Sie sind auf Seite 1von 46

CLIMA-6000

Service station for air conditioning


systems of vehicles with
refrigerant gas R-134a.
Service Manual
Ver. 1.0
CLIMA-8500evo

CAP. 1 - INDEX

CAP. 1 - INDEX ..................................................................... 2


CAP. 2 - INTRODUCTION ........................................................ 4
2.1 GENERAL INFORMATION .................................................4
2.2 SUMMARY .....................................................................4
CAP. 3 - SAFETY CONDITIONS ............................................... 5
3.1 IMPORTANT SAFETY INFORMATION .................................5
3.2 ENVIRONMENTAL PRECAUTIONS ..............................................5
CAP. 4 - MANUAL USE STRUCTURE ....................................... 6
4.1 MANUAL USE .................................................................6
4.2 SYMBOLS ......................................................................6
4.2.1 Safety .....................................................................6
4.2.2 Marking ...................................................................6
CAP. 5 - INSTALLATION ......................................................... 7
5.1 EQUIPMENT INSTALLATION .............................................7
5.1.1 Unpacking CLIMA-6000 .............................................8
5.1.2 Connections .............................................................8
5.1.3 Contrast and language adjustment ..............................9
5.1.4 Programming ...........................................................9
5.1.4.1 Programming through serial cable...............................9
5.1.4.2 Programming through ACU device ..............................9
5.1.5 Registration ...........................................................10
5.1.6 Warranty Documentation and EC declaration of
conformity and Use and maintenance manual .........................10
5.1.7 Initial Check ............................................................12
5.1.7.1 First tank filling ......................................................12
5.1.8 Container filling .......................................................13
5.1.8.1 New oil container filling ............................................13
5.1.9 Optional accessories presentation .............................13
5.1.10 Working parameters setting .....................................13
CAP. 6 - MAINTENANCE ...................................................... 15
6.1 EQUIPMENT MAINTENANCE...........................................15
6.2 VACUUM PUMP OIL REPLACEMENT................................15
6.3 DEHYDRATOR FILTER REPLACEMENT .............................16
6.4 WEAR CHECK OF THE RED AND BLUE LOAD PIPES AND THE
HP RED AND LP BLUE QUICK COUPLERS...................................16
6.5 COOLANT GAS SCALE CHECK WITH SAMPLE WEIGHT AND
EVENTUAL CALIBRATION (SERVICE KIT).....................................17
6.6 WEAR CHECK AND CAPACITY OF THE SOLENOID VALVE
PISTONS OF THE MANIFOLD ....................................................17
6.7 WEAR CHECK OF THE OR2-106 4.42X2.62 NBR O-RING OF
THE PRESSURE SENSOR PRESENT ON THE MANIFOLD ..............19
6.8 CHECK PRESENCE AND WEAR OF O-RINGS OR2212
53.7X1.78 NBR OF THE OIL CONTAINERS.................................19
CAP. 7 - CALIBRATION ........................................................ 20
7.1 SERVICE KIT .................................................................20
7.2 PRESSURE CALIBRATION (SERVICE KIT) ..........................21
7.3 GAS WEIGHT CALIBRATION (SERVICE KIT)........................22
CAP. 8 - UPDATE ................................................................ 23

ENGLISH 2 / 46 CAP. 1 - INDEX


CLIMA-8500evo

8.1 SOFTWARE UPDATE .....................................................23


8.2 NEW DATABASE PURCHASE AND ACTIVATION................23
CAP. 9 - EQUIPMENT AND SIMULATORS .............................. 25
CAP. 10 - COOLANT FLUID CIRCUIT ..................................... 26
10.1 COOLANT FLUID CIRCUIT ...............................................26
10.2 OPERATIONAL CYCLES .................................................29
10.3 RECEIVING TANK ..........................................................31
10.4 MANIFOLD CHART ........................................................32
10.5 SUCTION UNIT CHART ...................................................33
CAP. 11 - ELECTRICAL CONNECTIONS ................................. 34
CAP. 12 - SPARE PARTS ..................................................... 36
CAP. 13 - REPLACEMENT INTERVENTIONS .......................... 39
13.1 EXTRAORDINARY MAINTENANCE SCHEDULE ..................39
13.2 EXTRAORDINARY MAINTENANCE...................................40
13.2.1 Replacement of components connected to coolant circuit
40
13.2.2 Replacement of logic electronic card with display..........40
13.2.3 Replacement of electronic power board ......................41
CAP. 14 - TROUBLE SHOOTING ............................................ 42
CAP. 15 - DIAGNOSTICS ...................................................... 43
15.1 FAILURE LIST ................................................................43

ENGLISH 3 / 46 CAP. 1 - INDEX


CLIMA-6000

CAP. 2 - INTRODUCTION

2.1 GENERAL INFORMATION


Careful attention was paid in the collection and checking of the documentation contained in this
manual; despite this, this publication could contain small technical errors or typos. No responsibility
shall be attributed to BRAIN BEE or to other persons or companies involved in the creation,
production and distribution of the product due to damage following use of the present
documentation.

BRAIN BEE reserves the right to bring improvements or changes to is instruments at any time
and without any notice.

It is possible for this manual to contain references or information regarding BRAIN BEE services or
products not yet on the market. Said references or information may not in any way mean that
BRAIN BEE intends to place said products or services on the market.

This publication may not be reproduced nor distributed, wholly or partially, without previous written
authorisation by BRAIN BEE (Law 22 April 1941 no.663 and following updates). Requests of
other copies of the present manual or further information must be addressed to an authorised
distributor or to a BRAIN BEE sales representative or to the email address contact@brainbee.com

All technical and sales documentation may also be found on the website: http://www.brainbee.com

BRAIN BEE is a registered trademark property of BRAIN BEE s.p.a., v. Quasimodo 4/a - 43100
Parma, Italy. Other names of products and companies mentioned in these pages may be registered
trademarks of their respective owners.

Any references to programs on use license or other BRAIN BEE products or services contained in
this publication do not mean that only said programs and/or products and/or services may be used.
In replacement to those supplied by BRAIN BEE equally functional products, programs or services
may be used that do not imply violation of BRAIN BEE intellectual property rights or other rights .
It is the user's responsibility to evaluate and verify the possibility to use other programs and/or
products and/or services, except for those expressly indicated by BRAIN BEE .

BRAIN BEE may have patents or pending patent applications relative to what is being treated in
the present publication. The supply of this publication does not imply concession of any license on
them.

2.2 SUMMARY
The present manual is intended for the assistance technician and has the objective to illustrate
clearly and coherently the use and function principles and to supply a basic guide to carry out
assistance and maintenance at the service station for air conditioning systems for vehicles with R-
134a cooling gas.

The manual chapters describe the functional groups of the CLIMA-6000 under the aspects of
structure, functioning, disassembly and assistance.

To access the service menu reserved to maintenance activities, the technician operating on the
device must know the password communicated by Brain Bee to the Assistance Centres.

________________________________________

ENGLISH 4 / 46 CAP. 2 - INTRODUCTION


CLIMA-6000

CAP. 3 - SAFETY CONDITIONS

3.1 IMPORTANT SAFETY INFORMATION


In installation, maintenance and technical assistance operations it is necessary to respect the
fundamental staff and workplace safety regulations.

Carefully respect all the indications reported on this


manual, on the device use manual and on the use manuals
of eventual equipment employed.
In particular the operator must see all the safety
prescriptions described in the use manual.

All the operations reported in this manual must be


carried out by trained staff, equipped with adequate
individual protection devices.

To move heavy loads or to handle the equipment and its


components always use gloves and clothing that may
guarantee adequate protection also from accidental
contact with the coolant.

To use instruments such as springs, drills, saws etc. and


to protect oneself against accidental contact with the
coolant, always use protection goggles.

To manually lift the loads (weights) limits are foreseen by


the enforced regulations of own country, carefully
respect the limits, above which appropriate lifting means
must be used.

