ACR2000 Service Manual

ACR2000 Refrigerant Service Solution Disclaimer The information contained in this manual was considered accurate at the time of printing. Any corrections should be directed to: SPX Corporation 8001 Angling Road Portage, MI 49024 Phone 269-329-7600 Fax 269-329-7712 This manual was made possible by the combined efforts of a number of individuals in the following departments: Technical Support, Engineering, and Sales. I wish to express my gratitude to everyone that contributed to this manual. — Scott Parde © 2003, SPX Corporation. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written permission of SPX Corporation. Printed in the USA. S.P. 06/2003 Rev C. 2 ACR2000 Refrigerant Service Solution TABLE OF CONTENTS Safety Precautions ............................................................................................... 4 General Information.............................................................................................. 5 ACR2000 Features ............................................................................................................. 6 Theory of Operation ......................................................................................................... 8 ACR2000 Views ................................................................................................................. 11 Operating Guidelines ....................................................................................................... 12 Depressurizing the Unit .................................................................................................... 13 Unit Specifications ............................................................................................................ 14 Maintenance Schedule .................................................................................................... 15 Parts & Components............................................................................................ 17 Plumbing Diagram & Parts List ....................................................................................... 18 Component Locations ...................................................................................................... 20 Component Assemblies .................................................................................................... 22 Component Descriptions .................................................................................................. 38 Alphabetical Parts List ..................................................................................................... 42 Parts & Components ......................................................................................................... 43 Diagnostics .......................................................................................................... 53 Functional Check .............................................................................................................. 54 Output Step Test ................................................................................................................ 56 Service Center Menu Options .......................................................................................... 57 Troubleshooting ................................................................................................................ 58 Service Procedures and Calibrations ............................................................................. 72 System Wiring ................................................................................................................... 95 Harness Schematics ......................................................................................................... 96 Component Wiring ............................................................................................................ 101 Component Identification ............................................................................................... 106 Component Application Chart ......................................................................................... 107 Flow Diagrams .................................................................................................................. 108 Service Bulletins .................................................................................................. 121 Labor Rates .......................................................................................................... 151 3 make tive clothing when working with refrig. previous configuration. exactly as your instruction sheet directs Read and follow all warnings in the you to do. certain the new parts are connected erants. use service equipment certified to meet nents. Avoid the use of extension cords be. Improper setup manual or this service manual for cor- and failure of the unit will result. violent explosion and possible injury or Make sure there is adequate ventilation death. Warnings: Use this unit only with the Always disconnect the unit from the specified refrigerants. When replacing components. Mark or label wire and plumbing disconnections so Disconnect hoses and tubes with ex. system or in the same container! However. Some mixtures of air/HFC-134a volume. connect the replacement manual before operating the unit. causing physical injury or are potentially dangerous and may re- death. If an instruction sheet was operator’s manual and this service not included. a non-refillable storage container. uid refrigerant under pressure. Use only ROBINAIR Designated Re- structions in this manual. 14 AWG minimum and should not exceed more Avoid breathing A/C refrigerant and lu- than 25 feet in length. fore servicing or replacing any compo. Refrigerant can cause injury. the cord must be No. placement Components when servicing tach any hoses or accessories until your equipment. Cross-contami- power source before making any re. if you must use an extension cord. ventilate erant. If acciden- Pressurized tanks contain liquid refrig. Do not recover refrigerants into in the vehicle servicing area. replacing the new parts will confirm the treme caution as they may contain liq. 4BW or DOT spec. nose. scale can overfill the tank. and throat. cause severe damage to the A/C sys- nents. removing R-134a from the A/C system. These mixtures pressure. If scale assembly and UL circuit are not calibrated. bricant vapor or mist. part just like the original. nation with other refrigerant types will pairs or replacements to the compo. DO NOT at. 4 . Additional health and safety information causing possible explosion and/or ve. tal system discharge occurs. Always wear eye protection and protec. the requirements of SAE J2210 (R- 134a recycling equipment). Do not mix refrigerant types through a cause the extension cord may overheat. may be obtained from refrigerant and lu- hicle overcharge. ACR2000 Refrigerant Service Solution SAFETY WARNINGS It is extremely important to follow the in. 4BA. Failure to monitor the level have been shown to be combustible at could result in excessive hydrostatic elevated pressures. rect replacement part number(s). Overfilling of the tank may cause work area before resuming service. sult in fire or explosion causing injury or property damage. When Always depressurize the machine be. HFC-134a service equipment or vehicle A/C systems should not be pressure Be sure that the refrigerant level in the tested or leak tested with compressed tank does not exceed 80% of the tank air. Fed- eral regulations require refrigerants to Keep hands away from moving parts. be transported only in containers meet- ing DOT spec. Exposure may irritate eyes. Refer to the operator’s prompted by the unit. Risk of electrical shock! tem and to service tools and equipment. bricant manufacturers. ............................................................................................................................ 10 ACR2000 Views ......... 14 Maintenance Schedule ... 10 Charging ....................................................................... 8 Testing ................................................................................................................................................................................................................................................................................................................................................................................................................ 12 Depressurizing the Unit .............. 11 Front View ......................................................... 9 Recovery .................................... 9 Evacuation/Vacuum ......................... 11 Operating Guidelines .............. 6 Theory of Operation ................... 11 Side View .............................................................................................................................................................................................................................................................................................................. 15 5 ...........................................................................................................................ACR2000 Refrigerant Service Solution 1 G E N E R A L I N F O R M AT I O N ACR2000 Features . 12 ACR2000 Control Panel ....................................................................................................................................... 13 Unit Specifications ............................................................................................................................................. • Internal vessel refill • Air Purge – done in the background. Snapshot. Vacuum. General Information ACR2000 Refrigerant Service Solution ACR2000 FEATURES Automatic Refrigerant ID • Fully integrated with unit’s operation • Automatically verifies 98% or better purity of refrigerant in vehicle prior to each recovery • Automatically verifies 98% or better purity of refrigerant in on-board vessel • Oil and liquid refrigerant protected • Protects equipment and pure refrigerant supply Interactive VGA Display • Date/Time • High/Low Side Pressures • Minimum Low Side Pressure/Maximum High Side Pressure • Ambient Temperature • Ambient Humidity • Identifier Results • % of Air • Chargeable Weight – amount of refrigerant available for charge • Voltage – disables circuitry if voltage under 105 or over 135 volts • Vehicles’s Air Vent Temperatures – front and back • Amount of Refrigerant Recovered/Charged • Multilingual Operation Prompts – step by step operation • Current Function Status • Recover.D. System Flush. No need to run recycle process • A/C system oil drain • Clearing Mode – immediately before/after recovery . Set-up On-board Printer • Snap-shot Mode – freezes current display and prints for records • Records current system and ambient conditions/pressures/temperatures • Records amount of refrigerant recovered/charged Automatic Functions • Refrigerant I. or 10 minutes is reached 6 . Tank Refill. Charge.recovery accuracy • Audible and visual signal – upon completion of each function • Printout of recovery results • Restart of recovery – if positive pressure detected after five minutes • Will not start with system pressure lower than 25 PSI pressure Evacuation • Oilless Vacuum Pump — ACR2000 • Default time is three minutes • Evacuates to 28” vacuum • Evacuation will continue past three minutes until 28” vacuum. current 3” • Optimum angle display panel – easily read from within vehicle • Light-weight construction with rounded corners – shop friendly 7 .00 lbs. Units can be toggled through pounds and hundredths pounds and ounces.ACR2000 Refrigerant Service Solution General Information • 6CFM Vacuum Pump — 342000 • Default time is 15 minutes • Shuts off automatically upon expiration of pre-programmed time • Will reach deeper vacuum compared to oilless vacuum pump • Will not start with system pressure of 25 PSI or higher Charging • Default is 2. and kilograms • Program amount according to manufacturers specifications • Accuracy is ± 1 oz. • Select high or low charging according to charging recommendations • Power Charge Mode – increases tank pressure to assist charge when insufficient pressure differential exists between tank and A/C system • Snap-shot records refrigerant charged and can be printed for records • “Topping-off” available up to ½ pound increments Oil Charge • Independent process on ACR2000 – separate injector required • Push button on 342000 A/C System Flushing Process • Requires special flushing adapter (J45268) to access system through compressor block • Works with orifice tube type systems • Uses liquid refrigerant to flush oil and other contaminants from system • Refrigerant is recycle back to SAE purity levels for reuse Maintenance • Filter only on ACR2000 – every 300 pounds – prompted by unit • Function controlled through interactive menu • Easy access • Technician is prompted through each step • Filter and vacuum pump oil on 342000 • Filter – every 300 pounds – operation same as ACR2000 • Vacuum pump oil – every 10 hours – prompted by unit Functionality and Ergonomics • “Side-winder” design – easier maneuverability in shop • Large pneumatic rear wheels and large front castors • Accessory tray in back • Upgradable software – future requirements • Automatic valve control – ACR2000 • 4” gauges – easier to read vs. ant Service Solution equipment will enter the fier that determines the percent of refrigerant. accu. age Vessel (ISV) will maintain a constant 12-15 lbs. automatic oil drain and R-134a refrigerant only. This procedure is known as first time tank fill. the technician is notified by a flashing of from the technician. During normal operation the • 12 and 110 volts to the relay board A/C unit will automatically fill the ISV from the • 12 and 24 volts to the control board (display external source tank mounted on the outside of the panel) ACR2000. recycles. during times of reduced or low voltage. General Information ACR2000 Refrigerant Service Solution THEORY OF OPERATION The ACR2000 is a complete air conditioning service Some of the additional features of the A/C unit center that is used to service vehicles that contain include automatic air purge. All R-134a refrigerant source tanks have an internal The ACR2000 Refrigerant Service Solution is check valve that will only allow the flow of new protected by two circuit breakers that are on the refrigerant from the source tank. There are many other internal checks and procedures that occur unknown to the technician during the The main electronics of the ACR2000 receives operation of the ACR2000.45-6. It is suggested that the power from the Power Supply assembly located ACR2000 is left running through out the entire work within the machine. and 15 amp. the ACR2000 Refriger- The A/C unit contains a built-in refrigerant identi. The ACR2000 Refrigerant single pass cycle. The technician The Power Supply controls voltage to the follow- will have the opportunity to abort the procedures if ing components: contaminants are detected. It is not possible to rear of the machine.) of refrigerant. hoses after each use. and contaminants within the vehicles system before the recovery process begins. If the power to the unit is 90 volts or less. • 5 volts to the printer ered and stored within the ACR2000 in the Internal • 12 volts to the identifier Storage Vessel (ISV).82kg. The external source tank on the outside • 5 volts to the transducers from the control board of the machine does not store recovered refrigerant. 8 . recover the excess refrigerant that will remain in the evacuates and recharges refrigerant quickly. The Internal Stor. The circuit breakers are 3 amp fill or refill R-134a source tanks. The ACR2000 also has the the red lamp on top of the machine and an audible capability to perform a complete A/C system flush. The ACR2000 will self-protect day for the machine to perform its necessary checks. The only time that the ISV will have to be manually filled with R-134a refrigerant is during the initial setup of the ACR2000 and after service if the ISV is drained. beep. The unit will automatically clear and Service Solution equipment recovers. When a specific process is rately and automatically with little attention needed completed. air self-protection mode and shut down. (5. The refrigerant is recov. The necessary 25 psi (172 kPa) of vessel of the machine. When the recover process is activated. The sample of refrigerant is tested for purity of the R-134a refrigerant and percent of air. refrigerant to the identifier.ACR2000 Refrigerant Service Solution General Information Testing Recovery The testing or sampling procedure is done to deter. The actual testing moisture and particles. travel through the high and low side hoses. automatically repeated one time only. the system. When the ACR2000 Refrigerant Service Solution equipment is powered and idle. The refriger- perform a clearing procedure to remove the contami. the ID drain solenoid opens. from the testing sample to be expelled into the external recovery bottle. the testing procedure will activate and test the refrigerant in the internal storage vessel. system pressure is determined by the low side transducer. It is extremely important that no (172 kPa) of system pressure in the vehicle to be contaminated refrigerant enters the internal storage recovered. expansion valve Anytime a procedure requires refrigerant from the and into the accumulator. This prevents contamina- identifier switch.36kg) of refrigerant has been recovered by the unit. If purity of the refrigerant is acceptable ered to close. through the recovery solenoid. ant will also enter the oil separator to remove oil from nated refrigerant from the hoses. The identifier switch opens at 25 psi (172 kPa) and closes at 40 psi (276 During the recovery process the refrigerant will kPa). At the same time content of the refrigerant. the ACR2000 will prompt the user to Menu for service of the filter assembly. solenoid will be powered to open and allow the At this point the technician will be notified about the flow of refrigerant from the vehicle. The prompts on the display screen will advise If the testing procedure fails. (136. The oil from the refrigerant will be collected in the external container when the oil If testing of the refrigerant is acceptable. The recovery process will not proceed automatically if The operation of the solenoids is controlled by the contaminants are detected. within the refrigerant. The switch allows the inlet test tion of the refrigerant within the Internal Storage solenoid to open and close controlling the flow of Vessel (ISV). If the test fails Follow the filter change prompts from the Main a second time. The recovery process will not begin until the ACR mine the content of the refrigerant that will enter the 2000 has determined that there is a minimum 25 psi ACR2000 machine. 9 . the front of the machine. refrigerant will be done automatically. Part of the recovery vehicle to enter the ACR2000. The external oil drain bottle is drain solenoid will open to allow any trapped oil marked for measurement purposes. air and contaminants within the ID drain solenoid (normally open) will be pow. Replacement of the filter of the refrigerant is done by the identifier assembly located on assembly will be after approximately 300 lbs. the inlet test identifier will examine the refrigerant to be recovered. the recovery process begins automatically. testing of the incoming process is to filter the refrigerant to remove acid. the When the testing procedure begins. the test will be the technician when changing the filter is required. Elevation affects the ability to side of the vehicle’s system.000 feet (1524 meters) the vacuum low side is also an option by manually operating the reading value will be approximately 24" Hg (81. at 5. After the charging process is complete. Select the charge mode from the Main activation of the vacuum pump. kPa). ing-2 solenoids to pressurize the internal storage vessel. Evacuation re. condition. achieve the same vacuum readings at sea level. The vacuum pump will continue to run solenoid will reopen to attempt transfer of the refrig- for a specified default time period of three minutes. The vacuum pump will also remove the During the high side charging mode the charge excess air from the system. erant for a second time. Vacuum is will run for 15 seconds to build pressure within the pulled from the high and low sides of the vehicles internal storage vessel. The default can be ant in the system will boil due to the low vacuum changed and reprogrammed for other weights.000 feet (305 meters) of elevation the value Charging refrigerant into the vehicles high side is will be approximately 1" Hg (3. During the power charge mode the high or vacuum pump begins to run. General Information ACR2000 Refrigerant Service Solution Evacuation/Vacuum Charging The air conditioning system must be evacuated After the evacuation/vacuum procedure and the whenever the system is serviced.4 kPa) higher. Charging into the example. it important that the change elevation setting from the Set-Up Menu is reviewed and The ACR2000 will use the power charge and clear- properly adjusted. If the full transfer of refriger- The default vacuum time is adjustable. The default of 2.00 lbs. pressure measured in inches of mercury (" Hg) does not satisfy the preset value. ant can not be completed the pressure build procedure will be repeated four times before the unit shuts If at the end of the vacuum time limit the vacuum down and notifies the operator. system has proven to hold vacuum. For a default pre-programmed setting. When the system is Menu. the ACR2000 will enter the power charge (normally open) solenoid will close after the mode. will be shown on the screen. At or near sea level the solenoid will open to allow flow of liquid refrigerant vacuum pump can achieve an approximate value of from the Internal Storage Vessel (ISV) to the high 28" Hg (94.8 kPa). Be sure the hoses are disconnected from the vehicle and the service couplers are closed. The high or low side charge A/C system. charging may moves the air and moisture from the system by begin. For each 1.91 kg) of refrigerant pulled to a vacuum the excess moisture and refriger. (. For grammed during the charge mode. the display will prompt the user to recover the refrigerant that remains in the hoses. The free air solenoid low side inlet solenoid will close and the compressor eases the start-up of the vacuum pump. the free air refrigerant. If pressures do not allow full transfer of the When the vacuum mode is requested. 