User Manual EN - AVL DiTEST

USER MANUAL

AVL DITEST ADS 310

AIRCONDITION DIAGNOSTIC SYSTEM

ID number: AT7861E

Revision: 09

Edition: 03/2020

Firmware version:

Data subject to change and errors excepted. All data valid at the time of print.

PASSION INNOVATES FUTURE

AVL DiTEST GmbH

Alte Poststrasse 156

8020 Graz

AUSTRIA

Tel: +43 316 787-0

Fax: +43 316 787-1460

[email protected]

www.avlditest.com

Copyright © 2020 AVL DiTEST GMBH, All rights reserved.

The content of this publication may not be reproduced in any way or forwarded to third parties, either in part or in full, without the prior written consent of AVL DiTEST. This publication was created with due care such that AVL DiTEST is not liable for any remaining errors or omissions or for any damages arising therefrom.

mailto:[email protected]

http://www.avlditest.com/

AVL DiTEST ADS 310 Warning and safety notices

User Manual I

Warning and safety notices

This user manual provides an overview of first start-up and the operation of the AVL DiTEST ADS 310. Despite partially giving detailed process descriptions, it does not claim to be comprehensive.

The product is intended only for the highly specific use described in the user manual. The most important prerequisites and safety measures for the use and operation of the product are also described to ensure faultless operation.

No warranty can be given and no liability is assumed for applications exceeding the described intended use, irrespective of observance of the necessary prerequisites and safety measures.

The product must only be used and operated by instructed personnel who, based on their qualifications, are capable of adhering to the necessary safety measures during use and operation. Only accessories and consumables supplied by AVL DiTEST or approved by AVL DiTEST must be used. The measurement results obtained from the product in question depend not only on the correct functioning of the product, but also on a series of general conditions. The results delivered by the product must therefore be evaluated by a specialist (e.g. plausibility check) before further action is taken on the basis of a delivered measurement.

Adjustment and maintenance works on open live devices may only be performed by trained specialists who are aware of the associated danger.

The product may only be repaired in the factory of origin or by specialists specifically trained to perform such repair.

When using the product, it must be ensured by a specialist that the test object or test system is not brought into any operational state that could result in damage to goods or endangerment of people.

Warning and safety notices AVL DiTEST ADS 310

II User Manual

AVL DiTEST ADS 310 SAFETY INSTRUCTIONS

User Manual III

SAFETY INSTRUCTIONS

Sign and symbols

Symbols with the following meanings are used in the safety instructions of the operating instructions, unpacking instructions or other supplied instructions as well as on the display of the tester during operation and on the products themselves:

DANGER

Indicates an extreme danger that can lead to death if not avoided.

WARNING

Indicates an imminent danger that can lead to death or severe injury if not avoided.

CAUTION

Indicates a danger that can lead to moderate or minor injuries.

Prohibition signs

Fire and open flames

prohibited

Warning signs

General Risk of electric shock

Hazardous gases

Warning of gas cylinders

Danger of suffocation

SAFETY INSTRUCTIONS AVL DiTEST ADS 130

IV User Manual

Mandatory signs

Wear protective goggles

Wear gloves Refrigerating agent cylinder

Secure CO2 (R744)

Wear protective

shoes

Wear respiratory protection

Wear protective clothing

Other symbols

Observe operating

instructions

Fuse First aid Gas cylinder

Notices:

NOTICE

This text points to situations or mal operations that can lead to damage or data loss.

Information

This text indicates important information or instructions. Failure to comply with these instructions will prevent or significantly hinder the successful implementation of the actions described in this documentation.

AVL DiTEST ADS 310 SAFETY INSTRUCTIONS FOR CARBON DIOXIDE CO2 (R744)

User Manual V

SAFETY INSTRUCTIONS FOR CARBON DIOXIDE CO2 (R744)

Always observe the manufacturer's safety data sheet!

WARNING

Contact with the product can cause cold burns or frostbite.

Gases/vapours are heavier than air. High concentration due to accumulation in closed rooms, work pits, cellars, etc. can cause asphyxiation, among other things. Symptoms: Loss of motor ability and consciousness. Affected persons do not realise that they are suffocating.

Do not allow carbon monoxide to enter sewage systems, pits or similar enclosures where gas accumulation may be dangerous.

Precautions and behaviour rules

WARNING

Storage: Store container in a well-ventilated place at a temperature below 50 °C. Protect container against impacts and falls (secure with chain).

Handling: Avoid contact with eyes and skin. Do not inhale the gas. Ensure that no water enters the gas cylinder/container. Prevent the gas from flowing back into the gas tank. Only use equipment that is suitable for this product and the intended pressure and temperature. Check fittings, connections and lines for leaks. Eating, drinking and storing food in the working area are prohibited.

Respiratory protection: Self-contained breathing apparatus.

Eye protection: Tightly fitting protective goggles.

Hand protection: Protective gloves (material: leather).

Body protection: Protective clothing.

SAFETY INSTRUCTIONS FOR CARBON DIOXIDE CO2 (R744) AVL DiTEST ADS 130

VI User Manual

Behaviour in the event of danger

After a gas leak: Keep unprotected persons away. Ventilate rooms well. Wear protective gear and self-contained breathing apparatus. Close valves / stop gas leak. Avoid entry into cellars, pits and similar enclosures (danger of suffocation).

In case of fire: Wear protective gear and self-contained breathing apparatus. Stop gas leak if possible. Cool cylinders with a water jet from a secure position and remove them from the fire zone if possible to prevent explosion! The product itself is non-flammable.

Extinguishing agents: All known extinguishing agents can be used.

Escape routes: Escape routes must be known to staff.

Accident phone: The accident phone must be known to staff.

First aid

Please observe the instructions for use and safety instructions of your refrigerant supplier.

AVL DiTEST ADS 310 SAFETY INSTRUCTIONS FOR NITROGEN N2

User Manual VII

SAFETY INSTRUCTIONS FOR NITROGEN N2

Always observe the manufacturer's safety data sheet!

WARNING

High concentrations of the gas can cause suffocation.

Loss of motor ability and consciousness.

Rapid release of large quantities creates cold and fog.

Gas may accumulate in cellars, pits, etc., because it is about as heavy as air.

Container may burst or explode in the event of a fire.

Precautions and behaviour rules

WARNING

Employees must be instructed in the use of the gas before being allowed to work with it.

Do not inhale cylinder gas.

Secure cylinders from falling over.

Ensure good ventilation when working.

Filter masks do not protect against asphyxiation!

Wear protective gloves when transporting the cylinder.

Use the cylinder trolley.

Never open valves forcibly (no pliers, etc.)

Store cylinder in well-ventilated location at a temperature <50 °C.

Only use suitable equipment (pressure/temperature/product).

Ensure that no water can enter or flow back into the gas cylinder.

Always close cylinders, even if they are empty, before transporting them and secure with lock not and protective cap.

Lash down cylinders when transporting them in a vehicle. The loading space should be separate from the driver's cab and have vents in the ceiling and floor areas.

SAFETY INSTRUCTIONS FOR NITROGEN N2 AVL DiTEST ADS 130

VIII User Manual

Behaviour in the event of danger

WARNING

Exposure to heat and fire may cause cylinders to burst/explode.

All extinguishing agents can be used.

If gas is escaping, close valve is possible.

Make sure that the gas does not enter cellars, recesses, pits, etc. where gas accumulation might be dangerous (danger of suffocation).

Fire: Remove container from the danger zone or, if this is not possible, cool it with water from a safe distance.

Ensure good ventilation.

In case a large quantity is released or in confined spaces: Evacuate area and enter only with self-contained breathing apparatus. Re-entry only after verification of safe level.

First aid

Please observe the instructions for use and safety instructions of your refrigerant supplier.

AVL DiTEST ADS 310 SAFETY INSTRUCTIONS FOR WORKING ON AIR CONDITIONING SYSTEM

User Manual IX

SAFETY INSTRUCTIONS FOR WORKING ON AIR CONDITIONING SYSTEM

WARNING

The device must not be used if the heating band or cable is damaged. Contact the respective AVL DiTEST branch / AVL DiTEST partner in your country!

NOTICE

The oil level of the vacuum pump must be checked regularly. Top up if necessary. After 60 operating hours a regeneration of the pump oil is necessary (user notification). The regeneration can be performed from the maintenance menu. After 500 operating hours or one year, the pump oil must be changed (user notification). Oil changes can also be performed via the maintenance menu. The pump oil will also be changed as part of the annual servicing of the device by the service partner.

NOTICE

A device check is performed automatically once a week. It can also be triggered manually in the maintenance menu. The device check ensures that the system is sealed and all components are operating correctly. In case of a malfunction, the device will have to be serviced.

NOTICE

The filling levels of the oil/additive containers must be checked at regular intervals. Full used-oil containers must be emptied. Empty clean-oil and UV contrast medium bottles must be refilled if necessary.

SAFETY INSTRUCTIONS FOR WORKING ON AIR CONDITIONING SYSTEM AVL DiTEST ADS 130

X User Manual

NOTICE

Check the available printer paper and replace the paper roll if necessary.

