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AGRAMKOW Fluid Systems A/S

Augustenborg Landevej 19
DK-6400 Sønderborg
Tel +45 74 12 36 36
Fax +45 74 43 36 46
agramkow@agramkow.com
www.agramkow.com

Instructions

Caterpillar do Brazil

Line-side A/C charging equipment

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Line-side AC charging equipment

Contents

Click here

1. Safety instructions .......................................................................................................... 4

2. Installation and connection ............................................................................................. 5

3. Service and maintenance instructions ............................................................................. 6


3.1 Pneuadapter - Drawings and parts lists ........................................................................... 7
3.1.1 Pneuadapter HP .............................................................................................................. 8
3.1.1.1 Pneuadapter complete ..................................................................................... 9
3.1.1.2 Mechan. Pneuadapter Charge ....................................................................... 10
3.1.1.3 Mechan. Remote control............................................................................... 11
3.1.1.4 El. Pneuadapter Charge ................................................................................ 12
3.1.1.5 Hoses ............................................................................................................ 13
3.1.2 Pneuadapter LP ............................................................................................................. 14
3.1.2.1 Pneuadapter complete ................................................................................... 15
3.1.2.2 Mechan. Pneuadapter Charge ....................................................................... 16
3.1.2.3 Hoses ............................................................................................................ 17
3.2 Pneuadapter - Service ................................................................................................... 18
3.3 Pneuadapter - Maintenance scheme.............................................................................. 19
3.4 Station - Maintenance scheme ...................................................................................... 20
3.5 How to contact AGRAMKOW service department ..................................................... 21

4. Function description ..................................................................................................... 22


4.1 Operator instructions .................................................................................................... 23
4.2 Process description ....................................................................................................... 24
4.3 Sub description ............................................................................................................. 25
4.4 Flow chart ..................................................................................................................... 26
4.5 PT-diagram ................................................................................................................... 27
4.6 Settings ......................................................................................................................... 28

5. Fault description ........................................................................................................... 29

6. Specifications ................................................................................................................ 30

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Line-side AC charging equipment

7. Mechanical drawings and parts lists, PI-diagram ......................................................... 34


7.1 Layout ........................................................................................................................... 35
7.2 Parts lists ....................................................................................................................... 36
7.3 PI-diagram .................................................................................................................... 37
7.4 Installation .................................................................................................................... 38

8. Electrical drawings and parts lists ................................................................................ 39

9. Trouble shooting ........................................................................................................... 40

10. Suppliers’ manuals list .................................................................................................. 43

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Line-side AC charging equipment

1. Safety instructions

The design of the Line-side charging equipment is based upon the most recent technique
mainly concentrated on safety and functional ability.

However, the equipment may be dangerous or not workable if the operator or the maintenance
dept. have not received a satisfactory training.

The equipment is designed to work with refrigerant R134a according to the following
sequences:

• Pressure test
• Vacuum test
• PAG Oil Filling
• Charging

AGRAMKOW cannot be held responsible for any other application than described in this
instruction manual.

No mechanical, electrical or software changes must be made without AGRAMKOW's


approval.

Service or maintenance must not be carried out while the equipment is working.

Service or maintenance must only be carried out by skilled personnel having received the
necessary training.

Only spare parts approved by AGRAMKOW can be used.

Please read these instructions before starting to use the equipment.

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Line-side AC charging equipment

2. Installation and connection

Installation

The equipment must only be placed or moved on horizontal (plane) floors. If the equipment
has to be transported on not horizontal floors (rake > 3°C), a fork-lift truck or other suitable
equipment must be used.

Connection

(Value/size: See specifications, section 6)

1. Connect the equipment to the power supply, see label on control panel. The supply has to
be in accordance with IEC 294-1 or EN 60204-1, clause 4.3.

2. Connect compressed air

3. Connect refrigerant supply

4. Connect He-supply

5. Turn on the main switch

6. Press CONTROL ON

7. Press START/RESET to reset fault

8. Press START/RESET to start the equipment

Please note:

• If any fault is indicated, correct the fault and press RESET. If EMERGENCY STOP has been
actuated, press RESET EMERGENCY STOP followed by START/RESET.

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Line-side AC charging equipment

3. Service and maintenance instructions

3.1 Pneuadapter - Drawings and parts lists ........................................................................... 7


3.1.1 Pneuadapter HP .............................................................................................................. 8
3.1.1.1 Pneuadapter complete ..................................................................................... 9
3.1.1.2 Mechan. Pneuadapter Charge ....................................................................... 10
3.1.1.3 Mechan. Remote control............................................................................... 11
3.1.1.4 El. Pneuadapter Charge ................................................................................ 12
3.1.1.5 Hoses ............................................................................................................ 13
3.1.2 Pneuadapter LP ............................................................................................................. 14
3.1.2.1 Pneuadapter complete ................................................................................... 15
3.1.2.2 Mechan. Pneuadapter Charge ....................................................................... 16
3.1.2.3 Hoses ............................................................................................................ 17
3.2 Pneuadapter - Service ................................................................................................... 18
3.3 Pneuadapter - Maintenance scheme.............................................................................. 19
3.4 Station - Maintenance scheme ...................................................................................... 20
3.5 How to contact AGRAMKOW service department ..................................................... 21

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Line-side AC charging equipment

3.1 Pneuadapter - Drawings and parts lists

3.1.1 Pneuadapter HP .............................................................................................................. 8


3.1.1.1 Pneuadapter complete ..................................................................................... 9
3.1.1.2 Mechan. Pneuadapter Charge ....................................................................... 10
3.1.1.3 Mechan. Remote control............................................................................... 11
3.1.1.4 El. Pneuadapter Charge ................................................................................ 12
3.1.1.5 Hoses ............................................................................................................ 13
3.1.2 Pneuadapter LP ............................................................................................................. 14
3.1.2.1 Pneuadapter complete ................................................................................... 15
3.1.2.2 Mechan. Pneuadapter Charge ....................................................................... 16
3.1.2.3 Hoses ............................................................................................................ 17

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Line-side AC charging equipment

3.1.1 Pneuadapter HP

3.1.1.1 Pneuadapter complete ..................................................................................... 9


3.1.1.2 Mechan. Pneuadapter Charge ....................................................................... 10
3.1.1.3 Mechan. Remote control............................................................................... 11
3.1.1.4 El. Pneuadapter Charge ................................................................................ 12
3.1.1.5 Hoses ............................................................................................................ 13

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Line-side AC charging equipment

3.1.1.1 Pneuadapter complete

310-110083B
3_Service and maintenance instructions\Filling head HP\310-110083B-01.pdf

315-010132A
3_Service and maintenance instructions\Filling head HP\315-010132A-00.pdf

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AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
310-011094A 1,00 Pcs Pneuadapter charge, Staubli HP AGRAMKOW

310-010870A 1,00 Pcs Mech. remote control AGRAMKOW

310-010871B 1,00 Pcs El remote control AGRAMKOW

310-010888A 1,00 Pcs Hose packet 7/8m AGRAMKOW

310-011224A 1,00 Pcs Harting connection straight AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Filling head complete HP 24330 315-010132A mkl 04-03-2008 00 00022805 MKL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01

048-1477401 2,00 Pcs 3 UH screw rustproof 3x6 mm BOSSARD

062-0005152 1,00 Pcs 4 Housing, pneuadapter AGRAMKOW 310-100234A-02

290-5746098 1,00 Pcs 7 Coupling HP Staubli AGRAMKOW

087-7881013 2,00 Pcs 8 O-ring ø10,82 x ø1,78 Neopren BUSAK+SHAMBAN

062-0002409 1,00 Pcs 9 Adaptor 1/4" Staubli 1/4" RG AGRAMKOW 310-101895A-00

062-0002199 1,00 Pcs 9 Adapter for coupling AGRAMKOW 310-100249A-06

048-1477116 4,00 Pcs 9 CH-screw BOSSARD

087-7881016 1,00 Pcs 9 O-ring 2347-016 15,60x1,78 NeopreneBUSAK+SHAMBAN

087-7881013 1,00 Pcs 10 O-ring ø10,82 x ø1,78 Neopren BUSAK+SHAMBAN

062-0000151 1,00 Pcs 11 Valve housing AGRAMKOW 596-100024B-08

087-7881016 2,00 Pcs 12 O-ring 2347-016 15,60x1,78 NeopreneBUSAK+SHAMBAN

048-1479009 2,00 Pcs 13 Pointed screw 3x20 BOSSARD

062-0002169 1,00 Pcs 14 Air hose connector for pneuadapter AGRAMKOW 596-100252A

062-0002169 1,00 Pcs 15 Air hose connector for pneuadapter AGRAMKOW 596-100252A

062-0002169 1,00 Pcs 16 Air hose connector for pneuadapter AGRAMKOW 596-100252A

066-7100152 1,00 Pcs 24 Male connector, 2-K16-118 HANSEN COUPLING

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Pneuadapter charge, Staubli HP 310-011094A tcl 17-09-2007 01 00005382 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
031-2244020 1,00 Pcs 25 Heater ACIM JOUANIN

042-2970000 1,00 Pcs 25 Cable w. plug AGRAMKOW

048-1477401 0,00 Pcs 31 UH screw rustproof 3x6 mm BOSSARD

062-0002200 1,00 Pcs 40-48 Evac. slide valves AGRAMKOW

062-0002201 1,00 Pcs 50-56 Filling slide valves AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Pneuadapter charge, Staubli HP 310-011094A tcl 17-09-2007 01 00005382 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 4
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 5
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 6
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 7
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
087-7886011 1,00 Pcs 40 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN

062-0002136 1,00 Pcs 41 Valve slide evac. part 2 AGRAMKOW 596-100061A-07

062-0002135 1,00 Pcs 42 Valve slide evac. part 1 A'GRAMKOW 596-100060A-02

087-7886013 2,00 Pcs 43 O-ring ø10,82 x ø1,78 HNBR BUSAK+SHAMBAN A/S

087-7889404 3,00 Pcs 44 Double Delta 110 BUSAK+SHAMBAN

087-7886011 3,00 Pcs 45 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN

087-7886016 1,00 Pcs 46 O-ring ø15,60 x ø1,78 HNBR BUSAK+SHAMBAN A/S

062-0002137 1,00 Pcs 47 Valve body evac. valve 3/8" AGRAMKOW 596-100069A-06

087-7881904 1,00 Pcs 48 O-ring ø8,92 x ø1,83 Neoprene BETECH SEALS

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. slide valves 062-0002200 mkl 24-08-2006 01 00010557 MKL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 8
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
310-110059C 1,00 Pcs Remote control AGRAMKOW 310-110059C-01

062-0005140 1,00 Pcs 07 Remote control box AGRAMKOW 310-100229A-06

062-0005141 1,00 Pcs 08 Washer AGRAMKOW 310-100231A-03

048-1477118 2,00 Pcs 09 CH-screw BOSSARD

048-1477115 2,00 Pcs 10 CH-screw BOSSARD

048-1475276 3,00 Pcs 11 Nut BOSSARD

052-3100181 1,00 Pcs 12 Mounting plate for push buttons AGRAMKOW 310-100181A-02

062-0005690 1,00 Pcs Protection AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech. remote control 310-010870A bd 04-03-2008 02 00020830 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 9
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
062-0005690-Y 1,00 Pcs Beskyttelse 60mm AGRAMKOW

041-2816441 0,03 m Conduit F30 30 x 42 EEGHOLM

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Protection 062-0005690 tcl 06-12-2007 00 00020829 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 10
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
310-110059C 1,00 Pcs Remote control AGRAMKOW 310-110059C-01

014-8910060 1,00 Pcs 01 Pushbutton, green Rafi

014-8910061 1,00 Pcs 02 Pushbutton, red Rafi

014-8910008 1,00 Pcs 03 Pushbutton, grey TELEMECANIQUE

014-8910008 1,00 Pcs 04 Pushbutton, grey TELEMECANIQUE

014-8910008 1,00 Pcs 05 Pushbutton, grey TELEMECANIQUE

014-8910008 1,00 Pcs 06 Pushbutton, grey TELEMECANIQUE

045-0000600 1,00 Pcs Pneudapter charge AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
El remote control 310-010871B tcl 10-03-2008 02 00022867 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 11
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01

310-110080A 1,00 Pcs Pneuadapter charge A'GRAMKOW

080-0769032 7,00 m 5 Protection hose, grey AGRAMKOW

080-5981006 9,00 m 14 Hose, blue 6/4 8152-06 REXROTH MECMAN

080-5981106 9,00 m 15 Nylon tube 6mm, white LEGRIS

080-5981107 9,00 m 16 Nylon tube ø6, red LEGRIS

081-3100066 1,00 Pcs 18 Evac. hose 3/8" PEX, L=8m AGRAMOW 310-140066A-00

081-3100067 1,00 Pcs 19 Charging hose 1/4" PEX, L=8m AGRANKOW 310-140067A-01

042-2812026 7,50 m Control cable 10 x 0,25 HPM

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Hose packet 7/8m 310-010888A tcl 22-11-2005 01 00012283 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 12
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
062-0002140 1,00 Pcs Hose connector evac. valve 3/8" AGRAMKOW 596-100070A-02

066-7101008 1,00 Pcs Coupling housing HANSEN COUPLING

310-140066A-Y 1,00 Pcs Evac. hose 3/8" PEX, L=8m 310-140066A-01

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. hose 3/8" PEX, L=8m 081-3100066 bd 21-01-2004 Evak slange 3/8" PEX L=8 m 00003022 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 13
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
062-0002138 1,00 Pcs Hose connector 1/4" straight A'GRAMKOW 596-100072A-03

310-140067A-Y 1,00 Pcs FYLDESLANGE 1/4" AS FX L = 8 M 310-140067A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Charging hose 1/4" PEX, L=8m 081-3100067 bd 21-01-2004 Fyldeslange 1/4" PEX, L=8m 00003021 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 14
14-03-2008
Parts List 12:18:50

Item number Quantity Unit Position Item name Make Drawing No.
310-200010B 0,00 Pcs El-diagram Eplan A/C Pneuadapter AGRAMKOW

310-310033A 0,00 Pcs Foto layout

041-9200125 1,00 Pcs Fitting M25 HSK-M-EMC crome Hummel

043-6314111 1,00 Pcs Cover for connector M25 HARTING

043-9200405 1,00 Pcs Frame top part HARTING

043-9200305 1,00 Pcs Crimp male conn. insert HARTING

043-6310300 12,00 Pcs Crimp pin 0,14-0,37 HARTING

043-9200050 1,00 Pcs Blind module Harting plug HARTING

043-9200500 1,00 Pcs Pneumatics module HARTING

043-9200105 3,00 Pcs Plug pneumatic WEXØE A/S

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Harting connection straight 310-011224A tcl 05-10-2005 03 00011761 TCL 24330 Caterpillar Bra 24
Line-side AC charging equipment

3.1.1.2 Mechan. Pneuadapter Charge

310-110083B
3_Service and maintenance instructions\Filling head HP\310-110083B-01.pdf

310-011094A
3_Service and maintenance instructions\Filling head HP\310-011094A-01.pdf

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AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:20:36

Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01

048-1477401 2,00 Pcs 3 UH screw rustproof 3x6 mm BOSSARD

062-0005152 1,00 Pcs 4 Housing, pneuadapter AGRAMKOW 310-100234A-02

290-5746098 1,00 Pcs 7 Coupling HP Staubli AGRAMKOW

087-7881013 2,00 Pcs 8 O-ring ø10,82 x ø1,78 Neopren BUSAK+SHAMBAN

062-0002409 1,00 Pcs 9 Adaptor 1/4" Staubli 1/4" RG AGRAMKOW 310-101895A-00

062-0002199 1,00 Pcs 9 Adapter for coupling AGRAMKOW 310-100249A-06

087-7881016 1,00 Pcs 9 O-ring 2347-016 15,60x1,78 NeopreneBUSAK+SHAMBAN

087-7881013 1,00 Pcs 10 O-ring ø10,82 x ø1,78 Neopren BUSAK+SHAMBAN

062-0000151 1,00 Pcs 11 Valve housing AGRAMKOW 596-100024B-08

087-7881016 2,00 Pcs 12 O-ring 2347-016 15,60x1,78 NeopreneBUSAK+SHAMBAN

048-1479009 2,00 Pcs 13 Pointed screw 3x20 BOSSARD

062-0002169 1,00 Pcs 14 Air hose connector for pneuadapter AGRAMKOW 596-100252A

062-0002169 1,00 Pcs 15 Air hose connector for pneuadapter AGRAMKOW 596-100252A

062-0002169 1,00 Pcs 16 Air hose connector for pneuadapter AGRAMKOW 596-100252A

066-7100152 1,00 Pcs 24 Male connector, 2-K16-118 HANSEN COUPLING

031-2244020 1,00 Pcs 25 Heater ACIM JOUANIN

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Pneuadapter charge, Staubli HP 310-011094A tcl 17-09-2007 01 00005382 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:20:36

Item number Quantity Unit Position Item name Make Drawing No.
042-2970000 1,00 Pcs 25 Cable w. plug AGRAMKOW

048-1477401 0,00 Pcs 31 UH screw rustproof 3x6 mm BOSSARD

062-0002200 1,00 Pcs 40-48 Evac. slide valves AGRAMKOW

062-0002201 1,00 Pcs 50-56 Filling slide valves AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Pneuadapter charge, Staubli HP 310-011094A tcl 17-09-2007 01 00005382 ZVM 24330 Caterpillar Bra 24
Line-side AC charging equipment

3.1.1.3 Mechan. Remote control

310-110059C
3_Service and maintenance instructions\Filling head HP\310-110059C-01.pdf

310-010870A
3_Service and maintenance instructions\Filling head HP\310-010870A-02.pdf

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AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:21:23

