COMPUTERIZED UNIT FOR Nitrogen test Azoidro test Refrigerant recovery Vacuum and vacuum test Refrigerant charge. User s manual ENGLISH

Transcription

1 COMPUTERIZED UNIT FOR Nitrogen test Azoidro test Refrigerant recovery Vacuum and vacuum test Refrigerant charge User s manual

2 INDEX Safety precautions...3 Technical regulations...3 Layout drawing...4 Hydraulic diagram...6 Electric diagram...7 Legend Introduction to KOMPACT unit Technical specifications Components description and standard equipment High vacuum pump Refrigerant electronic scale Flexible hoses Lock-Valve quick couplers and connections Built-in electronic vacuum gauge Built-in ambient temperature probe Printer Micro-sd Control module Preparing unit KOMPACT for use Charging the unit with oil and checking the vacuum pump oil level Using unit KOMPACT Refrigerant recovery N2 testing N2+H2 testing Discharge Vacuum + Vacuum Test Refrigerant Charge Auto 1 (R+T+V+C) Auto 2 (T+V+C) Disconnecting the unit from the system Setting menu Service Procedures Calibration menu Refrigerant scale calibration Pressure sensor calibration Digital vacuum gauge calibration Zero pressure Zero scale Periodic operations Accessories and spare parts Spare parts Accessories Dimensions and weight

3 WARNING Safety precautions a) This equipment is designed for trained personnel only, who must know the refrigeration fundamentals, cooling systems, refrigerants and possible damage that pressurized equipment may cause. b) Carefully read the instructions contained in this manual; strict observance of the procedures described is fundamental to the operator s safety, the perfect state of the unit and constant performances as declared. c) During nitrogen discharge operations, make sure that the silencer (ref. 14) is mounted on the suitable connection on the unit. d) Before performing any operation, make sure that the hoses used for connections have been previously 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 cause freezing. 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 and the environment. i) Always make sure that the unit is connected to a suitably protected mains supply provided with an efficient earth connection. j) Before performing maintenance operations or when the unit will not be used for a long period of 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 atmosphere m) 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 a refrigerant polluted environment. o) The equipment must always work under the operator s control p) Protect the unit from dripping q) 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 the circulation 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 air and it can be used with gases R32 and R1234yf. The operator must have attended specific training courses before using these gases. Technical regulations a) The unit is equipped with an independent ventilation system able to flux the inside air and it can be used with gases R32 and R1234yf. The operator must have attended specific training courses before using these gases. The ventilation system starts automatically 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 of the volume of the room in which we operate. Such value must be compared with the quantity of 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 tube piercing valves, as for example model W341 part number Perform soldering operations only when it is sure at 100% that there is no gas inside the circuit and after having performed a good vacuum process (especially with R600a and R290). 3

4 Layout drawing 4

5 5

6 Hydraulic diagram Figure 1 Hydraulic diagram 6

7 Electric diagram Figure 2 Electric diagram for KOMPACT without printer Figure 3 Electric diagram for KOMPACT with printer 7

8 Legend EV1 Solenoid valve nitrogen discharge line / 10 Vacuum pump oil sight glass recovery line EV4 Solenoid valve - vacuum pump suction line 11 Vacuum pump oil drain plug EV13 Solenoid valve - refrigerant charging line 12 Discharge / Recovery connection EV19 Solenoid valve - oil/additive charging line 13 Complete frame EV20 Solenoid valve - digital vacuum gauge 14 Silencer for N2 discharge CV1 Check valve - refrigerant charging line 15 Handle CV2 Check valve - nitrogen charging line 16 Power cable TR15 Pressure sensor 0 50 bar 17 Bearing for bottle without tube VA18 Digital vacuum sensor 18 RG180 (Adapter 5/16 SAE f - 1/4 SAE m) CEL1 Load cell 35 Kg (refrigerant) 68 Main power switch 1 Vacuum pump connecting hose PRT Printer (optional) 2 Vacuum gauge connecting hose PWR Transformer 3 Refrigerant charging hose CPU Control module 4 Central connection for system T1 Connecting hose to the system 5 Connection for nitrogen or azoidro (95%nitrogen T2 Connecting hose to the bottle with valve + 5% hydrogen) bottle 6 Vacuum pump V1 Lock valve 1/4 SAE 7 Scale pan V2 Lock valve 5/16 SAE 8 Fan 9 Vacuum pump oil filler plug 8

