Professional Documents
Culture Documents
Clima 6000 Plus MA8501-53-0 - GB
Clima 6000 Plus MA8501-53-0 - GB
CAP. 1 - CONTENTS
CAP. 1 - CONTENTS .............................................................. 2
CAP. 2 - GENERAL INSTRUCTIONS ......................................... 4
2.1 GENERAL NOTES .............................................................4
2.2 GENERAL INSTRUCTIONS .................................................4
2.3 MANUFACTURER IDENTIFICATION .....................................4
2.4 WARRANTY.....................................................................5
2.5 TECHNICAL SERVICE CENTERS .........................................6
2.5.1 Repairs....................................................................6
2.6 MARKING ........................................................................6
CAP. 3 - SAFETY CONDITIONS ............................................... 7
3.1 PERSONAL SAFETY INFORMATION ....................................7
3.1.1 Definitions................................................................7
3.1.2 Personal safety information ........................................7
3.1.3 Precautions For Operators Safety...............................8
3.2 IMPORTANT INFORMATION ON TOOL SAFETY ..................13
3.3 SAFETY DEVICES ...........................................................13
CAP. 4 - LAYOUT OF THE MANUAL ...................................... 14
4.1 USE OF THE MANUAL.....................................................14
4.2 SYMBOLS .....................................................................14
4.2.1 Safety ...................................................................15
4.3 GLOSSARY....................................................................16
4.4 GUIDELINES FOR THE HANDLING OF REFRIGERANT...........17
4.4.1 Precautions for refrigerant storage ...........................17
4.4.2 Conditions of refrigerant and system .........................17
4.4.3 Recycling capacity ...................................................17
CAP. 5 - GENERAL DESCRIPTION ......................................... 18
5.1 EXTERNAL VIEW OF 6000 PLUS - FRONT SIDE ..................18
5.2 INTERNAL VIEW OF 6000 PLUS - FRONT SIDE ...................19
5.3 6000 PLUS RIGHT SIDE VIEW ..........................................19
5.4 6000 PLUS RIGHT SIDE VIEW ..........................................20
5.5 6000 PLUS TOP FRONT VIEW .........................................20
5.6 USER INTERFACE...........................................................21
5.7 ECO LOCK® QUICK COUPLERS ........................................22
5.8 INCLUDED ACCESSORIES ...............................................22
5.9 OPTIONAL ACCESSORIES ...............................................22
CAP. 6 - TECHNICAL FEATURES........................................... 23
CAP. 7 - INSTALLATION ....................................................... 25
7.1 EQUIPMENT INSTALLATION.............................................25
7.1.1 Unpacking 6000 PLUS ............................................25
7.2 DURING USE..................................................................25
7.3 WHEN THE TOOL IS NOT USED ........................................25
7.4 CLEANING – DISMANTLING AND DISPOSAL.......................25
CAP. 8 - COMMISSIONING ................................................... 27
8.1 CONNECTIONS ..............................................................27
8.1.1 Positioning and hookup.............................................27
8.2 FIRST TANK FILLING .......................................................29
8.3 NEW OIL BOTTLE FILLING ................................................30
CAP. 9 - SETUP ................................................................... 31
CAP. 10 - A/C SYSTEM RECHARGE ...................................... 33
10.1 PRELIMINARY OPERATIONS ........................................33
Pressure equipment undergoes checks before commissioning and periodical checks during
operation in compliance with rules and law provisions in force in the country where the tool is
used.
The operator shall be responsible for the UNIT use in compliance with rules in force in their
country.
The UNIT is a tool designed for recovery and recycling of R134a refrigerant of A/C systems of
cars.
This unit is to be used exclusively by duly trained operators having a good knowledge on cooling,
cooling systems, refrigerants and possible damages caused by pressure equipment.
To correctly and safely use the unit it is necessary for the user to carefully read this manual.
The user shall not be entitled to open the Unit since maintenance operations are reserved to the
authorised service centre.
2.4 WARRANTY
DEFINITION
The warranty provides for free replacement or repair of faulty components due to fabrication.
APPLICATION
The following warranty conditions are inclusive and substitute and legal guarantees in relation to
failures of conformity, and exclude any other liability of the manufacturer and reseller in relation
to the product. The purchaser may not make any claim other than those envisaged in these
warranty conditions, for damages, reduced price or cancellation of the contract. Once the
warranty has expired, no claims may be made against the reseller or manufacturer.
WARRANTY PERIOD
- 12 (twelve) months from the date of online activation by the reseller.
- 6 (six) months for replacement parts
EXCLUSIONS
This warranty is provided on condition of full payment of the purchase price and the purchaser
may not make claim under it if he has suspended payments for any reason whatever. The
warranty does not cover parts found to be defective for reasons of:
The warranty does not cover any work done to install and hook up the equipment to its power
supplies and feeds.
The warranty is void in all cases of improper use and failure to run the scheduled maintenance
detailed in the manual. Brain Bee S.p.A. accepts no responsibility for any damage deriving from
the non respect of the prescriptions indicated in the instructions and in particular those
concerning the tool installation, use and maintenance.
2.5.1 Repairs
In case of failures or anomalies, the user can contact directly or through his own regional
reseller a Brain Bee S.p.A authorised service centre to get help.
2.6 MARKING
The 6000 PLUS equipment has been manufactured in compliance with the Community Directives
listed in the Declaration of Conformity supplied with the pressure equipment.
The equipment falls in the PED risk category II (97/23/EC).
Pressure equipment shall undergo checks before commissioning and periodical checks during
operation, in compliance with the rules and law provisions in force in the country where the
equipment is used.
The characteristic data of the equipment are indicated on the specific data plate applied onto the
equipment side part.
It is prohibited to remove damage or tamper with the equipment “data plate”.
NAMEPLATE
Fac-Simile
CE MARKING: The CE declaration is enclosed to the tool. Store correctly and provide on request.
