HABILIS III

MODEL "T"

AUTOMATIC EVACUATING AND

REFRIGERANT FLUID CHARGING
EQUIPMENT

INSTRUCTIONS FOR USE AND

INSTALLATION

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 1/43

 GALILEO TP
PROCESS EQUIPMENT
Via di Castelpulci 17/M
50018 SCANDICCI (Firenze) - ITALY

HABILIS III T

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 2/43

 INDEX
1 INTRODUCTION ...................................................................................................................... 5
1.1 GENERAL INFORMATION, SAFETY AND CONTROLS DEVICES .......................................................6
1.2 STORAGE AND HANDLING .........................................................................................................6
1.3 VERSIONS AND OPTIONS ..........................................................................................................7
1.4 TECHNICAL FEATURES .............................................................................................................8
2 INSTALLATION...................................................................................................................... 10
2.1 ELECTRICAL SUPPLY INSTALLATION .......................................................................................10
2.2 COMPRESSED AIR SUPPLY INSTALLATION ...............................................................................10
2.3 REFRIGERANT SUPPLY INSTALLATION ....................................................................................11
2.4 VACUUM PUMP DISCHARGE INSTALLATION .............................................................................11
2.5 SERIAL LINES CONNECTION (PRINTER, BARCODE READERS, PC, PLC ETC.) .................................11
2.5.1 INPUT DATAS (WORKING CYCLE SELECTION CODES)........................................................12
2.5.2 OUTLET DATAS (WORKING CYCLE REPORT) .....................................................................12
2.5.3 CONNECTIONS (COM1) ...................................................................................................13
2.5.4 CONNECTIONS COM2 (DATA IN MODE 2) .........................................................................14
3 PROGRAMMING, CALIBRATION AND DIAGNOSTIC ............................................................. 15
3.1 SINGLE WORK CYCLE PROGRAMMING .....................................................................................16
3.2 GLOBAL PROGRAMMING OF WORK CYCLES..............................................................................18
3.3 GENERAL SETTINGS...............................................................................................................18
3.4 REFRIGERANT COUNTERS ......................................................................................................19
3.5 REFRIGERANT TABLES ...........................................................................................................20
3.6 DOSING SYSTEMS REFRIGERANT TYPE....................................................................................21
3.7 CALIBRATION........................................................................................................................21
3.7.1 CALIBRATION OF VACUUM SENSOR IN ATMOSPHERE........................................................21
3.7.2 CALIBRATION OF VACUUM SENSOR AT VACUUM FULL SCALE ............................................21
3.7.3 DOSING SYSTEM CALIBRATION .......................................................................................22
3.7.4 PROGRAM CC/IMPULSE DOSING SYSTEM..........................................................................22
3.8 UNIT OF MEASURE.................................................................................................................23
3.9 DIAGNOSTIC AND MAINTENANCE ...........................................................................................24
3.9.1 FUNCTIONAL DIAGNOSTICS ............................................................................................24
3.9.2 MEMORY ZEROING..........................................................................................................25
3.9.3 SAVE PARAMETERS IN FLASH ..........................................................................................25
3.9.4 PARAMETERS RECOVERY FROM FLASH .............................................................................25
3.9.5 SENSORS EXCLUSION......................................................................................................26
3.10 SERIAL PORT (COM1) MANAGEMENT....................................................................................26
3.10.1 TABLE TITLE PERSONALIZATION ..................................................................................27
3.11 CYCLE SELECTION CODE MANAGEMENT...............................................................................27
3.11.1 BAR CODES PROGRAMMING .........................................................................................27
3.11.2 CODES MASK PROGRAMMING.......................................................................................28
3.11.3 SETTINGS ...................................................................................................................28
3.12 OPERATOR CODE MANAGEMENT .........................................................................................29
3.12.1 OPERATOR CODES PROGRAMMING...............................................................................29
3.12.2 SETTINGS ...................................................................................................................29
4 WORK PHASE ........................................................................................................................ 30
4.1 MANUAL CYCLE SELECTION (THROUGH KEYBOARD) .......................................................................30
4.2 BAR CODES CYCLE SELECTION ...............................................................................................31
4.3 FUNCTIONS ENABLED IN STAND BY PHASE ..............................................................................32
4.3.1 DISPLAYING EQUIPMENT VERSION AND SENSORS ............................................................32
4.3.2 REPORT PRINT ...............................................................................................................32
4.3.3 REPORT DISPLAY ............................................................................................................32
4.3.4 ITEM CODE MANUAL INPUT.............................................................................................32
4.3.5 RESIDUAL DOSE EXECUTION ...........................................................................................33
4.4 WORK CYCLE EXECUTION ......................................................................................................33

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 3/43

 4.4.1 EVACUATION PHASE .......................................................................................................34
4.4.2 LEAK TEST PHASE ...........................................................................................................34
4.4.3 INJECTION PHASE...........................................................................................................34
5 ALARMS AND FAILURE SEARCH............................................................................................ 35
5.1 ALARM 01 .............................................................................................................................36
5.1.1 REFRIGERANT GROUP CONNECTED IN VACUUM LEAK .......................................................36
5.1.2 INCORRECT TIME AND EVACUATION SET POINT PROGRAMMED ........................................36
5.1.3 LEAK ON THE FILLER QUICK COUPLER .............................................................................36
5.1.4 ROTARY PUMP BAD FUNCTIONING...................................................................................37
5.1.5 FAULT AT THE VACUUM SENSOR .....................................................................................37
5.1.6 LEAK IN THE VACUUM LINE .............................................................................................37
5.1.7 LEAK OF THE INJECTION VALVE ON THE FILLER ...............................................................37
5.2 ALARM 02 .............................................................................................................................38
5.2.1 REFRIGERANT GROUP CONNECTED IN VACUUM LEAK .......................................................38
5.2.2 INAPPROPRIATE LEAK TEST SET POINT ...........................................................................38
5.3 ALARM 03 , 04 .......................................................................................................................38
5.3.1 REFRIGERANT SUPPLY PRESSURE OUT OF RANGE ............................................................39
5.3.2 REFRIGERANT INLET FILTER CLOGGED ............................................................................39
5.4 ALARM 06 .............................................................................................................................40
5.4.1 GROUP TO BE CHARGED CLOGGED ..................................................................................40
5.4.2 PROBLEMS ON THE FITTINGS ..........................................................................................40
5.4.3 INJECTION SOLENOID VALVE ON THE FILLER WHICH DOES NOT OPEN .............................40
5.4.4 PROBLEMS ON THE ROTOR OF THE TURBINE DOSING SYSTEM .........................................40
5.5 ALARM 07 .............................................................................................................................41
5.6 ALARM 11 AND 12 ...................................................................................................................41
6 MAINTENANCE GUIDE .......................................................................................................... 42

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 4/43

1 INTRODUCTION

HABILIS III is planned and manufactured to meet the

exigencies of average production lines demanding the
utmost employment flexibility (displacing the equipment
from one production line to another, from one item to
another, etc.).

The equipment is made of structure in painted plate

provided with wheels, which contains all the parts requested
for the functioning:
Electronic control unit with microprocessor.
Vacuum line to empty refrigerant circuits to be charged.
Dosing systems for CFC, HCFC, HFC, blends (except
inflammable gases).
Filles for refrigerant fluids charge.
Support for the installation of refrigerant tank on the
equipment (optional).

The equipment can work with refrigerant supply from tank without the help of pressurisation
systems (i.e. transfer pump).

The system is of modular kind and it allows providing the equipment with the most convenient
version which is supplied with several fillers and dosing systems (1 or 2). The work cycle includes:
Evacuation (optional with 2 fillers)
Search for leaks in vacuum (static and dynamic method)
Test on group to be worked out (clogged group)
Refrigerant injection

At the same time, it carries out a series of diagnosis tests, which allow highlighting the presence of
possible anomalies of the equipment and/or circuit to be treated.
All the functions can be programmed through a touch-keyboard of 31 keys; the display is a high
brightness, back-lighted, LCD graphic one. This specific technology allows the messages display
even in work areas insufficiently lighted.

This manual shows how to use the equipment correctly; moreover it provides the information
necessary for start-up and maintenance.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 5/43

1.1 GENERAL INFORMATION, SAFETY AND CONTROLS DEVICES

The equipment is planned and manufactured in compliance with the strictest international rules on
the functioning safety and the environment protection.

It suits the standards foreseen by CE directive (89/392, 91/368, 93/44 e 93/68).

In particular, electric and electronic devices comply with the standards on electric safety (EN
60204-1) and on electromagnetic compatibility (EMC).