9 1. Introduction to KOMPACT unit KOMPACT unit enables the quick and efficient recovery of refrigerant from the system (by means of an external recovery system), nitrogen test, azoidro mixture test, system s evacuation, check for tightness with a precision electronic vacuum gauge, the subsequent charge with refrigerant and the system diagnosis. Thanks to its microprocessor, KOMPACT unit permits the control of all the functions by means of 1 electronic scale which controls the refrigerant charge TECHNICAL SPECIFICATIONS Model KOMPACT Refrigerants all halogenated refrigerants Electronic scale capacity 35 kg Max working pressure 50 bar Power supply 230/1/50 Absorption A Power input W Storage temperature C Ambient working temperature C Protection degree IP20 Noise 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 for pressing, ambient air and vapour contained in it as well as water possibly formed through vapour condensation. The high vacuum pump the unit is equipped with is rotary vane type, dual stage, lubricated by oil injection. KOMPACT is available with a vacuum pump with swept volume of either 46 l/min or 90 l/min 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 operating pressures 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 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) 9

10 2.5. BUILT-IN ELECTRONIC VACUUM GAUGE The unit is equipped with a high precision electronic vacuum gauge. It allows to measure vacuum and check the system s tightness during the vacuum test. The measuring range is Pa BUILT-IN AMBIENT TEMPERATURE PROBE The unit is equipped with one ambient temperature probe (built in the main board) for reading the ambient temperature inside the unit PRINTER The printer (optional) allows to print on thermic type paper with a chart size of 57mm width a report ticket with the values programmed by the operator and performed by the unit 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) CONTROL MODULE Test N2 Test N2+H2 Recovery Discharge Micro-sd card connector Refrigerant charge Vacuum Vacuum test Arrow UP Zero-Scale Access to Menu Exit key (Back) Arrow DOWN Zero Pressure Auto 1 Auto 2 Start / Stop key Access to the functions: - Test N2 (nitrogen) - Test N2+H2 (azoidro mixture) - Refrigerant recovery - Discharge N2 / N2+H2 10

11 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 parameters During 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 function During a function under way if pressed for more than 3 seconds, stops the function for emergency Shift through the various ranges and modify the numerical values Standby if pressed for more than 3 seconds, it performs the scale reset procedure (Tara) Shift through the various ranges and modify the numerical values Standby if pressed for more than 3 seconds, it performs the pressure sensor reset procedure (atmospheric zero) 11

12 3. Preparing unit KOMPACT for use IMPORTANT! The synoptic sticker does not exempt the operator from carefully reading this user s manual and from strictly observing the illustrated procedures. IMPORTANT When the unit is started, the ventilation system will start automatically. The system is suitable for removing the residual gases inside the working area. 3.1 CHARGING THE UNIT WITH OIL AND CHECKING THE VACUUM PUMP OIL LEVEL IMPORTANT! Never use the vacuum pump without filling oil into it because it will damage the pump. Always check that there is enough oil inside the pump before use. 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 sight glass. Before checking the oil level, the unit must be placed on a level surface and its power supply must be turned off. WARNING! Do not pollute environment with oil; it is a special waste and must be disposed of according to the regulations in force 12

13 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 below figure). In case you need to connect to both LOW and HIGH connections of the system, use a manifold. 2. Turn the handwheel of the V1 or V2 lockvalve to enable the connection between the system and the unit. 3. Turn the 68 switch to position I. 4. Press the key. T e s t N 2 T e s t N 2 + H 2 5. Shift downwards by means of the key until you select Recovery from the menu. Confirm with R e c o v e r y D i s c h a r g e 6. The unit sets the recovery function on ALL by default: in this way, the unit recovers all the refrigerant 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 to recover appears on the display. R a A L L 13

14 7. Confirm with. 8. The display will advise that you have to connect a recovery system. C o n n e c t r e c o v e r y u n i t 9. Connect the recovery system (EasyRec120 code or EasyRec120R100 code ) as shown in figure. Confirm with 10. The display will advise that you have to connect the recovery bottle. S u i t a b l e b o t t l e f o r r e c o v e r y 11. Connect the bottle previously evacuated by means of the T2 service hose. Press the key to proceed. 12. The display will advise that you can start the recovery system. S t a r t r e c o v e r y u n i t 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 KOMPACT will 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 is reached. A message will appear on the display and a beep will be heard. This means that the operator can turn off the recovery system (according to its user s manual). T u r n o f f r e c o v e r y u n i t 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). R a k g 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. 14