Item number Quantity Unit Position Item name Make Drawing No.
310-110059C 1,00 Pcs Remote control AGRAMKOW 310-110059C-01

062-0005140 1,00 Pcs 07 Remote control box AGRAMKOW 310-100229A-06

062-0005141 1,00 Pcs 08 Washer AGRAMKOW 310-100231A-03

048-1477118 2,00 Pcs 09 CH-screw BOSSARD

048-1477115 2,00 Pcs 10 CH-screw BOSSARD

048-1475276 3,00 Pcs 11 Nut BOSSARD

052-3100181 1,00 Pcs 12 Mounting plate for push buttons AGRAMKOW 310-100181A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech. remote control 310-010870A bd 04-03-2008 02 00020830 TCL 24330 Caterpillar Bra 24
Line-side AC charging equipment

3.1.1.4 El. Pneuadapter Charge

310-110059C
3_Service and maintenance instructions\Filling head HP\310-110059C-01.pdf

310-010871B
3_Service and maintenance instructions\Filling head HP\310-010871B-02.pdf

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AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:22:07

Item number Quantity Unit Position Item name Make Drawing No.
310-110059C 1,00 Pcs Remote control AGRAMKOW 310-110059C-01

014-8910060 1,00 Pcs 01 Pushbutton, green Rafi

014-8910061 1,00 Pcs 02 Pushbutton, red Rafi

014-8910008 1,00 Pcs 03 Pushbutton, grey TELEMECANIQUE

014-8910008 1,00 Pcs 04 Pushbutton, grey TELEMECANIQUE

014-8910008 1,00 Pcs 05 Pushbutton, grey TELEMECANIQUE

014-8910008 1,00 Pcs 06 Pushbutton, grey TELEMECANIQUE

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
El remote control 310-010871B tcl 10-03-2008 02 00022867 TCL 24330 Caterpillar Bra 24
Line-side AC charging equipment

3.1.1.5 Hoses

310-110083B
3_Service and maintenance instructions\Filling head HP\310-110083B-01.pdf

310-010888A
3_Service and maintenance instructions\Filling head HP\310-010888A-01.pdf

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AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:22:50

Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01

310-110080A 1,00 Pcs Pneuadapter charge A'GRAMKOW

080-0769032 7,00 m 5 Protection hose, grey AGRAMKOW

080-5981006 9,00 m 14 Hose, blue 6/4 8152-06 REXROTH MECMAN

080-5981106 9,00 m 15 Nylon tube 6mm, white LEGRIS

080-5981107 9,00 m 16 Nylon tube ø6, red LEGRIS

081-3100066 1,00 Pcs 18 Evac. hose 3/8" PEX, L=8m AGRAMOW 310-140066A-00

081-3100067 1,00 Pcs 19 Charging hose 1/4" PEX, L=8m AGRANKOW 310-140067A-01

042-2812026 7,50 m Control cable 10 x 0,25 HPM

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Hose packet 7/8m 310-010888A tcl 22-11-2005 01 00012283 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:22:50

Item number Quantity Unit Position Item name Make Drawing No.
062-0002140 1,00 Pcs Hose connector evac. valve 3/8" AGRAMKOW 596-100070A-02

066-7101008 1,00 Pcs Coupling housing HANSEN COUPLING

310-140066A-Y 1,00 Pcs Evac. hose 3/8" PEX, L=8m 310-140066A-01

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. hose 3/8" PEX, L=8m 081-3100066 bd 21-01-2004 Evak slange 3/8" PEX L=8 m 00003022 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:22:50

Item number Quantity Unit Position Item name Make Drawing No.
062-0002138 1,00 Pcs Hose connector 1/4" straight A'GRAMKOW 596-100072A-03

310-140067A-Y 1,00 Pcs FYLDESLANGE 1/4" AS FX L = 8 M 310-140067A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Charging hose 1/4" PEX, L=8m 081-3100067 bd 21-01-2004 Fyldeslange 1/4" PEX, L=8m 00003021 BD 24330 Caterpillar Bra 24
Line-side AC charging equipment

3.1.2 Pneuadapter LP

3.1.2.1 Pneuadapter complete ................................................................................... 15


3.1.2.2 Mechan. Pneuadapter Charge ....................................................................... 16
3.1.2.3 Hoses ............................................................................................................ 17

\\AGSERVER\Data\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\Manual 315-400028A-00.doc


14
Line-side AC charging equipment

3.1.2.1 Pneuadapter complete

310-110083B
3_Service and maintenance instructions\Filling head LP\310-110083B-01.pdf

315-010133A
3_Service and maintenance instructions\Filling head LP\315-010133A-00.pdf

\\AGSERVER\Data\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\Manual 315-400028A-00.doc


15
AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
310-011096A 1,00 Pcs Mekanisk pneudapter charge AGRAMKOW

310-010888A 1,00 Pcs Hose packet 7/8m AGRAMKOW

310-011499A 1,00 Pcs Harting plug for oil pneuadapter AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Filling head complete LP 24330 315-010133A bd 04-03-2008 00 00022806 MKL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01

310-110080A 1,00 Pcs Pneuadapter charge A'GRAMKOW

048-1477401 2,00 Pcs 3 UH screw rustproof 3x6 mm BOSSARD

062-0005152 1,00 Pcs 4 Housing, pneuadapter AGRAMKOW 310-100234A-02

290-5745998 1,00 Pcs 7 Coupling LP Staubli AGRAMKOE

087-7881013 2,00 Pcs 8 O-ring ø10,82 x ø1,78 Neopren BUSAK+SHAMBAN

062-0002409 1,00 Pcs 9 Adaptor 1/4" Staubli 1/4" RG AGRAMKOW 310-101895A-00

062-0002199 1,00 Pcs 9 Adapter for coupling AGRAMKOW 310-100249A-06

048-1477116 4,00 Pcs 9 CH-screw BOSSARD

087-7881016 1,00 Pcs 9 O-ring 2347-016 15,60x1,78 NeopreneBUSAK+SHAMBAN

087-7881013 1,00 Pcs 10 O-ring ø10,82 x ø1,78 Neopren BUSAK+SHAMBAN

062-0000151 1,00 Pcs 11 Valve housing AGRAMKOW 596-100024B-08

087-7881016 2,00 Pcs 12 O-ring 2347-016 15,60x1,78 NeopreneBUSAK+SHAMBAN

048-1479009 2,00 Pcs 13 Pointed screw 3x20 BOSSARD

062-0002169 1,00 Pcs 14 Air hose connector for pneuadapter AGRAMKOW 596-100252A

062-0002169 1,00 Pcs 15 Air hose connector for pneuadapter AGRAMKOW 596-100252A

062-0002169 1,00 Pcs 16 Air hose connector for pneuadapter AGRAMKOW 596-100252A

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mekanisk pneudapter charge 310-011096A tcl 18-10-2007 Mekanisk pneudapter charge 00010902 AH 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
066-7100152 1,00 Pcs 24 Male connector, 2-K16-118 HANSEN COUPLING

048-1477401 0,00 Pcs 31 UH screw rustproof 3x6 mm BOSSARD

062-0002200 1,00 Pcs 40-48 Evac. slide valves AGRAMKOW

062-0002201 1,00 Pcs 50-56 Filling slide valves AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mekanisk pneudapter charge 310-011096A tcl 18-10-2007 Mekanisk pneudapter charge 00010902 AH 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 4
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 5
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 6
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 7
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
087-7886011 1,00 Pcs 40 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN

062-0002136 1,00 Pcs 41 Valve slide evac. part 2 AGRAMKOW 596-100061A-07

062-0002135 1,00 Pcs 42 Valve slide evac. part 1 A'GRAMKOW 596-100060A-02

087-7886013 2,00 Pcs 43 O-ring ø10,82 x ø1,78 HNBR BUSAK+SHAMBAN A/S

087-7889404 3,00 Pcs 44 Double Delta 110 BUSAK+SHAMBAN

087-7886011 3,00 Pcs 45 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN

087-7886016 1,00 Pcs 46 O-ring ø15,60 x ø1,78 HNBR BUSAK+SHAMBAN A/S

062-0002137 1,00 Pcs 47 Valve body evac. valve 3/8" AGRAMKOW 596-100069A-06

087-7881904 1,00 Pcs 48 O-ring ø8,92 x ø1,83 Neoprene BETECH SEALS

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. slide valves 062-0002200 mkl 24-08-2006 01 00010557 MKL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 8
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01

310-110080A 1,00 Pcs Pneuadapter charge A'GRAMKOW

080-0769032 7,00 m 5 Protection hose, grey AGRAMKOW

080-5981006 9,00 m 14 Hose, blue 6/4 8152-06 REXROTH MECMAN

080-5981106 9,00 m 15 Nylon tube 6mm, white LEGRIS

080-5981107 9,00 m 16 Nylon tube ø6, red LEGRIS

081-3100066 1,00 Pcs 18 Evac. hose 3/8" PEX, L=8m AGRAMOW 310-140066A-00

081-3100067 1,00 Pcs 19 Charging hose 1/4" PEX, L=8m AGRANKOW 310-140067A-01

042-2812026 7,50 m Control cable 10 x 0,25 HPM

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Hose packet 7/8m 310-010888A tcl 22-11-2005 01 00012283 TCL 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 9
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
062-0002140 1,00 Pcs Hose connector evac. valve 3/8" AGRAMKOW 596-100070A-02

066-7101008 1,00 Pcs Coupling housing HANSEN COUPLING

310-140066A-Y 1,00 Pcs Evac. hose 3/8" PEX, L=8m 310-140066A-01

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. hose 3/8" PEX, L=8m 081-3100066 bd 21-01-2004 Evak slange 3/8" PEX L=8 m 00003022 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 10
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
062-0002138 1,00 Pcs Hose connector 1/4" straight A'GRAMKOW 596-100072A-03

310-140067A-Y 1,00 Pcs FYLDESLANGE 1/4" AS FX L = 8 M 310-140067A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Charging hose 1/4" PEX, L=8m 081-3100067 bd 21-01-2004 Fyldeslange 1/4" PEX, L=8m 00003021 BD 24330 Caterpillar Bra 24
AGRAMKOW Fluid Systems A/S Page 11
14-03-2008
Parts List 12:23:38

Item number Quantity Unit Position Item name Make Drawing No.
310-200010B 0,00 Pcs El-diagram Eplan A/C Pneuadapter AGRAMKOW

310-310033A 0,00 Pcs Foto layout

041-9200125 1,00 Pcs Fitting M25 HSK-M-EMC crome Hummel

043-6314111 1,00 Pcs Cover for connector M25 HARTING

043-9200405 1,00 Pcs Frame top part HARTING

043-9200050 2,00 Pcs Blind module Harting plug HARTING

043-9200500 1,00 Pcs Pneumatics module HARTING

043-9200105 3,00 Pcs Plug pneumatic WEXØE A/S

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Harting plug for oil pneuadapt 310-011499A tcl 27-09-2007 00 00019896 TCL 24330 Caterpillar Bra 24
Line-side AC charging equipment

3.1.2.2 Mechan. Pneuadapter Charge

310-110083B
3_Service and maintenance instructions\Filling head LP\310-110083B-01.pdf

310-011096A
3_Service and maintenance instructions\Filling head LP\310-011096A-00.pdf

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16
AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:24:35

Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01

310-110080A 1,00 Pcs Pneuadapter charge A'GRAMKOW

048-1477401 2,00 Pcs 3 UH screw rustproof 3x6 mm BOSSARD

062-0005152 1,00 Pcs 4 Housing, pneuadapter AGRAMKOW 310-100234A-02

290-5745998 1,00 Pcs 7 Coupling LP Staubli AGRAMKOE

087-7881013 2,00 Pcs 8 O-ring ø10,82 x ø1,78 Neopren BUSAK+SHAMBAN

062-0002409 1,00 Pcs 9 Adaptor 1/4" Staubli 1/4" RG AGRAMKOW 310-101895A-00

062-0002199 1,00 Pcs 9 Adapter for coupling AGRAMKOW 310-100249A-06

048-1477116 4,00 Pcs 9 CH-screw BOSSARD

087-7881016 1,00 Pcs 9 O-ring 2347-016 15,60x1,78 NeopreneBUSAK+SHAMBAN

087-7881013 1,00 Pcs 10 O-ring ø10,82 x ø1,78 Neopren BUSAK+SHAMBAN

062-0000151 1,00 Pcs 11 Valve housing AGRAMKOW 596-100024B-08

087-7881016 2,00 Pcs 12 O-ring 2347-016 15,60x1,78 NeopreneBUSAK+SHAMBAN

048-1479009 2,00 Pcs 13 Pointed screw 3x20 BOSSARD

062-0002169 1,00 Pcs 14 Air hose connector for pneuadapter AGRAMKOW 596-100252A

062-0002169 1,00 Pcs 15 Air hose connector for pneuadapter AGRAMKOW 596-100252A

062-0002169 1,00 Pcs 16 Air hose connector for pneuadapter AGRAMKOW 596-100252A

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mekanisk pneudapter charge 310-011096A tcl 18-10-2007 Mekanisk pneudapter charge 00010902 AH 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:24:35

Item number Quantity Unit Position Item name Make Drawing No.
066-7100152 1,00 Pcs 24 Male connector, 2-K16-118 HANSEN COUPLING

048-1477401 0,00 Pcs 31 UH screw rustproof 3x6 mm BOSSARD

062-0002200 1,00 Pcs 40-48 Evac. slide valves AGRAMKOW

062-0002201 1,00 Pcs 50-56 Filling slide valves AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mekanisk pneudapter charge 310-011096A tcl 18-10-2007 Mekanisk pneudapter charge 00010902 AH 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:24:35

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 4
14-03-2008
Parts List 12:24:35

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 5
14-03-2008
Parts List 12:24:35

Item number Quantity Unit Position Item name Make Drawing No.
065-3212027 1,00 Pcs Fitting 1/8xd6 FESTO

596-100252A 1,00 Pcs Fittings with lifting pipe 596-100252A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Air hose connector for pneuada 062-0002169 mpm 20-03-2006 00 00008990 ZVM 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 6
14-03-2008
Parts List 12:24:35

Item number Quantity Unit Position Item name Make Drawing No.
087-7886011 1,00 Pcs 40 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN

062-0002136 1,00 Pcs 41 Valve slide evac. part 2 AGRAMKOW 596-100061A-07

062-0002135 1,00 Pcs 42 Valve slide evac. part 1 A'GRAMKOW 596-100060A-02

087-7886013 2,00 Pcs 43 O-ring ø10,82 x ø1,78 HNBR BUSAK+SHAMBAN A/S

087-7889404 3,00 Pcs 44 Double Delta 110 BUSAK+SHAMBAN

087-7886011 3,00 Pcs 45 O-ring ø7,65 x ø1,78 HNBR BUSAK+SHAMBAN

087-7886016 1,00 Pcs 46 O-ring ø15,60 x ø1,78 HNBR BUSAK+SHAMBAN A/S

062-0002137 1,00 Pcs 47 Valve body evac. valve 3/8" AGRAMKOW 596-100069A-06

087-7881904 1,00 Pcs 48 O-ring ø8,92 x ø1,83 Neoprene BETECH SEALS

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. slide valves 062-0002200 mkl 24-08-2006 01 00010557 MKL 24330 Caterpillar Bra EUR
Line-side AC charging equipment

3.1.2.3 Hoses

310-110083B
3_Service and maintenance instructions\Filling head LP\310-110083B-01.pdf

310-010888A
3_Service and maintenance instructions\Filling head LP\310-010888A-01.pdf

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17
AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:25:33

Item number Quantity Unit Position Item name Make Drawing No.
310-110083B 1,00 Pcs Pneuadapter charge AGRAMKOW 310-110083B-01

310-110080A 1,00 Pcs Pneuadapter charge A'GRAMKOW

080-0769032 7,00 m 5 Protection hose, grey AGRAMKOW

080-5981006 9,00 m 14 Hose, blue 6/4 8152-06 REXROTH MECMAN

080-5981106 9,00 m 15 Nylon tube 6mm, white LEGRIS

080-5981107 9,00 m 16 Nylon tube ø6, red LEGRIS

081-3100066 1,00 Pcs 18 Evac. hose 3/8" PEX, L=8m AGRAMOW 310-140066A-00

081-3100067 1,00 Pcs 19 Charging hose 1/4" PEX, L=8m AGRANKOW 310-140067A-01

042-2812026 7,50 m Control cable 10 x 0,25 HPM

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Hose packet 7/8m 310-010888A tcl 22-11-2005 01 00012283 TCL 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:25:33

Item number Quantity Unit Position Item name Make Drawing No.
062-0002140 1,00 Pcs Hose connector evac. valve 3/8" AGRAMKOW 596-100070A-02

066-7101008 1,00 Pcs Coupling housing HANSEN COUPLING

310-140066A-Y 1,00 Pcs Evac. hose 3/8" PEX, L=8m 310-140066A-01

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Evac. hose 3/8" PEX, L=8m 081-3100066 bd 21-01-2004 Evak slange 3/8" PEX L=8 m 00003022 BD 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:25:33

Item number Quantity Unit Position Item name Make Drawing No.
062-0002138 1,00 Pcs Hose connector 1/4" straight A'GRAMKOW 596-100072A-03

310-140067A-Y 1,00 Pcs FYLDESLANGE 1/4" AS FX L = 8 M 310-140067A-02

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Charging hose 1/4" PEX, L=8m 081-3100067 bd 21-01-2004 Fyldeslange 1/4" PEX, L=8m 00003021 BD 24330 Caterpillar Bra EUR
Line-side AC charging equipment

3.2 Pneuadapter - Service

3_Service and maintenance instructions\Service of AC Pneuadapter_20K.pdf

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18
AC Pneuadapter

AC Pneuadapter
Service

Service of pneuadapter

In the following you will find a description of how to service the A/C pneuadapter, and which
spare parts to be used. Read this description carefully before starting the service to obtain
the best service result and to avoid accident due to the refrigerant pressure in the filling
hoses.

