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.
CAP. 3 - SAFETY CONDITIONS 8 / 74 ENGLISH
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.
ENGLISH 9 / 74 CAP. 3 - SAFETY CONDITIONS
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
CAP. 3 - SAFETY CONDITIONS 10 / 74 ENGLISH
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.
ENGLISH 11 / 74 CAP. 3 - SAFETY CONDITIONS
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
ENGLISH 17 / 74 CAP. 5 - GENERAL DESCRIPTION
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)
ONLY MAINTENANCE TECHNICIANS MAY REMOVE THE FRONT AND REAR
DOORS OR THE TOP COVER
5
6
7
8
CAP. 5 - GENERAL DESCRIPTION 18 / 74 ENGLISH
ClimFill Maxi
5.3 REAR VIEW (EXTERIOR)
9. Caster wheels, with brakes
10. Handling wheels
11. Rear door
ONLY MAINTENANCE TECHNICIANS MAY REMOVE THE FRONT AND REAR
DOORS OR THE TOP COVER
10
9
11
ENGLISH 19 / 74 CAP. 5 - GENERAL DESCRIPTION
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
ONLY MAINTENANCE TECHNICIANS MAY REMOVE THE FRONT AND REAR
DOORS OR THE TOP COVER
14
13
15
16
18
12
17
CAP. 5 - GENERAL DESCRIPTION 20 / 74 ENGLISH
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
ENGLISH 21 / 74 CAP. 5 - GENERAL DESCRIPTION
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
CAP. 5 - GENERAL DESCRIPTION 22 / 74 ENGLISH
ClimFill Maxi
5.7 FRONT SIDE VIEW
24. Touch Screen graphic display
24
ENGLISH 23 / 74 CAP. 5 - GENERAL DESCRIPTION
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.
CAP. 5 - GENERAL DESCRIPTION 24 / 74 ENGLISH
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
ENGLISH 25 / 74 CAP. 5 - GENERAL DESCRIPTION
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).
CAP. 5 - GENERAL DESCRIPTION 26 / 74 ENGLISH
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
ENGLISH 27 / 74 CAP. 5 - GENERAL DESCRIPTION
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.
Hold down to print out the latest service report.
CAP. 5 - GENERAL DESCRIPTION 28 / 74 ENGLISH
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
ENGLISH 29 / 74 CAP. 5 - GENERAL DESCRIPTION
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
CAP. 8 - COMMISSIONING 36 / 74 ENGLISH
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.
CAP. 8 - COMMISSIONING 38 / 74 ENGLISH
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.
� POSSIBLE ERROR INDICATION
System pressurised
� POSSIBLE ERROR INDICATION
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
Category IV (Dir. 97/23/EC)
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.
CAP. 13 - MAINTENANCE 54 / 74 ENGLISH
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
ENGLISH 55 / 74 CAP. 13 - MAINTENANCE
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.
CAP. 13 - MAINTENANCE 56 / 74 ENGLISH
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
ENGLISH 57 / 74 CAP. 13 - MAINTENANCE
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.
CAP. 13 - MAINTENANCE 58 / 74 ENGLISH
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.
Check that the equipment hoses are not connected and positioned in the hose winder.
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.
ENGLISH 59 / 74 CAP. 13 - MAINTENANCE
ClimFill Maxi
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 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.
CAP. 13 - MAINTENANCE 60 / 74 ENGLISH
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);
ENGLISH 61 / 74 CAP. 13 - MAINTENANCE
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
Category IV (Dir. 97/23/EC)
• If the automatic safety valve trips, contact technical service to have the unit
checked over, resolve any problems and replace the valve if necessary.
CAP. 13 - MAINTENANCE 62 / 74 ENGLISH
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
Category IV (Dir. 97/23/EC)
• 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.
CAP. 16 - MESSAGE AND ALARM CODES 68 / 74 ENGLISH
ClimFill Maxi
CODE MESSAGE When it can
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
Fill the internal tank
A036 VESSEL
REFRIGERANT
QUANTITY TOO
LOW
During the
gas injection
and flushing
phase
Gas amount in
internal tank
less than
required
Fill the internal tank
ClimFill Maxi
ENGLISH 69 / 74 CAP. 16 - MESSAGE AND ALARM CODES
CODE MESSAGE When it can
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)
CAP. 16 - MESSAGE AND ALARM CODES 70 / 74 ENGLISH
ClimFill Maxi
CODE MESSAGE When it can
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
(follow the procedure
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
(follow the procedure
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
technician signature
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
technician signature
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