Before accessing to execute operations within the


instruments, always disconnect the power supply and use
tools with insulated handles.

3.2 Environmental precautions


Any service operation on the equipment must be carried out by being careful not to disperse R134a
gas into the environment, in order to avoid contributing to global warming and the subsequent global
heating of the planet. The release of R134a coolant gas in the atmosphere is prohibited by laws
that were issued in the Kyoto protocol.
For information, for the European Union we quote in particular regulation (CE) no. 842/2006 on
certain fluorinated gases with global warming effect (regulation on F-gases).

The waste coming from the service activities must be placed in the collection points foreseen by the
enforced laws, they must not be dispersed in the environment and they must not be disposed of
with urban waste.

ENGLISH 5 / 46 CAP. 3 - SAFETY CONDITIONS


CLIMA-6000

CAP. 4 - MANUAL USE STRUCTURE


4.1 MANUAL USE

The present service manual must be used in context to the use and
maintenance manual of the equipment, it must be kept by the Authorised
Assistance Centre or by the Distributor of Brain Bee products and made
available to own assistance staff.
• The content of this manual was written according to the guidelines of regulation UNI
10893:2000.
• Sharing, changing, or using the present manual for own purposes is forbidden to all.
• While writing the manual, the choice was made to use clear symbols that bring attention to
precise points, in order to make consultation simpler and quicker.
• It includes all information regarding the technical aspect, functioning, equipment rest,
maintenance, spare parts and safety.
• In case of doubts regarding the correct interpretation of the instructions, refer to the
technical assistance service to obtain the necessary explanations.

The operations that represent a potentially dangerous situation for the operators
are highlighted through the symbol reported on the side.
Said operations may cause serious physical damage.

The operations that require particular attention are highlighted through the
symbol on the side.
Said operations must be carried out correctly in order to not damage things or
the surrounding environment. This symbol also highlights information which
particular attention must be paid.

The operations that require a careful reading of the indications supplied on the
use and maintenance manual are highlighted through the symbol on the side.

4.2 SYMBOLS

This paragraph described the symbology relative to safety which may be present on the exterior of
the equipment.

4.2.1 Safety

ALTERNATING CURRENT

PROTECTION GROUND

CONSULT THE INSTRUCTIONS MANUAL

ATTENTION! RISK OF ELECTRIC SHOCK

ATTENTION !: DO NOT TRY TO REMOVE THE COVER


(operations reserved to qualified technicians)

4.2.2 Marking

EC CONFORMITY SEAL

ENGLISH 6 / 46 CAP. 4 - MANUAL USE STRUCTURE


CLIMA-6000

CAP. 5 - INSTALLATION
5.1 EQUIPMENT INSTALLATION
The order of the following listed steps is the one advised even if the same could be carried out in a
different order.
C/O DISTRIBUTOR HEADQUARTERS (INTERNET CONNECTION REQUIRED)
It is advised to lift the carton, connect electricity and switch on the equipment

1° Contrast Adjustment (if necessary) and Language selection.


(after this step, the device may already be used to show the software potentials without use of the
gas).
2° Check the software version and eventually reprogram the equipment
3° Final equipment and client data registration on the website www.brainbee.com (distributor
reserved area).
Registration may postponed also to after initial checking and it will be proposed again when the
database is selected, or at every equipment switch on. In case of missed registration, the automatic
cycles and the database will not be active.
4° Pack the equipment for final transport to the client.

C/O FINAL CLIENT HEADQUARTERS


5° Unpack, position the equipment and execute the electrical connections. Check that the empty
containers of the new and exhaust oil are inserted.

6° Carry out Initial checking as proposed by the software according to the following points:
• Check gas scale zero
• Relative pressure zero setting according to local atmospheric pressure
• Internal tank filling (with value of at least 2 Kg until the maximum allowed by the equipment)
Initial checking, if passed, enables use of the equipment with gas.
Checking may be interrupted at each of its points, if not completed it will be proposed again at every
following CLIMA machine switch on or in case one attempts to carry out the recharge operation.
If the checking is not passed, it may be necessary to proceed to equipment scale or electronic
gauge calibration; for said operation described as follows the appropriate Brain Bee SERVICE KIT is
required.

7° New oil container filling, the use of Brain Bee WARRANTY LINE consumable products is
recommended.

8° Delivery and illustration of the warranty conditions, of the EC declaration of conformity and the
use and maintenance manual to the final client.

9° Optional accessories presentation

10° Working parameters and shop data (final client) setting

ENGLISH 7 / 46 CAP. 5 - INSTALLATION


CLIMA-6000

5.1.1 Unpacking CLIMA-6000

RISK OF OVERTURNING - CRUSHING - BUMPING

Position the pallet on a level surface, remove the carton after having eliminated the straps that bind
it. Free the equipment from the pallet by cutting the straps that block it. Remove the unit from the
base pallet of the package by using suitable means. Once on the ground, the unit is handles on the
four wheels; brakes may be applied to the two smaller wheels.

5.1.2 Connections
In proximity of where the machine must be used, there should be a schuko type current socket
available protected by a differential switch. The nominal current voltage and absorbed power data
are indicated on the unit identification tag positioned near the turn on switch. Connect the
equipment through the supplied cable.

Connection to the Connector for


A/C system electrical network

The equipment includes connecting pipes of about a 3 m length that when not in use must be kept in
the appropriate pipe winder with the gaskets closed.
Further views of the equipment and technical characteristics are reported in the use manual.

ENGLISH 8 / 46 CAP. 5 - INSTALLATION


CLIMA-6000

5.1.3 Contrast and language adjustment


At the first switch on, the equipment proposes language and contrast adjustment that will have to

be carried out with the left and right keys and saved with the START key .
For subsequent changes to the contrast or the language it is possible to enter the settings pages

by switching on the equipment and keeping the start key pressed until it "beeps".

After the beep, proceed to adjusting contrast with the left and right keys and save with

the START key .

5.1.4 Programming
The equipment already includes multi-language application software, it is however advised to check
that the version installed is updated compared to what is available on the website
www.brainbee.com.
PROGRAMMING the CLIMA station with the last version available on the website www.brainbee.com
at the time of installation guarantees installing of the latest versions:
• of the CLIMA machine management software and
• the vehicle database (whose use license for the specific version starts at the time of
registration).

5.1.4.1 Programming through serial cable


The following is necessary for programming:
• Windows PC with a COM serial port or USB-Serial adaptor
• programming cable included in the BRAIN BEE CLIMA SERVICE KIT
• CLIMA UPDATE software (execute download and set up)
• CLIMA 6000 application software (execute download and unzip)

The version number is only indicative, refer to


the one present on the website

The equipment programming procedure foresees:


• double click on the .cli software icon
• press the “Program (F3)” button then switch on the equipment

5.1.4.2 Programming through ACU device


With the ACU device (contained in the CLIMA SOLUTION product) is it possible to update the CLIMA
machines software without a serial cable. By following the instructions contained in the CLIMA
SOLUTION product install the CLIMA SOLUTION program on a Windows PC connected to the
internet.

If on the website www.brainbee.com on the internet a new version is available, this will be
transferred on the PC automatically.

Connect ACU to the PC to obtain transfer of the new version of the software on the ACU mobile
device.

To obtain updating of the clima station, connect ACU to the serial port, and switch the equipment
on again, it will be updated with the latest version.

ENGLISH 9 / 46 CAP. 5 - INSTALLATION


CLIMA-6000

5.1.5 Registration
To start the warranty period and to activate the automatic cycles it is necessary to carry out
REGISTRATION which foresees:
• access in the distributor reserved area on the website www.brainbee.com
• selection of the registration page CLIMA REGISTRATION
• entering the serial number of the CLIMA equipment and final client data (user)
• waiting for the counter code which will have to be entered into the equipment.

Until the counter code is entered into the equipment, it will always be requested. Print the warranty
documentation to deliver to the final client.