3.1.1 Definitions
DANGEROUS AREAS:
Any area within or close to the equipment implying risk for the safety and health of exposed
persons.
EXPOSED PERSON:
Any person completely or partially standing in a dangerous area.
OPERATOR:
The person/s in charge of operating the appliance for the set purpose.
CLASSIFICATION OF OPERATORS
The operator can be classified according to two main categories, which, in some cases, refer to
one single person:
• The operator charged with the equipment operation has the duty to:
o Start and check the machine automatic operation;
o Carry out simple setting operations;
o Remove the causes of equipment stop not implying breakings of members but
simple operation anomalies.
• The operator charged with the machine maintenance is a qualified technician who can
intervene on the machine, with guards open, and on mechanic and electrical members to
carry out setting, maintenance and repair operations.
USER
Body or person legally responsible for the equipment.
PERSONAL SAFETY: Use coolant R134a only. The mixture with other types of coolant causes sever
damage to the A/C and cooling systems and to the service equipment. It is advisable to wear
suitable protections such as goggles, gloves and protective clothing, the contact with the coolant
may cause blindness and other body injuries to the operator. Avoid the contact with skin; the low
boiling temperature (about –30 °C) may cause burns. Avoid inhaling of the coolant fumes. Do
not expose it to the direct sunbeams and rain. Use the station in ventilated rooms. Do not smoke
near the station and during the operations. Use the station clear of heat sources, open flames
and/or sparks. Further medical and safety information may be obtained from the lubricants and
coolants producers.
6000 PLUS SAFETY: Before carrying out connections between the unit and a A/C system or
external tank, be sure that all the valves are closed. Before disconnecting the unit, be sure that
the phase is completed and all the valves are closed so that the coolant is not dispersed in the
atmosphere. Do not change the calibration of the safety valves and control systems. Do not use
external tanks or other storage containers that are not homologated or without safety valves. Do
not leave the unit live unless it is used in the near future; cut off the power supply before a long
period of inactivity of the unit. The unit shall have to be always attended. The unit shall have not
to be used in an explosion-risk environment.
REFRIGERANT: The car service equipment and A/C systems containing R134a should not be
tested using compressed air. Some mixtures of air and HCF 134a showed to be inflammable at
high pressures. These mixtures are potentially dangerous and can cause risk of fire and explosion
therefore causing damages to people, animals and property. Check on the vehicle or on the
documents provided by the car manufacturer the type of coolant used by the A/C system.
WORKING ENVIRONMENT: The unit must operate in open places or rooms with a good
ventilation (at least 4 changes of air per hour).
Work away from open flames and hot surfaces; the coolant breaks down at high temperatures
releasing toxic and aggressive substances which are harmful to both the operator and the
environment.
Avoid inhaling the system coolants and oils. The exposure can irritate eyes and the respiratory
tract.
The tool has not to be used in explosion risk environments (potentially explosive atmospheres).
STOP FOR LONG PERIOD: Store the equipment in a safe place, disconnected from the mains,
away from excessive temperatures, humidity and the risk of damaging impact.
Contact the Technical Service for equipment stop and securing, empting and recycling of R134a
gas, in compliance with the laws in force in the country where the equipment has been
commissioned.
TRANSPORT: Contact the Technical Service for empting and recycling of R134a gas, in
compliance with the laws in force in the country where the equipment has been commissioned, as
well as for locking of the load cell of the inner vessel (gas vessel).
GENERAL PRECAUTIONS
• All the operators shall not be under the effect of tranquillizers, drugs or alcohol when
performing their job
• Before starting their job, operators shall be perfectly aware of the position and operation
of all the controls of the equipment and of the user manual content.
• Always pay attention to any danger sign affixed on the installation and within the
company of the user.
• The employer is responsible for the spreading of this document to the whole personnel
that is going to work on the equipment.
• Besides the obligation to strictly comply with the instructions contained in this manual, the
operators shall inform their heads on any deficiency or potentially dangerous situation
that might occur.
• In case of equipment malfunctioning, check the procedures outlined in the various
chapters.
• Always refer to the safety standards adopted by the company employing the equipment
with a view to avoiding useless risks.
ATTENTION: for HAZARDS related to handling, use and storage of R134a gas and PAG/POE oils
of vehicle A/C systems, you shall ask your refrigerant supplier for the technical and safety data
sheets and comply with the requirements included therein.
In general, refrigerant fluids may cause ASPHYXIA, FROSTBITE, BURNS, ARRHYTHMIA (irregular
heart activity) and even DEATH.
Refrigerant gases within the vessel are stored in liquefied and pressurized form, IF WARMED UP,
THEY MAY EXPLODE /CATCH FIRE. Always use the equipment within the temperature range
identified on the CLIMA station data plate.
ENSURE SUITABLE VENTILATION OF WORKING PREMISES; do not use in areas with or close to
pits (ex. Vehicle service pits), excavations, sewers, cellars;
any outflow /leaks of R134a gas (heavier than air) may lead to hazardous concentrations and
reduce the amount of oxygen (cause of asphyxia).
PPE (Personal Protective Equipment): use GOGGLES /EYESHADE, GLOVES AND PROTECTIVE
CLOTHING specifically suitable for R134a and the additional PPE required by the safety data
sheet of the gas manufacturer.
DURING THE ACTIVITIES WITH THE CLIMA STATION, SMOKING AND APPROACHING
WITH/TO OPEN FLAMES, SPARKS AND HEAT SOURCES IS ABSOLUTELY FORBIDDEN.
RISK OF ASPHYXIA
REFRIGERANT GAS
High concentrations of refrigerant gases may cause asphyxia, they are heavier than air and may
cause suffocation by reducing the oxygen available for breathing. The requirements stated in the
safety data sheet of the manufacturer of the refrigerant being used shall compulsorily be read
and complied with.
GASOLINE ENGINES
Exhaust gases of gasoline vehicles contain carbon monoxide, a colourless and odourless gas
which, if inhaled, can cause serious physical problems.