Warning

Gaskets and O-rings must be ordered through AGRAMKOW.


Please refer to data number when ordering.

Material, shore specification and dimension tolerances are not unique


from make to make. Consequently AGRAMKOW cannot guarantee function or durability
of filling heads if other material than AGRAMKOW packing material is used.

Before maintenance make sure, that the filling head is without any pressure
and that the pneumatic and the fluid supply are disconnected.

See the assembly drawings and parts lists for the pneuadapters:
Evacuation/charging pneuadapter 310-110083B
Evacuation pneuadapter 310-110084C

Order number for service set:


287-0000650-E (English) complete
287-0000650-T (German) complete

T:\Master Pistoldok 
AC Pneuadapter

Demounting/mounting of the pneuadapter (complete)

• Turn off the station (no voltage), turn off the compressed air supply
• Disengage the pneuadapter from the filling equipment
• Demount the HK2 coupling for the refrigerant supply
• Demount the Harting plug. Demount the holder of the hose control
• The pneuadapter can now be taken down

Important!!
Before the adapter is used, the filling hose must be emptied of refrigerant.
This must be made with suitable recovery equipment.

When mounting, follow the above procedure in reverse order.

Important!!
Before the refrigerant supply is connected, the air supply for the pneuadapter must
be connected, so that the internal valves will be positioned correctly (Harting plug).
If not, the internal valves might be damaged, and refrigerant might be
let out in the surroundings.

T:\Master Pistoldok 
AC Pneuadapter

Demounting/mounting of the pneuadapter ­filling housing

Demounting
Loosen the 2 Allen screws, pos. 3 (310-110083B) at the adapter.
Now the valve housing can be pulled out of the cap.
(The housing can be screwed on the safety hose in order to improve the access).

Mounting
Pull the cap surrounding the valve housing, and turn it until the threaded holes in
the housing fit the cap.

Note:
This manual uncoupling mechanism is omitted on some types of adapters.

T:\Master Pistoldok 
AC Pneuadapter

Demounting/mounting of the filling hose

Demounting

Important!
Before the adapter is demounted, the filling hose must be emptied of refrigerant
(and recovered). Demount the adapter housing (see 3).

Remove the safety screw, pos. 13 (310-110083B). Now the filling hose can be pulled out of
the valve housing (straight direction).

Mounting
Check that the O-rings are OK. Put in the filling hose carefully, and press it until it reaches
the bottom. Put in the safety screw.

T:\Master Pistoldok 
AC Pneuadapter

Demounting/mounting of the evacuation hose

Demounting

• Demount the housing of the valve housing (see 3).


• Remove the safety screw, pos. 13 (310-110083B).
• Remove the safety screw, pos. 10 310-110084C.
• Now the evacuation hose can be pulled out of the valve housing
(straight direction).

Mounting
• See ‘Mounting of filling hose’.

The filling hose and the evacuation hose cannot be mixed up, as the diameters are different.

T:\Master Pistoldok 
AC Pneuadapter

Demounting/mounting of the heater device

Demounting
• Demount the electrical connection in the pushbutton housing.
• Lead colour (standard): violet/black.
• For more information see encl. „Standard connection Harting combined plug“
incl. photo and description: Harting plug A-C.doc
• Demount the housing of the valve housing, see 3
• The heater device can be demounted by means of a spanner, 13 mm
(right-hand thread).

Important!
When mounting, use compound; code No 100-7720191.

Use a spanner when mounting the heater device.


Connect the electrical connections.

Place the cable in a loop before installation to avoid it from being pulled out of the sensor
during operation

T:\Master Pistoldok 
MM Filling head Coolant fluid

Demounting/mounting of the control air hoses

Important!
The control air hoses must always be filled with 10 cm PAG oil
(measured from the coupling). If the oil level is not high enough,
the lifetime of the adapter will be shorter.
When filling, no air bubbles may be visible at the adapter.

Demount the valve housing (see 3).

The control air hoses can now be demounted:


press the coupling ring and pull the air hose.

When mounting, the control air hose must be led as much as possible into the fitting.

T:\Master Pistoldok 
AC Pneuadapter

Demounting/mounting of the valve slide (evacuation/filling)

Important!!
Demounting must only be made on a clean mat free of dirt and dust.

Demount the valve housing


See 3.

Evacuation valve
See drawing No 310-110083B or 310-110084C
Demount the vacuum hose, see 5 (photo 4).
The valve slide can now be taken out by means of the tool delivered with the adapter
(please check that the tool catches hold of the inside of the valve slide correctly).

Damaged valve slides must never be used. Only assembled valve slides must be used,
which should be taken out of the original wrapping immediately before the mounting.

Demonting

Mounting

T:\Master Pistoldok 
AC Pneuadapter

Filling valve
See drawing 310-110083B
Demount the filling, hose; see 4.
The same procedure as for the evacuation valve.

Change of parts
The change of parts must be treated hygienically.

Service intervals
The valves must be changed every 40,000 couplings.

T:\Master Pistoldok 
AC Pneuadapter

Push-button box

To prevent unintended start, place item no. 062-0005690 between hoses and push buttons
(see photo).

T:\Master Pistoldok 10
Line-side AC charging equipment

3.3 Pneuadapter - Maintenance scheme

3_Service and maintenance instructions\Service and Maintenance scheme Pneuadapter.pdf

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19
Customer: Caterpillar Case: 24330
Service and Maintenance scheme Filling head, On-Line A/C charging equipment

Intervals Main-
Carried out by
Components / Aggregate / tenance Operational Safety references,
Pos No Remedy Division ON / OFF
Function period tools Safety equipment
d w m 1/4y 1/2y 1y (Employee)
[min]
Filling head, mech. Drawing 310-
110083B-01
28-16 O-ring in 134a-coupling Lubricate x 1 Vacuum oil Maintenance OFF
department
28-16 O-ring in 134a-coupling Replace x 10 Vacuum oil Maintenance OFF Rubber gloves
department
40-48 Valve Replace after 40.000 chargings x Vacuum oil Maintenance OFF Rubber gloves
department
50-56 Valve Replace after 40.000 chargings x Vacuum oil Maintenance OFF Rubber gloves
department
30 in all

Note!
Sediments from the liquid, cuttings sucked up into the gun and sharp edges, where
the main gasket(s) grasp(s) will shorten the lifetime of the gasket and thereby also
the service intervals.

22-04-2008 Service and Maintenance scheme Pneuadapter Seite 1 von 1


Line-side AC charging equipment

3.4 Station - Maintenance scheme

3_Service and maintenance instructions\Service and Maintenance scheme Line-side AC.pdf

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Customer: Caterpillar Project: 24330
Service and maintenance scheme Line-side A/C charging equipment

Intervals Main-
8 h/day operation Carried out by
Pos Components / Aggregate / tenance Operational Safety references,
No
Remedy Division ON / OFF
Function period tools Safety equipment
d w m 1/4y 1/2y 1y (Employee)
[min]
The positon numbers refer to PI-diagram 315-120046A and layout 315-110078A

6 Helium/Nitrogen filter Replace filter x 15 Tools OFF Rubber glovese

15 Compressed air filter, Ultrafilter Replace filter x 15 Tools OFF Rubber gloves

19 Compressed air filter, Festo Replace filter element x 10 Tools OFF Rubber glovese

42 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
54 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
61 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
62 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
70 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
81 R134a Filter Replace filter x 20 Tools OFF and Rubber gloves and safety
evacuated glasses
92 Massflow, Rheonik Check that the displayed weight (gram) is the x 7 ON without PAG
same as the weight of the content in the oil filling
external test tank
85 Pressure accumulator Check pre pressure setting and adjust if x 10 Tools OFF Rubber gloves
necessary
102 Vacuum sensor, Leybold DI 201 Check by means of test nipple pos. 106 x 10 ON
Calibration: See supplier's instructions
(Calibration only by maintenance
departm.)
100 Pressure sensor, IFM Check that the displayed pressure is the x 7 Manual mode
same at the pressure in the external test tank
(Calibration in the PLC only by trained
personnnel)

108 Exhaust filter, vacuum pump, SMC Replace filter element, see supplier's x 15 Tools OFF Rubber gloves
instructions
109 Vacuum pump, Leybold D16B Check oil level, see supplier's instructions x 5 Tools OFF Rubber gloves

109 Vacuum pump, Leybold Change oil, see supplier's instructions x 15 Tools OFF Rubber gloves

113 PAG oil filter Replace filter element x 15 Tools OFF Rubber gloves

117 Compressed air filter, Ultrafilter Replace filter x 15 Tools OFF, pos 12 dis- Rubber gloves
mantled
121 Sika Flow meter See supplier's instructions x 10 Tools OFF Rubber gloves
Clean filter

22-04-2008 Service and Maintenance scheme Line-side AC Page 1 of 2


Customer: Caterpillar Project: 24330
Service and maintenance scheme Line-side A/C charging equipment

Intervals Main-
8 h/day operation Carried out by
Pos Components / Aggregate / tenance Operational Safety references,
No
Remedy Division ON / OFF
Function period tools Safety equipment
d w m 1/4y 1/2y 1y (Employee)
[min]
121 The
Sika positon numbers refer to PI-diagram
Flow meter Check315-120046A and layout
that the displayed 315-110078A
volume is the same x 10 Tools Manual mode Rubber gloves
at the volume in the external measuring
meaker
(Calibration in the PLC only by trained
personnel)
131 Exhaust filter, vacuum pump, Replace filter element, see supplier's x 15 Tools OFF Rubber gloves
Leybold AMC 610-10 instructions
133 Vacuum pump, Leybold D16B Check oil level, see supplier's instructions x 5 Tools OFF Rubber gloves

133 Vakuum pump, Leybold Change oil, see supplier's instructions x 15 Tools OFF Rubber gloves

140 Photo sensor, Sensick WT 150 HGA Clean optics with a soft lint-free cloth x 1 OFF
141
Check and retighten all x 20 Tools OFF
Bosch screwed connections

Warning
Components in the A/C system are NOT to be removed till the A/C system is OFF and emptied
This is because of the safety of persons and because of the environment. Use the drain nipples pos. 67 and pos. 78
and drain manifold pos. 106

Use rubber gloves and safety glasses

No service and maintenance is necessary concerning the electrical part of the equipment

22-04-2008 Service and Maintenance scheme Line-side AC Page 2 of 2


Line-side AC charging equipment

3.5 How to contact AGRAMKOW service department

AGRAMKOW
Fluid Systems A/S
Augustenborg Landevej 19
DK-6400 Sønderborg
Denmark
Tel.: +45 74 12 36 36
Fax: +45 74 43 36 46
www.agramkow.com
agramkow@agramkow.dk

Please inform us about:

Serial no.: xxxxxxxx yyyyy

xxxxxxxx

yyyyy

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Line-side AC charging equipment

4. Function description

4.1 Operator instructions .................................................................................................... 23


4.2 Process description ....................................................................................................... 24
4.3 Sub description ............................................................................................................. 25
4.4 Flow chart ..................................................................................................................... 26
4.5 PT-diagram ................................................................................................................... 27
4.6 Settings ......................................................................................................................... 28

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Line-side AC charging equipment

4.1 Operator instructions

4_Function description\LS AC Operator instruction EN.doc

Recovery:
4_Function description\LS AC Recovery Operator Instruction .doc

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Operator Instructions

Contents

Starting the system ..................................................................................................................... 2

Stopping the system .................................................................................................................... 2

Emergency stop of the system .................................................................................................... 2

Manuel operation ........................................................................................................................ 3

Automatic operation without charging ....................................................................................... 4

Automatic operation with charging ............................................................................................ 5

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Type01 18-04-2006 RJE 1/5
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Operator Instructions

Text Description
Starting the system Handling Check the following:
- Compressed air supply is connected
- Refrigerant supply is connected
- Main switch on control cabinet is switched ON
- EMERGENCY STOP is not activated

1. Press CONTROL ON
- CONTROL ON lamp lights up

2. Press the RESET EMERGENCY STOP button.


- The RESET EMERGENCY STOP light turns off.

3. Press the RESET STATION FAULT button.


- The STATION FAULT light turns off.

Controls • MAIN SWITCH


• RESET EMERGENCY STOP button
• CONTROL ON button
• RESET STATION FAULT button

Trouble shooting The equipment is not turning on:


- Check the power supply and the main fuses.

The equipment is not going into to READY mode:


- Look up the failure on the operator panel and find in Action
in the Fault description what to do.
Stopping the system Handling The process must be completed and in READY mode.
Press CONTROL OFF
- CONTROL ON lamp turns off
Controls • CONTROL OFF button
Trouble shooting None
Emergency stop of the Handling If an unsafe situation occurs and the EMERGENCY STOP
system button is pressed, the system is shut down immediately.
1. All moving parts are stopped (Charging pump, vacuum
pumps etc.)
2. An ongoing process is aborted.

To start the equipment again, please read the Fault


description what to do.
Controls • EMERGENCY STOP button
• RESET EMERGENCY STOP button
Trouble shooting The EMERGENCY STOP cannot be reset.
- Look up the failure on the operator panel, and find in Action
in the Fault description what to do.

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Type01 18-04-2006 RJE 2/5
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Operator Instructions

Text Description
Manuel operation Handling Check the following:
• MAN/AUTO switch must be in MAN mode
• Process selection is set to CHARGING ON
• Charging head is in parking position
• The READY / IN PROCESS lamp is flashing

1. Release the charging and vacuum head. When the


START button lamp is flashing the charging head is
ready.

2. Connect the Charging and vacuum head on the A/C


system of the vehicle.

3. Select charging amount on the charging hose.

4. Pressing the START button can stepwise do the process.


No process fault occurs. Switching the process selector
from MAN to AUTO mode will interrupt the sequence.

5. When the process is finished the READY/IN PROCESS


lamp will flash and the buzzer will sound constantly for
3 sec.

6. Disconnect the charging and vacuum head, and replace


it in each parking position.

Controls • Process MAN/AUTO switch


• START button (located on the charging hose)
• STOP button (located on the charging hose)
Trouble shooting The process is aborted with a station fault:
- Look up the failure on the operator panel and find in Action
in the Fault description what to do.

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Type01 18-04-2006 RJE 3/5
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Operator Instructions

Text Description
Automatic operation Handling Check the following:
without charging • MAN/AUTO switch must be in AUTO mode
• Process selection is set to CHARGING OFF
• Charging and vacuum head is placed in parking position

1. The READY/IN PROCESS lamp light is flashing.

2. Connect the charging and vacuum head to the A/C


system of the vehicle.

3. Select the charging amount on the charging hose.

4. Press the START button on the charging hose.

5. The process continues automatically until the evacuation


is finished.

6. The process can be stopped temporarily in each step by


switching process selector from AUTO to MAN mode.
By pressing the STOP button the process is interrupted.

7. When the process is finished, the READY/IN PROCESS


lamp will flash and the buzzer will sound constantly for
3 sec.

8. Disconnect the charging and vacuum head and replace it


in the parking position.

Controls • Process MAN/AUTO switch


• CHARGING ON/OFF switch
• START button (located on the charging hose)
• STOP button (located on the charging hose)
Trouble shooting The process is aborted with a station fault:
- Look up the failure on the operator panel and find in Action
in the Fault description what to do.

The process is aborted with a process fault:


- Check the car for the current process fault.
- Check the process settings.

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Type01 18-04-2006 RJE 4/5
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Operator Instructions

Text Description
Automatic operation with Handling Check the following:
charging • MAN/AUTO switch must be in AUTO mode
• Process selection is set to CHARGING ON
• Charging and vacuum head is placed in each parking
position

1. The READY/IN PROCESS lamp light is flashing.

2. Select the charging amount on the charging hose.

3. Connect the charging and vacuum head on the A/C


system of the vehicle.

4. Press the START button on the charging hose.

5. The process continues automatically until it has finished.

6. The process can be stopped temporarily in each step by


switching process selector from AUTO to MAN mode.
By pressing the STOP button the process is interrupted.

7. When the process is finished the READY/IN PROCESS


lamp will flash and the buzzer will sound constantly for
3 sec.

8. Disconnect the charging and vacuum head and replace it


in each parking position

Controls • Process MAN/AUTO switch


• CHARGING ON/OFF switch
• START button (located on the charging hose)
• STOP button (located on the charging hose)
Trouble shooting The process is aborted with a station fault:
- Look up the failure on the operator panel and find in Action
in the Fault description what to do.

The process is aborted with a process fault:


- Check the car for current process fault
- Check the process settings

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Type01 18-04-2006 RJE 5/5
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Operator Instruction, Recovery

Content

Start of the equipment ................................................................................................................ 2

Stop of the equipment ................................................................................................................. 2

Emergency stop of the equipment .............................................................................................. 2

Operation .................................................................................................................................... 3

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 1/3
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Operator Instruction, Recovery

Text Description
Start of the equipment Handling 1. Check the following :
• Compressed air supply connected
• Refrigerant bottle supply is connected
• Main switch for control cabinet is ON
• EMERGENCY STOP is not activated

2. Press CONTROL ON (control cabinet)


• The CONTROL ON lamp lights up

3. Press the RESET EMERGENCY STOP button.


• The Reset Emergency Stop light turns off

4. Press the RESET STATION FAULT button.


The System fault light is turned off.

Operating control • MAIN SWITCH


• RESET EMERGENCY STOP button
• CONTROL ON button
• RESET STATION FAULT button

Trouble shooting Equipment does not start :


- Check the power supply and the main fuses.