Skilled staff only, i.e. technical engineers with specific electro technical, electronic or
mechanical skills must perform maintenance and installation procedures.

MANUFACTURERS WILL NOT BE HELD RESPONSIBLE FOR:

Incorrect use of the equipment.

Incorrect installation.
Failing in the electrical and/or refrigerant supply and compressed air not complying the
technical data (see par. 1.4)
Lack of observance of maintenance instructions.
Non-authorised adjustments and/or interventions.
Use of non-original or non-specific spare parts.
Lack of observance of the instructions.

This symbol identifies operations that - if not carried out according to the

! instructions might damage the equipment or injure the people working at

it.

1.2 STORAGE and HANDLING

The equipment should be stored in a place sheltered from bad weather and direct heat sources.
Places with condensing vapour should also be avoided (the allowed temperatures are indicated in
par. 1.4). Should the equipment be stored for a long period, it would be expedient to cover it by
introducing a hygroscopic salt bag inside the cabinet box. The equipment should be transported
and stored in a vertical position to avoid the spill of the oil contained inside the vacuum pump.
The equipment has four wheels: two of them are rotating and have a brake, can be easily moved
by hand, once unpacked, and be placed in its work area.
Once installed (chapter 2), the equipment can be moved only after deactivation and disconnection
of all the supplies requested for its functioning (compressed air, electric supply and refrigerant
supply line if used by a centralized supply line).

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 6/43

1.3 VERSIONS and OPTIONS

The equipment is available in two versions:

T1 : One dosage/injection line

T2 : Two dosage/injection lines

The equipment can be provided with the following options:

KIT BARCODE READER code 2.002.2.079

The barcode reader allows selecting the work cycles by means of reading the barcode on
the refrigerant group.
KIT INTERNAL MINI-PRINTER code 2.002.2.101
The kit consists of a mini-printer large 57,5 mm. for standard sheets to print each
refrigerant group processed report.
OPTION LIGHT TOWER code 2.002.2.022
The light tower is provided with 3 lamps (green, yellow, red) and an acoustic signal to
identify the various phases of the cycle.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 7/43

1.4 TECHNICAL FEATURES

Number of filler 12
Filler length 3,5 m

Connection to refrigerant circuit " Hansen female quick coupler
Number of dosing systems 12
Type of dosing system Turbine metering system
Programmable work cycles 200
Programmable codes Up to 1000 (bar code reader optional)

Measure units (programmable)

Refrigerant g, oz
Vacuum Pa, Hg
Pressure KPa, psi
Temperature C, F

LCD graphic display 128x240 (text 16 lines x 40

Data reading
characters)
Interface RS-232 for barcode reader
RS-232 for printer/PC
RS-485 for PCIS (optional)

Work temperature +10 +45 C

Stocking temperature -25 +70 C
3 3
Rotary pump Two-stage, capacity 12 m /h (18 m /h on request)
-2 -4
Rotary pump final vacuum 1x10 Pa (1x10 mbar)
Cabinet size (HxLxP) 1400x800x700 mm
Weight 155 Kg (HABILIS III T1)
Electric Supply 200 230/390 415 V 50 Hz 3 Ph
200 230/460 V 60 Hz 3 Ph
Power Absorbed 550 W (50Hz)
Noise < 63 dB (A)
Compressed air pressure 500 700 kPa (57 bar)
Air must be filtrated at 20 and dehumidified

Refrigerants CFC, HCFC, HFC, mixtures (not inflammable)

Charge range 5 99999 g
Minimum charge increase 1g
Accuracy at 50 g/s(doses < 200 g) +1g
(doses > 200g) + 0,5%
Accuracy at 100 g/s(doses < 300 g) + 1.5 g
(doses > 300g) + 0,5%
Refrigerant supply pressure max 3500 kPa (35 bar)
Maximum charge speed 60 g/s (R134a) std 110 g/s (R134a) with KIT HS

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 8/43

HABILIS III VHS - Technical feature changed compared with the standard one
(HABILIS III T)

Accuracy (doses < 600 g) +3g

Accuracy (doses > 600 g) + 0,5%
Refrigerant supply pressure 3500 KPa max (35 bar)
Charge speed 220 g/s (R134a @ 27 bar)

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 9/43

2 INSTALLATION

WARNING: Only skilled staff should execute the operations described in this

! chapter, i.e. technical staff specialized in the electro-technical, electronic, or

mechanical sector, according to the requested operations.

Before any operation, the equipment should be correctly positioned with its wheels properly
blocked.

The working area where the equipment must be installed should have a flat, levelled and not
sloping surface. The environment should be aired and well lighted.

2.1 ELECTRICAL SUPPLY INSTALLATION

Before connecting the plug to electric line, please make sure the voltage

! suits the value shown on the equipment label.

Its strictly forbidden to use the equipment without the earth conductor.

Electrical power should be supplied through a cable 3 poles + ground with section threads 2,5
mm2. The socket should have a protection device against short circuits. This device can be
realised with fuses max. value 20A, characteristic gL or with automatic magnetothermic switch
with the equivalent features.
The power supplied must be at least 2KVA.

Operations to be carried out for the installation:

Open the equipment left door by using the key on issue, after having turned the handle
sectioning switch on "0"
Pass the power supply cable through the cable gland placed at the back of the electrical
cabinet Check that the cable with its relative pin is not inserted in the socket, then, with a
screwdriver connect the three poles of the cable to the terminals 1, 3 and 5 of the switch
(S1). Connect the ground to the screw marked as (PE) placed on the switch. The ground
cable must be provided with an eyelet terminal.
Check that the vacuum pump turns in the right way. All this can be made activating
the equipment by pressing the (I) push-button and checking that on the pump discharge
there is a considerable overpressure; then, disconnecting the suction flange, check the
presence of an efficient suction on that side. In this case it is possible to go on. Otherwise
it is necessary to deactivate the equipment by pressing (0), after taking off the pin from
the socket, to exchange two phases in the terminals of the door block switch.

WARNING : every time the power socket is changed it is necessary to test

!
the proper rotation of the vacuum pump engine. Otherwise the pump might
break.

2.2 COMPRESSED AIR SUPPLY INSTALLATION

Compressed air (COMPR. AIR SUPPLY) which is necessary to open pneumatic valves and move
dosing cylinder must be supplied through an 8x6 mm pipe. Working pressure 5 7 bar.
A sectioning tap must be provided on the supply line.
Compressed air must be dehumidified and filtered with filters of at least 20.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 10/43

2.3 REFRIGERANT SUPPLY INSTALLATION

WARNING: Before entering refrigerant into the dosing system, please make
sure it is empty (no refrigerant inside) through the discharging procedures.
! When you are certain it is empty, you must always carry out the evacuation
procedures.

The equipment allows the user to manage 1 or 2 dosing systems (REFR. X SUPPLY).
Refrigerant must be supplied at the liquid state at a pressure value higher of at least 1000 Kpa
than the vapour pressure of the refrigerant used. The refrigerant supply tubes can be flexible or
rigid with an inner diameter of at least 3/8
The refrigerant supply line must be equipped with an interception valve. The equipment
connection pipes must have a working pressure of at least 50 bar.
Refrigerant inlet maximum pressure is 3500 KPa (35 bar). It is advisable to work at an inlet
pressure higher than the vapour pressure of at least 1000 Kpa (10 bar).

WARNING : A filter able to hold back particles with the minimum dimension

! of 25 should be always inserted on the refrigerant inlet tubes.

2.4 VACUUM PUMP DISCHARGE INSTALLATION

The vacuum pump is provided of a flexible hose on the discharge that conveys to the lower part of
the equipment. If refrigerant groups contain air or some other gas (i.e. nitrogen, helium, etc.), it is
necessary to convey the discharge into a pipeline sending the vapours issued out of the work
environment. If refrigerant groups to be charged are pre-evacuated then the route of the pipe will
be enough to trap the oil vapours issued by the pump. In this case, you would be recommended
to install a filter to trap the vapours and not to spread them into the environment.
For any request and for the use and maintenance procedures of the vacuum pump
please see relevant manual attached to the equipment documents.

2.5 SERIAL LINES CONNECTION (PRINTER, BARCODE READERS, PC, PLC etc.)

The serial ports connections COM1 and COM2 are located on the back of the machine.
For eventual connections not mentioned on this chapter, we beg you to contact GALILEO TP
Process Equipment S.r.l. engineering department to evaluate the technical feasibility of the
request.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 11/43

2.5.1 INPUT DATAS (WORKING CYCLE SELECTION CODES)
A bar code reader, a PC or a PLC can be used to send to the machine the working cycles selection
codes and they can work as per the following modalities:
DATA IN MODE 1: the mode 1 forecasts the connection at the COM1 port if the code
reading must be enabled both when the machine is in stand by and when the cycle is on
execution.
This connection is useful in case it will be necessary to send the code to the machine
before the ending of the cycle (i.e. in line production installation of a bar code reader on
fixed placement).
During the cycle execution only the last code read is used to select the cycle, all the other
are rejected.
On stand by phase, after the first code reading, all the following read codes canceled the
one used and carry out a new cycle selection.