NOTICE

We recommend that you have the device serviced by your service partner once a year. As part of every servicing the vacuum pump oil is changed and the calibration checked. If necessary, a recalibration is performed.

NOTICE

The ADS 310 may only be operated on a level and solid foundation. The refrigerating agent cylinder must be upright in the device. Any tilting may result in incorrect measurements by the cylinder scales and thus incorrect filling quantities!

NOTICE

Open the manual valve of the connected refrigerating agent cylinder before switching on.

If the ADS 310 is not being used, shut of the gas supply by closing the manual valve.

NOTICE

The ADS 310 performs a self-test when it is switched on. This is indicated by the brief sounding of the siren.

NOTICE

If the ADS 310 is not used for a prolonged period, the manual valve must be closed.

AVL DiTEST ADS 310 GENERAL OBLIGATIONS OF THE PERSONNEL

User Manual XI

GENERAL OBLIGATIONS OF THE PERSONNEL

WORKING ON/IN ELECTRICAL COMPONENTS

Opening and working on the electrical components of the ADS 340 may only be carried out by appropriately trained electricians (skilled personnel). Failure to do so may result in danger to life due to dangerous electrical voltage.

OPERATING AND AUXILIARY MATERIALS

Before using operating and auxiliary materials, the material safety data sheets for the

product and the manufacturer's instructions must be read.

An appropriate safety concept must be developed and adhered to based on these material safety data sheets.

GENERAL SAFETY INSTRUCTIONS AVL DiTEST ADS 130

XII User Manual

GENERAL SAFETY INSTRUCTIONS

WARNING

Read all instructions carefully!

DANGER

Danger of life due to electrical voltage

The cylinder heater is operated via the mains voltage! Only connect/disconnect the ADS 310 when it is switched off.

WARNING

Change the gas cylinder only with assembly gloves. When changing the gas cylinder, touching with unprotected hands the not yet installed gas cylinder with connected heating cable and the air conditioner with unprotected hands can cause an unpleasant but harmless electrical discharge.

CAUTION

The weight can result in persons or body parts being trapped. Ensure wheel brakes are applied during operation. Ensure that there is a minimum distance of 1.5 m to walls.

KEEP THESE INSTRUCTIONS IN A SAFE PLACE!

AVL DiTEST ADS 310 Contents

User Manual XIII

Contents

Warning and safety notices ......................................................................... I

SAFETY INSTRUCTIONS ............................................................................ III

SAFETY INSTRUCTIONS FOR CARBON DIOXIDE CO2 (R744) ................. V

SAFETY INSTRUCTIONS FOR NITROGEN N2 .......................................... VII

SAFETY INSTRUCTIONS FOR WORKING ON AIR CONDITIONING SYSTEM ............................................................................ IX

GENERAL OBLIGATIONS OF THE PERSONNEL ..................................... XI

WORKING ON/IN ELECTRICAL COMPONENTS ....................................... XI

OPERATING AND AUXILIARY MATERIALS .............................................. XI

GENERAL SAFETY INSTRUCTIONS......................................................... XII

1 General .............................................................................................. 1 1.1 General Description ............................................................................................................ 1

1.2 Frontal view ......................................................................................................................... 2

1.3 Right side view .................................................................................................................... 3

1.4 Rear View ........................................................................................................................... 4

1.5 Quick Couplings .................................................................................................................. 5

1.6 Refrigerant bottle CO2 (R744) ............................................................................................ 6

1.7 Operating controls ............................................................................................................... 8

1.8 User interface - operation ................................................................................................... 9

1.9 User prompts .................................................................................................................... 10

1.10 Text and number entry ...................................................................................................... 10

1.11 Operating mode overview ................................................................................................. 11

2 Commissioning .............................................................................. 2-1 2.1 Unpacking ........................................................................................................................ 2-1

2.2 Installation location / stability ........................................................................................... 2-1

2.3 Checking vacuum pump oil .............................................................................................. 2-2

2.4 Connection to the power supply ...................................................................................... 2-2

2.5 Connecting the refrigerant bottle CO2 (R744) ................................................................. 2-3

2.6 Pressure zeroing .............................................................................................................. 2-6

2.7 Oil/UV additive scales zeroing ......................................................................................... 2-7

2.8 Refrigerating agent cylinder CO2 (R744) ........................................................................ 2-8

2.9 Filling Hoses LP (blue) and HP (red) ............................................................................. 2-19

2.10 First filling/refilling and emptying the oil tank ................................................................. 2-20

2.11 Switching On .................................................................................................................. 2-21

3 Automated cycle "air conditioning service" ................................ 3-1

4 Manual cycle .................................................................................. 4-1 4.1 Emptying clearing ............................................................................................................ 4-3

4.2 Data.................................................................................................................................. 4-3

4.3 Release ............................................................................................................................ 4-4

4.4 Evacuation ....................................................................................................................... 4-5

4.5 Injection ............................................................................................................................ 4-6

4.6 Pressure test .................................................................................................................... 4-7

4.7 HP/LP Pressure test ........................................................................................................ 4-8

4.8 External Pressure test...................................................................................................... 4-9

5 Setup .............................................................................................. 5-1 5.1 Units ................................................................................................................................. 5-1

Contents AVL DiTEST ADS 310

XIV User Manual

5.2 Date and time ................................................................................................................... 5-1

5.3 Firmware update .............................................................................................................. 5-2

5.4 Garage Data .................................................................................................................... 5-2

5.5 Balance sheet .................................................................................................................. 5-2

5.6 Language ......................................................................................................................... 5-2

5.7 Printing text size ............................................................................................................... 5-2

6 Maintenance ................................................................................... 6-1 6.1 Maintenance Plan ............................................................................................................ 6-1

6.2 Regular maintenance ....................................................................................................... 6-3

6.2.1 Changing the vacuum pump oil ....................................................................................... 6-3

6.2.2 Check oil level (vacuum pump oil) ................................................................................... 6-6

6.2.3 Refrigerant CO2 (R744) ................................................................................................... 6-6

6.2.4 Bottle adapter ................................................................................................................... 6-7

6.2.5 ND and HD filling hoses ................................................................................................... 6-7

6.2.6 Quick couplings ND and HD ............................................................................................ 6-8

6.2.7 Bottle heating (heating tape) ............................................................................................ 6-8

6.2.8 Device check .................................................................................................................... 6-8

6.3 Irregular maintenance, if required .................................................................................... 6-9

6.3.1 Replacement refrigerant bottle CO2 (R744) .................................................................... 6-9

6.3.2 Pressure Zero ................................................................................................................ 6-25

6.3.3 OIL/UV additive weight zero .......................................................................................... 6-26

6.3.4 Save Logs ...................................................................................................................... 6-27

6.3.5 Change printer paper ..................................................................................................... 6-28

6.3.6 Changing the fuses ........................................................................................................ 6-29

6.4 Additional maintenance information ............................................................................... 6-30

6.4.1 System information ........................................................................................................ 6-30

6.4.2 Operating hours ............................................................................................................. 6-30

6.4.3 Replace the quick coupling seal .................................................................................... 6-31

7 Service ............................................................................................ 7-1

8 Overview ......................................................................................... 8-1

9 Shutdown and restart / storage .................................................... 9-1 9.1 Shutdown ......................................................................................................................... 9-1

9.1 Transportation .................................................................................................................. 9-1

9.2 Storage ............................................................................................................................ 9-1

9.3 Restart ............................................................................................................................. 9-1

9.4 Cleaning ........................................................................................................................... 9-2

10 List of possible faults / troubleshooting .................................... 10-1

11 Warranty ....................................................................................... 11-1 11.1 New Devices .................................................................................................................. 11-1

11.2 Replacement or Loaned Devices ................................................................................... 11-1

11.3 Damage Claims ............................................................................................................. 11-1

11.4 AVL DiTEST service address ........................................................................................ 11-1

12 Shipping Package ........................................................................ 12-1 12.1 System Delivery ............................................................................................................. 12-1

12.2 Consumables and operating material ............................................................................ 12-2

12.3 Spare parts .................................................................................................................... 12-2

13 Technical Data ............................................................................. 13-1

14 List of Abbreviations ................................................................... 14-1

15 Index ............................................................................................ 15-1

AVL DiTEST ADS 310 General

User Manual 1-1

1 General

1.1 General Description

AVL DiTEST ADS 310 (ADS: AirCondition Diagnostic System) is used to refill or renew the refrigerant CO2 (R 744) in vehicle air conditioning units.

The AVL DiTEST ADS 310 is designed for auto workshops and garages or comparable institutions. It is to be exclusively used by professionals who are familiar with the basics of cooling, cooling systems, refrigerants, pressure equipment-related regulations and associated potential damages. Follow the regulations applicable in your country! Read and observe this user manual, particularly the safety instructions contained therein! Prior to its commissioning, the AVL DiTEST ADS 310 was inspected carefully, and it needs to undergo regular inspections (in compliance with relevant laws and regulations applicable in the country where it is used) during its operation period.