The equipment does not continue to READY mode:


- Look up the fault on the operator panel and find under
Action in the Fault description what to do.
Stop of the equipment Handling The process must be completed and in READY mode.
1. Press CONTROL OFF
• CONTROL ON lamp turns off
Operating control • CONTROL OFF
Trouble shooting None
Emergency stop of the Handling If an unsafe situation occurs and the Emergency Stop button
equipment is pressed, the system is shut down immediately.
1. All moving parts are stopped (filling pump, vacuum
pumps etc.)
2. An ongoing process is aborted.

To get the system restarted, please read the Fault description


what to do.
Operating control • EMERGENCY STOP button
• EMERGENCY STOP RESET button
Trouble shooting The Emergency Stop cannot be reset
- Look up the fault on the operator panel and find under
Action in the Fault description what to do.

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 2/3
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Operator Instruction, Recovery

Text Description
Operation Handling To recovery the A/C system of the vehicle please check the
following:

1. Recovery must be switched on.


• The green RECOVERY PROCESS READY lamp
lights.
• The recovery process is in READY TO START.

2. Fasten the recovery hoses for high and low pressure side
to the A/C system on the vehicle.

3. Press the RECOVERY START Button on the control


panel.

4. The process continues automatically until the A/C


system of the vehicle is empty. The recovery process is
in recovery mode when the red lamp is on.

5. When the recovery process is completed the READY /


IN PROCESS lamp light is flashing and the buzzer will
sound constantly for 3 sec. In the process display at the
operator panel PROCESS END is issued.

6. Replace the recovery hoses for high and low pressure


side in each parking position.

7. Press the RECOVERY STOP button. The recovery


process returns to the READY TO START and a new
recovery process can be repeated.

8. Please note: When the green lamp “drain the P.A.G. oil
(manually) “OK“ lights, it is possible to bleed the P.A.G.
oil from the recovery process.

Operating control • RECOVERY ON/OFF switch


• RECOVERY START button
• RECOVERY STOP button
Trouble shooting The process is aborted by a station fault:
- Look up the failure on the operator panel and find under
Action in the Fault description what to do.

The process is aborted with a process fault:


- Check the car for the current process fault.
- Check the process settings.

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 3/3
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Operator Instruction, Recovery

Content

Start of the equipment ................................................................................................................ 2

Stop of the equipment ................................................................................................................. 2

Emergency stop of the equipment .............................................................................................. 2

Operation .................................................................................................................................... 3

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 1/3
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Operator Instruction, Recovery

Text Description
Start of the equipment Handling 1. Check the following :
• Compressed air supply connected
• Refrigerant bottle supply is connected
• Main switch for control cabinet is ON
• EMERGENCY STOP is not activated

2. Press CONTROL ON (control cabinet)


• The CONTROL ON lamp lights up

3. Press the RESET EMERGENCY STOP button.


• The Reset Emergency Stop light turns off

4. Press the RESET STATION FAULT button.


The System fault light is turned off.

Operating control • MAIN SWITCH


• RESET EMERGENCY STOP button
• CONTROL ON button
• RESET STATION FAULT button

Trouble shooting Equipment does not start :


- Check the power supply and the main fuses.

The equipment does not continue to READY mode:


- Look up the fault on the operator panel and find under
Action in the Fault description what to do.
Stop of the equipment Handling The process must be completed and in READY mode.
1. Press CONTROL OFF
• CONTROL ON lamp turns off
Operating control • CONTROL OFF
Trouble shooting None
Emergency stop of the Handling If an unsafe situation occurs and the Emergency Stop button
equipment is pressed, the system is shut down immediately.
1. All moving parts are stopped (filling pump, vacuum
pumps etc.)
2. An ongoing process is aborted.

To get the system restarted, please read the Fault description


what to do.
Operating control • EMERGENCY STOP button
• EMERGENCY STOP RESET button
Trouble shooting The Emergency Stop cannot be reset
- Look up the fault on the operator panel and find under
Action in the Fault description what to do.

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 2/3
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\LS AC Recovery Operator Instruction .doc Rev. 00
Operator Instruction, Recovery

Text Description
Operation Handling To recovery the A/C system of the vehicle please check the
following:

1. Recovery must be switched on.


• The green RECOVERY PROCESS READY lamp
lights.
• The recovery process is in READY TO START.

2. Fasten the recovery hoses for high and low pressure side
to the A/C system on the vehicle.

3. Press the RECOVERY START Button on the control


panel.

4. The process continues automatically until the A/C


system of the vehicle is empty. The recovery process is
in recovery mode when the red lamp is on.

5. When the recovery process is completed the READY /


IN PROCESS lamp light is flashing and the buzzer will
sound constantly for 3 sec. In the process display at the
operator panel PROCESS END is issued.

6. Replace the recovery hoses for high and low pressure


side in each parking position.

7. Press the RECOVERY STOP button. The recovery


process returns to the READY TO START and a new
recovery process can be repeated.

8. Please note: When the green lamp “drain the P.A.G. oil
(manually) “OK“ lights, it is possible to bleed the P.A.G.
oil from the recovery process.

Operating control • RECOVERY ON/OFF switch


• RECOVERY START button
• RECOVERY STOP button
Trouble shooting The process is aborted by a station fault:
- Look up the failure on the operator panel and find under
Action in the Fault description what to do.

The process is aborted with a process fault:


- Check the car for the current process fault.
- Check the process settings.

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 3/3
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Line-side AC charging equipment

4.2 Process description

4_Function description\LS AC Process description EN.doc

Recovery:
4_Function description\LS AC Recovery Process description .doc

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Process description

Contents

Seq02: Ready block .................................................................................................................... 2

Seq03: Pressure block ................................................................................................................. 3

Seq04: Vacuum block ................................................................................................................. 6

Seq05: Filling Pag oil ................................................................................................................. 9

Seq06: Charging R134a block .................................................................................................. 10

Seq07: Calibrate filling head block .......................................................................................... 13

Seq08: Sniffer block ................................................................................................................. 15

Seq09, Calibrate Massflow R134a ........................................................................................... 17

Seq10: Process end block ......................................................................................................... 18

Seq11: Calibrate Pag filling head block ................................................................................... 19

Project no.: Customer: Equipment: Created date: Init.: Page:


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Process description

Seq02: Ready block

Step Text Description


00 Stop (not in process) Process This process step is active when the
equipment is out of the process mode and one
of the following situations has occurred:
• Critical fault (e.g.: emergency stop
activation)
• Control OFF selected
Fault None
Measurement None
Settings None
20 Ready Process This process step is active when the
equipment is ready to perform a charging
process, i.e. no active critical equipment faults
active and control is ON.
Before a process can be performed a charging
amount has to be selected on the keypad on
the charging hose.
Fault None
Measurement None
Settings None
21 Venting Process The purpose of this step is to check if the A/C
system of the vehicle is already charged in
measuring the actual pressure in the A/C
system. Further the process step 21 allows
aborting the process before the timer
Step21_T has elapsed by pressing the stop
button on keypad, which is placed on the hose
of the charging head.
When the timer Step21_T has elapsed (and the
start button has not been pressed) then the
process will jump to the next process step.
Fault PF21: Already charged
The evacuation valve (127A) in the charging
head and the venting valve M46 are open. If
the measured pressure in the A/C system of
the vehicle is still above the venting set-point
PSet1 when the process timer PF21_T has
elapsed, then the A/C system of the vehicle is
charged with refrigerant. The process is then
aborted issuing the process fault PF21.
Measurement P1: Pressure level from the pressure sensor
M100
Settings Step21_T: Abort time [sec.]
PF21_T: Test time, already charged [sec.]
PSet1: Venting level [bar]
Fault None
Measurement None
Settings None

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 2/19
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Process description

Seq03: Pressure block

Step Text Description


02 Stop in process with pressure Process This process step is active when the
equipment is in process mode and one of the
following situations has occurred:
• Critical Fault (e.g.: emergency stop
activation)
• Control OFF selected
Fault None
Measurement None
Settings None
03,33,34 Venting Process This process step used to equalize the pressure
level in the A/C system of the vehicle.
P (bar)
Fault SF101: Venting Fault
When the pressure level stays on a level above
SF101_T
the venting set point PSet1 when the timer
SF101_T has elapsed, then the station fault
SF101 is issued.
Measurement P1: Pressure level from the pressure sensor
PSet1 M100
Atm.
Settings SF101_T: Venting Fault time [sec.]
PSet1: Venting level [bar]
t (s)
T=2s

30 Pre evacuation Process This process step pre-evacuates the A/C


system of the vehicle. When the timer
Step30_T has elapsed then the process will
jump to the next process step.
Please note: Only major vacuum leak is
monitored.
Fault PF30: Major vacuum leak
When the vacuum level has not reached the set
point PSet2 before the timer PF30_T has
elapsed then the process fault PF30 is issued.
Measurement P2: Vacuum level from the vacuum sensor
M102
Settings Step30_T: Evacuation time [sec.]
PF30_T: Major vacuum leak time [sec.]
PSet2: Major vacuum leak level [mbar]
Please note: The preset value for Step30_T
must be higher than the timer value for
PF30_T.

Project no.: Customer: Equipment: Created date: Init.: Page:


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Process description

Step Text Description


31 Pressure inlet Process This process step is active by inlet of air into
the A/C system of the vehicle. The pressure
level to reach is given by the pressure set point
PSet3. To ensure a proper pressure level in the
whole A/C system of the vehicle, the inlet of
air will continue for T = Step31_T seconds
when the pressure set point PSet3 is reached.
Fault PF31: Major pressure leak
If the pressure level has not reached the
pressure set point PSet3 within T = PF31_T
seconds the process fault PF31 (”Major
pressure leak”) will be issued.
Measurement P1: Pressure level from the pressure sensor
M100
Settings Step31_T: Pressure set point delay time [sec.]
PF31_T: Major pressure leak time [sec.]
PSet3: Pressure set point [bar]
Please note: PSet3 must be adjusted to a lower
level than the regulator for the inlet pressure.
32 Pressure test Process This process step is active to test if the A/C
system of the vehicle can keep a stable
pressure level. When the timer Step32_T has
elapsed then the process will jump to the next
step.
Fault PF32: Pressure test fault.
The fault can be detected in two ways:
1. When the pressure falls to a level below
the pressure test set point PSet2.
2. When the timer PF32_T has run out, the
pressure difference (P1-P1z) is checked
according to the pressure diff. Set point
dPSet1. If the actual pressure difference
level is below the set point dPSet1, the
process fault PF31 is issued.
Measurement P1: Pressure level from the pressure sensor
M100
Settings Step32_T: Pressure test time [s]
PF32_T: Time delay, Pressure diff. level [s]
PSet2: Pressure test level [bar]
dPSet1: Pressure difference level [bar/s]
Note: The pre-set value for Step32_T has to be
higher than the value for PF32_T.

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 4/19
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Process description

Step Text Description


33 Sniffing Process In this process step the operator can find a
minor leakage in the A/C system with a
P (bar) helium sniffer.
Fault None
Measurement None
Settings P1: The pressure level from the pressure
PSet2
sensor M100

Atm.

t(s)

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 5/19
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Process description

Seq04: Vacuum block

Step Text Description


06 Stop in vacuum Process This process step is active when the
equipment is out of the process mode and one
of the following situations has occurred:
• Critical fault (e.g.: emergency stop
activation)
• Control OFF selected
Fault None
Measurement None
Settings None
07,43 Equalize vacuum Process This process step used to equalize the vacuum
level in the A/C system of the vehicle. The
process step is only performed, when a fault
has occurred during process step 30, 40..42.
Fault SF107: Equalize vacuum Fault
When the vacuum level stays on a level below
the equalize set point PSet4 when the timer
SF107_T has elapsed, then the station fault
SF107 is issued.
Measurement P2: Vacuum level from the vacuum sensor
M102
Settings SF107_T: Equalize vacuum fault time [sec.]
PSet4: Equalize vacuum level [mbar]

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 6/19
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Process description

Step Text Description


40 1. Evacuation Process This process step is used to perform the 1.
Evacuation of the A/C system of the vehicle.
When the vacuum level PSet1 is reached the
evacuation will continue until the process
timer Step40_T has elapsed and the process
will jump to the next process step. The
purpose of this “post evacuation” is to ensure
a proper vacuum in the A/C system of the
vehicle. During the evacuation the A/C system
is monitored for any vacuum leaks.
Fault PF40A: Major vacuum leak
When the vacuum level does not reach the set-
point for major vacuum leak before the
process timer PF40A_T has elapses then the
process fault PF40A is issued.
PF40B: Minor vacuum leak
When the vacuum level does not reach the
vacuum level set point PSet1 before the
process timer PF40B_T elapses then the
process fault PF40B is issued.
In case of an active process fault the process is
aborted.
Measurement P2: Vacuum level from the vacuum sensor
M102
Settings Step40_T: Post evacuation process time [sec.]
PF40A_T: Process time to reach the major
vacuum leak level [sec.]
PF40B_T: Process time to reach the vacuum
level [sec.]
PSet1: Vacuum level [mbar]
PSet3: Major vacuum level [mbar]
41 Vacuum test Process This process step is active to test if the A/C
system of the vehicle can maintain a stable
vacuum level when no evacuation is
performed. When the process timer Step41_T
has elapsed then the process will jump to the
next process step.
Fault PF41: Vacuum test fault
When the measured vacuum level raise to a
level above the vacuum test set point PSet2
before the process time Step41_T has elapsed
then the process fault PF41 is issued and the
process is aborted.
Measurement P2: Vacuum level from the vacuum sensor
M102
Settings Step41_T: Vacuum test time [sec.]
PSet2: Vacuum test level [mbar]

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Line side AC charging equipment 20-04-2006 RJE 7/19
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Process description

Step Text Description


42 2. Evacuation Process This process step is used to perform the 2.
Evacuation of the A/C system of the vehicle.
When the vacuum level PSet1 is reached the
evacuation will be continued until the process
timer Step42_T has elapsed and the process
will jump to the next process step. The
purpose of this “post-evacuation” is to ensure
a proper vacuum in the A/C system of the
vehicle. During the evacuation the A/C system
is controlled for a minor vacuum leak.
Fault PF42: Minor vacuum leak
When the vacuum level does not reach
the vacuum level set-point PSet1
before the process timer PF42_T has
elapses, then the process fault PF42 is
issued and the process is aborted.
Measurement P2: Vacuum level from the vacuum sensor
M102
Settings PF42_T: Process time to reach the vacuum
level [sec.]
PSet1: Vacuum level [mbar]

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Line side AC charging equipment 20-04-2006 RJE 8/19
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Process description

Seq05: Filling Pag oil

Step Text Description


01 Stop (in process) Process This process step is active when the
equipment has been in process and the A/C
system is not under pressure. Or if one of the
following situations occurs:
• Critical fault (e.g.: emergency stop active)
• Control OFF
Fault None
Measurement None
Settings None
04 Stop Filling Pag oil Process This process step is active when the
equipment is in process mode and one of the
following situations has occurred:
• Critical fault (example.g. emergency stop
activation)
• Control OFF selected
Fault None
Measurement None
Settings None
50 Filling Pag oil Process In this process step the pre-evacuated A/C
system of the vehicle is charged with Pag oil.
M (g) When the actual filling amount is equal to the
PF50_T
selected amount, the process Will stop filling,
SA106
VSet2 To go to next step press Start button on filling
VSet1 head.
VSet3
Fault PF50: No fill flow Pag.
SA105: Filling amount to small
SA105
dVSet1 SA106: Filling amount to large
Measurement V: Volume flow counter (M121)
PF50 Settings PF50_T: Process time to reach the Filling flow
t (s)
level dVSet1 [g.]

51 3. Evacuation Process This process step is used to perform the 3.


Evacuation of the A/C system of the vehicle.
When the vacuum level PSet1 is reached the
evacuation will be continued until the process
timer Step51_T has elapsed and the process
will jump to the next process step.
Fault PF51: Minor vacuum leak
When the vacuum level does not reach the
vacuum level set-point PSet1 before the
process timer PF51_T has elapses, then the
process fault P51 is issued and the process is
aborted.
Measurement P2: Vacuum level from the vacuum sensor
M102
Settings PF51_T: Process time to reach the vacuum
level [sec.]
PSet1: Vacuum level [mbar]

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 9/19
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Process description

Seq06: Charging R134a block

Step Text Description


05 Stop charging R134a Process This process step is active when the
equipment is in process mode and one of the
following situations has occurred:
• Critical fault (example.g. emergency stop
activation)
• Control OFF selected
Fault None
Measurement None
Settings None
60 Charging R134a Process In this process step the pre-evacuated A/C
system of the vehicle is charged with
M (g) refrigerant. When the actual charging amount
SF103_T is equal to the selected amount, the process
SA102
MSet2 sequence will jump to the next process step (=
MSet1 ”Process end”).
SA101
MSet3
It is possible to interrupt the process
temporarily by pressing the stop button on the
SF103
charging head key pad on the hose. In case of
an operator stop of the R134a charging
process step the process will jump to process
t (s)
step61 (= “Stop charging R134a”).

