ClimFill Maxi - Elitimg.elit.cz/rgcmedia/s/051/188/c41b4481c95641ed823d921b07bd58… · temperature (about –26 °C for R134a) may cause burns. Further information about safety can

ClimFill® Maxi

Service station for air conditioning systems of

vehicles with refrigerant gas R-134a.

Use and maintenance manual

Ver. 2.0

ENGLISH 2 / 74 CAP. 1 - CONTENTS

ClimFill Maxi

CAP. 1 - CONTENTS CAP. 1 - CONTENTS .................................................................................................................. 2 CAP. 2 - GENERAL INSTRUCTIONS............................................................................................ 4 2.1 GENERAL NOTES...................................................................................................................4 2.2 GENERAL INSTRUCTIONS .....................................................................................................4 2.3 MANUFACTURER IDENTIFICATION ......................................................................................4 2.4 MARKING ..............................................................................................................................5 CAP. 3 - SAFETY CONDITIONS.................................................................................................. 6 3.1 PERSONAL SAFETY INFORMATION ......................................................................................6

3.1.1 Definitions........................................................................................................ 6 3.1.2 Personal safety information ........................................................................... 6

3.2 IMPORTANT INFORMATION ON SERVICE EQUIPMENT SAFETY .......................................11 3.3 SAFETY DEVICES..................................................................................................................11 CAP. 4 - LAYOUT AND USE OF THE MANUAL ......................................................................... 12 4.1 USE OF THE MANUAL ..........................................................................................................12 4.2 SYMBOLS .............................................................................................................................12

4.2.1 Safety ............................................................................................................ 12 4.3 GLOSSARY...........................................................................................................................13 4.4 GUIDELINES FOR HANDLING REFRIGERANT .....................................................................14

4.4.1 Precautions for refrigerant storage............................................................. 14 4.4.2 Refrigerant conditions.................................................................................. 14 4.4.3 Recycling capacity...................................................................................... 14

CAP. 5 - GENERAL DESCRIPTION............................................................................................ 15 5.1 FRONT VIEW (EXTERIOR).....................................................................................................16 5.2 FRONT VIEW (INTERIOR) .....................................................................................................17 5.3 REAR VIEW (EXTERIOR).......................................................................................................18 5.4 REAR VIEW (INTERIOR)........................................................................................................19 5.5 RIGHT SIDE VIEW .................................................................................................................20 5.6 LEFT SIDE VIEW.....................................................................................................................21 5.7 FRONT SIDE VIEW ................................................................................................................22 5.8 TOUCHSCREEN ...................................................................................................................23 5.9 STATUS BAR..........................................................................................................................24 5.10 FUNCTION KEYS............................................................................................................26 5.11 CLIMFILL®-LOCK PATENTED TECHNOLOGY QUICK COUPLERS ...............................28 5.12 INCLUDED ACCESSORIES............................................................................................28 5.13 OPTIONAL ACCESSORIES............................................................................................29 CAP. 6 - TECHNICAL FEATURES .............................................................................................. 30 CAP. 7 - INSTALLATION........................................................................................................... 32 7.1 EQUIPMENT INSTALLATION ................................................................................................32

7.1.1 Unpacking ClimFill® Maxi.............................................................................. 32 CAP. 8 - COMMISSIONING .................................................................................................... 34 8.1 CONNECTIONS...................................................................................................................34 8.2 POSITIONING AND ELECTRIC CONNECTIONS ..............................................................................34 8.3 FIRST TANK FILLING..............................................................................................................36 8.4 NEW OIL BOTTLE FILLING ....................................................................................................37 8.5 DETECTION DYE BOTTLE FILLING........................................................................................38 CAP. 9 - SETUP......................................................................................................................... 39 CAP. 10 - A/C SYSTEM RECHARGE ........................................................................................ 42 10.1 REMARKS ......................................................................................................................42 10.2 NON-CONDENSABLE GAS DISCHARGE VALVE........................................................43

CAP. 1 - CONTENTS 3 / 74 ENGLISH

ClimFill Maxi

10.3 RECHARGE Q-MODE AND S-MODE...........................................................................44 CAP. 11 - AUTOMATIC CYCLES.............................................................................................. 45 11.1 AUTOMATIC A/C SYSTEM SERVICE.............................................................................45 11.2 AUTOMATIC CYCLE (BUSES) .......................................................................................45

11.2.1 Last cycle ...................................................................................................... 45 11.2.2 User-defined cycles...................................................................................... 45 11.2.3 Search parameters by vehicle registration plate number........................ 45

11.3 AUTOMATIC CYCLE (OTHER VEHICLES).....................................................................45 11.3.1 Vehicle selection from database ............................................................... 45 11.3.2 Last cycle ...................................................................................................... 45 11.3.3 User-defined cycles...................................................................................... 46 11.3.4 Search parameters by vehicle registration plate number........................ 46 11.3.5 Automatic cycle parameters configuration.............................................. 46 11.3.6 OIL TYPE REPLACEMENT................................................................................ 47

CAP. 12 - MANUAL CYCLES ................................................................................................... 48 12.1 PRELIMINARY OPERATIONS.........................................................................................48 12.2 RECOVERY....................................................................................................................48 12.3 VACUUM PHASE ..........................................................................................................48 12.4 INJECTION ....................................................................................................................49 12.5 OPERATION CONTROL (EXCLUDING BUSES).............................................................50 12.6 EMPTYING HOSES.........................................................................................................50 12.7 FLUSHING......................................................................................................................50 12.8 NITROGEN TEST.............................................................................................................51 CAP. 13 - MAINTENANCE....................................................................................................... 52 13.1 SELF LEAK TEST...............................................................................................................53 13.2 PUMP MONITORING SYSTEM SPECIAL FUNCTION - VACUUM PUMP OIL CHANGE

53 13.3 DRYER FILTER CHANGE................................................................................................55

13.3.1 MESSAGE FOR FILTER ALMOST EXHAUSTED ................................................. 58 13.4 COUNTERS....................................................................................................................58 13.5 VESSEL FILLING (A/C SERVICE STATION TANK) ..........................................................58 13.6 NON-CONDENSABLE GAS DISCHARGE ....................................................................59 13.7 TANK REFRIGERANT INTERNAL RECYCLING...............................................................59 13.8 SYSTEM INFORMATION ................................................................................................60 13.9 MAINTENANCE OF PRINTER ........................................................................................60 13.10 PERIODIC CHECKS.......................................................................................................60 CAP. 14 - DISPOSAL................................................................................................................ 63 14.1 A/C SERVICE UNIT DISPOSAL ......................................................................................63 14.2 RECYCLED MATERIALS DISPOSAL...............................................................................63 14.3 PACKAGING DISPOSAL ..............................................................................................63 CAP. 15 - SPARE PARTS........................................................................................................... 64 CAP. 16 - MESSAGE AND ALARM CODES.............................................................................. 65 CAP. 17 - MAINTENANCE FORMS .......................................................................................... 71

CAP. 2 - GENERAL INSTRUCTIONS 4 / 74 ENGLISH

ClimFill Maxi

CAP. 2 - GENERAL INSTRUCTIONS

2.1 GENERAL NOTES

All rights reserved.

This manual may not be reproduced, in part or entirely, either in printed or digital form.

It may be printed out solely for use by the user and operators of the equipment to

which it refers.

VALEO SERVICE and resources used for the drawing up of this manual will not be held

responsible for the incorrect use of the manual while they guarantee that information in

the manual have been duly checked.

The product can be subject to changes and improvements. VALEO SERVICE reserves

the right to change without notice the information contained in the manual.

2.2 GENERAL INSTRUCTIONS

Pressure equipment undergoes checks before commissioning and periodical checks

during operation in compliance with rules and law provisions in force in the country

where the equipment is used.

The operator is responsible for operating the equipment in conformity with local

legislation.

The equipment is designed for recovering and recycling R134a refrigerant fluid from

A/C systems of buses, cars and similar vehicles.

The equipment is intended to be used by repair and service garages for buses, cars

and similar vehicles.

This equipment is intended solely for use by professionally trained operators familiar with

the basics of refrigeration, refrigeration systems, refrigerants and the hazards associated

with pressurised equipment.

Careful reading of the present manual by the owners, the users and the operators is

required for a correct and safe use of the equipment.

The user shall not be entitled to open the product since maintenance operations are

reserved to the authorised service centre.

2.3 MANUFACTURER IDENTIFICATION

The ClimFill® Maxi equipment is manufactured by:

VALEO SERVICE

70 rue Pleyel Cedex

93285 Saint Denis (France)

ENGLISH 5 / 74 CAP. 2 - GENERAL INSTRUCTIONS

ClimFill Maxi

2.4 MARKING

The ClimFill® Maxi equipment has been manufactured in compliance with the European

Union directives listed in the Declaration of Conformity supplied with the pressure

equipment.

The equipment is a PED risk class III device (97/23/EC).

The characteristic data of the equipment are indicated on the specific data plate

applied onto the equipment side part.

It is prohibited to remove, damage or tamper with the equipment

“data plate”.

NAMEPLATE

CE MARKING: The present CE declaration is enclosed to the equipment. Store correctly

and provide on request.

Fac-Simile

CAP. 3 - SAFETY CONDITIONS 6 / 74 ENGLISH

ClimFill Maxi

CAP. 3 - SAFETY CONDITIONS

3.1 PERSONAL SAFETY INFORMATION

3.1.1 Definitions

DANGEROUS AREAS:

Any area within or close to the equipment implying risk for the safety and health of

exposed persons.

EXPOSED PERSON:

Any person completely or partially standing in a dangerous area.

OPERATOR:

The person/s charged with operating the machine for its intended purpose.

CLASSIFICATION OF OPERATORS

The operator can be classified according to two main categories, which, in some

cases, refer to one single person:

• The operator charged with the equipment operation has the duty to:

o Start up and monitor the machine's automatic cycle;

o Carry out simple setting operations;

o Remove the causes of equipment stop not implying breakings of

members but simple operating anomalies.

