AC 690 Service Eng

AC650PRO/AC690PRO
SERVICE MANUAL
9206171
Rel. 2
02/07
_____________________________________________________________________ AC650PRO/AC690PRO
INDEX
1.0 -
GENERAL RULES FOR MAINTENANCE
1.1 -
Working environment
2.0 -
SPARE PARTS
3.0 -
OPERATING PRINCIPLE
10
3.1 -
Recovery
10
3.2 -
Oil drain
12
3.3 -
Vacuum and recycle (simultaneously)
13
3.4 -
Vacuum test
15
3.5 -
Recycle
16
3.6 -
Oil replenishing
17
3.7 -
Charge
18
3.8 -
Replenishing compressor oil
19
3.9 -
Discharge of non condensable gases
20
3.10 -
Dye injection
21
4.0 -
DISPLAYED MESSAGES
22
4.1 -
Service messages
22
4.2 -
Error messages
22
5.0 -
EVACUATION OF THE TOOL
23
6.0 -
TROUBLESHOOTING AND DEFECT ANALYSIS
24
6.1 -
The station does not recover
24
6.2 -
The station does not pull the vacuum
26
6.3 -
The station does not perform recycle
27
6.4 -
Non condensable gases are not discharged
28
6.5 -
The station does not recycle
28
SERVICE MANUAL
AC650PRO/AC690PRO ______________________________________________________________________
7.0 -
COMPONENTS CHECK AND MAINTENANCE
29
7.1 -
Pump
29
7.2 -
Pressure transducer P1
30
7.3 -
Safety pressure gauge P2
31
7.4 -
Expansion valve
31
7.5 -
Filter dryer change
32
7.6 -
Reset counter filter dryer
33
7.7 -
Vacuum pump oil change
34
7.8 -
Reset oil counter vacuum pump
34
7.9 -
Refrigerant scale calibration
35
7.10 -
Transducer calibration
36
7.11 -
Oil replenishing scale calibration
39
7.12 -
Oil purge scale calibration
40
8.0 -
TEST AND PARAMETERS SELECTION
41
8.1 -
LCD test
41
8.2 -
Outputs test
41
8.3 -
Inputs test
42
8.4 -
Helium test
43
8.5 -
Printer test
43
8.6 -
Counters
43
8.7 -
Service printing
44
8.8 -
Oil discharge
44
8.9 -
Parameters modification
45
8.10 -
Software update
48
9.0 -
DIAGRAMS
49
9.1 -
Flow diagram
49
9.2 -
Power card
50
9.3 -
Display card
51
9.4 -
Flow diagram components description
52
10.0 -
GLOSSARY OF TERMS
54
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
1.0 -
GENERAL RULES FOR MAINTENANCE
It is necessary to wear suitable protections such as goggles and gloves, the

contact with the refrigerant can cause blindness as well as other injuries to the
operator.
Avoid the contact with the skin, the low boiling temperature (about -30 C) may
provoke freezing.
Do not inhale refrigerating gases fumes.
Before connecting the AC650PRO/AC690PRO unit to an A/C system or to an

external tank, make sure all the valves are closed.
Before disconnecting the AC650PRO/AC690PRO unit, make sure the cycle has been
completed and all the valves are closed thus avoiding to disperse the refrigerating
gas in the air.
Do not modify the safety valves and the control systems calibration.
Do not use tanks or other storing containers which are not type-tested or without
safety valve.
Never charge any container beyond 85% of its capacity, explosion risks may arise.
Never leave the unit live if an immediate use is not scheduled, stop the electrical
supply before a long period of unit inactivity or before internal maintenance
interventions.
Be careful while servicing the unit since connecting hoses may contain pressurised
refrigerant.
Extraordinary maintenance interventions have to be performed by authorised staff

only.
Pressure of leaks of the HCF-134a service equipment or of the air conditioning

systems of the vehicle must not be tested by using compressed air. Some
air/HCF-134a mixtures can burn at high pressures. These mixtures can be
dangerous and may cause fires or explosions and subsequent injuries or damages.
Further information on the operators health and safety can be obtained from the
refrigerant producers.
SERVICE MANUAL
AC650PRO/AC690PRO ______________________________________________________________________
1.1 -
Working environment
The unit has to work in a sufficiently ventilated environment.

ATTENTION:
Work far from free flames and hot surfaces; at high temperatures the
refrigerant decomposes freeing toxic and aggressive substances
which are noxious for the user and the environment.
For a correct functioning the unit has to work on an even surface; do not drop nor
bump it.
Do not subject the AC650PRO/AC690PRO unit to dripping.