10 . the vacuum It is important the proper charge setting is pro- pump will continue to run for 10 more minutes.27 low side charge and following the screen prompts. this reason. power Casters cords. grates Side View High Side and Low Side Convenient Handle Hoses with Field for moving unit Service Couplers. inverted) Tank Strap to secure tank to unit Shelf for Source Tank source tank Hose 11 .ACR2000 Refrigerant Service Solution General Information ACR2000 VIEWS Front View "Cycle Complete" Red Indicator Light Control Panel Convenient Built-in Handle and Hose Storage Shelf for tools and accessories Filter-Drier Access Polypropylene Oil Drain Bottle Cabinet for durability and light weight Large Wheels for mobility across Locking air lines. color coded Power Cord Oil Drain Source Tank Bottle (disposable. The function keys (F1-F5) change depending on service operation and unit status. Numeric Keys Refrigerant Identifier Filter Used to input numerical values. Low Side High Side Gauge Gauge Display Function Keys Numeric Keys Main Power Switch Refrigerant Arrow Display Contrast Identifier Filter Printer Keys Keys 12 . pressing “Up” will increase the num- Function Keys ber. screen. vice maintenance tasks. General Information ACR2000 Refrigerant Service Solution OPERATING GUIDELINES ACR2000 Control Panel Low Side Gauge Main Power Switch Shows the A/C system’s low side pressure. Moves the cursor on the screen in that direction (Up. If this filter begins to turn red. vacuum levels. Prints the snapshot information displayed on the ing to their corresponding keys. sensor. Supplies electrical power to the unit. pressing “Down” will decrease the number. Used to increase or decrease the display contrast. replace it immediately. The function Printer choices are listed at the bottom of the display point. change evacuation Inlet filter used to protect the refrigerant identifier time. during numeric programming. High Side Gauge Display Contrast Keys Shows the A/C system’s high side pressure. or Left). Right. Display Arrow Keys Shows options and gives instructions for most ser. Down. Additionally. or recharge weight. Contact with refrigerant can cause eye injury. Unit is NOT Functional 1. Any remaining “high side” pressure will need 4. Open the filter access door and remove cap to port cap. be sure to close the service service clear mode from the Service Diagnostic valves on the Internal Storage Vessel (is so equipped) Menu before any service or component replacement and source tank before disconnecting lines or removing is performed. The auxiliary unit will from the vehicle. 13 . 5.ACR2000 Refrigerant Service Solution General Information DEPRESSURIZING THE UNIT WARNING: Always wear safety goggles when working with refrigerants. Remove the separate recovery unit from the compressor service port and reinstall service 3. Make sure both service couplers are closed. Verify the unit is “OFF” and unplugged. Connect the high and low shut off when the refrigerant from the low side side hose service couplers to their respective is recovered. Disconnect lines and hoses with extreme caution! Pressurized refrigerant may be present in lines and hoses. storage couplers on the unit. Start the auxiliary recovery unit and allow it to recover refrigerant from the low side of the 2. 6. WARNING: Always unplug the station from the power source before removing any of the shroud- ing or beginning any service work. components. Always point lines and hoses away from you and anyone nearby. Unit is Functional Refrigerant must be internally recovered by using the After the service clear. Connect a separate auxiliary recovery unit to to be slowly bled off as components are re- the compressor service port. compressor service port. Disconnect the high and low side service hoses unit being serviced. 4. moved or accessed. 55 CU IN Capacity (BTU/HR): 5821 Oil Charge Capacity (Initial/Recharge): 13./7. (25 ft.4 in.38 cm Unit Depth: 22. or less) 14 .382 psig Design Pressure: Low .15.02 cm Unit Width: 34.34 kg Unit Height: 50.8 oz (400 cc/350 cc) POE Oil Type: 150 Viscosity Vacuum Pump (Thomas) Volts: 115V * Frequency: 60 Hz Running Amps: 4. Extension cords must be a minimum of 14 AWG and kept as short as possible.1 in.171 psig Storage Temperature Range: 0 to 140°F/ -18 to 60°C Operating Temperature Range: 35 to 120°F/ 2 to 49°C Tank Weight (empty): 17 lbs.0A R-134a Automotive Refrigerant Refrigerants: 98 Class III.5A Locked Rotor Amps: 30.5 oz/11. ARI 98 Class IV High .0A .3 oz (300 cc/275 cc) POE Oil Type: 150 Viscosity Hermetic Compressor (Cubigel) Volts: 115V * Frequency: 60 Hz Running Amps: 8.0A Speed: 3500 RPM Capacity (BTU/HR): 5054 Oil Charge Capacity (Initial/Recharge): 10. General Information ACR2000 Refrigerant Service Solution UNIT SPECIFICATIONS ACR2000 Unit .4A Locked Rotor Amps: 30.13 cm UL Certified Certified: SAE-J-1770 Hermetic Compressor (Americold) Volts: 115V * Frequency: 60 Hz Running Amps: 8./56./87.1 oz/9.6 m.4 in.0A Horsepower: 1/3 HP Speed: 1690 RPM Capacitor: 15 mfd @370V AC 50/60 Hz * The voltage at the unit must be ±10% of the unit's rated voltage.General Information Volts: 115V * Frequency: 60 Hz Amps: 12.0A Displacement: ./128./6.7A Locked Rotor Amps: 14. (342000) E very 10 hours of operation A fter rec overing 300 lbs . refrigerant or after rec overing refrigerant from a burned-out s y s tem . the ACR2000 requires regular maintenance to guarantee safe operation and optimum performance. Lubric ate M onthly bearings and brak e c om ponents if nec es s ary . Ins pec t hos es and power c ord for c uts and abras ions . M onthly Clean (vac uum ) c ondens er panel. 15 . Chec k S c ale. M onthly Chec k c as ters and wheels for proper operation. Daily Due to normal wear and tear. The following chart provides a schedule of the recommended maintenance tasks.ACR2000 Refrigerant Service Solution General Information MAINTENANCE SCHEDULE Te st Re quire d Re com m e nde d Fre que ncy Change vac uum pum p oil.36 k g) of Change the Filter/Drier. M onthly Clean c abinet and c ontrol panel. M onthly Chec k for Leak s . (136. General Information ACR2000 Refrigerant Service Solution NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 16 . ........................................ 38 Check Valves Used in the ACR2000 ...................... 32 Keypad & Bezel Assembly ........................................................................................... 23 Upper Manifold Block Assembly .......................................................................................................................................................... 31 Vacuum Pump Assembly ....... 40 Solenoids Used in the ACR2000 ....................................................... 35 Condenser Assembly ............................ 22 Base Assembly .................................................................................................................. 26 Internal Tank Assembly (New Style) ...................................... 38 Major Parts & Components Illustrated in Diagrams ....................... 41 Alphabetical Parts List .................................................................................................................. 30 Compressor (Cubigel) ....................................................... 20 Component Assemblies .............. 37 Component Descriptions ...................................................................... 17 .............. 42 Disclosure: Although most parts are listed............................................................. 18 Component Locations ......................................................................................................................................................... some part numbers are part of an assembly available only to manufacturing.......... 33 Neutronics Identifier Module ................... 34 Thermal Printer Assembly .. Information and part numbers contained in this publication were accurate at the time it was written.....................ACR2000 Refrigerant Service Solution 2 PARTS & COMPONENTS Plumbing Diagram & Parts List .................. 22 Control Panel ..................................................................................................................................................................................................................... 28 Internal Tank Assembly (Old Style) ............................................ 24 Oil Drain Manifold Assembly ............................................................................................................................................................. 36 Scale Assembly ...................................................................... Any discrepancies should be brought to the attention of Robinair Technical Support........................................................................... 29 Compressor (Americold) ................................................................................................................................................................................................................................................................................................................................................ Parts & Components ACR2000 Refrigerant Service Solution PLUMBING DIAGRAM IDENTIFIER LOW SIDE HIGH SIDE GAUGE GAUGE VACUUM PUMP P Q S R D E HIGH SIDE SERVICE HOSE LOW SIDE SERVICE HOSE F M CONDENSER INTERNAL STORAGE VESSEL N CV12+13 W C V K J A B X O TO SUPPLY TANK I T OIL DRAIN BOTTLE U H TEST G FITTING L Y Z COMPRESSOR NOTE: See following page for the plumbing diagram parts list. 18 . NYLON 1/8 OD X .070 ID REF 121583 U 121633 1 TUBE. OIL DRAIN V 111858 1 TEE. COMPRESSOR PROCESS (CUBIGEL) H 121624 1 TUBE. CONDENSER TO TANK O 123026 1 TUBE. TEE. 1/8 NPTF (FEMALE) W RA19504 2 CHECK VALVE. 1 TUBE. COMPRESSOR SUCTION (AMERICOLD) I 515982 1 TUBE. COMPRESSOR PROCESS (AMERICOLD) G 515980 1 TUBE. ISV & RECOVERY FEEDBACK X 119984 1 ELBOW. Description A RA19638 1 HOSE. ISV VAPOR (NEW STYLE ISV) B RA19637 1 HOSE.070 ID REF 121583 S --. ISV AIR PURGE (NEW STYLE ISV) E 121621 1 TUBE. NYLON 1/8 OD X .ACR2000 Refrigerant Service Solution Parts & Components PLUMBING DIAGRAM PARTS LIST No. LOW SIDE INLET G 121623 1 TUBE. NYLON 1/8 OD X .070 ID REF 121583 R --. COMPRESSOR DISCHARGE (AMERICOLD) H 515981 1 TUBE. COMPRESSOR SUCTION (CUBIGEL) J 123025 1 TUBE. 1 TUBE. HIGH SIDE INLET F 121622 1 TUBE. Qty. SOURCE TANK FILL C RA19636 1 HOSE.070 ID REF 121583 T --. 1 TUBE. COMPRESSOR DISCHARGE (CUBIGEL) I 121625 1 TUBE. BACKGROUND TANK FILL P 120165 21" TUBING. ISV LIQUID SUPPLY (OLD STYLE ISV) C 123628 1 HOSE. SYSTEM OIL DRAIN M 122613 1 TUBE. ISV LIQUID SUPPLY (NEW STYLE ISV) D RA19635 1 HOSE. 3/8" OD BLOCK TO PUMP Q --. OIL RETURN L 121628 1 TUBE. 1/8 MP X 1/4 O-RING Y 103383 1 VALVE CORE Z 740569 1 CAP 19 . 1 TUBE. NYLON 1/8 OD X . BLOCK TO BLOCK K 122614 1 TUBE. ISV VAPOR (OLD STYLE ISV) A 123627 1 HOSE. ISV AIR PURGE (OLD STYLE ISV) D 123629 1 HOSE. Part No. HIGH SIDE TO CONDENSER N 123023 1 TUBE. LOGO 121586 17 FRONT PANEL 121573 18 TANK FILL HOSE RA19637 19 STRAP VELCRO 121925 20 PANEL. CONDENSER 122094 20 .THOMAS RA19610 6 INTERNAL TANK ASSEMBLY RA19798 7 COMPRESSOR ASSEMBLY RA19865 8 VACUUM PUMP SHELF 122260 9 CENTER DIVIDER 122259 10 SCALE ASSEMBLY RA19603 11 OIL DRAIN BOTTLE 17756 12 CONDENSER ASSEMBLY RA19615 13 CONTROL PANEL SUPPORT 122268 14 UNIT TOP 121576 15 AC BULKHEAD BRACKET 121667 16 DECAL. Description Part No. Parts & Components ACR2000 Refrigerant Service Solution COMPONENT LOCATIONS 14 1 25 5 13 15 24 23 16 22 12 17 8 21 11 9 20 18 19 6 10 BASIC UNIT COMPONENTS No. 1 CONTROL PANEL ---------- 2 BASE ASSEMBLY 122206 3 UPPER MANIFOLD BLOCK ASSEMBLY RA19600 4 OIL DRAIN MANIFOLD ASSEMBLY RA19601 5 VACUUM PUMP . 21 REAR DOOR 121575 22 POWER CORD RA19641 23 POWER CORD BRACKET 121909 24 DECAL. GM REPAIR 122080 26 SEAL. Description Part No. UL 122093 21 . 15 AMP RA17549 38 BREAKER. ANALOG INPUT 121830 40 DECAL.ACR2000 Refrigerant Service Solution Parts & Components 26 28 27 38 37 29 39 36 30 35 34 40 3 4 31 33 32 2 7 BASIC UNIT COMPONENTS No. COMPRESSOR (AMERICOLDI) 121875 31 CAPACITOR. SERVICE HOSES 121426 25 DECAL. 3 AMP RA17548 39 DECAL. LAMP 121778 27 LIGHT KIT RA19647 28 CONTROL MODULE/BOARD RA19606A 29 RELAY BOARD RA19602 30 SIDE SUPPORT 121574 31 CAPACITOR. COMPRESSOR (CUBIGEL) 517112 32 FAN 115V RA17416 33 DOOR LATCH KIT RA19632 34 AMBIENT BOARD RA19609 35 POWER SUPPLY RA19642 36 ANALOG INPUT BOARD RA19605 37 BREAKER. LOW SIDE RA19614 3 GAUBE. Description Part No. Parts & Components ACR2000 Refrigerant Service Solution COMPONENT ASSEMBLIES CONTROL PANEL 2 3 4 5 6 7 1 8 9 CONTROL PANEL ASSEMBLY No. 1 IDENTIFIER RA19604A 2 GAUGE. CONTROL PANEL RA19660 5 RAIN SHIELD 121780 6 PRINTER. ON/OFF RA19343 * Printer Paper Part Number – 34215 22 . THERMAL * RA19611 7 BEZEL 121677 8 KEYPAD & BEZEL ASSEMBLY RA19644 9 SWITCH. HIGH SIDE RA19613 4 OVERLAY. 1/4 X 1" PLASTITE 121110 23 . 1/2" ID FLAT 102755 5 COTTER PIN 100723 6 AXLE 121591 7 CASTER. X 2" WIDE RA19631 8 SCREW. 5" DIA. PNEUMATIC 10" 19676 4 WASHER.ACR2000 Refrigerant Service Solution Parts & Components BASE ASSEMBLY 122206 1 2 3 4 6 5 7 8 BASE ASSEMBLY No. Description Part No. 1 BASE 121572 2 BUSHING. WHEEL 121782 3 WHEEL. Parts & Components ACR2000 Refrigerant Service Solution UPPER MANIFOLD BLOCK ASSEMBLY RA19600 19 25 5x 26 2x 17 18 15 14 16 27 2 8 3x 11 2x 4 3 5 11 13 1 6 12 24 24 . Description Part No. 2 TOP BLOCK. MACHINED * 121758 1 INLET TEST SOLENOID RA19258 3 ID BLOCK. 1/8OD X .O. 1/8 MP X O-RING SEAL 119984 10 VACUUM SOLENOID RA19258 12 BRACKET. Sol.ACR2000 Refrigerant Service Solution Parts & Components 10 23 3x 27 29 CV7 28 CV5 27 7 3x 5 12 3 8 CV3 9 20 2 7 11 CV2 27 11 4 CV1 11 21 27 1 6 10 19 14 11 13 9 15 22 27 27 27 28 CV4 UPPER MANIFOLD BLOCK ASSEMBLY SOLENOID IDENTIFICATION No. 1/4 .20 X 2. 1 BOTTOM BLOCK.25" NA 18 BRACKET. Description Part No. SOLENOID NA Check Description Part No. 1/8 MP X 1/8 PNEUMATIC 121771 7 LOW SIDE CHARGE SOLENOID RA19258 9 LOW SIDE PRESSURE TRANSDUCER RA19640 8 HIGH SIDE CHARGE SOLENOID RA19258 10 HI SIDE PRESSURE TRANSDUCER RA19633 9 FREE AIR SOLENOID (N. MACHINED * 121757 2 LOW SIDE INLET SOLENOID RA19258 4 LIQ/VAC BLOCK. MACHINED * 121756 No. 1/4 NPT NA CV3 HIGH SIDE CHARGE CHECK VALVE RA19871 27 CUPPLUG 123067 CV4 FILTER/VACUUM CHECK VALVE RA19645 28 CHECK VALVE RA19645 CV5 CLEARING CHECK VALVE RA19645 29 CHECK VALVE RA19282 CV7 DISCHARGE CHECK VALVE RA19282 * Not Sold Separately 25 .75ID 121773 6 FILTER/VACUUM SOLENOID RA19258 8 FITTING.) RA19648 11 ELBOW.O. MANIFOLD LEFT 121683 19 EXPANSION VALVE RA19550 20 VACUUM SWITCH 13" RA18752 21 PRESSURE SWITCH INDENTIFIER RA19634 CHECK VALVE IDENTIFICATION 22 HEX PLUG FOR N. MANIFOLD RIGHT 121682 11 PRESSURE FEEDBACK SOLENOID RA19258 13 ELBOW . 23 CHECK VALVE RA19871 Valve # 24 SCREW. 1/4-20 x 2" NA CV2 LOW SIDE CHARGE CHECK VALVE RA19871 26 PIPE PLUG. 1/8MP X O-RING SEAL 119983 5 CLEARING 1 SOLENOID RA19258 7 BLACK NYLON TUBE.SWIVEL (PARKER) 12 POWER CHARGE SOLENOID RA19258 14 FILTER DRIER. 1/4-20 x 5/8" NA CV1 INLET CHECK VALVE RA19871 25 SCREW. SPIN ON 34724 13 ID/AIR PURGE SOLENOID RA19258 15 COMP OIL SEPARATOR ASSY NA 14 TANK TEST SOLENOID RA19258 16 SYSTEM OIL SEPARATOR ASSY NA 15 OIL RETURN SOLENOID RA19258 17 SCREW. MACHINED * 121759 3 HIGH SIDE INLET SOLENOID RA19258 5 IDENTIFIER OIL SEPARATOR RA19657 4 RECOVER SOLENOID RA19258 6 UNION. as part of the debris control change implemented mid-production. For additional information. Parts & Components ACR2000 Refrigerant Service Solution OIL DRAIN MANIFOLD ASSEMBLY RA19601 1 16 15 CV8 17 13 2 3 2x 19 18 16 4 28 CV10 14 2x SEE NOTE 18 19 NOTE: Check Valve CV10 was removed. and the pasage plugged. refer to Service Bulletin # 0149 26 . Refer to 19 SCREW PLUG 123005 Service Bulletin # 0149 20 LABEL NA * Not Sold Separately 27 .ACR2000 Refrigerant Service Solution Parts & Components 10 9 CV11 5 11 20 4 8 7 17 CV9 9 6 12 2 OIL DRAIN MAINIFOLD ASSEMBLY SOLENOID IDENTIFICATION No. Description Part No. HIGH PRESSURE CUTOUT RA19427 Description Part No. as part of the debris control 18 COIL. 2 ELBOW.042. 1/8MP x 1/8FP x 1/8FP 116420 CV8 OIL DRAIN CHECK VALVE RA19282 12 BRACKET. 1/8FP x 1/8 PNEUMATIC 121772 † Check Valve (CV10) was removed. Description Part No. Sol. 1/8NPT x O-RING SEAL 119984 16 TANK FILL SOLENOID RA19258 3 HEX CAP FOR N. 1/8MP x 1/8FP 111161 CHECKVALVE IDENTIFICATION 9 CHECK VALVE RA19504 Check 10 SWITCH.O. FIG 123066 pasage plugged. 1/8 OD (24" LONG) 121773 No. . HARNESS ASSEMBLY 123063 change implemented mid-production. OIL DRAIN RA19297 CV10 INITIAL FILL CHECK VALVE † ------------- 14 SCREW. 1/4-20 x 3/8" (TAPTITE) 123062 CV11 TANK FILL CHECK VALVE RA19504 15 CHECK VALVE RA19282 16 ELBOW. OIL DRAIN 121669 CV9 ID DRAIN CHECK VALVE RA19504 13 SWITCH. OIL DRAIN * 123020 19 CLEARING 2 SOLENOID 123060 6 ORIFICE UNION. 1 BLACK NYLON TUBE. 1/4MP x 1/8FP 110392 8 ELBOW. OIL DRAIN 121312 7 ADAPTER. and the 17 POLYTITE. SOLENOID 123061 17 ID DRAIN SOLENOID RA19648 4 CUPPLUG 123067 18 OIL DRAIN SOLENOID RA19258 5 MANIFOLD BLOCK. Valve # 11 TEE. ISV LIQUID SUPPLY 123628 HOSE. INTERNAL STORAGE VESSEL HOSES HOSE. 450 PSI RA19499 4 QUICK SEAL. Description Part No.30 lbs. ISV AIR PURGE 123629 HOSE. 1 INTERNAL TANK. 1/4 FL X 1/4NPT 123610 5 SCREEN. 1/4MP x 1/4FP x 1/4FP 121719 3 PRESSURE RELIEF. Parts & Components ACR2000 Refrigerant Service Solution INTERNAL TANK ASSEMBLY (New Style) RA19798 4 4 4 2 5 3 Air Purge Liquid Vapor 1 Tank Tare Weight = 16. UNIVERSAL 121837 2 TEE. BRASS SOLENOID 107021 28 . ISV VAPOR 123627 INTERNAL TANK ASSEMBLY No. ACR2000 Refrigerant Service Solution Parts & Components INTERNAL TANK ASSEMBLY (Old Style) RA19612 INTERNAL STORAGE VESSEL HOSES HOSE. Description Part No. 1/8 MP X 1/8 MP 112870 7 TANK. HOSE.50 lbs. ISV AIR PURGE RA19635 HOSE. 1/4 MPT X 1/8 FPT 110392 2 TEE.2WAY 117470 4 NIPPLE HEX PIPE .(1/8 NPTF) 101307 5 RELIEF VALVE. UNIVERSAL INTERNAL 121837 29 . 450 PSI RA19499 6 ELBOW. 1/8MP X 1/8FP X 1/8FP 116420 3 BALL VALVE . ISV VAPOR RA19638 INTERNAL TANK ASSEMBLY No. ISV LIQUID SUPPLY RA19636 Tank Tare Weight = 17. 1 ADAPTER. Parts & Components ACR2000 Refrigerant Service Solution AMERICOLD COMPRESSOR (Discontinued) RA19458 (110V) RA19457 (220V) Oil Return (Intake) Suction Discharge Compressor Electrical Box Oil Return (Intake) Suction Discharge 30 . Use this kit if you are replacing the Americold compressor with the newer style Cubigel compressor.ACR2000 Refrigerant Service Solution Parts & Components CUBIGEL COMPRESSOR (New Style) * RA19865 (110V) RA19868 (220V) Discharge Suction Oil Return (Intake) Oil Return (Intake) Suction Discharge * RA19853 (ACR2000 CUBIGEL COMPRESSOR UPGRADE KIT) . 31 . 1/4MP x 3. Parts & Components ACR2000 Refrigerant Service Solution VACUUM PUMP ASSEMBLY RA19610A 2 NOTE: Vacuum Pump As- sembly (RA19610). does NOT include the rubber mounts (feet) and the bolts to attach rubber mounts to pump assembly. Description Part No. RUBBER (Not Included) 117502 32 . 1 VACUUM PUMP THOMAS RA19610 2 ELBOW. 1 3 4 VACUUM PUMP ASSEMBLY No.8 PNEUMATICS 3 BOLT. 1/4-20 FLANGED (Not Included) 119105 4 FOOT. 1 BEZEL * 121677 2 KEYPAD * 121668 * Not Sold Separately 33 .ACR2000 Refrigerant Service Solution Parts & Components KEYPAD & BEZEL ASSEMBLY RA19644 1 2 BEZEL & KEYPAD ASSEMBLY No. Description Part No. Parts & Components ACR2000 Refrigerant Service Solution NEUTRONICS ACR2000 IDENTIFIER MODULE RA19604 FLOW ID OIL FILTER – P/N 16912 34 . 3A.ACR2000 Refrigerant Service Solution Parts & Components THERMAL PRINTER ASSEMBLY RA19611 Model: FT190-T3 Power Supply: 5V DC.34215 35 . 5Apk Interface: RS232 Printer Paper: P/N . Parts & Components ACR2000 Refrigerant Service Solution CONDENSER ASSEMBLY RA19615 CONDENSER COIL ASSEMBLY No. 1 CONDENSER COIL 121589 2 ELBOW. Description Part No. SOLDER X 1/4" O-RING 120253 36 . 3 Ohms Insulation Resistance: >2000M Ohm 37 .15 Ohms Output: 350 +/.0 mV +/-10% Zero Balance: +3%/-0% of RO Temperature Range (Safe): -30°C to +70°C Temperature Range (Op): +10°C to +50°C Electrical: Recommended Excitation: 10 VAC or VDC Maximum Excitation: 15 VAC or VDC Impedance: Input: 415 +/.ACR2000 Refrigerant Service Solution Parts & Components SCALE ASSEMBLY RA19603 SPECIFICATIONS Rated Capacity (RC): 35 Kg Rated Output (RO): 2. into the system oil separator. GAUGE. sample. CONTROL PANEL OVERLAY — Affixed to control panel sheet metal. the overlay is used to identify BASE — Molded base for the ACR2000 unit. the refrigerant from the A/C system being serviced into the internal tank on the unit. HIGH SIDE — Monitor high-side pressure of COMPRESSOR OIL SEPARATOR — Removes the the vehicle being serviced. The allowable tolerance of the valve is 35 ± 5 psi (241 ± 34 kPa). Panel also acts as a ventilation grid for the ID OIL FILTER — Removes oil from the refrigerant condenser. current demand required by the compressor on start-up. COMPRESSOR CAPACITOR — Used to start the hermetic compressor. Also divides the ISV side of the unit from the manifold side. FAN. and controls. BREAKER. 38 . GAUGE. and axle. BREAKER. and door latch receptacle. FOOT. wheels. retainer. CONTROL/DISPLAY MODULE — Front display panel ID OIL SEPARATOR — Prevents oil from entering ID and main control of the ACR2000. 115V — Keeps the hermetic compressor’s CENTER DIVIDER — Used to support most of the electrical components cool. components within the ACR2000. CASTER — 5” x 2” wheels used for maneuvering unit. CONTROL PANEL SUPPORT — Sheet metal bracket containing casters. unit. used for supporting the control panel assembly. 3 AMP — Protects the unit from drawing to EXPANSION VALVE —Meters the flow of refrigerant much current. SPIN-ON — Used to remove moisture and particles from refrigerant. HIGH PRESSURE CUTOUT SWITCH — Switch opens CONDENSER — Turns vapor refrigerant to liquid at 435 ± 10 psi (2999 ± 69 kPa) and resets at 320 ± 20 psi refrigerant for delivery to the Internal Storage Vessel (2066 ± 137 kPa). the switch opens stopping all functions. system exceeds 435 psi (2999 kPa). 15 AMP — Protects the unit from drawing DOOR LATCH KIT — Used to replace spring-loaded to much current. recharging. FILTER DRIER. If pressure in the high side of the (ISV). latch. Helps reduce the initial high FRONT PANEL — ACR2000 molded front door panel. CONDENSER PANEL — Condenser assembly mounts to this panel. Parts & Components ACR2000 Refrigerant Service Solution COMPONENT DESCRIPTIONS Major Parts and Components Illustrated in Diagrams AXLE — Used to mount 10” pneumatic wheels. CONTROL PANEL ASSEMBLY — User interface panel INLET SCREEN — Replacement in-line disc screen for controlling refrigerant recovery. BASE ASSEMBLY — ACR2000 base assembly. VIBRATION MOUNT — Used to reduce excessive pump vibration. The stored oil is returned to the compres. gauges. displays. compressor oil from the refrigerant that is leaving the compressor. power. recycling and filter for copper tubing. LOW SIDE — Monitors low-side pressure of sor when the oil return/equalization solenoid receives the vehicle being serviced. Should be changed every COMPRESSOR — 1/3 HP Hermetic compressor moves time 150 lbs of refrigerant is recovered. PCBA. Stops recovery at 13 psi. The analog board is where the external IDENTIFIER — Samples refrigerant for air content. HI SIDE — Measures the OIL DRAIN SWITCH — The pressure feedback pressure of incoming refrigerant from the high side of a solenoid opens to supply refrigerant pressure to the system. check valves safety valve use to releases pressure from internal tank and switches. LOW SIDE — Measures pressure and expel the stored oil from the bottom of the the pressure of incoming refrigerant from the low side of accumulator. AMBIENT — Circuit board that measures ISV CHECK VALVE — Prevents the vapor from the top temperature and humidity. The switch will reset at 27 ± 3 psi block assembly that contains solenoids. is also on the analog board. The oil drain switch reads the pressure and control/display board. · 12 volts to the identifier Vapor. RELAY — Relay Control for ACR2000. liquid. PRESSURE TRANSDUCER. The oil drain solenoid opens to relieve the PRESSURE TRANSDUCER. based on pressure. Pressure readings are then relayed to the accumulator. IDENTIFIER — This normally OIL DRAIN BOTTLE — Recovers the used oil during closed switch will cause the inlet test solenoid to close the oil drain process. of the ISV from returning to the condenser when the compressor shuts off. 450 PSI — Spring loaded block assembly that contains solenoids. At 9 psi (62 kPa) the oil drain solenoid a system. cord to unit. The switch controls flow of refriger- OIL DRAIN MANIFOLD ASSEMBLY — Lower internal ant to the identifier. sensors are connected. LAMP SEAL — Used to provide a seal between the lamp assembly and unit top cover. closes the pressure feedback solenoid at 16 psi (110 kPa). The RS-232 communication port contaminants and refrigerant type. internal components. POWER SUPPLY — Controls voltage to the entering ID unit. POWER CORD — Supplies main power to the unit. The oil drain solenoid will open and close control board. UPPER — Internal PRESSURE RELIEF VALVE. PRESSURE SWITCH. LIGHT KIT — Used to inform the operator when a cycle POWER CORD BRACKET — Used to secure power has been completed. check valves (276 ± 21 kPa). assembly for proper distribution. IDENTIFIER OIL SEPARATOR — Prevents oil from PCBA. and air purge access is on-top of tank. 39 . INTERNAL STORAGE VESSEL (ISV) — Storage tank · 5 volts to the printer that the recovered and recycled refrigerant is stored. ANALOG INPUT — Located on the top rear of the ACR2000. PCBA. MANIFOLD BLOCK ASSEMBLY. · 12 and 110 volts to the relay board · 12 and 24 volts to the control board (display panel) KEYPAD — Touch-pad cover for the front of the · 5 volts to the transducers from the control board control board. and switches. purge device during recycling. Also determines if recovery is needed several times. UNION— Fitting used to reduce the flow at the top of the ISV to enter the lower cavity of the air rate. Pressure readings are then relayed to the closes. if the pressure of the sampled refrigerant is above 40 ± 3 psi (276 ± 21 kPa). PCBA.ACR2000 Refrigerant Service Solution Parts & Components ISV AIR PURGE HOSE — Allows air pressure trapped ORIFICE. Many of the circuits operate on reduced voltage. Refrigerant will pass through the manifold assembly if pressure exceeds 450 psi. and during evacuation. INITIAL FILL (CV10) — Mounted in- ± 3" Hg (10 ± 10 kPa) If the vacuum at the inlet is greater side oil drain block. between tee and tube “N” to condenser.) clear process. CHECK VALVE. CHECK VALVE. refrigerant from opening the charge solenoid and entering the liquid side of the ISV. SIDE SUPPORT — ACR2000 molded side support CHECK VALVE. This process prevents liquid direction only. VACUUM PUMP — 110V oilless pump designed to remove moisture and air from an A/C system. CHECK VALVE. DISCHARGE (CV7) — Mounted causing saturated vapor and accumulated liquid inside the compressor oil separator. tion displayed on the screen. CLEARING (CV5) — Installed in end panel. CAR TEST (CV6) — Trapped between top and ID blocks. ing the filter vacuum solenoid during normal operations. CHECK VALVE. and the than 13" Hg (44 kpa). recovery. Internal Storage Vessel. (NOTE: This was removed. CHECK VALVE. Prevents incoming refrigerant from open- refrigerant being charged and recovered. 