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MAHLE ACX120 User Manual

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EN | 1 | ACX120/220 | CONTENTS
© MAHLE
1 CONTENTS
1 CONTENTS 1
2 General instructions 3
2.1 General Notes 3
2.2 General instructions 3
2.3 Manufacturer identification 3
3 Safety conditions 3
3.1 Personal safety information 3
3.1.1 Definitions 3
3.1.2 Personal safety
information 4
3.1.3 Important information on
service equipment safety 7
3.2 Safety devices 7
4 Layout of the manual 7
4.1 Use of the manual 7
4.2 Symbols 8
4.2.1 Safety 8
4.3 Glossary 8
4.4 Guidelines for the handling of
refrigerant 9
4.4.1 Precautions for
refrigerant storage 9
4.4.2 Conditions of refrigerant
and system 10
4.4.3 Recycling capacity 10
5 Product description 10
5.1 Application 10
5.2 Scope of delivery 10
5.3 Description of the unit 10
5.4 User interface 11
5.4.1 Main menu 12
5.5 E³ connect quick couplers 12
6 Technical features 13
7 Installation 15
7.1 Equipment installation 15
7.1.1 Unpacking ACX120/220
15
8 Commissioning 16
8.1 Connections 16
8.1.1 Positioning and
connection 16
8.2 Initial verification 17
9 Setup 18
10 A/C system charge 19
10.1 Preliminary operations 19
10.2 Non-condensable gas
discharge 20
10.3 Quick mode and zero
tolerance charge mode 20
11 Automatic cycle 21
11.1 Automatic cycle data loading
21
11.1.1 Database (optional) 21
11.1.2 Last cycle 21
11.1.3 My database 21
11.1.4 Direct Input 22
11.2 Automatic cycle data setting 22
11.2.1 Electric Compressor
Function (Optional) 22
12 Manual cycle 22
12.1 Recovery 22
12.2 Vacuum 23
12.3 Charge 23
12.4 Flushing (with optional
accessories) 23
12.5 Hoses drain 24
13 Special test 24
13.1 Ac performance test 24
13.2 Refrigerant clean 24
14 Maintenance 24
14.1 Report exporting 25
14.2 Internal cylinder fill 25
14.3 Self leak test 25
14.4 Cylinder pressure check 26
14.5 Cylinder refrigerant view 26
14.6 Air purge system 26
14.7 Air purge 26
14.8 Pressure zero 26
14.9 Counters 26
14.10 E³ pump - vacuum pump oil
change 26
14.10.1 Oil pump visual check 28
14.11 Dryer filter replacement 28
14.12 System info 29
14.13 System update 29
14.14 Maintenance of printer
(optional) 29

Table of Contents

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MAHLE ACX120 Specifications

General IconGeneral
RefrigerantR134a
Voltage220-240 V
Frequency50/60 Hz
Power800 W
Recovery Speed300 g/min
Oil DrainAutomatic
TypeAir Conditioning Service Unit
Operating ModesAutomatic, Manual

Summary

General Instructions

General Notes

Provides general notes and copyright information for the manual.

General Instructions Overview

Details pressure equipment checks and operator responsibilities.

Manufacturer Identification

Identifies the manufacturer and provides contact details.

Safety Conditions

Safety Definitions

Defines dangerous areas, exposed persons, and operators.

Personal Safety Information

Provides crucial general safety instructions for equipment use.

Service Equipment Safety

Details prohibited operations that could cause danger or damage.

Safety Devices

Describes key safety components like pressure switches and valves.

Layout of the Manual

Using the Manual

Explains the manual's integral role and its accompanying requirements.

Safety Symbols

Describes various safety symbols used on the service equipment.

Glossary of Terms

Lists important technical terms, including refrigerant definitions.

Handling Refrigerant Guidelines

Provides essential guidelines for handling and storing refrigerants safely.

Refrigerant Storage Precautions

Details care in handling refrigerants and correctly marking storage cylinders.

Product Description

Application Overview

States suitability for hybrid/electric vehicles and required A/C service functions.

Scope of Delivery

Lists all items included in the product package upon purchase.

Unit Description

Details the unit's core functions like recovery, recharging, and flushing.

User Interface

Explains access to settings and functions via LCD display and keyboard.

Main Menu Functions

Lists the primary selectable functions available in the graphical interface.

E3 Connect Quick Couplers

Describes the intelligent coupler function for reducing gas formation.