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 10/19
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Process description

Step Text Description


Fault • PF60: No charging flow.
If the charging flow does not reach the
level fSet1 (fixed PLC setting: fSet1)
within 1 second after start charging then
the process is aborted and the process
fault PF60 is issued.
• SF102: Reset Massflow fault.
If the charging of refrigerant into the A/C
system of the vehicle has not finished
within 3 seconds after the charging valves
have closed then the process is aborted
and the station fault SF102 is issued.
• SF103: Time out at charging R134a.
If the actual charging amount has not
reached the selected amount MSet before
the process timer SF103_T has elapsed,
then the process is aborted and the station
fault SF103 is issued.
• SA101: R134a Charging amount too
small
When the R134a charging process is
finished, the actual R134a charging
amount is compared to a minimum
charging amount (fixed PLC setting :
MSet3). If the actual charged amount is
below this minimum set point, the station
alarm SA101 is issued. The process
continues normally.
• SA102: R134a charging amount too large.
When the R134a charging process is
finished the actual charged amount is
compared to a maximum charging amount
(fixed PLC setting: MSet2). If the actual
charged amount is above this max. limit,
the station alarm SA102 is issued. The
process continues normally.
• SA103: R134a charging flow to low.
If the charging flow is below a minimum
value (fixed PLC setting: fSet12), then the
station alarm SA103 is issued. The
process continues normally.
• SA104: R134a charging flow too high.
If the Charging flow is above a maximum
limit (fixed PLC setting: fSet3), then the
station alarm SA104 is issued. The
process continues normally.

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 11/19
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Process description

Step Text Description


60 Measurement M: Charging amount from Massflow M92
Settings MSet: R134a charging amount set point
The charging amount set point is selected as a
channel selection on the keypad on the hose of
the charging head.

Fixed PLC Settings:


fSet1: NoflowFault_Limit [Hz]
fSet2: FlowFault_Min [Hz]
fSet3: FlowFault_Max [Hz]
MSet2/3: Deviation_Limit [%]
61 Stop Charging R134a Process In this process step the charging is temporary
interrupted by the operator by pressing the
stop button on the charging head key pad,
which is placed on the hose, or if a soft station
fault has occurred during the charging.

If the equipment is re-started, when this stop


step is active and the charging head has not
been placed in the parking position, then it is
possible to finish the charging by pressing the
start button on the charging head key pad. If
the charging head is placed in its parking
position, then the process is aborted and the
process sequence will jump to the process step
“Process end”.
Fault None
Measurement None
Settings None

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 12/19
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Process description

Seq07: Calibrate filling head block

Step Text Description


00 Stop (not in process) Process This process step is active when the
equipment is out of process or if one of the
following situations occurs:
• Critical fault (e.g. emergency stop active)
• Control OFF
Fault None
Measurement None
Settings None
70 Charging R134a Process This process step will perform four times of
M (g) charging of each 500 gram according to
determine average delay time for closing the
+1%
charging valves.
500
If the charging flow measure is outside the
-1% window defined by the fixed PLC settings
fSet5 and fSet4, then the calibration process
will jump to the process step 91 “Calibration
fault”.
Fault SF102: Reset Massflow fault.
If the charging has not been finished within 3
t (s) seconds after the charging valves have been
f (g/s) closed, then the process is aborted and the
station fault SF102 is issued.
Measurement M: Charging amount from Massflow M92
fSet5 Settings Fixed PLC settings:
fSet4
fSet4: Learn_Min_freq [Hz]
fSet5: Learn_Max_freq [Hz]
Please note: The charging flow window for
charging head calibration must be lower than
the corresponding window for the R134a
charging (fSet1 and fSet2).
t (s)

71 Calibration end Process If this process step is active then the


calibration of the charging head was
performed without any errors, i.e. a new delay
time for closing the charging valves is
determined. If the determined average value
for the charging valve closing time is within
the limit values 100 – 500 ms then the delay
time is transferred to an actual Settings in the
PLC and is used to perform all following
chargings until the next charging head
calibration is performed.
Fault None
Measurement None
Settings Fixed PLC settings:
DelayCalc_Min [msec.]
DelayCalc_Max [msec.]

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 13/19
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Process description

Step Text Description


72 Calibration fault Process If this process step is active then the
calibration of the charging head was aborted.
Possible causes to abort the Charging head
calibration could be:
• SF102 Reset Massflow fault.
• The Charging flow is outside the window
fSet4 - fSet5.
Fault None
Measurement None
Settings None

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 14/19
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Process description

Seq08: Sniffer block

Step Text Description


02 Stop with pressure Process This process step is active when the equipment
is out of process or if one of the following
situations occurs:
• Critical fault (e.g. emergency stop active)
• Control OFF
Fault None
Measurement None
Settings None
03 Venting Process This process step will blow off the pressure in
P (bar) the A/C system of the vehicle. When the
pressure has dropped below the venting level
SF101_T PSet1 for 2 sec. then the process will jump to
the next process step.
Fault SF101: Venting fault
If the pressure does not fall to a level below
PSet1 before the timer SF101_T elapses then
PSet1 station fault SF101 is issued.
Atm. Measurement P1: Pressure level from the pressure sensor M100
Settings SF101_T: Venting fault time [sec.]
t (s) PSet1: Venting level [bar]
T=2s
80 Leak detection Process The operator can choose to find the leakage
with a helium sniffer.
When pressing the start button on the keypad on
the charging hose, the process will jump to ”He
inlet”. When pressing the stop button the
process is aborted and the process will jump to
the next step.
Fault None
Measurement None
Settings None
81 He injection Process This process step is Charging the A/C system
with helium until the timer Step81_T has
elapses.
The timer becomes active when the inlet level is
above PSet2.
Fault PF81: Major pressure leak
If the pressure is not reached before the timer
PF81_T has elapses the process fault PF81 is
issued.
Measurement P1: Pressure level from the pressure sensor M100
s
Settings PF81_T: Major pressure leak time [sec.]
PSet2: Inlet level
Please note: PSet2 must be adjusted to a lower
pressure level than the pressure regulator for
helium inlet.

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 15/19
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Process description

82 Sniffing Process In this process step the operator can find the
P (bar) leakage in the A/C system with a helium sniffer.
Fault None
Measurement P1: The pressure level from the pressure sensor
M100
PSet2
Settings PSet2: Inlet level [bar]

Atm.

83,8 Venting Process This process step will equalize the pressure in
4 P (bar) the A/C system of the vehicle. When the
pressure drops below the venting level PSet1 for
SF101_T 2 sec. the process will jump to the next step
”Process end”.
Fault SF101: Venting fault
If the pressure drops to a level below PSet1
before the timer SF101_T has elapses, the
PSet1 station fault SF101 is issued.
Atm. Measurement P1: Pressure level from the pressure sensor
M100
Settings
t (s) SF101_T: Venting fault time [sec.]
T=2s PSet1: Venting level [bar]

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 16/19
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Process description

Seq09, Calibrate Massflow R134a

Step Text Description


00 Stop (not in process) Process This process step is active when the
equipment is out of process or if one of the
following situations occurs:
• Critical fault (e.g. emergency stop active)
• Control OFF
Fault None
Measurement None
Settings None
90 Initialise calibration Process To proceed a proper reset of the Massflow unit
requires that no incoming pulses or signal
from the Massflow transducer is active. For
this purpose this process step will remain
active for 10 seconds.
Fault None
Measurement None
Settings None
91 Reset Process In this process step the massflow unit is reset
by setting the reset input on the massflow unit
for 20 seconds.
Fault None
Measurement None
Settings None
92 Calibration end Process Massflow calibration is done.
Fault None
Measurement None
Settings None

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 17/19
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Process description

Seq10: Process end block

Step Text Description


00 Stop (not in process) Process This process step is active when the
equipment is out of process or if one of the
following situations occurs::
• Critical fault (e.g. emergency stop active)
• Control OFF
Fault None
Measurement None
Settings None
01 Stop (in process) Process This process step is active when the
equipment has been in process and the A/C
system is not under pressure. Or if one of the
following situations occurs:
• Critical fault (e.g.: emergency stop active)
• Control OFF
Fault None
Measurement None
Settings None
100 Process end Process When this process step is active then the
charging process has finished and the operator
can unclamp the charging head from the A/C
system of the vehicle. By pressing the start
button on the charging head key pad, the
process will jump to the next.
Fault None
Measurement None
Settings None
101 Process finished Process In this process step the charging process is
done and restart cannot be performed.

The process step may be used for writing


process data to a data unit on the vehicle or to
unclamp the Charging head automatically
from the A/C system of the vehicle.
Fault None
Measurement None
Settings Step101_T: The time the process sequence
remains in this step when the process mode is
in ”Auto” mode.

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 18/19
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Process description

Seq11: Calibrate Pag filling head block

Step Text Description


04 Stop Filling Pag oil Process This process step is active when the
equipment is in process mode and one of the
following situations has occurred:
• Critical fault (example. emergency stop
activation)
• Control OFF selected
Fault None
Measurement None
Settings None
01 Stop (in process) Process This process step is active when the
equipment has been in process and the A/C
system is not under pressure. Or if one of the
following situations occurs:
• Critical fault (e.g.: emergency stop active)
• Control OFF
Fault None
Measurement None
Settings None

Project no.: Customer: Equipment: Created date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 19/19
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Process description Recovery

Contents

Recovery process ................................................................................................................................................................................................ 2

Project no.: Customer: Equipment: Date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 1/2
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Process description .doc Rev. 00
Process description Recovery

Recovery process
Step Text Description
00 Stop Process This process step is active when the equipment is out of
the process mode and one of the following situations has
occurred:
Critical fault (e.g.: emergency stop activation)
Control OFF selected
Recovery process switched off
Fault None
Measurement None
Settings None
01 Ready Process This process step is active when the
equipment is ready to perform recovery
(recovery process is selected) when no critical
station faults are active and control is ON.
Fault None
Measurement None
Settings None
02 Empty? Process In this process step the equipment tests the
A/C system in the vehicle if it’s empty or full
with refrigerant. When the A/C system is full
a recovery process restarts. If the A/C system
is empty “Process end“ is indicated.
Fault None
Measurement None
Settings Step02_T = 180 [Sec.]
03 Recovering Process This process step emptying the A/C system of
the vehicle.
Fault None
Measurement None
Settings Step03_T = 10 [Sec.]
04 Empty? Process This process step tests the A/C system of the
vehicle if it’s really empty or still full. When
the A/C system is full a new emptying process
is performed. If the A/C system is empty
“Process end“is indicated.
Fault None
Measurement None
Settings Step04_T =30[Sec.]
05 Process end Process In this process step the recovering of the A/C
system of the vehicle has been performed and
finished.
Fault None
Measurement None
Settings None

Project no.: Customer: Equipment: Date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 2/2
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Process description .doc Rev. 00
Line-side AC charging equipment

4.3 Sub description

4_Function description\LS AC Sub description EN.doc

Recovery:
4_Function description\LS AC Recovery Sub description EN.doc

\\AGSERVER\Data\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\Manual 315-400028A-00.doc


25
Sub Description

Content

Sub101 - Evacuation of filling heads in parking position .......................................................... 2

Sub102 - Heating filling head ..................................................................................................... 2

Sub103 - Heating filling head ..................................................................................................... 2

Sub104 – Air/N2/Helium supply ................................................................................................ 2

Sub105 – Filling PAG supply tank ............................................................................................. 3

Project No.: Customer: Equipment: Date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 1/3
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Sub Description

Sub101 - Evacuation of filling heads in parking position

Sub Text Description


Sub101 Evacuation of filling heads in Function Evacuation of the filling head on the pressure side
parking position and the filling head on the vacuum side, when both
filling heads are in parking position. This evacuation
process is only performed for 10 seconds.
I/O Filling head (pressure side) in parking position:
Filling head (vacuum side) in parking position:
Settings TEvacuation = 10 sec.
Fault None

Sub102 - Heating filling head

Sub102 Heating filling head: Function This Subroutine is performed outside the charging
process.
50 sec. OFF and 3 sec. ON
I/O None
Settings TOff = 50 sec.
TOn = 3 sec.
Fault None

Sub103 - Heating filling head

Sub103 Heating filling head: Function When a charging of the A/C system is performed the
Disabled
filling head must be extra heated.
Charging + 25 sec. (max. 60 sec.)
I/O None
Settings TRunning time = 25 sec. (max. 60 sec. incl. charging)
Fault None

Sub104 – Air/N2/Helium supply

Sub104 Air/N2/Helium supply Function When the pressure drops below PSet2 the valve M99
Disabled
will open to ensure that there is enough
Air/N2/helium pressure in the A/C system of the
vehicle.
I/O None
Settings PSet2
Fault None

Project No.: Customer: Equipment: Date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 2/3
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Sub Description

Sub105 – Filling PAG supply tank

Sub105 Filling PAG supply tank Function When the tank is under setpoint level then the tank is
Enable
refilled
I/O Level switch
Settings None
Fault None

Project No.: Customer: Equipment: Date: Init.: Page:


Line side AC charging equipment 20-04-2006 RJE 3/3
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Sub description, Recovery

Content

Sub01 .......................................................................................................................................... 2

Sub02 .......................................................................................................................................... 2

Sub03 .......................................................................................................................................... 2

Sub04 .......................................................................................................................................... 2

Sub05 .......................................................................................................................................... 3

Sub06 .......................................................................................................................................... 3

Sub07 .......................................................................................................................................... 3

Project no.: Customer: Equipment: Date: Init: Page:


Line side AC charging equipment 20-04-2006 RJE 1/3
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Sub description, Recovery

Sub Text Description


Sub01 Control of the inlet valve for Function The valve for the inlet of refrigerant can only be
refrigerant opened when the level switch in the operating
container (mech. pos. no. 62) is not activated.
I/O Mech. pos. no. 51
Settings Activation time = 2 sec.
Fault None
Sub02 Control of the inlet valve for buffer Function The valve for the inlet of refrigerant into the buffer
tank O1 tank O1 is closed when the buffer tank O1 is full
(detected by the level switch (mech. pos. no. 53)).
When the switch “Recovery Alarm” is activated, the
recovery process continues, however a new start
cannot be performed as long as the buffer tank O1 is
not empty. When the switch “Stop recovery” is
activated, the recovery process is immediately
stopped and the station fault is indicated in operator
panel.
I/O Mech. pos. no. 67
Settings None
Fault None
Sub03 Control of the condenser Function The condenser is operating during the recovery
process. When the recovery process has finished
then the condenser has a running time TRunning time
before it stops.
I/O Mech. pos. no. 68
Settings TRunning time = 5 min.
Fault Common, SF003 = Motor protection(s) not okay
Sub04 Control of air to the P.A.G. oil Function When the pressure in the operating container (mech.
release valve pos. no. 62) reaches a pressure that is below 0.3 bar
(measured with the pressure sensor (mech. pos. no.
52)) for the first time, then compressed air for the
release valve (mech. pos. no. 76) is supplied. When
a recovery process has finished then compressed air
is supplied to the release valve to. The P.A.G. oil
release function only operates once per recovery.
I/O Mech. pos. no. 76
A lamp is indicating that the P.A.G. oil release valve
can be activated by the operator.
Settings None
Fault None

Project no.: Customer: Equipment: Date: Init: Page:


Line side AC charging equipment 20-04-2006 RJE 2/3
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\LS AC Recovery Sub description EN.doc rev. 00
Sub description, Recovery

Sub05 Control of the compressor Function The compressor operates only when the pressure of
the pressure switch (mech. pos. no. 52) is above the
limit value of 0.3 bars and the safety pressure switch
(mech. pos. no. 59) has not reached a value above 15
bars.
The compressor stops when the pressure of the
pressure switch (mech. pos. no. 52) is below -0.1 bar
in a delay time of TOff seconds. The compressor also
stops immediately when the safety pressure switch
(mech. pos. no. 59) has reached 15 bars.
I/O Mech. pos. no. 58
Mech. pos. no. 59
Settings TOff = 3 min.
Fault SF102 = Pressure level in compressor too high
Common, SF003 = Motor protection(s) not okay
Sub06 Release valve for control of return Function The valve opens, if the process is not in
oil to the compressor RUNMODE, and close again after the delay time
TReturn time.
I/O Mech. pos. no. 69
Settings TReturn time = 5 - 10 sec.
Fault None
Sub07 Control the draining of the buffer Function The valve opens when the GTL pump is switched on
tank O1. and the level in the tank O1 is above the limit value
“Lo”. In this case the valve M45 closes to avoid
double supply.
I/O Mech. pos. no. 77
Settings None
Fault None

Project no.: Customer: Equipment: Date: Init: Page:


Line side AC charging equipment 20-04-2006 RJE 3/3
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\LS AC Recovery Sub description EN.doc rev. 00
Line-side AC charging equipment

4.4 Flow chart

4_Function description\Flowchart\LS AC Flowchart.doc


4_Function description\Flowchart\LS AC Flowchart(TP170B).EN.doc

\\AGSERVER\Data\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\Manual 315-400028A-00.doc


26
Flowchart
Contents

Process sequence ........................................................................................................................ 2

Seq02, Ready.............................................................................................................................. 3

Seq03, Pressure .......................................................................................................................... 4

Seq03.1, Pressure ....................................................................................................................... 5

Seq04, Vacuum .......................................................................................................................... 6

Seq05, Filling Pag oil ................................................................................................................. 7

Seq06, Charging ......................................................................................................................... 8

Seq07, Calibrate Filling head R134a.......................................................................................... 9

Seq08, Sniffing Helium ............................................................................................................ 10

Seq09, Calibrate Massflow R134a ........................................................................................... 11

Seq10, Process end ................................................................................................................... 12

Seq11, Calibrate filling head PAG oil ...................................................................................... 13

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 1/13
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\Flowchart\LS AC Flowchart.doc Rev. 00
Flowchart
Process sequence

Seq02
Ready

Seq02.TrPas 3

Seq03
Seq03.TrRes+.TrErr
Seq03.TrSnif Pressure test

Seq03.TrPas4

Seq04
Seq04.TrSnif Seq04.TrRes+.TrErr
Vacuum

Seq04.TrPas5

Seq05
Seq05.TrSnif Seq05.TrRes+.TrErr
Filling PAG oil

Seq05.TrPas6

Seq08 Seq06
Sniffing Seq06.TrRes+.TrErr
Charging R134a
(Disabled)

Seq06.TrPas10
Seq08.TrPas10+
Seq08.TrErr+
Seq08.TrRes
Seq10
Process end

Seq10.TrPas+.TrRes

Seq02.TrPas7 Seq02.TrPas9 Seq02.TrPas11

Seq07 Seq09 Seq11


Calibrate Calibrate Calibrate
filling head massflow filling head PAG oil
R134a R134a (disabled)

Seq07.TrPas2 +. Seq9.TrPas2+. Seq11.TrPas2 +.


