to both LOW and HIGH connections of the system, use amanifold.Connect the recovery system on the bottle VAPOR inlet.Connect the charging line on the bottle LIQUID outlet.



4. Press the key5. Select cycle 1 R+T+V+C6. The display will show the message concerning the recovery function

7. The unit sets the recovery function on ALL by default: in this way, the unit recovers all therefrigerant there is inside the system. In case you want to recover a definite quantity of

refrigerant, modify the value by means of the or keys, until the quantity you want torecover appears on the display.

8. Confirm with .9. The display will show the information on the N2 test.

R e c o v e r yR 1 3 4 a A L L

LIQUIDVAPOR

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10. Set the value of the testing pressure (range 2 ÷ 49 bar) by means of the arrows or .

11. Confirm with .


13. Confirm with .

WWAARRNNIINNGG!! IInn ccaassee tthhee ppaarraammeetteerrss ooff tthhee NN22 tteesstt aarree lleefftt oonn 00,, tthhee ffuunnccttiioonn wwiillll bbee sskkiippppeedd..

14. The display will show the information on the Vacuum + Vacuum Test function


16. Press to confirm.17. The display will show the information on the refrigerant charge.


19. Press to confirm.20. The display will show all the values set for each function in the scrolling menu.

21. Press to start the AUTO 1 cycle.22. The display will advise to connect the recovery system

23. Connect the recovery system (EasyRec120 code 13001015 or EasyRec120R100 code

13001016) as shown in the figure. Confirm with24. The display will advise the operator to connect the refrigerant stocking bottle.

25. Connect the bottle (previously evacuated) by means of the T2 service hose. Press the keyto proceed.

P 1 5 b a rT i m e 1 0 ‘


R 1 3 4 a 0 , 3 0 0 k g

C o n n e c tr e c o v e r y u n i t

S u i t a b l e b o t t l ef o r r e c o v e r y

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26. The display will advise the operator to start the recovery system.

27. Start the recovery system according to the user’s manual of the recovery system you are using.It is recommended to use the recovery system with a disarmed pressure switch. Unit KOMPACTwill inform the operator when it is necessary to turn off the recovery system.

28. The recovery process will stop automatically, when a pressure of -0.2 bar inside the system isreached. A message will appear on the display and a beep will be heard. This means that theoperator can turn off the recovery system (according to its user’s manual.

29. Confirm with .30. The unit will go directly to the N2 test function (when set)31. When the function is completed, the unit will go directly to the vacuum + vacuum test cycle.

WWAARRNNIINNGG!! DDuurriinngg tthhee NN22 tteesstt aanndd vvaaccuuuumm pphhaassee,, pprroovviiddee ttoo ccoonnnneecctt tthhee bboottttllee,, iiff iitt wwaass nnoottddoonnee pprreevviioouussllyy,, ffoorr tthhee ffoolllloowwiinngg rreeffrriiggeerraanntt cchhaarrggiinngg ffuunnccttiioonn..

32. The last function to be performed is the refrigerant charge.

IIMMPPOORRTTAANNTT!! AAtt tthhee eenndd ooff eeaacchh ffuunnccttiioonn,, tthhee uunniitt wwiillll pprriinntt aa rreeppoorrtt ((iiff tthhee uunniitt iiss eeqquuiippppeedd wwiitthhaa pprriinntteerr))..

33. When all the cycles from the AUTO 1 are completed, the summary screen will appear on thedisplay.

34. Press to leave the summary screen.35. If no other operations need to be done, turn the 68 switch to position 0 in order to turn off the unit

S t a r tr e c o v e r y u n i t

T u r n o f fr e c o v e r y u n i t

EENNGGLLIISSHH

4.8 AUTO 2 (T+V+C)

The Auto 2 cycle includes the following functions:a. Test with nitrogen N2b. Vacuum + vacuum testc. Refrigerant charge

1. Perform the connection to the system by means of the hose supplied with the unit (see belowfigure). In case you need to connect to both LOW and HIGH connections of the system, use amanifold.Connect the charging line on the bottle LIQUID outlet

2. Turn thethe unit.

3. Turn the

4. Press the5. Select cy6. The displ

7. Set the v

8. Confirm w

9. Set the v

10. Confirm w

WWAARRNNII

PT i m e

25

handwheel of the V1 or V2 lockvalve to enable the connection between the system and

68 switch to position I I.

keyle 2 T+V+Cay will show the message concerning the N2 test

alue of the testing pressure (range 2 ÷ 49 bar) by means of the arrows or .

ith .

alue of the testing time (range 1 ÷ 9999 minutes) by means of the arrows or .

ith .