Special attention is always required when working within pits, as exhaust gases components are
heavier than air and consequently deposit on the bottom of the pit.
DIESEL ENGINES
Diesel engine exhaust gas composition is not always the same. It can change according to: type
of engine, intake, conditions of use and fuel composition.
Diesel exhaust is made up of gases (CO, CO2, NOX and HC) and particulate (soot, sulphates,
etc.); the small particles of carbon making up soot remain suspended in the air and can thus be
breathed. Toxic components, albeit in small quantities, are present as well.
SAFETY MEASURES:
Always ensure good ventilation and air aspiration (especially in the pits).
In closed premises, always start the exhaust gas aspiration system.
When carrying out operations on the fuel system (injectors, fuel and gasoline pump, etc.) there is
risk of fire or explosion due to the fuels employed and/or vapours formed by them.
SAFETY MEASURES:
Disable start.
Let the engine cool down.
Do not use free flames or sparks sources.
Do not smoke.
Collect the outflowing fuel.
Start the aspiration units in closed premises.
Civil or industrial electric power distributions, as well as vehicles electric systems, do imply
dangerous voltages. When an operator is in contact with testing tools or live parts of the engine,
risk of electrocution exists. For instance, this might be caused by cables with damaged insulation
(ex. Bites of animals on power cords).
This is especially true of the vehicle starting system and testing tools connections.
SAFETY MEASURES:
Connect the testing tools to an electric socket safety relay and correctly grounded.
For the testing tool connection, use exclusively the cables provided with the tool itself, making
sure insulation is not damaged.
Make sure the testing tool is grounded before turning it on.
When carrying out interventions on the electrical system of a vehicle (connection of testing tool,
replacement of starting system parts), supply voltage shall be unplugged (ex. battery).
During checks and setting operations with the engine turned on, attention shall be paid to avoid
touching those vehicle live components (for instance the starting system) without the suitable
precautions (for instance insulating gloves).
RISK OF BURN
When intervening on the engine, protect face, hands and feet with suitable protective devices,
avoid contact with hot surfaces, such as sparking plugs, radiators, pipings of the cooling system
and electromechanic sensors. Catalytic mufflers reach extremely high temperatures and can
cause burns or fires.
Attentions shall thus be paid to avoid touching these objects without suitable precautions.
SAFETY MEASURES:
Wear protective gloves.
Let cool down the engine and other independent accessories, if any.
Do not install testing tools connection cables over or close to hot parts
Do not keep the engine turned on once checks have been completed.
RISK OF INTOXICATION
The pipes that are used for exhaust gases sampling if subject to high temperatures (exceeding
250 °C or due to fires) release a highly toxic gas which, in case of inhalation, can be harmful for
health.
SAFETY MEASURES:
In case of inhalation, immediately contact a doctor.
To remove combustion residues wear neoprene or PVC gloves.
Fire residues can be neutralized with a calcium hydroxide solution. This leads to the formation of
calcium fluoride that can be removed with water.
ELECTRICAL CONTACTS: Never allow the positive and negative terminals of the battery to be
connected by metal parts. In particular, contact with quick couplers of the CLIMA station or other
tools or metal personal objects shall be avoided.
In case of contact and short-circuit a significant quantity of current might flow through the metal,
thus leading to the risk of battery explosion, heat emission, smoke emission and fire, as well as
burning of the metal object connecting the two terminals, with emission and projection of
splinters and hazardous chemicals.
CONTACT WITH FLUIDS: Never allow for fluids used for the CLIMA station to be in contact with
the vehicle battery, Such fluids might damage the battery and cause hazards for the operator.
INTERNAL FLUID: In case the batteries fluid comes in contact with your eyes, do not rub them.
Rinse with tap water and then see a doctor immediately. In case the fluid is not completely
removed, this can seriously damage the eyes.
DISASSEMBLY: Never try to disassemble the batteries container or to modify it. The container has
safety and protective devices ensuring safe operations. By damaging these devices, there is the
risk of heat emissions, smoke emission, fluids leak, batteries container explosion and fire.
During measurements on the vehicle, noise levels can exceed 90dB. Such noise levels can be
reached with ultrasonic cleaning or with the vehicle’s engine high rpm.
If a person is exposed to such noise sources for a long period of time, this can cause irreversible
hearing damage.
SAFETY MEASURES:
The operator shall adopt personal protective equipment (safety ear muffs).
The operator shall also protect from noise the working stations close to the areas where
test on the vehicle.
RISK OF INJURY
Engines, both working and in standstill, include moving parts (belts or other parts) which might
injure hands and arms. In the vehicles, the cooling fan starts automatically by means of a
temperature sensor even when the engine is off; always pay attention when operating close to it
and disconnect it if needed.
SAFETY MEASURES:
When the engine is turned on, do not put hands into the moving parts area.
When operating close to electrically started fans, let the engine cool down beforehand
and then remove the fan plug from the engine.
Keep the testing tools connection cables far from the engine moving parts.
RISK OF SMASHING
If the vehicles are not correctly secured by means of mechanic devices, the operator might get
smashed against a working bench or against a wall. Even the equipment placed on unstable
supports might fall and squash the operator’s limbs.
SAFETY MEASURES:
Make sure the vehicle has been secured by pulling the hand brake and locking the
wheels.
Make sure the equipment has been positioned on a stable support and, in case of trolley,
that its wheels have been locked before use.
When using the tool, the following operations are not allowed as they might cause, under certain
circumstances, danger for persons and cause permanent damage to the tool itself.
- Do not remove or make unreadable labels, signs and/or dangers signs placed
on the tool and in the area nearby.
- Non authorized personnel must not open the equipment. Within the tool there
are parts that, if touched, can cause electrocution: power off before opening the
tool to carry out repair operations.
OVERPRESSURE VALVES: they intervene when the pressure inside the system
reaches an excessive level.