It is the user's responsibility to use the air conditioning service device in accordance with the regulations applicable in their country.

Fig. 1-1

General AVL DiTEST ADS 310

1-2 User Manual

1.2 Frontal view

Fig. 1-2

1 Display

2 Multifunctional dial

3 Grab rail

4 Printer

5 Locking wheel

1

2

3

4

5


User Manual 1-3

1.3 Right side view

Fig. 1-3

1 Extensible collection tank for drained vacuum pump oil

2 Allen screw to drain vacuum pump oil

3 Inspection glass for vacuum pump oil

1

3

2


1-4 User Manual

1.4 Rear View

Fig. 1-4

1 Chain to secure the refrigerant bottle carbon dioxide CO2 (R744)

2 250ml fresh oil tank

3 250ml UV additive tank

4 250ml used oil tank

5 Wheel

6 High-pressure hose connection HP/HP, red

7 USB socket

8 Power switch with fuse link

9 Low-pressure hose connection NP/LP, blue

10 Inlet for forming gas

2

3

1

5

7

8

9

6

4


User Manual 1-5

1.5 Quick Couplings

Your AVL DiTEST ADS 310 is equipped with a quick coupling system.

These quick couplings provide the following safety functions:

▪ It is mechanically impossible to uncouple the quick couplings under pressure.

▪ The quick couplings are self-venting.

▪ Are mechanically protected from mixing up high and low pressure side.

WARNING

The quick couplings may be unscrewed only by authorized persons!

Fig. 1-5


1-6 User Manual

1.6 Refrigerant bottle CO2 (R744)

Fig. 1-6 Example:

NOTE

The AVL DiTEST ADS 310 is suitable for standard refrigerant bottles CO2 (R744) with integrated riser. The following bottle sizes can be used: 5 kg, 6 kg, 10 kg or 20 kg. Requested purity equal to or better than carbon dioxide 3.0 (purity of 99.9%).

WARNING

Frostbite on parts of the body due to refrigerant

Only trained personnel is permitted to change bottles. Follow the instructions on the AVL DiTEST ADS 310 step by step. Mind safety instructions on the refrigerant bottles!

CAUTION

Injuries to parts of the body.

Depending on its size, the supply bottle can weigh up to 50 kilograms. Two people should lift the new supply bottle onto the AVL DiTEST ADS 310 together.


User Manual 1-7

NOTE

Use the AVL DiTEST ADS 310 only when the filling hoses are connected correctly! Filling the device with the filing hoses mixed up damages the compressor unit of the AVL DiTEST ADS 310!

NOTE

AVL DiTEST ADS 310 comes without the refrigerant bottle CO2 (R744). This is to avoid any shipping damage.

Definition: Quick coupling “screwed in” / “unscrewed”

Screwed in: Unscrewed:

Turned clock-wise turned counter-clockwise

Valve open Valve closed

Fig. 1-7 Fig. 1-8


1-8 User Manual

1.7 Operating controls

Fig. 1-9

1 Power switch (rear panel)

2 Display adjustable

3 Multifunctional dial

The multifunctional dial features a display.

Meaning of the display:

Meaning Condition of the display

System start Blue light

Status in order / finished Green light

Procedure in process Yellow light

User information e.g. entry Flashing yellow (1-2 Hz)

Error e.g. process has failed Flashing red (1-2 Hz)

System error e.g. CO2 alarm Flashing red quickly (10 Hz)

2

3

1


User Manual 1-9

1.8 User interface - operation

The user interface is operated via a multifunctional dial. Turning the dial, one selects the individual functions (buttons) and starts them by pressing.

Fig. 1-10

HP High Pressure High pressure gauge HD of the refrigerant cycle

LP Low Pressure Low pressure gauge ND of the refrigerant cycle

Multifunctional dial To select and start the functions

Operating Modes

Automatic mode chap. 3 "Automatic cycle"

Manual mode chap. 4 "Manual mode"

Maintenance chap. 6 "Maintenance"

Setups chap. 5 "Setups"

Service chap. 7 "Service"

Overview chap. 8 “Overview”

1

2

3

4

4

1 2 3


1-10 User Manual

1.9 User prompts

Up Selects the previous function.

Down Selects the next function.

Back Goes one step back.

Start Starts functions.

Cancel Cancels the ongoing process.

RESET Set values.

OK Starts function, confirms questions with "yes" or "ok". Confirms questions with “no”

Continue Proceeds by one step in the process.

Printing Prints protocols.

1.10 Text and number entry

In case the device requires you to enter numbers/letters, turning the multifunctional dial shows the letters and digits. They can be selected by pressing.

Fig. 1-11 Example input:

RESET


User Manual 1-11

1.11 Operating mode overview

Operating mode Function Description

Automated cycle Automated process:

1. Prepare equipment 2. Draining 3. Vacuumizing 4. Pressure check (if activated) 5. Filling

See chap. 3

Manual cycle Hose clearing See chap. 4.1

Release See chap. 4.3

Evacuation See chap. 4.4

Injection See chap. 4.5

Pressure check See chap. 4.6

HP/LP Pressure check See chap.

External Pressure check (Option9 See chap.

Settings Units See chap. 5.1

Date/Time See chap. 5.2

Firmware Update See chap. 5.3

Garage data See chap. 5.4

Balance sheet See chap. 5.5

Language See chap. 5.6

Printing text size See chap. 5.7

Maintenance System info See chap. 6.4.1

Operating hours See chap. 6.4.2

Vacuum pump oil See chap. 6.2.1

Bottle exchange See chap. 6.3.1

Pressure Zero See chap. 6.3.2

Oil/UV additive weight zero See chap. 6.3.3

Save Logs See chap. 6.3.4

Device check See chap. 6.2.8

Service

password-protected

for authorized service only!

---

Overview

Status information is displayed see chap. 8


1-12 User Manual

AVL DiTEST ADS 310 Commissioning

User Manual 2-1

2 Commissioning

WARNING

The machine must be taken into service by expert personnel strictly complying with these instructions.

2.1 Unpacking

Required tools:

- Scissors/side cutter - Size-14 spanner - Size-25 spanner

1. Cut the packing tape and remove the carton.

2. Carefully remove the protective foil from the ADS 310

3. Use the scissors/side cutter to cut the four zip ties used to additionally secure the ADS 310 to the pallet.

WARNING

Crushing hazard!

AVL DiTEST ADS 310 may tilt and fall off the pallet.

Carefully lift the AVL DiTEST ADS 310 off the pallet with the help of a 2nd person.

2.2 Installation location / stability

WARNING

Make sure that the AVL DiTEST ADS 310:

▪ is standing horizontally and stable

▪ is in a room with adequate ventilation and air exchange

▪ has a minimum distance of 10 cm to other objects

▪ is protected from rain, humidity, direct sunlight and/or excessive dust

▪ is not operated in an explosive environment

Commissioning AVL DiTEST ADS 310

2-2 User Manual

2.3 Checking vacuum pump oil

Check the oil level by means of the inspection glass. If necessary, complete the vacuum pump oil, see chap. 6.2.1 .

Fig. 2-1

2.4 Connection to the power supply

Use the supplied power cable to connect the AVL DiTEST ADS 310.

Connect the power cable to the power supply.


User Manual 2-3

2.5 Connecting the refrigerant bottle CO2 (R744)

NOTE

Observe the specifications on the refrigerant bottle CO2 (R744), see chap. 1.6!

NOTE

The AVL DiTEST ADS 310 must not be connected to the vehicle when changing the refrigerant bottle!!

1. Fix the fixing wheels.

Fig. 2-2

2. Switch on the ADS 310.

Fig. 2-3


2-4 User Manual

3. The following message appears after a successful self-test.

Fig. 2-4 Self-test successful

4. Continue with .

5. You are in the main menu.

Fig. 2-5 Main menu


User Manual 2-5

6. Tap Settings.

Fig. 2-6 Main menu - Settings

7. Tap Language.

Fig. 2-7 Settings - Language

8. Select your language.

Fig. 2-8 Language - Language selection

9. The ADS 310 restarts and performs a self-test after a language has been selected.


2-6 User Manual

2.6 Pressure zeroing

1. Select Maintenance in the main menu.

Fig. 2-9 Maintenance

2. Select Reset to zero.

Fig. 2-10 Pressure zeroing

3. Start pressure zeroing with .

Fig. 2-11 Pressure zeroing - Start

Pressure zeroing takes about 60 seconds. The counter is displayed. Wait until the process is complete.

4. "Pressure zeroing" is complete.

5. Exit "Pressure zeroing" with .


User Manual 2-7

2.7 Oil/UV additive scales zeroing

1. Select Reset Oil/UV additive scales to zero.

Fig. 2-12 Oil/UV additive scales zeroing

2. Start Oil/UV additive scales zeroing .

Fig. 2-13 Scales zeroing

Follow the instructions on the display. (e.g. mount empty oil/UV additive containers, etc.). Note: The mounted oil containers must be completely empty for zeroing. If this is not the case, an error message may occur during zeroing.

3. "Oil/UV additive scales zeroing" is complete.