40 . as part of the debris control change implemented mid-production. SWITCH ON/OFF — Allows the unit to be turned ON and OFF. into the low side of the unit when the equalization/oil return solenoid opens to return compressor oil and TANK FILL HOSE — Attached to the external supply repressurize the system oil separator. OIL DRAIN (CV8) — Mounted to hole- UNIT TOP — Molded top cover for the ACR2000 unit. ISV (CV13) — Inline. the switch opens and stops the passage plugged. from returning to condenser when compressor shuts off. CHECK VALVE. Parts & Components ACR2000 Refrigerant Service Solution Check Valves Used in the ACR2000 PRINTER. INLET (CV1) — Mounted in top block. CHECK VALVE. ing tank hoses to the ISV. Prevents incoming rain and moisture. PNEUMATIC 10” — Transport wheels. tank. Check valve stops outside air pressure from entering the oil drain. THERMAL — Prints the snapshot informa. 1 on the oil drain block. RECOVERY FEEDBACK (CV12) — In- line. during recycling. FILTER VACUUM (CV4) — Installed in SCALE ASSEMBLY — Measures the amount of end of top block. CHECK VALVE. Allows flow in one direction only. ID DRAIN (CV9) — Mounted to hole-7 on the oil drain block. Prevents refrigerant and pressure from refrigerant from entering the compressor and separates the Internal Storage Vessel (ISV) being equalized back the refrigerant oil. used primarily for mounting the pump assembly. Prevents vapor from top of ISV WHEEL. Allows flow in one refrigerants to evaporate. VELCRO STRAP — Used for securing the external tank. CHECK VALVE. TANK FILL (CV11) — Mounted to hole- VACUUM PUMP SHELF — Located just above the 9 on the back of the oil drain block. SYSTEM OIL SEPARATOR — Heat exchanger with high-side coils that provide internal heat to the canister CHECK VALVE. of top block. LOW & HIGH SIDE CHARGE (CV2 RAIN SHIELD — Protects the printer assembly from & CV3) — Mounted in top block. Prevents refrigerant from escaping after QUICK SEAL 1/4 FL X 1/4 NPT — Used for connect. between tee and tube “O” to the oil drain block. towards the recovery solenoid. REAR DOOR — ACR2000 molded rear door panel. VACUUM SWITCH 13” — Normally closed sensor that opens at 13 ± 3" Hg (44 ± 10 kPa) vacuum and resets at 3 CHECK VALVE. Prevents the discharged pressure from the compressor from entering the clearing capillary tube. The solenoid will open after CLEARING 2 SOLENOID (19) — Without power. The solenoid should maintain power for indicate an empty external supply tank. of refrigerant into ISV from the external supply tank. The sole. charge and the compressor oil separator. ID/AIR PURGE SOLENOID (13) — Opens when the ID pling process. TANK FILL SOLENOID (16) — Solenoid opens dur- HIGH SIDE CHARGE SOLENOID (8) — Allows re. Allows flow from the system to the vacuum pump when powered. OIL DRAIN SOLENOID (18) — Solenoid opens during the oil drain sequence. The tank fill solenoid will close if there is This process allows the vacuum pump to start with free a reading of 13" Hg (44 kPa). When the compressor to recover the high side of the machine. It controls the flow frigerant from ISV to enter the vehicle. 41 . Allows the vacuum solenoid receives power for three seconds when the com- pump to draw a vacuum on the filter/drier after replace. POWER CHARGE SOLENOID (12) — Opens to re- circulate refrigerant to build pressure for power charging.44 kg). During the lator of oil when the oil drain solenoid opens. the solenoid receives power and opens noid is controlled by oil drain switch. pressor is de-energized. The solenoid opens during routine operation to refill the FREE AIR SOLENOID (9) — Normally open solenoid ISV and maintain a chargeable refrigerant weight of 12 receiving power one second after the vacuum pump starts. this recovery to apply refrigerant pressure into the accumula. self-clear cycle. (5. lowing sequence: erant from the high side of a system to enter the ACR • Two 5 minute intervals 2000 unit. LOW SIDE INLET SOLENOID (2) — Allows refrig. detects air in the ISV. • Four 15 minute intervals Air will be purged from the tank during this procedure. sure on the high and low side of the compressor. The ing the filter/drier change procedure. The solenoid is controlled by the identifier switch. erant into the vacuum pump. three way solenoid is open between the compressor dis- tor. If the pressure transducer reads 0 psi the sole- frigerant from ISV to enter the vehicle when low side noid will be energized for 3 seconds. eration. When powered. TANK TEST SOLENOID (14) — Opens when sam- erant from the low side of a system to enter the ACR2000 pling the ISV for contaminated refrigerant. lbs. The solenoid will again be energized for 3 seconds every 10 minutes of compressor op- LOW SIDE CHARGE SOLENOID (7) — Allows re. OIL RETURN/EQUALIZATION SOLENOID (15) CLEARING 1 SOLENOID (5) — Powered only during — Prevents flow of refrigerant from the high side of the the clearing cycle. powered. ing the automatic tank fill procedure. pressor is energized and for 20 seconds after the com- ment. The vacuum reading would air on the inlet. noid closes when identifier samples.ACR2000 Refrigerant Service Solution Parts & Components Solenoids Used in the ACR2000 INLET TEST SOLENOID (1) — Opens during the sam. it returns compressor oil from the compressor oil separator to the compressor and equalizes the pres- FILTER/VACUUM SOLENOID (6) — Powered dur. PRESSURE FEEDBACK SOLENOID (11) — Used during the oil drain function. erant into the system oil separator. ID DRAIN SOLENOID (17) — Normally open sole- VACUUM SOLENOID (10) — Prevents flow of refrig. RECOVER SOLENOID (4) — Prevents flow of refrig. the complete vacuum cycle. the tank test solenoid will open momentarily and sample the refrigerant in the fol- HIGH SIDE INLET SOLENOID (3) — Allows refrig. ACR2000 idle and powered. The refrigerant pressure is used to clear the accumu. With the unit. between the compressor and the clearing capillary tube. charge is manually selected. the solenoid allows unit back into the low side while not powered. Parts & Components ACR2000 Refrigerant Service Solution ALPHABETICAL PARTS LIST DESCRIPTION PART # NOTES AC POWER CORD RA19641 ADAPTER. 15 AMP RA17549 BREAKER. AC BULKHEAD 121667 BRACKET. 3 AMP RA17548 BULKHEAD. WHEEL 121782 CABLE. MANIFOLD LEFT 121683 BRACKET. CAPACITOR MOUNT 121876 BRACKET. IDENTIFIER 121644 BRACKET.25 ID 122256 BUSHING. PRINTER 121847 42 . 1/4MP X 1/8FP 110392 AMBIENT BOARD RA19609 ANALOG INPUT BOARD RA19605 AXLE. POWER CORD 121909 BRACKET. ANALOG BOARD 121656 BRACKET. OIL DRAIN MANIFOLD 121669 BRACKET. 2-WAY 117470 BASE ASSEMBLY 122206 BEZEL.68 OD X . OIL DRAIN 17756 BRACKET. RUBBER 1. IDENTIFIER 121645 BEZEL FOR KEYPAD & DISPLAY 121677 BOLT. 1/2 ACME X 1/8 NPT W/CORE 117235 BUMPER. 1/4-20 FLANGED (PUMP) 119105 BOTTLE. WHEEL 121591 BALL VALVE. STABILIZER 122421 BREAKER. MANIFOLD RIGHT 121682 BRACKET. HIGH SIDE CHARGE (CV3) RA19871 CHECK VALVE. ID OIL DRAIN 121633 CASTOR. AMERICOLD (220V) RA19457 Discontinued COMPRESSOR. DISCHARGE (CV7) RA19282 CHECK VALVE. Part of manifold assembly CHECK VALVE. OIL DRAIN (CV8) RA19282 CHECK VALVE. INITIAL FILL (CV10) ---------. CLEARING (CV5) RA19645 CHECK VALVE. QUICK SEAL 1/4” FLAIR (TEST FITTING) 740569 CAPACITOR. INLET (CV1) RA19871 CHECK VALVE. CAR TEST (CV6) ---------. Removed mid-production CHECK VALVE. CUBIGEL (110V) RA19865 COMPRESSOR. UL CIRCUIT 122030 CAP. ISV (CV13) RA19504 CHECK VALVE. X 2” WIDE RA19631 CENTER DIVIDER 122259 CHECK VALVE.ACR2000 Refrigerant Service Solution Parts & Components DESCRIPTION PART # NOTES CABLE. RECOVERY FEEDBACK (CV12) RA19504 CHECK VALVE. FILTER/VACUUM (CV4) RA19645 CHECK VALVE. 5” DIA. TANK FILL (CV11) RA19504 COMPRESSOR. AMERICOLD (110V) RA19458 Discontinued COMPRESSOR. CUBIGEL (220V) 516242 COMPRESSOR CAPACITOR 121875 COMPRESSOR OIL SEPARATOR ---------- 43 . COMPRESSOR 121875 CAPPLUG 123068 CAPTUBE. LOW SIDE CHARGE (CV2) RA19871 CHECK VALVE. ID DRAIN (CV9) RA19504 CHECK VALVE. SERVICE HOSES 121426 DECAL. LOGO ACR2000 121586 DECAL. Parts & Components ACR2000 Refrigerant Service Solution DESCRIPTION PART # NOTES COMPRESSOR UPGRADE KIT (FOR CUBIGEL) RA19853 CONDENSER ASSEMBLY RA19615 CONDENSER PANEL 122094 CONTROL MODULE PCBA RA19606A CONTROL PANEL OVERLAY RA19660 CONTROL PANEL SHEET METAL 122512 CONTROL PANEL SUPPORT 122268 CORE SCHRADER 103383 COTTER PIN (WHEEL) 100723 COUPLER. CAUTION MOVING PARTS 122234 DECAL. UL 122093 DOOR LATCH KIT RA19632 ELBOW. 1/8MP X 1/8FP 111161 ELBOW. RELAY BOARD 122214 CUPPLUG 123067 DECAL. ANALOG BOARD 122582 DECAL. ANALOG INPUT 121830 DECAL. 1/8MP X 1/8MP 112870 ELBOW. 1/8FP X 1/8FP 118974 ELBOW. 1/8MP X 1/4 O-RING SEAL 119984 EXPANSION VALVE RA19550 44 . OIL DRAIN RA19581 COVER. MALE. 1/8FP X 1/8 PNEUMATIC 121772 ELBOW. GM REPAIR 122080 DECAL. ISV LIQUID SUPPLY (NEW STYLE ISV) 123628 HOSE. COMPRESSOR 122278 HIGH PRESSURE CUTOUT SWITCH RA19427 HIGH SIDE PRESSURE TRANSDUCER RA19633 HIGH SIDE SERVICE COUPLER (R-134A) 18191A HOSE. SOURCE TANK FILL RA19637 ID OIL FILTER 16912 45 . ISV VAPOR (OLD STYLE ISV) RA19638 HOSE. ISV VAPOR (NEW STYLE ISV) 123627 HOSE. COMMUNICATIONS 122254 HARNESS. LOW SIDE (BLUE ENVIRO-GUARD) 62096 HOSE. ISV AIR PURGE (NEW STYLE ISV) 123629 HOSE. LOW SIDE RA19614 HARNESS. ISV AIR PURGE (OLD STYLE ISV) RA19635 HOSE. 1/8MP X 1/8 PNEUMATIC 121771 FOOT. HIGH SIDE (RED ENVIRO-GUARD) 63096 HOSE. HIGH SIDE RA19613 GAUGE. 5 AMP SLO BLOW 121513 GAUGE LENS RA19639 GAUGE. ISV LIQUID SUPPLY (OLD STYLE ISV) RA19636 HOSE. RUBBER (PUMP) 117502 FUSE HOLDER 1/4 X 1-1/4 122337 FUSE.ACR2000 Refrigerant Service Solution Parts & Components DESCRIPTION PART # NOTES FAN 115V RA17416 FILTER/DRIER SPIN-ON 34724 FILTER. ACR2000 121783 HARNESS. ID OIL 16912 FITTING. HOSE SCREEN RA19203 INTERNAL STORAGE VESSEL ASSY (NEW STYLE) RA19798 Requires new-style ISV hoses INTERNAL STORAGE VESSEL ASSY (OLD STYLE) RA19612 Requires old-style ISV hoses INTERNAL TANK (NEW OR OLD STYLE) 121837 ISV AIR PURGE HOSE (OLD STYLE ISV) RA19635 ISV AIR PURGE HOSE (NEW STYLE ISV) 123629 ISV LIQUID HOSE (OLD STYLE ISV) RA19636 ISV LIQUID HOSE (NEW STYLE ISV) 123628 ISV VAPOR HOSE (OLD STYLE ISV) RA19638 ISV VAPOR HOSE (NEW STYLE ISV) 123627 KEYPAD/BEZEL ASSEMBLY RA19644 LIGHT. OIL DRAIN RA19601 MANIFOLD BLOCK ASS’Y. RED. Parts & Components ACR2000 Refrigerant Service Solution DESCRIPTION PART # NOTES ID OIL SEPARATOR RA196572 IDENTIFIER RA19604A IDENTIFIER SWITCH. SEAL 121778 LOW SIDE PRESSURE TRANSDUCER RA19640 LOW SIDE SERVICE COUPLER (BLUE) 18190A MANIFOLD BLOCK ASS’Y. AMBIENT RA19609 46 . UPPER RA19600 NIPPLE.042 121312 O-RING (PARKER #5-124) NEOPRENE 105358 PCBA. 40 PSI RA19634 INLET. HEX PIPE (1/8 NPTF) 101307 OIL DRAIN BOTTLE 17756 OIL DRAIN SWITCH RA19297 ORIFICE UNION. REPLACEMENT KIT RA19647 LIGHT. . LIGHT 121778 SHELF. ANALOG INPUT RA19605 PCBA.ACR2000 Refrigerant Service Solution Parts & Components DESCRIPTION PART # NOTES PCBA. RELAY RA19602 POWER CORD. BRASS SOLENOID 107021 SEAL. 1/4 FL X 1/4NPT 123610 QUICK SEAL CAP. FILTER/VACUUM RA19258 SOLENOID. OIL RETURN/EQUALIZATION RA19258 SOLENOID. CLEARING 1 RA19258 SOLENOID. LOW SIDE RA19640 PRINTER ASSEMBLY RA19611 PRINTER CABLE 121847 PRINTER PAPER 34215 PRINTER RAIN SHIELD 121780 QUICK SEAL. HIGH SIDE RA19633 PRESSURE TRANSDUCER. 15’ RA19641 POWER CORD BRACKET 121909 POWER SUPPLY RA19642 PRESSURE RELIEF. FREE AIR RA19648 47 . VACUUM PUMP 122260 SOLENOID. CONTROL MODULE RA19606A PCBA. 1/4 FLAIR (TEST FITTING) 740569 RELAY BOARD RA19602 SCALE ASSEMBLY RA19603 SCREEN. CLEARING 2 123060 SOLENOID. 450 PSI RA19499 PRESSURE TRANSDUCER. ANALOG INPUT BOARD 121779 SEAL. OIL DRAIN RA19297 SWITCH. 13” VACUUM RA18752 SYSTEM OIL SEPARATOR ---------- 48 .) RA19648 SPACER. POWER CHARGE RA19258 SOLENOID. HIGH SIDE INLET RA19258 SOLENOID. PRESSURE FEEDBACK RA19258 SOLENOID. INLET TEST RA19258 SOLENOID. HIGH SIDE CHARGE RA19258 SOLENOID. RECOVER RA19258 SOLENOID.) RA19258 SOLENOID REBUILD KIT (N. Parts & Components ACR2000 Refrigerant Service Solution DESCRIPTION PART # NOTES SOLENOID. ID DRAIN RA19648 SOLENOID.C. ON/OFF RA19343 SWITCH.O. ID/AIR PURGE RA19258 SOLENOID. LOW SIDE INLET RA19258 SOLENOID. 1/2” 111740 STA STRAP 8” LONG X 3/16 102338 STRAP. TANK FILL RA19258 SOLENOID. 115V REPL RA19491 SOLENOID REBUILD KIT (N. VACUUM RA19258 SOLENOID COIL. HIGH PRESSURE CUTOUT RA19427 SWITCH. LOW SIDE CHARGE RA19258 SOLENOID. OIL DRAIN RA19258 SOLENOID. IDENTIFIER 40 PSI RA19634 SWITCH. TANK TEST RA19258 SOLENOID. VELCRO 121925 SWITCH. 3/8 O. BLOCK TO BLOCK 123025 TUBE. COMPRESSOR DISCHARGE (AMERICOLD) 121624 TUBE. BLOCK TO PUMP 120165 UNION. LOW SIDE INLET 121622 TUBE. COMPRESSOR PROCESS (AMERICOLD) 121623 TUBE. 1/8MP X 1/8FP X 1/8FP 116420 TEE. OIL DRAIN 121633 TUBE. 15’ 17915 TEMP PROBE.D. 1/8 NPTF (FEMALE) 111858 TEMP PROBE. 1/4MP X 1/4FP X 1/4FP 121719 TEE. 30’ 17930 TUBE. COMPRESSOR SUCTION (AMERICOLD) 121625 TUBE. BLACK NYLON. 1/8MP X O-RING SEAL 119983 UNIT BASE 121572 UNIT BASE ASSEMBLY W/WHEELS 122206 UNIT FRONT PANEL 121573 49 . 1/8OD (24” LONG) 121773 TUBE. COMPRESSOR SUCTION (CUBIGEL) 515982 TUBE. CONDENSER TO TANK 123023 TUBE. COUPLING.ACR2000 Refrigerant Service Solution Parts & Components DESCRIPTION PART # NOTES TEE. HIGH SIDE TO CONDENSER 122613 TUBE. OIL RETURN 122614 TUBE. COMPRESSOR PROCESS (CUBIGEL) 515980 TUBE. STRAINER. COMPRESSOR DISCHARGE (CUBIGEL) 515981 TUBE. BACKGROUND TANK FILL 123026 TUBE. HIGH SIDE INLET 121621 TUBE. SYSTEM OIL DRAIN 121628 TUBING. CASTOR 5” X 2” RA19631 WHEEL. 2-WAY BALL 117470 VALVE CORE (CORE SCHRADER) 103383 VELCRO STRAP 121925 WHEEL. COMPRESSOR FAN GROUND 122419 WIRE. 13” RA18752 VALVE. VACUUM PUMP GROUND 122418 50 . AXLE 121591 WHEEL BUSHING 121782 WHEEL. Parts & Components ACR2000 Refrigerant Service Solution DESCRIPTION PART # NOTES UNIT FRONT PANEL ASS’Y W/LOGO 122293 UNIT REAR DOOR 121575 UNIT SIDE SUPPORT 121574 UNIT SIDE/HANDLE ASSEMBLY 122207 UNIT TOP COVER 121576 VACUUM PUMP (110V) RA19610 VACUUM SWITCH. PNEUMATIC 10” 19676 WIRE. ACR2000 Refrigerant Service Solution P a r ts & C o m p o n e n ts NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 51 . P a r ts & C o m p o n e n ts ACR2000 Refrigerant Service Solution NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 52 . ....................................................................................................................................................................................................................................................................................................................................................................................................................................... 78 RA19612 – Replacing the Old Style ISV ............................................................................................................... 72 Cubigel Compressor Specifications & Service ................................ 54 Output Step Test ..................................... 57 Troubleshooting .............. No Beeps............................................................................................................................................................................................................... 58 Polarity Problem ......................................................... 59 Unit Indicates Low AC Voltage ..................... 58 Unit Will Not Power-Up............................................................................. 90 UL Circuit Calibration Procedure . 65 Will Not Clear Low Side ............................ 86 Vacuum Switch Specifications & Service ......................................................................... 79 RA19645 – Instructions for Pipe Valve Rebuild Kit ............................. 70 Service Procedures and Calibrations .......................................... 82 High Pressure Cutout Switch Specifications & Service ............. 108 53 .............. 106 Component Application Chart ...................................... 107 Flow Diagrams ............................................................ No Display .................................................................... 66 Will Not Clear High Side .............. 67 Will Not Recover ................................................................ 61 Flow Test for ACR2000 Identifier ............. 88 Identifier Switch .............................................................ACR2000 Refrigerant Service Solution 3 DIAGNOSTICS Functional Check ............................................................................................................................................................................................................................................................. 91 Expansion Valve Adjustment ....................................................................... 72 Americold Compressor Specifications & Service ................................ 63 Will Not Evacuate ............................................ 92 System Wiring ........................................................................... 89 Scale Calibration Procedure .......................................................................................................................................... 63 Will Not Charge .................................................................................................................................................. 64 Slow Charge ................................................................................................. 95 Harness Schematics ................................................................................................................... 96 Component Wiring ......... 88 Pressure Switch .............. 62 Will Not Drain Oil .................................................................................................................................................................................................................... 59 Printer Not Printing ........................................................................................................................................................................................................... 68 Contaminated System ..................................................... 60 Identifier Reads R134a–0................................................................................................................. 87 Oil Drain Switch .............................................................. 67 Fan Will Not Operate ................................................ 80 Software Upgrade Procedures ...................................................................... 68 Slow Recovery .................................................................. 75 Thomas Vacuum Pump Specifications & Service ................................................................... 65 “High Pressure” Message ......................................................................................09% and Air–99...................................................... 101 Component Identification ............................................................................................ 69 Additional Problems & Issues ............................ 60 Identifier Will Not Calibrate ........................................................... 56 Service Center Menu Options .................................................................................................................................................................................................................................9% ............................................................ press Watch for the unit to test the vehicle. If there is no pressure. the unit should have you recover the hoses. NOTE: The 13” vacuum switch controls the Clearing process. Verify elevation is correct for your area. 18.9% 134a and 0% air. the this. Once the vacuum cycle is complete. 17. then will not hold this amount. RECOVER HOSES needs to be “disabled. switch over to the recovery mode. 14. Open the vapor valve and allow the pressure 4. Plug unit in and turn power on. During VACUUM. 3. 16. If there is pressure in the lines. the compressor. If a lower version appears. Exit to Main Menu. Verify that the temp probes are accurate and the play ACR2000. Close the vapor valve on the Internal Storage Vessel (if so equipped). down to 13” of vacuum (low side clearing is completed). The Recovery process is con- 9. Go to the Main Menu and select SNAPSHOT. At this point. Verify the unit at. The unit will then pull the gauge into a 13” 8. clearing solenoids 7. Press [START]. Gauge should pull will turn on. trolled by the low side pressure transducer. 2. 13. then begin [1-2-2-4] then [ENTER]. If not. Screen should dis. The unit will build up pressure and shut down. with SOFTWARE VERSION highlighted. For testing purposes. sure on your gauges to rise between 25-35 psi. The unit will reset itself. Select VACUUM. 15. Charge . then VERSION 2. From the Main Menu. a low then 6. Then charge . Now find RECOVER the clearing process. 10. The unit will default to high side clearing should take place. To verify 3:00. go to the main menu. The hoses vacuum (high side clearing is completed). With pressure present in the unit.15 lbs into the low side. 54 . 11. watch the pressure gauge connected to the unit will attempt to do a tank fill. Select Set-Up Menu then select SET ELEVA. Select RECOVER. go to Set-Up Menu and calibrate ABLED. 