CIRCUIT BREAKER: It allows the safety sectioning of the electric line for the
maintenance interventions and emergency stop
Should any of the above-mentioned safety rules not be observed, every type of warranty on the
station shall lapse.
• This manual is aimed at providing the user with all the information required for a correct
use of the equipment and to enable the user to manage it in the safest and most
independent way.
• It includes information concerning the technical side, operation, machine stop,
maintenance, spare parts and safety.
• Before carrying out any operation on the equipment, operators and qualified technicians
shall carefully read the instructions outlined in this manual.
• In case of doubts on the correct interpretation of the instructions, please contact our
technical service to obtain the required clarifications.
This manual is integral part of the equipment; the purchaser shall keep it with
the utmost care; it shall be placed closed to the equipment, within a specific
container and, above all, it shall be protected from anything that might
jeopardize its readability
• This manual shall accompany the equipment in case this is passed on to a new user.
• The content of this manual has been drawn up in compliance with the guide lines of the
UNI standard 10893:2000.
• Diffusion, modification or use of this manual for own aims is forbidden.
• When drawing up the manual, few but clear warning symbols have been selected for an
easier and simpler consultation.
Operations which are potentially hazardous for the operator are highlighted
with this symbol.
Such operations can cause serious injury.
4.2 SYMBOLS
This paragraph describes the safety symbols which may be posted on the service equipment's
housing.
4.2.1 Safety
ALTERNATING CURRENT
SAFETY GROUNDING
4.3 GLOSSARY
To make the reading of this manual easier, we have prepared the list of most important technical
terms used in the manual.
Refrigerant: Refrigerant fluid used in advanced motor vehicle A/C systems. The refrigerant used
by the station is R134a (CH2FCF3), chemical name: 1,1,1,2-tetrafluoroethane.
Unit: 6000 PLUS equipment for the recharge of car A/C systems.
Recovery: Removal of refrigerant under any condition from a tool and charge of refrigerant into
a bottle external to the A/C system without any refrigerant analysis or treatment.
Recycling: Reduction of contaminants from used refrigerants by means of oil separation, removal
of non condensable gases and single or multiple passage through elements allowing reduction
of humidity, acidity, and particulates.
Disposal: removal of refrigerant aimed at storage for the next distribution or at delivery to
disposal centres.
Vacuum: Draining of non condensable gases and humidity from and A/C system by means of a
vacuum pump.
Oil injection: Injection of oil into the A/C system to restore the correct amount indicated y the
manufacturer.
Charge: Charge of refrigerant inside the A/C system as per indication of the manufacturer.
Non condensable gases: Vapor phase air accumulation in the refrigerant drawn from A/C
systems or bottles.
ATTENTION: For handling, use and storage of Refrigerant R134a, ask the
refrigerant supplier for the technical and safety data sheets and comply with
their requirements.
Fac-Simile
The condition of the refrigerant is critical to the operation of the vehicle's A/C system. Running
repairs properly following failure of damage safeguards the quality of the refrigerant itself
(particulates, acids and water).
Filtering systems of the recycling unit have to be replaced regularly to preserve the recycling
equipment performance.
2
3
7
10
4
5
9
6
4. Dryer filter
5. Compressor
6. Vacuum pump
7. Distiller
8. Oil separator
9. Ventilated condenser
10. Refrigerant vessel
11
12
13
DO NOT USE THE STATION WHEN (HP – LP) CHARGE HOSES ARE
DISCONNECTED
5.4 6000 PLUS RIGHT SIDE VIEW
15
14
14. Main switch and connector for 2.5 m mains cable with shuko plug
15. Tool programming connector
16 20
17
18
19
21
16. LP Gauge
17. Graphic Display
18. HP Gauge
19. Multifunction Keyboard
20. Inner refrigerant bottle gauge
21. Pre-arranged for Thermal Printer (option)
The selection menu has a tree structure where different functions can be selected through a 6-key
keypad.
Details for the user are displayed on an alphanumerical LCD display having 4 lines of 20-digit
each.
The first line shows the menu title, while the lines below show the operations available for that
menu: the selected function flashes.
Key functions:
“STOP\EXIT” key : if pressed once within the menu it cancels the operation; by holding it
down for more than 1s the system exits the database and goes back to the initial page
“START” key : if pressed once within the menu it confirms the operation; by holding it down
for more than 1s from the first level of the menu the system goes back to the database
Besides accessories already mounted on the UNIT , the standard set of accessories includes
You can ask your Reseller or sales partner for the other optional accessories available, such as:
• NITROGEN LEAK TEST KIT - Kit for per leak test (under pressure conditions) with nitrogen
(pressure reducer and cylinder not supplied)
• HYBRID PRO KIT - Kit for cleaning of the station pneumatic circuit in case POE oil for
hybrid vehicles is used
• CLIMA PRINTER KIT – 24-column thermal printer (option) for report printing
• New oil containers (it is recommended to buy one for every different type of oil to be
used)
• UV leak detection kit (UV kit)
• Degreasing detergent, to remove fluorescent tracer residues (Spray multinet)
• Degreasing detergent for condenser (Condenser cleaner)
• Flushing kit
• Car A/C system sanitary spray
• Cabin sanitary agent spray
• Management software for A/C stations (Clima Solutions) and memory mobile device
(ACU) that allows the data transfer from the CLIMA appliance to the management
software for A4 report printing and annual balance management for gas
charge/discharge (ref. Reg. EC 842/2006).
CAP. 7 - INSTALLATION
7.1 EQUIPMENT INSTALLATION
Remove the unit from the pallet constituting the base of the packing.
The unit is handled by means of four wheels; the two smaller wheels have brakes.
RISK OF OVERTURNING
EQUIPMENT USE: The use of the equipment is clearly described in this manual:
anything differing from what is explicitly stated is to be considered as IMPROPER
USE. The manufacturer disclaims all responsibility for damage to objects,
persons or to the machine itself resulting from accidents caused by non
compliance with the equipment instructions.