DATA IN MODE 2: the mode 2 forecasts the connection at the COM2 port if the code
reading must be enabled only when the machine is in stand by.
When the code is accepted , eventual other readings are rejected and it is necessary to
carry out the manual erasing (pushing key CLEAR) to enable a new reading.

The data protocol transmission to the machine is the following:

Start transmission (header character) = 02H

Code = Caratteri del codice (fino a 32)
End transmission (one character terminator) = 0DH

Baud rate DATA IN MODE 1 = 1200(default) ,N,8,1.

The baud rate is programmable (see chap.3.10)

Baud rate DATA IN MODE 2 = 1200,N,8,1

On chapter 2.5.3 the possible configurations are shown.

2.5.2 OUTLET DATAS (WORKING CYCLE REPORT)

For the recording of the sent report from the machine at the end of each working cycle can be
used an internal miniprinter, an external printer, a PC or a PLC. To program the outlet parameters
see chapter 3.10 of the instruction manual.

On chapter 2.5.3 the possible configurations are shown.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 12/43

2.5.3 CONNECTIONS (COM1)

2.5.3.1 CONNECTIONS (COM1)

This connection is carried out on factory in case of installation of an internal miniprinter. At the
COM1 port a 9 pin connector is connected. It operates the above mentioned jumpers:

Tx : PIN 3

Rx : PIN 2

GND : PIN 5

Tx stampante : PIN 6

Rx stampante : PIN 7

GND : PIN 9

The printer is configured on factory with the XON-XOFF protocol enabled and at the data
reception/transmission speed = 1200 baud.

2.5.3.2 ONLY EXTERNAL MINIPRINTER (XON-XOFF enabled)

The external printer must be set to manage the flow control = XON/XOFF and the baud rate like
the one programmed on the machine (chapter 3.10 of the instruction manual).
Tx : PIN 3 Rx stampante
Rx : PIN 2 Tx stampante
GND : PIN 5 GND stampante

2.5.3.3 INTERNAL MINIPRINTER (XON-XOFF disabled) + BAR CODE READER/PC (DATA IN

MODE 1)
To carry out this connection the XON/XOFF protocol must be disabled and the baud rate = 300
must be set (see chapter 3.10 of the instruction manual). Also the miniprinter and the bar code
reader must be configured with baud rate = 300.

Tx : PIN 3

Rx : PIN 2 Tx lettore di codici a barre/PC

GND : PIN 5 GND lettore di codici a barre/PC

Rx stampante : PIN 7

GND : PIN 9

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 13/43

2.5.3.4 BAR CODE READER/PC (DATA IN MODE 1) + PRINTER/PC
This configuration can be used when the machine is connected to a PC to send the code selection
cycle and the acquiring of the cycle report.

In case of connection of a printer it is not possible to manage the flow control. The printer must be
a reception buffer of at least 1 kbytes.

Tx : PIN 3 Rx stampante/PC
Rx : PIN 2 Tx lettore di codici a barre/PC
GND : PIN 5 GND stampante/lettore di codici a barre/PC

2.5.4 CONNECTIONS COM2 (DATA IN MODE 2)

A bar code reader, a PC or a PLC can be connected at the COM2 port to send cycle selection
codes at the machine.

Rx : PIN 2 Tx lettore codici a barre/PC

GND : PIN 5 GND lettore codici a barre/PC

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 14/43

3 PROGRAMMING, CALIBRATION AND DIAGNOSTIC

To enter the main programming menu, push the key (PROG).

To enter the programming phase you are requested to enter a PASSWORD. When the equipment
is provided the password is disabled (=000000) so you can enter the programming phase directly.
When the password is enabled, you are demanded to enter it PASSWORD: 000000.
If you forget the password, please get in touch with GALILEO to get the two unblock codes.

Main programming menu:

PROGRAMMING/CALIBRATION/DIAGNOSTIC

SINGLE WORK CYCLE PROGRAMMING

GLOBAL WORK CYCLES PROGRAMMING
GENERAL PARAMETERS
REFRIGERANT COUNTERS
REFRIGERANT TABLES
DOSING SYSTEMS REFRIGERANT TYPE
CALIBRATION
UNITS OF MEASURE
DIAGNOSTIC and MAINTENANCE
SERIAL PORT(COM1)MANAGEMENT
CYCLE SELECTION CODE MANAGEMENT
OPERATOR CODE MANAGEMENT

Use the arrows up and down to select the item requested from the sub-menu then press
(ENTER).

GENERAL NOTES FOR PROGRAMMING:

1. Function keys (F1) = SAVE and (F2) = CANCEL are enabled at the bottom of
parameters programming pages. Pushing (CANCEL.) you can zero all parameters. You can
also find key (DEFAULT), which allows resetting all default parameters.
Warning: if you modify the parameters and leave the programming page with (EXIT),
relevant parameters will not be saved.
2. Use the arrows left and right to seek into data setting.
3. Key (EXIT) has the following functions: Leave programming pages without saving, going
back to main menu from sub-menus, going back to work phase from main menu, stopping
alarm signals, etc.
4. Key (ENTER) has the function to confirm (without saving) data set.

AFTER HAVING PROGRAMMED ALL WORK PARAMETERS YOU ARE SUGGESTED TO SAVE ALL
DATA IN FLASH MEMORY (SEE CHAP. 3.9.3 and 3.9.4) TO RECOVER THEM IN CASE OF THEIR
LOSS, REPLACEMENT OR DAMAGE TO THE ELECTRONIC CARD.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 15/43

3.1 SINGLE WORK CYCLE PROGRAMMING

Work cycles are programmed through this function. The programmable cycles are 200: from 0 to
199.

When entering the function the following line will be displayed:

WORK CYCLE PROGRAMMING 000
Enter the number of cycle requested from 0 to 199 press (ENTER).

If you choose cycle 002, which is not set, you will see:
WORK CYCLE PROGRAMMING 002
SELECTED CYCLE NOT PROGRAMMED
and function keys F1 and F2 at the bottom of the page
(NEW) e (COPY)

Choosing (F1) = NEW you can enter the cycle programming page with all parameters set at zero.

Pushing (F2) = COPY you will be asked from which cycle to copy the parameters:

COPY PARAMETERS FROM CYCLE 000

Enter the number of the cycle requested from 0 to 199 example 001 and press (ENTER).
After you have chosen the cycle, you can enter the cycle programming page with all the cycles
parameters set like in cycle 001.

If you have chosen to program work cycle 001 (NEW), you will see:

WORK CYCLE PROGRAMMING 1

REFRIGERANT TYPE : ----

REFRIGERANT WEIGHT
VACUUM TOTAL TIME
EVACUATION TIME
LEAK TEST TIME
EVACUATION SET POINT
LEAK TEST SET POINT
VACUUM CYCLE
: 00000 g
: 0000 s
: 0000 s
: 0000 s
: 000000 Pa
: 000000 Pa
:S.P. evacuat.+L.T.

Programmable parameters:

REFRIGERANT TYPE:
Use the arrows up and down to select the refrigerant requested among the pre-set ones.

REFRIGERANT WEIGHT:
Enter refrigerant weight to be filled into refrigerant group.
If refrigerant type is left ----, relevant cycle will not be programmed even if the other parameters
are correctly entered.

VACUUM TOTAL TIME:

Maximum vacuum time you can have a number of evacuation and leak test cycles within. If time
set is = 0, the vacuum phase is skipped and the equipment carries out the injection directly.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 16/43

EVACUATION TIME:
Time within which the vacuum in refrigerant group must achieve the evacuation set point.

LEAK TEST TIME:

refrigerant group static leak test time the leak test set point must not be exceeded within. If the
vacuum reaches the set point within this time, then the program carries out the evacuation phase
again. If leak test time is 0, this phase is skipped.

EVACUATION SET POINT:

The evacuation set point is the vacuum value that must be achieved within the end of evacuation
time.

LEAK TEST SET POINT:

The leak test set point is the maximum vacuum value to be achieved within the end of leak test
time.

VACUUM CYCLE:
Vacuum cycle can be set in 4 different ways:
1. Set point evacuation + leak test S.P. evacuat.+L.T.
2. Time evacuation + leak test Time evacuat.+L.T
3. Leak test + Set point evacuation L.T.+ S.P. evacuat.
4. Leak test + Time evacuation L.T.+ Time evacuat.