4. Exit "Oil/UV additive scales zeroing" with .


2-8 User Manual

2.8 Refrigerating agent cylinder CO2 (R744)

NOTICE

The ADS 310 is suitable for standard CO2 (R744) refrigerating agent cylinders with a built-in riser tube. The following cylinder sizes can be used: 5 kg, 6 kg, 10 kg or 20 kg.

Required purity equal or better than carbon dioxide 3.0 (99.9% purity).

Refrigerating cylinders can vary in size and design depending on the country. In these instructions the two most common types are described.

1. Select Replace refrigerating agent cylinder in the maintenance menu.

Fig. 2-14 Replacing refrigerating agent cylinder

2. Now select Cylinder content.

Fig. 2-15 Replacing refrigerating agent cylinder


User Manual 2-9

3. Enter the weight of the cylinder content. (= nominal quantity of the content / nominal capacity of the cylinder, not the actual cylinder capacity!) Incorrect entries inevitably result in incorrect calculations of the available/usable cylinder capacity.

Fig. 2-16 Cylinder capacity

4. Select tare weight.

Fig. 2-17 Tare weight


2-10 User Manual

5. Refrigerating agent cylinder with protective cap: a) In order to read the tare weight, the protective cap must be removed from the

refrigerating agent cylinder.

Fig. 2-18 Protective cap

b) Note down the tare weight. The tare weight represents the net weight of the used cylinder (empty). This weight is usually shown on the cylinder, sometimes embossed.

Fig. 2-19 Ttare weight


User Manual 2-11

c) Mark the location of the outlet valve on the refrigerating agent cylinder.

Fig. 2-20 Mark

d) Re-attach the protective cap.

Fig. 2-21 Protective cap


2-12 User Manual

6. Enter the tare weight.

Fig. 2-22 Tare weight

7. Press to continue replacing the cylinder.

Fig. 2-23 Start

8. Skip this message by clicking . The hose is automatically emptied.

Fig. 2-24 Unscrew the screw connection


User Manual 2-13

9. Continue with .

Fig. 2-25 Disconnecting the quick connectors

10. Continue with .

Fig. 2-26 Close manual valve

11. Continue with .

Fig. 2-27 Disconnecting refrigerating agent cylinder


2-14 User Manual

12. Follow the instructions. Make sure the scales are unladen.

Fig. 2-28 Information

13. Continue with .

14. Follow the instruction.


WARNING

The following work may only be carried out with assembly gloves!

a) Attach the cylinder heater (heating band) around the lower third of the cylinder. Important: The closure of the cylinder heater must be located on the opposite side of the outlet valve.

Fig. 2-30 Heating band

Outlet valve


User Manual 2-15

b) Make sure that the cylinder heater (heating band) is connected.

Fig. 2-31 Connecting heating band

c) Place the new refrigerating agent cylinder onto the refrigerating agent scales. Note that the bottle heating cable is not placed on the balance during the assembly of the bottle. Attach the securing chain.

Fig. 2-32 Securing chain

15. Continue with .


2-16 User Manual

16. Refrigerating agent cylinder with protective cap: Remove the protective cap. Make sure that the connection of the refrigerating agent cylinder is facing the device and not away.

Fig 2-33 Information

17. Zeroing and hose emptying are performed automatically.

Fig. 2-34 Refrigerating agent cylinder

18. Remove the hose from the plastic cap if necessary.

Fig. 2-35 Plastic cap


User Manual 2-17

19. Remove the plastic cap on the outlet valve if necessary.

Fig. 2-36 Refrigerating agent cylinder with Plastic cap

20. Attach the supplied cylinder adapter. Torque: 30 … 32 Nm, max. 35 Nm.

Fig. 2-37 Refrigerating agent cylinder with cylinder adapter

21. Connect the hose to the cylinder adapter. Spanner width: 14 mm Torque: 16 … 18 Nm, max. 20 Nm.

Fig. 2-38 Connect the hose to the cylinder adapter


2-18 User Manual

22. Continue with .

23. Make sure that the hose/hose connection is facing the device. It must not lead away from the rear of the device. This could lead to a faulty measurement of the cylinder weight.

Fig. 2-39 Hose connection

24. Make sure that the hose/hose connection does not point centrally to the front, but approx. 20 ... 25 degrees to the left.

Fig. 6-40

25. Follow the instructions and open the manual valve of the refrigerating agent cylinder.


✓

20 … 25 °


User Manual 2-19

Fig. 2-42 Manual valve

26. End the replacement of the refrigerating agent cylinder with . The system is flushed with CO2, i.e. the filling hoses are first flooded with CO2, then the CO2 is discharged. The ADS 310 must not be connected to the vehicle at this time.

27. Exit the menu with .

28. Select to return to the main menu.

29. The ADS 310 is now ready for use.

2.9 Filling Hoses LP (blue) and HP (red)

Fig. 2-43

WARNING

Make sure that the filling hoses LP (blue) and HP (red) get no contact with hot parts! Only use filling hoses approved by AVL DiTEST hoses!

Damaged filling hoses (buckled, worn, etc.) must not be used!

Regularly perform a visual check!


2-20 User Manual

2.10 First filling/refilling and emptying the oil tank

WARNING

Mind the safety data sheets for the oil and the UV additive!

Fig. 2-44

1. Remove the oil tank by the releasing sleeve of the quick coupling:

- pushing the slotted nut on the fresh oil tank (top right) up a bit

- pushing the slotted nut on the UV additive tank (top right) down a bit

- pushing the slotted nut on the used oil tank (top right) up a bit

2. Unscrew and remove the cover.

3. Fill in fresh oil / additive or empty the tank.

4. At the end of the filling / emptying process, close the container and reconnect it using the

quick connector.

Fig. 2-45 Example: Used oil bottle

Tank for

Fresh oil 250ml

Tank for

UV additive 250ml Tank for

Used oil 250ml


User Manual 2-21

2.11 Switching On

Turn on the AVL DiTEST ADS 310 by using the power switch. After switching on, the device performs a safety selftest.

Fig. 2-46 Symbolic image

Symbol description:

Pressure at high pressure side

Pressure at low pressure side

Pressure at refrigerant connection

CO2 concentration in %

Measures bottle fill level

Measured usable bottle fill level

Measured, actual fresh oil quantity

Measured, actual amount of UV additive

Measured amount of oil in the used oil container


2-22 User Manual

Once the self-check has been successfully completed, select to get to the main screen:

Fig. 2-47

AVL DiTEST ADS 310 Automated cycle

User Manual 3-1

3 Automated cycle "air conditioning service"

There are max. 3 preset configurations are available. They differ in the default values. The default values can be accepted and changed. Changed values are automatically saved in the selected configuration.

Select Automated cycle in the main menu.

Fig. 3-1

The following functions are performed during the automated cycle:

1. Prepare equipment

2. Release

3. Evacuaution

4. Pressure check (if activated)

5. Injection

Input values:

Button Parameters Unit Selection

Name of configuration

Amount of refrigerant g 0 … 1500

Amount of oil g 0 … 50

Oil filling mode* REC+/ABS/NO

Amount of UV additive g 0 … 50

Vacuum duration min 1 … 90

Vacuum test duration min 1 … 90

Connection LP / HP+LP

Pressure check

Off / 10 % / 75 g /

20 % / 75g/100g/150g/200g/250g/300g

Duration of pressure test min 1 … 30

Pressure loss mbar 100 … 1000

Customer data

Automated cycle "air conditioning service" AVL DiTEST ADS 310

3-2 User Manual

Oil-filling mode:

NO: No oil is introduced into the air conditioning system of the vehicle. The set oil quantity is ignored

ABS: The set oil quantity is entered into the air conditioning system of the vehicle brought in.

REC+: Depending on the quantity of recovered oil, this amount will be plus Of the adjusted oil quantity into the air conditioning system of the vehicle. Eg: Recovered oil quantity = 8 grams of waste oil, Adjusted oil quantity = 10 grams, -> 18 grams of oil are added to the vehicle

Check your entries and confirm entry with . The automated cycle starts.

Follow the instructions on the screen.

The functions Prepare equipment, release, evacuation pressure check (if activadet) and injection are carried out automatically. Also observe the color display of the multi-function rotary wheel, see chap

At the end of it Automatic Cycle you can print out all the results with .

Fig. 3-2

Results:

Drained amount of refrigerant

Drained amount of oil

Pressure during vacuum tightness test

Pressure loss during pressure test

Injected amount of refrigerant during filling procedure

Injected amount of oil

Injected amount of UV additive

AVL DiTEST ADS 310 Manual cycle

User Manual 4-1

4 Manual cycle

NOTE

Do not connect the quick couplings to the air-conditioning system until the AVL DiTEST ADS 310 prompts you to do so.

Fig. 4-1

In the manual cycle execute the following functions separately:

▪ Hose clearing The filling hoses are completely emptied. Disconnect the filling hoses from the vehicle.

▪ Customer data

To log the following procedures, customer data from the existing database can be loaded or re-entered.