WORK STATION: The operator shall stand in front of the machine, in a
comfortable position to reach the equipment controls and parts.
SUPPLY VOLTAGE: Disable all the supply switches and power off when the
equipment is not used for a long period of time.
PROTECTION: If the equipment is not used for a long period of time, it is
advisable cover it with a protective sheet.
CLEANING: the power supply unit cleaning can be performed even by unskilled
personnel provided they have been previously informed about the main controls
to cut the power supply unit from the mains. When the outer surfaces need to be
cleaned, avoid using detergents containing alcohol, ammonia or gasoline; only
use neutral detergents with slightly moistened soft cloths.
DISMANTLING AND DISPOSAL: The product was designed and assembled with
high quality materials and components that may be recycled and reused.
If one product displays a symbol showing a bin with wheels barred by an “X”,
this means that the product meets the requirements of the Community Directive
2002/96/EC.
For the disposal no particular devices are needed since the power supply unit is
not made with noxious materials.
The disposal shall have to be carried out by complying with the local regulations
for the disposal of waste: do not throw the product into the ordinary domestic
waste but bring it to the special collection centres present over the territory
according to what is provided for by the current regulations in force.
At the end of the equipment working life the following operations shall be
carried out:
• Ask the service department to recover the whole gas in the unit circuit, by
making sure that the gas storage internal tank is completely emptied.
COOLANT AND LUBRICANTS: The coolants recovered from the systems that
cannot be used again must be delivered to the gas suppliers for their necessary
disposal.
The lubricants taken from the systems must be delivered to the exhausted oil
collecting centres.
CAP. 8 - COMMISSIONING
8.1 CONNECTIONS
The unit has to be taken near the car A/C system and positioned on a horizontal surface to ensure
the correct operation.
The unit has to be connected to the electric mains following instructions on the identification plate of
the unit applied next to the main switch, mainly as to applicable voltage and power.
HANDLING: During handling, the minimum devices required for correct handling
shall be ensured, as provided for by accident prevention provisions.
POSITIONING: Position the unit in a room with proper ventilation and/or air
change. The unit must be placed at a distance of at least 10 cm from any object
that could obstruct internal ventilation and access to the on/off switch. Protect and
do not use under conditions of rain and atmospheric events. Protect the unit
against rain or excessive humidity to avoid irreparable damage of it. In addition,
the equipment must never be directly exposed to the sunrays or to excessive dust.
During use, securing the equipment by the brake is recommended.
INSTALLATION: The installation shall be carried out by specialized personnel,
strictly complying with the instructions contained in this manual. The use of the
equipment in explosive atmosphere is forbidden.
CONNECTIONS: this being an electric equipment connected to the mains supply,
correct use of the ground pin, placed on the supply plug, is compulsory. If the
ground pin is willingly not being used or in case of connection of the supply plug
to a supply socket not provided with suitable grounding, this might damage the
tool. These procedures are forbidden and put the operator’s life at risk. Place the
station such that the mains socket can be easily accessed by the operator.
ATTENTION: Leave the quick coupling taps closed when the unit is not in use
and at the end of vehicle service operations.
Let us consider as first filling the one carried out during the initial check with internal tank of the
equipment free of refrigerant gas and containing air.
Set the quantity of gas to fill (at least 2 kg) and follow the guided procedure shown on the display.
Check that the equipment hoses are not connected and positioned in the hose winder. Start the
procedure that initially implies the creation of vacuum in the internal tank. This phase will take 15
minutes and will act on the whole equipment,
Only when the message appears to connect the recharge tank, connect the HP quick coupler (red) of
the unit to an external refrigerant gas tank using the supplied adaptor.
Open the coupler by turning the knob clockwise. Open the valve on the external tank.
Just right before reaching the planned quantity of refrigerant, the unit will stop and ask the user to
close the external refrigerant tank. Then, the device will continue the recovery from the hoses and
ends when these are empty. Hence, it is necessary to open the LP quick-coupler and disconnect it
from the external tank. Thanks to the ECO-LOCK function, the refrigerant - usually kept between the
cylinder fitting and the hose quick-coupler until the end of the process - will not be released in the
environment.
There may be two types of source tanks: with plunger and without plunger.
Tanks with plunger shall remain upright to be able to transfer liquid refrigerant; for this type of tanks
connect to the L (liquid) coupler.
Tanks without plunger have only one valve, so they must be turned upside down to transfer the
liquid refrigerant.
The new oil bottle is on the left – looking at the unit from the front side.
To fill it, it has to be extracted from its housing by means of the quick coupler on the top of the
bottle; slightly press downward the coupler ring nut to extract it.
Fill the bottle by paying special attention to the “oil care” valve.
This valve is made of a silicon polymer membrane; it compensates pressure variations within the
bottle and stops humid air infeed inside thus preserving the new oil inside.
After filling, close the bottle and place it back in its seat.
CAP. 9 - SETUP
From the SETUP menu it is possible to select parameters and activations before starting cycles:
HYBRID FUNCTION
• by selecting this entry, one may change the type of Oil to inject into the A/C system.
Attention: the HYBRID KIT PRO (optional accessory) is required in order to run this function
•
ECO LOCK®
• by selecting this entry, you can enable the ECO LOCK® function (the ECO LOCK® quick
coupler must be present on the car).
PRESSURES ZERO
• by selecting this entry, one may carry out calibration of the atmospheric pressure.
RECHARGE MODE
• by selecting this entry, one may decide whether to enable use of the Quick Mode or Zero
Tolerance recharge method
MULTIPASS
• by selecting this entry, one may decide whether or not to enable the multipass function,
which enables an additional recycling, within the station itself, started in automatic when it is
switched on but not in use. This function ensures a higher level of purity of the recycled
refrigerant to the advantage of the service quality.
PRESSURE CHECK
• by selecting this entry, one can enable or disable the pressure check.
DISPLAY CONTRAST
• selecting this entry, you can change the display contrast level.