With kit of second filler for vacuum installed , 4 vacuum cycles can be added (marked number 2).
The cycles are the same as the previous but they also foresee the execution of the vacuum phases
using two fillers for the evacuation on both sides of the refrigeration unit.

Description of set point evacuation phase:

This way you can carry out the refrigerant group evacuation until you reach the evacuation set
point. This set point must be achieved within the evacuation time; otherwise, the group is skipped.
When the set point is achieved, the program carries out the Leak Test.

Description of time evacuation phase:

This way you can carry out the evacuation of refrigerant group for all the time set. If at the end of
time the vacuum value is lower than the evacuation set point the group is accepted and the leak
test start, otherwise it is skipped.

Description of Leak Test phase:

The leak test is carried out for all the leak test time set. If at the end of time the vacuum value in
the refrigerant group is lower than the leak test set point, the group is accepted and the
refrigerant charge is executed. If the leak test set point is achieved during the tie, the program
carries out the Evacuation phase again.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 17/43

3.2 GLOBAL PROGRAMMING OF WORK CYCLES

Through this function, you can program with a single setting all the work cycles parameters. Then
it will be necessary to enter the weight of refrigerant to be injected in the single cycles.

Example of global programming:

WORK CYCLES GLOBAL PROGRAMMING

REFRIGERANT TYPE : 134a

VACUUM TOTAL TIME : 0000 s
EVACUATION TIME : 0000 s
LEAK TEST TIME : 0000 s
EVACUATION SET POINT : 000000 Pa
LEAK TEST SET POINT : 000000 Pa
VACUUM CYCLE :S.P. evacuat.+L.T.

3.3 GENERAL SETTINGS

GENERAL SETTINGS

LEAK DETECTION DOSE : 00000 g

VACUUM MEAS.WAITING : 1
PASSWORD : 000000
LANGUAGE : English
DATE : 16/03/04
TIME : 10:32

Programmable parameters:

LEAK DETECTION DOSE:

If alarms 01 or 02 of failed evacuation or leak test intervene during the vacuum cycle, you can
carry out a little test dose. Then you can search and identify the refrigerant leak point through a
normal halogen leak detector. See work phase to carry out the dose for leak detection.

VACUUM MEAS. WAITING:

This programming takes place when the Set point evacuation phase is set. At the beginning of the
evacuation phase it might be necessary to wait for a few seconds before carrying out the test on
the vacuum set point. This test brings on the passage to the phase of Leak Test if the vacuum
value measured is lower than the low set point programmed. It is required to wait since
sometimes it takes a few seconds of pumping to get a real reading of the vacuum value inside
them.

PASSWORD:
The password programming prevents the entry to the programming phase. When the equipment is
provided the password is disabled = 000000 so the entry to the programming is direct.
Should you forget the password please get in touch with GALILEO TP to get the two unblock
codes.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 18/43

LANGUAGE:
Use the arrows up and down to select the language requested among those ones available.

DATE and TIME:

Warning: Pushing (SAVE) the clock inside the equipment memorizes the date and the hour
displayed. Consequently, before using control (SAVE) please check on the current hour.

3.4 REFRIGERANT COUNTERS

REFRIGERANT COUNTERS

REFRIGERANT 1 = R134a
REFRIGERANT 2 = R404a
REFRIGERANT 3 = R407a
REFRIGERANT 4 = R407c
REFRIGERANT 5 = R410a
REFRIGERANT 6 = R022
REFRIGERANT 7 = R502
REFRIGERANT 8 = R507
REFRIGERANT 9 = R012
REFRIGERANT 10 = R000

Using the arrows up and down , please select the type of refrigerant whose counters you
want to display then press (ENTER).

REFRIGERANT COUNTERS

QUANTITY COUNTER : 0000000 g

QUANTITY SET POINT : 0000000 g
INJECTIONS COUNTER : 0000000
INJECTIONS SET POINT : 0000000

Programmable parameters:

QUANTITY COUNTER:
The quantity counter displays the refrigerant consumed during the job of the equipment.

QUANTITY SET POINT:

The quantity set point makes the equipment signal when the quantity counter overtakes the set
point value. If set point is 0 the control on the counter is not performed.
The set point can be used to signal the end of the stocking cylinder. When using a 40 kg. cylinder
and programming the set point at 38000g (38kg), the equipment signals the cylinder is almost
exhausted when this value is reached.
WARNING: Please remember to zero the counter when replacing the empty cylinder with the full
one.

INJECTIONS COUNTER:
the injection counter displays all the charging cycles ended correctly.

INJECTIONS SET POINT:

The injections set point makes the equipment signal when the injections counter overtakes the set
point value programmed. If set point is 0 the control on the counter is not performed.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 19/43

3.5 REFRIGERANT TABLES

The table of specific weight (range 0 50 C) of 9 refrigerants here below mentioned is in the
memory of the equipment. There is also one empty table (REFRIGERANT 10 = R000) to enter a
new refrigerant.
The tables of 9 preset refrigerants can be modified.
The new refrigerant (not inflammable) must comply with the following materials the dosing line
is made of:
Neoprene gaskets (CR).
PTFE gaskets (Teflon ).
Thermoplastic polyester tubes (Hytrel ).
Brass, bronze, aluminium, and steel.

Moreover, you must check on the vapor pressure at the highest work temperature so that it does
not go beyond 25 bar.

The programming of the new refrigerant type can be performed memorizing refrigerant at liquid
state specific weight (liquid density) at the temperatures of , 10, 20, 30, 40 e 50 C.

REFRIGERANT TABLES

REFRIGERANT 1 = R134a
REFRIGERANT 2 = R404a
REFRIGERANT 3 = R407a
REFRIGERANT 4 = R407c
REFRIGERANT 5 = R410a
REFRIGERANT 6 = R022
REFRIGERANT 7 = R502
REFRIGERANT 8 = R507
REFRIGERANT 9 = R012
REFRIGERANT 10 = R000

Using the arrows up and down, select the refrigerant whose page of densities you wish to
display then press (ENTER).

Example of R134a refrigerant table:

LIQUID DENSITY TABLE (g/cm3)

REFRIGERANT TYPE : 134

VALUE AT TEMP. 00C
VALUE AT TEMP. 10C
VALUE AT TEMP. 20C
VALUE AT TEMP. 30C
VALUE AT TEMP. 40C
VALUE AT TEMP. 50C
: 1.294
: 1.261
: 1.225
: 1.188
: 1.147
: 1.102

Enter the values requested then press (SAVE) to memorize the new table. Pressing (DEFAULT)
and then (SAVE) you can reset default values of refrigerant R134a.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 20/43

3.6 DOSING SYSTEMS REFRIGERANT TYPE

The dosing systems installed must be assigned to the type of refrigerant used. Default refrigerant
assigned are R134a for dosing system 1 and R404a for dosing system 2 (if present). You must also
assign the high pressure and low pressure set points according to the nominal supply pressure.
The under mentioned example is for 2500 kPa. WARNING: DO NOT PROGRAM THE HIGH
SET POINT WITH VALUES OVER 3800 kPa.

DOSING SYSTEMS REFRIGERANT TYPE

DOSING SYSTEM 1 : R134a

INLET LOW SET POINT: 1500 kPa
INLET HIGH SET POINT: 3500 kPa
DOSING SYSTEM 2 : R404a
INLET LOW SET POINT: 1500 kPa
INLET HIGH SET POINT: 3500 kPa

3.7 CALIBRATION

CALIBRATION

VACUUM SENSOR AT ATM PRESSURE

VACUUM SENSOR IN VACUUM FULL SCALE
DOSING SYSTEM 1
DOSING SYSTEM 1 (CC/impulse program)
DOSING SYSTEM 1 (offset program)
DOSING SYSTEM 2
DOSING SYSTEM 2 (CC/impulse program)
DOSING SYSTEM 2 (offset program)
Using the arrows up and down select the calibration to perform then press (ENTER).

3.7.1 CALIBRATION OF VACUUM SENSOR IN ATMOSPHERE

The calibration of the sensor in atmosphere is requested only if the readings at high vacuum
values result to be incorrect; normally it is not necessary to carry it out.

While calibrating it will be displayed the following:

VACUUM SENSOR CALIBRATION IN PROCESS....

ATTENTION: During calibration the hansen
female filler coupler must be free to
aspirate air at atmospheric pressure.