• Maintenance technician: a technician trained by an authorised VALEO SERVICE

centre, capable of working on the machine’s mechanical and electrical

components with its guards open to make adjustments and to service and repair

it.

USER

Body or person legally responsible for the equipment.

3.1.2 Personal safety information

The VALEO SERVICE ClimFill® Maxi A/C service station is particularly simple and reliable

due to its adjustments and functions. When used correctly it presents no hazard for the

operator, provided he observes the following general safety instructions and that the

service station is regularly serviced (incorrect maintenance/use compromise the

equipment's safety).

Before operating the service station for the first time, read these instructions carefully. If

any part of the instructions is unclear, contact your reseller or VALEO SERVICE. This

service station may be used by only one equipment operator, familiar with A/C and

refrigeration systems and the hazards associated with refrigerants and high pressure

equipment.

ENGLISH 7 / 74 CAP. 3 - SAFETY CONDITIONS

ClimFill Maxi

WORKPLACE: The equipment must be operated outdoor or in a well-ventilated location

(at least 1 air change per hour). The workshop has to be equipped with ventilation

systems able to ensure air change in every environment area or carry out a periodical

ventilation by opening the areas. Use the equipment away from heat sources or hot

surfaces . The equipment must not be used in explosion risk environments (potentially

explosive atmospheres). Before using it, put the equipment on a levelled plane and

secure position, blocking it with suitable wheel stops.

Do not expose the tool to direct sunrays, heat sources, rain and jets of water. Do not

smoke close to the equipment and during operations (keep at a distance of at least 1

m).

The work area must be monitored by the operator while the equipment is operating.

ATTENTION: the R134a refrigerant fumes/gases are heavier than air and can gather on

the floor or inside cavities/holes and cause choke by reducing the oxygen available for

breathing.

At high temperatures, the refrigerant breaks down releasing toxic and aggressive

substances, harmful for the operator and the environment.) Avoid inhaling the system

coolants and oils. Exposure can irritate eyes and the respiratory tract.

ELECTRICAL CONNECTION: Connect the power cord solely to a mains supply which

conforms with the ratings on the machine's nameplate (mounted on its side). Make sure

the mains socket is grounded.

Maximum impedance allowed in the point of connection to the mains shall comply

with standard EN 61000-3-11. Starting currents can cause short voltage drops, which

may affect other equipments under unfavourable conditions. If impedance in the point

of connection to the mains is not compliant, this may lead to interference so please

consult the electrical power network operator before connecting the equipment.

Never use the service station with a defective power cord or a different one from that

supplied with the machine. If damaged, immediately have it replaced with an original

spare part or equivalent by a VALEO SERVICE centre. Before opening the service

station, extract completely the supply cable from the plug, or you can get an electric

shock.

Do not tamper with or bypass the safety equipment and settings.

Do not leave the machine powered up when not in use; shut off the power supply

before leaving the equipment unused for a long time. Do not forget that the tool

(pressure tool) must always be protected.


ClimFill Maxi

REFRIGERANTS AND LUBRICANTS – PERSONAL PROTECTION EQUIPMENT AND

PRECAUTIONS: The refrigerants and the pressure vessels have to be handled with care,

otherwise there will be possible health risks.

The operator must wear safety glasses, gloves and protective clothing suitable to the

work. Contact with the refrigerant can cause blindness (eyes) and other physical

damage (freezing) to the operator. Avoid contact with the skin; the low boiling

temperature (about –26 °C for R134a) may cause burns.

Further information about safety can be obtained from the safety sheets of lubricant

and refrigerant producers.

Do not inhale refrigerant or oil vapour. Keep away from the vent valves and ventilation

coupling, especially when non-condensable gas is being vented.

Never direct the quick couplings (taps) towards your face or other persons or animals.

OTHER PROHIBITIONS AND USE LIMITATIONS: Use only pure R134a refrigerant, and do not

use it on vehicles containing other types of refrigerants. The mixture with other types of

refrigerant produces serious damage to the conditioning and cooling systems. Mixed

gases have to be disposed of according to current regulations. Do not use the ClimFill®

Maxi station with compressed air systems, R134a and air mixtures can be potentially

explosive.

Do not modify calibration of safety devices. Do not remove seals of safety valves and

of control systems. Do not use external tanks or other storage containers that are not

type-approved or without safety valves.

Make sure the equipment's aeration and ventilation ports are not obstructed or

covered while the equipment is operating.


ClimFill Maxi

HOSE CONNECTIONS: Hoses may contain pressurised refrigerant. Before changing the

service couplers, check the respective pressures in the hoses (pressure gauge).

Before connection to a car A/C system, to an external tank/vessel, check that the

quick couplers are closed (unscrewed HP and LP valves).

Scrupulously follow the instructions on the equipment's display.

QUICK COUPLERS CLOSING/OPENING:

MAINTENANCE/GENERAL CLEANING: The equipment has to be serviced at the intervals

indicated by the equipment itself. These controls include also a leak self-test that the

equipment performs automatically.

The service station maintenance has to be performed according to the procedures

described in this manual and to the current safety regulations.

Use only VALEO SERVICE original parts.

When the equipment requires the dryer filter and the vacuum pump oil to be changed,

you have to be careful in the replacement.

A/C service station maintenance can be carried out exclusively by a trained operator

or by a service man of a VALEO SERVICE certified seller. If the maintenance is not

performed according to the expected schedule, the equipment will be blocked.

Do not use chemical agents for the service station cleaning, as they could attack the

material or the surface.

Closing (detach from the

vehicle): counter clockwise

Opening (connect to the

vehicle): clockwise


ClimFill Maxi

STOP FOR LONG PERIOD: Store the equipment in a safe place, disconnected from the

mains, away from excessive temperatures, humidity and the risk of damaging impact.

Contact the Technical Service to run a safety shutdown of the equipment, and if

scrapping the unit, to drain and recycle the R134a gas as required by local legislation.

To resume operation, repeat the installation (there is no need to register the unit anew

on the website) and run the commissioning trials and regular operational checks as

required by local legislation.

TRANSPORT: If the equipment has to be transported, you have to screw the safety screw

in order to fix the equipment scale. The safety device for transport is on the back of the

equipment and it consists of a bolt with wing-nut. Commissioning: Slacken the wing-nut,

unscrew the screw for about 4 mm. and fix it again with the wing-nut. Transport: slacken

the wing-nut, screw the screw by hand and then fix it again with the wing-nut. For the

transport of the R134a refrigerant, specific regulations are in force in every country.

Therefore, refer to your reseller or your authorised service centre for information.


ClimFill Maxi

3.2 IMPORTANT INFORMATION ON SERVICE EQUIPMENT SAFETY

When using the equipment, the following operations are not allowed as they might

cause, under certain circumstances, danger for persons and cause permanent

damage to the equipment itself.

- Do not remove or make unreadable labels, signs and/or dangers signs

placed on the equipment and in the area nearby.

- Do not disable the unit's safety devices.

- Use only fuses identical to the originals as specified on the nameplate;

do not tamper with or attempt to repair the fuses.

If the power supply is known or can be expected to vary beyond the

limits specified for the service equipment, immediately disconnect it.

- The electrical system to which the service equipment is connected

must be configured as provided for by local legislation.

- Only operators or qualified staff instructed or certified for the

equipment maintenance can open the equipment. The equipment

contains parts which can cause electrocution: shut off power to the

equipment before servicing/repairing it.

3.3 SAFETY DEVICES

ClimFill® Maxi is equipped with the following safety devices:

SAFETY PRESSURE SWITCH: It stops the compressor in case of excessive

pressure.

SAFETY VALVE: The safety valve opens when the pressure inside the

system reaches a level higher than the fixed limits.

MAIN SWITCH: Switches the equipment off by interrupting the power

supply. It is advisable to pull the power cord plug out of the mains

socket in any case before starting maintenance work.

ANY TAMPERING WITH THE ABOVE-MENTIONED SAFETY DEVICES IS

PROHIBITED.

Failure to observe any of the above safety instructions voids the equipment's warranty.

CAP. 4 - LAYOUT AND USE OF THE MANUAL 12 / 74

ENGLISH

ClimFill Maxi

CAP. 4 - LAYOUT AND USE OF THE MANUAL

4.1 USE OF THE MANUAL

� This manual is an integral part of the equipment and must be kept

near the equipment by the purchaser

• This manual shall accompany the equipment in case this is passed on to a new

user.

• 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 symbols which may be posted on the service

equipment.

4.2.1 Safety

ALTERNATING CURRENT

SAFETY GROUNDING

CONSULT THE INSTRUCTIONS MANUAL

ATTENTION! ELECTROCUTION HAZARD

CAUTION !: DO NOT REMOVE THE COVER

(maintenance technicians only)

USE PROTECTIVE GLOVES

WEAR PROTECTIVE GOGGLES

USE ANTI-SMASH SAFETY SHOES

ENGLISH 13 / 74 CAP. 4 - LAYOUT AND USE OF THE MANUAL

ClimFill Maxi

4.3 GLOSSARY

To make the reading of this manual easier, we have prepared the list of the most

important technical terms used in the manual.

Refrigerant: Refrigerant fluid used in advanced motor vehicle A/C systems.

The following refrigerant fluids may be used:

o R-134a C2H2F4 - 1,1,1,2-Tetrafluoroethane

A/C system: air conditioning system.

Equipment: ClimFill® Maxi service station for recovering, recycling, draining and

charging the A/C system.

External tank: Refrigerant bottle used to fill the internal vessel.

Internal vessel: vessel for refrigerant storage.

Phase: Performance of a single function.

Cycle: Sequence of steps.

Recovery: Extraction of refrigerant from the vehicle.