15 4.2 N2 TESTING WARNING! The unit is suitable to be connected to a 1 litre nitrogen cylinder in its standard version. For the connection to a bigger cylinder, it is necessary to use a pressure regulator (code ). WARNING Make sure that the silencer ref. 14 is mounted on the connection ref. 12 on the rear of the unit, to limit the nitrogen emission. 1. Perform the connection to the system by means of the hose supplied with the unit (see below figure). In case you need to connect to both LOW and HIGH connections of the system, use a manifold. 2. Insert the BN2/1-TPED 1 litre nitrogen cylinder into its dedicated place or connect the bigger cylinder through a pressure regulator (code AZ200-50) 3. Turn the handwheel of the V1 or V2 lockvalve to enable the connection between the system and the unit. 4. Turn the 68 switch to position I. 5. Press the key T e s t N 2 T e s t N 2 + H 2 6. Select N2 test by means of the key P 1 5 b a r T i m e

16 Suggested pressure values: Refrigerant type Pressure range (MPa) Test duration ( ) Systems up to 5 kw R134a 1,5-2,7 30 R1234yf 1,5-2,7 30 R404A 2,8-3,2 30 R407C 2,8-3,2 30 R507 2,8-3,2 30 R22 2,8-3,2 30 R410 4,0-4,2 30 R32 4,0-4,2 30 R12 1,4-1,6 30 R502 2,6-3,0 30 WARNING! The above are suggested values; consider the test parameters supplied by the system s manufacturer anyway. 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 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 will start. S t a r t 1 5 b a r P 1 5 b a r 13. The nitrogen pressure value at the start of the test will be indicated on the first line; this value is the reference the unit considers to detect the leak. 14. The pressure value read in real time inside the system in alternation with the remaining testing time (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 the end of the test. Furthermore, a report of the test performed will be printed (if the printer is installed). P. S t a r t b a r P b a r 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 the system. 18. If there is a leakage, discharge will not be performed. The operator must locate the leak in the system by means of suitable items (for instance spray leak detector GAS CONTROL code ). 19. Discharge of nitrogen from the system must be performed manually (see chapter 3.4). 16

17 20. If no other operations need to be done, turn the 68 switch to position 0 in order to turn off the unit. IMPORTANT! At the end of each N2 testing, the result of the test is saved on the micro-sd card. The file is created in the following way: AAMMGG_X where: o AA Year of the testing o MM Month of the testing o GG Day of the testing o 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 WARNING! The unit is suitable to be connected to a 1 litre nitrogen cylinder. WARNING! Make sure that the silencer ref. 14 is mounted on the connection ref. 12 on the rear of the unit, to limit the nitrogen emission 1. Perform the connection to the system by means of the hose supplied with the unit (see below figure). In case you need to connect to both LOW and HIGH connections of the system, use a manifold. 2. Insert the AZOIDRO 1 litre cylinder into its dedicated place. 3. Turn the handwheel of the V1 or V2 lockvalve to enable the connection between the system and the unit. 4. Turn the 68 switch to position I. 5. Press the key T e s t N 2 T e s t N 2 + H 2 6. Select Test N2+H2 by moving downwards by means of the key or key P 1 5 b a r T i m e

18 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. 9. Set the value of the testing time (range 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. 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 ). 14. In case you need to stop the test before completion, it is possible to do so by pressing the key. 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 WARNING! Make sure that the silencer ref. 14 is mounted on the connection ref. 12 on the rear of the unit, to limit the nitrogen emission 1. In case the N2 test has detected a leak, the system is kept under pressure to enable the operator to perform the nitrogen discharge manually. 2. Press the key T e s t N 2 T e s t N 2 + H 2 18

19 3. Shift downwards by means of the key until you select Discharge in the menu. Confirm with R e c o v e r y D i s c h a r g e 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 1. Perform the connection to the system by means of the hose supplied with the unit (see below figure). In case you need to connect to both LOW and HIGH connections of the system, use a manifold. 2. Turn the handwheel of the V1 or V2 lockvalve to enable the connection between the system and the unit. 3. Turn the 68 switch to position I. 4. Press the key V a c u u m T i m e Set the vacuum time by means of the arrows or. In order to make an efficient service on the system, we suggest to set a vacuum time of at least 30 minutes. 19

20 IMPORTANT! For systems with rated output below 6 kw, we suggest to perform a vacuum cycle of at least minutes. 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 will start. 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 of 200 mbar absolute 10. In case the function stops with positive result, the display will show the vacuum time performed and the test result. A report of the test performed will be printed (if the unit is equipped with the printer) confirming the maximum vacuum level reached. V a c u u m 3 0 V a c u u m t e s t O K IMPORTANT! If, on the report, ---- appears for the vacuum level, it means that the vacuum time performed was too short. IMPORTANT! At the end of each N2 testing, the result of the test is saved on the micro-sd card. The file is created in the following way: AAMMGG_X where: o AA Year of the testing o MM Month of the testing o GG Day of the testing o 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 1. Perform the connection to the system by means of the hose supplied with the unit (see below figure). In case you need to connect to both LOW and HIGH connections of the system, use a manifold. 20