3.7.2 CALIBRATION OF VACUUM SENSOR AT VACUUM FULL SCALE

The zero calibration is necessary only in case the sensor grows old; normally it is not necessary to
carry it out. Default bit are 370. Please replace them according to the following note:

BIT AT VACUUM FULL SCALE = 000

NOTE : Increase bit number to decrease
the read value and vice versa.
Digit 000 to reload the default table
in case of problem.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 21/43

3.7.3 DOSING SYSTEM CALIBRATION
The procedure here below mentioned is used to calibrate doses. This operation must be performed
if the mistake in doses weighted respect to the ones programmed is higher than the accuracy
declared in technical features. To calibrate the doses you are requested to be provided with a test
cylinder with a Hansen male coupler which can stand pressures until 40 bar as well as with a
precision scale to test weights.
Please perform the following operations:
Program an average dose among the ones used (possibly over 300 g) with vacuum
parameters suitable to the vacuum execution in the test cylinder.
Carry out the work cycle in the cylinder stopping it (by pushing STOP) at the end of the
Evacuation phase. This is necessary to suction the air inside the cylinder.
Disconnect the cylinder from the filler and calculate the tare weight. This way youll be
certain there is no more air inside the cylinder (it might involve a tare mistake).
Connect the cylinder to the filler and carry out a complete cycle (vacuum + charge).
At the end of the cycle weight the real dose filled and carry out the procedure under mentioned:

CC/IMPULSE CALCULATION DOSING SYSTEM

WEIGHED DOSE : 0000.0 g

PROGRAMMED DOSE : 0000.0 g

CURRENT CC/IMPULSE = 0.0600

NOTE FOR CALIBRATION:
Insert the really charged dose (WEIGHED)
and the programmed dose (PROGRAMMED)
than press (CALIB.).
Press (FCORR=1) to reload the default
dose correction factor.

WARNING : Pay attention to the way you enter the weighed and preset

! grams in the memory. A wrong entry of data can cause an incorrect

calculation of the calibration factor.

Pushing (CALIBR.), the message CALIBRATION EXECUTED will be displayed for 2 seconds.
Cc/impulses of the turbine are calculated during the calibration. The calibration page displays
cc/impulses currently calculated.
Discharge refrigerant inside the cylinder and repeat the dosing to make sure the weight is right.
Repeat the calibration and, if necessary, make the doses more precise.

3.7.4 PROGRAM CC/IMPULSE DOSING SYSTEM

This function allows entering directly the calibration number of the turbine (if known) avoiding to carry out
the calculation procedure described in the previous chapter.

PROGRAM CC/IMPULSE DOSING SYSTEM

CC/IMPULSE TURBINE : 0.0600

WARNING: cc/impulses are the calibration

number of the turbine. Take note of such
number to re-enter it should you cancel
the memory. This is to avoid calculating
cc/impulses again.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 22/43

3.7.5 OFFSET CALCULATION DOSING SYSTEM

Normally it is not demanded to carry out the offset calibration. Only if you carry out doses within a large
range (i.e. from 100g to 2000g) you might need to adjust the offset.

OFFSET CALCULATION DOSING SYSTEM

WEIGHED DOSE : 0000.0 g

PROGRAMMED DOSE : 0000.0 g

CURRENT OFFSET = 3.5 g

INFO ON OFFSET CALCULATION:

Offset calibration must be carried out
only with doses less than 300g.
Enter the dose charged and the dose
programmed then press (CALIBR.).

3.8 UNIT OF MEASURE

Through this function, you can change the default units of measure.
The units that might be programmed are the following: mercury micron (hg) and Pascal (Pa) for
vacuum, C e F for temperature, grams (g) and ounces (oz) for weight.

MEASUREMENT UNITS

VACUUM UNIT : Pa
TEMPERATURE UNIT : C
WEIGHT UNIT : g

If the weight unit of measure changes, after pressing (SAVE), you are demanded to zero the
weight in all the work cycles. If you have programmed no cycle theres no difference in answering
YES or NO.

ATTENTION: Vacuum measurement unit

changed. Zeroing the vacuum set points
of all working cycles ?

If the weight unit of measure changes, after pressing (SAVE), you are demanded to zero the
weight in all the work cycles. If you have programmed no cycle, theres no difference in answering
YES or NO.

ATTENTION : Weight measurement unit

changed. Zeroing the weight in all
working cycles ?

CONVERSION FORMULA:

1 Oz = 28,35 grams
1 F = 1,8 x C + 32
1 Pa = 7,6 Hg

All the functions described in the manual refer to the following units of measure: grams, C, Pa.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 23/43

3.9 DIAGNOSTIC AND MAINTENANCE

DIAGNOSTIC and MAINTENANCE

FUNCTIONAL DIAGNOSTIC
DOSING SYSTEM EVACUATION
DOSING SYSTEM REFRIGERANT DISCHARGE
RAM MEMORY ZEROING
SAVE PARAMETERS IN FLASH
RESTORE PARAMETERS FROM FLASH
SENSORS EXCLUSION

3.9.1 FUNCTIONAL DIAGNOSTICS

The functional diagnostic allows starting the 24 Vac devices installed on the equipment (solenoid
valves, lamps, etc.). To assign the exits please refer to the functional diagram hereby attached.
Moreover you can display the values of the sensors installed, which are put up to date each
second. Pushing (BIT/VAL), you can alternate the display of bit and of sensors values.

FUNCTIONAL DIAGNOSTICS

Vacuum : 3 Pa
Temperature : 1= 17.8 C 2= 18.0 C
Position : 1= 39 mm 2= 115 mm
Contacts: AIR=1 ST1=0 EX1=0 ST2=0 EX2=0

11 12 13 14 15 17 18
19 1A 1B
GL YL RL BZ

ON/OFF SELECT. RESET BIT/VAL

How to activate exits:

To activate one exit you are previously requested to select it using the 4 arrows (i.e.
solenoid valve 15) and press (F2)=SELEZ. Relevant exit is selected with two stars
[*15*]. If you press (F2), the exit is deselected.
Press ON/OFF to energize the solenoid valve. The exit is selected [*15*]
Press back ON/OFF to de-energize the solenoid valve. The exit is deselected [*15*].
You can start one or more than one exit contemporaneously or in following steps selecting
them using (SELECT.) and starting them with (ON/OFF). The status is shown by the
selection.
Pressing (RESET) you can de-energize and deselect all the exits.

WARNING: Pay attention during the solenoid valves opening sequence;

! wrong operations during the opening phase can cause dangerous conditions
or damage the sensors or the gaskets.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 24/43

3.9.2 MEMORY ZEROING
Display of operations carried out by RAM memory zeroing:
WARNING : This function cancels all
the programmed parameters (work cycles,
calibrations, general parameters etc.)
reloading default values.
Press (START) to start the procedure.

After pressing (START), the message ZEROING IN PROCESS will be displayed for a few
seconds. Then the program re-starts:

3.9.3 SAVE PARAMETERS IN FLASH

Operations carried out by the saving of parameters in flash:
This function save in FLASH memory all
the programmed parameters (work cycles,
calibrations, general parameters etc.)
to recover them in case of their loss.
Press (START) to start the procedure.

When pressing (START) the message SAVING IN PROGRESS is displayed for a few seconds.

3.9.4 PARAMETERS RECOVERY FROM FLASH

Display of operations carried out by the parameters recovery from flash:

ATTENTION: This function overwrites

the current parameters (work cycles,
calibrations, general parameters etc.)
with those memorized in FLASH memory.
Press (START) to start the procedure.

Date of latest saving: 01/03/04 11:55

When pressing (START) the message RECOVERY IN PROGRESS is displayed for a few
seconds.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 25/43

3.9.5 SENSORS EXCLUSION
This function allows excluding the vacuum and temperature sensors to keep on working even in
case of their breakdown while waiting for their replacement. If vacuum sensor is excluded during
the phases of Evacuation and Leak Test, the value 1 Pa is constantly displayed. Consequently, you
are suggested to carry out the vacuum cycle with time evacuation. When the temperature sensor
is excluded, the fixed temperature entered in this function is the one the equipment considers.

SENSOR EXCLUSION IN CASE OF TROUBLE

EXCLUDE VACUUM : YES

EXCLUDE TEMPERATURE1: YES
TEMPER.REFRIGERANT 1: 020 C
EXCLUDE TEMPERATURE2: YES
TEMPER.REFRIGERANT 2: 000 C

WARNING: The exclusion of the sensors is to be considered an emergency

! work mode. When the sensors are excluded, it is not possible to grant the
precision characteristic of the dosing and of the test on the refrigerant
groups sealing.