In the CLIMA-6000 the registration does not enable the internal vehicle database, which may be
purchased separately.
Following purchase it is necessary to carry out the enabling as described in chapter 8.2.

5.1.6 Warranty Documentation and EC declaration of


conformity and Use and maintenance manual

To start the warranty, it is necessary to carry out registration of the CLIMA station as described in
the previous point, print the warranty documents to deliver to the client from the website.

ENGLISH 10 / 46 CAP. 5 - INSTALLATION


CLIMA-6000

Deliver the EC Declaration of conformity document attached to the equipment to the client, it will
have to be carefully guarded by the final client.
Deliver and illustrate the use and maintenance manual attached to the equipment which will have to
be carefully guarded by the final client and made available to the operators.

ENGLISH 11 / 46 CAP. 5 - INSTALLATION


CLIMA-6000

5.1.7 Initial Check


Execute the following actions in sequence by following the display guided procedure and the
illustrations on the synthetic sheet attached to the equipment:

• Gas weight check


• Pressure check
• First tank filling

It is possible to interrupt the initial check and print a report with the equipment printer in which the
checking status is reported.

5.1.7.1 First tank filling

CAREFULLY ABIDE BY THE FOLLOWING


INSTRUCTIONS TO AVOID DANGER TO
PERSONS, THE DISCHARGE OF
COOLANT IN THE ATMOSPHERE

Let us consider as first filling the one carried out during the initial check to the internal tank of the
equipment free of coolant gas and containing air.

Set the quantity of gas to fill (with value of at least 2 Kg until the maximum allowed by the
equipment) and follow the guided procedure on the display.
Check that the equipment piping is not connected and is positioned in the pipe winder. Start the
procedure that initially foresees the creation of vacuum in the internal tank.

Only when the message appears to connect the recharge tank, connect the quick coupler HP (colour
red) of the unit to an external R134a coolant gas tank using the supplied adaptor.

Open the attachment by rotating the knob clockwise. Open the valve placed on the external tank.
There are two types of source tanks: with pick-up and without pick-up.

The tanks with pick-up must remain in erect position in order to transfer the liquid coolant, for this
type of tank connect to joint L (liquid).

The tanks without pick-up only have one valve, they must then be overturned to transfer the liquid
coolant.

The HP gauge indicates the pressure inside the external tank.

After a few minutes the unit automatically concludes the function.


At the end the display shows the weight of the loaded coolant.

ENGLISH 12 / 46 CAP. 5 - INSTALLATION


CLIMA-6000

5.1.8 Container filling


5.1.8.1 New oil container filling
The new oil container is on the left, looking at the equipment from the front.
To fill it it must be removed from its seat by using a quick joint, placed on the head of the container
itself; it is sufficient to exercise slight downwards pressure on the ring nut of the joint in order to
unslip it.

Fill the container, paying particular attention to the “oil care” valve.
This valve which consists in a membrane of cured silicon, it is necessary to compensate the
pressure variations inside the container and to block the inlet of humid air, thus preserving the new
oil inside.

At the end of the filling, close the container and place it back in its seat.

5.1.9 Optional accessories presentation


The CLIMA-6000 station may be equipped with further accessories such as
• kit for washing system components (Flushing kit) and
• kit for leak search (UV kit) with tracer and UV lamp.

FLUSHING KIT UV KIT

• attachment joint to recharge R134a gas from external tank


• additional bottles to use for oil of a different density and/or tracer
• vehicle database enabling (first activation/update)
• tank heating strap.

5.1.10 Working parameters setting


Inside the SETTINGS menu it will be possible to set various parameters and various activations
before beginning the cycles:

HYBRID FUNCTION
• by selecting this entry, one may decide to change the type of Oil to enter into the A/C
system

PRESSURE ZERO
• by selecting this entry, one may carry out zero setting of relative pressure to account for
atmospheric pressure (which depends on the altitude of the shop location).

OIL INJECTION MODE


• by selecting this entry, it will be possible to define the "manual" or "automatic" oil recharge by
identifying the type of oil (ISO46 or ISO100 or ISO150).

RECHARGE MODE
• by selecting this entry, one may decide whether to enable use of the Quick Mode or Zero
Tolerance recharge method.
“Quick Mode” is the quick recharge through HP with automatic compensation of the gas
tail in the pipe. “Zero Tolerance” is the precise recharge with LP which foresees switching
on the vehicle A/C. The machine will account for said preference on condition that the
vehicle in recharge is equipped with the necessary type of attachment (HP or LP),

ENGLISH 13 / 46 CAP. 5 - INSTALLATION


CLIMA-6000

otherwise the choice of “Quick Mode” or “Zero Tolerance” will be carried out automatically
by the machine. The “Zero Tolerance” procedure foresees impulsive injections in the
vehicle air conditioning system through the LP side. After the injection and before the
following one, one waits for the pressure to lower to the typical system value. The
pressure threshold to set contextually to the "Zero Tolerance" option must be slightly
higher than the typical value of the system. In case the threshold is too low, the loading
procedure stop, in case the threshold is too high, the integrity of the compressor would
be compromised. Said threshold is preset to a typical value of 3 bar.

TANK HEATING
• by selecting this entry, one may decide whether to enable use of the heating strap within the
vacuum phase. (Attention, the heating strap is optional and if one intends to enable it it
must be installed first)

MULTIPASS ENABLING
• by selecting this entry, one may decide whether or not to enable the multipass function,
which enables an additional recycling, within the station itself, started in automatic when it is
switched on but not in use. This mode guarantees a more elevated level of recycled
coolant purity, benefiting the quality of the service rendered.
During the multipass there is a decrease of the counter of the dehydrator filter equal only
to 1/10 of the weight of the filtered coolant

PRESSURE CONTROL ENABLING


• by selecting this entry, one may decide whether or not to enable the control of the
pressures of the vehicle conditioning system after the recharge.

DISPLAY CONTRAST
• by selecting this entry, it will be possible to adjust the display contrast

HOSE LENGTH
• by selecting this entry, it will be possible to enter the length of the discharge pipes, this data
affects the accuracy of the charge carried out with the Quick Mode method.

MEASURE UNIT
• by selecting this entry, it will be possible to change the measure unit relative to the
pressure (switching from Bar to Pascal)

LANGUAGE
• by selecting this entry, any language present in the database may be set. In case a language
with incomprehensible characters is chosen, one may switch directly to the language setting

menu by keeping the key pressed.

RIGHT\LEFT DRIVE
• by selecting this entry, one may set the vehicle driving side on which to carry out a recharge
inside the database. Normally it is on the left, it is necessary to select the right side only
when the machine is installed in countries such as England, with different driving sides.

SWITCH ON SCREEN
• by selecting this entry, one may decide if the initial switch on screen of the unit will be the
one relative to the database or the one relative to the main menu.

STANDARD SETTINGS
• by selecting this entry, one may reset the unit's standard settings.

DATA SAVING MODE


• Through this selection, one may decide the exportation mode of the data of the carried out
operations with the equipment on the external ACU device (Automatic cycles or Reg EC
842/2006 (both automatic and manual cycles are saved)).

DATABASE ACTIVATION
• by selecting this entry, it will be possible to activate the database acquired during a following
update.

ENGLISH 14 / 46 CAP. 5 - INSTALLATION


CLIMA-6000

CAP. 6 - MAINTENANCE
6.1 EQUIPMENT MAINTENANCE
The interventions foreseen for periodical and preventive maintenance are listed as follows:

• VACUUM PUMP OIL replacement (every 60 hours of pump work)


• DEHYDRATOR FILTER replacement (every 27 kg of recovered gas)
• Wear check of the RED AND BLUE LOAD PIPES and the HP RED AND LP BLUE QUICK
COUPLERS
• Coolant gas scale check with sample weight and eventual calibration (SERVICE KIT)
• Check and calibration of the internal pressure sensor (SERVICE KIT)
• Wear check and capacity of the SOLENOID VALVE PISTONS of the MANIFOLD
• Wear check of the OR2-106 4,42x2,62 NBR O-RING of the pressure sensor present on
the MANIFOLD
• Presence and wear check of the OR2212 53,7x1,78 NBR O-RINGS of the oil and tracer
containers

6.2 VACUUM PUMP OIL REPLACEMENT


The vacuum pump oil must be replaced every 60 hours of functioning.
When it is time to change the vacuum pump, the message –will appear on the display.