Seq07.TrRes Seq9.TrRes Seq11.TrRes

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 2/13
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Flowchart
Seq02, Ready

ResetSEQ Init

Step20 + Step 21

Step 00
Stop
not in process

Not "ResetSeq" * "Start" Step20


Ready

Not "Parked" * "Interlock3" * Not "Parked" * Not "Parked" *


"StepOns" * "Mode3" "StepOns" * "StepOns" *
"Interlock2" * "Interlock4" * "Interlock1" *
"Mode2" "Mode4" "Mode1"

TrPas7 TrPas9 TrPas11

(Not "Auto" *
"StepOns")+
("Auto" * Step21
Step21T_Dn) "StopOp"
Abort/Venting

Not Evacuation * Not Evacuation* Not Evacuation * Evacuation + PF21 +


Not Pressure * Not Pressure * Not Pressure * (Not Evacuation "StopSF"
Not Vacuum * not Vacuum Vacuum * Pressure)
Not FillPAG.

Seq2TrPas6 Seq2TrPas5 Seq2TrPas4 Seq2TrPas3 TrErr

Control:
Auto: Automatic mode
StepOns: Step oneshot
StopOp: Stop sequence (operator)
StopSF: Stopp sequence (station fault)
Parked: Filling head in parking position
Mode1: Charging mode
Mode2: Calibrate R134a filling head mode
Mode3: Calibrate massflow mode
Mode4: Calibrate PAG oil filling head mode
Interlock1: Release charging mode (mode1)
Interlock2: Release calibrate R134a filling head mode (mode2)
Interlock3: Release calibrate massflow mode (mode3)
Interlock4: Release calibrate PAG oil filling head mode (mode4)

Process fault:
PF21: Car already charged

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 3/13
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Flowchart
Seq03, Pressure

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 4/13
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\Flowchart\LS AC Flowchart.doc Rev. 00
Flowchart
Seq03.1, Pressure

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 5/13
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Flowchart
Seq04, Vacuum

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 6/13
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Flowchart
Seq05, Filling Pag oil

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 7/13
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\Flowchart\LS AC Flowchart.doc Rev. 00
Flowchart
Seq06, Charging

ResetSEQ Init

Not "ChargR134a" "ChargR134a" Not "StopOp" * Not "StopSF" *


Step 05 Not "Parked" * "StepOns"
Stop
Charging R134a

Not "ResetSEQ" *
"Start" Not "Parked" *
Step 60 "StopOp" + "StopSF"
Not ”Mode2”
Charging R134a

FillState_4H Step 61
Stop
FillState_1H+ Charging R134a
"Parked" * FillState_2H+
Not ”Mode2" + FillState_3H+
Not "Parked" FillState_9H
* ”Mode2" + ResetSEQ
"Parked" +
ResetSEQ

TrRes Seq6.TrPas10 TrErr

Enable:
ChargR134a: Release Seq06 block (charging R134a)

Control:
StepOns: Step oneshot
StopOp: Stop sequence (operator)
StopSF: Stop sequence (station fault)
Parked: Filling head in parking position

FillState:
_1H: No charging flow
_2H: Charging amount too small
_3H: Charging amount too large
_4H: Charging done
_9H: Massflow calibration fault

Process fault:
PF60: No charging flow (FillState_1H)

Station fault:
SF103: Timeout at charging R134a

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 8/13
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\Flowchart\LS AC Flowchart.doc Rev. 00
Flowchart
Seq07, Calibrate Filling head R134a

ResetSEQ Init

Not parked *
Interlock 2 *
Step60 + Step61 +
Mode 2
Step70 + Step71 +
Step72 + Step73 Step70
Charging R134a
Step05 500 g
Stop
Charging R134a
FillState_1H + FillState_2H +
FillState_9H FillState_3H + Step71T_DN
SA103 + FillState_4H (T[2s])
Not "ResetSEQ" SA104
* "Start" Step71
Charging
Done

Not "Mode2"
FillState._6H FillState._5H * Parked

Step73 Step72
Calibration Calibration
Failed Done

Not "Mode2" Not "Mode2"


* Parked * Parked

TrRes Seq7.TrPas2

Control:
Mode2: Calibration of R134a filling head

FillState:
_1H: No filling flow
_2H: Deviation min
_3H: Deviation max
_4H: Filling OK
_5H: Calibration of R134a filling head OK
_6H: Calibration of R134a filling head NOK
_7H: Charging too slow
_8H: Charging too fast
_9H: Massflow reset fault

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 9/13
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Flowchart
Seq08, Sniffing Helium

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 10/13
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Flowchart
Seq09, Calibrate Massflow R134a

ResetSEQ Init

"Mode3" *
Interlock 3

Step 90
Not "Mode3"
Init calibration

Step 00
Stop Step 90T_DN
Not in Process T[10s]

Not "ResetSEQ" * "Start"

Step91

Reset massflow

Step 91T_DN
T[20s]

Step92

Calibration done

Not "Mode3"

TrRes Seq9.TrPas2

Jump:
TrPas: Block OK
TrRes: Block NOK (reset sequence)

Control:
Mode3: Calibration of massflow
Start: Start sequence
ResetSEQ: Reset sequence

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 11/13
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Flowchart
Seq10, Process end

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 12/13
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Flowchart

Seq11, Calibrate filling head PAG oil

ResetSEQ Init

Not Parked * Mode 4 *


Interlock 4 * step
Step 111 +
Step 112 + Step 113 Step 110
Not "Mode4"
Evacuation

(Not Auto * Step) +


( Auto * Step 42T_DN *
LeqPset1)

Step 04 Step 111


Stop Not "Mode4"
Filling PAG oil
Filling PAG oil

Step 112T_DN * GeqVset2 *


Not Step 111C_DN LeqdVSet1

Not "ResetSEQ" *
"Start" *
("Parked" * Step 112
Not ”Mode4") + Not "Mode4"
Filling Done
(Not "Parked"
* ”Mode4")
Step 111C_DN

Step 113
Calibration
done

Not "Mode4"

TrRes Seq11.Trpas20

Control:
Mode4: Calibration of PAG oil filling head mode
Start: Start sequence
ResetSEQ: Reset sequence

Jump:
TrPas: Block OK
TrRes: Block NOK (reset sequence)

FillPagControl (filling set point):


GeqVSet1: Filling amount (V>=VSet1)

Project no.: Customer: Equipment: Created date: Init.: Page:


LS Ac Charging equipment 05-10-2005 RJE 13/13
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\Flowchart\LS AC Flowchart.doc Rev. 00
TP170B Structure

Project no.: Customer: Equipment: Created date: Init.: Page:


Lineside AC charging equipment 16-06-2006 RJE 1/2
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\Flowchart\LS AC Flowchart(TP170B).EN.doc Rev. 00
TP170B Structure

Start screen
START
Screen No: 1

Process Overview Process


PROCESS PROCESS_1
Screen No: 2 Screen No: 21

Diagnostics Alarm Archive


DIAG ALARM
Screen No: 4 Screen No: 41

Hardware diagnostics
HW_DIAG
Screen No: 42

Password
level 9
Force valves & pumps
FORCE
Screen No: 43

Reporting Last process result


REPORT PRO_HISTORY
Screen No: 5 Screen No: 51

Process trend curves


PRO_TREND
Screen No: 52

Password
level 9

Service (TPM)
SERVICE
Screen No: 6

Information
INFO
Screen No: 9

Project no.: Customer: Equipment: Created date: Init.: Page:


Lineside AC charging equipment 16-06-2006 RJE 2/2
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\Flowchart\LS AC Flowchart(TP170B).EN.doc Rev. 00
Line-side AC charging equipment

4.5 PT-diagram

4_Function description\PT-Diagram\AC Process PT_Diagram.ENV1.0.doc

Recovery:
4_Function description\PT-Diagram\LS AC Recovery Process.PT.doc

\\AGSERVER\Data\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\Manual 315-400028A-00.doc


27
PT-Diagramm

Content:

Seq02, Ready ..................................................................................................................................................................................................................................................2


Seq03, Pressure test .......................................................................................................................................................................................................................................3
Seq03, Pressure test .......................................................................................................................................................................................................................................4
Seq04, Vacuum..............................................................................................................................................................................................................................................5
Seq04, Vacuum..............................................................................................................................................................................................................................................6
Seq05, Filling Pag .........................................................................................................................................................................................................................................7
Seq06, Charging ............................................................................................................................................................................................................................................8
Seq07, Calibration filling head ......................................................................................................................................................................................................................9
Seq08, Sniffing helium .................................................................................................................................................................................................................................10
Seq08, Sniffing helium ................................................................................................................................................................................................................................11
Seq09, Calibration massflow .......................................................................................................................................................................................................................12
Seq10, Process end ......................................................................................................................................................................................................................................13

Project no.: Customer: Equipment: Created date: Init: Page:


24176 Avtovaz A/C Charging Equipment 03-01-2008 JIN 1/13
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\PT-Diagram\AC Process PT_Diagram.ENV1.0.doc Rev. 00
PT-Diagramm

Seq02, Ready

Symbolic Output Text Step20 Step21


Ready Venting
YV60.6 M127A Fillinghead Pressureside, Evacuation Sub101
YV60.7 M127B Fillinghead Pressureside, Close valve Sub101
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation Sub101
YV80.1 M137B Fillinghead Vacuumside, Close valve Sub101
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil Sub 105 Sub 105
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil Sub 105 Sub 105
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Reset Massflow

Process fault: Subroutines


PF21 Already filled Sub101 Evacuation, Fillinghead parked (10 sec)
Sub102 Heating Fillinghead: 50 sec Off, 3 sec On
Sub103 Heating Fillinghead: Filling + 25 sec (max 60 sec)
Sub105 Filling PAG Tank

Project no.: Customer: Equipment: Created date: Init: Page:


24176 Avtovaz A/C Charging Equipment 03-01-2008 JIN 2/13
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\PT-Diagram\AC Process PT_Diagram.ENV1.0.doc Rev. 00
PT-Diagramm
P (mbar)

PF30_T
Seq03, Pressure test Atm.

P2Set3

t (s)
Step30_T

Step 30 Step 31 Step 32


Symbolic Output Text
Pre evacuation Pressure inlet Pressure test
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check Xsub_M103
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102 Sub102
KM41.2 M114 PAG Pump Sub105 Sub105 Sub105
Q43.2 R_Mass Calibration Massflow

Process- and Station fault: Subroutines:


PF30 Major Vacuum leak Sub102 Heating filling head: 50 sec. off, 3 sec. on
PF31 Major pressure leak Xsub_M103 Time delay before open M103. 1 sec.
PF32 Pressure test fault

Project no.: Customer: Equipment: Created date: Init: Page:


24176 Avtovaz A/C Charging Equipment 03-01-2008 JIN 3/13
F:\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\4_Function description\PT-Diagram\AC Process PT_Diagram.ENV1.0.doc Rev. 00
PT-Diagramm
P (bar)

Seq03, Pressure test


PSet3

Atm.

t(s)

Step 33 Step 03,34,35


Symbolic Output Text
Sniffing Venting
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test Sub104
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow

Process- and Station fault: Subroutines:


SF101 Sub102 Heating filling head: 50 sec. off, 3 sec. on
Sub104 HeliumPressure is P<PSet2

Project no.: Customer: Equipment: Created date: Init: Page:


24176 Avtovaz A/C Charging Equipment 03-01-2008 JIN 4/13
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PT-Diagramm

Seq04, Vacuum

Step40 Step41
Symbolic Output Text
1. evacuation Vacuum test
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check Xsub_M103
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


PF40A Major vacuum leak Sub102 Heating filling head: 50 sec. off, 3 sec. on
PF40B Minor vacuum leak Xsub_M103 Time delay before open M103. 1 sec.
PF41 Vacuum test fault

Project no.: Customer: Equipment: Created date: Init: Page:


24176 Avtovaz A/C Charging Equipment 03-01-2008 JIN 5/13
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PT-Diagramm

Seq04, Vacuum

Step 42 Step 07,43


Symbolic Output Text
2. evacuation Equalize vacuum
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


PF42 Minor vacuum leak Sub102 Heating filling head: 50 sec. off, 3 sec. on
SF107 Equalize vacuum fault

Project no.: Customer: Equipment: Created date: Init: Page:


24176 Avtovaz A/C Charging Equipment 03-01-2008 JIN 6/13
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PT-Diagramm

M (g)
PF50_T
Seq05, Filling Pag VSet3
SA106

VSet2
VSet1

SA105
dVSet1

PF50
t (s)

Step 50 Step 51
Symbolic Output Text
Filling Pag 3. evacuation
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil Sub 105
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil Sub 105
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


PF50 No fill flow Pag Sub102 Heating filling head: 50 sec. off, 3 sec. on
PF51 Minor vacuum leak
SA105 Pag oil filling amount to small
SA106 Pag oil filling amount to large
Project no.: Customer: Equipment: Created date: Init: Page:
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PT-Diagramm
M (g)
SF103_T
Seq06, Charging MSet3
SA102

MSet2
SA101
MSet1

SF103

t (s)

Step 60 Step 61
Symbolic Output Text
Charging R134a Stop at charging R134a
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub103 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


PF60 No filling flow Sub102 Heating filling head: 50 sec. off, 3 sec. on
Sub103 Heating filling head: filling + 25 sec. (max. 60 sec.)

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PT-Diagramm
M (g)

Seq07, Calibration filling head MSet3

500
MSet2

t (s)
f (g/s)

FSet2
FSet3

t (s)

Step 72,73
Step 70 Step 71
Symbolic Output Text Calibration, fault or
Charging R134a (4x 500 g) Charging, Done
done
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub103 Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105 Sub105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


Sub102 Heating filling head: 50 sec. off, 3 sec. on
Sub103 Heating filling head: filling + 25 sec. (max. 60 sec.)
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PT-Diagramm

P (bar)
Seq08, Sniffing helium
PF81_T

PSet3
PF81

Atm.

t(s)
T=2s

Step80 Step 81
Symbolic Output Text
Snif on leak? Inlet helium
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


Sub102 Heating filling head: 50 sec. off, 3 sec. on
Sub103 Heating filling head: filling + 25 sec. (max. 60 sec.)

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PT-Diagramm

Seq08, Sniffing helium

Step 82 Step 03,83,84


Symbolic Output Text
Sniffing Venting
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test Sub 104
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 R134a supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


SF101 Venting fault Sub102 Heating filling head: 50 sec. off, 3 sec. on
Sub103 Heating filling head: filling + 25 sec. (max. 60 sec.)
Sub104 Filling HE

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PT-Diagramm

Seq09, Calibration
massflow

Symbolic Output Text Step 90 Step 91 Step 92


Initialize calibration Reset massfolw Calibration end
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105 Sub105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


Sub102 Heating filling head: 50 sec. off, 3 sec. on

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PT-Diagramm

Seq10, Process end

Step 100 Step 101


Symbolic Output Text
Process end Process done
YV60.6 M127A Fillinghead Pressureside, Evacuation
YV60.7 M127B Fillinghead Pressureside, Close valve
YV61.0 M127C1 Fillinghead Pressureside, Filling R134a
YV61.1 M127C2 Fillinghead Pressureside, Close filling valve
YV80.0 M137A Fillinghead Vacuumside, Evacuation
YV80.1 M137B Fillinghead Vacuumside, Close valve
YV80.2 M137C1 Fillinghead Vacuumside, Filling PAG
YV80.3 M137C2 Fillinghead Vacuumside, Close filling valve
YV80.4 M143 Filling PAG Oil
YV60.3 M99 Pressure test
YV60.2 M101 Venting
YV60.4 M145 Filter Protection
YV43.6 M139 Filling Pressure PAG Oil
YV60.1 M103 Vacuum check
YV43.5 M91 Refrigerant supply
YV60.0 M104 Evacuation
KM41.0 M109 Vacuum pump
KA41.4 E1 Heating Fillinghead Sub102 Sub102
KM41.2 M114 PAG Pump Sub 105 Sub 105
Q43.2 R_Mass Calibration Massflow

Process fault: Subroutines:


Sub102 Heating filling head: 50 sec. off, 3 sec. on

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PT-Diagram
Contents

Seq00 Recovery .................................................................................................................................................................. 2

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PT-Diagram

Seq00 Recovery

Symbolic Output Description Step 01 Step 02 Step 03 Step 04 Step 05


Ready Empty? Recovering Empty? Process end
YV43.3 M51 Inlet valve for refrigerant Sub01 Sub01 Sub01
KM44.4 M58 Compressor Sub05 Sub05 Sub05
YV44.5 M67 Filling O1 Sub02 Sub02 Sub02
KM44.3 M68 Fan Sub03 Sub03 Sub03 Sub03 Sub03
YV44.6 M69 Return oil Sub06 Sub06
YV61.5 M76 Compressed air for P.A.G. oil release
Sub04 Sub04
valve
YV61.4 M77 Emptying O1 Sub07 Sub07 Sub07 Sub07 Sub07

Process and Station fault/alarm: Subroutines:

SF101 Level too high in buffer tank O1 Sub01 Control of inlet valve for refrigerant
SF102 Too high pressure from high pressure side of the compressor Sub02 Control of inlet valve for refrigerant in buffer tank O1
SA101 High level in buffer tank O1 Sub03 Control of condenser
SA102 Pressure too high in buffer tank O1 Sub04 Control of air for P.A.G. oil release valve
SA103 Recovery Bottle full (Pos144) Sub05 Control of compressor
Sub06 Control of return oil for compressor release valve
Sub07 Control of emptying refrigerant buffer tank O1