3.10 SERIAL PORT (COM1) MANAGEMENT

SERIAL PORT (COM1) MANAGEMENT

REPORT OUTPUT : Disabled

XON XOFF ENABLE : YES
BAUD RATE : 1200
LINE FEED END REPORT : 3

Programmable parameters:

REPORT OUTPUT:
The report printing can be set in 3 ways.
Disabled = The table is never print (default).
Enabled = The table is always print at end cycle, in case of alarm and pressing (PRINT)
while in stand by.
Only alarms = The table is print only in case of alarm and pressing PRINT) while in stand by.

XON XOFF ENABLE:

XON/XOFF protocol activation

BAUD RATE:
BAUD RATE can be programmed 300, 600, 1200, 2400, 4800 e 9600.

LINE FEEDS END REPORT:

Through this programming, you can define the number of paper sliding at the end of the table to
adjust the point of tear of paper.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 26/43

3.10.1 TABLE TITLE PERSONALIZATION
The default chart heading is the following:

************ HABILIS III T ************

Pushing the key (F3) = TITLE you join the heading personalization function.
The heading can be made of 40 alphanumerical characters made of: numbers, all the capital
alphabetical letters, +-*/# and SPACE.

TABLE TITLE PROGRAMMING:

************ HABILIS III T ************

3.11 CYCLE SELECTION CODE MANAGEMENT

Connecting a barcode reader (COM 2 port) to the machine you can select work cycles coupling
them to the codes read:

CYCLE SELECTION CODE MANAGEMENT

BAR CODES PROGRAMMING

CODES MASK PROGRAMMING
SETTINGS

3.11.1 BAR CODES PROGRAMMING

The number of programmable codes depends on their length. The number is automatically
calculated according to the mask programmed.
WARNING: Before programming the codes it is necessary to define the filter mask of
codes acquired (see chap. 3.11.2).
The equipment is provided as default with the programming of 151 codes with 32 significant
characters. Normally the code significant characters for cycle selection are definitely less than the
above number (usually 3 or 4). The maximum number of programmable codes is 1000 (from 000
to 999).
Since the codes memory is 5000 characters and each code memorized consists of significant
characters + 1 character for the number of cycle coupled, with 3 or 4 significant characters the
codes programmable are 1000. With a higher number of characters the number of programmable
codes can easily be calculated dividing 5000 for the number of characters + 1.

BAR CODE PROGRAMMING : 000

(Number of programmable codes= 1000)

Enter the progressive number of the code to be programmed (i.e. 001), and then press (ENTER).
The whole page of code inlet and cycle coupled is displayed.
The undermentioned example relates to code 3456, which selects cycle 003:

BAR CODE PROGRAMMING : 001

(Number of programmable codes= 1000)

Code : 3456
Cycle associated to the code : 003

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 27/43

Program the characters of the code, and then press (ENTER).
Couple the code to the number of the cycle, and then press (ENTER).

You can program (so the machine can adquire) codes of 32 alphanumerical characters consisting
of: numbers, all the capital letters of the alphabet, , +-*/# e SPACE.
To program characters different from numbers, keep pressed continuously the key showing the
letter/character requested, then release the key as soon as the character is displayed. Pressing the
keys shortly, youll get the normal numerical selection.

3.11.2 CODES MASK PROGRAMMING

The mask is a 32 characters matrix filtering the barcode acquired. Inside The sinificant characters
identifying the work cycle are programmed within the mask.

ACQUIRED BAR CODE MASK:

(1=valid 0=masked)

11111111111111111111111111111111

I.e.: The code used is 16 characters long:

1234567890ABCDEF

After pressing (ENTER) you will be demanded to accept the modification to the mask.
The modification involves the zeroing of all the codes programmed.

0011110000000000000000000000000000
Quando si programma il codice si inserisce solo il codice 3456.

After pressing (ENTER) you will be demanded to accept the modification to the mask.
The modification involves the zeroing of all the codes programmed.

ATTENTION : MASK MODIFIED.

Press (YES) to accept the modify and
cancel all the programmed codes.
Press (NO) to exit.

3.11.3 SETTINGS
Through this function you can assign the cycle selection mode:
Manual = Cycle selection by means of numerical keyboard
Through barcode = Cycle selection by means of barcone

BAR CODES MANAGEMENT SETTINGS

CYCLE SELECTION : bar code

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 28/43

3.12 OPERATOR CODE MANAGEMENT

This function allows to detail a code (up to 20) at each user that has to use the machine. The code
entry request at start must be activated being at default deactivated.
Should you forget the codes please get in touch with GALILEO TP to get the unblock code.
A code is required (from 1 to 5 alphanumerical charters) to allows the start of working and
programming phases. The code is then carried out on a report filled out at the end of each cycle.

OPERATOR CODE MANAGEMENT

CODES PROGRAMMING
SETTINGS

Use the arrows up and down to select the item requested from the sub-menu then press
(ENTER).

3.12.1 OPERATOR CODES PROGRAMMING

OPERATOR CODE NUMBER (00...19) : 00

Enter the progressive number of the code to be programmed (i.e. 01), and then press (ENTER).

Operator code (up to 5 char.):

Put up to 5 alphanumerical charters, then press (ENTER).

3.12.2 SETTINGS
With this function the user is allowed to activate ad deactivate the user code at the start up of the
machine:

Enabled = The user code is required at the start up of the machine

Disabled = No user code is required at the start up of the machine

OPERATOR CODES MANAGEMENT SETTINGS

CODE REQUEST : Disabled

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 29/43

4 WORK PHASE

After the switching on, the equipment prepares the WORK phase.

The prealarm VACUUM SENSOR NOT CALIBRATED can occur for 2 seconds. By this alarm the
equipment can go on working but the vacuum measurement is not granted and the relative alarms
indication. Please perform the calibration procedure in atmosphere as described in charter 3.7.1.

The are two functioning modes available:

MANUAL CYCLE SELECTION (through keyboard)
CYCLE SELECTION THROUGH BARCODE

4.1 MANUAL CYCLE SELECTION (through keyboard)

The following message is displayed after the switching on of the equipment or when leaving the
programming phase:

Cycle not
programmed
(0)..(9) o (CYCLE) = Cycle selection.
(PROG) = Programming.

Press key (0)(9) for the immediate selection of the cycle. Press (CYCLE) to select cycles from
10 to 199.

Example of cycle 1 selected:

Cycle 1
R134a 300g
Evacuation : 30 Pa time 50 s
Leak test : 200 Pa time 5 s

Refrigerant counter : 30000 g

Charged groups : 150

When the cycle is selected, the equipment prepares the STAND BY phase.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 30/43

4.2 BAR CODES CYCLE SELECTION

The following message is displayed after the switching on of the equipment or when leaving the
programming phase:

Waiting
bar code
(PROG) = Programming
(CODE) = Code entering by keyboard
(CLEAR) = Clear code after reading

You are demanded to read the barcode relevant to the refrigerant group to be charged.
In this phase only keys:
(PROG) to go in the programming phase
(LAST) to display the report of the last carried out cycle
(CLEAR) to erase the code after the reading
(CODE) to insert the code by keyboard

The following message is displayed if the cycle is not programmed:

Code not
programmed
(PROG) = Programming
(CODE) = Code entering by keyboard
(CLEAR) = Clear code after reading

The stand by page is displayed if the code is programmed and correctly coupled to a cycle:

Code : 1234567890ABCDEF

Cycle 1
R134a 300g
Evacuation : 30 Pa time 50 s
Leak test : 200 Pa time 5 s

Refrigerant counter : 30000 g

Charged groups : 150

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 31/43

4.3 FUNCTIONS ENABLED IN STAND BY PHASE

4.3.1 DISPLAYING EQUIPMENT VERSION AND SENSORS

Pressing the key (MENU) you can display the page with the name and the programs revision on
EPROM and FLASH as well as the values read by vacuum sensors, temperature, compressed air
pressure switch and filler push buttons (START and EXIT).
Press (EXIT) to go back to the STAND BY page.

4.3.2 REPORT PRINT

If the equipment is connected to a printer, you can get the print of the report by pushing key
(PRINT).

4.3.3 REPORT DISPLAY

Pressing the key (LAST) you can display the page with the report of the last cycle performed.
Here below relevant example:

************ HABILIS III T ************

Date : 16/03/04 Time : 17:54

Cycle : 01 Operator:
Code : 1234567890ABCDEF

End Evacuation vacuum value : 30 Pa

End Leak test vacuum value : 145 Pa

Refrigerant : 134a Weight: 200 g

Temperature : 15.8 C
Injected dose : 199.8 g

Cycle time : 52 s
Cycle result : 00 - PASS

The EXIT from cycle can be:

99 - INTERRUPTED If cycle is interrupted by pushing key (STOP).
00 - PASS If the cycle ends correctly.
XX - ALARM If the cycle stops because of an alarm (please consult the table of alarms to
identify the alarm displayed).