Recycling: Cleaning of refrigerant, includes: separating out oils, removal of non-

condensable gas and single/multiple pass through filters to reduce the humidity,

acidity and particulate content of the fluid.

Disposal: disposal of refrigerant for storage followed by destruction/scrapping by an

authorised waste management centre.

Vacuum cycle: Draining out of a motor vehicle A/C system and separation out of

condensed matter and humidity, using only the vacuum pump.

Oil injection: Injection of oil into an A/C system to ensure the correct charge as

specified by the vehicle's manufacturer.

Charge: filling of refrigerant into the A/C system in the amount specified by the

manufacturer.

System flushing: Cleaning phase for the removal of possible polluting substances from

the A/C system or parts of it.

Non condensable gases: Gas stored in the gaseous phase, including air and nitrogen.

CAP. 4 - LAYOUT AND USE OF THE MANUAL 14 / 74

ENGLISH

ClimFill Maxi

4.4 GUIDELINES FOR HANDLING REFRIGERANT

4.4.1 Precautions for refrigerant storage

The refrigerant removed from the A/C system must be handled with care to prevent or

minimise the risk of mixing with other refrigerants.

This equipment is designed to handle refrigerant R134a.

The external vessels used to store the refrigerants must be clearly marked to prevent

mixing different refrigerants.

The vessels must be free of oil and other contaminants.

ATTENTION: when handling, using and storing R-134a gas and dealing

with emergency situations, MAKE SURE to refer to the product's safety

sheet.

GET THE SAFETY SHEET FROM YOUR REFRIGERANT SUPPLIER AND FOLLOW

ITS INSTRUCTIONS

4.4.2 Refrigerant conditions

The condition of the refrigerant is critical to the operation of the vehicle's A/C system.

Running repairs properly following failure or damage ensures the quality of the

refrigerant itself (particulates, acids and water).

4.4.3 Recycling capacity

The service equipment's filtering systems must be replaced regularly (see maintenance

messages) to ensure effective recycling.

Fac-Simile

ENGLISH 15 / 74 CAP. 5 - GENERAL DESCRIPTION

ClimFill Maxi

CAP. 5 - GENERAL DESCRIPTION

The advanced technology and innovative concept employed in designing and

fabricating ClimFill® Maxi makes it extremely simple and reliable in operation.

With its vessel holding up to 32 kg of refrigerant, ClimFill® Maxi has been specifically

designed for the maintenance and service of vehicle A/C systems containing large

amounts of refrigerant, particularly buses.

However, it can also be used to recharge vehicles with smaller amounts, such as cars.

ClimFill® Maxi is assembled by the manufacturer according to established EU standards

and undergoes service trials on completion.

The ClimFill® Maxi as recharge methods uses two modes, the Q-Mode (Quick Mode) or

S-Mode (Suction Mode).

The Q-Mode for this model ClimFill® Maxi is based on the patented technology

Supercharge which allows for increasing the refrigerant injection speed by charging

an A/C loop from the HP side while recovering, at the same time, from LP (if available).

The S-Mode (Suction Mode) assure to complete the refrigerant recharge, but needs

always to turn on the vehicle engine and the A/C system to recharge refrigerant from

LP side.

CAP. 5 - GENERAL DESCRIPTION 16 / 74 ENGLISH

ClimFill Maxi

5.1 FRONT VIEW (EXTERIOR)

1. New PAG oil container 250 cc

2. Exhausted oil container 250 cc

3. UV contrast fluid container 250 cc

4. Handles

ONLY MAINTENANCE TECHNICIANS MAY REMOVE THE FRONT AND REAR

DOORS OR THE TOP COVER

1 3 2

4


ClimFill Maxi

5.2 FRONT VIEW (INTERIOR)

5. Vacuum pump

6. Refrigerant tank 40 L

7. Load cell

8. Non-condensable gas vent valve (automatic)



5

6

7

8


ClimFill Maxi

5.3 REAR VIEW (EXTERIOR)

9. Caster wheels, with brakes

10. Handling wheels

11. Rear door



10

9

11


ClimFill Maxi

5.4 REAR VIEW (INTERIOR)

12. Manifold

13. Distiller

14. Dryer filter

15. Safety pressure switch

16. Oil separator

17. Vented condenser

18. Compressor



14

13

15

16

18

12

17


ClimFill Maxi

5.5 RIGHT SIDE VIEW

19. HP hose and quick coupling

20. LP hose and quick coupling

DO NOT USE THE UNIT UNLESS THE CHARGING HOSES (HP – LP) ARE

CORRECTLY CONNECTED

19

20


ClimFill Maxi

5.6 LEFT SIDE VIEW

21. RS232 serial port (updating software installation interface)

22. Main switch

23. 230 VAC MAINS SUPPLY FUSES (5x20 T 10A 250V)

21

22

23


ClimFill Maxi

5.7 FRONT SIDE VIEW

24. Touch Screen graphic display

24


ClimFill Maxi

5.8 TOUCHSCREEN

All settings, controls and service functions are available on the touchscreen display. It

also displays the service equipment’s status, the progress of A/C system service and any

alarms and error messages.

The touchscreen is the basic operator interface and can be operated with the fingers

or some other object, such as a pen.

When a button is pressed, a beep sounds.

The following functions are available:

scroll left: previous menu

scroll up: top menu

scroll down: lower menu

press: confirm / enter

press and hold: open the function to change it or press the ''home'' button

double press: supplementary functions

To select a MENU (e.g. MANUAL CYCLES), press the text MANUAL CYCLES: the selection

occurs when the finger is released, the selected entry is pointed out with a different

colour and the menu screen page changes.

If there are descriptions that need more space on the screen page, for example the

manual cycles list (see the screen page below), or in case of setup, it is possible to

display the different entries by moving the scroll bar to the side. For this reason, it is

necessary to touch the grey point on the scroll bar and slide up or down with the finger.

Lift the finger when you are on the desired position.

By touching the scroll bar once, the menu moves one line up or down depending on

whether it is touched over or under the grey dot.

The “home” icon is the button to “interrupt/return to the main menu’’.

To access to the main menu you have to touch it for 2 seconds. Sliding to the left with

the finger you can access to the previous menu.


ClimFill Maxi

If you need to enter free text or identify a set of data, a keypad automatically appears

(for example, for entering workshop data or at the end of the service cycle).

5.9 STATUS BAR

The status bars belong to two groups: the first two are in the upper part of the screen.

When the product is turned on, the low pressure LP indicator (blue) is displayed on the

right and the high pressure HP indicator (red) on the left.

Two other status bars may be displayed alternatively by sliding your finger upwards

starting from the bottom or vice versa.

The two bars are respectively the vessel pressure (brown) on the left and the residual

gas weight in the vessel (green) on the right.

Press for symbols


ClimFill Maxi

These indicators are always available on all the screen pages.

The following status bars are available.

BLUE status bar

• indicates the pressure level inside the LP side (value

expressed in Bar).

RED status bar

• indicates the pressure level inside the HP side (value

expressed in Bar).

BROWN status bar

• indicates the pressure level inside the vessel (value

expressed in Bar).

GREEN status bar

• indicates the amount of refrigerant inside the vessel

(value expressed in Kg).


ClimFill Maxi

5.10 FUNCTION KEYS

ClimFill® Maxi function keys are listed below:

Refrigerant

amount

By pressing this key for at least 2 seconds, the refrigerant amount to be

charged inside the vehicle A/C system may be modified. Once the

value has been changed, press the icon again to quit.

System type

By pressing this key for at least 2 seconds, the type of system to which

ClimFill® Maxi will be connected may be set:

• A/C system with LP only

• A/C system with HP only

• A/C system with LP and HP

• A/C system with HP (LP) *

*Several Renault vehicles (in particular Megane II, Scenic II, Laguna II) are equipped with just one coupler: its size

is that of an HP coupler but it may actually be an LP coupler.

If the database is enabled, the amount is obtained directly from the

database.

Oil Injection

Press the button to select the following oil injection modes:

• No OIL: does not inject new oil inside the A/C system

• REC+: the same amount of new oil is recharged plus an

additional amount of oil (initially set at 0 g) to replace the

discharged oil.

• Oil: charges the desired new oil amount (according to the

manufacturer instructions)

By pressing the icon once, the different operating procedures change.

Hold down for at least 2 seconds to set the amount of new oil to be

injected into the vehicle's A/C system (arrow up or down).

Press the button twice (like a mouse double click) to determine

whether to also add detection dye into the A/C system. If so, the

button changes as follows:

If the database is enabled and the vehicle is included inside it, the

INFO to display the new oil amount to be injected into the specific

system may be consulted. Unlike oil, detection dye is not weighed,

therefore the amount of injected fluid will be timed (about 8-10 ml of

detection dye).

Press the button to select the following oil types:

• PAG46

• PAG100

• PAG150

• POE

When switching from PAG oil to POE oil, cleaning must be mandatorily


ClimFill Maxi

performed through the ELECTRIC COMPRESSOR function (STANDARD

type with cleaning of only internal hoses or, if the function EXTERNAL

ELECTRIC COMPRESSOR FUNCTION KIT is enabled in the settings menu

and the specific kit is available, the EXTERNAL ELECTRIC COMPRESSOR

FUNCTION KIT function, which also cleans the external charge hoses)

By pressing the button, the heating belt of the refrigerant internal vessel

can be activated.

OFF ON

By pressing the button, you can choose whether to activate the leak

test in compliance with the standard SAE J2843 through the injection of

a small amount of refrigerant before the refrigerant injection phase.

OFF ON

Vacuum

phase

duration

By pressing for 2 seconds this button, you can change (arrow up or

down) the time of the vacuum phase (30 min. default) and the time of

vacuum holding (2 min. default).

Info

By pressing this key for at least 2 seconds, data relating to the selected

vehicle may be read, if the vehicle is included in the Autodata

database.

Component

position

By pressing this key for at least 2 seconds, the A/C system composition

of the selected vehicle may be displayed, if the vehicle is included in

the Autodata database.