▪ Release This function is used to drain the refrigerant CO2 from the motor vehicle in a controlled manner. The sub-function oil separation is also performed at this stage. Oil separation: The amount of oil that is dragged along out of the air conditioning unit is removed. The quantity of waste oil is weighed and stored for logging.

▪ Evacuation A vacuum is created in the air conditioning system. Possible leaks in the vehicle's air conditioning system are detected.

▪ Injection In the process, the amount of oil drained from the air conditioning system in the draining process is compensated by injecting fresh oil in accordance with the adjusted parameters. After that, the vehicle's air conditioning system is filled with refrigerant CO2 (R744).

Manual cycle AVL DiTEST ADS 310

4-2 User Manual

▪ Pressure check This function is used to fill the vehicle air conditioning unit with a set refrigerant quantity of 70 to 300 grams. A pressure loss over the selected time period is determined. A possible leak in the climate system of the vehicle is thus detected.

▪ HD/ND Pressure check

This function is used to measure and display the pressure of the vehicle air conditioning system during operation.

▪ External Pressure check

With this function, the vehicle air conditioning system is acted upon by a forming gas / nitrogen bottle at a pressure of 90 to 100 bar. A pressure loss over the selected time period is determined.


User Manual 4-3

4.1 Emptying clearing

In the main menu, select Manual mode│Hose clearing.

The “hose emptying” function allows you to entirely empty the filling hoses.

Hoses should not be emptied when the vehicle is connected.

4.2 Data

In all manually selectable procedures (except for bag emptying), customer data can be entered for logging purposes.

Fig. 4-2


4-4 User Manual

4.3 Release

In the main menu, select Manual mode│Release.

This function is used to drain the refrigerant CO2 (R744) from the vehicle.

Fig. 4-3

Input values:


Customer data

Results:

Drained refrigerant oil

Drained oil

Duration of draining process


User Manual 4-5

4.4 Evacuation

In the main menu, select Manual mode│Evacuation.

A vacuum is created in the air conditioning system. Possible leaks in the vehicle's air conditioning system are detected.

Fig. 4-4

Input values:


Vacuum time min 1 … 90

Vacuum test duration min 1 … 90

Customer data

Results:

Absolute pressure of the vacuumizing process

Pressure increase.

Number of repetitions

Vacuum test duration

Vacuum test okay / not okay, only on expression

Remark: If vacuuming is used as a device-internal leak test (no air-conditioning system or test tank connected) it is recommended to set the duration of the vacuum to at least 60 minutes. Otherwise, mis-interpretation of the result due to excessive pressure rise due to re-gas effects of the refrigerant CO2.


4-6 User Manual

4.5 Injection

In the main menu, select Manual mode│Injection.

In the first step, the adjusted oil quantity and UV additive quantity are injected into the air conditioning system of the vehicle. It is then filled with the pre-set refrigerant CO2 (R744).

Fig. 4-5

Input values:


Refrigerant quantity g 0 … 1500

Oil amount g 0 … 50

UV additive quantity 0 … 50

Connection LP/HP+LP

Pressure check Off / 10 % / 7 5 g / 20 % / 75 g


Pressure loss mbar 100 … 1000

Customer data

Results:

Injected amount of refrigerant

Injected amount of oil

Injected amount of UV additive


User Manual 4-7

4.6 Pressure test

In the main menu, select Manual mode│Pressure checkt.

The air conditioning system of the vehicle is charged with a preset amount of refrigerant. After a stabilization phase, the pressure change is determined over the set duration of the test. The actual pressure loss is determined and compared with the set max. Permissible pressure loss.

Fig. 4-6

Input values:


Refrigerant amount g 70 … 300


Pressure loss mbar/min 100 … 1000

Customer data

Results:

Injected amount of refrigerant

Pressure at the end of the injection process

Pressure loss during pressure test


4-8 User Manual

4.7 HP/LP Pressure test

In the main menu, select Manual│HD / ND Pressure Check. This function is used to measure the pressure of the air conditioning system during operation. This means you have the possibility to control the high pressure and low pressure side during operation. The procedure starts with a pre-filling of the hoses with CO2. This ensures the lowest possible loss of refrigerant from the air conditioning system of the vehicle. The minimum bottle pressure must not be less than 50 bar. You will then be asked to turn on the air conditioning system of the vehicle. Confirm this on ADS 310. The procedure must be terminated by the user.

Fig. 4-7

Result:

On completion, the test duration, the highest pressure achieved on the HD side including the associated pressure ND side are printed out.


User Manual 4-9

4.8 External Pressure test

In the main menu, select Manual│External Print Test. With an external pressure bottle - forming gas or nitrogen - the air conditioning system can be tightly tested with a pressure of 90-100 bar. The nitrogen bottle is connected to the external connection of ADS 310 by means of a pressure reducer and a hose. BO7948, external pressure test set, consisting of pressure reducer, and external hose are available as an option, see chap. 2.11.2.

Fig. 4-8

Input values:



Pressure loss mbar/min

100 … 5000 in 100 mbar steps

Customer data


4-10 User Manual


User Manual 5-1

5 Setup

The Setup menu item allows you to change various parameters and perform various settings and approvals.

Fig. 6-1

Select the desired function.

Follow the instructions on the display.

5.1 Units

This function is used to select the unit of measure for the pressure (bar / psi), temperature (° C / ° F), and for the oil quantities (g / ml).

5.2 Date and time

The current date and time can be entered / changed. Furthermore, the date / time format can be selected country-specific, eg USA.

Setup AVL DiTEST ADS 310

5-2 User Manual

5.3 Firmware update

This function allows you to update the firmware of the AVL DiTEST ADS 310.

1. Remove the cover on the right hand side (below the power switch) and plug in the USB

flash drive with the firmware.

Files must not be stored in a sub-folder on the USB flash drive!

Fig. 6-2

2. Go to Setup│Firmware Update.

3. Confirm your selection with .

4. The firmware update starts automatically.

5. Follow the instructions on the screen of the ADS 310.

5.4 Garage Data

Here, you can enter/edit workshop data (company, address, E-mail, telephone number).

5.5 Balance sheet

The balance sheet provides the key date-related evacuation of the amounts of refrigerant and recovered oil, as well as new refrigerant and new oil. The evacuation is displayed in this menu, can be printed or reset here.

5.6 Language

Allows you to select the language.

5.7 Printing text size

Allows you to select the text size on the printout.

Information

AVL DiTEST reserves the right to add new parameters to make the AVL DiTEST ADS 310 even more versatile and adjust it to market requirements.

AVL DiTEST ADS 310 Maintenance

User Manual 6-1

6 Maintenance

6.1 Maintenance Plan

To guarantee its trouble-free function, the AVL DiTEST ADS 310 must be serviced at regular intervals. The maintenance work carried out needs to be recorded in the inspection log book.

If required, for instance in case of problems, additional maintenance work can be carried out or information can be requested.

Component / assembly / function Interval Description

Regular maintenance

Changing the vacuum pump oil Every 500 operating hours or at least once a year

Chapter 6.2.1

Check oil level (vacuum pump oil) Weekly Chapter 6.2.2

Check refrigerant bottle CO2 (R744) Weekly Chapter 6.2.3

Check bottle adapter Weekly Chapter 6.2.4

Check ND and HD hoses Weekly Chapter 6.2.5

Check quick couplings Weekly Chapter 6.2.6

Check bottle heating (heating tape) in switched off state

Daily Chapter 6.2.7

Device check Weekly Chapter 6.2.8

Irregular maintenance (if required)

Bottle exchange As required Chapter 6.3.1

Pressure Zero As required Chapter 6.3.2

Oil/UV additive weight zero As required Chapter 6.3.3

Save Logs As required Chapter 6.3.4

Printer Change printer paper As required Chapter 6.3.5

Fuses Fuse replacement As required Chapter 6.3.6

Additional maintenance information

System info --- Chapter 6.4.1

Operating hours --- Chapter 6.4.2

Replace seals --- Chapter

WARNING

Danger to life from electric current

Prior to opening the AVL DiTEST ADS 310, make sure it has been disconnected from the power supply!

Maintenance AVL DiTEST ADS 310

6-2 User Manual

WARNING

Do not alter the AVL DiTEST ADS 310 in any way not described in this chapter!

WARNING

Use original AVL DiTEST spare parts only!


User Manual 6-3

6.2 Regular maintenance

6.2.1 Changing the vacuum pump oil

Once the vacuum pump has reached 500 operating hours, or at least once a year, the vacuum pump oil needs to be changed. The AVL DiTEST ADS 310 points out the required vacuum pump oil change to you.