5. identifiers reads 99. select #1 & #2 should energize then allow the pres- [CHARGE].” Under Set-Up Menu. HOSES and toggle to OFF. the unit needs to be updated. Disconnect service hoses from service ports. Verify the digital display reads “0” psi for both displaying “HIGH PRESSURE OUTPUTS DIS- sides. to enter the tank. Hook a manifold gauge to the service port on erant has been recovered.10 or greater.” pressures. TION.50 lbs into the high side. After the refrig. select RECOVERY. The compressor compressor service port. Diagnostics ACR2000 Refrigerant Service Solution FUNCTIONAL CHECK 1. 12. the unit will go to the main menu. tempts to use the POWER CHARGE feature. Return to the Main Menu. When Recovery is complete. 26. Set the timer for 5:00 and press [START]. AIR PURGE and OIL RETURN. the unit should clear the NOTE: During RECOVERY. Select TANK FILL by pressure building on the service port. OIL RETURN will be noticed 25. 28. 20. Verify the service lines hold a vacuum. power. 23. Verify the OIL DRAIN solenoid receives 27. two features lines. 29.5 lbs +/- FEEDBACK solenoid opening. ½ lb. (Refer to power. Verify the setting of the UL Circuit. page-91 for UL calibration instructions. Disconnect the service hoses and hook a ½ acme x ½ acme hose between the two ports. pressure should placing a known weight of 25 lbs on the scale. Verify the expansion valve is set between 30 .ACR2000 Refrigerant Service Solution Diagnostics 24. Select OIL FLUSH. 55 . Verify scale accuracy by removing the tank and 19. After the timer times-out. You will need to have 10 lbs of refrigerant to perform this procedure. This is the PRESSURE The chargeable weight should read 4. Charge pressure into the lines and leak check the entire unit. increase on the gauge. Then perform an oil drain. After leak check is completed. then shuts off. 30. AIR PURGE will be noticed by hearing air being and verify the TANK FILL solenoid is receiving purged. Turn the RECOVER HOSES option back on.40 psi by watching the gauge set hooked up to the compressor service port. may happen in the background. 22. recover refrigerant.) 21. valve. From the Main Menu screen. perform any test for an extended time period. From the Set-Up Menu screen. Press [ENTER].”) Fol- low any screen prompts during test. Do not Menu.F ree A ir S olenoid 12 P res s ure F eedbac k S olenoid 13 P ow er C harge S olenoid 14 Lam p 15 Tank Tes t S olenoid 16 F ilter/V ac uum S olenoid 17 H igh S ide Inlet S olenoid 18 ID A ir P urge S olenoid 19 ID D rain S olenoid 20 S pare/342000 O il Injec t 21 S pare 22 E qualiz ation/O il R eturn S olenoid 23 O il D rain S olenoid 56 . press [8787] on NOTE: The step test will activate the solenoid. during the step tests. the key pad to access the Service Diagnostic or motor associated with the specific test. (Tests “0” through “23. 2. Diagnostics ACR2000 Refrigerant Service Solution OUTPUT STEP TEST NOTE: A magnetic solenoid tester (P/N 17763) 1. From the Service Diagnostic Menu. use the arrow keys to highlight “Output Step Tests” and press [ENTER]. 3. S T EP T ES T # EN ER G IZED C O M P O N EN T 0 V ac uum P um p 1 Tank F ill S olenoid 2 R ec over S olenoid 3 Low S ide C harge S olenoid 4 Inlet Tes t S olenoid 5 F an M otor 6 Low S ide Inlet S olenoid 7 C learing-2 S olenoid 8 H igh S ide C harge S olenoid 9 C learing-1 S olenoid 10 C om pres s or M otor 11 V ac uum S olenoid . select Set-Up should be used to check operation of the solenoids Menu. Use this when you have completed repairs and want to vacuum the air in the unit. Identifier will purge to. the unit will do only the high should increase the same as the weight on the scale. When the Change Air Level — Sets the percentage that the unit is turned back on. cuit board and software updates and revisions. This is useful for finding leaks after repairs. Change Recovery Level — Allows vacuum level that Prepare to Ship — When activated and the unit is recovery stops to be changed. it will set the unit to all defaults. The P1 pot is located on the left side of the relay pensation entered in the setup menu for charging. tions. and calibrate the UL Circuit. Remove the weight and Chargeable Weight should Recover Hoses — Enabled will recover the hoses af. The chargeable weight high side clear. turned off. Otherwise the Service Vacuum — Close ISV valves and start. Service Leak Check — Ensure the source tank has MING OR SERVICE CODES TO CUSTOM. WARNING: Never change the default settings Service Clear — The unit will do a high side clear. on Accurate Recovery — Enabled. the user will have to set language. NEVER leave a customer with a There is no way to check the live scale reading as on disabled ID! other models. press [8-7-8-7]. Leak check will ERS. Do not leave leak check on for more than 10 minutes. press [1-2-2-4]. Reset Board Memory — This function when activated. set elevation. pressurize the entire unit. Longer times may flood the compressor Programming Menu with liquid refrigerant. vacuum the ISV. ter a charge. WARNING: NEVER GIVE THE PROGRAM. This unit may fail to operate properly. To access the Service Options Menu. time/date. After calibration place over 20 lbs. Calibrate UL Circuit — Follow on-screen instruc- Hose Comp — Enabled will use the hose length com. decrease the same amount. Some options may be added or deleted in future cir. 57 . then [ENTER] from the Setup Menu. board. low side clear and Place a weight on the scale. Identifier on or off. time. the unit will attempt to vacuum the entire to be changed. Output Step Test — Sends power to the item listed To access the Programming Menu. It will also reset refrigerant management. Input Step Test — Displays the status of the different switches. will make the user calibrate the scale. side clear. refrigerant and the valve is open. unless directed from the factory. [ENTER] from the Setup Menu. high side clear. recover. the unit will do a low the scale so that the scale reads something chargeable. in the vehicle. calibrate the transducers. Refrigerant Test Enable — This mode will turn the Calibrate Scale — Follow on-screen instructions. the unit will restart recover Hide Air Percentage — Air percentage of the ISV if left idle after recovery and more than 10 PSI is present will not be displayed. Disabled. unit and then fill the ISV next time unit is turned on. Auto-Recover — Enabled. First Time Tank Fill — When activated and the unit Change Charge Level — Allows the default charge is turned off. then on display. side clear. Change Vacuum Time — Sets the default vacuum and perform the first time tank fill.ACR2000 Refrigerant Service Solution Diagnostics SERVICE CENTER MENU OPTIONS NOTE: These are the Programming and Service Service Options Menu Options at the time of printing this service manual. will vacuum the entire unit. cal pressure. Replace if neces. proceed to next step. • If line voltage is not present. Verify line voltage is present across the “Main” 15 amp circuit breaker. Check if the “Main” 15 amp circuit breaker (lo. • If one or more supplies are not present or out • If line voltage is not present at power switch of the 5% tolerance. proceed to next step. 8. check connections between power supply. No Beeps. 5. 2. 4. connector 23 of the power supply board. If all the proceeding steps test OK. Verify the following DC power supply outputs on a good AC power source at receptacle. switch and AC plug. re. place power switch. reset the circuit breaker. If Pin 3 (White) 24 VDC breaker trips after reset and AC power has Pin 4 (Not Used) ----- been tested good. put of switch. replace the power sup- input. Verify AC power cord is properly connected to 6. (Brown=hot. proceed to next step. 7. unplug unit and check the cir. proceed to next step. If breaker trips again after Pin 6 (Not Used) ----- being replaced. check connections between circuit breaker and power switch. Verify line voltage is present at input of main • If all supplies are present and within a 5% tol- power switch and at output with switch turned erance. and power switch. the circuit breaker needs Pin 5 (White) 5 VDC to be replaced. 58 . No Display 1. blue=neutral). Pin 2 (Blue) DC ground • If tripped. • If line voltage is not present. Pin 13 (Not Used) ----- 3. Perform function test after repairs. Pin 12 (Red) 12 VDC sary. control board and perform unit setup. Pin 1 (Not Used) ----- cated on back of unit) has tripped. replace the but not at output with switch turned ON. Verify line voltage is present at the power supply input connector 44. • If line voltage is present. Diagnostics ACR2000 Refrigerant Service Solution TROUBLESHOOTING Unit Will Not Power-Up. check connections between power ply assembly. the 15 amp circuit breaker. • If line voltage is present at both input and out. ON. Pin 11 (Red) 12 VDC cuit breaker for continuity. check the following: Pin 7 (Black) ground √ shorted power supply Pin 8 (Black) ground √ shorted high pressure switch Pin 9 (Black) ground √ shorted relay board Pin 10 (Black) ground • If not tripped. • If line voltage is present at power switch input. • If line voltage is present. • If all supplies are present and within a 5% tolerance. proceed to next step.ACR2000 Refrigerant Service Solution Polarity Problem Unit Indicates Low AC Voltage 1. proceed to next step. replace the power sup- the correct terminals. Repair as board. replace the relay 6. Check AC power cord wires for continuity. Re. board. proceed to next step. Check ambient board for a loose or poor con. repair or replace the power cord. Repair as needed. Recheck the unit for problems. Check wiring and connections to the control board. ply assembly. En. or voltage. (See step-6 on the previous page. cate another outlet that provides proper voltage. 2. Check for correct wiring to power switch. properly grounded. 59 . Repair as needed. voltage range for the ACR2000 is 105–135 • If the electrical outlet is wired correctly and VAC. Check • If not. • If the AC voltage at the electrical outlet falls check the unit for problems. 4. then notify shop outside the required voltage range. and relay board. for loose connections. proceed to next step. 5. Check wiring and connections to vacuum sensor nection. The rectly. Verify that the electrical outlet the ACR2000 is plugged into is properly grounded and wired cor. Check unit for loose ground wires. tify shop technician of power problem. Perform function test after repairs. plugged into is providing proper voltage. Verify that the electrical outlet the ACR2000 is 1. locate an outlet that is.) needed. 5. properly grounded. 4. • If one or more supplies are not present or out sure the hot and neutral wires are connected to of the 5% tolerance. Verify the DC power supply outputs on connector 23 of the power supply 3. Repair as needed If the wiring and connections appear OK. try to lo- technician of unsafe outlet. 3. Perform function test after repairs. then no- 2. replace the control board and perform unit setup. If the wiring and connections appear OK. • If the AC power cord checks good. • If the electrical outlet provides the required AC • If the electrical outlet is not wired correctly. Check wiring to power supply assembly. check the 5 amp slo-blow fuse. This internal software are known to be unreliable. Verify that the printer paper is installed correctly.9% 1. Perform function test after repairs. check the hose for contamination and clear or replace the hose. step.) hose. as it can tion. check wiring and NOTE: Refrigerant in the cabinet or in the shop can connections between the control board and give false calibration of the Identifier. VDC is supplied to the printer through this fuse.09% and Air–99.9%. Slight air volume should be felt from discharge hose during the identifier calibration. 5. setup of ACR2000. NOTE: Always make sure the altitude and pres- Check paper feed mechanism for proper opera. proceed to assembly. proceed to next test. 60 . if there is a leak in the cabinet. replace the identifier assembly. reset the print speed to · If air volume is not felt from the discharge LOW. identifier. the complete identifier assem- age or corrosion. 2. 4. Check for proper power source. Perform initial 3. Be suspicious printer. sure transducers are properly calibrated. · If the identifier will not calibrate and reads • If a “test” printout is not printed.10. If defective. Verify power to printer.09% and Air–99. Produce a “test” printout on the printer. Check for proper power source. 3. check circuit NOTE: DO NOT attempt to adjust or calibrate the breakers and check electrical connectors for dam. 5 AMP SLO BLOW — 121513 breakers and check electrical connectors for damage or corrosion. Replace control board if all else fails. If there is no power to NOTE: Identifiers built before 2001 with 2. If the printer will not respond. 2. Once the 30 minutes and then restart unit. · If the discharge hose is clear. This can be achieved by holding down the paper feed but. replace printer R134a–0. (5 software level is a minimum 2. NOTE: If printout is too light.03 the printer. Repair as needed. 4. 6. ACR2000 Refrigerant Service Solution Printer Not Printing Identifier Reads R134a–0. printing begins. effect operation. · If the identifier calibrates perform function • If a “test” printout is achieved. (Refer to S.00/2. release the paper feed button. Re- fuse is mounted on the center divider panel to the place identifiers with an RA19604a and ensure unit upper-right of the power supply assembly. bly must be replaced. # 129 in Section “4”. Check identifier discharge hose for obstruction. next step.B.) 1. Turn the power to the ACR2000 OFF for ton while switching ON the ACR2000. check circuit FUSE. · If the discharge hose is clear. If defective. Re. damage or corrosion.ACR2000 Refrigerant Service Solution Diagnostics Identifier Will Not Calibrate NOTE: It is suggested that a magnetic solenoid 4. NOTE: Identifiers built before 2001 with 2. Check for proper power source. Ensure ID filter has no kinks place identifiers with an RA19604a and ensure unit in hoses and filter flow is in correct direction. 3.10. the complete identifier assem. · If the tank test solenoid is defective. · If the identifier calibrates. give false calibration of the Identifier.00/2. proceed to next ACR2000 Refrigerant Service Solution equipment. Turn the power to the ACR2000 OFF for 30 minutes and then restart unit. · If air volume is not felt from the discharge hose. step.03 check the hose for contamination and clear or internal software are known to be unreliable. hose during the identifier calibration. Check identifier discharge hose for obstruction. replace NOTE: Always make sure the altitude and pressure the solenoid and perform function test. to next step. · If the identifier will not calibrate. proceed operation. agnostic Menu. 1. Ensure the ISV tank valves are open. check circuit breakers and check electrical connectors for 7. Remove the external covers from the ACR 2000 and check for internal refrigerant leaks. check for proper operation of the bly must be replaced. Using the output step test from the Service Di- identifier. perform function test. tank test solenoid. 2. proceed to next step. software level is a minimum 2. Perform function test after repairs. tester (P/N 17763) be used when troubleshooting the • If the tank valves are open. 61 . replace the hose. Be suspicious Slight air volume should be felt from discharge if there is a leak in the cabinet. repair as necessary and perform function test. transducers are properly calibrated. NOTE: DO NOT attempt to adjust or calibrate the 5. replace the identifier assembly. proceed to next step. NOTE: Refrigerant in the cabinet or in the shop can 6. · If no refrigerant leaks are present. · If the refrigerant leaks are found. as it can effect · If the tank test solenoid is operational. but this should be a slight flow. carefully re- insert end of exhaust line into the bottom of the 4. Blocking the line will cause the pressure switch to deactivate the solenoid until released. runs. With positive pressure on the gauges as above and in SNAPSHOT. As the unit attempts to test. go into SNAP. good sample is tested or the control is sure in hoses either by vacuuming and charging. It is difficult to describe. solenoid. When complete. 9. con- siderable flow will be noted. reconnect the line. Under certain conditions there actu- ally could be a vacuum. If there is a high flow through the identifier. If there is no flow through the exhaust line and none of the identifier lines are pinched or kinked. 7. 2. With pressure showing on gauges. 5. suspect the block. 62 . circuit immediately after adding to the tank in TANK FILL mode. If there is no flow. the Identifier will give a false tank contamination and lockout the control until a 3. check the flow from the block. You should feel slight air flow from the exhaust line as the ACR2000 air pump CAUTION: In this mode without flow. (or manually adding weight NOTE: Make sure identifier is enabled in software. as it could damage the identifier. manual reset. there should be no flow from bottom of the ACR2000 the tube. SHOT. To check for flow during test. Pull long rubber identifier exhaust line from the test or tank test. ACR2000 Refrigerant Service Solution Flow Test for ACR2000 Identifier WARNING: Do not block flow of identifier ex. Turn power ON. disconnect the black line from the identifier. get positive pres. 6. or pressure switch. cabinet. ensure it is not pinched or blocked. 8. This test should also be completed on the tank haust line. during the process). Refrigerant vapor should be felt coming from the exhaust hose as above. the identifier regulator might not be properly set. NOTE: If the ACR2000 is not in either car 1. or running the output step test in the Set-Up Menu. ACR2000 Refrigerant Service Solution Will Not Drain Oil Will Not Evacuate NOTE: It is suggested that a magnetic solenoid tester NOTE: It is suggested that a magnetic solenoid tester (P/N 17763) be used when troubleshooting the (P/N 17763) be used when troubleshooting the ACR2000 Refrigerant Service Solution equipment. ACR2000 Refrigerant Service Solution equipment. 1. Check for proper power source, check circuit 1. Check for proper power source, check circuit breakers and check electrical connectors for breakers and check electrical connectors for damage or corrosion. damage or corrosion. 2. Using the output step test from the Service 2. Using the output step test from the Service Diagnostic Menu, check for proper operation Diagnostic Menu, check for proper operation of the pressure feedback solenoid. of the vacuum pump. · If the pressure feedback solenoid is defec- · If the vacuum pump defective, replace the tive, replace the solenoid and perform func- vacuum pump assembly. Perform function tion test. test. · If the pressure feedback solenoid is opera- · If the vacuum pump is operational, proceed tional, proceed to next step. to next step. 3. Check the 0.042" orifice between the accumu- 3. If the vacuum pump operates, use the output lator and the oil drain solenoid for debris. step test from the Service Diagnostic Menu · If the orifice is contaminated or defective, and check for proper operation of the vacuum replace or service the block assembly. Per- solenoid (stuck closed). form function test. · If the vacuum solenoid is defective, replace · If the orifice is operational, proceed to next the solenoid and perform function test. step. · If the vacuum solenoid is operational, proceed to next step. 4. Using the output step test from the Service Diagnostic Menu, check for proper operation 4. Using the output step test from the Service of the oil drain solenoid. Diagnostic Menu, check for proper operation · If the oil drain solenoid is defective, replace of the free air solenoid (stuck open). the solenoid and perform function test. · If the free air solenoid is defective, replace · If the oil drain solenoid is operational, pro- the solenoid and perform function test. ceed to next step. · If the free air solenoid is operational, perform function test. 5. Inspect the oil drain check valve for proper operation. 5. Perform function test after repairs. · If the oil drain check valve is defective, replace the check valve and perform function test. · If the oil drain check valve is operational, proceed to next step. 6. Perform function test after repairs. 63 Diagnostics ACR2000 Refrigerant Service Solution Will Not Charge NOTE: It is suggested that a magnetic solenoid tester 9. Using the output step test from the Service Di- (P/N 17763) be used when troubleshooting the agnostic Menu, check for proper operation of the ACR2000 Refrigerant Service Solution equipment. low side charge solenoid. · If the low side charge solenoid is defective, 1. Check for proper power source, check circuit replace the solenoid and perform function breakers and check electrical connectors for test. damage or corrosion. · If the low side charge solenoid is operational, proceed to next step. 2. Ensure ISV tank valves are open. 10. Inspect the low side check valve for proper op- 3. Check and ensure the vehicle has been evacuated. eration. · If the low side check valve is defective, replace 4. Ensure that the high and low service hose couplers the check valve and perform function test. are connected and open. · If the low side check valve is operational, perform function test. 5. Ensure chargeable weight is greater than desired charge. 11. Perform function test after repairs. 6. Use the calibrate scale procedure from the Ser- vice Diagnostic Menu. · If the scale does not calibrate, replace the scale assembly and perform function test. · If the scale calibrates proceed to next step. 7. Using the output step test from the Service Di- agnostic Menu, check for proper operation of the high side charge solenoid. · If the high side charge solenoid is defective, replace the solenoid and perform function test. · If the high side charge solenoid is operational, proceed to next step. 8. Inspect the high side check valve for proper operation. · If the high side check valve is defective, replace the check valve and perform function test. · If the high side check valve is operational, proceed to next step. 64 ACR2000 Refrigerant Service Solution Diagnostics Slow Charge “High Pressure” Message NOTE: It is suggested that a magnetic solenoid tester NOTE: It is suggested that a magnetic solenoid tester (P/N 17763) be used when troubleshooting the (P/N 17763) be used when troubleshooting the ACR2000 Refrigerant Service Solution equipment. ACR2000 Refrigerant Service Solution equipment. 1. Check for proper power source, check circuit 1. Verify the ISV tank valves (if so equipped) are open. breakers and check electrical connectors for damage or corrosion. 2. Verify the ISV is not overfilled. If full, remove refrigerant from tank. 2. Ensure ISV tank valves are fully open. 3. Verify the identifier filter is not installed back- 3. Check and ensure that there is a good vacuum in wards. Repair as needed. the vehicle being tested. 4. Verify that the Identifier is enabled in the software 4. Verify that there is sufficient pressure in the ISV to allow purge. to transfer refrigerant. 5. Verify if there is high pressure in the tank. Purge 5. Ensure chargeable weight is greater than desired excess air from tank as needed. charge. 6. Check for a leak in the low side which may allow 6. Verify that the ISV liquid and vapor lines are not for excessive air to be recovered. reversed. 7. Check for stuck inlet check valve at manifold 7. Verify the charge couplers are completely open block. and the vehicle ports actuated. 8. Check high pressure switch for proper operation. 8. Check for debris in any of the charging circuit (See page 86 for troubleshooting the high pres- solenoids. Clean or replace if necessary. sure switch.) 