Save

Hold down for at least 2 seconds to save data.

Value reset

Hold down for at least 2 seconds to cancel the values in the respective

menu.

Start

By pressing this button, you can start the selected function or the

complete cycle.

Home

Hold down for at least 2 seconds to return to the previous screen.

Print

Hold down to print out the latest service report.


ClimFill Maxi

5.11 CLIMFILL®-LOCK PATENTED TECHNOLOGY QUICK COUPLERS

ClimFill®-Lock patented technology is the INTELLIGENT COUPLER, that with the suitable

automated procedure in the software enables to:

1. reduce the non condensable gas formation inside the vessel ;

2. avoid the refrigerant dispersion in the air during disconnection ( puff effect);

3. check possible SCHRADER valve leaks before disconnection.

5.12 INCLUDED ACCESSORIES

The basic set of accessories includes:

Vessel LP

fitting

User

manual


ClimFill Maxi

5.13 OPTIONAL ACCESSORIES

The following optional accessories are available from your reseller or commercial

partner:

• NITROGEN LEAK TEST KIT - Kit for leak test (under pressure conditions) with nitrogen

(pressure reducer and cylinder not supplied)

• EXTERNAL ELECTRIC COMPRESSOR FUNCTION KIT - Kit for cleaning of station

pneumatic circuit in case POE oil for hybrid vehicles is used

• New air-tight oil containers (it is recommended to buy one for every different

type of oil to be used)

• UV leak detection kit (UV kit)

• Degreasing detergent, to remove fluorescent detection dye residues

• Degreasing detergent for capacitor

• Flushing kit

• Car A/C system sanitary spray

• Cabin sanitary agent spray

• Management software for A/C stations (ClimFill® Solutions) and memory mobile

device (ACU) that allows the data transfer from the ClimFill® appliance to the

management software for A4 report printing and annual balance management

for gas charge/discharge (ref. Reg. EC 842/2006).

CAP. 6 - TECHNICAL FEATURES 30 / 74 ENGLISH

ClimFill Maxi

CAP. 6 - TECHNICAL FEATURES

Vessels for R134a fluids

Capacity 40 l

Maximum operating pressure (PS) 20 bar

PED category (Dir.97/23/EC) II

Weight of gas content Scale

Safety valve

Type Nuova General Instruments

D7/S

Calibration pressure 20 bar

PED category (Dir.97/23/EC) IV

Containers for oil and detection dye

Recovered oil container capacity 250 ml

New PAG oil hermetic container capacity 250 ml, with OIL CARE valve

UV detection dye hermetic container capacity 250 ml, with OIL CARE valve

Pneumatic circuit

Vacuum pump flow rate 167 l/min in single stage

Vacuum level 0.05 mbar

Vacuum pump oil life 60h – extensible to max 1000 h with Pump

Monitoring System procedure

Refrigerant recovery compressor cubic capacity 14 cc

Dryer filter life Replacement every year since

installation date

Non-condensable gas vent automatic

HP and LP taps automatic

Safety pressure switch

Type 13/18bar ¼ SAE

Trip pressure 18 bar

PED category (Dir.97/23/EC) IV

Pneumatic fittings

Net length of external HP and LP hoses 4,5 m

Digital HP and LP pressure gauges 32 bar, class I sensors

Vessel pressure gauge 32 bar, class I sensor

Interface and software

Display Graphic 4,3” WideScreen 480x272, 65536

colours

Keypad Touch screen

Updating RS232 (accessible externally via cable or

ClimFill® Solution accessory)

Printer Thermal, 24 columns

Functions

R-134a recovery, exhausted oil recovery, vacuum

pump, recharge, oil and detection dye injection

Automatic and manual

Recycling mode Single or “Tank refrigerant internal

recycling”

Recovered oil measurement Automatic weighing, accuracy ±10 g

New oil automatic injection Automatic with scales

UV detection dye automatic injection Timed

Flushing “Regular” function (standard)

ENGLISH 31 / 74 CAP. 6 - TECHNICAL FEATURES

ClimFill Maxi

High intensity flushing available with

external accessory (option)

Database Electronic

System pressure diagnostics Automatic or manual (cars only)

Overall dimensions

WxDxH 652x728x1198 mm

Loadless weight 135 kg

Power supply

Frequency 50 Hz

Voltage 230 V ~

Power 1000 W

Fuses Retarder fuses 250V T10A

Installation category II

Environmental conditions

Operating temperature 5-45°C

Humidity 10-90% R.H. (non condensing)

Ambient pressure 75 kPa until 106 kPa

CAP. 7 - INSTALLATION 32 / 74 ENGLISH

ClimFill Maxi

CAP. 7 - INSTALLATION 7.1 EQUIPMENT INSTALLATION

7.1.1 Unpacking ClimFill® Maxi

RISK OF OVERTURNING

The manufacturer disclaims all responsibility for damage to objects and/or persons

resulting from the equipment being wrongly removed from the pallet, or from the

operation being made by unsuitable personnel, with improper means/protections and

without complying with the existing laws on manual handling of loads and with the

operations described in this manual.

1) Cut the strap and remove the carton.

2) Cut the straps securing the unit to the pallet.

Remove the equipment from the pallet (2 operators required)

3) Lift both front wheels by levering with

the front handles and on rear wheels (this

way the operators must not lift the full

weight of the unit)

4) Slowly lower the unit from the pallet by

means of the rear wheels

Keep the pallet, carton and scratch protection film for use when returning the unit. The

unit rolls on wheels; the two smaller wheels can be locked.

ENGLISH 33 / 74 CAP. 7 - INSTALLATION

ClimFill Maxi

ClimFill® Maxi is supplied with the accumulation tank empty. This prevents problems in

shipping the unit.

GAS SCALE SCREW RELEASE

The equipment is transported, with the scale blocked by a locking screw to avoid load

cell damage. The scale locking screw is placed on the equipment bottom (see the box

shown above) and is made up of a bolt with wing-nut. For commissioning, slacken the

wing-nut, unscrew the screw by 4 mm from the fixing ring nut and fix the wing-nut

again.

CAP. 8 - COMMISSIONING 34 / 74 ENGLISH

ClimFill Maxi

CAP. 8 - COMMISSIONING

8.1 CONNECTIONS

The product has to be positioned on a horizontal surface to ensure the correct

operation.

The unit has to be connected to the electric mains following instructions on the

identification plate of the product applied next to the main switch, mainly as to

applicable voltage and power.

8.2 Positioning and electric connections

HANDLING: During handling, the personal protective equipment (safety

shoes and protective gloves) required for correct handling shall be

ensured, as provided for by accident prevention provisions.

POSITIONING: Place the unit in a stable place. The location must be well

ventilated, with a good rate of change of air. The unit must be located

at least 10 cm from any object that could obstruct internal ventilation.

Keep the unit away from rain and excessive humidity as they can

irreparably damage it. In addition, the equipment must never be

directly exposed to sunrays or to excessive dust.

INSTALLATION: The installation shall be carried out by specialized

personnel, strictly complying with the instructions contained in this

manual. The use of the equipment in explosive atmosphere is forbidden.

CONNECTIONS: since the unit is connected to the mains power supply, it

must be properly grounded with its power plug GND pin. Failure to

ground the unit can damage it and constitutes a risk of fatal injury to the

operator. Position the unit so that the power plug is easy for the operator

to access.

ENGLISH 35 / 74 CAP. 8 - COMMISSIONING

ClimFill Maxi

ATTENTION: Leave the quick coupling taps closed when the unit is not in

use and at the end of vehicle service operations.

Power mains

connection

Connections to the A/C

system


ClimFill Maxi

8.3 FIRST TANK FILLING Execute the following actions in sequence by following the display guided procedure

and the illustrations on the summary sheet provided with the equipment:

• Gas weight check

• Oil weight check

• Pressure check

• First tank filling

It is possible to interrupt the initial check and print a report with the equipment printer in

which the checking status is reported.

The equipment cannot operate in automatic mode until all the steps of the initial check

have been completed.

CAREFULLY ABIDE BY THE FOLLOWING

INSTRUCTIONS TO AVOID DANGER TO

PERSONS AND 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) 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 implies the creation of vacuum in the internal tank. This

phase will take from 22 to 45 minutes and will act on the whole equipment.

Only when the message appears asking to connect the recharge tank, connect the

supplied HP quick coupler (colour red) in case of R134a or the LP quick coupler of the

product to an external refrigerant gas tank using the supplied adaptor.

Open the coupler by turning the knob clockwise. Open the valve on the external tank.

Right before reaching the planned quantity of refrigerant, the product will stop and ask

the user to close the external refrigerant tank. Then, the device will continue the

recovery from the hoses and ends when these are empty. Hence, it is necessary to

open the LP quick-coupler and disconnect it from the external tank. Thanks to the

ClimFill®-Lock patented technology function, the refrigerant - usually kept between the

cylinder fitting and the hose quick-coupler until the end of the process - will not be

released in the environment.

There may be 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 37 / 74 CAP. 8 - COMMISSIONING

ClimFill Maxi

The LP gauge indicates the pressure inside the external tank.

After some minutes the product will automatically end the function.

At the end, the weight of the charged refrigerant will be displayed.

8.4 NEW OIL BOTTLE FILLING

The new oil container is on the left, looking at the product 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 bottle; slightly press downward the coupler ring nut to extract it.

Fill the bottle 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 inside, thus preserving the new oil inside.

After filling, close the bottle and place it back in its seat.


ClimFill Maxi

8.5 DETECTION DYE BOTTLE FILLING

The detection dye 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 detection dye can therefore be used to detect leaks of a small entity inside the

vehicle A/C system.

The detection dye container is on the right, looking at the product 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 bottle; slightly press downward the coupler ring nut to extract it.

Fill the bottle 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 inside, thus preserving the new oil inside.