ATTENTION:
While operating do not disperse the refrigerant in the environment.
Such a precaution, besides being required by the international rules
for the environment protection, is necessary to prevent the possible
presence of refrigerant in the working environment from making it
difficult to detect possible leaks.
Work in environments with sufficient lighting.
Avoid inhalation of the refrigerants and oils in the A/C systems. Exposure may
cause irritation to eyes and the respiratory tract. To remove R134a from the
A/C system, use only the special recycling-units for R134a. If the refrigerant is
accidentally released into the atmosphere, ventilate the work area before resuming
service.
Do not use the unit under direct sunrays; sun exposure can cause excessive
temperatures and malfunctioning. Working temperatures indicated refer to the unit
being not directly exposed to the sun.
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
2.0 -
SPARE PARTS
3
4
6
5
1. Red hose tank

Blue hose tank 1450 mm + O'RING
5117418
SL31407
2. Yellow hose 600 mm + O'RING
SL31408
3. 244 cm High side red hose
5117474
4. High side quick coupler

5. 244 cm Low side blue hose
6. Low side quick coupler
7. O'RING Kit for quick couplers
SERVICE MANUAL
RA18191A
5117475
RA18190A
RA19150
AC650PRO/AC690PRO ______________________________________________________________________
10
12
8. Vacuum pump oil 0,45 l
11
13
RA13119B
Vacuum pump oil 0,95 l
RA13203B
Vacuum pump oil 3,8 l
RA13204B
9. Piston for solenoid valve 4,5 mm

Piston for solenoid valve 2,5/3 mm
5125014
5125015
10. Tank adapting coupler
5117228
11. Tank quick coupler
5117226
12. Joints for 1/4 SAE hoses
RA40083
13. O'RING 3037 14
1107031
O'RING 2031 11
1107004
O'RING 10078 10
1107060
O'RING 2018 8
1107006
SERVICE MANUAL
____________________________________________________________________________________________________________________________________________________________________________________________ AC650PRO/AC690PRO
48
47
46
45
43
41
44
42
37
35
39
38
36
18 19
24
17
40
49
55
25
56
57
50
58
16
15
27
28
23
22
14
51
26
59
52
29
30
31
20
54
21
53
32
34
SERVICE MANUAL
33
AC650PRO/AC690PRO ____________________________________________________________________________________________________________________________________________________________________________________________
14. AC650PRO Frontal thermoform

AC690PRO Frontal thermoform
AC650PRO Sticker
AC690PRO Sticker
SPX ROBINAIR Sticker
0643165
0643165TM
3602525
3602617
3602474
38. Pressure transducer (P1)

Peak suppressor
SL31410
3119165
39. Check valve Kit
5604044
40. Safety pressure gauge (P2)
5117334
15. Printer
Power supply cable for printer
Serial cable for printer
Roll of printer paper
2657040
2303283
2303284
5607069
41. Pipes side thermoform
0643169
42. Power card
2659270
43. Union tee
5117340
44. Uncondensate discharge valve
5117358
16. Front panel
0111296
45. Cylindrical gear reducer
5117341
17. Inside tank pressure meter (M3)
1601033
46. Tank security valve
5117344
18. Low side gauge (M1)
1601035
47. Double profile for AC Robinair
1107071
19. Display card

Display card with Cyrillic characters
2659269/C
2659269RUS
48. AC650PRO Rear thermoform

AC690PRO Rear thermoform
0643166
0643166TM
20. High side gauge (M2)
1601034
49. 20 Kg Storage tank (7)
SL31259
21. Red handle
5111022
50. Oil injection assembled bottle
SL31373
22. Blue handle
5111023
51. Dye assembled bottle
SL31374
23. Pressure meters capillary tube
5117406
52. Oil discharge assembled bottle
24. Dashboard valve
5117400/1
SL31373/F
53. Bottle loading cell
SL31311
25. Expansion valve (3)
5117398
54. Bottles side thermoform
0643167
26. Filter dryer (F2)
5117399
55. 1/8 F L-shaped coupler
5117280
27. Drying filter strap
5109062
56. 1/8 M Straight coupler for pipe 4
5117460
28. Filter-compressor pipe
5117467
57. Male quick coupler
5117332
29. 4,5 mm Solenoid valve
3109094
58. Female quick coupler
5117342
30. Still
SL31382
59. Straight coupler for pipe 6
5117459
31. Complete ventilated exchanger