HOSES LENGTH
• by selecting this entry, it will be possible to change the length of the charge hoses.
UNIT OF MEASUREMENT
• selecting this entry, you can modify the pressure unit of measurement (switching from Bar to
PSI)
CLOCK ADJUSTMENT
• by selecting this entry, date and time of the station may be changed.
GARAGE DATA
• by selecting this entry, one can enter the garage data to be printed on the end of cycle
report.
LANGUAGE
• by selecting this entry, any language present in the database may be set. In case you choose
a language with unintelligible characters, hold down the button in the starting screen-
page and you will directly return to the language setting menu.
STARTUP SCREEN
• By selecting this entry, you can decide whether the startup screen of the unit will be the
databank page or the main menu page.
DEFAULT SETUP
• By selecting this entry, you can restore the unit default settings.
DATABASE ACTIVATION
• by selecting this entry, you will receive the “database activation request code” to be provided
to your distributor in order to be able to buy the database update and subsequently receive
the “database activation code”.
The recovery and recharge operations have be carried out after the car /AC system has run for
some time; however, an excessively hot A/C system has to be avoided since the next recharge phase
could be adversely affected by high pressures.
The vehicle must not be prepared in a special way; connecting hoses have to be attached by
identifying their position.
Vehicle details necessary for the performance of the charge/recovery/vacuum cycle are the amount
of refrigerant and the type and quantity of oil. These data are often found on the engine
compartment plate or on the technical manuals.
As to oil quantity technical manuals of cars, systems as well as available details in general indicate
the total quantity of oil in the system.
Indeed the amount of oil to be recharged is that extracted during the refrigerant recovery phase
which is very small.
FEATURES
Your new A/C service station is equipped with new ECO LOCK® quick couplers. These new couplers
offer the following functions:
1. Avoid dispersion of the gas, allowing the recovery by the tool (thus protecting the
environment and saving refrigerant).
2. Automatic leak test of the car A/C system valve at the end of the service.
After connecting the quick couplers to the (high pressure) HP and (high pressure) LP connectors of
the vehicle, screw the valves only when required by the messages on the tool display.
To recharge the A/C system, you have to know the refrigerant type and also the suitable type of oil.
These data are usually available in the vehicle user manual or on the engine compartment plate.
The car manufacturer specifications can be another source of information.
As to the oil amount, remember that technical data of the A/C systems and instructions usually
present in the vehicle show the total oil amount in the system. In the car A/C system you have to add
only the oil amount necessary to restore the amount set by the car manufacturer.
The non condensable gases vent valve shall be activated when air is present within the system; this
can be verified by reading the vessel pressure gauge and by checking on the °C scale of the HP and
LP pressure gauges the temperature corresponding to the vessel pressure: if this is significantly
higher than the ambient temperature, presence of air in the vessel is likely.
VALVOLA
SCARICO
INCONDENSABILI
6000 PLUS can apply two different refrigerant recharge modes; the first one is called Quick
mode and features the opening of the recharge valve by injecting gas through the HP port. By the
Quick Mode part of the refrigerant remains into the hoses and is compensated by software
calculation.
Whenever the recharge is not completed the UNIT shifts automatically to the Zero Tolerance
mode.
The Zero Tolerance function is the second recharge procedure, an alternative to the Quick Mode.
It features a more accurate recharge and guarantees a successful recharge (it however requires a
longer time and the operator's intervention).
If the car A/C system is equipped with both couplers or with LP coupler only, there are two slightly
different working modes; in any case if only the HP coupler is available the Zero Tolerance mode
is not applicable.
With both HP and LP couplers available the Zero Tolerance features the injection of the selected
refrigerant amount into the system through the HP hose; then refrigerant remained into the HP
hose is sucked by the car system – engine and compressor running – through LP (after
disconnecting and closing the HP coupler).
In case the LP coupler only is available the station charges the system with 50% of the selected
amount with car compressor off and waits for 10 minutes before recalling the operator. This wait
time – quite rare since most of cars are equipped with HP coupler too – allows the refrigerant
injected near the compressor – that is LP side – to evaporate to prevent any damage to the
compressor during the admission of liquid phase refrigerant. Then, after car and A/C system
switch ON recharge continues through timed injection of refrigerant through hose LP, such
injections start exclusively if the LP pressure is lower than 3 bar.
Upon tool switch-on, the menu of the database storing vehicles divided by maker, model, and type
of A/C system is displayed.
The selected car flashed, press to change selection and to confirm selection.
Press to go back to the previous field.
• Oil type: It sets the oil type being used. PAG (ISO46/100/150) or POE
• Injection type: It allows selecting from which hose the service is carried out, according to the
type of system.
o Injection from HP hose (red)
o Injection from LP hose (blue)
o Injection from HP hose (red) and LP hose (blue)
o Injection from HP hose (red) on the system low pressure side. Specific for some
Renault models.
• Vacuum phase
Vacuum duration
Leak test duration
The value of each selected field (flashing) can be either increased or decreased .
Through the selected value is confirmed and the next field is entered.
Press to go back to the previous field.
At the end of the setup press on the “START" option to start the automatic cycle.
From the main menu use keys until selection of MANUAL CYCLES and then press .
Through keys select the desired phase and press
12.2 RECOVERY
In the MANUAL CYCLES menu, position on RECOVERY through the keys ,then push to start
the phase.
In case of problems or errors during this phase, a message will be displayed, identifying the type of
error.
It is possible to interrupt the phase in progress at any time, by pushing .
At the end of the process the display will show the quantity of recovered oil, together with a message
stating that the phase is over.
12.3 VACUUM
In the MANUAL CYCLES menu, position on VACUUM through the keys , then push to start
the phase.
By means of the keys , you can set the vacuum time and the test duration.
Push to confirm the entered values and start the phase.
In case of problems or errors during this phase, a message will be displayed, identifying the type of
error.
It is possible to interrupt the phase in progress at any time, by pushing .