NNGG!! IInn ccaassee tthhee ppaarraammeetteerrss ooff tthhee NN22 tteesstt aarree lleefftt oonn 00,, tthhee ffuunnccttiioonn wwiillll bbee sskkiippppeedd

1 5 b a r1 0 ‘

LIQUID

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11. The display will show the information on the Vacuum + Vacuum Test function


13. Press to confirm.14. The display will show the information on the refrigerant charge


16. Press to confirm.17. The display will show all the values set for each function in the scrolling menu.

18. Press to start the AUTO 2 cycle.19. The unit will start the N2 test function directly20. When the function is completed, the unit will go directly to the vacuum + vacuum test cycle

WWAARRNNIINNGG!! DDuurriinngg tthhee NN22 tteesstt aanndd vvaaccuuuumm pphhaassee,, pprroovviiddee ttoo ccoonnnneecctt tthhee bboottttllee,, iiff iitt wwaass nnoottddoonnee pprreevviioouussllyy,, ffoorr tthhee ffoolllloowwiinngg rreeffrriiggeerraanntt cchhaarrggiinngg ffuunnccttiioonn

21. The last function to be performed is the refrigerant charge.

IIMMPPOORRTTAANNTT!! AAtt tthhee eenndd ooff eeaacchh ffuunnccttiioonn,, tthhee uunniitt wwiillll pprriinntt aa rreeppoorrtt ((iiff tthhee uunniitt iiss eeqquuiippppeedd wwiitthhaa pprriinntteerr))..

22. When all the cycles of the AUTO 2 are completed, the summary screen will appear on thedisplay.

23. Press to leave the summary screen.24. If no other operations need to be done, turn the 68 switch to position 0 in order to turn off the unit

4.9 DISCONNECTING THE UNIT FROM THE SYSTEM

When the service on the system is completed, it is necessary to disconnect the unit in order to removeall the refrigerant from the hoses.1. Start the system so that it can suck all the refrigerant.2. As soon as the pressure read on the unit reaches the value of the suction pressure of the system,

close the lock-valve (V1 or V2) and disconnect the unit.


R 1 3 4 a 0 , 3 0 0 k g

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4.10 SETTING MENU

If you press the key in the standby screen, you can gain access to the setting menu.

System serial number by pressing the key, it is possible to type the serial number of the systemon which you are making the maintenance; you can modify each single field by

means of the arrows or , and move forward by means of the

key. Move forward up to the last field available with .

Refrigerant by pressing the key, it is possible to select the type of refrigerant. Shift through

the refrigerants by means of or and confirm with

Language by pressing the key, it is possible to change the language of the unit. Shift

through the languages by means of or and confirm with

Unit of measurement by pressing the key, it is possible to modify the unit of measurement of

the sensors. Shift by means of or and confirm with

Date and Hour by pressing the key, it is possible to set the date and hour. Modify each value by

means of or and confirm with

Calibration see chapter 5.1

Service by pressing the key, it is possible to make some service operations using severalkeys combinations

Password - - - : Cancellation of all the data saved on the SD-Card

Contrast regul. by pressing the key, it is possible to modify the value of the display contrast by

means of or and confirm with .

Data exportation by pressing the key, it is possible to export the services performed by the unitinto the SD-card. The unit creates a .txt file to import into your own PC. In case themessage “ERROR CODE 08” appears, re-start the unit and try again the exportationprocedure.

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To cancel all the data saved in the memory card, follow the procedure explained at“Service”

Operator’s data by pressing the key, it is possible to modify the 6 lines available on the report towrite some information about your own workshop. Once the information have beenwritten, they will be printed on each report.

5. Service Procedures

5.1. CALIBRATION MENU

IMPORTANT! The calibration operations are very delicate. Mistakes in this phase cancompromise the functioning of the whole unit. These operations must be effected by qualifiedpeople! In order to perform the calibration operations, it is necessary to have certifiedinstruments supplied by Wigam and follow the procedures explained in this user’s manual veryaccurately.

By pressing the key in the standby screen and selecting Calibration, you can gain access to thecalibration menu of the unit.To be able to enter the menu, it is necessary to type the following password (combination of keys in

succession): - - - .

5.1.1. REFRIGERANT SCALE CALIBRATION

1. Make sure there is no weight on the scale2. Make sure the unit is on a level surface3. Select “Refrigerant” from the calibration menu

4. Press the key to memorize value Zero5. Then place the sample weight on the refrigerant scale

6. Press the key to memorize the weight

7. Type the weight value by means of the arrows or ; confirm with

5.1.2. PRESSURE SENSOR CALIBRATION

1. Make sure there is no pressure source on the connection ref. 42. Select “ Press. Sensor” from the calibration menu3. The display will advise to place the ambient pressure (1.0 bar absolute). Proceed and then

confirm with4. Wait for the unit to memorize the data.5. Now connect a known pressure source (suggested value of 15 bar absolute). Check the

pressure value by means of a sample pressure gauge.

6. If the pressure has the correct value, press to memorize.

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7. When the memorization is completed, set the pressure value by means of or typingthe value in mbar absolute.