21 2. Turn the handwheel of the V1 or V2 lockvalve to enable the connection between the system and the unit. 3. Turn the 68 switch to position I. 4. Press the key 5. 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 the connection to the scale pan as shown in the below figure. WARNING! The charging function must be performed with a system which has been previously evacuated. R a 0, k g 6. Set the refrigerant quantity by means of the arrows or. 7. Press to confirm and start the function. WARNING! The refrigerant charge cycle is performed by steps in order to reach a high precision. 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 the display will show the information on the cycle just performed. A report of the charge performed will be printed (if the unit is equipped with a printer). R a 0, k g 9. If no other operations need to be done, turn the 68 switch to position 0 in order to turn off the unit. 21

22 4.7 AUTO 1 (R+T+V+C) The Auto 1 cycle includes the following functions: a. Refrigerant recovery b. Test with nitrogen N2 c. Vacuum + vacuum test d. Refrigerant charge 1. Perform the connection to the system by means of the hose supplied with the unit (see below figure). In case you need to connect to both LOW and HIGH connections of the system, use a manifold. Connect the recovery system on the bottle VAPOR inlet. Connect the charging line on the bottle LIQUID outlet. VAPOR LIQUID 2. Turn the handwheel of the V1 or V2 lockvalve to enable the connection between the system and the unit. 3. Turn the 68 switch to position I. 4. Press the key 5. Select cycle 1 R+T+V+C 6. The display will show the message concerning the recovery function R e c o v e r y R a A L L 7. The unit sets the recovery function on ALL by default: in this way, the unit recovers all the refrigerant 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 to recover appears on the display. 8. Confirm with. 9. The display will show the information on the N2 test. 22

23 P 1 5 b a r T i m e Set the value of the testing pressure (range 2 49 bar) by means of the arrows or. 11. Confirm with. 12. Set the value of the testing time (range minutes) by means of the arrows or. 13. Confirm with. WARNING! In case the parameters of the N2 test are left on 0, the function will be skipped. 14. The display will show the information on the Vacuum + Vacuum Test function V a c u u m T i m e Set the vacuum time by means of the arrows or. In order to make an efficient service on the system, we suggest to set a vacuum time of at least 30 minutes. 16. Press to confirm. 17. The display will show the information on the refrigerant charge. R a 0, k g 18. Set the refrigerant quantity by means of the arrows or. 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 C o n n e c t r e c o v e r y u n i t 23. Connect the recovery system (EasyRec120 code or EasyRec120R100 code ) as shown in the figure. Confirm with 24. The display will advise the operator to connect the refrigerant stocking bottle. S u i t a b l e b o t t l e f o r r e c o v e r y 25. Connect the bottle (previously evacuated) by means of the T2 service hose. Press the key to proceed. 23

24 26. The display will advise the operator to start the recovery system. S t a r t r e c o v e r y u n i t 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 KOMPACT will 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 is reached. A message will appear on the display and a beep will be heard. This means that the operator can turn off the recovery system (according to its user s manual. T u r n o f f r e c o v e r y u n i t 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. WARNING! During the N2 test and vacuum phase, provide to connect the bottle, if it was not done previously, for the following refrigerant charging function. 32. The last function to be performed is the refrigerant charge. IMPORTANT! At the end of each function, the unit will print a report (if the unit is equipped with a printer). 33. When all the cycles from the AUTO 1 are completed, the summary screen will appear on the display. 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 24

25 4.8 AUTO 2 (T+V+C) The Auto 2 cycle includes the following functions: a. Test with nitrogen N2 b. Vacuum + vacuum test c. Refrigerant charge 1. Perform the connection to the system by means of the hose supplied with the unit (see below figure). In case you need to connect to both LOW and HIGH connections of the system, use a manifold. Connect the charging line on the bottle LIQUID outlet LIQUID 2. Turn the handwheel of the V1 or V2 lockvalve to enable the connection between the system and the unit. 3. Turn the 68 switch to position I I. 4. Press the key 5. Select cyle 2 T+V+C 6. The display will show the message concerning the N2 test P 1 5 b a r T i m e 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 minutes) by means of the arrows or. 10. Confirm with. WARNING! In case the parameters of the N2 test are left on 0, the function will be skipped 25