1. Select Maintenance│Vacuum pump oil.

2. The following is being displayed: - Time since last oil regeneration - Remaining time for oil regeneration - Time since last oil change - Remaining time for oil change - Start the regeneration of the vacuum pump oil - Reset counter for vacuum pump oil (for vacuum pump oil exchange)

3. Switch off the ADS 310 and additionally disconnect the mains plug!

4. Switch off the AVL DiTEST ADS 310 and additionally disconnect the mains plug!

5. Unscrew the Allen screw to drain the oil (a). The oil drains into the extensible oil collector tank (b). Fig. 6-1

6. Refit the Allen screw (c).

7. Empty the oil collector tank (b). When it comes to dispose of the vacuum pump oil, please mind the current legislation in your country!

b

a


6-4 User Manual

8. Remove the blue housing part (d). Solve this the 2 screws (c), pull the housing part (d) only slightly outwards and then push it forward. Fig. 6-2

9. Unscrew the cap (e) and fill in the oil, amount: 250 ml. Only use the vacuum pump oil stated in chapter 11.3 “consumables”. Screw on the cap (e). Fig. 6-3

10. Check the oil level in the inspection glass.

Fig. 6-4

c

e

f

c

d


User Manual 6-5

11. Bring the blue housing part again (d), see Section 7. Make sure that before the tightening of the housing part snap the 3 white knobs in the black plastic parts.

Fig. 6-5

12. Turn the unit back on. Go to the menu Maintenance│ Vacuum Pump Oil│Set off Vacuum Pump Oil Reset. The values shown in section 2 are reset.


6-6 User Manual

6.2.2 Check oil level (vacuum pump oil)

Check the oil level in the inspection glass weekly. If necessary, complete or change the vacuum pump oil, see chap. 6.2.1 .

Fig. 6-6

6.2.3 Refrigerant CO2 (R744)

Check the refrigerant bottle for corrosion, leaks and damage weekly.

In normal operating conditions a minimum life of 20 years is expected (provided there is no wear or other damage).

Fig. 6-7


User Manual 6-7

6.2.4 Bottle adapter

Check the bottle adapter for corrosion, leaks and damage weekly.

Fig. 6-8 (sample photo):

6.2.5 ND and HD filling hoses

Check the filling hoses ND (blue) and HD (red) for leaks, defects or damages weekly.

Fig. 6-9


6-8 User Manual

6.2.6 Quick couplings ND and HD

Check the quick couplings ND (blue) and HD (red) for leaks, defects or damages weekly.

Fig. 6-10 (Symbol photo)

6.2.7 Bottle heating (heating tape)

WARNING

Check bottle heating (heating tape) only when the mains plug is disconnected!

If the heating tape or cable is damaged, the device must not be put into operation. Contact the AVL DiTEST branch office / AVL DiTEST partner in your country!

Check the bottle heating / cables for defects or damages daily.

Make sure the bottle heating is correctly connected.

Fig. 6-11

6.2.8 Device check

Performs an internal self-check, whereby all valves are actuated and the system's tightness is checked. This self-test is also actively requested automatically after 7 days.


User Manual 6-9

6.3 Irregular maintenance, if required

6.3.1 Replacement refrigerant bottle CO2 (R744)

Proceed as following:

30. Switch on the AVL DiTEST ADS 310.

31. The following message appears after a successful self-test.

Fig. 6-12

32. Continue with .

33. You are in the main menu. Tap Maintenance.

Fig. 6-13


6-10 User Manual

34. Select Replace refrigerating agent cylinder in the maintenance menu.

Fig. 6-14

35. Now select Cylinder content.

Fig. 6-15


User Manual 6-11

36. Enter the weight of the cylinder content. (= nominal quantity of the content / nominal capacity of the cylinder, not the actual cylinder capacity!). Incorrect entries inevitably result in incorrect calculations of the available/usable cylinder capacity.

Fig. 6-16

37. Select tare weight.

Fig. 6-17


6-12 User Manual

38. Refrigerating agent cylinder with protective cap: a) In order to read the tare weight, the protective cap must be removed from the

refrigerating agent cylinder

Fig. 6-18

b) Note down the tare weight. The tare weight represents the net weight of the used cylinder (empty). This weight is usually shown on the cylinder, sometimes embossed.

Fig. 6-19


User Manual 6-13

c) Mark the location of the outlet valve on the refrigerating agent cylinder.

Fig. 6-20

d) Re-attach the protective cap.

Fig. 6-21


6-14 User Manual

39. Enter the tare weight.

Fig. 6-22

40. Press to continue replacing the cylinder.

Fig. 6-23


User Manual 6-15

41. Follow the instruction and release the screw fitting at the connectors.

Fig. 6-24

42. Continue with . The hose is automatically emptied.

43. Disconnect the quick connectors from the vehicle.

Fig. 6-25

44. Continue with .


6-16 User Manual

45. Close the manual valve on the refrigerating agent cylinder. Continue with .

Fig. 6-26


Fig. 6-27

WARNING

The following work may only be carried out with assembly gloves!

a) Disconnect the hose from the cylinder adapter. Spanner width: 14 mm

Fig. 6-28


User Manual 6-17

b) Unscrew the cylinder adapter

Fig. 6-29

c) Unscrew the protective cap

Fig. 6-30

d) Release the securing chain and remove the refrigerating agent cylinder from the refrigerating agent scales.

Fig. 6-31


6-18 User Manual

e) Place the securing chain on the ADS 310 as illustrated.

Fig. 6-32

f) Remove the cylinder heater (heating band).

Fig. 6-33

47. Continue with .

48. The scales are reset to zero. Follow the instructions. Make sure the scales are unladen.

Fig. 6-34


User Manual 6-19

49. Continue with .


Fig. 6-35

a) Attach the cylinder heater (heating band) around the lower third of the cylinder. Important: The closure of the cylinder heater must be located on the opposite side of the outlet valve.

Fig. 6-36

b) Make sure that the cylinder heater (heating band) is connected.

Fig. 6-37

Outlet valve


6-20 User Manual

c) Place the new refrigerating agent cylinder onto the refrigerating agent scales. Note that the bottle heating cable is not placed on the balance during the assembly of the bottle. Attach the securing chain.

Fig. 6-38

51. Continue with .

52. Refrigerating agent cylinder with protective cap: Remove the protective cap. Make sure that the connection of the refrigerating agent cylinder is facing the device and not away.

Fig. 6-39


User Manual 6-21

53. Zeroing and hose emptying are performed automatically.

Fig. 6-40

54. Remove the hose from the plastic cap if necessary.

Fig. 6-41

55. Remove the plastic cap on the outlet valve if necessary.

Fig. 6-42


6-22 User Manual

56. Attach the supplied cylinder adapter. Torque: 30 … 32 Nm, max. 35 Nm.

Fig. 6-43

57. Connect the hose to the cylinder adapter. Spanner width: 14 mm. Torque: 16 … 18 Nm, max. 20 Nm.

Fig. 6-44

58. Continue with .


User Manual 6-23

59. Make sure that the hose/hose connection is facing the device. It must not lead away from the rear of the device. This could lead to a faulty measurement of the cylinder weight.

Fig. 6-45

60. Make sure that the hose/hose connection does not point centrally to the front, but approx. 20 ... 25 degrees to the left.

Fig. 6-46

61. Follow the instructions and open the manual valve of the refrigerating agent cylinder.

Fig. 6-47

✓

20 … 25 °


6-24 User Manual

Fig. 6-48

62. End the replacement of the refrigerating agent cylinder with . The system is flushed with CO2, i.e. the filling hoses are first flooded with CO2, then the CO2 is discharged. The ADS 310 must not be connected to the vehicle at this time!

63. Exit the menu with .

64. Select to return to the main menu.


User Manual 6-25

6.3.2 Pressure Zero



2. Select Reset to zero.

Fig. 6-50 Pressure zeroing

3. Start pressure zeroing with .

Fig. 6-51 Pressure zeroing – Start

Pressure zeroing takes about 60 seconds. The counter is displayed. Wait until the process is complete.

4. "Pressure zeroing" is complete.

5. Exit "Pressure zeroing" with .


6-26 User Manual

6.3.3 OIL/UV additive weight zero



6. Select Reset Oil/UV additive scales to zero.

Fig. 6-53 Oil/UV additive scales zeroing


User Manual 6-27

7. Start Oil/UV additive scales zeroing .

Fig. 6-54 Scales zeroing

Follow the instructions on the display. (e.g. mount empty oil/UV additive containers, etc.). Note: The mounted oil containers must be completely empty for zeroing. If this is not the case, an error message may occur during zeroing.

8. "Oil/UV additive scales zeroing" is complete.

9. Exit "Oil/UV additive scales zeroing" with .

6.3.4 Save Logs

Log files are being recorded in the background which can be stored on a USB flash drive in the event of a malfunction and sent to the AVL DiTEST service department for error analysis.

The log file is started / stopped with .

Remark:

After the log function is started, it is not deactivated by switching off the device.


6-28 User Manual

6.3.5 Change printer paper

Press the black flap outwards and open the cover.

Fig. 5-55

Remove the empty paper reel and insert a new one. Note the turning direction.

Fig. 5-56

Pull out the paper until it flash drives out of the printer.

Close the cover.

Fig. 5-57

Press the black flap inwards. The printer is now ready for use.

Fig. 5-58


User Manual 6-29

6.3.6 Changing the fuses

NOTICE

Use only the original AVL DiTEST fuses with the ID number EV0051 or fuses with the same specification: glass fuse 5x20 mm, 6.3 A, 250 V, anti-surge.