If the cycle stops because of an alarm, the parameters relevant to the following phases result to
be empty.

4.3.4 ITEM CODE MANUAL INPUT

Pushing key (CODE) it is possible to insert an item identification code that will be put on the cycle
report.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 32/43

4.3.5 RESIDUAL DOSE EXECUTION
The execution of residual dose can be started from the report display page. In case of cycle
incomplete because of the end of refrigerant stocking cylinder, the report page will display the
following message in the last line:

DOSE INCOMLETE: (F1)=SELECT RESIDUAL

Pushing (F1) you will display the residual dose page:

Residual dose
R134a 115g
PRESS (START) TO CARRY OUT THE RESIDUAL
DOSE SKIPPING VACUUM PHASE.

Pushing (START) you will carry out the residual charge automatically (in this case 115 g) skipping
the vacuum phase.

Selecting any cycle you will cancel the residual dose execution.

4.4 WORK CYCLE EXECUTION

Once you have selected the appropriate work cycle, connect the filler to the refrigerant group.
The cycle is started pressing key (START) on the filler or key (START) on the control panel.
When starting the cycle the equipment carries out the control on the congruence between the
refrigerant types selected and the cycle and refrigerant assigned to the filler. If there is no
congruence, the alarm REFRIGERANT NOT ASSIGNED is displayed.
The cycle will be carried out automatically. At the end of the cycle the user is advised by means of
an acoustic signal. You can stop the cycle pushing key (STOP) during all the phase of vacuum
controls.
The message WAITING FOR AIR is displayed during the cycle execution to indicate the lack of
compressed air or its insufficient pressure.
If the equipment is provided with a light tower, the cycle phases will be indicated as it follows:
Green Lamp: Its switched on for all the stand by phase. It indicates that the equipment is
ready to carry out the cycle of vacuum and charge.
Yellow Lamp: When it is switched on it indicates that the equipment is carrying out the
work cycle.
Red Lamp: It shows that an alarm signal is involved and it stays on until the exit from the
alarm itself.
Acoustic signal: It shows that an alarm is involved and it keeps on ringing until you leave
the alarm by EXIT. Moreover, it signals the end of each cycle with a signal during about
one second.
Please find here below the phases of cycle whose values correspond to those ones of the example
no. 1 of the above-mentioned cycle.

WARNING: Do not disconnect the filler from the circuit during the

! refrigerant injection phase. The disconnection can cause the coming out of
the refrigerant under pressure heavily cooling the body parts accidentally
touched.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 33/43

4.4.1 EVACUATION PHASE
During the evacuation phase, you can display the following values:

Vacuum value (updated each half second)

Residual evacuation time (updated each second)
Bar graph vacuum value (updated each half second): this indicates the values between the
2 set points of evacuation and leak test. When the vacuum value is higher than the leak
test set point, the bar graph is completely full with an arrow flashing on the right.

Display:

Evacuation
30
76 Pa 11s 200

4.4.2 LEAK TEST PHASE

During the Leak Test phase, you can display the following values:

Vacuum value (updated each half second)

Residual Leak Test Time (updated each second)
Bar graph vacuum value (updated each half second); this indicates the values between the
two set points of evacuation and leak test.

Display:

Leak test
30
152 Pa 3s 200

4.4.3 INJECTION PHASE

During the injection phase the bar graph will be displayed to bring back the dosing flow from 0 to
the value of the dose set.

On the display:

Injection
0 300

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 34/43

5 ALARMS AND FAILURE SEARCH

During the performance of the work cycle the equipment checks on all the parameters concerning
it. In case of parameters out of the values admitted, the alarms get involved.
The alarm is signalled acoustically and with a message on the display. If the light tower is
installed, the red lamplights on and the beeper rings.

The display is made of a number showing the reference of the alarm. To get out of the acoustic
signal, press key (EXIT) or (EXIT) push-botton on the filler.

IMPORTANT NOTE:

WARNING: Before carrying out operations relative to components (dosing

! system, filler, etc.) and to the tubes containing refrigerant, it is necessary to
discharge the dosing line (par 3.9)

WARNING: Before carrying out any operation disconnect the equipment by

! positioning the general SWITCH placed on the right door on '0'.

WARNING: Before carrying out operations relative to components (solenoid

! valves, dosing system, etc.) and to the tubes containing compressed air
disconnect the air supply line and depressurised it.

WARNING: The operations described in this paragraph must be carried out

! only by skilled staff i.e. by technical staff with a special skill in the electro-
technical, electronic, and mechanical sector, according to the requested
operation.

IF ALL THE ABOVE MENTIONED OPERATIONS ARE CORRECTLY PERFORMED, THERE ARE NO
CONDITIONS OF DANGER FOR THE STAFF WHO TAKES CARE OF THE MAINTENANCE.

Example of alarm display:

Alarm 01
EVACUATION FAILED :
VACUUM SET POINT NOT REACHED WITHIN TIME
PROGRAMMED.

MEASURED VALUE: 245 Pa

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 35/43

5.1 ALARM 01

EVACUATION FAILED:
VACUUM SET POINT NOT REACHED WITHIN TIME
PROGRAMMED.

This alarm takes place during the EVACUATION phase if vacuum does not reach the set point
programmed within the time set. The alarm intervenes even if the total vacuum time is expired.
Actually there can be several Evacuation Leak Test phases which can give a positive result within
the total time.

POSSIBLE CAUSES OF MALFUNCTIONING:

5.1.1 REFRIGERANT GROUP CONNECTED IN VACUUM LEAK

The refrigerant group is not vacuum-sealed and it is therefore impossible to evacuate it until the
vacuum limit programmed.

Corrective Action: Disconnect the group. To find out where the leak is, you can program a little
refrigerant dose (i.e. 20 g.: the dose depends on the volume of the circuit and it must be sufficient
to make the refrigerant pressure inside he group to be higher than the atmospheric pressure). This
way it will be possible to carry out the leak detection with a sniffer. To program the test dose see
par. 3.3. If the test dose programmed is different from zero you can display the following message
on the alarm display page:
PRESS (START) TO CARRY OUT THE LEAK
DETECTION DOSE TO DETECT LEAKS.

5.1.2 INCORRECT TIME AND EVACUATION SET POINT PROGRAMMED

The evacuation time programmed is not enough to evacuate the circuit volume until the vacuum
value requested.
Corrective action: Re-program the work cycle parameters in compliance with the circuit so that
you can evacuate increasing the vacuum time or accepting a higher vacuum value.

5.1.3 LEAK ON THE FILLER QUICK COUPLER

The HANSEN quick coupler of the filler is provided with an OR2056 O-ring in neoprene, which
assures a good sealing between the female coupler of the filler and the corresponding male
coupler on the group to be evacuated. If this O-Ring is not well positioned or damaged, the
appropriate vacuum seal is not granted anymore.
Corrective action: Replace the damaged O-Ring with a new one, paying attention to the way it
is placed into its location.
OR2056 must be made in NEOPRENE (hardness 70/80 shore).

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 36/43

5.1.4 ROTARY PUMP BAD FUNCTIONING
The vacuum issued by the pump is not enough; in stand-by phase after having pressed key
(menu), you will display a value < than 10 Pa. This can be caused by:
a) Pump oil polluted by wet residues or refrigerant previously aspired from other evacuated
circuits.
b) Low-level pump oil.
c) Internal mechanical parts of the pump worn.
Corrective action: You can deal with each one of the above-mentioned cases as it follows:
a) Make the pump work leaving the air gas ballast open for 20 minutes so that the impurities
can be easily expelled.
b) Reset the right oil level with appropriate oil (see relevant pump manual).
The pump must be overhauled by the technical assistance.

5.1.5 FAULT AT THE VACUUM SENSOR

The vacuum sensor filament can be controlled with an ohmmeter making sure that the resistance
measured at its extremities is 49 ohm 3 ohm; in case of necessity please replace it. In case of
damage you can also work without the sensor; see chapter 3.9.5 for the isolation procedure.

5.1.6 LEAK IN THE VACUUM LINE

Some components of the vacuum line (filler vacuum valve, connection pipeline, couplers, EV15
leak test vacuum valve) do not assure anymore the correct sealing. It is possible to make the
following check: open the EV15 permanently and wait for the vacuum value measured by the
Pirani sensor to be stable. Take note of the V0 vacuum value achieved (i.e. V0 = 50 Pa). Close the
EV15 and check on the vacuum value ascent speed: if the leak is in the vacuum line, the vacuum
value read will ascend with a speed of V0 Pa each 5 sec. This test cannot be used for leaks
between the vacuum pump and the EV15 valve.
Corrective action: Check on the components of the vacuum line and eventually replace them.
You can identify a vacuum leak spraying some alcohol on the vacuum line itself; through the
Diagnostic function you can display the vacuum value. When alcohol gets into the line, the vacuum
value increases suddenly.