Necessary equipment:
• 1 Medium size Phillips screwdriver
• 1 Medium size flathead screwdriver
• 1 Hex key (10 mm)

For replacement follow the instructions indicated as follows:


1. Disconnect the unit from the electrical network.
2. Remove the screws (6) that fix the front door of the unit and remove it.
3. Position a collection tray under the machine, in correspondence to the pump oil drain hole.
Open the top plug and subsequently the bottom plug to let flow the exhaust oil contained
inside the vacuum pump.

TOP PLUG

SIGHT
GLASS

BOTTOM
PLUG

4. Once the pump is emptied, rescrew the bottom plug.

5. Fill the pump with the new oil by pouring it in the top aperture, eventually using a funnel.
Bring the new oil level in correspondence to half of the inspection device.
6. Once the pump is filled, close the top plug.

After replacing the oil, turn on the unit and select PUMP OIL REPLACEMENT from the
MAINTENANCE menu: press the "ZERO SETTING" key to reset the counter.

ENGLISH 15 / 46 CAP. 6 - MAINTENANCE


CLIMA-6000

6.3 DEHYDRATOR FILTER REPLACEMENT


The dehydrator filter must be replaced after having dehydrated 27 kg of coolant fluid, since its capacity to
keep the humidity present in the coolant will run out.

To replace the dehydrator filter, select REPLACE DEHYDRATOR FILTER from the MAINTENANCE menu:
press "ZERO SETTING" to reset the counter and to proceed with the filter replacement. Wait for execution of
the R134a gas emptying from the pipes.

To proceed to filter replacement the following equipment is necessary

• 1 Medium size Phillips screwdriver


• 1 Hex key (24 mm)

and follow the instructions indicated as follows


1. Disconnect the unit from the electrical network.
2. Remove the screws that fix the front shutter of the unit.
3. Unscrew the 2 filter connection nuts with the hex keys.
4. Cut the two plastic straps that bind the filter

DEHYDRATOR NUTS
FILTER

5. Install the new filter being careful of the position of the washers and the direction of the arrow that
points towards the fluid passage.
6. Screw the two filter connection nuts.
7. Reclose the equipment before reconnecting it to the electrical network.

6.4 WEAR CHECK OF THE RED AND BLUE LOAD


PIPES AND THE HP RED AND LP BLUE QUICK
COUPLERS
Check that the entire length of the piping does not present:
• abrasions, cracks, cuts, irreversible folds, deformations, twists.

Check that the contact points between the piping and the joints with quick couplers and with the
equipment do not present:
• abrasions, cracks, cuts, irreversible folds, deformations, twists.

Check that the quick couplers do not present:


• abrasions, excessive plays, cracks, deformations.

TESTS of the piping capacity and quick couplers with upkeep tests in vacuum and in pressure.
• Close the gaskets of the quick couplers of the CLIMA-6000 equipment;
• launch the function inside the Maintenance Menu "Capacity test", check that the test is passed
successfully.
• From the Service Menu - "Manual activations", activate the "R" and "I" valves and check that the pipes
are pressured (at least 5 bar) and check that the pressure does not drop in a time slot equal to 30
minutes and that gas leaks do not occur.

ENGLISH 16 / 46 CAP. 6 - MAINTENANCE


CLIMA-6000

6.5 COOLANT GAS SCALE CHECK WITH SAMPLE


WEIGHT AND EVENTUAL CALIBRATION
(SERVICE KIT)
Place a sample weight on the tank and check that the changes in weight are adequately detected by the
machine scale.

Place the clamp that is part of Position a 5 kg sample weight


the service kit under the tank on the clamp and check that
the weight increases by 5 kg +/-
50 g, in case of errors in
excess execute a new
calibration of the gas weight.

6.6 WEAR CHECK AND CAPACITY OF THE


SOLENOID VALVE PISTONS OF THE
MANIFOLD

1. Close the gaskets counter clockwise.


2. Switch off the machine, remove the power supply cable and open the cover and the front panel.
3. Close central gasket (liquid side) of the yank with service kit key
4. Reconnect the power supply cable, turn on the machine (careful not to touch terminals or electronic
cards)
5. Reach the service menu
6. Select manual activations
7. In manual activations activate OUT R, OUT I, OUT A, C, wait for the LP gauge to show a pressure of
at least - 0.4 bar
8. Switch off the machine and remove the power supply network cable
9. Close the other gasket (gas side) of the tank with service kit key
10. Close the gasket along the connecting pipe towards the condensator
11. Dismantle the solenoid valve reel block with a wrench or 14mm spark plug wrench (No.1 in the
following figure)
12. With the 24 spark plug wrench (No.2 in the following figure) using the screwdriver as handle, the valve
sleeve is removed
13. Evaluate whether the rubber is visibly ruined and swollen (the presence of a circular trace is normal,
but there must not be swells and grooves different from the circular one)
14. Blow the piston air channels with compressed air
15. Blow inside the sleeve and the manifold seat where the valve is screwed
16. Blow the seat of the valve on the aluminium base of the MANIFOLD
17. Do not use chemical products or cloths and brushes
18. In case of deteriorated washer, it is preferable to replace the entire piston

ENGLISH 17 / 46 CAP. 6 - MAINTENANCE


CLIMA-6000

19. Reassemble the solenoid valve by first mounting the piston and subsequently the block of the electrical
reel.
20. Once the solenoid valve mounting is complete, reopen the gaskets/valves of the tank
21. Reclose panel and cover, reconnect the power supply cable and turn on the machine again.

TEST UNDER PRESSURE


From the Service Menu . "Manual activations", in function of the replaced valve open (activate) or keep closed
the solenoid valves represented in the chart reported as follows.
Ensure that the tank pressure reaches the valve in question in the maintenance activity.
Check that the valve in question does not present coolant leaks through the identification of leaks or
pressure drops (over 200 mbar)

TEST IN VACUUM
Launch the function inside the Maintenance Menu "Capacity test", check that the test is passed successfully.

ENGLISH 18 / 46 CAP. 6 - MAINTENANCE


CLIMA-6000

6.7 WEAR CHECK OF THE OR2-106 4.42x2.62


NBR O-RING OF THE PRESSURE SENSOR
PRESENT ON THE MANIFOLD

1. Close the gaskets counter clockwise.


2. Switch off the machine, remove the power supply cable and open the cover and the front panel.
3. Close central gasket (liquid side) of the tank with service kit key
4. Reconnect the power supply cable, turn on the machine (careful not to touch terminals or electronic
cards)
5. Reach the service menu
6. Select manual activations
7. In manual activations activate OUT R, OUT I, OUT A, C, wait for the LP gauge to show a pressure of
at least - 0.4 bar,
8. Switch off the machine and remove the power supply network cable
9. Close the other gasket (gas side) of the tank with service kit key
10.Close the gasket along the connecting pipe towards the condensator
11.Cut the straps if necessary and disconnect the sensor cable.
12.Insert the cable in the key, position the key on the sensor and unscrew it by using the screwdriver as
handle.
13.Clean the seat of the pressure sensor using compressed air and keeping the bronze filter still with a
screwdriver.
14.Check the state of the bronze filter, and eventually replace it is case of impurities present.
15.Check the state of the O-Ring inside the manifold cavity and in case of wear or deformation replace
with a new one.
16.Remount the sensor in its seat.
17.Once the solenoid valve mounting is complete, reopen the gaskets/valves of the tank
18.Reclose panel and cover, reconnect the power supply cable and turn on the machine again.