12.4 INJECTION
In the MANUAL CYCLES menu, position on INJECTION through the keys , then push to
start the phase. The main page will be displayed with the following preset values:
amount of refrigerant that will be charged into the system and the amount of refrigerant contained
in the inner tank of the UNIT.
Oil type: It sets the oil type being used. PAG (ISO46/100/150) or POE
Injection type: It allows selecting from which hose the service is carried out, according to the type of
system.
Injection from HP hose (red)
Injection from LP hose (blue)
Injection from HP hose (red) and LP hose (blue)
Injection from HP hose (red) on the system low pressure side. Specific for some Renault models.
In case of problems or errors during this phase, a message will be displayed, identifying the type of
error.
It is possible to interrupt the phase in progress at any time, by pushing .
12.5 FLUSHING
After performing a lot of recharge cycles or after replacing components or parts of the /AC circuit
on a vehicle it is advisable to carry out a system flushing.
The system washing (Flushing) consists in purifying the vehicle cooling system through several
R134a or R1234yf gas flushes, by recovering it each time, so that the impurities can be filtered
little by little through the additional filter.
Thanks to its specific design, 6000 PLUS can automatically manage the flushing process so that
the process becomes fully automatic.
To carry out the flushing the operator has to purchase the flushing kit
Once that you have installed the flushing kit, in the MANUAL CYCLES menu, position on
FLUSHING through the keys then push to start the phase.
In case of problems or errors during this phase, a message will be displayed, identifying the type
of error.
It is possible to interrupt the phase in progress at any time, by pushing .
To check the vehicle A/C system status – for instance in case there is no flow of cold air from
flaps – pressure values can be checked.
Connect the HP - LP couplers or the single coupler to the vehicle system.
In the MANUAL CYCLES menu push to select PRESSURE CHECK, then push to confirm.
Open couplers (or the single coupler) rotating knobs clockwise.
After the refrigerant injection, a check of the pressure on HP and LP sides will be requested; make
sure that both values on LP and HP gauges fall within the values shown on the display.
In case of problems or errors during this phase, a message will be displayed, identifying the type
of error.
It is possible to interrupt the phase in progress at any time, by pushing .
To empty the charge hoses completely perform the HOSES EMPTYING phase.
In the MANUAL CYCLES menu push to select HOSES EMPTYING (we refer to the external
Blue and Red charge hoses), then push to confirm.
In case of problems or errors during this phase, a message will be displayed, identifying the type
of error.
It is possible to interrupt the phase in progress at any time, by pushing .
This test allows checking the tightness of the vehicle A/C system through nitrogen pressurization.
This test requires the NITROGEN LEAK TEST KIT (optional accessory) and a nitrogen cylinder with
pressure reducer, not supplied with the accessory.
CAP. 13 - MAINTENANCE
6000 PLUS is a remarkably reliable unit, manufactured using the highest quality components,
making use of the most advanced production techniques.
Please contact an authorized technical service centre for all maintenance interventions and to
purchase spare parts. The equipment includes parts subject to the PED Directive. The PED
“Pressure Equipment Directive” 97/23/EC defines and regulates all those parts that are subject to
pressure, with a specific ratio between their pressure and volume. Therefore, such parts cannot
be disassembled or handled. Under the owner’s responsibility, the equipment and its PED parts
must be verified on commissioning and regularly thereafter as provided by local legislation.
The parts subject to the PED Directive are:
• 12l RECEIVER
Category II (Dir. 97/23/EC)
SUCTION UNIT
Art. 3.3 (Dir. 97/23/EC)
In the main menu select MAINTENANCE and then select “SELF LEAK TEST”.
In case of failed leak test, it is necessary to check the charge hoses conditions and the quick
couplers tightness, and make the possible repair and then repeat the test.
13.2 LONG LIFE PUMP SPECIAL FUNCTION - VACUUM PUMP OIL CHANGE
The tool is equipped with a special function named LONG LIFE PUMP that enables to optimize
the vacuum pump oil use by avoiding the replacement every 60 hours of operation.
LONG LIFE PUMP is a Brain Bee patented special function allowing to extend even to 1000 hours
the life of the pump oil used in the station.
LONG LIFE PUMP function performance is suggested at the end of 60-hour operation intervals of
the vacuum pump and can be manually activated in the MAINTENANCE menu.
LONG LIFE PUMP procedure has to be started only after checking and, if necessary, topping up
the pump oil level and lasts 1 hour: during this time the tool cannot be used.
During the procedure the oil is automatically purified from the gaseous polluting residues
absorbed during the emptying operations of vehicles air conditioning systems.
At the end of the procedure, the vacuum pump performance check is carried out and a result to
the operator is signalled.
In case of negative result you have to replace the vacuum pump oil.
After 1000 hours of vacuum pump operation since the last oil change, the LONG LIFE PUMP
procedure cannot be activated anymore and you have to replace the oil according to the
following instructions.
Required equipment:
2 Remove the screws that fix the front door of the unit and remove it.
3 Place a bowl underneath the machine, right under the pump oil drain hole. Open the upper
plug and then the lower plug to drain the exhausted oil contained within the vacuum pump.
TAPPO
SUPERIORE
SIGHT
GLASS
TAPPO
INFERIORE
4 Once the pump has been emptied, screw the lower plug again.
5 Fill the pump with new oil through the upper opening, using a funnel if needed. Bring new oil
level halfway through the sight glass.
6 Once the pump has been filled, close the upper plug.
Once oil has been replaced, switch on the unit and from the MAINTENANCE menu select PUMP
OIL REPLACEMENT: press the “RESET” key to set the counter to zero.
The dryer filter shall be replaced once 45 kg of refrigerant fluid have been dehydrated, because
the filter depletes its capacity of retaining the moisture present in the refrigerant.
To replace the dryer filter, from the MAINTENANCE menu select DRYER FILTER REPLACEMENT:
press “RESET” to set the counter to zero and to start the filter replacement procedure.