5.1.7 LEAK OF THE INJECTION VALVE ON THE FILLER

The vacuum value does not reach the values demanded because of a refrigerant leak on the
refrigerant EV11 valves on the filler. This might be caused by a deterioration of the shutter gasket
or by some dirt lying in its location. If you pay attention, you can feel this refrigerant leak from the
filler quick coupler.
Corrective action: Carry out the automatic discharge of the dosing system line as indicated in
par. Errore. L'origine riferimento non stata trovata.. Disassemble the solenoid valve to
check on the wear status of the shutter gasket. Clean the sealing location and eventually replace
the solenoid valve.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 37/43

5.2 ALARM 02

STATIC LEAK TEST FAILED :

TOTAL RESIDUAL TIME NOT ENOUGH TO
PERFORM VACUUM CYCLE AGAIN

If during the leak test time the vacuum value goes beyond the set point programmed, the
program goes back to the evacuation phase. This happens only if there is still total residual time
otherwise the alarm gets involved.

POSSIBLE CAUSES OF MALFUNCTIONING:

5.2.1 REFRIGERANT GROUP CONNECTED IN VACUUM LEAK

The refrigerant group is vacuum-sealed and it is impossible to keep a vacuum value lower than the
programmed leak test set point within the time set.
Corrective action: SEE CHAP. 5.1.1.

5.2.2 INAPPROPRIATE LEAK TEST SET POINT

The programmed leak test is too low to measure the static vacuum of refrigerant group.
Corrective action: Program the leak test set point appropriately accepting a higher static
vacuum value.

5.3 ALARM 03 , 04

Alarm 04:
REFRIGERANT INLET LOW PRESSURE :
MEASURED INLET PRESSURE LESS THAN LOW
PRE-SET SETPOINT.

Alarm 03:
REFRIGERANT INLET HIGH PRESSURE :
MEASURED INLET PRESSURE OVER THAN HIGH
PRE-SET SETPOINT.

Alarms 03 and 04 intervene during the charging of the dosing system with the refrigerant coming
from the supply line. If the pressure value measured is higher than the inlet high set point alarm
04 is given, if it is lower (for more than 15 s) alarm 03 intervenes.

POSSIBLE CAUSES OF MALFUNCTIONING:

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 38/43

5.3.1 REFRIGERANT SUPPLY PRESSURE OUT OF RANGE

a) The values of the preset high and set points are not suitable for the normal working
conditions.
b) The inlet pressure is too high or too low.
Corrective operation:
a) Set the pressure set points with proper values referring to the vapour pressure at the
working temperature of the refrigerant used. The default values usually assure a correct
functioning. The refrigerant must be injected in the liquid state.
b) Keep the inlet pressure about 1000 KPa higher than the refrigerant vapour pressure. If the
value of the preset low set point is too near to the value of the working pressure there
might be interruptions in the charge with the message WAIT PRESSURE being displayed.
If the correct pressure value is not restored within 15s, alarm 03 is given. In this case the
user should decide whether to increase the supply pressure or to lower the value of the low
set point.

5.3.2 REFRIGERANT INLET FILTER CLOGGED

The refrigerant inlet filter is clogged and the pressure value inside the dosing system does not
reach the low set point because of the insufficient flow.
Corrective operation:
Replace the inlet filter installed on the dosing system.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 39/43

5.4 ALARM 06

REFRIGERANT INJECTION STOPPED :

MEASURE OF DOSING TURBINE LACK OF
MOVEMENT

During the refrigerant charge it was detected that the dosing turbine was rotating too slowly or
that it was not rotating at all.

POSSIBLE CAUSES OF MALFUNCTIONING:

5.4.1 GROUP TO BE CHARGED CLOGGED

The refrigerant group has some clogs, which prevent the refrigerant from entering correctly.
Corrective action: Disconnect the refrigerant group and send it to be repaired.

5.4.2 PROBLEMS ON THE FITTINGS

The fittings between the compressor of the refrigerant circuit and the filler are throttled and the
refrigerant does not flow properly. A possible cause might be the closing gasket of the Hansen
male coupler of the butterfly fitting.
Corrective operation: check the fittings of the refrigerant circuit and if no problem is observed
disconnect the circuit and send it to the assistance to be repaired.

5.4.3 INJECTION SOLENOID VALVE ON THE FILLER WHICH DOES NOT OPEN
The injection solenoid valve on the EV11 filler does not open and this prevent the regular flow of
refrigerant. To check on the right functioning of this solenoid valve you can open it for a while
using the functions of Diagnostic and make sure the air compressed is coming out from the filler
quick coupler.

WARNING: Make sure no people or things are in close proximity of the filler

! quick coupler during those operations. They might be stroke be the casting
of refrigerant in pressure!

5.4.4 PROBLEMS ON THE ROTOR OF THE TURBINE DOSING SYSTEM

If the injected refrigerant is not properly filtered, the rotor of the turbine might block.
The block of the turbine rotor may also be caused by residues of the refrigerant supply tubes (e.g.
shavings or Teflon).
Corrective operation: if the turbine (ref. 6 draw. 2.005.0.008) is blocked it is necessary to
disassemble and clean it.
Carry our the follwing operations:
Discharge the refrigerant present in the dosing line.
Disassemble the turbine inlet tube.
Disassemble the turbine of the distributor.
Unscrew the clamping collar of the turbine rotor.
Take off the turbine rotor and clean it.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 40/43

5.5 ALARM 07

WRONG INJECTED DOSE :

REFRIGERANT LEAK IN VACUUM LINE WHILE
CHARGING.

During the phase of injection, you can measure the vacuum value in line. If the value is too much
high, it means that some refrigerant is drawing inside the vacuum line. The problem is due to a
fault to the pneumatic valve shutter of the filler (ref. 6 drw. 2.004.0.020), which does not assure a
correct, sealing.

Corrective Action: Check on the status of the sealing gasket and eventually clean it. If
necessary, replace it.

5.6 ALARM 11 and 12

LOW or HIGH REFRIGERANT TEMPERATURE

This fault takes place during the refrigerant injection phase if the refrigerant temperature
measured by the system is not within 0 50 C. This might be due to a fault or to the
temperature, which is really out of the set points programmed.

Corrective Action: In case of fault, it is however possible to work excluding the temperature
sensor (see chapter 3.9.5 for the excluding procedure).

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 41/43

6 MAINTENANCE GUIDE

This guide plans the equipment maintenance so as to keep its efficiency and its functional
characteristics.
The main parts to be periodically controlled are:
a) FILLER
b) DOSING SYSTEM
c) VACUUM PUMP (see the relative user and maintenance manual)

The following table shows operations to be carried out on every part.

The column * lists the operations to be carried out frequently, according to the production type
(for example once a week).
The operations listed in the column * must be also carried out in PERIODS 1 and 2.
The operations carried out in PERIOD 1 must be also performed in PERIOD 2.

PART * PERIOD 1 PERIOD 2

Every 1000 hours Every 2000 - 3000
hours
FILLER Replace the gasket Replace the gaskets of the
OR2056 of the quick kit 2.002.1.058.
coupler.
DOSING Verify doses calibration Replace the refrigerant
SYSTEM (par. 3.7.3) filter 2.009.0.013.
VACUUM Verify vacuum Clean vacuum sensor Replace the oil in the
PUMPING pump oil level and line by pump
GROUP (see pump eliminating the (for oil characteristics and
manual). residual oil sucked in replacement procedure
Pump ballasting by the circuits. see the relative user and
(see pump Clean pump filter maintenance manual).
manual). (see pump manual)
If the vacuum During the
value in stand by evacuation of highly
conditions does humid groups it could
not remain < di be necessary to
15 20 Pa it substitute the oil in
could be the pump.
necessary to
carry out the
PERIOD 1
procedure.

It is necessary to register in a table (example in the next page) all the operations necessary for the
ordinary and extraordinary maintenance and the operations carried out by our technical
assistance.

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 42/43

 EQUIPMENT MAINTENANCE TABLE

EQUIPMENT TYPE :

SERIAL NUMBER :

DATE OF INSTALLATION :

OPERATION DATE FUNCTION OPERATIONS CARRIED OUT PARTS REPLACED

TIME

Code: 8.003.3.051_rev.05 Translated from original code: 8.003.3.050_rev.04 pag. 43/43