9. Perform function test after repairs. 9. Check the oil return and clearing-1 solenoid for proper operation. Repair or replace as necessary. 10. Check for an open connection between the high pressure switch and the relay board. Repair as needed. 11. Check wiring between relay board and control board. 12. Replace the relay board. 13. Replace the control board and calibrate unit. 65 Diagnostics ACR2000 Refrigerant Service Solution Will Not Clear Low Side NOTE: It is suggested that a magnetic solenoid tester · If the power charge solenoid is operational, (P/N 17763) be used when troubleshooting the proceed to next. ACR2000 Refrigerant Service Solution equipment. 7. Attach an external gauge to the ¼ inch fitting 1. Check for proper power source, check circuit on the compressor assembly and measure the breakers and check electrical connectors for pressure with the compressor operating. damage or corrosion. · If the compressor pressure is not 10 psi (69 kPa), replace the defective compressor and 2. Disable the accurate recovery mode. perform function test. · If the compressor pressure is 10 psi (69 kPa) 3. Close valve on external source tank, followed by or more, proceed to next step. the liquid line on the ISV (if so equipped) in sequence approximately two minutes apart. 8. If the compressor pressure is 10 psi (69 kPa) or more, perform the output step test from the 4. If the ACR2000 clears from closing the external Service Diagnostic Menu and check for proper source line, perform the output step test from the operation of the oil return solenoid. Service Diagnostic Menu and check for proper · If the oil return solenoid is defective, replace operation of the tank fill solenoid. the solenoid and perform function test. · If the tank fill solenoid is defective, replace · If the oil return solenoid is operational, pro- the solenoid and perform function test. ceed to next. · If the tank fill solenoid is operational, proceed to next step. 9. If the compressor pressure is 10 psi (69 kPa) or more, perform the output step test from the 5. If the ACR2000 clears from closing the liquid line, Service Diagnostic Menu and check for proper perform the output step test from the Service operation of the clearing No. 1 solenoid. Diagnostic Menu and check for proper opera- · If the clearing No. 1 solenoid is defective, tion of the pressure feedback solenoid. replace the solenoid and perform function · If the pressure feedback solenoid is defec- test. tive, replace the solenoid and perform func- · If the clearing No. 1 solenoid is operational, tion test. proceed to next. · If the pressure feedback solenoid is operational, proceed to next step. 10. If the low side gauge reads 17" Hg (58 kPa) or greater, perform the output step test from the 6. If the ACR2000 clears from closing the liquid line, Service Diagnostic Menu and check for proper perform the output step test from the Service operation of the vacuum switch. Diagnostic Menu and check for proper opera- · If the vacuum switch is defective, replace tion of the power charge solenoid. the switch and perform function test. · If the power charge solenoid is defective, · If the vacuum switch is operational, proceed replace the solenoid and perform function to next. test. 11. Perform function test after repairs. 66 If replacing the relay board fails to provide power to fan. Perform function test after repairs. From the Service Diagnostic Menu. such as the scale harness. Press [ENTER]. • If there are no obstructions. Verify the fan rotates freely. wires to the fan. From the Main Menu screen. • If AC is present on the yellow wires proceed 5. check circuit (P/N 17763) be used when troubleshooting the ACR breakers and check electrical connectors for dam- 2000 Refrigerant Service Solution equipment. Verify High Side Clear check valve is opening. 67 . 6. 5. 3. check circuit 2. check the wiring between the fan and the relay board. row keys to highlight “Output Step Tests” and press [ENTER]. remove the obstruction and recheck fan operation. rect places. next step. 1. • If AC is not present. Turn OFF the unit and check for obstructions in the fan assembly. 7. Ensure all copper tubing is connected to the cor. repair or replace as 4. replace the control board and perform unit setup. If check valve is stuck. Check for 13-18” Hg at compressor service port. Step test #5 provides AC 3. Check for proper power source. replace the fan assembly (RA17416) and retest. press [8787] on 2.ACR2000 Refrigerant Service Solution Diagnostics Will Not Clear High Side Fan Will Not Operate NOTE: It is suggested that a magnetic solenoid tester 1. select Set-Up breakers and check electrical connectors for Menu. Perform function test after repairs. age or corrosion. Check for proper power source. the key pad to access the Service Diagnostic If check valve is functioning properly. replace the relay board. From the Set-Up Menu screen. power to the fan. damage or corrosion. Verify that AC power is present on the yellow 4. to next step. use the ar- needed. If wiring checks good. proceed to Menu. • If the fan blades are obstructed. Using the output step test from the Service Di- agnostic Menu. breakers and check electrical connectors for damage or corrosion. Check for debris in any of the recovery circuit so- solenoids would have to fail for this fault to be lenoids. of the recover solenoid. 1. Both 7. replace the solenoids and perform 8. 5. retest. agnostic Menu. · If the high and low side inlet solenoids are operational. 5. check valve and perform function test. check for proper operation 4. < 50 degrees F. pro. ACR2000 Refrigerant Service Solution equipment. proceed to 6. Repair as needed. remove · If the recover solenoid is operational. Check the ISV for excessive pressure. 2. check circuit 1. the solenoid and perform function test. Repair as valve. Perform function test after repairs. ACR2000 Refrigerant Service Solution Will Not Recover Slow Recovery NOTE: It is suggested that a magnetic solenoid tester NOTE: It is suggested that a magnetic solenoid tester (P/N 17763) be used when troubleshooting the (P/N 17763) be used when troubleshooting the ACR2000 Refrigerant Service Solution equipment. 7. 4. ant from tank. proceed to the · If the recover solenoid is defective. Clean or replace if necessary. Ensure that present. age or corrosion. · If the check valve is operational. 68 . replace the and the vehicle ports actuated. perform function test. 2. Perform function test after repairs. Ensure the ISV tank valves are fully open. or in the vehicle. Inspect the inlet check valve for proper operation. 9.) needed. Check for leaks in the low side of the ACR2000 function test. If so. Using the output step test from the Service Di. · If the high and low side inlet solenoids are defective. try to find a means of in- creasing the ambient or vehicle temperature and 6. replace next step. (See page 70 for instructions to adjust the expansion 3. 3. check for proper operation of the high and low side inlet solenoids. • If pressure in the ISV is excessive. pressure by purging air or removing refriger- ceed to next step. strainer kit (RA19733) is installed. Is the ambient or vehicle temperature very low? next step. Check for proper power source. Check for proper power source. Verify the charge couplers are completely open · If the inlet check valve is defective. Recalibrate transducers. Check operation of vacuum switch. check circuit breakers and check electrical connectors for dam. • If pressure in the ISV is normal. Verify the expansion valve is properly set. is contaminated. does not automatically test the virgin tank prior to the ACR2000 will prompt you to disconnect the hoses adding refrigerant to the Internal Storage Vessel from the vehicle. When the ISV WARNING: The ACR2000 must be discon. Once sample is complete. 9. close tank valves. To sample a source tank. Turn “ON” the ACR2000. contaminates will be transferred to the ISV. Detach blue service hose from the unit. The ACR2000 second time. The ACR2000 will now sample the source tank. After a tank fill. the unit will display “Unit Contami- nected from the vehicle before starting the nated. the ACR2000 will automatically test a prior to installing on the ACR2000. 4. If a source tank contains contaminants.ACR2000 Refrigerant Service Solution Contaminated System Before every recovery. It is illegal to leave unit at. IMPORTANT 2. NOTE: Please refer to your garage guidelines for dealing with a contaminated system. 10.” The ACR2000 will lock out cleaning process. If a system fails the purity Robinair recommends all non-virgin tanks be sampled level required. Attach any ½” Acme x ½” acme R-134a hose available to the low side service opening of the unit Refer to Service Bulletin # 134 in Section 5. 6. Press [Start]. 5. for and the vapor valve of the source tank. the ACR2000 automatically Suspect Source Tank samples the refrigerant in the system. In the event the system fails a second time. all functions until a certified service center decontami- tached to car. recover the hoses. 69 . The operator may not bypass this procedure. follow instructions for tank fill. Then follow on-screen prompts in (ISV). 7. the procedure to clean a contaminated unit. Call Service. This decontamination will not be covered by the warranty. and reattach blue service hose. nates the unit. those order to clean out the ACR2000. Contamination Cleaning Process 3. Open vapor valve on source tank. Press [Snapshot] key. follow these instructions: 1. Recover any refrigerant left in hoses. If source tank is uncontaminated. 8. the unit will sample the ISV. pow er supply. scale or control problem. Input/output function problem s Diagnose 5A f use. pow er supply. replace compressor Source tank is empty. and relay board before replacing control board Over/undercharge/calibration Understand w hy the technician f eels the unit is under/over charging before changing the control board.also vent port Check manif old blocks Will not shut off from Recovery Recalibrate transducers Low side gauge pegging out Low and High side gauges have reversed plumbing Unit continuously drains oil Check for debris in oil drain solenoid Vacuum pum p w ill not shut off Faulty transducer reading. recalibrate or replace 28" vacuum on high side. relay board and connections before changing control board. valve is not open.don't over-tighten Check filter and O-ring seal . relay board. toggles betw een ID Replace pow er supply and Identifier calibration & testing tank Pressure rises during vacuum on lines Pow er charge & inlet solenoid may be reversed Unit charges but w ill not show on Check pow er charge and high side coils to see if they are reversed gauges Identifier stays on Check for debris in tubing to inlet of identifier Unit stuck in Filter Change process Replace control board Low side inaccurate Replace transducer 70 . scale. Scale problem s Diagnose 5A f use. Compressor not running. sample good R134a to unlock control Lines in display Replace control board High pressure Diagnose for actual pressure. solenoids. Check vacuum sw itch Leaks (use a good quality leak detector) Check all connections Check ISV threaded f ittings and ISV hoses Check all O-ring connections . (The f act that "charge" and "recovery" do not match does not necessarily indicate a calibration. or connected to w rong port. display show s 12 lbs.) Won't add refrigerant from source tank Refrigerant not required. ACR2000 Refrigerant Service Solution Additional Problems & Issues PROBLEM POSSIBLE FIX Stays in initialization Check all harness connections Check keyboard cable connection on back of control board Replace control board Display is blank on pow er-up Check contrast setting Replace control board Display blanks or freezes Add ferrite and recheck f or blanking Check for scale ground strap Replace control board Locked in tank test Make repair to the Identifier circuit. 3" on low Check tubing f rom upper block to low er block Check for missing O-rings Stays in Equalizing Reset transducers Unit charging instead of recovering Remove debris from charge solenoids or replace Unit stuck on Check Source Tank Check vacuum sw itch Check relay board Hum idity w on't change Replace ambient board UL w on't calibrate Replace relay board Unit reads testing all the tim e Check for contaminated ref rigerant Unit locked-up. w iring. check HP sw itch. and sw itches before changing control board. ACR2000 Refrigerant Service Solution NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 71 . 10. • If there is no voltage to the compressor’s start components. 1. 22. Diagnostics ACR2000 Refrigerant Service Solution SERVICE PROCEDURES & CALIBRATION Americold Compressor Specifications & Service (Discontinued) Specifications Checking Oil Level Make: 1/3 HP Americold Hermetic Voltage: 115V / 60Hz Capacity (BTU/HR): 5054 Running Amps: 8. Check for voltage to the compressor (110/220V). The compressor may also be 3. If the compressor still doesn’t run. locked rotor amperage. Power Charge. but leave the “discharge” port open. If there is no amp draw. keep add. 1. with a cap. proceed to next step. SUCTION 4” 30° Replacements: 110V . replace the ther- itself. 500.RA19458 220V . If it is okay. inspect the start each addition until a proper level is achieved. 4. If it is drawing 3. 2. Depressurize the unit.3oz Refrigerants: R-12. If it is still low. Oil Flush (stage-1). end of hose into bottle containing (2) ounces of POE type oil (150 viscosity). Place the compressor on a flat surface. Tilt the compressor 30 degrees (see diagram). If the compressor runs. Verify that ground wire is securely fastened to Adding Oil compressor electrical box and unit chassis.1oz (INTAKE) Recharge . Check the oil level between sor. take an amp draw on The compressor will pull the oil from the bottle into the compressor. Low Side Clear- 2.9. NOTE: The compressor operates during the following test modes: High Side Clearing. mal overload. Remove compressor from unit. 72 . energized manually by selecting Step-Test # 10. components and replace as necessary.5A Speed: 3500 RPM Locked Rotor Amps: 30. Recheck the oil level. At Compressor Will Not Run this angle. 502. there should be oil in the suction fitting.RA19457 DISCHARGE ➤ ➤ Checking Oil Level Troubleshooting Compressor 1. Start the compressor and plug the “intake” fitting • If there is voltage. ing.0A OIL RETURN Oil Charge Capacity: Initial . and Vacuum/Tank Fill. replace the compres- ing 2 ounces at a time. take another amp draw. jumper the thermal overload. Install hose onto “suction” fitting and place loose 2. Recovery. 134a ➤ POE Oil Type: 150 Viscosity ➤ Net Weight (Less Oil) 23 lbs. Start the compressor and monitor the suction 5. Cap the intake fitting.S. Remove the junction box cover from the side of the compressor. 73 . 6. suction. replace the compressor. If line voltage is present. check the interface harness between the relay board and control board for bad connec. an R-134a manifold set. Close the vapor and liquid valves on the tank. Repair as 7. suction. Remove the panels or shrouds to access the structed. • If voltage is not present. The compressor should pull a 25” compressor intake. problem. 5. 9. • If voltage is present. Install a low side gauge on the suction fitting. Replace control board and recalibrate unit. pressor. an RA19853 (Cubigel 1. pins 1 & 2. If the oil level is okay or oil was added with no NOTE: Be careful that the lines do not twist.S. 6. pins 1 & 2 of the relay require an o-ring fitting to seal. Disconnect the hoses or copper lines from the readings. check the oil level and add if necessary. Use a 120063 hose (1/4” flare o-ring X 1/2” ACME 3. needed. Use a 120063 board. Install a high pressure gauge on the discharge fitting. NOTE: The fittings used on these compres. sors require an o-ring fitting to seal.) with relay board. 4. Q. 5. Replacing the Americold Compressor Suction and Discharge Pressure Test NOTE: If an Americold Compressor is being replaced with a Cubigel compressor. replace the hose (1/4” flare o-ring X 1/2” ACME Q. 2. Verify that the discharge fitting is unob. four minutes. If the compressor has weak tings. Remove refrigerant from the non-operating unit.85 bar) vacuum. fitting. 4. Verify that the intake fitting is unobstructed.ACR2000 Refrigerant Service Solution Diagnostics 3. compressor. Compressor Upgrade Kit) must be used to accommodate the fitting and tubing locations of the new com- 2. improvement. Check for voltage from the relay board on con. 3. Disconnect the low side gauge from the suction nector P8 (56). If replacing the relay board fails to correct the 8.) with an R-134a manifold set. (Refer to the recovery unit operating manual. and discharge fit- (.) 4. replace the compressor. Unplug the electrical cord from the power source. check for line voltage NOTE: The fittings used on these compressors at connector P2 (45). If the pressure doesn’t reach at least 350 psi (24 bar). Start the compressor and monitor the pressure for tions or loose wires. check wiring between the relay board and the compressor. Disconnect all fittings from the compressor. 1. Diagnostics ACR2000 Refrigerant Service Solution Americold Compressor Specifications & Service (continued) 7. Disconnect the wires from terminals on the old 12. Replace the o-rings on the hoses or copper lines compressor. Note the connections and orienta- with the new ones provided. Apply a thin coat of tion of the capacitor/bracket assembly. vacuum grease or vacuum pump oil to the o-rings after installing. 8. Remove and retain the four hex nuts and washers from the old compressor. 13. Connect the hoses or copper lines to the new compressor. Refer to the compressor diagram on 9. Remove the compressor from the unit and install the previous page for plumbing hookup. the new compressor using the hex nuts and washers removed from the previous step. 14. Install the junction box cover and clip to the new compressor. 10. Install the capacitor/bracket assembly in the same orientation as on the old compressor. 15. Pressure the unit and check for leaks. If necessary, repair leaks before use. 11. Connect the wires to the correct terminals on the new compressor. Refer to the wiring diagram 16. Install the panels or shrouds. The unit is now ready below. for operation. GRN or AMERICOLD GRN/YEL 76 COMPRESSOR WIRING 57 58 57 GRN or GRN/YEL 76 58 74 ACR2000 Refrigerant Service Solution Diagnostics Cubigel Compressor Specifications & Service (New Style) Specifications Compressor Fittings Make: 1/3 HP Cubigel Voltage: 115V / 60Hz Oil Return Capacity (BTU/HR): 5821 (Intake) Suction Running Amps: 8.4A Speed: 3500 RPM Locked Rotor Amps: 30.0A Oil Charge Capacity: Initial - 13.5 oz Recharge - 11.8 oz Discharge Refrigerants: R-12, 22, 500, 502, 134a 404a POE Oil Type: 150 Viscosity Weight w/oil: 23.8 lbs. Replacements: 110V - RA19865 220V - 516242 Adding Oil to Compressor Troubleshooting Compressor Due to the configuration of the Cubigel suction and dis- NOTE: The compressor operates during the follow- charge fittings, there is no easy method of checking or ing test modes: High Side Clearing, Low Side Clear- removing oil from the compressor. ing, Oil Flush (stage-1), Power Charge, Recovery, and Vacuum/Tank Fill. The compressor may also be The following procedure is the recommended method energized manually by selecting Step-Test # 10. for changing oil in the Cubigel compressor: Compressor Will Not Run 1. Connect a refrigerant supply tank to one of the compressor’s suction ports. 1. Verify that ground wire is securely fastened to compressor electrical box and unit chassis. 2. Connect a portable recovery unit to the other suction port. 2. Check for voltage to the compressor (110/220V). • If there is no voltage to the compressor’s start 3. Cap the discharge port on the compressor. components, proceed to next step. • If there is voltage, jumper the thermal overload. 4. Run the recovery unit to completely flush all oil If the compressor runs, take an amp draw on from the compressor. the compressor. If it is okay, replace the thermal overload. If the compressor still doesn’t 5. Disconnect everything and add 13.5 oz. of new run, take another amp draw. If it is drawing oil (150 viscosity) to the compressor. locked rotor amperage, replace the compressor. If there is no amp draw, inspect the start components and replace as necessary. 75 Diagnostics ACR2000 Refrigerant Service Solution Cubigel Compressor Specifications & Service (New Style) (continued) 3. Check for voltage from the relay board on con- 7. Install a high pressure gauge on the discharge fit- nector P8 (56), pins 1 & 2. ting. • If voltage is present, check wiring between the relay board and the compressor. Repair as NOTE: The fittings used on these compres- needed. sors require an o-ring fitting to seal. Use a • If voltage is not present, check for line voltage 120063 hose (1/4” flare o-ring X 1/2” ACME at connector P2 (45), pins 1 & 2 of the relay Q.S.) with an R-134a manifold set. board. If line voltage is present, replace the relay board. 8. Verify that the intake fitting is unobstructed. 4. If replacing the relay board fails to correct the 9. Start the compressor and monitor the pressure problem, check the interface harness between the for four minutes. If the pressure doesn’t reach relay board and control board for bad connec- at least 350 psi (24 bar), replace the compres- tions or loose wires. sor. 5. Replace control board and recalibrate unit. Replacing the Cubigel Compressor NOTE: If an Americold Compressor is being re- Suction and Discharge Pressure Test placed with a Cubigel compressor, an RA19853 (Cubigel Compressor Upgrade Kit) must be used to 1. Disconnect all fittings from the compressor. accommodate the fitting and tubing locations of the new compressor. 2. Cap the intake fitting. 1. Unplug the electrical cord from the power source. 3. Install a low side gauge on the suction fitting. 2. Remove the panels or shrouds to access the NOTE: The fittings used on these compres- compressor. sors require an o-ring fitting to seal. Use a 120063 hose (1/4” flare o-ring X 1/2” ACME 3. Disconnect the vapor and liquid hoses from the Q.S.) with an R-134a manifold set. internal storage vessel using extreme caution. Pressurized refrigerant may be present in 4. Verify that the discharge fitting is unobstructed. hoses. 5. Start the compressor and monitor the suction 4. Disconnect the copper tubes from the old com- readings. The compressor should pull a 25” (.85 pressor. bar) vacuum. If the compressor has weak suction, check the oil level and add if necessary. If NOTE: Do not twist the copper tubes. the oil level is okay or oil was added with no improvement, replace the compressor. 5. Remove the clip from the junction box and then remove its cover. 6. Disconnect the low side gauge from the suction fitting. 76 Replace the panels or shrouds. Do a Leak Check. Compressor Process 515980 1 11.) sor. Tube. capacitor. Compressor Discharge 515981 1 Tube. The unit is now ready for operation. Remove the old compressor from the unit. 8. Compressor Suction 515982 1 12. (You may need to use a needle. (Refer to Operator’s Manual 7. Schrader Core 103383 1 Quick Seal Cap 740569 1 77 . and 13.) CONTENTS: Tube. O-rings 105358 6 sel. Install the cover to the junction box. RA19853 Cubigel Compressor Upgrade Kit 10.ACR2000 Refrigerant Service Solution Diagnostics 57 76 58 CUBIGEL COMPRESSOR WIRING 6. Remove relay. Install the new compressor using the nuts removed earlier. for instructions. Fill the internal storage vessel with refrigerant. Remove the nuts from the base of the compres. 15. ground wires.) nose plier to remove the wires.) 14. Reconnect the hoses to the internal storage ves. (Refer to Operator’s Manual for instructions. 