Pull out the fuse and replace the fuse.

Fig. 5-59


6-30 User Manual

6.4 Additional maintenance information

If you experience problems, you can execute various maintenance tasks using the maintenance menu.

Select the desired function.

Follow the instructions on the screen

6.4.1 System information

The menu "System information" shows

▪ the software version

▪ the type of device

▪ the serial number

▪ the hardware version

6.4.2 Operating hours

Shows the total operating hours of the device, the total vacuum pump running time and the number of switching cycles of the individual solenoid valves of the valve block.


User Manual 6-31

6.4.3 Replace the quick coupling seal

Tools required

▪ 2 slot screwdrivers (2 mm wide) ▪ Tweezers

Important: The screwdrivers and tweezers must have been carefully deburred and rounded.

Overview

The seal consists of two parts:

▪ 1 x O-ring

▪ 1 x supporting ring

Fig. 6-60

Supporting ring O-ring


6-32 User Manual

Removing the rings

Remove O-ring and supporting ring with screwdrivers.

Apply caution to avoid damaging the service connection.

Fig. 6-61

Installing the O-ring and supporting ring

1. Bend the supporting ring slightly in the middle. Do not bend it together completely as otherwise it will be damaged.

Fig. 6-62


User Manual 6-33

2. Insert the supporting ring into the connector with your fingers.

Fig. 6-63

3. Push the supporting ring further into the connector and then position it in the O-ring groove. The supporting ring must fit perfectly in the groove without exhibiting any unevenness or damage.

Fig. 6-64

4. Press the O-ring together and push it into the connector.

Fig. 6-65


6-34 User Manual

5. Position the O-ring as shown in the following figures. The correct position is behind the supporting ring. The correct position is essential to the proper functioning of the connector and must be adhered to.

Fig. 6-66


User Manual 6-35

6. Press one side of the O-ring under the supporting ring and into the O-ring groove. O-ring Supporting ring O-ring

Fig. 6-67

7. Push the O-ring further into the groove until the O-ring is seated evenly in the groove as shown in the figures.

Supporting ring O-ring Seated evenly all round

Fig. 6-68 If you experience problems or have any questions, please contact your AVL DiTEST service partner.


6-36 User Manual

AVL DiTEST ADS 310 Service

User Manual 7-1

7 Service

The operating mode "Service" is password-protected and reserved for the authorized AVL DiTEST service department!

Service AVL DiTEST ADS 310

7-2 User Manual

AVL DiTEST ADS 310 Overview

User Manual 8-1

8 Overview

The overview shows all current system values.

Fig. 8-1

Symbol description:

Pressure on high pressure side

Pressure on low pressure side

Pressure at refrigerant connection

CO2 concentration in %

Measures bottle fill level

Measured usable bottle fill level

Measured, actual fresh oil quantity

Measured, actual UV additive quantity

Measured oil quantity in the used oil container

Overview AVL DiTEST ADS 310

8-2 User Manual

AVL DiTEST ADS 310 Shutdown and restart / storage

User Manual 9-1

9 Shutdown and restart / storage

9.1 Shutdown

For the emptying and recycling of refrigerant CO2 (R744), observe the regulations in force in the country of use. If necessary, please contact your service partner.

9.1 Transportation

Information

All applicable safety instructions and accident prevention regulations in the country of use must be observed when transporting this air conditioning service device.

WARNING

Transport only without CO2 bottle, empty or removed bottles, pressure-free ADS 310 and in an upright position!

9.2 Storage

Disconnect the AVL DiTEST ADS 310 from the power supply and place it at a secure location protected from high temperatures, air humidity and any risk of colliding with another object that could damage it. Please also refer to the technical data. The device must also be covered with the enclosed cover. For long storage times, the ext. Remove refrigerant bottle and store separately.

WARNING

Remove CO2 bottle and heating tape when stored above 50 °C!

9.3 Restart

Prior to being taken back into service, the AVL DiTEST ADS 310 must be inspected in accordance with the laws and regulations applicable in the country where it is used.

Shutdown and restart / storage AVL DiTEST ADS 310

9-2 User Manual

9.4 Cleaning

Wipe the ADS 310 with a lint-free cloth. The cloth may be moistened with water or an alkaline detergent. It may be damp but not wet.

CAUION

Before cleaning remove the mains plug! The device must not be pressurized!

Be sure that no liquid is flowing into the housing of the ADS 310!

AVL DiTEST ADS 310 List of possible faults / troubleshooting

User Manual 10-1

10 List of possible faults / troubleshooting

Please try to determine the fault and locate it as precisely as possible.

Follow the recommended solutions on the screen and perform all actions offered where possible.

If a fault cannot be corrected, please contact the responsible AVL DiTEST branch/AVL DiTEST partner in your country.

Warnings:

Warnings Possible cause(s), Solution

Warning A warning indicates a problem during execution. However, the current operation can be continued. Charging indicator: Flashing yellow!

Insufficient refrigerant pressure.

Hand valve not open, refrigerant bottle not connected or empty. Self-check is performed regardless.

No enough printer paper, replace paper roll.

The printer no longer has enough paper to print. Please replace the paper roll.

Device unstable. Please stabilize device.

Before the filling the bottle weight is monitored. If the system detects a discrepancy (for example, by fluctuations in the bottle), the filling process is not started. Stabilize the device, so that the filling can be started.

Not enough refrigerant, refrigerant bottle must be replaced. Continue anyway?

Before an action that needs refrigerant, it is checked whether there is enough of it available. Otherwise, this message is issued. An exchange of the refrigerant cylinder is necessary. Should still be trying to perform the desired action?

Refrigerant container not connected or almost empty!

Refrigerant cylinder disconnected or empty. Connect a refrigerant cylinder with sufficient refrigerant charge!

Oil injection incomplete. Continue anyway?

Desired amount of oil could not be sprayed within the given time. If the injection process to continue anyway?

UV additive injection incomplete. Continue anyway?

Desired UV additive amount could not be injected within the given time. If the injection process to continue anyway?

List of possible faults / troubleshooting AVL DiTEST ADS 130

10-2 User Manual

Error messages:

Error message Possible cause(s), Solution

Error An error indicates that the current operation should be discontinued because of a problem. Charging indicator: flashing red.

Pressure at CO2 outlet erroneous. Maintenance/repair required.

The measured pressure at the CO2 outlet is faulty.

A maintenance / repair by a service technician is required.

Leak detected! Target pressure the evacuation could not be achieved within the stipulated time. Test the unit for leaks!

Release failed! Drain the refrigerant has failed. Remaining pressure could not be reduced within the time provided. Repeat the process!

A/C system pressurized, aborting.

A refrigerant charging is not possible because the vehicle apparently is already or still filled.

If you want to perform a filling, let the refrigerant from previously.

Pressure during evacuation too high, aborting.

During vacuuming an overpressure was found that could damage the vacuum pump. The operation was canceled.

Drain existing refrigerant from the system and repeat the process.

Injection incomplete. Replace refrigerant bottle.

The filling cannot be completed due to insufficient amount of refrigerant. The refrigerant cylinder must be replaced.

Pressure check failed. Replace refrigerant bottle.

The pressure test cannot be completed due to insufficient amount of refrigerant. The refrigerant cylinder must be replaced.

Pressure check failed. Leak in A/C system.

Excessive pressure drop in the system during the pressure test. Typical reason is a leak in the vehicle air conditioning system.

Hose clearing failed. Hose emptying takes too long, may be canceled.

Possibly the vehicle is still connected, or the valve to the vehicle is leaking.

Device unstable, aborting. During the filling process, the bottle weight is monitored. If the system detects a discrepancy (for example, by fluctuations in the bottle), the filling process is terminated. Repeat the filling and do not touch the device during operation.

Refrigerant hand valve still open, aborting.

After the request to close the manual valve on the bottle, the system pressure cannot be broken. This typically occurs when the manual valve was not properly closed. Check

Internal pressure test failed. Maintenance/repair required.

When internal pressure test an error was detected. A maintenance / repair by a service technician is required.

Device check failed. Maintenance/repair required.

When the device probing an error was detected. A maintenance / repair by a service technician is required.

AVL DiTEST ADS 310 List of possible faults / troubleshooting

User Manual 10-3

Device check incomplete. Replace refrigerant bottle.

The device scan can not be completed due to insufficient amount of refrigerant. The refrigerant cylinder must be replaced.

Measurement data invalid, calibration failed.

If during calibration incorrect measured data calibration is detected aborted with this error message.

Not enough refrigerant for calibration, refrigerant bottle must be replaced.

The calibration can not be performed because the amount of refrigerant required for the calibration is not available. The refrigerant bottle must be replaced.

Error message Possible cause(s), Solution

System error An error indicates that the device because of a problem cannot be used for the time being or permanently. Charging indicator: red flashing quickly.

Check pressure sensors! It was detected an invalid signal on one of the pressure sensors.

All pressure sensors must be checked!

Check temperature sensors!

It was detected an invalid signal on one of the temperature sensors. All temperature sensors must be checked!