TEST UNDER PRESSURE


From the Service Menu . "Manual activations", in function of the replaced valve open (activate) or keep closed
the solenoid valves represented in the chart reported as follows
Ensure that the tank pressure reaches the sensor in question in the maintenance activity.
Check the sensor in question does not present coolant leaks through the identification of leaks or pressure
drops.

TEST IN VACUUM
Launch the function inside the Maintenance Menu "Capacity test", check that the test is passed successfully.
6.8 CHECK PRESENCE AND WEAR OF O-RINGS
OR2212 53.7X1.78 NBR OF THE OIL
CONTAINERS
Check the presence of the O-RING which acts as sign of the oil level on new, exhaust and tracer oil
containers. In case of signs of deterioration replace them with new ones.
In case of problems when inserting the connector on the machine joint proceed to replacing the bottle.

ENGLISH 19 / 46 CAP. 6 - MAINTENANCE


CLIMA-6000

CAP. 7 - CALIBRATION

7.1 SERVICE KIT


The service kit is made up of a series of equipment identified as follows, necessary for the programming,
calibration and maintenance activities of the CLIMA line equipment.

1. Service Kit Case


2. 24 mm spark plug to disassemble pressure sensors
3. Distance clamp for lifting tank
4. Sample weight support clamp
5. 7 mm box end wrench for opening / closure tank gaskets
6. 303 g sample weight for new oil scale calibration
7. 293 g sample weight for exhaust oil scale calibration
8. Gauge for Unit pressure sensors calibration
9. DB9 M/F pin to pin serial cable

ENGLISH 20 / 46 CAP. 7 - CALIBRATION


CLIMA-6000

7.2 PRESSURE CALIBRATION (SERVICE KIT)

From the SERVICE menu select the PRESSURE CALIBRATION menu through keys and

press .

Disconnect the quick LP and HP attachments from any system and press .
Wait until the following message to open HP.

Rotate the HP quick coupler to open it and press

Wait for the message to connect the reference gauge contained in the service kit.

Close the quick HP attachment by rotating it counter clockwise and connect it to the gauge present

in the SERVICE KIT, open the quick HP attachment by rotating it clockwise and press .

SAFETY NOTE:
ATTENTION NOT TO POINT THE GAUGE TOWARDS ONESELF OR OTHER PEOPLE UNTIL
ONE HAS THE ABSOLUTE CERTAINTY THAT THE CONNECTION WITH THE QUICK COUPLER
IS SAFE.

OPEN THE GASKET OF THE QUICK COUPLER BY POINTING THE GAUGE TOWARDS THE
GROUND, ALWAYS KEEP THE GAUGE TOWARDS THE GROUND EXCEPT IN THE MOMENTS
IN WHICH THE GUIDED PROCEDURE REQUIRES ENTERING THE VALUE DISPLAYED ON THE
SAMPLE GAUGE.

Measure the pressure reached by the SERVICE KIT gauge and, through keys set it on the

Unit and press .

Subsequently the equipment will execute the vacuum, at the end of which one will be asked to check

that the gauge reach -1 bar, when requested by the guided procedure press to confirm
calibration.

ENGLISH 21 / 46 CAP. 7 - CALIBRATION


CLIMA-6000

7.3 GAS WEIGHT CALIBRATION (SERVICE


KIT)

From the SERVICE menu select the GAS WEIGHT CALIBRATION menu through keys and

press .

Unscrew the tank, lift it and insert below it the distance clamp in order to keep it detached from the

loading cell. Press to acquire the loadless cell signal.

Remove the distance clamp and re-screw the tank to the loading cell, insert the weight holder clamp
without the sample weight.

Press to acquire the signal of the cell with tank and clamp.

Rest a sample weight of at least 5 kg on the weight holder clamp and press : one will be asked
to insert the value of the weight just set on the clamp

Press keys to set the value of the sample weight and press to acquire the signal of
the cell with tank, clamp and sample weight.

Subsequently remove the sample weight and the weight holder clamp and press .

When requested by the guided procedure press to confirm the calibration.

ENGLISH 22 / 46 CAP. 7 - CALIBRATION


CLIMA-6000

CAP. 8 - UPDATE
8.1 SOFTWARE UPDATE
To update the equipment and the relative database it is necessary to proceed to a new
programming of the equipment as described in point 5.1.4 "programming" with the serial cable
available in the Service Kit or through the ACU device (Automatic Clima Update).

8.2 NEW DATABASE PURCHASE AND


ACTIVATION

In the “Service” area of the website www.brainbee.com

Enter the "Reseller" area with the PassWord for "Service Area"

Enter the “CLIMA Registration” area

ENGLISH 23 / 46 CAP. 8 - UPDATE


CLIMA-6000

Press "Purchase a clima database update ..."

Digit the “DATABASE ACTIVATION REQUEST CODE” database activation code displayed on the
equipment screen when attempting to access to the vehicles entered in the new version of the
database.

Before confirming (green arrow) check that the e-mail is correct, otherwise contact the Brain Bee
sales office.
After confirmation you will receive an e-mail (order confirmation) which enables to obtain the code to
enter into the CLIMA equipment to activate the new database version.

ENGLISH 24 / 46 CAP. 8 - UPDATE


CLIMA-6000

CAP. 9 - EQUIPMENT AND SIMULATORS


The following equipment is necessary

Equipment
• CLIMA 8501 SERVICE KIT
• ACU - AUTOMATIC CLIMA UPDATER

Software (available in the website http://www.brainbee.itby entering the “Download” Service Area)
• Clima Update Software
• Clima 6000 Software

ENGLISH 25 / 46 CAP. 9 - EQUIPMENT AND SIMULATORS


CLIMA-6000

CAP. 10 - COOLANT FLUID CIRCUIT


10.1 COOLANT FLUID CIRCUIT
The chart of the coolant fluid circuit of the CLIMA-6000 equipment is reported as follows.

1 Vacuum pump

2 Compressor

3 Condensator fan

4 Coolant load solenoid valve

5 New oil injection solenoid valve

7 – 8 Vacuum solenoid valves couple

9 – 10 Coolant absorption solenoid valves couple

11 Exhaust oil discharge solenoid valve

12 Compressor upstream high pressure safety pressure switch

13 HP branch pressure gauge

14 LP branch pressure gauge

15 LP + HP pressure sensor

16 Accumulation receiver safety valve (20 bar)

ENGLISH 26 / 46 CAP. 10 - COOLANT FLUID CIRCUIT


CLIMA-6000

17 Condensable gas discharge solenoid valve

18 Mechanical no return valve of the new oil injection branch

20 Automatic mechanical expansion valve

21-22 HP-LP interception solenoid valves couple

23 Vapour phase interception sphere valve

24 Liquid phase interception sphere valve

25 Schrader valve for testing socket 1

26 HP vehicle quick coupler (SAEJ639)

27 LP vehicle quick coupler (SAEJ639)

28 Loading branch mechanical no return valve

29 New oil container

30 Testing socket 1 with plug

31 Exhaust oil container

32 Schrader valve for testing socket 2

33 Testing socket 2 with plug

34 Compressor oil restore capillary circuit

35 Coolant accumulation receiver

36 Coolant scale

37 Condensator

38 Dehydrator filter

39 Compressor oil restore separator receiver

40 Exhaust oil distillator double chamber receiver

41 Solenoid valve manifold /pressure sensor

ENGLISH 27 / 46 CAP. 10 - COOLANT FLUID CIRCUIT


CLIMA-6000

The circuit is made up of 3 main parts:


• the coolant fluid tank equipped with three joints,
o recovered coolant inlet, and outlet towards condensable gases discharge valve
o coolant outlet for recharge,
o safety valve.
• The manifold, joint aluminium block, equipped with channeling on which the valves and other
devices are mounted,
o inlet from fluid tank,
o new oil container inlet,
o piping with HP gauge towards vehicle,
o piping with LP gauge towards vehicle,
o outlet towards vacuum pump
o outlet towards coolant recovery group
• the coolant recovery group, which through its own components enables the following
operations, expansion of the gas recovered from the vehicle, evaporation with exhaust oil
separation, coolant dehydration, compression, condensation.
o recovered coolant inlet,
o exhaust oil outlet,
o liquid coolant outlet towards the tank,
o safety pressure switch.