9. (See diagram above. thermal protector. Reconnect the wires to the new compressor. If line voltage is present. pins 1 & 2 of the relay board. the relay board via the 516820 compressor harness. check Vacuum Pump Operation continuity of the harness between the relay board and the vacuum pump.0A pump will need to be replaced. check Capacitor: 15MFD @370V 50/60 Hz for line voltage on the relay board at connector P8 (56).7A (brown wire). During 3. 4. the vacuum Locked Rotor Amps 14.0A . If voltage is not present. check for line voltage at this procedure the vacuum pump receives power from connector P2 (45). replace the relay board. If replacing the relay board fails to correct the problem. Horsepower: 1/3 HP Speed: 1690 RPM 2. If power is present. Diagnostics ACR2000 Refrigerant Service Solution Thomas Vacuum Pump Specifications & Service Specifications Vacuum Pump Not Running Make: Thomas 1. replace the control board. If power is present. If power is not present at the vacuum pump. NOTE: The vacuum pump operates only during the ACR2000’s Vacuum/Tank Fill procedure. THOMAS VACUUM PUMP 78 . Verify power is being applied to the vacuum Voltage: 115V / 60Hz pump at connections 59 (blue wire) and 60 Running Amps: 4. pins 3 and 4.15. 1. When you are finished assembling the ISV. Install the half union coupling (P/N 119983) to the ball valve similar to how the old tank was. of the included thread sealant. 3. Carefully remove all three black hoses from the ISV. Reconnect all three hoses and open all three tank valves. taking note of which valve they are on. Pull a vacuum on the tank and then refill. Open front door to access ISV compartment. using the 1/2” ACME fitting (P/N 117235) for R-134a. The service replacement for the new ISV is RA19798. 7. ISV VALVE FITTINGS (OLD STYLE) Vapor Valve 119983 Used for hose connections on the ACR2000 Air Purge Valve 117235 Used for the liquid tank valve access fitting for R134A Liquid Valve 112243 79 . 4. replace the tank on the scale and secure. continued and no-longer available. 5. 6.ACR2000 Refrigerant Service Solution Diagnostics RA19612 — Replacing the Old Style Internal Storage Vessel (ISV) NOTE: These instructions are provide for reference NOTE: When installing fittings. Install the access port fitting on the liquid valve 2. use 1 or 2 drops only. The replacement ISV listed here is now dis. WARNING: Liquid refrigerant may be present. Close internal storage vessel (ISV) valves. MANIFOLD MODULE sonal injury or property damage. it is mandatory that all parts be properly installed. Reference the check valve loca. They are an important part for the magnetic circuit. when reassembling. DETAIL B PARTS INCLUDED WITH THIS KIT A E PART QTY. #2 The check valve rebuild kit contains all of the components needed to rebuild any ONE (1) of the check valves shown in Detail A or B. DESCRIPTION A 1 Pipe Plug B 1 Check Valve C 1 Hollow Set Screw B F D 1 In-line Screen E 1 Screw Plug F 1 Set Screw with Orifice G 3 Flat Washers H 1 O-Ring C D G H 80 . DETAIL A AXV tions (right) with the corresponding parts detail (next page). and recover fluid before servicing the valve. #3 Detail B: Check valve location #3 is on the oil drain manifold block (underside). #1 NOTE: If a solenoid was disassembled. Check valve location #2 is on the manifold top block at side nearest AXV. See correction instructions on next page. Diagnostics ACR2000 Refrigerant Service Solution RA19645 — Instructions for Checkvalve Rebuild Kit WARNING: To prevent the possibility of per. OIL DRAIN MANIFOLD Detail A: Check valve location #1 is on the manifold FRONT VIEW top block at side opposite AXV. See next page for installation instructions and list of parts needed for each set. TOP VIEW trical power. depressurize valve. This check valve is no longer needed and should be removed on older model units. turn off elec. flat end in first. Remove and discard the check valve. The three check valve locations (1. so that the E). it is re. washer. and set screw. chamfered end in first. Order of Installation: DETAIL E 81 . Insert the O-ring. Torque to 20 in. 5. Apply Locktite #567 to screw plug threads (Part 1. stallation: 3.-lbs. 1. terminal. This valve is designed to valve was omitted on newer models. obtained in this rebuild kit. Location #1 fered end of the check valve. Disassemble the check valve assem. terminal. Insert into cavity and tighten down. then torque to 120 in. Order of In. Insert the in-line screen. or use parts not when rebuilding the manifold. to 100 in. DO NOT mix old parts with new parts.-lbs. modify. Apply Locktite #567 to pipe plug threads. (See Detail D) DO NOT alter. 4. DO NOT Remove Check Valve Assembly mix old parts with new parts. but if your station perform properly when installed in correct order (See has a check valve in this location it should be removed Detail C. Location #2 Check Valve Instructions: Check valve is found on the side of the top manifold near DETAIL D the AXV. Insert an additional one or two flat washers until assembly is taut after set screw is tightened down. or use parts not obtained in this rebuild kit. cluded in this kit. This valve is designed to perform Location #3 properly when installed in correct order. manifold beneath elbow (See Detail E). that the flat end is visible after assembling. then torque to 120 in. for identification of each part as you remove them. Insert the O-ring. DETAIL C 6. 2. Screw down in firmly. 3. Location #2 7. Apply Locktite #567 to pipe plug. Screw the hollow set screw down in firmly and check for washer additions.- lbs. then bly that you wish to replace by using the exploded views torque pipe threads to 20 in. O-ring. Torque chamfered end is visible after assembling. Positioning and Reassembling Location #3 Check Valve Instructions: Location #1 Check Valve Instructions: Check valve is found on the underside of the oil drain Check valve is found on the side of the top manifold.-lbs. Insert the check valve.) DO NOT alter. so different parts and you may not use all of the parts in. positioning it level on the cham. Screw the orifice set screw down in firmly. quired to use all of the new parts needed for this set. For best operation. Screw the pipe plug down firmly. 2. This check opposite the AXV. Insert one flat washer. Disassemble the elbow and adapter fitting. it is required to X use all of the new parts needed for this set. positioning it level and resting flat in the bottom of the cavity.-lbs. Insert the check valve. For best operation. and 3) require 2. 3.ACR2000 Refrigerant Service Solution Diagnostics Valve Disassembling 1. 2. 4. modify. one open COM port. • Microsoft Windows 95 • CD-ROM drive The following are instructions on how to upgrade the software on the ACR2000. and the upgrade CD. Double click ADD/REMOVE PROGRAMS. Software Installation • Your computer system must be fully set up and the operating system required installed. Windows START icon. Diagnostics ACR2000 Refrigerant Service Solution Software Upgrade Procedures Before You Begin WARNING: Make sure no other programs are running and that the PC is not logged onto any • To install and use the ACR2000 update program. Attention GM Wholesale Personnel! CAUTION: This software is intended for use on a Dealer’s Techline PC only. 5. 2. 82 . The minimum hardware requirements and software op. DO NOT attempt to load this software on your GM ONLINE PC. erating system required to install the ACR2000 upgrade application are as follows: 6. place the CD Upgrade nents of your personal computer system must be disk on the drive carrier. you should have a working knowledge of the personal computer (PC) and Microsoft Windows. To perform this procedure. • At least one serial port (also called a COM port) must be open (not assigned). and close the drive. Installation wizard should auto-start as shown to the right. Open the CD-ROM drive. 4. doing so could cause a fatal error and render the PC inoperable. The command line to load the installation • 16 MB RAM program is SETUP. Click NEXT to begin installation. • 1 unused serial (COM) port • VGA color monitor (640x480) 7. Point to SETTINGS. click on the port to plug the ACR2000 into the PC. network before beginning installation. and then click CONTROL System Requirements PANEL. All compo. Use the open serial 3. Follow the instructions on your screen to load soft- • 486/66 MHz computer ware. working together properly before additional programs are installed. If installation wizard does not start. Tech 2 serial data cable that is normally used to update the Tech 2.EXE. 1. the following will be required: PC that meets the above minimum GM requirements. or BACK to revise them. 9. When the reboot is complete. Click NEXT to accept the default program folder. Agree to software license as shown on next page. the update process can begin.dll files. Launch upgrade program using the following steps: A. . 83 . When the installation is complete. Click NEXT to accept the displayed 14. ACR2000 Upgrade. 12. The screen will now show a summary of the install options. you should answer NO. Perform Upgrade 13. 10. or select an alternate folder. prompts you to overwrite any . WARNING: If the installation program Continue to next page . B. or click BROWSE to select an alternate location. Move arrow to PROGRAMS. options. C. Click on ACR2000 Upgrade. the computer will reboot. 11. Remove the CD from the CD-ROM drive and press OK to begin the reboot.ACR2000 Refrigerant Service Solution Diagnostics 8. Click NEXT to accept the default installation di- rectory. Click START. . When the screen below is displayed. Update complete. Connect NOTE: At the time of writing this service manual. Click OK. serial cable (same as the Tech 2 serial cable) to the current version of software for the ACR2000 is PC and to the connector labeled RS-232 on the 2. 18. turn on ACR2000. Click on COM 1 or COM 2. The screen will give the message “Set up communication port first. depending on minutes. Click on SETUP. The serial cable can be removed. The upgrade process takes approximately five D. 20. ACR2000 Refrigerant Service Solution Software Upgrade Procedures (continued) 17. Make sure ACR2000 is turned OFF. it is not recommended to update the unit. Move arrow to COM PORT. click on OK and the ACR2000 will automatically reboot. Once the download is complete. 16. a which port on the PC is being used as shown progress bar is displayed on the PC Screen as in the figure to the right.13M. and allow system to boot. 84 . riencing any problems. C. The upgrade will then automatically begin. If a unit is at version 2. B. While the upgrade is in process.10 and is not expe- rear of the ACR2000. 15. shown below. 19.” Then: A. and select the next COM port the check mark so that changes can be made.” the COM port is OK. Is the ACR2000 serial cable plugged securely into a COM port on the PC? If There are Conflicts: 2. Reboot in the Safe Mode. next COM port and check it using the above steps. and clear any problems close the window.This will reboot the PC. 85 . select the 4. the COM port with the conflict. matic Settings” text on the Resources screen of 3. Click on the Windows START icon. problem between your personal computer and your 3. Conflicts. review each COM lowing: port to see if there is a conflicting device. Click on the Device Manager tab from the open System Properties window. you are unable to resolve number by clicking on the existing setting. may have a communication problem. From the System Properties window. Click on the white box next to the “Use Auto- make your ACR2000 selections again. you may have a conflict double click on a new setting. Troubleshooting Installation 5. with your COM ports. (select “Safe Mode” 2.Select Start. ACR2000. and then click CONTROL by-step procedure to help find and fix a communication PANEL. Repeat step 2. Restart. Select the Resources tab from the Communica- during reboot). and click ing Devices box at the bottom. 4. tions Port Properties window. available.” choose a different basic configuration If. after the above suggestions. Then the communication problem. Clear the PC’s memory by closing all programs and shutting down the computer. From the list of available COM ports. Shut off power to the PC. Once the Windows desktop appears: 3. 2. 3. If it says “No Yes. In the pull down list next to the text “Setting based on. look at the Conflict- . Follow this step. then restart and 1. 1. associated with the reboot. Double-click on Ports (COM & LPT). 1. On the Resources screen. Troubleshooting Routine 5. 4. This will remove click COM port.ACR2000 Refrigerant Service Solution Troubleshooting Access the Device Manager If you are having difficulty downloading the upgrade. 2. If your PC appears to freeze for an extended period of Review for Conflicts time in a DOS screen during reboot with a message such as “Updating Window files. contact Robinair. If PC fails to reboot. Point to SETTINGS. 2. Click OK to . Double click System. Review your settings with the following step-by-step procedure. If communication is not established. Shutdown. you 1. Double click on the COM port to be verified. 1. click SETUP.” then proceed with the fol. Check all COM ports to be sure there are no conflicts. 1. which then forces the center contact to disengage the 1 and 3 contacts and engage the 1 7. Replace the panel(s) or shrouds. Replacing the High Pressure Cutout Red Wire Red/Black Wire 2 1. Disconnect the red and red/black wires from the high pressure cutout switch. Wash after skin contact. Operate the unit and check for leaks. eration of unit at or below designed pressure. the pressure forces AWAY FROM CHILDREN! up on the drive pin. Remove the panel(s) or shroud to access the manifold block. 3. and 2 contacts. 4. Check the wiring. 2. 11. the 1 and 3 contacts are closed. Replace the high pressure cutout. Apply thread sealant to only the male pip reaches 435 ± 10 psi. Clean the fitting by wiping away dirt. 8. High Pressure Cutout does not discontinue op. Close the tank valves and depressurize the unit. 6. Replace the high pressure cutout. The pressure is detected through an orifice in the CAUTION: Sealant contains ADHHM- base of the sensor. 2. When ester. KEEP 435 psi is introduced to the orifice. The unit is ready to resume operation. Reconnect the red and red/black wires to the new switch. Verify that there are no discharge obstructions. Install the new high pressure cutout switch. DO NOT apply thread at 320 ± 20 psi. High Pressure Cutout discontinues operation prematurely. grease and signed to shut off the unit if the discharge pressure oil. 1. (See Illustration) Troubleshooting the High Pressure Cutout 9. The switch will reset and close threads of the fittings. Diagnostics ACR2000 Refrigerant Service Solution High Pressure Cutout Switch Specifications & Service The high pressure cutout is a normally closed sensor de. In the normal setting (less than 435 128 anaerobic adhesive and methacrylic psi on the orifice). sealant to any internal threads. 10. Open the tank valves. Turn OFF the MAIN POWER switch and unplug the unit from the power source. Carefully remove the high pressure cutout switch. 12. HIGH PRESSURE CUTOUT SWITCH 86 . the unit halts operation and displays the “HI-P” message on the display. 1 3 2. 5. When this happens. Plug the unit into the power source. 2. Reconnect the orange and orange/white wires to the replacement vacuum switch. the spring contact has room to force there is nothing attached to the inlet of the unit. open the oil drain 4. Replace the panel(s) or shrouds. 9. Remove the orange and orange/white wires solenoid. 8. Completely depressurize the unit. Install new vacuum switch into unit. Turn OFF the MAIN POWER switch and un- off the unit. The switch should have continuity at this from the vacuum switch. The switch functions during the clearing. Operate the unit and check for leaks.ACR2000 Refrigerant Service Solution Diagnostics Vacuum Switch/Sensor Specifications & Service The vacuum switch is a normally closed switch. is shutting off before reaching a 13” Hg vacuum. 10. recovery and tank fill modes. Troubleshooting the Vacuum Switch 3. If Vacuum Switch/Sensor Replacement a 13” ± 2” Hg rating is reached at the intake. Plug the unit into the power source. Be sure the lower cavity. 6. 7. vided to the threads on the replacement switch/ sensor. replace the switch. With pressure in the accumulator. 87 . When a 13” Hg vacuum is achieved in plug the unit from the power source. check the inlet for obstructions before replacing the 5. Apply a small amount of the thread sealant pro- switch. shutting 1. If it does not. NOTE: You may need to remove the open terminals and crimp on the 1/4” terminals provided. VACUUM PUMP PROTECTION SWITCH The unit is ready to resume operation. Open the tank valves. the switch opens and breaks the coil contacts. If the unit vacuum switch. away from the mating contact. Carefully remove the point. Remove the units panel(s) or shrouds. OIL DRAIN SWITCH (2 Styles) Identifier Switch The identifier switch is a normally closed switch designed to control refrigerant flow to the identifier The switch will open if the pressure reaches 40 ± 3 psi. The switch is a two pin pressure switch with an orifice in the base of the switch. The oil that passes through the solenoid is collected in the external bottle for measurement purposes. When the switch detects the specific pressure the switch will signal the opening of the oil drain solenoid to remove the oil that has collected in the accumulator. The switch is used to stop the flow of refrigerant to the Identifier. The switch is a two pin pressure switch with an orifice in the base of the switch. The switch will reset and close at 27 ± 3 psi. if pressure rises to 40 psi or above. Diagnostics ACR2000 Refrigerant Service Solution Oil Drain Switch The oil drain switch is a normally closed switch designed to open when the switch pressure reaches 16 ± 3 psi. The switch will reset and close at 9 ± 3 psi. IDENTIFIER SWITCH 88 . 9. 2. Press the [SET-UP MENU] key—the Set-Up Menu should appear. 5. Press [ENTER]. Disconnect the service hoses from the rear of the ACR2000. From the Main Menu prompt.ACR2000 Refrigerant Service Solution Pressure Transducer The pressure transducer measures the pressure of incoming refrigerant from the high or low side of a system. 89 . 7. 4. the trans. or 1 oz. Recover any refrigerant from the service hoses. With the service hoses connected. The transducers should now be calibrated and 5. (atmospheric pressure on the transducers) on the ambient board and will need to be and press [START]. Test Pressure Transducer 1. Reconnect the service hoses. 3. Go into the Charge Mode and enter approximately . 8. pull a brief vacuum. 4. 3. Press [START] to charge the hoses. The Low Side Pressure Transducer stops the recovery process at 9 psi. press [NEXT] until the “SET-UP” key appears. PRESSURE TRANSDUCER 2. Be sure the hoses are disconnected as instructed ducer connections (P13 and P14) are reversed above. the high side pressure reading on the display will increase 6. Pressure readings are then relayed to the Control/ Display PCBA. Press the [UP ARROW] key until “CALI- BRATE PRESSURE” is highlighted. Press [RECOVER] to clear the hoses. read approximately “0” in Hg. (High Side Charge). Press [MAIN MENU] twice to return to nor- Calibrate Pressure Transducer mal operation. If the high side gauge and low side pressure reading increases. 1.1 lb. 10. If the transducers are properly connected. switched. ” If 2. lb. Display reads “ENTER KNOWN WEIGHT” and “REFERENCE WEIGHT = 20. Press the [DOWN ARROW] until “CALI- ways wear safety glasses. will take you into the Diagnostic Service Menu. 8. 12.) Set the ISV 11. display returns to the Diagnostic Service Menu. The display reads “APPLY off to the side. (Remove the three torx screws inside the back panel and the two on the front of the unit. Press [F4] for the Set-Up Menu. holding the ISV to the scale platform. Press [F5] for the Scroll Menu. 20. ACR2000 Refrigerant Service Solution Scale Calibration Procedure CAUTION: Observe all safety precautions. then press [ENTER].00 lb. Al. 7. Remove the weight. Turn power on. Remove the white internal storage vessel (ISV) weight is different.00LB. and use gloves when BRATE SCALE” is highlighted on the display. ACR2000 SCALE ASSEMBLY 90 . The unit is now ready to use. 7]. Press [ENTER]. (You may need to remove the three tank hoses. 5. weight to complete this procedure. to 25. Press [EXIT] to return to Main Menu.” panel.00 screen. 8. and close up the cabi- 6. Press [8. handling refrigerant hoses. the weight on the scale platform and press [START]. install the tank. The display reads “EMPTY WEIGHT FROM 1. Open the back cabinet door and take off the front SCALE AND PRESS START. Press [ENTER] and follow the prompts on the NOTE: You will need a known 20.00LB (or whatever weight you have entered with the keypad) AND PRESS START.) 10.” Place 3. use keypad to change weight from the scale by removing the two 3/8” bolts on display. which net. The scale is now calibrated and the 4. 7. 9. power. 9.8. handling refrigerant hoses. NOTE: If the potentiometer is already set so that the relay continuously clicks. Al. When the circuit trips. 19. Add “1 lb. turn the screw counterclockwise. remove the “1 2.” weight and check that the screen changes from age Vessel (ISV). Press [F4] for the Setup Menu. Press the [DOWN ARROW] key until “UL Calibration” appears highlighted on the screen. Place “42 lbs. lb. 7. 5. trips. 15. Adjust the potentiometer on the relay board so that the UL circuit just trips as indicated by a continual clicking noise caused by a relay on the board. 91 . ignore this step. Press [F5] for Scroll Menu. “Error” to “OK. 1. 3.” Press the function key underneath the Main Menu option to exit. Calibration is complete. 18. 16. UL Calibration Potentiometer 11. 13. 4. and use gloves when option. 14. 8.” on the scale. 17.” to the scale (making the total weight NOTE: You will need a known weights to complete on the scale 43 lbs. Disconnect unit from power. Press the function key beneath the Main Menu ways wear safety glasses. then turn the potentiometer clockwise to trip the circuit. Press [8. RELAY BOARD 12. 10.7. Then slowly turn the potentiometer counterclockwise until you hear the relay board stop clicking. then press [ENTER]. Disconnect unit from power. Remove the side panel to access the Internal Stor. When the error message appears.) and make sure the circuit this procedure. Re-install ISV and secure to scale with the two screws removed earlier. If the light is on. Re-install the unit’s side panel and reconnect the 6. Remove the two screws securing the ISV to scale. Tilt tank back and rotate as it is lifted out of the unit. an error message will appear on the screen.7]. If the lamp is not illuminated. Reconnect power and turn on the power switch.ACR2000 Refrigerant Service Solution UL Circuit Calibration Procedure CAUTION: Observe all safety precautions. ACR2000 Refrigerant Service Solution Expansion Valve (RA19550) Adjustment Instructions 5. Clear the high and low side hoses. 40 psi (207-276 kPa). 4. Attach the red and blue high and low side hoses. 6. 2. 1. 10. ting on the compressor assembly. activate the oil flush mode and run for one minute. From the Main Menu screen. 11. Noting the location for reassembly. Attach an external service gauge to the test fit. the external service ports of the ACR2000 together. 9. Adjust the expansion valve until the reading is 30- the ACR2000. remove the red and blue 96" external service hoses from 7. Observe the attached external service gauge for a reading of 30-40 psi (207-276 kPa). 