Check weight sensors! One of the scales provides an invalid signal.

All balances must be checked!

CO2 concentration is above safety limit! Air the room!

CO2 concentration is above the recommended limit. Make sure there is good ventilation and you leave the room until the CO2 concentration has fallen back to normal levels and the red flashing light goes out!

CO2 sensor is not available. CO2 sensor is not connected.

The device cannot be used for safety reasons.

The CO2 sensor must be checked.

Pressure of refrigerant bottle too high!

The pressure of the refrigerant cylinder is outside the safety limits. The device cannot be used until the pressure is back within the safety limits!

System pressure too high! The pressure at the couplings exceed the safety limits.

The device cannot be used until the pressure is at the couplings again within the safety limits!

Error/Error messages, electrical:

Error/Error message Possible cause(s) Solution

Cannot be switched on No power supply Check power supply. Check fuses.

Error/Error messages, mechanical:

Error/Error message Possible cause(s) Solution

Self-check is not starting No gas supply Connect or open supply

Disconnect vehicle

Close gas bottle and drain manually

Not enough oil available Oil tank empty Fill oil bottle

Check connection Vehicle not connected or empty

Connect quick coupling to vehicle

Oil filling – fill level not reached

Oil tank empty Fill oil bottle

Circuit under pressure Perform draining

List of possible faults / troubleshooting AVL DiTEST ADS 130

10-4 User Manual

AVL DiTEST ADS 310 Warranty

User Manual 11-1

11 Warranty

11.1 New Devices

The warranty period for new devices is 12 months.

The agreements made with your supplier apply.

The date on the delivery slip to the end customer applies for handling claims.

The warranty becomes void in the case of:

▪ unscheduled or improper and/or incomplete maintenance

▪ mechanical damage (e.g. if dropped, etc.)

▪ ingress of liquids (e.g. water, oil, acids, etc.)

▪ unauthorized intervention (e.g. repair attempts by unauthorized persons)

▪ incorrect operation (e.g. screen damaged with sharp or pointed objects, cleaning with compressed air)

▪ incorrect storage, maintenance and care (e.g. cleaning the device with solvent-based cleaning agents)

The warranty excludes:

▪ consumables (e.g. paper, filters, oils)

▪ parts subject to natural wear

11.2 Replacement or Loaned Devices

The agreements made with your supplier apply.

The date on the delivery slip to the end customer applies for handling claims.

11.3 Damage Claims

In the event of a damage please contact the AVL DiTEST branch / AVL DiTEST partner in your country.

11.4 AVL DiTEST service address

AVL DiTEST GmbH

Schwadermühlstraße 4

90556 Cadolzburg

Germany

Telefon: +49 9103 7131-0

Fax: +49 9103 7131-112

Mail: [email protected]

mailto:[email protected]

Warranty AVL DiTEST ADS 130

11-2 User Manual

AVL DiTEST ADS 310 Shipping Package

User Manual 12-1

12 Shipping Package

12.1 System Delivery

Description Order no.

AVL DiTEST ADS 310 incl. first filling and power cable BO7885

AVL DiTEST ADS 310 quick start guide, printed AT7862E

AVL DiTEST ADS 310 startup instructions, printed AT7863E

AVL DiTEST ADS 310 inspection log book, printed AT7864E

Filling hose CO2 HP red GE7520

Filling hose CO2 LP blue GE7522

Connection hose CO2 red SS7520

Connection hose CO2 blue SS7521

Cover hood MK7519

Bottle adapter W21.8x1/14“

incl. seal to connect R744 bottle to AVL DiTEST ADS 310

Remark:

It is possible that the supplied bottle adapter does not match with a bottle available in your country. Therefore, a choice of adapters is available as an option. See "Available Accessories".

DN7469

AVL DiTEST ADS 310 documentation DVD

Acceptance report

Shipping Package AVL DiTEST ADS 130

12-2 User Manual

12.2 Consumables and operating material


Vacuum pump oil, 250 ml (0,13 gallons) (2 per package)

GE7427

Printing paper thermos 57 mm (minimum order quantity 5 pieces)

HP7003

12.3 Spare parts


Bottle heating (heating tape) incl. Connector

BV8261

External pressure test set

BO7948

Bottle adapter including seal: W21,7x1 / 14 "

DN7470

Bottle adapter including seal: 0,860 "x14TPI

DN7471

Bottle adapter incl. seal: G3 / 4 "

DN7472

Bottle adapter incl. seal: 0.825 "x14NGO

DN7473

Bottle adapter incl. seal: W27x2mm

DN7474

NOTE

Use original accessories by AVL DITEST only!

Contact the AVL DiTEST branch/AVL DiTEST partner in your country.

AVL DiTEST ADS 310 Technical Data

User Manual 13-1

13 Technical Data

General data

Refrigerant R744

Rated voltage 230 VAC

Frequency 50 Hz

Power draw 1.2 kW

Weight approx. 75 kg

Dimensions 80x80x152 cm

Display 7 inch TFT color display

Input device Multifunctional dial

Pressure gauge Digital (HP and LP)

PC interface USB interface

Max. pressure HP 140 bar; LP 130 bar

Hose length 2.5 m

Printer Thermo printer, 24 columns

Interface USB standard

Refrigerant

Refrigerant R744

Bottle weight 5, 6, 10 or 20 kg

Type of bottle bottle with integrated riser pipe

Weighing cell Max. 50 kg

Scale accuracy ± 10g

Oil / UV

Oil tanks 3 (1 fresh oil tank, 1 used oil tank, 1 additive tank)

Oil tank volume 250 ml

Weighing cell Max. 3 kg

Accuracy of oil / tracer ± 2 g / ± 2 g

Vacuum pump

Suction capacity 3 m³/h

Ultimate pressure 0,002 mbar

Service interval 500 h

Climatic conditions

Operating temperature +10 ... +50 °C

Storage and transport temperature -25 ...+50 °C

Air humidity 10 ... 90 %, non-condensing

Disposal

This product by AVL DiTEST is a high-quality electrical and electronic device that must not be disposed of with household waste.

For disposal, it is essential to comply with local legal obligations!

Technical Data AVL DiTEST ADS 130

13-2 User Manual

AVL DiTEST ADS 310 List of Abbreviations

User Manual 14-1

14 List of Abbreviations

Abbreviation Description

ADS AirCondition Diagnostic System

CE Communauté Européenne (European Community)

CO2 Carbon dioxide

EC European Community

HD High pressure

HP High Pressure

IP Internet Protocol

Kfz Motor vehicle

ND Low pressure

HV High Voltage

USB Universal Serial Bus

UV Ultra violet

R744 Workshop name for carbon dioxide CO2

TFT Thin-film transistor display

List of Abbreviations AVL DiTEST ADS 130

14-2 User Manual

AVL DiTEST ADS 310 Index

User Manual 15-1

15 Index

A

Automated cycle"air conditioning service" 3-1

B

Balance sheet 5-2 Bottle adapter 6-7

C

Change printer paper 6-28 Changing the fuses 6-29 Changing the vacuum pump oil 6-3 Check oil level (vacuum pump oil) 6-6 Checking vacuum pump oil 2-2 Cleaning 9-2 Commissioning 2-1 Connecting the refrigerant bottle CO2 (R744) 2-3 Connection to the power supply 2-2 Consumables and operating material 12-2

D

Damage claims 11-1 Data 4-3 Date and time 5-1

E

Emptying clearing 4-3

F

Firmware update 5-2 First filling/refilling and emptying the oil tank 2-20 Frontal view 2

G

Garage Data 5-2 General 1 General Description 1

I

Injection 4-6 Installation location / stability 2-1 Irregular maintenance, if required 6-9

L

Language 5-2 List of Abbreviations 14-1 List of possible faults / troubleshooting 10-1

M

Maintenance 6-1 Maintenance Plan 6-1 Manual cycle 4-1

N

ND and HD filling hoses 6-7

O

OIL/UV additive weight zero 6-26 Operating controls 8 Operating hours 6-30 Operating mode overview 11 Overview 8-1

P

Pressure test 4-7 Pressure Zero 6-25 Printing text size 5-2

Q

Quick Couplings 5 Quick couplings ND and HD 6-8

R

Rear View 4 Refrigerant bottle CO2 (R744) 6 Refrigerant CO2 (R744) 6-6 Regular maintenance 6-3 Release 4-4 Replace the quick coupling seal 6-31 Replacement or loaned devices 11-1 Restart 9-1 Right side view 3

Index AVL DiTEST ADS 130

15-2 User Manual

S

SAFETY INSTRUCTIONS III Save Logs 6-27 Service 7-1 Setup 5-1 Shipping Package 12-1 Shutdown 9-1 Shutdown and restart / storage 9-1 Storage 9-1 Switching On 2-21 System Delivery 12-1 System information 6-30

T

Technical Data 13-1 Text and number entry 10 Transportation 9-1

U

Units 5-1 Unpacking 2-1 User interface - operation 9 User prompts 10

W

Warning and safety notices I Warranty 11-1

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