8. Confirm with

5.1.3. DIGITAL VACUUM GAUGE CALIBRATION

1. Make sure connection ref. 4 is connected to an empty bottle of at least 2 litres volume with areference digital vacuum gauge.

2. Connect a temperature probe near the vacuum gauge of the unit.3. Select “Vacuum gauge” from the calibration menu.4. The display will advise to type the vacuum gauge temperature value. Wait a little bit until the

system is completely stable. Modify the temperature value by means of or .

5. Proceed and then confirm with6. The message “Vacuum Start proceed” will appear on the display. Make sure there is a vacuum

value of about 30 Pa on the reference vacuum gauge and that the value is very much stable.

Press to turn off the vacuum pump and wait for the value to stabilize (ideal value around

50 Pa). Modify the value by means of the arrows or and confirm with .

7. Wait for the end of the memorization procedure. Press to leave.8. In case the value should not be acceptable, repeat the complete procedure.

5.2. ZERO PRESSURE

IMPORTANT! If this function is performed with a different unit inner pressure than theatmospheric one, this could cause an incorrect calibration of the unit.

Zero pressure function must be used when one wants to know with the utmost accuracy the readingvalue of pressure near zero.To perform this operation, it is necessary to bring the inner pressure of the unit to the atmospheric

value, go into the standby screen and press the key for more than 3 seconds. Then follow theinstructions on the display.

5.3. ZERO SCALE

IMPORTANT! If this function is performed with a weight different from zero on the scale, yyoouuccoouulldd hhaavvee nneeggaattiivvee vvaalluueess oonn tthhee ddiissppllaayy..

This function must be performed when the weight value read on the unit is not 0.000kg although thereis no weight on the scale.To perform this function, make sure that the scale has no weight on it, go into the standby screen ad

press the key for more than 3 seconds. Then follow the instructions on the display.

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5.4. PERIODIC OPERATIONS

1. The vacuum pump oil must be changed each time the alarm message appears on the display(see chapter 1.12)

2. Check the vacuum pump oil level; this must be done with the pump turned off.3. Check all the gaskets of the hoses and connections supplied with the unit each time you use

these hoses and connections to connect to the unit and to the system to be serviced.

6. Accessories and spare parts

6.1. SPARE PARTS

Ref. Code Model Description- 12002003 K1 L Vacuum pump mineral oil- 14020014001 G19020-WIG Kit 10 gaskets 1/4”SAE- 09009056 PLUS/PAPER Thermic paper for printer

V1 05059049001 LOCK-VALVE1/4-WIG Lock valve ¼”SAEV2 05059050001 LOCK-VALVE5/16-WIG Lock valve 5/16”SAE18 05059023001 RG180/5- RG180/5-4-WIG Adapter 5/16”F SAE – 1/4”M SAET1 06021006001 WSS/4-4/60/B Flexible hose, 1500mmT2 06027004003 V/WSS/4-4/36/Y Flexible hose, 900mm with valve14 14015028 - Silencer for Kompact

6.2. ACCESSORIES

Ref. Code Model Description- 04022031 PF2PF80/A4/5/K1 2-way manifold- 05015003 V/WSA/1M-4/6Y/PF80/N2-K1 Hose with valve and gauge- 06030011 3WSA/4-4/56V4/BRY Kit of 3 hoses, 1500 mm 1/4”SAE with

valve- 06030003 3WSA/4-4/60/BRY Kit 3 hoses, 1500 mm 1/4”SAE

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7. Dimensions and weight

Net weight: 17 kg

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Wigam spa reserves the rightto discontinue, or change atany time specifications ordesigns without notice andwithout incurring obligationsaccording to her policy ofalways improving herproducts.

Layout : Wigam S.p.A.Printed in ItalyFirst edition : January 2014

WIGAM S.p.A.Loc.Spedale 10/b

52018 Castel San Niccolò(AR) Italy

Tel. 0575 / 5011Fax. 0575 / 501200

Declaration of conformity

We, signers of this declaration, declare under our own exclusive responsibility, that units,model :

KOMPACTAnd all its variants

Manufactured in our factory and to be used for:

refrigerant gas recovery, recycling and charge

Are designed according to the following directives prescriptions:

2006/42/EC Machines directive 2004/108/EC Directive on electromagnetic compatibility 2006/95/EC Directive on low voltage IEC 34-11 (EN 60034) General standards on single phase electric, rotative

machines

Castel San Niccolò07/05/2014

Gastone Vangelisti(President)

Loc.Spedale 10/b 52018 Castel San Niccolò (AR) ITALYTel. ++39-0575-5011 Fax. ++39-0575-501200www.wigam.com - [email protected]

http://www.wigam.com/

COMPUTERIZED UNIT FOR Nitrogen test Azoidro test ......external recovery system), nitrogen test,...

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Transcript of COMPUTERIZED UNIT FOR Nitrogen test Azoidro test ......external recovery system), nitrogen test,...