ENGLISH 28 / 46 CAP. 10 - COOLANT FLUID CIRCUIT


CLIMA-6000

10.2 OPERATIONAL CYCLES


The equipment enables, with a single series of operations, to recover and recycle the refrigerant
fluids without dispersions in the environment, also removing humidity and the various deposits
contained on the oil from the A/C system. In fact inside the equipment there is an
evaporator/separator present through which oil and other impurities are removed from the
refrigerant fluid recovered from the A/C system, then collected in an appropriate container. The
fluid is then filtered and reinserted, perfectly recycled, inside the tank present in the equipment.
Through the equipment it is also possible to carry out some A/C system functioning and capacity
tests.

RECOVERY

HP HP+LP OIL INJECTION

ENGLISH 29 / 46 CAP. 10 - COOLANT FLUID CIRCUIT


CLIMA-6000

HP HP+LP LOAD

FLUSHING

ENGLISH 30 / 46 CAP. 10 - COOLANT FLUID CIRCUIT


CLIMA-6000

10.3 RECEIVING TANK


The tank is the component which determines the category of the entire equipment according to PED
directive.
The PED “Pressure Equipment Directive” 97/23/EC defines and disciplines all those parts subject to
pressure with a given ratio between their pressure and their volume.

Safety against the risk due to pressure of the coolant fluid inside the receiving tank is assigned to
the safety valve installed during manufacturing. In case of replacement, use of new and original
spare parts not contaminated with other substances is recommended as well as requesting the
relative declaration of conformity proving the effective test of the components in the beginning.

The assistance centre assumes responsibility for regulation assembly and for checking before new
commissioning according to the prescriptions determined by the regulation in force in the country of
use, particularly the assistance centre will have to guarantee that the assembly will ensure a perfect
capacity and that the safety components are installed appropriately so to not compromise
functioning.

RECEIVER 7.6 liters


Category I (Dir. 97/23/EC)

SAFETY VALVE 20 bar R 1/4 GAS


Category IV (Dir. 97/23/EC)

Notes regarding operator safety:


Attention presence of dangerous 230 VAC voltage in proximity to tank, disconnect the
equipment from the electrical network before each maintenance intervention.

Attention presence of coolant fluid under pressure, in case of disassembly of the tank or of its
components, ensure that the tank is empty and closed, the connecting pipe between tank and
manifold is empty and the connecting pipe between tank and pneumatic group is empty.
Emptying with the aid of a second CLIMA line equipment is advised.
Do not disperse gas into the environment.

ENGLISH 31 / 46 CAP. 10 - COOLANT FLUID CIRCUIT


CLIMA-6000

10.4 MANIFOLD CHART


The manifold chart, where the identification letters of the sectioning valve are highlighted, is
reported as follows:
• V = vacuum;
• A = recovery;
• I = interception (HP side and LP side separation);
• L = new oil
• R = coolant
The valves (V,A,I) which must lead the gas flow in both directions must necessarily be double
since the single valve is not able to guarantee bidirectional closure.

Notes regarding operator safety:


Attention presence of dangerous 230 VAC voltage on the solenoid valve terminals and in
proximity of the manifold, disconnect the equipment from the electrical network before each
maintenance intervention.

Attention presence of coolant fluid under pressure, in case of disassembly of manifold or its
components ensure that the tank is closed, the connection pipe between the tank and the
manifold is empty, the LP and HP connectors are disconnected from any system and closed,
that a pipe emptying operation has been made, and the manifold has been completely emptied
(for further details see CHAP.13).

Tank gauge
LP Gauge New oil

V A I
R

Vacuum Recovery HP Gauge

ENGLISH 32 / 46 CAP. 10 - COOLANT FLUID CIRCUIT


CLIMA-6000

10.5 SUCTION UNIT CHART


The suction unit is a group made up of various pressurised equipment interconnected through
brazed piping, which according to the PED directive fall under article 3 paragraph 3.
A foreseen ordinary maintenance operation is the replacement of the dehydrator filter the
procedure for which is illustrated in the use manual.
Safety against the risk due to pressure of the coolant fluid inside the suction unit is assigned to the
presence of a safety gauge installed during manufacturing.
In case of replacement of the pressure switch or the unit, use of new and original spare parts not
contaminated by other substances is recommended as well as requesting the declaration of
conformity proving the effective test of the components in the beginning.
The assistance centre assumes responsibility for regulation assembly and for checking before new
commissioning according to the prescriptions determined by the regulation in force in the country of
use, particularly the assistance centre will have to guarantee that the assembly will ensure a perfect
capacity and that the safety components are installed appropriately so to not compromise
functioning.
SUCTION UNIT Art. 3.3 (Dir. 97/23/EC)

DECANTER

EXPANSION SAFETY
VALVE PRESSURE
SWITCH

DISTILLATOR

IMPELLER
AND
RADIATOR

EXHAUST OIL
COMPRESSOR DEHYDRATOR
DISCHARGE
FILTER
SOLENOID VALVE

13/18bar 1/4SAE PRESSURE SWITCH Category IV (Dir. 97/23/EC)

ENGLISH 33 / 46 CAP. 10 - COOLANT FLUID CIRCUIT


CLIMA-6000

CAP. 11 - ELECTRICAL CONNECTIONS


The principle chart of the CLIMA-6000 equipment electrical connections is reported as follows, with
the connections among the main components and the electronic cards making up the equipment.

ENGLISH 34 / 46 CAP. 11 - ELECTRICAL CONNECTIONS


CLIMA-6000

Connections between power board and actuators on the manifold.

LOGIC BOARD CONNECTION

AC
NETWOR

CHASSIS
GROUND

OPTIONAL

ENGLISH 35 / 46 CAP. 11 - ELECTRICAL CONNECTIONS


CLIMA-6000

CAP. 12 - SPARE PARTS


The necessary components for ordinary and extraordinary maintenance are made available.

Ordinary maintenance includes the replacement of components subject to wear, such as thermal
paper of the printer, or to use, such as: loading pipes, quick couplers and piping and solenoid valve
washers.

Extraordinary maintenance includes the replacement of other components such as, for example:
the loading cells, the vacuum pump, the pressure sensors, the printer, the keyboard, the gauges,
the safety valve and the suction unit.

In the www.brainbee.com spare parts website, the complete list is available with the relative codes
to order them.

Enter the “Service Area” with own Password received from the Brain Bee Sales Department.

Enter the "Reseller" area with the PassWord for "Service Area"

ENGLISH 36 / 46 CAP. 12 - SPARE PARTS


CLIMA-6000

ENGLISH 37 / 46 CAP. 12 - SPARE PARTS


CLIMA-6000

Enter the “Spare Parts Management” area

Select the area of the CLIMA product line and the model in question.
For the correct display of the spare parts it is necessary to have Acrobat Reader available and the
appropriate NetSpares Plugin available for installation after download.
In case the page display is not complete, act on the zoom of own internet browser (example
Explorer).

Once the equipment has been selected from the appropriate list a .pdf file will open and the Net-
Spares functions will be available among the Acrobat Reader tools. It is advised to view the use

manual, accessible through the key .