Technical Features

Technical Specifications

Details cylinder capacity, pressure, PED categories, circuits, and safety features.

Pneumatic and Electrical Features

Covers pneumatic fittings, gauges, power supply, and environmental conditions.

Installation

Equipment Installation Steps

Provides instructions for unpacking and preparing the unit for use.

Unpacking the ACX120/220

Detailed steps for safely removing the unit from its pallet.

Commissioning

Connections and Positioning

Details positioning requirements and electrical connection for safe operation.

Initial Verification Procedures

Guides through essential checks like refrigerant weight and first tank filling.

Setup

A/C System Charge

Preliminary Operations

Covers pre-charge operations, vehicle details, and hose connection.

Hose Length Adjustment

Allows users to adjust the length of the charge hoses.

Unit of Measure Setting

Enables modification of the pressure unit of measurement.

Clock Adjustment

Allows changing the station's date and time settings.

Garage Data Entry

Enables entry of garage data for inclusion on end-of-cycle reports.

Language Selection

Allows users to set the interface language.

Right/Left-Hand Drive Setting

Sets database for R/L-hand drive vehicles and charge values.

Startup Screen Configuration

Configures the unit's initial startup screen display.

Database Activation Process

Details obtaining activation codes for enhanced database features.

Default Setup Restoration

Restores the unit to its factory default settings.

Non-Condensable Gas Discharge

Automates purging of non-condensable gas for optimal station performance.

Charge Modes: Quick vs. Zero Tolerance

Explains two distinct modes for refrigerant charging operations.

Automatic Cycle

Automatic Cycle Data Loading

Covers loading data from database, last cycle, or user's saved cycles.

Database (Optional) Features

Enhances unit potential with vehicle A/C system data.

Loading Last Cycle Parameters

Loads parameters from the most recent automatic cycle.

My Database Functionality

Allows loading previously saved automatic cycle parameters.

Direct Input for Automatic Cycles

Loads default parameters for automatic cycles.

Automatic Cycle Data Setting

Sets refrigerant amount, charge type, vacuum phase, and leak test duration.

Electric Compressor Function

Cleans hoses from oil residue when an electric compressor is selected.

Manual Cycle Operations

Refrigerant Recovery

Initiates refrigerant recovery from the vehicle A/C system.

Vacuum Phase and Test

Performs vacuum phase and vacuum test on the A/C system.

Refrigerant Charging

Details refrigerant charging amounts and types for the A/C system.

System Flushing Procedure

Cleans the vehicle cooling system using refrigerant flushes.

Hose Draining

Empties charge hoses completely after service operations.

Special Tests

AC Performance Test

Checks A/C system status by monitoring pressure values.

Refrigerant Clean Function

Allows additional recycling for higher refrigerant purity.

Maintenance Procedures

Report Exporting

Exports service reports to a USB key for PC management.

Internal Cylinder Refill

Guides through filling the unit's internal refrigerant cylinder.

Self Leak Test

Checks the tightness of internal circuits, including dryer filter leak test.

Cylinder Pressure Check

Connects internal tank to HP gauge for reading refrigerant pressure.

Cylinder Refrigerant View

Displays available refrigerant and minimum quantity left.

Air Purge System Operation

Automatically runs non-condensable gas discharge when needed.

Manual Air Purge

Checks and manually starts discharge of non-condensable gas.

Pressure Zero Calibration

Determines and stores the atmospheric pressure value.

Counters and Usage Display

Displays pump/compressor hours and maintenance intervals.

E3 Pump Oil Change

Optimizes vacuum pump oil life and provides oil change instructions.

Oil Pump Visual Check

Allows checking oil level and clearness without opening the equipment.

Dryer Filter Replacement

Details replacement of the dehydrator filter after 150 kg of refrigerant.

System Information Display

Displays software version and serial number.

System Update Procedure

Details firmware update procedure using a USB stick.

Printer Maintenance (Optional)

Provides instructions for changing the printer paper roll.

Periodic Checks and Inspections

Regularly checks corrosion, leakage, safety valves, and hoses per legislation.

Disposal Procedures

A/C Service Unit Disposal

Instructions for refrigerant recovery and unit consignment for disposal.

Recycled Materials Disposal

Consigning recovered refrigerant and lubricants for proper disposal.

Packaging Disposal

Ensures electronic/electrical equipment is recycled per local legislation.

Spare Parts Information

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