3. Turn on the ACR2000 main power switch and allow the self-test to perform. Remove the testing hose. Install ½" x ½" acme testing hose to connect 8. Exit the oil flush mode. SINGLE PORT EXPANSION VALVE 92 . ACR2000 Refrigerant Service Solution Diagnostics NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 93 . Diagnostics ACR2000 Refrigerant Service Solution NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 94 . ACR2000 Refrigerant Service Solution Diagnostics SYSTEM WIRING 95 . 96 Control Harness (122254) CONTROL HARNESS (122254) CONNECTOR # CONNECTS TO: CONNECTOR # CONNECTS TO: 1 Display/Control Board 15 Relay Board 2 Display/Control Board 16 Relay Board 3 Display/Control Board 17 Relay Board 4 Display/Control Board 18 Low Pressure Sw itch 5 Display/Control Board/Pow er Connector 19 Low Pressure Sw itch 8 Lamp 20 Low Side Pressure Sw itch 9 Lamp 21 High Side Pressure Sw itch 10 Analog Input Board 22 Ambient Input Board 11 Printer 23 DC Pow er Supply Diagnostics Control Harness (122254) 12 Refrigerent Identifier 24 Fuse Holder 13 Oil Drain Sw itch 25 Fuse Holder 14 Oil Drain Sw itch ACR2000 Refrigerant Service Solution . ACR2000 Harness (121783) ACR2000 HARNESS (121783) CONNECTOR # CONNECTS TO: CONNECTOR # CONNECTS TO: 31 Main Pow er Sw itch 41 Pow er Cord 32 Main Pow er Sw itch 42 Pow er Cord Bracket 33 Main Pow er Sw itch 43 Pow er Supply Ground 34 Main Pow er Sw itch 44 Pow er Supply Input 35 3A Circuit Breaker 45 Relay Board 36 3A Circuit Breaker 46 Main Ground Stud 37 15A Circuit Brieaker 47 Unit Ground Stud 38 15A Circuit Brieaker 48 Unit Ground Stud ACR2000 Refrigerant Service Solution 39 Pow er Cord 49 High Pressure Sw itch 40 Pow er Cord 50 High Pressure Sw itch ACR2000 Harness (121783) Diagnostics 97 . Diagnostics ACR2000 Refrigerant Service Solution Compressor (&Vacuum) Harness (122278) COMPRESSOR HARNESS (122278) CONNECTOR # CONNECTS TO: 56 Relay Board 57 Compressor (Thermal Protection) 58 Compressor (Start Relay) 59 Vacuum Pump (Blue) 60 Vacuum Pump (Brow n) Printer Harness (121847) PRINTER HARNESS (121847) CONNECTOR # CONNECTS TO: 61 Printer 62 Display Control Board 98 . ACR2000 Refrigerant Service Solution Diagnostics UL Circuit Cable (122030) UL CIRCUIT CABLE (122030) CONNECTOR # CONNECTS TO: 63 Relay Board 64 Display/Control Board CATV Harness (121848) CATV HARNESS (121848) CONNECTOR # CONNECTS TO: 71 Analog Mounting Bracket 72 Display/Control Board 99 . Diagnostics ACR2000 Refrigerant Service Solution Compressor/Fan Ground Wire (122419) COMPRESSOR/FAN GROUND WIRE (122419) CONNECTOR # CONNECTS TO: 75 Unit Ground Stud 76 Compressor 77 Fan Vacuum Pump Ground Wire (122418) VACUUM PUMP GROUND WIRE (122418) CONNECTOR # CONNECTS TO: 73 Vacuum Pump 74 Unit Ground Stud 100 . ACR2000 Refrigerant Service Solution Diagnostics COMPONENT WIRING AMBIENT SENSOR BOARD ANALOG INPUT BOARD RELAY BOARD DISPLAY/CONTROL BOARD 101 . Diagnostics ACR2000 Refrigerant Service Solution REFRIGERANT IDENTIFIER POWER SUPPLY SCALE COMPRESSOR PUMP PRINTER 102 . ACR2000 Refrigerant Service Solution Diagnostics FAN LAMP GROUND POINTS FUSE HOLDER 3AMP 15AMP CIRCUIT BREAKER MAIN POWER SWITCH POWER CORD 103 . Diagnostics ACR2000 Refrigerant Service Solution LOWER OIL DRAIN MANIFOLD ASSEMBLY UPPER MANIFOLD ASSEMBLY 104 . ACR2000 Refrigerant Service Solution Diagnostics NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 105 . PRESSURE VALVE TRANSDUCER SYSTEM OIL LOW SIDE INLET SEPARATOR SOLENOID ID SWITCH PRESSURE/FEEDBACK SOLENOID SOLENOID INLET CHECK VALVE VACUUM SOLENOID TANK TEST SOLENOID FILTER/VACUUM CHECK VALVE ID/AIR PURGE FREE AIR SOLENOID RECOVER SOLENOID INLET TEST OIL RETURN FILTER/VACUUM SOLENOID FILTER SOLENOID SOLENOID SOLENOID UPPER MANIFOLD BLOCK ASSEMBLY OIL DRAIN HIGH PRESSURE SWITCH CUTOUT SWITCH CLEARING-2 TANK FILL OIL DRAIN SOLENOID CHECK VALVE SOLENOID TANK FILL ID DRAIN SOLENOID SOLENOID OIL DRAIN CHECK VALVE ORIFICE ID DRAIN INITIAL FILL CHECK VALVE CHECK VALVE (Removed mid-production) LOWER OIL DRAIN BLOCK ASSEMBLY 106 .S. PRESSURE LOW SIDE CHARGE TRANSDUCER SOLENOID EXPANSION L.S. Diagnostics ACR2000 Refrigerant Service Solution COMPONENT IDENTIFICATION CLEARING-1 CLEARING HIGH SIDE CHARGE SOLENOID COMPRESSOR OIL CHECK VALVE LOW SIDE CHARGE SOLENOID HIGH SIDE CHARGE SEPARATOR CHECK VALVE HIGH SIDE INLET CHECK VALVE POWER CHARGE DISCHARGE SOLENOID SOLENOID CHECK VALVE H. (7) Low Side Inlet ON ON ON ON Solenoid (2) Oil Drain ON Solenoid (18) Pow er Charge ON Solenoid (12) Pressure Feedback ON Solenoid (11) Recover ON ON Solenoid (4) Tank Fill ON Solenoid (16) Tank Test ON Solenoid (14) Vacuum Pum p ON Vacuum ON Solenoid (10) * Normally Open Solenoid. (8) High Side Inlet ON ON Solenoid (3) ID Drain ON ON Solenoid * (17) ID Air Purge Solenoid (13) Identifier ON ON Inlet Test ON Solenoid (1) Low Side ON Charge Sol. ** 3-Way Solenoid 107 .ACR2000 Refrigerant Service Solution Diagnostics Component Application Chart Charging Charging High Side Low Side Oil Flush Pow er Vehicle Vacuum / Oil Drain Recovery Tank Test (High Side) (Low Side) Clearing Clearing (Stage 1) Charge Testing Tank Fill Clearing-1 ON Solenoid (5) Clearing-2 ON ON Solenoid ** (19) Com pressor ON ON ON ON ON ON Equalization/ Oil Return Solenoid (15) Fan Motor ON ON ON ON ON ON Filter/Vacuum Solenoid (6) Free Air ON Solenoid * (9) High Side ON ON Charge Sol. Neutronics PRESSURE Inlet Test Solenoid ENERGIZED Low Side Inlet Solenoid ACR2000 Refrigerant Service Solution .108 Vehicle Testing Diagnostics FLOW DIAGRAMS CV Energized Components: ID Drain Solenoid Identifier. NOTE: Vacuum switch stops low side clearing Low Side Clearing ACR2000 Refrigerant Service Solution CV SUCTION Diagnostics DISCHARGE Energized Components: Compressor Fan Motor (Not Shown) PRESSURE ENERGIZED 109 . 110 High Side Clearing Diagnostics NOTE: Condenser will be in a vacuum after High Side Clearing CV SUCTION Energized Components: Clearing-1 Solenoid DISCHARGE Clearing-2 Solenoid PRESSURE Compressor Fan Motor (Not Shown) ENERGIZED ACR2000 Refrigerant Service Solution . NOTE: Low Side Pressure Transducer stops recovery at ~ 9” vacuum. Recovery ACR2000 Refrigerant Service Solution CV SUCTION Energized Components: Compressor Diagnostics DISCHARGE Fan Motor (Not Shown) High Side Inlet Solenoid PRESSURE Low Side Inlet Solenoid ENERGIZED Recover Solenoid 111 . 112 Oil Drain Diagnostics ○○○○○○ ○ ○ NOTE: Opens for 20 seconds ○ ○ ○ ○ ○ ○ ○ ○○○○○○○○○ ○ ○ ○○ ○ ○ ○ CV ○ ○ PRESSURE Energized Components: Oil Drain Solenoid OIL DRAIN ○ ○ ○ ○ ○ Pressure Feedback Solenoid ENERGIZED ACR2000 Refrigerant Service Solution . Vacuum/Tank Fill ACR2000 Refrigerant Service Solution CV SUCTION DISCHARGE Diagnostics PRESSURE Energized Components: Compressor Low Side Inlet Solenoid Fan Motor (Not Shown) Tank Fill Solenoid VACUUM Free Air Solenoid Vacuum Pump ENERGIZED High Side Inlet Solenoid Vacuum Solenoid 113 . Diagnostics ACR2000 Refrigerant Service Solution Charge (High Side) ENERGIZED PRESSURE Energized Components: High Side Charge Solenoid CV 114 . ACR2000 Refrigerant Service Solution Diagnostics Charge (Low Side) ENERGIZED PRESSURE Energized Components: Low Side Charge Solenoid CV 115 . 116 Power Charge Diagnostics CV SUCTION Energized Components: Clearing-2 Solenoid Compressor DISCHARGE Power Charge Solenoid ENERGIZED ACR2000 Refrigerant Service Solution . ACR2000 Refrigerant Service Solution CV Oil Flush — Stage 1 (Stage 2 is normal recovery cycle) SUCTION Diagnostics DISCHARGE Energized Components: Compressor Low Side Inlet Solenoid PRESSURE Fan Motor (Not Shown) Recover Solenoid ENERGIZED High Side Charge Solenoid 117 . 118 Tank Test Diagnostics CV Energized Components: ID Drain Solenoid PRESSURE Neutronics Identifier Tank Test Solenoid ENERGIZED ACR2000 Refrigerant Service Solution . ACR2000 Refrigerant Service Solution Diagnostics NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 119 . Diagnostics ACR2000 Refrigerant Service Solution NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 120 . .................................. 131 ACR2000 Upgrade (#140) ................................................................................. 142 Revised Function Check and Component Replacement Times (#169) .............................................................................................................. 134 Tank Tare Weight (#143) ............................................................................................................................................. 148 121 ....................................................................... 125 ACR2000 Scale Error with UL Circuit Tripped (#132) ................. 2....................... 127 ACR2000 Blank Display (#135) .........................................................ACR2000 Refrigerant Service Solution 4 SERVICE BULLETINS ACR2000 Printer (#129) . 141 ACR2000 Extended Warranty Contracts (#163) ............................................................................................................................... 129 ACR2000/342000 Unit Contaminated (#139) .............................................. 146 New Torque Specs for O-ring Connections (#176) ........................................................................................... 147 Possible Crossed Wires (#177) ...............................................................................................................................Revised 7/14/00 (#131) ...... 137 Internal Tank Fill & Vacuum Pump Issues (#156) ........................................................................ 133 ACR2000 Upgrade Troubleshooting (#142) .................................... 145 Repair Time for Leaking Tank Valves (#174) ......................................................................... 135 342000 Software (#145) ........................................................................... 136 ACR2000 Strainer Update Kit (#149) ...........................................................10) (#171) .............................. 123 ACR2000 Refrigerant Service Tool Filter Change Lockup Procedure (#130) .......................... 143 ACR2000 Software Upgrade (Rev.......................... 140 ACR2000/342000 Controls & Keypad Adapter (#158) ................................................................ 132 Automatic Oil Drain (#141) ...................................................................................................................................................................................................... 124 ACR2000 UL Calibration Procedure ............................ 126 ACR2000 Contamination Cleaning Process (#134) ................................................................................................. Service Bulletins ACR2000 Refrigerant Service Solution Place Service Bulletins for the ACR2000 Refrigerant Service Solution Unit here. 122 . Press the print button until you get the following line: BAUD RATE=1200 Push the feed to lock this option in. 11. Press the print button until you get the following line: BUFFER 1K BYTE Push the feed to lock this option in. Press the print button until you get the following line: SPEED/CURRENT=NORMAL Push the feed to lock this option in. Press the print button until you get the following line: CR-LF IGNORE CR Push the feed to lock this option in. 13.1 Push the feed to lock this option in 14. Press the print button until you get the following line: MODE=LITTLE Push the feed to lock this option in. press and hold the print and feed buttons. Press the print button until you get the following line: PRINT=NORMAL Push the feed to lock this option in. 7. Press the print button until you get the following line: PRINT KEY TRANSMIT $OD Push the feed to lock this option in. 4. Then. 8. Then the printer should print *END PROGRAM* 123 . the printer should print *SERIAL MODE*. Press the print button until you get the following line: 40 COLUMNS (font 9x24) Push the feed to lock this option in.N. 16. 9. 12. Press the print button until you get the following line: FOLW CONTROL = XON-XOFF Push the feed to lock this option in. Turn on the Main Power switch. Press the print button until you get the following line: FONT 1 Push the feed to lock this option in. 6. With unit off. 15. With main power switch on release both buttons. Press the print button until you get the following line: RED INTENSITY =5 Push the feed to lock this option in. Press the print button until you get the following line: AUTOFEED =ENABLED Push the feed to lock this option in. 10. 3. Press the print button until you get the following line: PROTOCOL = 8.ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0129 DATE: 23 May 00 SUBJECT: ACR2000 Printer FROM: Technical Service and Support Resetting the ACR2000 printer 1. 5. 2. 4. MATERIALS REQUIRED: A piece of solid core jumper wire A flat-blade screwdriver A T30 Torx driver INITIAL CONDITIONS: During the filter change routine. SHORT PINS #2 & #3 TOGETHER 124 . improper calibration of the pressure transducers. Hold the wire in place until the vacuum pump turns off and the lamp and buzzer operate. 5. 3. 6. or a bad low-side pressure transducer. Some possible causes of this problem include a leak in the system. the unit begins to pull the system into a vacuum. Remove all three shrouds from the unit. check for leaks in the system or a bad low-side pressure transducer. Turn the unit on and restart the filter change routine. but the low-side pressure transducer reading will not come down to 20 “Hg. Press MAIN MENU to continue. Reconnect the plug to the low-side pressure transducer. Disconnect the plug from the low-side pressure transducer. 2. using the jumper wire. Service Bulletins ACR2000 Refrigerant Service Solution SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0130 DATE: 5 July 00 SUBJECT: ACR2000 Refrigerant Service Tool Filter Change Lockup Procedure FROM: Technical Service and Support SCOPE: To provide procedures to reset the unit in case of lockup during the filter change routine. Perform the pressure transducer calibration procedure. Short pins 2 and 3 of the plug together. NOTE: Disconnect the high-side and low-side hoses from the unit before calibrating the pressure transducers. PROCEDURE: 1. If the unit locks up during the filter change procedure again. The display will read FILTER CHANGE COMPLETE. The display will read EVACUATING FILTER AUTOMATICALLY STOPS WHEN LOW-SIDE REACHES 20 “HG. 125 . Use the function key underneath the Scroll option at the bottom right hand corner of the screen until the Setup menu option appears on the bottom of the screen. 6. If the light is on then turn the potentiometer clockwise to trip the circuit. Press the function key beneath the Main Menu option. Tilt tank back and rotate as it is lifted out of the unit.ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0131 DATE: 14 July 00 SUBJECT: ACR2000 UL Calibration Procedure (REVISED 7/14/00) FROM: Technical Service and Support 1. 2. Add 43 pounds to the scale and make sure the circuit trips and an error message appears on the screen. Remove side panel to access the ISV. 3. Remove 2 screws holding ISV on scale. Calibration is complete. 16. 10. Then press the function key that is directly beneath the Setup option. Disconnect power and re-shroud the unit. Scroll down the list of options using the Down Arrow key until UL Calibration is highlighted and press the function key underneath the Enter option. Disconnect unit from power. Place 42 pounds on the scale. 14. 15. 13. press the function key underneath the Main Menu option to rest. You will hear the relay board stop clicking. When the error message appears. 8. 8. Adjust the potentiometer on the relay board so that the UL circuit just trips as indicated by a continual clicking noise caused by a relay on the board. Press 8. 7. 11. 9. Reconnect to power and turn on the power switch. Note: If the potentiometer is already set so that the relay continually clicks ignore this step. 7 (in this order) followed by the function key underneath the Enter option. remove one pound and make sure the screen changes from error to OK. 4. 12. 5. 7. Then slowly turn the potentiometer counterclockwise. If the lamp is not illuminated turn the screw counter clockwise. ) 5. 8. Open the valve on the end of the service hose. Service Bulletins ACR2000 Refrigerant Service Solution SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0132 DATE: 14 July 00 SUBJECT: ACR2000 Scale Error with UL Circuit Tripped FROM: Technical Service and Support When the display is reading Scale Error and the UL circuit is tripped. 7. 8. 7. (IN THE FOLLOWING STEPS DO NOT ALLOW THE COMPRESSOR TO RUN AS IT WILL NOT BE LUBRICATED AND WILL BURN UP. 4. Take and tilt the unit back onto its’ handle. Scroll to the output step test and then push enter. and reset the UL trip point according to service bulletin 0131. 7. Pull a vacuum on a reusable recovery tank. Install a 16301 adapter onto the low vapor valve of this tank then connect the low side service hose to this fitting. This should cause the excess weight to be removed from the scale. then enter. Turn the unit on and the go the out put step test. 2. Energize the low side charge solenoid and allow as much refrigerant flow out of the unit into the reusable recovery tank. To get to the out put step test go into setup menu and then push 8. 6. 126 . perform the following procedure. 3. 1. ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0134 DATE: 27 October 00 SUBJECT: ACR2000 Contamination cleaning process FROM: Technical Service and Support 1. 8. Push ENTER (F4) once. Connect one end of the Identifier reset fitting to the hose that was removed from the center valve. 12. and 7. Plug unit into proper voltage outlet. 3. 4. Close center tank valve. Turn unit on and allow the identifier to reset. then remove the side panel and top hood covering the scale. Mark the two remaining hose as to which valve they are connected to. 7. Once the system resets push SCROLL MENU (F5) once. the tank will need to be replaced 6. 25. • NOTE: IF IDENTIFIER DOES NOT RESET REPLACE IDENTIFIER. Open filters access door. 24. 23. Holding all 3 tank hoses pointed in a safe direction. 17. Now slowly remove these hose from the tank valves. If tank does not come up contaminated then the identifier need to be tested. 15. 8. then push ENTER (F4) once. Push the blue arrow down button 25 times until the OUTPUT: 23 OIL DRAIN SOELNOID is displayed. for kinks. Highlight OUTPUT STEPTEST by pressing the blue arrow button.Press MAIN MENU (F5) once. Display will show SERVICE CLEAR CLEARING. Push 8. 20. 21. When display shows “PRESS MAIN MENU TO EXIT” close the other 2 remaining tank valves. Highlight the SERVICE CLEAR by pressing the blue arrow keys. 10. 11. Push the START (F2) once. 13. 14. Remove hose from center valve. Push the SET-UP MENU (F4) once. Push the ENTER (F4) once. • If the tank comes up contaminated. 19. 2. Check the piece of black tubing. one button at a time. which goes from the main manifold block to the identifier. 127 . 5. Take another identifier and then connect it to the valve that you removed the hose from. 9. 18. 7. Connect the other end to a hose that is connected a VIRGIN REFRIGERANT SUPPLY (VAPOR ONLY). 22. 16. Service Bulletins ACR2000 Refrigerant Service Solution 26. When 5 minutes has elapsed highlight SERVICE VACUUM by pressing on the blue arrow keys.Turn the vacuum pump on. 33. Push MAIN MENU (F5) once. Push MAIN MENU (F5) once.When the tank fill procedure is complete shut unit off. 37. Then turn unit back on so that it will do a source tank test. Push START (F2) once. 41. •It is their responsibility to dispose of the contaminated refrigerant properly. Push EXIT (F5) once. according to how you marked them when they were removed. Remove the internal storage tank from unit and give to customer. Reconnect hoses to valve on the ISV. 30. Connect an external vacuum pump to the ISV access port. 39. 28. Push MAIN MENU (F5) once.Allow the service vacuum to time out. 35. 38. Open all three of the tank valves and allow the pump to run for 5 minutes. Refer to operation manual for testing source tank. After source tank has been identified as good refrigerant go through the tank refill procedure. 42. 32. 27. 34. 29. 36. 40. 31. Install new internal storage vessel making sure to RECONNECT THE GROUNDING STRAP. Push ENTER (F4) once. Identifier Test Fitting 119983 117328 THIS END THIS END CONNECTS CONNECTS TO THE TO THE HOSE FROM HOSE FROM VIRGIN REFRIGERANT UNIT TANK 128 . We will provide these parts to you at no charge. If you are doing service to a unit for the customer that is not for warranty. You will be payed 15 minutes for installation of this component in warranty only if you are there for a warranty call. You will need to order part number RA19772 (115623) Ferrite Bead and install it on every ACR2000 that you are out on. You will need to remove the top shroud from the unit and locate the harness that connects to the left side of the controller board.ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0135 (Revised 20 April 01. Supercedes previous 0135) DATE: 20 April 2001 SUBJECT: ACR2000 Blank Display FROM: Technical Service and Support In testing ACR2000 220-volts for overseas use we found that when the display would go blank during operational processes. At the same time it was discovered that this would also eliminate this problem in the 110-volt units. If you are out to repair a unit that has this problem do not replace board until the ferrite bead is installed and then the unit is powered up and tested. To cure this problem a ferrite bead was installed on the wiring harness going to the controller board. RA19772 Board Ferrite Connections Bead Ferrite Bead Sta-strap Note: When Installing the wires into the ferrite bead it will be a tight fit so make sure that it snaps closed. Please order only what you will need. Find the connections that connect to the board and move back to the first sta- strap then install the ferrite bead just ahead of it (See diagram below and the one on the following page for correct location). Page 1 129 . you will not be paid for installing the part. Service Bulletins ACR2000 Refrigerant Service Solution Circuit Board Connections 1. &3 Ferrite bead Wiring Harness 121231 Page2 130 .2. If the unit does not come up contaminated again. the identifier must have calibrated incorrectly the first time. Tech Support will then give the customer the • number to the closest service center. Robinair will cover the cost of the repair under warranty.ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0139 DATE: 22 April 2001 SUBJECT: ACR2000/ 342000 Unit Contaminated FROM: Technical Service and Support Current Robinair policy on units reading contaminated: The customer should call Robinair Technical Support. Should the unit display “Unit Contaminated” a second time. We will use the current warranty rates for the repair. 131 . If the service center finds the unit to have a defective identifier or other component. The customer may continue to use the unit as normal. please call tech service to open a service order. If a component is defective. Tech Support will ask the customer to cycle the power and attempt to use the unit once again. The customer will need to contact the service center. The service center will set up an appointment and inform the customer that the service will be charged at regular repair rates if the unit is truly contaminated. Service Bulletins ACR2000 Refrigerant Service Solution S P X ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0140 DATE: 10 May 2001 SUBJECT: ACR2000 Upgrade FROM: Technical Service Department The ACR2000 software is ready for field use. If you are on a non warranty call.09 software. please call 1-800-822-5561 132 . Copies will be sent to all GM dealerships by July. Catastrophic failure will result if ACR2000 software is loaded on a 342000. We will be sending all service centers a free copy of Version 2. please do the update as a curiosity to the dealership. Once you receive the software. Do Not !!! Update 342000’s with this software. Upgrade cable 19674.09. The ACR2000 software is incompatible with the 342000. please update all ACR2000’s that you recieve a warranty call. When you close the call please document this on the form with ACR2000 Software Updated. This will be the term we use to pay 15 minutes labor for the update. For more information. March production and newer units are already programed with Version 2. Updates for the 342000 will follow. It will receive power for 20 seconds. the compressor will stop and the recovery solenoid receives power. 