ENGLISH 38 / 46 CAP. 12 - SPARE PARTS


CLIMA-6000

CAP. 13 - REPLACEMENT INTERVENTIONS

13.1 EXTRAORDINARY MAINTENANCE


SCHEDULE

INTERVENTION DESCRIPTION TIME in hours


Vacuum pump replacement 1,5
Vacuum pump oil replacement 1
Replacement of PNEUMATIC SUCTION UNIT which includes 2,5
Mechanical expansion valve
Distillator receiver
Compressor
Compressor oil reset separator receiver
Heat exchanger
Cleaning and/or replacement coolant load Solenoid valve 1
Cleaning and/or replacement new oil injection Solenoid valve 1
Cleaning and/or replacement HP-LP interception solenoid valves couple 1
Cleaning and/or replacement vacuum solenoid valves Couple 1
Cleaning and/or replacement exhaust oil discharge Solenoid valve 1
LP branch pressure Sensor Replacement 2
Accumulation receiver safety Valve Replacement (20 bar) 1
Replacement of quick coupler to HP vehicle 1
Replacement of quick coupler to LP vehicle 0,5
Dehydrator filter replacement 0,5
Coolant accumulation Receiver Replacement 2,5
Coolant Scale Replacement 2
HP branch pressure Gauge Replacement 1
LP branch pressure Gauge Replacement 1
Replacement of logic electronic card with display 2
Replacement of electronic power board 1
Replacement/installation tank heating strap 1

ENGLISH 39 / 46 CAP. 13 - REPLACEMENT INTERVENTIONS


CLIMA-6000

13.2 EXTRAORDINARY MAINTENANCE

13.2.1 Replacement of components connected to coolant


circuit
The equipment contains parts subject to directive PED Pressure Equipment Directive 97/23/EC.
The components (pressurised equipment) constituting/connected to the coolant fluid circuit
through permanent junctions such as sealing or brazing, can in no way be disassembled,
replaced, changed or handled.

Before each check and/or replacement intervention of components inside the machine it is
recommended to firstly carry out the following operation:

1. Wind the 2 pipes in the supports foreseen on the side of the machine and close the gaskets
in a counter clockwise fashion.
2. Switch off the machine, remove the power supply cable and open the cover and the front
panel.
3. Close central gasket (liquid side) of the tank with service kit key
4. Reconnect the power supply cable, turn on the machine (careful not to touch terminals or
electronic cards)
5. Reach the service menu
6. Select manual activations
7. In manual activations activate OUT R, OUT I, OUT A, C, wait for the LP gauge to show a
pressure of at least - 0.4 bar,
8. Switch off the machine and remove the power supply network cable

In case of replacement of pipes equipped with o-rings use 577 loctite thread locker and replace the
internal o-ring.

In case of replacement of pipes without o-ring insert the lubricated copper washer.

It is recommended to not disperse the coolant in the atmosphere.

If it is necessary to provide for emptying of the internal tank, it is necessary to carry out coolant
recovery with a second machine, after having interconnected the equipment with the HP pipe and
having placed the machine to empty with the open tank and an open OUT R valve.

As an alternative it is possible to disconnect the inlet to the tank on the gas side by connecting the
pipe to an external tank to fill and by activating OUT R, OUT I, OUT A, C until obtaining a tank
pressure of about -0,4 bar,

13.2.2 Replacement of logic electronic card with display


After having excluded any problem regarding software, power supply, fuses on the switch block,
connection cables, faults in the power board, faults to the micro SD card (512 Mb, max 2 Gb),
faults to the sensors, foresee a replacement in case of:
• Impossibility to correctly complete card programming.
• Incorrect display function
• Block in the acquisition and display of the analogue signals not caused by faults in the
sensors or by a miscalibration.
• Incorrect activation of command relays.
• Evident damage to card components and circuits.
For the replacement of the card it is recommended to position the new card alongside the one to
replace. Disconnect and reconnect the cables in sequence one by one:
• Gas scale loading cell (J1 W. TANK)
• LP pressure sensor (J8 P. LP)
• Power board connection (J3 I/O INTERFACE)
• Serial programming connector (J18 RS232 PRG)
• Keyboard connector (J15)
• Reprogram the machine with the updated software.
• Select the language
• Carry out gas scale calibration
• Carry out pressure calibration
• Enter the machine registration code (it can be obtained through the Brain Bee service website
in the service area by selecting "Clima Registration" "Registration Status" and selecting the
machine serial number on which one is operating.
• Carry out the machine settings as in paragraph 05.01.10.

ENGLISH 40 / 46 CAP. 13 - REPLACEMENT INTERVENTIONS


CLIMA-6000

13.2.3 Replacement of electronic power board


After having excluded any problem relative to power supply, fuses on the switch block, connection
cables, faults to the logic board, faults to the controlled actuators, foresee the replacement in case
of:
• Incorrect functioning of the power supplier section.
• Incorrect activation of the command relays or the actuators connected to them.
• Evident damage to card components and circuits.
For the replacement of the card it is recommended to position the new card alongside the one to
replace. Disconnect and reconnect the cables in sequence one by one:
• FST7 OUT A (Gas recovery)
• FST2 OUT R (Gas injection)
• FST3 OUT L (new oil)
• FST4 OUT T (Connect electrical cable marked with label OUT I)
• FST5 OUT S (exhaust oil)
• FST6 OUT H (if optional tank heating strap present)
• FST10 OUT V (vacuum)
• FST11 OUT V (vacuum)
• FST14 PROTECT (pressure switch)
• FST13 OUT C (compressor)
• FST1 LINE IN (AC electrical network)
• FST16 GROUND (grounding)
• J1 I/O INTERFACE (Interface cable with logic board)

ENGLISH 41 / 46 CAP. 13 - REPLACEMENT INTERVENTIONS


CLIMA-6000

CAP. 14 - TROUBLE SHOOTING

MALFUNCTION POSSIBLE CAUSE POSSIBLE SOLUTION


1. If the “SD card not present” SD card absent or not 1. Insert or check SD card
message is shown during switch mounted well. insertion.
on and/or during software 2. Reprogram recharge station.
update just downloaded from
web.

2. Slow or not possible coolant Joints fixing rubbers cut for 1. Localisation of the defects
injection. excessive locking (they relative to the rubber components
cause clogging of pipes and or dirt residue and replacement or
operational block of the cleaning.
machine, with different 2.Carry out emptying of the gas as
consequences based on the described in chap.13.2.1
position of the rubber - in 3. If yellow pipes are present, check
any case it is always and eventually replace the fixing
regarding clogging of a pipe washers placed inside the pipe
or dirt in the solenoid which connects the solenoid valve
valves). group to the tank.

3. During the recovery phase Dirt inside the Oil discharge 1.Cleaning of the solenoid valve
there is an evident coolant leak solenoid valve. OUT – S.
from the exhaust oil container. 2. Check of the washer efficiency.
The capacity test is negative.

4. Difficulty in the recovery and Closed coolant tank. 1. Open the tank valve by
recharge phase Fixing washers, broken or unscrewing it counter clockwise.
deformed, are obstructing 2.Carry out emptying of the gas as
the pipes. described in chap.13.2.1
3. Reset the normal fixing
conditions of the HP-LP gasket
washers and the HP-LP joints, both
internal and external.
4. If yellow pipes are present, check
and eventually replace the fixing
washers placed inside the pipe
which connects the solenoid valve
group to the tank.
5. During the automatic cycle it Oil loading cell out of 1. Calibration of the exhaust and
is not possible to inject and calibration or defective. new oil scales.
recover the oil. 2. Eventual replacement.

6. Vacuum pump emits Defective vacuum pump Vacuum pump replacement


disturbing vibrations

7. After the vacuum phase the This may occur when the When a vacuum time less than 20
capacity test has a negative vacuum time is too short, minutes is set, the following
result. 4-5 minutes. message appears:
“Less than 20 minutes of vacuum
do not guarantee the execution of a
correct procedure. Continue?”.
The solution is keeping to the 20
minutes vacuum time.
8. The gas scale appears Loading cell locking screw Unscrew the locking screw of the
blocked at a certain value. not sufficiently unscrewed. cell more, ensuring that it is not in
contact with the cell during use.