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Line-side AC charging equipment

4.6 Settings

4_Function description\AC Settings.EN.doc

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28
Settings
Contents

Seq02. Ready ...................................................................................................................................................................... 2

Seq03, Pressure test ............................................................................................................................................................ 3

Seq04, Vacuum ................................................................................................................................................................... 4

Seq05, Filling Pag ............................................................................................................................................................... 5

Seq06, Charging R134a ...................................................................................................................................................... 6

Seq09, Calibrate Filling head .............................................................................................................................................. 7

Channel depended settings .................................................................................................................................................. 8

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Settings

Seq02. Ready

Step 20 Step 21
Settings Ready Venting
Default FAT SAT Default FAT SAT
Process time [s]
Step21_T [s] 5.0 5.0
PF21_T [s] 1.0 2.0
PSet1 [bar] 0.20 0.20 0.20

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Settings

Seq03, Pressure test


P (bar) P (bar)

PF31_T PF32_T
PF32
P1Set3
PF31 dP1Set1

P1Set2
Atm.
PF32
Atm.
t(s)
Step31_T t (s)
Step32_T

Step 30 Step 31 Step 32 Step 03,34,35


Settings Pre evacuation Pressure inlet Pressure test Venting
Default FAT SAT Default FAT SAT Default FAT SAT Default FAT SAT
Process time [s]
Step03X_T [s] 2.0
Step30_T [s] 2.0
Step31_T [s] 2.0
Step32_T [s] 10.0
PF30_T [s] 5.0
PF31_T [s] 20.0
P1Set1 [bar] 0.20
P1Set2 [bar] 4.50
P1Set3 [bar] 5.00
P2Set2 [mbar] 60.00
SF101_T [s] 10.0

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Settings

Seq04, Vacuum

Step 40 Step 41 Step 42 Step 07,43


Settings 1. evacuation Vacuum test 2. evacuation Equalize vacuum
Default FAT SAT Default FAT SAT Default FAT SAT Default FAT SAT
Process time [s]
Step40_T *) [s] 5.0
Step41_T *) [s] 10.0
Step42_T *) [s] 5.0
Step07X_T **) [s] 2.0
PF40A_T *) [s] 10.0
PF40B_T *) [s] 60.0
PF42_T *) [s] 5.0
PSet1 *) [mbar] 5.0 5.01
PSet2 *) [mbar] 10.0
PSet3 *) [mbar] 60.0
PSet4 **) [mbar] 200.0
SF107_T [s] 15.0
1
Similar to PSet1 from 1. evacuation

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Settings
Seq05, Filling Pag

Step 60
Settings Filling R134a
Default FAT SAT
Process time [s]
MSet2 [g] +1.0% of MSet1 +1.0% of MSet1 +1.0% of MSet1
MSet3 [g] -1.0% of MSet1 -1.0% of MSet1 -1.0% of MSet1
FSet1 [g/s] 20.0 20.0 20.0
FSet2 [g/s] 70.0 70.0 70.0
FSet3 [g/s] 130.0 130.0 130.0
MSet2 *) [g] 650
SF103_T *) [s] 15.0

2
500 - 3000 g
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Settings

Seq06, Charging R134a

Step 60
Settings Filling R134a
Default FAT SAT
Process time [s]
MSet2 [g] +1.0% of MSet1 +1.0% of MSet1 +1.0% of MSet1
MSet3 [g] -1.0% of MSet1 -1.0% of MSet1 -1.0% of MSet1
FSet1 [g/s] 20.0 20.0 20.0
FSet2 [g/s] 70.0 70.0 70.0
FSet3 [g/s] 130.0 130.0 130.0
MSet3 *) [g] 650
SF103_T *) [s] 15.0

3
500 - 3000 g
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Settings

Seq09, Calibrate Filling head

Step 90
Settings Filling R134a
Default FAT SAT
FSet4 [g/s] 80.0
FSet5 [g/s] 120.0

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Settings

Channel depended settings

Channel 1 Channel 2 Channel 3 Channel 4 Channel 5


Default FAT SAT Default FAT SAT Default FAT SAT Default FAT SAT Default FAT SAT
Seq04, Vacuum
Step40_T [s] 5 5 5 5 5
Step41_T [s] 10 10 10 10 10
Step42_T [s] 5 5 5 5 5
PF40A_T [s] 10 10 10 10 10
PF40B_T [s] 60 60 60 60 60
PF42_T [s] 5 5 5 5 5
P2Set1 [mbar] 2 2 2 2 2
P2Set2 [mbar] 7 7 7 7 7
P2Set3 [mbar] 50 50 50 50 50
Seq06, Charging
MSet [g] 500 550 600 650 700
SF103_T [s] 20 21 22 23 24

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Line-side AC charging equipment

5. Fault description

5_Fault descriptions\LS AC Fault description EN.doc

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29
Fault Description

Contents

[Common] SF00X Major Station Fault ...................................................................................... 2

[Common] SA00X Station Alarm .............................................................................................. 3

[Process] SF1XX Minor Station Fault ....................................................................................... 4

[Process] SA1XX Station Alarm ................................................................................................ 5

[Pump cabinet] SF1XX Minor Station Fault .............................................................................. 6

[Pump cabinet] SA1XX Station Fault ........................................................................................ 8

[Recovery] SF1XX Station fault ................................................................................................ 9

[Recovery] SA1XX Station alarm .............................................................................................. 9

[Arm] SF1XX Minor Station Fault .......................................................................................... 10

[Arm] SA1XX Station Alarm ................................................................................................... 10

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Fault Description

[Common] SF00X Major Station Fault

No. Name Description


SF001 Fuse tripped FAXX Caused by This fault is generated if a fuse in the control
panel is tripped. When this fault occurs the
equipment will shut down
Action To start up the equipment again, the fuse must
be switched on and the “Reset Station fault”
button pressed.
IO FAXX
Parameter None
SF002 Motor protection QMXX Caused by This fault is generated if an overload relay in
the control panel is tripped. When this fault
occurs the equipment will shut down.
Action To start up the equipment again, the overload
relay must be switched on and the “Reset
Station fault” button pressed.
IO QMXX
Parameter None
SF003 Emergency stop activated Caused by When the Emergency stop on the control
panel is activated the equipment will shut
down.
Action To start-up the equipment again, the
“Emergency stop” button must be released
and the
“Reset Emergency stop” and “Reset Station
fault” pressed.
IO SB4
Parameter None
SF004 Air pressure fault Caused by This fault occurs when the air supply pressure
drops below the set point for more than
5 seconds. The fault will cause the equipment
to shut down.
Action To start up the equipment again, the air supply
pressure must be above the set point and the
“Reset Station fault” button pressed.
IO SP45.0
Parameter T =5.0 [Sec.]
SF008 PLC module fault Caused by This fault is software generated, and occurs if
there is a failure at a PLC module.
Action After fixing the fault, press the “Reset Station
fault” button.
IO Software FB8
Parameter None

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Fault Description

[Common] SA00X Station Alarm

Nr. Name Description


SA001 TPM alarm active Caused by This alarm occurs if a TPM event is active.
Check the TPM screen on the display to view
which TPM event has to be solved.
Action Solve the TPM event and reset the TPM
counter(s) and/or timer(s)
IO None
Settings None
SA002 Scanner fault Caused by This fault is generated when an illegal barcode is
read or when a configuration failure on the
scanner occurs.
Action Read a legal barcode or change the scanner
configuration, and press the “Reset Station fault”
button.
IO Software
Parameter None
SA003 Datalink Caused by None
Action None
IO Software
Parameter None

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Fault Description

[Process] SF1XX Minor Station Fault

No. Name Description


SF101 Venting fault Caused by This fault occurs when the air pressure can not
be equalizing to the pressure level PSet1
before the time SF101_T has run out.
Action Check the pressure sensor M100, valves M101
and M127A. After fixing the fault press the
“Reset Station fault” button.
IO B272, (M100)
Parameter SF101_T
SF102 Reset massflow fault Caused by The calibration of the massflow unit is not
correct and does not measure correctly.
Action Perform a “Massflow calibration”.
IO A_Mass
Settings None
SF103 Timeout charging R134a Caused by The time to perform a charging has run out.
Action Please check the timer settings for timer
SF103_T or the charging pressure level.
IO None
Settings SF103_T = 5 [Sec.]
SF104 Timeout filling Pag oil Caused by The time to perform a filling has run out.
Action Please check the timer settings for timer
SF104_T or the filling pressure level.
IO None
Settings SF104_T = 5 [Sec.]
SF105 Equalize vacuum fault Caused by This fault occurs when the vacuum level can
not be equalizing to the pressure level
Vac.PSet4 before the time SF105_T has run
out.
Action Check the vacuum sensor M102, valves M101
and M127A. After fixing the fault press the
“Reset Station fault” button.
IO B274 (M102)
Parameter SF105_T = 15 [Sec.]

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Fault Description

[Process] SA1XX Station Alarm

No. Name Description


SA101 R134a charging amount to small Caused by Charging amount is too small, i.e. 1% lower
than the required amount.
Action Perform a “Calibrate filling head”.
IO 2H
Settings Fixed settings in the PLC: Set point – 1%
SA102 R134a charging amount to large Caused by Charging amount is too large, i.e. 1% or
higher than the required amount.
Action Perform a “Calibrate filling head”.
IO 3H
Settings Fixed Settings in the PLC: Set point + 1%
SA103 R134a charging to slow Caused by The charging flow is below the allowed flow
level (default value < 70g/sec.)
Action Check if the supply pressure is too low at
gauge (mech. pos. no. 88).
IO 7H
Settings Fixed setting in the PLC
SA104 R134a charging to fast Caused by The charging flow exceeds the allowed flow
level (default value > 130g/sec.)
Action Check if the supply pressure is too high at
gauge (mech. pos. no. 88).
IO 8H
Settings Fixed setting in the PLC
SA105 Pag oil filling amount to small Caused by Filling amount is too small, When the filled
amount is lower than the required amount.
Action Perform a “Calibrate Pag filling head”.
IO None
Settings Vset1
SA106 Pag oil filling amount to large Caused by Filling amount is too large, When the filled
amount is higher than the required amount.
Action Perform a “Calibrate Pag filling head”.
IO None
Settings Vset3

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Fault Description

[Pump cabinet] SF1XX Minor Station Fault

No. Name Description


SF101 R134a main supply fault Caused by The refrigerant supply pressure is too low to
perform a charging.
Action Check charging pressure at gauge mech. pos.
no. 89.
IO SP45.2 (M89)
Settings SF101_T = 5 [Sec.]
SF102 Massflow fault Caused by The Massflow function is not okay. Perform a
“Massflow calibration”.
Action If the fault is still active, change the Massflow
unit. For further information see the “Trouble-
shooting manual” at section 5.
IO A_MASS
Settings None
SF103 R134a bottle supply fault Caused by The supply pressure of R134a is too low to
perform a charging when the R134a bottle
supply is selected.
Action Check the pressure gauge at mech. pos. no. 88
and change the bottle or change to main
supply. When switching the GTL pump off
and the main supply on, the bottle supply is re-
initialized.
IO SP45.2 (M89)
Settings SF103_T = 5 [Sec.]
SF104 R134a bottle 1 & 2 are empty Caused by The bottle supply pressure of R134a is too low
to perform a charging when the R134a bottle
supply is selected.
Action Check the pressure gauge at mech. pos. no. 88
and change at least one bottle or change to
main supply. When switching the GTL pump
off and the main supply on, the bottle supply
is re-initialized.
IO SP45.2 (M89)
Settings SF104_T = 5 [Sec.]
SF105 Temperature too high Caused by The temperature difference between GTL
Option 2 pump input and output is bigger than the set
point given by the temp. diff. switch (mech.
Pos 47)
Action Check if the cooling unit is operating proper.
IO ST45.4 (M47)
Settings SF105_T = 30 [Sec.]

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Fault Description

No. Name Description


SF106 High level in Pag oil tank 01 Caused by This fault occurs if the supply level in the
buffer Pag oil tank 01 reaches the set point for
High level and stays there for more than
SF101_T seconds. The filling routine will
stop.
Action Check the electronic level sensor on the Pag
oil buffer tank 01 (M116) and the filter M113
and pump M114 for any defects. After the
fluid has dropped below the set point for High
level, press the “Reset station fault” button to
reset the fault.
IO SL46.7 (M116)
Parameter SF106_T = 2.0 [Sec.]
SF107 Low level in Pag oil tank 01 Caused by This alarm occurs if the supply level in the
buffer Pag oil tank 01 reaches the set point for
Low level and stays there for more than
SF107_T seconds.
Action Check the electronic level sensor on the Pag
oil buffer tank 01 (M116) and the filter M113
and pump M114 for any defects. After the
fluid is above the set point for Low level,
press the “Reset station fault” button to reset
the fault.
IO SL46.4 (M116)
Parameter SF107_T = 2.0 [Sec.]
SF108 Pag oil supply fault Caused by The supply pressure of Pag oil is too low to
perform a Pag oil filling process.
Action Check the supply pressure at gauge (mech.
pos. no. 120).
IO SP45.3 (M120)
Settings SF108_T = 5 [Sec.]
SF109 Pressure test supply fault Caused by The supply pressure of N2/helium is too low
to perform a pressure test.
Action Check the supply pressure at gauge (mech.
pos. no. 8).
IO SP45.2 (M8)
Settings SF109_T = 5 [Sec.]

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Fault Description

[Pump cabinet] SA1XX Station Fault

No. Name Description


SA101 R134a bottle 1 empty Caused by Bottle supply is selected and the R134a supply
pressure from bottle 1 is too low, i.e. bottle is
empty. The supply source is automatically
switched to bottle 2.
Action Change the bottle.
IO SP45.2 (M89)
Settings SA101_T = 5 [Sec.]
SA102 R134a bottle 2 empty Caused by The supply pressure of R134a is too low to
perform a charging when the R134a bottle
supply is selected.
Action Check the pressure gauge at mech. pos. no. 88
and change the bottle or change to main
supply. When switching the GTL pump off
and the main supply on, the bottle supply is re-
initialized.
IO SP45.2 (M89)
Settings SA102_T = 5 [Sec.]
SA103 LDS1000 Not ready Caused by The Leak detector has not reached ready state
within the time SA103_T.
Action Try to restart the leak detector.
IO LDS_Q1
Settings SA103_T = 30 [Sec.]

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Fault Description

[Recovery] SF1XX Station fault

No. Name Description


SF101 Level to high in buffer tank O1 Caused by The level of the refrigerant in the buffer tank
is above the limit for the “Hi Hi“ level.
Action Release the refrigerant in buffer tank O1 and
exchange the levelling sensor M53.
IO SL48.1 (M53)
Settings None
SF102 To high pressure on the high pressure Caused by The pressure is too high on the pressure side
side of the compressor of the compressor (P > 15 bar) to perform
recovery.
Action Test the compressor M58 and the pressure
switch M59. If necessary than exchange the
defect parts.
IO SP46.1 (M59)
Settings None

[Recovery] SA1XX Station alarm

No. Name Description


SA101 High level in buffer tank O1 Caused by The refrigerant in buffer tank O1 is above the
limit for the “Hi“ level.
Action Release the refrigerant tank O1 until the
refrigerant is below the high (“Hi”) level.
IO SL48.2 (M53)
Settings None
SA102 Pressure to high in buffer tank O1 Caused by The pressure of NGK gases in the buffer tank
O1 is too high (P > 9 bar).
Action Test the temperature compensated pressure
switch M65 and release the valve M64. If
necessary exchange the defect parts.
IO SP46.2 (M65)
Settings None

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Fault Description

[Arm] SF1XX Minor Station Fault

No. Name Description


SF101 Switch activated line stop Caused by This fault occurs when the arm has reached
the maximum position in forward direction.
Action Disconnect filling head from the car and move
arm away from line stop switch.
To reset the fault, press the “Reset station
fault” button.
IO KA1 (I/E47.1)
Settings None

[Arm] SA1XX Station Alarm

No. Name Description


SA101 Switch activated line alarm Caused by This fault occurs when the arm has reached
the switch for line alarm.
Action To reset the fault, please press the “Reset
station fault” button.
IO SL47.0
Settings None
SA102 Override line stop is active Caused by The switch for override line stop is activated
on the control board.
Action To remove this alarm, please turn the key off.
IO SA41.4
Settings None

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Line-side AC charging equipment

6. Specifications

Date: 16-04-2008
Rev: 00
Customer: Caterpillar do Brazil
Project: 24330

General data:
Placing: The equipment must be placed indoors
Ambient air temperature: 5-40°C
Atmospheric humidity: 30-90% (not condensing)
Transportation and storage: -25 to +55°C
Colour: RAL 7035
Electrical performance: According to IEC 204-1 or EN 60204-1
Article no.: 315-000037A

Power supply:
Power consumption Abt. 3,0 kVA
Supply voltage See marking on cabinet
Frequency See marking on cabinet

Dimensions: 800x1400x1650 mm
Weight: Ca. 290 kg

Pressure switch: IFM


Pos number 8
Type PN3003
Pressure range 0 to 25 bar
Max. pressure 25 bar
Connection DIG/PLC,

Pressure sensor: Ifm


Pos number 100
Type PA3023
Pressure range 0 to 25 bar
Max. pressure 25 bar
Connection AN/PLC, M12 plug
Output 4-20mA(2 wires)

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Line-side AC charging equipment

Pressure switch: Alco


Pos number 89
Type MDR-F16HG
Pressure range 1 to 16 bar
Max. pressure 36 bar
Connection DIG/PLC, HAN 3E