NUTS
DRYER FILTER
5 Install the new filter paying attention to the position of gaskets and to the direction of the arrow
indicating the fluid flowing direction.
6 Screw the two connection nuts of the filter.
13.4 COUNTERS
In the COUNTERS menu, at any time, the vacuum pump and compressor hours of life can be
displayed; besides, remaining time before replacement of vacuum pump oil and dryer filter can
also be displayed.
To access the COUNTERS menu, from the main menu enter the MAINTENANCE menu and press
COUNTERS.
There are two types of source tanks: with plunger and without plunger.
Tanks with plunger shall remain upright to be able to transfer liquid refrigerant; for this type of
bottles connect to the L (liquid) coupler.
Tanks without plunger have only one valve, so they must be turned upside down to transfer the
liquid refrigerant.
The HP gauge shows the pressure level into the external tank.
Push to select the submenu VESSEL FILLING, then push to enter it.
In the following screen page set the quantity of refrigerant you wish to charge.
The field RESIDUAL shows the quantity of refrigerant being currently present in the vessel.
Position the cursor into the field TO CHARGE that will suggest, by default, the maximum quantity
of refrigerant to charge.
Please note that when the system warns that the maximum selected weight has been reached,
after the closing of the external bottle valve, the unit still absorbs a small amount of refrigerant.
In case of problems during the internal vessel filling phase, a specific message will appear on the
last line of the display.
It is possible to interrupt the phase in progress at any time, by pushing .
After some minutes the unit will automatically end the function.
Position the roll of paper inside the housing in the rotation direction indicated in the picture;
Pull the paper out of the housing as indicated in the picture and close the lid ;
The A/C service stations shall undergo periodical checks, as provided for by relevant national
laws.
Checks will be performed by competent authorities, in compliance with their procedures. Here
below, some possible checks on components subject to the PED directive are outlined. Depending
on local legislation, the checks may be extended to other components to verify the metrological
characteristics of the integrated instrumentation and the presence of essential equipment and
accessories.
12l RECEIVER
Category I (Dir.97/23/EC)
• To check the refrigerant vessel date of manufacture, see the vessel plate
Fac-
• Make sure no corrosion or leakage is present; under normal conditions of use, the vessel
life is at least 20 years.
In case of intervention of the automatic safety valve, it is advisable to contact the technical service
that will replace the valve.
SUCTION UNIT
Art. 3.3 (Dir. 97/23/EC)
• Make sure no corrosion and leakages are
present.
HOSES
• Periodically check external charge hoses,
red (HP) and blue (LP), to verify their
perfect conditions and the lack of
damages which could compromise their
correct operation.
OTHER CHECKS
• Make sure lubricants and filters have been replaced in line with the intervals required to
ensure correct operation of the equipment.
CAP. 14 - DISPOSAL
14.1 EQUIPMENT DISPOSAL
At the end of the equipment working life the following operations shall be carried out:
• Ask the service department to recover the whole gas in the unit circuit, by making sure
that the gas storage internal tank is completely emptied.
• Deliver the unit to a disposal centre.
The coolants recovered from the systems that cannot be used again must be delivered to the gas
suppliers for their necessary disposal.
The lubricants taken from the systems must be delivered to the exhausted oil collecting centres.
CONSUMABLES
Vacuum pump oil PAG 46 oils PAG 100 oils PAG 150 oils
Further spare parts are available through the Service Centres authorised by Brain Bee S.p.A. or
by its reseller.
WARNING
Using non-original / unapproved spare parts or accessories can compromise the safety of 6000
PLUS.
Brain Bee SpA recommends using original Brain Bee parts or parts of equivalent quality.
Notice/Warning messages are coded with Wxxx code on the title of the window.
CODE MESSAGE When it occurs Possible Actions
situations
W025 REFRIGERANT During the Amount Decrease the set
QUANTITY TOO programming of required greater quantity.
HIGH the inner tank than that
charge amount available in
internal tank
W026 RECHARGE VESSEL During the tank Recharging tank Check tank, hoses, taps.
EMPTY OR filling phase empty or
DISCONNECTED hoses/taps
clogged/closed
W029 VESSEL NEARLY During the The tank is Decrease quantity of gas
FULL refrigerant close to its by filling (injecting) an
recovery or hoses maximum external suitable tank
emptying phase. capacity. (with safety valve)
A048 HP LEAKAGE During the At the end of the Empty the vehicle (follow
gas recovery gas injection, in the procedure guided by
and hoses the ECO LOCK the displayed messages)
emptying quick coupler
phase disconnection
phase during
the vehicle
fittings leak test
A049 LP AND/OR HP During the At the end of the Empty the vehicle (follow
LEAKAGE gas recovery gas injection, in the procedure guided by
and hoses the ECO LOCK the displayed messages)
emptying quick coupler
phase disconnection
phase during
the vehicle
fittings leak test
MAINTENANCE FORM
Vacuum pump oil change
Date Maintenance technician identification Maintenance technician
signature and stamp
MAINTENANCE FORM
Dryer filter change
Date Maintenance technician identification Maintenance technician
signature and stamp
MAINTENANCE FORM
Dryer filter change
Date Maintenance technician identification Maintenance technician
signature and stamp
MAINTENANCE FORM
R134a or R1234yf gas receiver load cell check
Date Result of check Maintenance technician Maintenance technician
(pass/fail) identification signature and stamp
MAINTENANCE FORM
R134a or R1234yf gas receiver load cell check
Date Result of check Maintenance technician Maintenance technician
(pass/fail) identification signature and stamp
MAINTENANCE FORM
Other checks/maintenance/repairs
Job Date Result of Maintenance Maintenance technician
check technician signature and stamp
(pass/fail) identification
MAINTENANCE FORM
Other checks/maintenance/repairs
Job Date Result of Maintenance Maintenance technician
check technician signature and stamp
(pass/fail) identification