10. The solenoid will stay open allowing the vacuum switch to detect a lose in vacuum. The unit stops recovery when the vacuum switch reaches 13” of vacuum +/. 342000 and the ACR2000 all have automatic oil drain. 6. 5. 34900. At the end of five minutes. These units have a normally closed equalization solenoid. 2. steady drain of oil. and 348002k that has software which supports Auto Recovery Restart. the recycle (pressure feedback) solenoid closes. the oil drain process stops. The recycle (pressure feedback) solenoid stays open allowing liquid refrigerant from the storage vessel to pressurize the system oil separator. 4. please call 1-800-822-5561 133 . 348002k.ACR2000 Refrigerant Service Solution Service Bulletins S P X ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #:0141 DATE: 05 Jun 2001 SUBJECT: Automatic Oil Drain FROM: Technical Support The 34900. Once recovery is complete. the unit will do a low side clear. the oil drain solenoid closes. Here is how the unit work. the recycle (pressure feedback in ACR2K style units) opens. 9. the recovery solenoid opens for an additional 2 minutes.3”. Once the oil drain switch detects 9 PSI for three seconds. 8. In the case of the 347002k. before the unit equalizes and returns compressor oil. Once the vacuum switch reaches 13” of vacuum. 1. 7. An orifice located between the oil separator and the oil drain switch slows down the refrigerant pushing out the oil. 11. The process for all these units is very similar. ACR2000 style units use the pressure transducers to restart recovery. Once the oil drain switch reaches 16 PSI. The unit will then do compressor equalization and oil return. if pressure exists the unit will restart recovery. When the oil drain switch detects 9 PSI. This is due to the orifice slowing down the refrigerant leaving from the separator. The slowing down of the refrigerant allows for a smooth. 3. Next the oil drain solenoid opens to allow the oil to be drained. The oil drain solenoid may open and close several times as the pressure on the oil drain switch increases and decreases. For more information. Once recovery stops. 347002k. 2. A. The software is designed to be used with the serial port and the 19674 cable. then control panel.Do the following steps. If the ACR2000 fails to recognize the software communication (the symptom is the software prompts to connect the upgrade cable and turn on ACR2000. Should the sleep or suspend mode activate will the update is taking place. the link has not been established with the ACR2000). E. G. This is the com port we have tested with the software and the HP Omnibook. Ensure you are not using the ethernet connection on your computer. You must figure out which program is holding the com port and get it to release the port. Turn off unit. the transfer could be interrupted. The network port on your PC will not work. F. D. Ensure the cable is securely attached to the main board inside the ACR2000. Insure the software has Com 1 selected for the com port. B. If you do not have an HP Omnibook you may need to experiment with the other Com port. Please disable these features. Please insure the sleep or suspend mode is turned off on the computer. 4. please call 1-800-822-5561 134 . Reboot the laptop and start the whole process over. Ensure you select the com port and then reboot your laptop prior to starting the install. Reinstall the ACR2000 software on your PC. Both can be found by going to Start. 5. If the Upgrade button on the computer’s display does not have the word upgrade turn dark. C. You might have a couple of icons labled Monitor/Display and Power/Power Management. This means on your PC you have a program that has taken over the comport that the software has been designed to use. Replace the cable that runs between the main board and the RJ45 jack on the outside of the unit. 3. Disconnect the cable. Sleep and suspend will be in at least two locations. Service Bulletins ACR2000 Refrigerant Service Solution S P X ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #:0142 DATE: 05 June 2001 SUBJECT: ACR2000 Upgrade Troubleshooting FROM: Technical Support Troubleshooting tips for upgrading an ACR2000 1. you could receive this message “Will not release com port” or some similar message. When you are installing the upgrade software on your PC. The ACR2000 must be turned off before the upgrade process can start. For more information. Ensure the upgrade cable is connected to the unit. 50 lbs. For more information. 348002k. The service manauls for these units explain how to set the tare weight. Please insure when you are calibrating scales on the 347002k. 342000 and ACR2000.30 lbs. you need to check the tank tare weight. Units with ISV’s that have quick seal connections have a tare weight of 16.ACR2000 Refrigerant Service Solution Service Bulletins S P X ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0143 DATE: 07 June 01 SUBJECT: Tank Tare Weight FROM: Technical Support Units with ISV’s that have ball valves on top have a tank tare weight of 17. 34900. please call 1-800-822-5561 135 . Also when installing a new board check to make sure the tare weight is set for the type of ISV in the unit. There is only one inconvenience if the new program is placed in a oilless 342000. The only way to know the difference by the unit label will be the date code. These units will have an external oil fill and drain port like the 347002k. There was no serial number sequencing change. These units were produced with an oilless vacuum pump just like the ACR2000. The customer can simply reset the timer. This program will work in all units. The RA19737 has been changed to the new vacuum pump program. 136 . A program to change between the two versions of software on the RA19737 will be sent by the first of August. The oiled pumps will all be 2001 and newer. The inconvenience will be a periodic reminder to change the vacuum pump oil. Service Bulletins ACR2000 Refrigerant Service Solution SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0145 DATE: 19 June 01 SUBJECT: 342000 Software FROM: Technical Service and Support The 342000 production started in year 2000. 342000 produced in year 2001 have a Robinair oiled vacuum pump. The software version in the oiled •pump unit has a default vacuum time of 15 minutes. The biggest change will be in the programing of the circuit board. the fan runs during vacuum to keep the pump cool and it has a oil change reminder. ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN BULLETIN #: 0149 DATE: 19 October 01 SUBJECT: ACR2000 Strainer Update Kit FROM: Technical Service and Support 137 . Service Bulletins ACR2000 Refrigerant Service Solution 138 . ACR2000 Refrigerant Service Solution Service Bulletins 139 . but does not run. SOLENOID Or: Refrigerant leakage at free air port on upper manifold block FREE assembly. Service Bulletins ACR2000 Refrigerant Service Solution SPX ROBINAIR TECHNICAL SERVICE BULLETIN HARDWARE SUBJECT: ff Internal Tank Fill & Vacuum Pump Issues NO: 00156-HW(b) EQUIP.) Lower Manifold Block Assembly For more information. repair unit. (See Figure 2. FREE AIR SOLENOID bly does not bleed down or bleeds slowly (or in some cases leaks positive pressure). Do NOT attempt to stretch or modify existing part to Figure 1. (Other failures may also cause this symptom. Replace with correct part. AFFECTED: ACR2000 R-134a Refrigerant Unit DATE: June 2002 ACTION REQUIRED: Informational AUTHOR: S. Figure 2. Upper Manifold Block Assembly Unit Won’t Add to the Internal Tank PROBLEM: The message SOURCE TANK EMPTY is displayed. VACUUM motor gets hot. pump hums. please call 1-800-822-5561 SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE.) SOLUTION: Replace check valve (P/N RA19504) between tank fill hose (strainer) and elbow at rear of lower manifold block assembly. (Other failures may also cause this symptom.) AIR PORT CAUSE: 3-WAY The 3-way free air solenoid on the upper manifold block assem. Vacuum Pump Won’t Start or Leakage at Free Air Port (Possibly intermittent) PROBLEM: Vacuum pump appears to be locked. has power. 140 .) SOLUTION: Replace spring and seat (P/N 123829) in the 3-way free air solenoid. date code 4/02 and higher. may be affected by this bulletin. CHECK VALVE 120453 (RA19504) CAUSE: ELBOW Excessive amounts of Loctite thread locker causes the check 111161 valve to stick shut. This is generally caused by the use of an incorrect spring and seat in the 3-way free air solenoid. Parde Potential ACR2000 Field Issues The following two issues are believed to have been contained and repaired in-house—with a few possible exceptions—Saturn Order SN 9500 and up. (See Figure 1. However. These controls require the use the Keypad Adapter. There is no part number change or clear date code when the internal change to the control assembly occurred (sometime in the first quarter of 2001). the early controls have a numbered triangle next to the input/output connectors and the late controls do not. Also. please call 1-800-822-5561 SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE. the Keypad Adapter should NOT be used when servicing the newer style control assemblies built since early 2001 on the ACR2000 and 342000 products.) Earlier Style Control Newer Style Control Note numbered triangles after connector Note “TL” in label. 141 . (See the illustrations below. These controls do NOT descriptions. Parde A Keypad Adapter (P/N 122360) must be used when replacing the Control Assembly on early ACR2000 and 342000 products.ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN HARDWARE SUBJECT: ACR2000/342000 Controls & Keypad Adapter NO: 00158-HW EQUIP. The easiest way to distinguish between the two controls are. (P/N RA19606A and RA19737 respectively). the late control assemblies have “TL” on the sticker indicating they were built by TL Industries. Keypad Adapter shown below. These controls do NOT require a keypad adapter. AFFECTED: 342000 & ACR2000 Products DATE: May 2002 ACTION REQUIRED: Informational AUTHOR: S. Keypad Adapter For more information. The second year of a two year extended warranty covers parts only. (See sample below. please call 1-800-822-5561 SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE. OH 49000-0011 ACR2000 Extended Contract UNITED STATES Telephone : 800-134-1212 information is provided here. OH 43543 Service Order Date : 04-12-02 [12:26] Page : 1 SSprd . NOTE: When performing repairs through the second year of the contract. RA19772 FERRITE BEAD For more information. The first year of the extended warranty covers everything except consumables. Location : 234567 Service Area : 000 AC SERVICE INC Planning Info : 52.00 miles Call Text UNIT WILL SHUT OFF WITH LOW VOLTAGE. 131. Service Centers should obtain a PO number for the additional charges. W/AMERICOLD COMP Installation : 01234/ACR2000 AIR CONDITION SPECIALISTS Counter Reading : 0 on Warranty to : 07-16-02 Service Package : ACR20002YR ACR2000 2 YEAR SVC CONTRACT Reported : 07-17-02 11:50 Contract : 000014 ACR2000 2 YEAR SVC CONTRACT Effective Date : 07-16-2002 Expiry Date : 07-16-2004 _________________________________________________________________________________ Work Site : AIR CONDITION SPECIALISTS 1234 COUNTRY ROAD PO BOX 134 FREON. THEY HAVE CONFIRMED THERE IS 110V TO THE MACHINE. 158 CHECK FOR THE FOLLOWING UPDATES: 2/10 SOFTWARE UPDATE. 156. GM. 135. along with the start (effective) and expiration date of the contract. 141. 139. 132.) The information will provide extended warranty duration (1 or 2 years). RI BULLETIN 129. 149.Production A/C Company : 250 _________________________________________________________________________________ Created By : rinair Rob Inair Service Order : 654321 LOW VOLTAGE Customer : M12134 AC SERVICE INC Install Type : ACR2000 RRR UNIT. 142 . 122360 KEYPAD ADAPTER (WHEN NECESSARY). H sAMPLE SPX CORPORATION ROBINAIR DIVISION 1224 ROBINAIR WAY MONTPELIER. 143. RA19733 STRAINER KIT. 140. 134. 130. Service Bulletins ACR2000 Refrigerant Service Solution SPX ROBINAIR TECHNICAL SERVICE BULLETIN INFORMATION SUBJECT: ff ACR2000 Extended Warranty Contracts NO: 00163-IN EQUIP. AFFECTED: ACR2000 Unit DATE: July 2002 ACTION REQUIRED: Informational AUTHOR: S. Parde All Service Centers ACR2000 Extended Warranty Contract information is now available on the service order. ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN INFORMATION SUBJECT: Revised Function Check and Component NO: 00169-IN Replacement Times DATE: August 2002 EQUIP. AFFECTED: Series ACR2000 AUTHOR: C. Bush ACTION REQUIRED: Informational S. Parde Function Check — Update ACR2000 Service Manual 1. Plug unit in and turn power on. Screen should display 12. Hook a manifold gauge to the service port on the com- ACR2000, then VERSION 2.10. If any other version pressor. appears, the unit needs to be updated. 13. Select RECOVER. 2. If there is pressure in the lines, the unit should have you recover the hoses. After the refrigerant has been 14. The unit will build up pressure and shut down, display- recovered, go to the main menu. If there is no pres- ing HIGH PRESSURE OUTPUTS DISABLED. sure, the unit will go to the main menu. 15. Open the vapor valve and allow the pressure to enter 3. Disconnect service hoses from service ports. Verify the tank. the digital display reads “0” psi for both sides. If not, go to SET-UP MENU and calibrate pressures. 16. The unit will reset itself. 4. Select SET-UP MENU, then select SET ELEVA- 17. From the main menu, select RECOVERY. Watch for TION. Verify elevation is correct for your area. the unit to test the vehicle, then begin the clearing process. 5. For testing purposes, RECOVER HOSES needs to be “disabled.” Under SET-UP MENU, with SOFT- 18. With pressure present in the unit, a low then high side WARE VERSION highlighted, press 1-2-2-4 then clearing should take place. To verify this, watch the ENTER. Now find RECOVER HOSES and toggle to pressure gauge connected to the compressor service OFF. Exit to main menu. port. Gauge should pull down to 13” of vacuum (low side clearing is completed). At this point, clearing 6. Select VACUUM. The unit will default to 3:00. Press solenoids #1 & #2 should energize then allow the pres- START. During VACUUM, the unit will attempt to sure on your gauges to rise between 25-35 psi. The do a tank fill. The compressor will turn on. unit will then pull the gauge into a 13” vacuum (high side clearing is completed), then switch over to the re- 7. Once the vacuum cycle is complete, select CHARGE. covery mode. 8. Charge .50 lbs into the high side. The hoses will not hold this amount. Verify the unit attempts to use the NOTE: The 13” vacuum switch controls the Clear- POWER CHARGE feature. Then charge .15 lbs into ing process. The Recovery process is controlled by the low side. the low side pressure transducer. 9. Go to the main menu and select SNAPSHOT. NOTE: During RECOVERY, two features may 10. Verify that the temp probes are accurate and the iden- happen in the background, AIR PURGE and OIL tifiers reads 99.9% 134a and 0% air. RETURN. OIL RETURN will be noticed by pressure building on the service port. AIR PURGE will 11. Close the vapor valve on the ISV. be noticed by hearing air being purged. Continued . . . SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE. 143 Service Bulletins ACR2000 Refrigerant Service Solution SPX ROBINAIR TECHNICAL SERVICE BULLETIN Function Check (continued) 19. When Recovery is complete, pressure should in- 25. Return to the main menu. Select TANK FILL and crease on the gauge. This is the PRESSURE FEED- verify the TANK FILL solenoid is receiving power. BACK solenoid opening. 26. Verify scale accuracy by removing the tank and plac- 20. Verify the OIL DRAIN solenoid receives power, then ing a known weight of 25 lbs on the scale. The charge- shuts off. able weight should read 4.5 lbs +/- ½ lb. 21. Verify the service lines hold a vacuum. 27. Verify the setting of the UL circuit by going into the UL CALIBRATION (8-7-8-7). Place 43 lbs on scale, 22. Disconnect the service hoses and hook a ½ acme x ½ the red light should come on. Remove “1” lb, the red acme hose between the two ports. light should go off. If this does not happen, the UL circuit will need to be set. 23. You will need to have 10 lbs of refrigerant to perform this procedure. Select OIL FLUSH. Set the 28. Charge pressure into the lines and leak check the en- timer for 5:00 and press START. Verify the expan- tire unit. sion valve is set between 30 - 40 psi by watching the gauge set hooked up to the compressor service port. 29. After leak check is completed, recover refrigerant. 24. After the timer times-out, the unit should clear the lines. 30. Turn the RECOVER HOSES option back on. Then perform an oil drain. Component Replacement Times — Update ACR2000 Service Manual Part Number Component Total Time RA19603 Scale Assembly (includes re-calibration) 30 minutes RA19458 Compressor Assembly 30 minutes RA19600 Manifold Assembly 45 minutes RA19615 Condenser 30 minutes NOTE: The authorized time for the replacement of all other parts is 15 minutes per part. Robinair authorizes 2 hours to troubleshoot and complete a full function test on units that are covered under factory warranty (including leak testing). This bulletin supersedes any information previously published. For more information, please call 1-800-822-5561 SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE. 144 ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN SOFTWARE SUBJECT: ACR2000 Software Upgrade (Rev. 2.10) NO: 00171-SW EQUIP. AFFECTED: ACR2000 Units (GM Dealerships) DATE: Sept. 2002 ACTION REQUIRED: Informational AUTHOR: S. Parde Problem: During the process of performing the software upgrade (Revision 2.10) to units deployed to GM dealerships, the ACR2000 control board can lose ‘synch’ with the PC performing the upgrade, causing the process to halt. If this happens and the ACR2000 is rebooted, the unit will be stuck in “initializing.” Recommendations: If the software upgrade has failed, as indicated above, restarting the software upgrade process should continue the upgrade at the point it lost ‘synch’ with the PC. The upgrade process may have to be restarted several times before the control board synchronizes with the PC and completes the software upgrade. If the control board fails to connect (synch) with the PC, or the on-screen progress bar indicates no progress is being made, the control board will need to be replaced. Replacement Control Board Assembly - RA19606A For more information, please call 1-800-822-5561 ACR2000 SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE. 145 please call 1-800-822-5561 SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE. Parde All Service Centers New Repair Time for Leaking Tank Valves Due to numerous requests. 146 . If you have any questions or concerns. regarding this information. AFFECTED: All Units with Internal Storage Vessels DATE: Feb. OH 43543-1952 USA Phone: 800-822-5561 For more information. Service Bulletins ACR2000 Refrigerant Service Solution SPX ROBINAIR TECHNICAL SERVICE BULLETIN INFORMATION SUBJECT: Repair Time for Leaking Tank Valves NO: 00174-IN EQUIP. please contact Robinair Technical Support at: SPX ROBINAIR SPX Corporation 1224 Robinair Way Montpelier. This authorization is valid only on units with Internal Storage Vessels (ISV’s). Please update your reference material’s “Labor Rates” section. Robinair has authorized a labor charge of 30 minutes to perform service and repairs on leaking tank valves. 2003 ACTION REQUIRED: Informational AUTHOR: S. MN 55060-0995 Phone: 800-822-5561 For more information. it is required that a holding wrench be placed on compressor and angle-orientated fittings during the torque process. (These specs also work nicely for flare tubes. please contact Robinair Technical Support at: SPX ROBINAIR SPX Corporation 655 Eisenhower Drive Owatonna. √ Use Loctite® 242® Threadlocker on all tube nuts.-lbs. please call 1-800-822-5561 SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE. Robinair has decided to change the procedure used to tighten the tube nuts and tube connections that use o-rings. ± 5 in. • 3/8” tube = 140 in.-lbs.ACR2000 Refrigerant Service Solution Service Bulletins SPX ROBINAIR TECHNICAL SERVICE BULLETIN INFORMATION SUBJECT: New Torque Specs for O-ring Connections NO: 00176-IN EQUIP. AFFECTED: All AC Equipment DATE: April 2003 ACTION REQUIRED: Informational AUTHOR: S. on any AC equipment. √ Depending on tube size the following torque specs should be used: • 1/4” tube = 95 in. ± 5 in. Going forward. 147 . Parde Service Center Alert There have been a few reports of loose tube nuts discovered on new units after shipment. To address this problem.-lbs.) When using these elevated torque specs. If you have any questions or concerns. are requested to use the following instructions to ensure that a tight connection on 1/4” and 3/8” tubes with o-rings is obtained. all service centers during a routine service call.-lbs. please call 1-800-822-5561 SPX Ser vice Solutions Service THIS DISCLOSURE TO BE MAINTAINED IN CONFIDENCE. Open the door and then check the switches and ensure that the wires match in the diagram below. To check the switches for proper wiring you will need to open the filter rear door by turning the 2- quarter turn locks screws counter clockwise. Service Bulletins ACR2000 Refrigerant Service Solution SPX ROBINAIR TECHNICAL SERVICE BULLETIN HARDWARE SUBJECT: Possible Crossed Wires NO: 00177-HW EQUIP. The wires are sets 13&14 and 18&19.. 13&14 connect to the Vacuum Switch and 18&19 connect to the Oil Drain Switch.Shaner & L. 148 . has a possibility of having two sets of wires crossed. Cogswell The 342000 that were most recently shipped to you. AFFECTED: 342000 Unit (S/N range 00474-00519) DATE: April 2003 ACTION REQUIRED: Informational AUTHOR: E. For more information. ACR2000 Refrigerant Service Solution Service Bulletins NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 149 . Service Bulletins ACR2000 Refrigerant Service Solution NOTES ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ 150 . Some items require an additional amount of time to facilitate installation. they are not covered under warranty. Part Number Component Total Time RA19603 Scale Assembly (includes re-calibration) 30 minutes RA19458 Compressor Assembly (discontinued) 30 minutes RA19865 (requires RA19853 comp. 151 . This includes parts and labor. prior authorization from Robinair is required. Leaking Tank Valves 30 minutes NOTE: Robinair considers filters to be a consumable item. The authorized time for parts replacement is 15 minutes per part.ACR2000 Refrigerant Service Solution 5 L A B O R R AT E S Robinair authorizes a labor charge of 2 hours to troubleshoot and complete a full function test on units that are covered under factory warranty (including leak testing). kit) Compressor Assembly (new style) 30 minutes RA19600 Manifold Assembly 45 minutes RA19615 Condenser 30 minutes -----------. If repairs are estimated to exceed two (3) hours. These items and their times are listed below. MN 55060-0995 Phone 800-822-5561 Model: ACR2000 Refrigerant Service Solution Rev C. SPX Corporation 655 Eisenhower Drive Owatonna. .

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