ENGLISH 42 / 46 CAP. 14 - TROUBLE SHOOTING


CLIMA-6000

CAP. 15 - DIAGNOSTICS

15.1 FAILURE LIST


The list of fault/failure codes that may be detected by the CLIMA-6000 machine software is
reported as follows, refer to Your Supplier or service Partner.

Attention messages are codified with the code Wxxx on the window title.

CODE MESSAGE When it can Possible causes Possible remedies


occur
W024 UNSTABLE MACHINE During phase Blows, Maintain the equipment in
of: Gas vibrations on stable position, check
recovery, tank the equipment absence of vibrations
filling, tracer during a
injection, oil procedure in
injection, gas which the
injection, measures of the
flushing. weights that
could be erred
are involved
W025 COOLANT QUANTITY During the Quantity Check possibility of
TOO ELEVATED tank filling requested for volume in the internal
phase recharge tank, if possible recharge
greater than ulterior gas.
the one available
in the internal
tank
W026 RECHARGE TANK During the Tank for Check tank, pipes,
EMPTY OR tank filling recharge empty gaskets.
DISCONNECTED phase or pipes/gaskets
clogged/closed
W027 DISCONNECT THE During the Check presence Disconnect the recharge
RECHARGE TANK tank filling of the recharge tank.
phase tank still
connected.
W029 TANK ALMOST FULL During the gas The tank is Decrease gas quantity
recovery phase close to the through external tank
or pipe maximum filling adequate for
emptying. quantity it may R1234yf
contain.
W030 EXHAUST OIL During the gas -- Empty the container and
CONTAINER FULL - recovery dispose according to the
EMPTY THE phase, or regulation in force in the
CONTAINER flushing country of use of the
exhaust oil
W031 EXHAUST OIL During the gas -- Empty the container and
CONTAINER ALMOST recovery dispose according to the
FULL - EMPTY THE phase, or regulation in force in the
CONTAINER flushing country of use of the
exhaust oil
W032 ABSENCE OF During gas Check connections and
PRESSURE - VEHICLE recovery phase eventual presence of
WITHOUT COOLANT leaks on the A/C system
OR DISCONNECTED
W036 IMPOSSIBLE TO During oil Insufficient Increase vacuum phase
INJECT FURTHER OIL injection phase vacuum level duration.
W037 NEW OIL CONTAINER During oil -- Fill oil container.
EMPTY - FILL THE injection phase
CONTAINER
W038 NEW OIL LEVEL TOO During oil -- Fill oil container.
LOW - FILL THE injection phase
CONTAINER

ENGLISH 43 / 46 CAP. 15 - DIAGNOSTICS


CLIMA-6000

CODE MESSAGE When it can Possible causes Possible remedies


occur
W039 DISCONNECT LP During gas -- Check that the LP pipe is
injection, disconnected.
vacuum or
pressure
control phase
W040 DISCONNECT HP During gas -- Check that the LP pipe is
injection, disconnected.
vacuum or
pressure
control phase
W042 DISCONNECT LP AND During the gas -- Check that the LP and
HP injection or HP pipes are
flushing phase disconnected.
W043 DISCONNECT HP AND During the -- Check that the HP pipe is
TURN ON THE pressure disconnected and switch
CONDITIONER control phase on the air conditioner of
the vehicle.
W044 EMPTY TANK During flushing -- Proceed to recharge
or multipass R1234yf gas in the
phase internal tank
W045 LP VERY LOW, During flushing LP pipe Reconnect LP and/or
CHECK THE CIRCUIT phase disconnected, joints and search for and
BEFORE PROCEEDING joints for eliminate eventual leaks.
flushing not
correctly fixed
or leak in circuit
undergoing
flushing.
W046 PRESENCE OF During Proceed to condensable
CONDENSABLE condensable gas discharge through
GASES gases test "OK" confirmation.
phase
W047 POSSIBLE LEAK During gas A/C vehicle --
recovery phase system with
possible leaks
W048 IMPOSSIBLE TO During gas Pipes not Attention, before any
INJECT FURTHER injection phase connected to action proceed with pipe
COOLANT vehicle A/C emptying function.
system; gasket
not open or
compressed air
not available or
sufficient.
W049 CONNECT THE During the -- --
RECHARGE TANK tank filling
phase
W050 CONNECT THE During the -- --
VEHICLE tank filling
phase

ENGLISH 44 / 46 CAP. 15 - DIAGNOSTICS


CLIMA-6000

Alarm messages are codified with the code Axxx on the window title.
The alarms cause the immediate stop of the procedure and do not allow to continue.

CODE MESSAGE When it can Possible causes Possible remedies


occur
A000 EEPROM NOT At the Damage to the Contact a Brain Bee S.p.A.
FUNCTIONING beginning of control authorised assistance
each working electronics centre
phase
A001 EEPROM CONTENT At the Damage to the Contact a Brain Bee S.p.A.
CORRUPTED beginning of control authorised assistance
each working electronics centre
phase
A002 ACTIVATED At the Presence of Contact a Brain Bee S.p.A.
COMPRESSOR beginning of R1234yf gas at authorised assistance
SAFETY each working elevated centre
phase pressure in the
circuit
A003 ADC NOT At the Damage to the Contact a Brain Bee S.p.A.
FUNCTIONING beginning of control authorised assistance
each working electronics centre
phase
A004 IMPELLER NOT At the Damage to the Contact a Brain Bee S.p.A.
FUNCTIONING beginning of control authorised assistance
each working electronics or to centre
phase the impeller
A005 CYLINDER NOT At the Damage to the Contact a Brain Bee S.p.A.
FUNCTIONING beginning of control authorised assistance
each working electronics or to centre
phase the
cylinder/piston
A032 SYSTEM STILL IN During Vehicle A/C Identify position of leak in
PRESSURE vacuum system with vehicle and proceed to repair
phase; tank pressure by trained/qualified staff
recharge; presence according to the enforced
capacity test despite vacuum regulation in the country of
phase execution use.
A033 LEAK IN THE During the -- Identify position of leak in
CIRCUIT vacuum vehicle and proceed to repair
phase, by trained/qualified staff
capacity test; according to the enforced
gas injection regulation in the country of
use.

ENGLISH 45 / 46 CAP. 15 - DIAGNOSTICS


CLIMA-6000

CODE MESSAGE When it can Possible causes Possible remedies


occur
A034 INSUFFICIENT During tracer Vehicle A/C Identify position of leak in
VACUUM LEVEL injection and system with vehicle and proceed to repair
oil injection pressure by trained/qualified staff
phase presence according to the enforced
despite vacuum regulation in the country of
phase execution use.
A035 EMPTY TANK During gas -- Recharge internal tank
injection
phase
A036 COOLANT During gas Gas available in Recharge internal tank
QUANTITY TOO injection the internal tank
ELEVATED phase less than what
requested
A037 IMPOSSIBLE TO During gas Pipes not Attention, before any action
INJECT FURTHER injection connected to proceed with pipe emptying
COOLANT phase vehicle A/C function.
system; gasket
not open or
compressed air
not available or
sufficient.
A038 LEAK IN THE During -- Check connection to the A/C
SYSTEM OR flushing system or
SYSTEM NOT phase
CONNECTED Identify position of leak in
vehicle and proceed to repair
by trained/qualified staff
according to the enforced
regulation in the country of
use.
A039 IMPOSSIBLE TO During oil Insufficient Increase vacuum phase
INJECT FURTHER injection vacuum level duration.
OIL phase

A042 TANK PRESSURE During the Possible Disconnect external tank.


TOO HIGH tank filling connection to
phase external tank
containing gas
A043 FULL TANK During the -- Decrease gas quantity
gas recovery through external tank filling
phase and adequate for R1234yf
pipe
emptying.

ENGLISH 46 / 46 CAP. 15 - DIAGNOSTICS