Vacuum sensor: Leybold


Pos number 102
Type DI 201
Range (abs.) 0,1 – 200 mbar
Max. overpressure 5 bar abs.
Connection AN/PLC,
Output 4-20mA(2 wires)

Air pressure switch: Festo


Pos 17
Type TN:527467
Range 0 to 10 bar
Max. pressure 10 bar
Connection DIG/PLC, M8 plug

Massflow: Rheonik
Pos 92
Type RHM4-GNT
Range 0,3-10 kg/min
Temperature range -20 - +120o
Max pressure 150 Bar
Connection NDC
Power 24VDC

Vacuum pump: Leybold


Pos 109
Type D16B
Supply voltage 3x380-420VAC/60Hz
Power 0,55 kW
Suction capacity 16 m3/hour
Connection HAN 6E
Power consumption 1,8A
Direction of rotation seen from fan site Anticlockwise

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Line-side AC charging equipment

Float: Wema
Pos 116
Type SS-F
Connection DIG/PLC, HAN 6E
Power 24VDC

Compressor unit: Danfoss


Pos 33
Type TL3GXT2
Supply voltage 1x220-240VAC/60Hz
Power 0,15Kw
Max. refrig. charges 600g R134a
Connection DIG/PLC, HAN 6E
Power consumption 0,9A

5/2 Valve Festo


Pos 34, 139
Type 15901MFH-5-1/4-B
Power 24V
Connection DIG/PLC

Thermostat Danfoss
Pos 47
Type RT 270
Temperature range -30-+40°C
Power consumption 24V
Connection DIG/PLC

Gear-Flow meter : Sika


Pos 121
Type VZ 0,2 AL-S
Flow rate 0-16 L/min
Pulses 4082/l
Connection CNT/PLC
Signal form Square wave pulse signal pnp
Supply voltage 12-30VDC

PAG oil pump: SHUR FLO


Pos 114
Type SUK 8000
Flow rate 4,5 L/min
Supply voltage 24 VDC
Power
Connection HAN 6E
Power consumption 0,6A

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Line-side AC charging equipment

Heater (Filling head): Acim Jouanin


Type HLP KE=1000mm
Power 24V/45W

Photo sensor (filling head parking): Sensick


Pos 140,141
Type WT 150 HGA
Connection DIG/PLC, M8
Supply voltage 24VDC

Switch (filling head balancer): Siemens


Type 3SE3120-1W
Connection DIG/PLC

Refrigeration inlet valve: Danfoss


Pos 91
Type 032F8095
Power 24VDC/20W

Refrigeration connection: Manual shut-off valve ½”


Allowable inlet pressure 14-20 bar
Inlet filter 10-15 micron

Compressed air connection: Manual shut-off valve ½”


Allowable inlet pressure 5-10 bar
Air consumption 500 Nl/min.
Max. oil consumption Non lubricated air

Ventilation connection: 1”

Please note:
Supply voltage and frequency in accordance with IEC 204-1 or EN 60204-1

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Line-side AC charging equipment

7. Mechanical drawings and parts lists, PI-diagram

7.1 Layout ........................................................................................................................... 35


7.2 Parts lists ....................................................................................................................... 36
7.3 PI-diagram .................................................................................................................... 37
7.4 Installation .................................................................................................................... 38

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Line-side AC charging equipment

7.1 Layout

7_Mechanical drawings & parts lists\315-110078A-00.pdf

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1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

G Matr. spec: Design: by: njn G


Changed: by:
Surface
treatment: Approved: by:
Title: Projection: Scale:
LS AC
Lay out
Caterpillar Brasil LTDA 24330 1:12

Item No.:
Drawing number:

315-110078A -
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.

1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: by njn


Changed: by
Surface
treatment: Approved: by
Title:
G LS AC G
Projection: Scale:
Lay out
Caterpillar Brasil LTDA 24330
Item No.:

Drawing number:

315-110078A
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
Line-side AC charging equipment

7.2 Parts lists

7_Mechanical drawings & parts lists\315-020070A-00.pdf

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AGRAMKOW Fluid Systems A/S Page 1
14-03-2008
Parts List 12:26:35

Item number Quantity Unit Position Item name Make Drawing No.
313-020123A 1,00 Pcs Option 4 helium / N2 tryktest 15 bar AGRAMKOW

313-020119A 1,00 Pcs Option 2 GTL Supply pump AGRAMKOW

313-020125A 1,00 Pcs Option 6, R134a changeover AGRAMKOW

068-5981251 1,00 Pcs 002 Sound absorber G1" MANNESMANN REXROTH A/S

276-3130110 1,00 Pcs 003 Connection manifold AGRAMKOW 313-100110A-03

066-4570020 1,00 Pcs 014 Coupling TEMA 1/2 TEMA

032-3211050 1,00 Pcs 017 Pressure switch 0-10 bar FESTO

068-3212450 1,00 Pcs 018 Shut-off valve 3/2 FESTO

068-3212401 1,00 Pcs 019 Compressed air filter FESTO

068-3212468 1,00 Pcs 026 Pressure regulator 0-7 bar FESTO

011-3215166 1,00 Pcs 027 Pressure gauge 0-10 bar FESTO

071-2040100 1,00 Pcs 085 Accumulator (membrane) HYDAC

276-3101898 1,00 Pcs 086 Manifold 2 std AGRAMKOW 310-101898A-01

066-7750148 1,00 Pcs 087 Sch.valve A-31484 REFCO

011-7040005 1,00 Pcs 088 Pressure gauge -1 -29 bar WIKA

032-3180004 1,00 Pcs 089 Pressure control MDR-F16HG ALCO CONTROLS

067-4160280 1,00 Pcs 090 Safety valve, 28 bar HANSA

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech.Parts LS AC 24330 Caterpi 315-020070A mkl 29-01-2008 00021529 NJN 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 2
14-03-2008
Parts List 12:26:35

Item number Quantity Unit Position Item name Make Drawing No.
036-2110045 1,00 Pcs 091 Solenoid valve EVR 10 DANFOSS A/S

146-7531005 1,00 Pcs 092 Sensor for Massflow RHEONIK

066-7750148 1,00 Pcs 093 Sch.valve A-31484 REFCO

066-7100102 1,00 Pcs 095 Hansen coupling, 2-H16-118 HANSEN COUPLING

310-011026A 1,00 Pcs 096 Harting connection AGRAMKOW

066-7101042 1,00 Pcs 098 Coupling nipple B3 T21-3/8 FPT HANSEN COUPLING

032-5993023 1,00 Pcs 100 Pressure sensor -25 bar IFM

036-0902870 1,00 Pcs 101 Angle-seat valve 1/2" type 2002 BÜRKERT

146-5799050 1,00 Pcs 102 Vacuum sensor DI 201 LEYBOLD

036-0902870 1,00 Pcs 103 Angle-seat valve 1/2" type 2002 BÜRKERT

036-0902870 1,00 Pcs 104 Angle-seat valve 1/2" type 2002 BÜRKERT

276-3100179 1,00 Pcs 105 Vac./test manifold AGRAMKOW 310-100211A-05

066-7750148 1,00 Pcs 106 Sch.valve A-31484 REFCO

067-7793020 1,00 Pcs 107 Ego ball valve 3/8" ENOLGAS

068-5981610 1,00 Pcs 108 Exhaust filter AMC 610-10 SMC PNEUMATIC A/S

210-5790266 1,00 Pcs 109 Leybold pump D16B LEYBOLD

038-7740300 1,00 Pcs 140 Sensor Sick WT150-P460 SICK A/S

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech.Parts LS AC 24330 Caterpi 315-020070A mkl 29-01-2008 00021529 NJN 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 3
14-03-2008
Parts List 12:26:35

Item number Quantity Unit Position Item name Make Drawing No.
038-7740300 1,00 Pcs 141 Sensor Sick WT150-P460 SICK A/S

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Mech.Parts LS AC 24330 Caterpi 315-020070A mkl 29-01-2008 00021529 NJN 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 4
14-03-2008
Parts List 12:26:35

Item number Quantity Unit Position Item name Make Drawing No.
315-120003A 1,00 Pcs PI-diagram AGRAMKOW

315-120004A 1,00 Pcs Line side AC standard 2 AGRAMKOW

067-3883070 1,00 Pcs 001 He Pressure regulator 1-16 Bar AHL

069-2250195 1,00 Pcs 006 Filter NUPRO

067-4160280 1,00 Pcs 007 Safety valve, 28 bar HANSA

032-5997025 1,00 Pcs 008 Pressostat 0-25 bar IFM

068-3880012 1,00 Pcs 009 H2,N2,CO2 pressure regulator AIR LIQUIDE

036-0902870 1,00 Pcs 099 Angle-seat valve 1/2" type 2002 BÜRKERT

067-0189122 1,00 Pcs 128 Throttle valve 1/2" FT257/2 ZENTGRAF

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Option 4 helium / N2 tryktest 313-020123A mkl 20-12-2007 01 00013469 SJU 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 5
14-03-2008
Parts List 12:26:35

Item number Quantity Unit Position Item name Make Drawing No.
068-3212468 1,00 Pcs 022 Pressure regulator 0-7 bar FESTO

011-3215166 1,00 Pcs 023 Pressure gauge 0-10 bar FESTO

062-0001055 1,00 Pcs 030 Bottle connection EV METALVÆRK

062-0001056 1,00 Pcs 030 ICI bottle connection 5/8" EV METALVÆRK

066-7100103 1,00 Pcs 031 Hansen coupling, 3HK HANSEN COUPLING

201-2112312 1,00 Pcs 033 Compressor unit TL3GXT2 DANFOSS A/S

036-3212699 1,00 Pcs 034 Solenoid valve 5/2 FESTO

068-3210044 1,00 Pcs 035 Quick bleeder 1/4" x 1/4" FESTO

068-3210044 1,00 Pcs 036 Quick bleeder 1/4" x 1/4" FESTO

275-5370110 1,00 Pcs 037 Pump module GTL AGRAMKOW

069-2110150 1,00 Pcs 038 Filter drier DANFOSS A/S

011-2117034 1,00 Pcs 039 Sight glass SGL 6S DANFOSS A/S

067-2111030 1,00 Pcs 040 Exp. valve TN2 -134a 068-3346 DANFOSS A/S

067-7793030 1,00 Pcs 041 Ball valve 3/4" ENOLGAS

069-8830165 1,00 Pcs 042 Filter 165F KENMORE

066-7750130 1,00 Pcs 043 Sch. valve A-3148 REFCO

067-3253186 1,00 Pcs 045 Ball valve AISI 3/4" RG AGRAMKOW

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Option 2 GTL Supply pump 313-020119A SJU 16-06-2006 01 00012320 SJU 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 6
14-03-2008
Parts List 12:26:35

Item number Quantity Unit Position Item name Make Drawing No.
276-5000197 1,00 Pcs 046 Manifold AGRAMKOW 500-100197A-03

031-2111031 1,00 Pcs 047 Diff. Thermostat RT270 DANFOSS A/S

287-0000018 0,00 Pcs reservedel Set of gasket incl piston rod

071-8837011 1,00 Pcs 144 Absorb accumulator KENMORE

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Option 2 GTL Supply pump 313-020119A SJU 16-06-2006 01 00012320 SJU 24330 Caterpillar Bra EUR
AGRAMKOW Fluid Systems A/S Page 7
14-03-2008
Parts List 12:26:35

Item number Quantity Unit Position Item name Make Drawing No.
066-7100153 1,00 Pcs 028 Male connector, 3-K21-118 HANSEN COUPLING

066-7100103 1,00 Pcs 029 Hansen coupling, 3HK HANSEN COUPLING

067-3253907 1,00 Pcs 032 Ball valve 3-way 3/4" return BEE

Name Item number Init. Last edited Rev. BOM Approved by Project Customer Currency
Option 6, R134a changeover 313-020125A SJU 16-06-2006 01 00013195 BLP 24330 Caterpillar Bra EUR
Line-side AC charging equipment

7.3 PI-diagram

7_Mechanical drawings & parts lists\315-120046A-00.pdf

\\AGSERVER\Data\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\Manual 315-400028A-00.doc


37
Line-side AC charging equipment

7.4 Installation

7_Mechanical drawings & parts lists\315-340009A-00.pdf

\\AGSERVER\Data\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\Manual 315-400028A-00.doc


38
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Matr. spec: Design: 21-03-2006 by MKL


Changed: by
Surface
treatment: Approved:12-03-2008 by MKL
Title:
G Installation layout G
Projection: Scale:
LS Aircon with change over
Caterpilar 24330
Item No.:

Drawing number:

315-340009A 00
H H
DK-6400 Sonderborg, Denmark File and pathname:

CONFIDENTIAL: Property of AGRAMKOW A/S, DENMARK. Not to be handet over to, copied or used by
third party. Two- or three dimensional reproduction of contents to be authorized by AGRAMKOW A/S.
1 2 3 4 5 6 7 8 9 10 11 12
Line-side AC charging equipment

8. Electrical drawings and parts lists

315-200022A

\\AGSERVER\Data\AUTO\PROJECT\Caterpillar\24330 LS Aircon, PAG, Plis\Ekstern dokumentation\LS AC\Manual 315-400028A-00.doc


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Line-side AC charging equipment

9. Trouble shooting

Caution

Out of consideration for the safety as well as the environment, no component in the station
must be demounted before all circuits are without pressure and have been emptied. The
station is equipped with draining nipples marked XH.

After the mounting, air bubbles must be eliminated from the circuit by repeated charging,
normally 5,000 g.

Contents

• Regular vacuum faults, i.e. every second or third vehicle


• Vacuum fault at every charging process
• SF102: Massflow fault
• SA001: Battery fault

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Line-side AC charging equipment

S = Symptom, H = Handling, R = Repair

S: Regular vacuum fault, i.e. every second or third vehicle


H: Repeat the process on the same vehicle once or twice. If the fault indication disappears,
the A/C system of the vehicle is moist.

R: Check the gaskets of the A/C components.

Extend the vacuum time of the first evacuation.

Raise the setting of the vacuum leak level.

S: Vacuum fault at every charging process.


H1: Check the O-ring of the SAE coupling.

R1: Replace the O-ring or the whole coupling, if necessary.

H2: Connect the vacuum gauge to the pneuadapter. Do the evacuation step in manual
position. The pressure gauge must indicate < 1 mbar.

R2: If the pressure gauge indicates 1 mbar or more, check the vacuum pump when the
pressure gauge is placed directly onto the pump, without any other connection. If the
pressure gauge does still not indicate < 1 mbar, the vacuum oil must be changed. If this
does not solve the problem either, the whole vacuum pump must be replaced.

H3: Run the process in automatic mode with a pressure gauge placed onto the pneuadapter,
and switch to manual mode in the step ‘Vacuum test’. Now wait 10-15 seconds, and
then the pressure gauge and the electronic vacuum gauge must show the same value (if
the symptom corresponds to R3 b, see below, the pressure gauge is not necessary).

R3: a) The pressure gauge and the electronic vacuum gauge do not indicate the same
value. Replace the electronic vacuum gauge. Please note the vacuum sensor and
the electronics have been calibrated together, which means both the sensor and
the electronics must be replaced.
b) The vacuum level increases slowly. The reasons could be:
1. The charging valve in the pneuadapter does not close correctly. This can be
checked as follows: Let the station remain in the position ‘READY’ for five
minutes and then open the SAE coupling manually. The pneuadapter must not
activate the end switch in the parking position! If there is a ‘puf’ due to
overpressure, the valve does not close easily. Demount the valve and replace the
valve, see spare parts.

2. The vacuum system is not completely tight. This fault occurs normally only when
components are being replaced. Check all connections and, if necessary, tighten
up.

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Line-side AC charging equipment

SF102: Massflow fault


Occurs, when the flow speed is too high, typically in connection with gas pockets. During
normal operation, there are normally no gas pockets, however, if this should happen, please
contact AGRAMKOW.

Gas pockets can be formed in connection with demounting/draining of components in the


charging circuit, therefore at least 5,000 g must be charged in order to remove the pockets.

Specifications of the devices for trouble-shooting

Pressure gauge for vacuum measurement


Must correspond to the range of measurement of the electronic vacuum gauge, i.e. 1-100 mbar
absolute with an accuracy of class 0.25.

Scale for check of charging amount:


Range of measurement: max. charging amount + test bottle with an accuracy of ±0.5 g.

Please note the test bottle is evacuated before the charging process, and the weight when
empty (tare) must be inserted.

SA001: Battery low


Replace the battery.

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10. Suppliers’ manuals list

1 Alco 10_Suppliers´ manuals\Pressure switch FF4.PDF


2 Danfoss 10_Suppliers´ manuals\Pressure controls (switches), type RT.pdf
3 Danfoss 10_Suppliers´ manuals\Solenoid valves_type EVR 2-40.pdf
4 Festo 10_Suppliers´ manuals\SDE5 Pressure and vacuum switch.pdf
5 Festo 10_Suppliers´ manuals\Solenoid.pneumatic valves_TIGER2000.pdf
6 Ifm 10_Suppliers´ manuals\Electronic pressure sensor PN30xx.pdf
7 Ifm 10_Suppliers´ manuals\Electronic pressure sensor PN5_PE5.pdf
8 Leybold 10_Suppliers´ manuals\Gauge head DI 200_DI 201_DI 2000.pdf
9 Leybold 10_Suppliers´ manuals\Rotary vane vacuum pump SD 16_25B.pdf
10 Rheonik 10_Suppliers´ manuals\Coriolis Mass Flowmeter RHM 04.pdf
11 Sick 10_Suppliers´ manuals\Miniature photoelectric switch W150.pdf
12 Sika 10_Suppliers´ manuals\Positive Displacement Flow Sensor VZ.pdf
13 Wema 10_Suppliers´ manuals\Wema SS-F4 420mm a.pdf

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