After filling, close the bottle and place it back in its seat.

ENGLISH 39 / 74 CAP. 9 - SETUP

ClimFill Maxi

CAP. 9 - SETUP

From the SETUP menu it is possible to select parameters and activations :

ELECTRIC COMPRESSOR FUNCTION

• by selecting this entry, one may change the type of Oil to inject into the A/C

system. Attention: the EXTERNAL ELECTRIC COMPRESSOR FUNCTION KIT (optional

accessory) is required in order to run this function

ClimFill®-Lock

• by selecting this entry, you can enable the ClimFill®-Lock patented technology

function (the ClimFill®-Lock patented technology quick couplers must be present

on the equipment).

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 Q-Mode

(Quick Mode) or S-Mode (Suction Mode) recharge method. The Q-Mode for this

model ClimFill® Maxi is based on the patented technology Supercharge which

allows for increasing the refrigerant injection speed by charging an A/C loop

from the HP side while recovering, at the same time, from LP (if available). The S-

Mode (Suction Mode) assure to complete the refrigerant recharge but needs

always to turn on the vehicle engine and the A/C system to recharge refrigerant

from LP side.

GAS AND RECOVERED OIL PRINT-OUT

• by selecting this entry, you can choose whether you want to enable displaying

and printing of the recovered gas quantity.

TANK REFRIGERANT INTERNAL RECYCLING

• by selecting this entry, one may decide whether or not to enable the “Tank

refrigerant internal recycling” function, which enables an additional recycling,

within the station itself, started in automatic 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.

OPERATION CONTROL

• by selecting this entry, one can enable or disable the pressure check.

HOSES LENGTH

• by selecting this entry, it will be possible to change the length of the charge

hoses (standard 3 m).

UNIT OF MEASUREMENT

• by selecting this entry, it will be possible to change the measure unit relative to

the pressure (switching from Bar to PSI)

CAP. 9 - SETUP 40 / 74 ENGLISH

ClimFill Maxi

CLOCK ADJUSTMENT

• by selecting this entry, date and time may be changed.

GARAGE DATA

• The type of data shown in the print-out are the following

Follow the instructions below:

When you click a line, the keyboard is displayed. Through this keyboard, you can enter

values and confirm with the button „Enter“. The screen-page automatically changes.

When the data are entered, save them through the disk icon.

LANGUAGE

• By selecting this entry, you can set the service station language. If you choose a

language with unintelligible characters you can turn the power off and on again

while pressing the screen with your finger, it will go directly to the menu language

setting.

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.

DEFAULT SETUP

• by selecting this entry, one may reset the unit's standard settings.

REPORT SAVING MODE

• by selecting this entry, you can decide whether to save the A/C services

performed on the equipment, choosing between automatic cycles only or

automatic and manuals cycles (through data transmission to ClimFill®-SOLUTION).

Row 1: Company name

Row 2: Address

Row 3: Postcode and city

Row 4: Telephone Number

Row 5: Fax number

ENGLISH 41 / 74 CAP. 9 - SETUP

ClimFill Maxi

REPORT DATA

• select what data you would like to include in the saved and printed report:

-license plate

-km

-owner

-attestation

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”.

VALEO SERVICE reserves the right to add new parameters to make the equipment

increasingly versatile and adaptable to market’s needs.

CAP. 10 - A/C SYSTEM RECHARGE 42 / 74 ENGLISH

ClimFill Maxi

CAP. 10 - A/C SYSTEM RECHARGE

10.1 REMARKS

The refrigerant recovery and the new recharge of a car A/C system work better if the

car engine is hot. The service station has to be recently switched on in order to enable

the possible vent of non condensable gases and complete the initial ventilation phase.

FEATURES

Your new A/C service station is equipped with the new ClimFill®-Lock patented

technology quick couplers. These new couplers offer the following functions:

1. Removal of the air from the fitting clearance at the beginning of the

recovery.

2. Avoid dispersion of the gas contained in the dead space in the air, allowing

the recovery by the equipment (protecting the environment and saving

refrigerant).

3. Automatic leak test of the car A/C system valve at the end of the service.

After connecting the quick couplers to the (high pressure) HP and (low pressure) LP

connectors of the vehicle, screw the valves only when required by the messages on the

equipment display.

To recharge the A/C system, you have to know the refrigerant type and also the

suitable type of oil. These data are usually available in the vehicle user manual or on

the engine compartment plate. The car manufacturer specifications can be another

source of information.

As to the oil amount, remember that technical data of the A/C systems and instructions

usually present in the vehicle show the total oil amount in the system. In the car A/C

system you have to add only the oil amount necessary to restore the amount set by the

car manufacturer.

ENGLISH 43 / 74 CAP. 10 - A/C SYSTEM RECHARGE

ClimFill Maxi

10.2 NON-CONDENSABLE GAS DISCHARGE VALVE

The non condensable gases discharge valve has been installed in order to allow the

non condensable gases and air automatic evacuation from the equipment internal

tank.

The check and the possible vent are ensured by the internal processor, which is able to

check air presence through the pressure and gas temperature measurement.

The processor can perform non condensable gases vent only when the car has been

stopped for 4 hours or when it has not made injections or refrigerant recoveries. It is

advisable to wait a few minutes after the switch on in order to allow the possible non

condensable gases discharge to the processor.

The vent valve also opens automatically while the internal tank is filling, if so required.

NON-CONDENSABLE GAS

DISCHARGE VALVE

WITH OUTLET EXTERNAL TO THE FAN

CAP. 10 - A/C SYSTEM RECHARGE 44 / 74 ENGLISH

ClimFill Maxi

10.3 RECHARGE Q-MODE AND S-MODE

ClimFill® Pro can apply two different refrigerant recharge modes; the first one is called

Q-Mode (Quick mode) and features the opening of the recharge valve by injecting

gas through the HP port.

The Q-Mode for this model ClimFill® Maxi is based on the patented technology

Supercharge which allows for increasing the refrigerant injection speed by charging

an A/C loop from the HP side while recovering, at the same time, from LP (if available).

The S-Mode (Suction Mode) assure to complete the refrigerant recharge but needs

always to turn on the vehicle engine and the A/C system to recharge refrigerant from

LP side.

The S-Mode (Suction mode) function is the second recharge procedure, an alternative

to the Q-Mode (Quick mode).

It features a more accurate recharge and guarantees a successful recharge (it

however requires a longer time and the operator's intervention).

If the car A/C system is equipped with both couplers or with LP coupler only, there are

two slightly different working modes; in any case, if only the HP coupler is available the

S-Mode (Suction mode) mode is not applicable.

With both HP and LP couplers available, the S-Mode (Suction mode) features the

injection of the selected refrigerant amount into the system through the HP hose; then

refrigerant remained into the HP hose is sucked by the car system – engine and

compressor running – through LP (after disconnecting and closing the HP coupler).

In case the LP coupler only is available, the station charges the system with 50% of the

selected amount with car compressor off and waits for 5 minutes before recalling the

operator. This wait time – quite rare since most of cars are equipped with HP coupler

too – allows the refrigerant injected near the compressor – that is LP side – to

evaporate to prevent any damage to the compressor during the admission of liquid

phase refrigerant. Then, after car and A/C system switch ON, recharge continues

through timed injection of refrigerant through hose LP; such injections start exclusively if

the LP pressure is lower than 3 bar.

ENGLISH 45 / 74 CAP. 11 - AUTOMATIC CYCLES

ClimFill Maxi

CAP. 11 - AUTOMATIC CYCLES

11.1 AUTOMATIC A/C SYSTEM SERVICE

It is necessary to connect both the LP (low pressure) – and HP (high pressure) couplers

to the vehicle A/C system (screw the valves only when required by the A/C station).

Select the service mode (manual or automatic) and follow instructions.

When the (automatic) service mode is selected, the following screen page is displayed.

11.2 AUTOMATIC CYCLE (BUSES)

Upon equipment switch-on, the menu of the database, with vehicles divided by maker,

model, and type of A/C system, is displayed (For the touchscreen use, see chap. 5.13).

5,13).

11.2.1 Last cycle It loads the parameters of the last automatic cycle

11.2.2 User-defined cycles It allows loading the parameters of the automatic cycle previously saved by the user.

11.2.3 Search parameters by vehicle registration plate number It allows loading the parameters of the automatic cycle previously saved for a specific

vehicle identified by its registration plate number.

11.3 AUTOMATIC CYCLE (OTHER VEHICLES)

Upon equipment switch-on, the menu of the database, with vehicles divided by maker,

model, and type of A/C system, is displayed (For the touchscreen use, see chap. 5.13).

5,13).

11.3.1 Vehicle selection from database VALEO SERVICE offers customers purchasing ClimFill® Maxi the possibility of enhancing

potentials of the product through the database.

This database contains all data related to the A/C system of most vehicles. Hence, it will

be possible to speed up the recharge operations of the system with the aid of the data

provided by the database. Type of vehicles

o European and Asian

o America

o Australian (option)

• Maker

• Model

• Version / engine capacity

• Year

• System

11.3.2 Last cycle It loads the parameters of the last automatic cycle

CAP. 11 - AUTOMATIC CYCLES 46 / 74 ENGLISH

ClimFill Maxi

11.3.3 User-defined cycles It allows loading the parameters of the automatic cycle previously saved by the user.

11.3.4 Search parameters by vehicle registration plate number It allows loading the parameters of the automatic cycle previously saved for a specific

vehicle identified by its registration plate number.

11.3.5 Automatic cycle parameters configuration After selecting the type of A/C system, the main page is shown with the following preset

values:

• amount of refrigerant that will be charged into the system and the amount of

refrigerant contained in the inner tank of the product.