26 11. The display will show the information on the Vacuum + Vacuum Test function V a c u u m T i m e Set the vacuum time by means of the arrows or. In order to make an efficient service on the system, we suggest to set a vacuum time of at least 30 minutes. 13. Press to confirm. 14. The display will show the information on the refrigerant charge R a 0, k g 15. Set the refrigerant quantity by means of the arrows or. 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 directly 20. When the function is completed, the unit will go directly to the vacuum + vacuum test cycle WARNING! During the N2 test and vacuum phase, provide to connect the bottle, if it was not done previously, for the following refrigerant charging function 21. The last function to be performed is the refrigerant charge. IMPORTANT! At the end of each function, the unit will print a report (if the unit is equipped with a printer). 22. When all the cycles of the AUTO 2 are completed, the summary screen will appear on the display. 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 remove all 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. 26

27 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 system on 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 Calibration see chapter 5.1 means of or and confirm with Service by pressing the key, it is possible to make some service operations using several keys 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 unit into the SD-card. The unit creates a.txt file to import into your own PC. In case the message ERROR CODE 08 appears, re-start the unit and try again the exportation procedure. 27

28 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 to write some information about your own workshop. Once the information have been written, 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 can compromise the functioning of the whole unit. These operations must be effected by qualified people! In order to perform the calibration operations, it is necessary to have certified instruments supplied by Wigam and follow the procedures explained in this user s manual very accurately. By pressing the key in the standby screen and selecting Calibration, you can gain access to the calibration menu of the unit. To be able to enter the menu, it is necessary to type the following password (combination of keys in succession): REFRIGERANT SCALE CALIBRATION 1. Make sure there is no weight on the scale 2. Make sure the unit is on a level surface 3. Select Refrigerant from the calibration menu 4. Press the key to memorize value Zero 5. 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 PRESSURE SENSOR CALIBRATION 1. Make sure there is no pressure source on the connection ref Select Press. Sensor from the calibration menu 3. The display will advise to place the ambient pressure (1.0 bar absolute). Proceed and then confirm with 4. 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. 28

29 7. When the memorization is completed, set the pressure value by means of or typing the value in mbar absolute. 8. Confirm with DIGITAL VACUUM GAUGE CALIBRATION 1. Make sure connection ref. 4 is connected to an empty bottle of at least 2 litres volume with a reference 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 with 6. 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 ZERO PRESSURE IMPORTANT! If this function is performed with a different unit inner pressure than the atmospheric 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 reading value 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 instructions on the display. key for more than 3 seconds. Then follow the 5.3. ZERO SCALE IMPORTANT! If this function is performed with a weight different from zero on the scale, you could have negative values on the display. This function must be performed when the weight value read on the unit is not 0.000kg although there is 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. 29

30 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 K1 L Vacuum pump mineral oil G19020-WIG Kit 10 gaskets 1/4 SAE PLUS/PAPER Thermic paper for printer V LOCK-VALVE1/4-WIG Lock valve ¼ SAE V LOCK-VALVE5/16-WIG Lock valve 5/16 SAE RG180/5- RG180/5-4-WIG Adapter 5/16 F SAE 1/4 M SAE T WSS/4-4/60/B Flexible hose, 1500mm T V/WSS/4-4/36/Y Flexible hose, 900mm with valve Silencer for Kompact 6.2. ACCESSORIES Ref. Code Model Description PF2PF80/A4/5/K1 2-way manifold V/WSA/1M-4/6Y/PF80/N2-K1 Hose with valve and gauge WSA/4-4/56V4/BRY Kit of 3 hoses, 1500 mm 1/4 SAE with valve WSA/4-4/60/BRY Kit 3 hoses, 1500 mm 1/4 SAE 30

31 7. Dimensions and weight Net weight: 17 kg 31

32 Wigam spa reserves the right to discontinue, or change at any time specifications or designs without notice and without incurring obligations according to her policy of always improving her products. Layout : Wigam S.p.A. Printed in Italy First edition : January

33 WIGAM S.p.A. Loc.Spedale 10/b Castel San Niccolò (AR) Italy Tel / 5011 Fax / Declaration of conformity We, signers of this declaration, declare under our own exclusive responsibility, that units, model : KOMPACT And 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 (EN 60034) General standards on single phase electric, rotative machines Castel San Niccolò 07/05/2014 Gastone Vangelisti (President)

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36 Loc.Spedale 10/b Castel San Niccolò (AR) ITALY Tel Fax info@wigam.com