• Injection mode and quantity of oil that will be injected into the system

o OIL: <value> g. It injects the quantity of oil that has been set.

o REC. + <value> g. It injects the quantity of recovered oil plus the quantity

of oil that has been set

o NO OIL. No oil is injected during the injection cycle

• Oil type: It sets the oil type being used. PAG (ISO46/100/150) or POE (see next

paragraph)

• UV: Option for the injection of detection dye

• Injection type: It allows selecting from which hose the service is carried out,

according to the type of system.

o Injection from HP hose (red)

o Injection from LP hose (blue)

o Injection from HP hose (red) and LP hose (blue)

o Injection from HP hose (red) on the system low pressure side. Specific for

some Renault models.

o Vacuum phase

� Vacuum duration

� Leak test duration

o Refrigerant vessel heating phase with heating belt

� Yes

� No

At the end of each automatic cycle, the equipment asks to fill in report data for

printing.

ENGLISH 47 / 74 CAP. 11 - AUTOMATIC CYCLES

ClimFill Maxi

Besides storing the printout report data in the internal memory, the software

automatically saves the cycle settings and associates them to the vehicle registration

plate number, so that these settings can be reused for the same customer vehicle.

11.3.6 OIL TYPE REPLACEMENT

In order to set the oil type, press several times the present icon until the icon that will be

used for the service will appear (you can set only the following 4 types ).

(Only when switching to different types of PAG or POE oil).

By selecting an oil type different from that used for the previous service, at the START the

equipment will compulsorily require the performance of the internal cleaning function

called “ELECTRIC COMPRESSOR function” .

The ELECTRIC COMPRESSOR FUNCTION will either be

• “STANDARD”, allowing for cleaning of internal hoses only, or

• “EXTERNAL ELECTRIC COMPRESSOR FUNCTION KIT”, which also cleans the

external charge hoses (only if the specific kit is available and if enabled in the

settings menu).

The EXTERNAL ELECTRIC COMPRESSOR FUNCTION, in order to be performed, requires

connecting the HP quick coupler to the LP quick coupler through the HP-LP fitting

shown in the following picture, which is part of the EXTERNAL ELECTRIC COMPRESSOR

FUNCTION KIT (optional accessory).

Once the two couplers are connected together, follow the automatic procedure.

CAP. 12 - MANUAL CYCLES 48 / 74 ENGLISH

ClimFill Maxi

CAP. 12 - MANUAL CYCLES

12.1 PRELIMINARY OPERATIONS It is necessary to connect both the LP (low pressure) – and HP (high pressure) couplers

to the vehicle A/C system (Screw the valves only when required by the A/C station).

12.2 RECOVERY

In the main menu, select MANUAL CYCLES and then the RECOVERY function. (For the

touchscreen use, see chap. 5,11)

Press and start the recovery function and follow the equipment instructions. If there is no

pressure inside the system, this function cannot be started.

� POSSIBLE ERROR INDICATION

Too high pressure in the A/C service unit.

Valves or couplers closed or system empty.

12.3 VACUUM PHASE

From the main menu, select MANUAL CYCLES and press VACUUM.

(For the touchscreen use, see chap. 5.11). Connect the HP – LP couplers or the single

coupler to the vehicle system and screw the couplers. Now set the vacuum time and

the test duration and whether you want to activate the heating belt during this phase.

The vacuum phase is automatically followed by the “vacuum test” phase.

Press START to start the vacuum phase.


System pressurised


System not tight

ENGLISH 49 / 74 CAP. 12 - MANUAL CYCLES

ClimFill Maxi

12.4 INJECTION

In the main menu, select MANUAL CYCLES and then INJECTION.

You can then set the injection values either from

• the electronic database (excluding BUSES) or

• from the last cycle, or

• from the database saved by the user, or

• by searching using the vehicle registration plate number.

The main page will be displayed with the following preset values: amount of refrigerant

that will be charged into the system and the amount of refrigerant contained in the

inner tank of the product.

You can change the settings shown on the display as needed, select Start and then

press the START button to start the phase .

Set the following items (see Section 5.10):

• amount of refrigerant that will be charged into the system and the amount of

refrigerant contained in the inner tank of the product.

• Injection mode and quantity of oil that will be injected into the system

o OIL <value> g. It injects the quantity of oil that has been set.

o REC. + <value> g. It injects the quantity of recovered oil plus the quantity

of oil that has been set

o NO OIL. No oil is injected during the injection cycle

• Oil type: It sets the oil type being used. PAG (ISO46/100/150) or POE

• UV: Option for the injection of detection dye

• Injection type: It allows selecting from which hose the service is carried out,

according to the type of system.

o Injection from HP hose (red)

o Injection from LP hose (blue)

o Injection from HP hose (red) and LP hose (blue)

o Injection from HP hose (red) on the system low pressure side. Specific for

some Renault models.

Connect the couplers to the vehicle fittings and follow the instructions on the screen

page.

Press START to begin the refrigerant filling phase.

CAP. 12 - MANUAL CYCLES 50 / 74 ENGLISH

ClimFill Maxi

� POSSIBLE ERROR INDICATION:

The amount of refrigerant in the A/C service units tank is less than that

required. Closed hoses, injection impossible.

12.5 OPERATION CONTROL (EXCLUDING BUSES) The pressure check requires the engine to be started once the service equipment has

been connected to the vehicle.

Before proceeding, refer to the original technical documentation to determine whether

this is allowed by the vehicle's manufacturer, and for any safety and operational

precautions.

We provide an example of a pressure check procedure below.

To check the condition of the vehicle's A/C system, for example if cool air does not

come out of the ports, you can check the system pressures. Connect the HP (High

Pressure) – LP (Low Pressure) couplings or single coupling to the vehicle’s A/C system.

In the main menu, select MANUAL CYCLES and OPERATION CONTROL. Then confirm

and enter the ambient temperature.

Open the couplings (or coupling) by turning the vales on the service couplings.

With the engine off:

• check that the quick couplings are properly connected;

• check that the hoses cannot interfere with moving parts and are not in contact

with hot or live parts or fluid systems;

• check that no persons, animals or foreign objects are close to or inside the

engine compartment;

• make sure no gears are engaged.

Start the engine and set the A/C system as follows:

• Start up A/C system (refrigerant compressor ON).

• Set minimum temperature on selector.

• Set fan to next to maximum setting, close all nozzles except for the central one

and set air delivery to centre.

• Run the engine at around 2500 rpm.

• Check the pressure values after about 3 - 5 minutes and verify whether the

pressure gauge readings are in the coloured sectors or at the manufacturer's

recommended values.

Also check whether the temperature at the cabin air vents is lower than 8°C.

PRESSURE VALUES CHANGE CONSIDERABLY WHEN AMBIENT TEMPERATURE

CHANGES.

12.6 EMPTYING HOSES

To empty the recharge hoses completely perform the HOSES EMPTYING phase. Select

in the menu the HOSES EMPTYING function (for the touch screen use, see table chap.

5.10).

12.7 FLUSHING

The ClimFill® Maxi station allows to perform the cleaning function to clean system parts

of the vehicle A/C system from particles or other impurities.

Two types of flushing are available:

ENGLISH 51 / 74 CAP. 12 - MANUAL CYCLES

ClimFill Maxi

• “Standard” – for which you need to buy the optional kit for the connection of the

station hoses to the components to be flushed,

• “High flushing mode” or high intensity flushing, for which you need to buy the

previous kit as well as an external optional accessory.

Once that you have installed the flushing kit/s, in the MANUAL CYCLES menu, go to the

FLUSHING function, set the flushing time by holding your finger on the time bar

then press to start the phase.

In case of problems or errors during this phase, a message is displayed indicating the

error type.

By pressing the following icon the phase in progress can be interrupted at any

moment.

12.8 NITROGEN TEST

This test allows checking the tightness of the vehicle A/C system through nitrogen

pressurization.

This test requires the NITROGEN LEAK TEST KIT (optional accessory) and a nitrogen

cylinder with pressure reducer, not supplied with the accessory.

Once this function has been selected, you need to set:

� Vacuum time

� Leak test time (under vacuum)

� Leak test under pressure (with nitrogen)

� Pressure drop limits for leak test (with nitrogen).

CAP. 13 - MAINTENANCE 52 / 74 ENGLISH

ClimFill Maxi

CAP. 13 - MAINTENANCE

ClimFill® Maxi is a highly reliable A/C service station with excellent quality parts,

manufactured with the most advanced available production techniques.

The equipment contains pressurised parts with safety equipment to eliminate associated

risks.

In the EU the PED “Pressure Equipment Directive” 97/23/EC defines a series of categories

which govern all pressurised equipment. Such parts may not be disassembled or

tampered with in any way.

Under the owner’s responsibility, the equipment and its PED parts must be verified on

commissioning and regularly thereafter as provided by local legislation.

40l RECEIVER

Category II (Dir. 97/23/EC)

SAFETY VALVE D7/S 20bar R 1/4 NPT

Category IV (Dir. 97/23/EC)

SUCTION UNIT ClimFill® Maxi

Art. 3.3 (Dir. 97/23/EC)

PRESSURE SWITCH 13/18bar 1/4SAE


The following operations may be carried out by operators:

• Having the skills and qualifications provided for by local legislation;

ENGLISH 53 / 74 CAP. 13 - MAINTENANCE

ClimFill Maxi

• trained in maintenance in line with the instructions given in the use and

maintenance manual.

INTERVENTIONS ON SERVICE STATION COMPONENTS WHICH ARE NOT

MENTIONED IN THE FOLLOWING PARAGRAPHS ARE PROHIBITED.

MAKE SURE THE EQUIPMENT IS UNPLUGGED FROM THE POWER MAINS

BEFORE OPENING.

13.1 SELF LEAK TEST

In the main menu, select MAINTENANCE and press “SELF LEAK TEST”.

A leak test is carried out on the internal components of ClimFill® Maxi.

This phase includes:

• Hoses emptying

• Vacuum test

This test allows to check the tightness of the internal circuits of the ClimFill® equipment from

the solenoid valve allowing the fluid outflow from the internal vessel to the manifold

(metallic component housing the check solenoid valves) to the compressor infeed,

including the dryer filter leak test.

In case of failed leak test, it is necessary to check the charge hoses conditions and the

quick couplers tightness, repair if needed and then repeat the test (for the touchscreen

use, see chap. 5.8).

13.2 PUMP MONITORING SYSTEM SPECIAL FUNCTION -

VACUUM PUMP OIL CHANGE

The equipment is equipped with a special function named PUMP MONITORING SYSTEM

that enables to optimize the use of vacuum pump oil, avoiding replacement every 60

hours of operation.

PUMP MONITORING SYSTEM is the special function allowing to extend up to 1000 hours the

life of the pump oil used in the station.

PUMP MONITORING SYSTEM 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.

PUMP MONITORING SYSTEM 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 equipment

cannot be used.

During the procedure, 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 provided to the operator.

In case of negative result you have to replace the vacuum pump oil.


ClimFill Maxi

After 1000 hours of vacuum pump operation since the last oil change, the PUMP

MONITORING SYSTEM procedure cannot be activated anymore and you have to replace

the oil according to the following instructions.

Required equipment:

Medium crosshead screwdriver

Hexagon wrench (6 mm)

funnel

Exhausted oil tank

For replacement (for the picture see the next page) follow the instructions indicated

below:

1. Disconnect the equipment from the mains.

2. Remove bolts (6) securing the front door and remove it.

3. 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.

4. Once the pump has been emptied, rescrew the bottom plug.

5. Fill the pump with new oil via the filler cap; use a funnel if necessary. Bring new oil

level halfway through the sight glass.

6. Once the pump is full, close the top cap.

Now switch the unit on and in the MAINTENANCE menu select PUMP OIL REPLACEMENT:

press RESET to reset the counter. (For the touchscreen use, see chap. 5.8)

When ClimFill® Maxi is switched on, if the 60-hour period is coming to an end (9 hours

before, that is 15 % of the period), a black bar is displayed as in the picture below.

Upon the 60-hour period expiry, the PUMP MONITORING SYSTEM function will be

proposed to the operator or the need to replace the oil.

OIL INSPECTION

WINDOWS

UPPER

FILLING

PLUG

LOWER

DRAIN PLUG


ClimFill Maxi

13.3 DRYER FILTER CHANGE

The software will notify when the dryer filer of ClimFill® Maxi must be replaced (see Chap.

13.3.2).

To replace the filters, select FILTERS REPLACEMENT from the MAINTENANCE Menu and press

on the display. (For the touchscreen use, see chap. 5.8)

Equipment:

• 1 Medium-sized cross-tip screwdriver

• 1 Hex key (24 mm)

• 1 Hex key (17 mm)

• 1 Hex torque key (24 mm)

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, switch off the disconnector and

disconnect the machine from the power supply.

DANGEROUS VOLTAGE HAZARD

Circuit breaker Position of the connection cable to the

mains.


ClimFill Maxi

5. Unscrew the bolts securing the rear door.

Position of the rear door.

Position of the fixing screws to be unscrewed using a cross-tip screwdriver.

6. Remove the strap that winds up the filter

7. Unscrew the 2 connection nuts of the filter by means of the hex keys.

Unscrew the upper nut of the filter using a 24-mm and 17-mm hex key in order to block the

filter and lever with it as shown in the next photo.

Be careful; pay the highest attention in order not to deform the hoses permanently.

NUTS

DRYER FILTER


ClimFill Maxi

Unscrew the lower nut of the filter using a 24-mm and 17-mm hex key in order to block the

filter and lever with it as shown in the next photo.

8. Set the new filter in the position shown by the arrow in the next photo; pay attention

to the position of the gaskets and to the direction of the arrow on the filter label

showing the liquid flow.

Caution: fitting the new filter the wrong way round compromises its filtering capacity.

9. Screw the two connection nuts of the filter.

Screw the upper nut with a dynamometric 24-mm hex key, set at 22 ±2 Nm, and a 17-mm

hex key in order to block the filter and lever with it as shown in the next photo.

Be careful; pay the highest attention in order not to deform the hoses permanently.

Screw the lower nut with a dynamometric 24-mm hex key, set at 22 ±2 Nm, and a 17-mm

hex key in order to block the filter and lever with it as shown in the next photo.

10. Refit the rear door.

Reposition the rear door as shown.


ClimFill Maxi

Position of the fixing screws to be screwed using a cross-tip screwdriver.

11. Reconnect the electric cable to the mains and switch the device on using the

circuit breaker.

12. Carry out the automatic leak test requested by the software when switched on

again after the filter replacement.

13.3.1 MESSAGE FOR FILTER ALMOST EXHAUSTED When ClimFill® Maxi is switched on, if the filter is almost exhausted (that is 15 % before the

due date), a black bar is displayed as in the picture below.

13.4 COUNTERS

In the COUNTERS menu, at any time, the vacuum pump and compressor life in hours can

be displayed; besides, remaining time before replacement of vacuum pump oil and dryer

filter can also be displayed.

To access the COUNTERS menu, from the main menu enter the MAINTENANCE menu and

press COUNTERS. (For the touchscreen use, see chap. 5,11)

COUNTERS display the following information:

13.5 VESSEL FILLING (A/C SERVICE STATION TANK)

STRICTLY COMPLY WITH INSTRUCTIONS BELOW TO AVOID REFRIGERANT

DISCHARGE INTO THE ATMOSPHERE

ALWAYS FOLLOW THE INSTRUCTIONS ON THE REFRIGERANT

MANUFACTURER'S SAFETY SHEET IN FULL

From the main menu select MAINTENANCE and press “VESSEL FILLING”.

Set the quantity of gas to fill and follow the guided procedure shown on the display.


Start the procedure that initially creates vacuum in the inner cylinder, this phase lasts over

20 minutes and acts on the whole equipment. A timer is displayed on the screen to show

the duration of this operation.


ClimFill Maxi


Start the procedure that initially implies the creation of vacuum in the internal tank. This

phase will take 15 minutes and will act on the whole equipment.

Only when the message appears asking to connect the recharge tank, connect the

supplied HP quick coupler (red) in case of R134a or the LP quick coupler (blue)of the

product to an external refrigerant gas tank using the supplied adaptor.

Open the coupler by turning the knob clockwise. Open the valve on the external tank.

Right before reaching the planned quantity of refrigerant, the product will stop and ask

the user to close the external refrigerant tank. Then, the device will continue the recovery

from the hoses and ends when these are empty. Hence, it is necessary to open the LP

quick-coupler and disconnect it from the external tank. Thanks to the ClimFill®-Lock

patented technology function, the refrigerant - usually kept between the cylinder fitting

and the hose quick-coupler until the end of the process - will not be released in the

environment.

There may be 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.

The LP gauge indicates the pressure inside the external tank.

After some minutes the product will automatically end the function.

At the end the weight of the charged refrigerant will be displayed.

ClimFill® Maxi has an automatic non-condensable gas vent valve.

� POSSIBLE ERROR INDICATION:

Tank empty or valves closed alarm

13.6 NON-CONDENSABLE GAS DISCHARGE By selecting this function, you can check the non condensable gases condition (high level

red area, low level green area ) and if necessary you can start manually the discharge.

13.7 TANK REFRIGERANT INTERNAL RECYCLING By selecting this function, you can start the Tank refrigerant internal recycling function,

allowing for a further recycle, within the station itself. This mode guarantees a higher level

of service quality.


ClimFill Maxi

13.8 SYSTEM INFORMATION By selecting this function, you can display the identifying codes and the electronic boards

software version of the ClimFill® Maxi station.

13.9 MAINTENANCE OF PRINTER To change the roll of paper follow instructions below:

Open the lid of the printer as shown.

Position the roll of paper inside the housing in the rotation direction indicated in the

picture;

Pull the paper (or the feed button) until you can extract it from the plate as indicated in

the picture and then close the door;

The printer is ready for printing.

13.10 PERIODIC CHECKS

A/C service stations (pressure equipment set) must be checked over regularly as provided

for by local legislation.

The frequency for the periodic requalification check of:

• functioning of the container and of the pressure equipment set and of the related

protection/safety devices/accessories is established to be every 2 years (according

to the Italian law D.M. 1/12/2004, No. 329);

• integrity of the container and of the pressure equipment set is established to be

every 10 years (according to the Italian law D.M. 1/12/2004, No. 329);

withstanding that:

• the national laws in force in the country where ClimFill® Maxi is commissioned do

not provide for a higher frequency (lower period of time);


ClimFill Maxi

• the bodies in charge, after the results of the previous checks performed (of

commissioning or period requalification) do not establish different frequencies.

The checks must be performed by the bodies in charge in the country where ClimFill® Maxi

is commissioned, in compliance with the national laws/rules and the respective

procedures. Please identify and contact these bodies in order to establish performance

times and modes of commissioning and periodic requalification checks (integrity,

functioning, or any other scheduled checks).

Depending on local legislation, the checks may be extended to other components to

verify the metrological characteristics of the integrated instrumentation and the presence

of essential equipment and accessories.

Here below, some possible checks on components subject to the PED directive are

outlined.

40l RECEIVER

Category II (Dir. 97/23/EC)

• Make sure no corrosion or leakage is present; under normal conditions of use, the

vessel life is at least 20 years (in the absence of wear and other types of damage).

SAFETY VALVE D7/S 20bar R 1/4 NPT


• If the automatic safety valve trips, contact technical service to have the unit

checked over, resolve any problems and replace the valve if necessary.


ClimFill Maxi

SUCTION UNIT ClimFill® Maxi

Art. 3.3 (Dir. 97/23/EC)

• Make sure no corrosion and leakages are present.

PRESSURE SWITCH 13/18bar 1/4SAE


• Check presence of the device with references indicated above, wholeness of

connection cables and connector, and the correct connection to the equipment

printed circuit board. In case the pressure switch trips, please contact the technical

customer service that will check the equipment and remove any defect.

HOSES

• Periodically check that the external charging hoses, red (HP) and blue (LP), are in

good order and undamaged. In case damages to the hoses are detected, stop

using ClimFill® Maxi and contact the technical customer service for replacement.

OTHER CHECKS

• Make sure lubricants (pump oil) and (dryer) filters have been replaced in line with

the intervals required to ensure correct operation of the equipment.

ENGLISH 63 / 74 CAP. 14 - DISPOSAL

ClimFill Maxi

CAP. 14 - DISPOSAL

14.1 A/C SERVICE UNIT DISPOSAL

At the end of its service life, the unit must be disposed of as follows:

• Contact the service centre to have the refrigerant in the unit recovered and

recycled.

• Deliver the unit to an authorised collection centre according to local legislation.

14.2 RECYCLED MATERIALS DISPOSAL

Deliver the refrigerant recovered from the unit to the refrigerant supplier for proper

disposal or recycling.

Lubricants extracted from systems must be delivered to an exhausted oil collection centre.

14.3 PACKAGING DISPOSAL

Electronic and electrical A/C service equipment must never be disposed of with domestic

waste, but recycled appropriately.

The packaging must be disposed of in conformity with local legislation.

This contributes to protecting the environment.

CAP. 15 - SPARE PARTS 64 / 74 ENGLISH

ClimFill Maxi

CAP. 15 - SPARE PARTS

Spare parts available to the user:

• 4.5 m red charging hose

• 4.5 m blue charging hose

• Blue LP quick coupler and red HP quick coupler

• Dryer filter

• Vacuum pump oil

Consumables available to the user:

• Vehicle A/C system oil

• UV detection dye

• Thermal paper rolls

Further spare parts are available through your reseller or through Service Centres

authorised by VALEO SERVICE.

WARNING

Using non-original / unapproved spare parts or accessories can compromise the safety of

ClimFill® Maxi.

VALEO SERVICE recommends using original VALEO SERVICE parts or parts of equivalent

quality.

CLIMFILL MAXI

CAP. 16 - MESSAGE AND ALARM CODES

Please find below the list of message and alarm codes that could be detected by the

software of the ClimFill® Maxi station. 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

When required

after Pump

Monitoring

System

procedure

Pump oil

contaminated

Replace pump oil

W009 REPLACE DRYER

FILTER

Every year since

installation

Filter capacity is

finished

Replace dryer filter

W025 REFRIGERANT

QUANTITY TOO

HIGH

During the

programming of

the inner tank

charge amount

Amount

required

greater than

that available

in internal tank

Decrease the set

quantity.

W026 RECHARGE

VESSEL EMPTY OR

DISCONNECTED

During the tank

filling phase

Recharging

tank empty or

hoses/taps

clogged/closed

Check tank, hoses,

taps.

W029 VESSEL NEARLY

FULL

During the

refrigerant

recovery or

hoses emptying

phase.

The tank is close

to its maximum

capacity.

Decrease quantity

of gas by filling

(injecting) an

external suitable

tank (with safety

valve)

W032 NO PRESSURE -

VEHICLE WITHOUT

REFRIGERANT OR

DISCONNECTED

During the

refrigerant

recovery phase

Check connections

and leaks in A/C

system

CAP. 16 - MESSAGE AND ALARM CODES 66 / 74 ENGLISH

ClimFill Maxi

CODE MESSAGE When it occurs Possible

situations

Actions

W036 FURTHER OIL

INJECTION NOT

POSSIBLE

During oil

injection phase

Insufficient

vacuum level

Increase the vacuum

phase time, check the

A/C system tightness.

W044 VESSEL EMPTY During flushing

or Tank

refrigerant

internal re

cycling phase

Gas level is

too low for the

procedure to

be completed

Fill the internal tank

with gas

W045 LP VERY LOW,

CHECK CIRCUIT

BEFORE

CONTINUING

During flushing

phase

LP hose

disconnected,

flushing

couplings not

properly

connected or

leak in circuit

being flushed.

Reconnect LP and/or

the fittings and

eliminate any leaks.

W047 POSSIBLE

LEAKAGE

During the

refrigerant

recovery phase

Vehicle A/C

system may

have leaks

--

ClimFill Maxi

ENGLISH 67 / 74 CAP. 16 - MESSAGE AND ALARM CODES

Alarm messages are coded Axxx in the window title bar.

Alarms immediately terminate the procedure and prevent its resumption.

CODE MESSAGE When it can

occur

Possible

causes

Actions

A000 EEPROM NOT

WORKING

Electronics

fault EEPROM

damaged

Replace the logic

electronic board

A001 EEPROM DATA

CORRUPT

Electronics

fault EEPROM

damaged

Replace the logic

electronic board

A002 PRESSURE SAFETY

SWITCH

ACTIVATED

Pressure

above 18

bar

High pressure

in the internal

tank or circuit

between

compressor

and tank

obstructed or

closed.

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 verify if the

valve between

compressor and

internal vessel are

open

A003 ADC NOT

WORKING

Electronics

fault

ADC analog-

digital

converter

damaged

Replace the logic

electronic board.

A032 CIRCUIT STILL

UNDER PRESSURE

During the

vacuum,

vessel filling

or leak test

phase in

vacuum

The vehicle

A/C system is

pressurized

Recover the refrigerant

gas from the vehicle

before starting another

vacuum phase.


ClimFill Maxi


occur

Possible

causes

Actions

A033 CIRCUIT LEAKAGE During

vacuum,

vessel filling

or leak test

phase, both

under

pressure

and in

vacuum

Leakage in the

circuit or in the

vehicle fittings.

Identify the leak position

in the vehicle or

connected system and

have it repaired by

trained and qualified

staff according to local

legislation.

A034 VACUUM LEVEL

TOO LOW

During

detection

dye

injection

and oil

injection

phase. The

necessary

vacuum

level is not

been

reached.

Vehicle A/C

system is

pressurised

notwithstandin

g the vacuum

phase,

possible

presence of

leakages

inside A/C

system.

Vacuum

phase time not

sufficient or

phase not

executed

(manual

cycle).

Repeat cycle, increase

vacuum time, if

leakages has been

identified, identify the

leak position in the

vehicle or connected

system and have it

repaired by trained and

qualified staff according

to local legislation.

A035 VESSEL EMPTY During the

gas injection

and flushing

phase

Refrigerant gas

is too low for

the procedure

to be

completed


A036 VESSEL

REFRIGERANT

QUANTITY TOO

LOW

During the

gas injection

and flushing

phase

Gas amount in

internal tank

less than

required


ClimFill Maxi

ENGLISH 69 / 74 CAP. 16 - MESSAGE AND ALARM CODES


occur

Possible

causes

Actions

A037 FURTHER

REFRIGERANT

INJECTION NOT

POSSIBLE

During gas

injection phase

Hoses not

connected to

vehicle A/C

system; tap

closed;

Vacuum not

sufficient

presence of

pressure in the

circuit

Caution: before

proceeding, empty

out the hoses.

Repeat the recovery

procedure and

increase the vacuum

phase duration

A038 CIRCUIT LEAKAGE

OR DISCONNECTED

During flushing

phase

Leakages or

obstructions in

the circuit to

be flushed

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.

A039 FURTHER OIL

INJECTION NOT

POSSIBLE

During oil

injection phase

Insufficient

vacuum level

Increase vacuum

phase duration.

A043 VESSEL FULL During the gas

recovery and

hoses

emptying

phase

Internal tank

full, maximum

capacity level

reached

Decrease quantity of

gas by filling (injecting)

an external suitable

tank (with safety valve)


ClimFill Maxi


occur

Possible

causes

Actions

A047 LP LEAKAGE During the

gas recovery

and hoses

emptying

phase

At the end of

the gas

injection, in

the ClimFill®-

Lock patented

technology

quick couplers

disconnection

phase, during

the vehicle

fittings leak

test

Empty the vehicle

(follow the procedure

guided by the

displayed messages)

A048 HP LEAKAGE During the

gas recovery

and hoses

emptying

phase

At the end of

the gas

injection, in

the ClimFill®-

Lock patented

technology

quick couplers

disconnection

phase, during

the vehicle

fittings leak

test

Empty the vehicle


guided by the

displayed messages)

A049 LP AND/OR HP

LEAKAGE

During the

gas recovery

and hoses

emptying

phase

At the end of

the gas

injection, in

the ClimFill®-

Lock patented

technology

quick couplers

disconnection

phase, during

the vehicle

fittings leak

test

Empty the vehicle


guided by the

displayed messages)

ClimFill Maxi

ENGLISH 71 / 74 CAP. 17 - MAINTENANCE FORMS

CAP. 17 - MAINTENANCE FORMS

ClimFill® Maxi Serial Number………………………………

MAINTENANCE FORM Vacuum pump oil change

Date Maintenance technician identification Maintenance

technician signature

and stamp

CAP. 17 - MAINTENANCE FORMS 72 / 74 ENGLISH

ClimFill Maxi

MAINTENANCE FORM Dryer filter change

Date Maintenance technician identification Maintenance


and stamp

ClimFill Maxi

ENGLISH 73 / 74 CAP. 17 - MAINTENANCE FORMS

MAINTENANCE FORM Gas receiver load cell check

Date Result of check

(pass/fail)

Maintenance

technician

identification

Maintenance


and stamp

CAP. 17 - MAINTENANCE FORMS 74 / 74 ENGLISH

ClimFill Maxi

MAINTENANCE FORM Other checks/maintenance/repairs

Job Date Result of

check

(pass/fail)

Maintenanc

e technician

identification

Maintenance technician

signature and stamp

Documents

ClimFill Maxi - Elitimg.elit.cz/rgcmedia/s/051/188/c41b4481c95641ed823d921b07bd58… · temperature (about –26 °C for R134a) may cause burns. Further information about safety can