Radiator support square
Exchanger
Fan
SL31372
0109524
5117449
3127032
32. Oil charge cell
SL31411
33. Vacuum pump (2) 183 l/min
3127033
34. Compressor (6)
SL31310
35. Mechanical filter (F1)
5117468
36. Solenoid valves set

Protection unidirectional valve
SL31420
5117473
37. Coil 220 Vac

8
AC350/500-3
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
60
61
62
63
66
65 64
60. Main power switch
3113125
61. Power cable
3119125
62. False HP quick coupler
5117311
63. False LP quick coupler
5117312
64. Wheel locking seeger
5109061
65. Rear wheel
0107025
66. Front wheel
0107026
SERVICE MANUAL
AC650PRO/AC690PRO ______________________________________________________________________
3.0 -
OPERATING PRINCIPLE
This chapter presents all of the operating stages. It also presents passage flows inside
the charge station by means of the flow diagram and a short description of active
components in each single function.
3.1 -
Recovery
The recovery is the function allowing to eliminate refrigerant from the vehicle A/C
system.
Connect the two service hoses T1 (low side) and T2 (high side) to the A/C system of
the vehicle and open the relevant valves on quick couplers: the contained refrigerant
reaches M1 and M2 and LOW and HIGH valves.
Open the two LOW and HIGH valves and the refrigerant reaches the EV10 and EV3
solenoid valves (usually closed) and gets in contact with the P1 pressure transducer.
The P1 pressure transducer checks for the presence of refrigerant in the car
A/C system.
Press the recovery key to start the function and the ecu excites the EV10, EV3 and
EV5 solenoid valves by opening them and starting compressor 6.
Now the refrigerant passes through the EV10, EV3 and EV5 solenoid valves, the F1
filter and the expansion valve 3 to reach the still/separator 4.
The expansion valve keeps the compressor inlet pressure constant to enable the best
performance.
Inside the still/separator 4, the recovered oil from the vehicle A/C system is separated
from the refrigerant.
Inside still-separator the refrigerant continues its flow through the filter/drier F2, is
sucked by the compressor, conveyed into the second still/separator 5 and then stored
into the tank.
The filter/drier F2 is used to remove from refrigerant humidity particles before storage
into the tank, while the second still/separator 5 is used to separate refrigerant from
compressor oil of recharge station.
When pressure on the P1 pressure transducer drops under the value set by the
software, the function stops automatically. The program waits for 5 minutes to check
possible pressure increases and, if necessary, restarts a second cycle.
At the end of these phases EV10, EV3, EV5 solenoid valves and compressor 6 are
closed.
10
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
The flow diagram below highlights the refrigerant flow inside the charge station during
the recovery function.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
SERVICE MANUAL
11

3.2 -
AC650PRO/AC690PRO ______________________________________________________________________
Oil drain
This operation is performed at the end of recovery and is necessary to know the
amount of new oil to add to the vehicle A/C system before recharge.
Open solenoid valve EV7 and, by drop effect, oil on the bottom of the still/separator 4
passes inside the graduated tank 9.
The scale 13, weighs the discharged oil and the electronics stores the value for the
subsequent charge phase.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
12
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
3.3 -
Vacuum and recycle (simultaneously)
The service station is set so that during the vehicle A/C system vacuum a refrigerant
recycle occurs too to favour non condensable gases discharge and obtain a purer
refrigerant before recharge.
Vacuum
The vacuum function allows to vacuum the vehicle A/C system.
Connect the two service hoses T1 (low side) and T2 (high side) of the vehicle A/C
system, open relevant valves on quick couplers: the A/C system is not in
communication with the recharge station.
Open LOW and HIGH valves to start communication between the vehicle A/C system
and pressure transducer P1.
If pressure on the sensor is lower than the value set by the software, an electric signal
is sent to the ecu thus enabling the vacuum function; on the contrary, if pressure is
higher the message CIRCUIT FULL PROCEED RECOVERY is displayed indicating
that there is refrigerant inside the vehicle A/C system.
Solenoid valves EV1, EV3 and EV10 are now closed.
Press the vacuum button to start the function; the ecu excites the EV10 and EV1
solenoid valves by opening them and starting the vacuum pump 2.
Pump starts sucking and eliminating gas residues and humidity from the system and
prepares it for recharge.
The vacuum pump has a capacity of final vacuum equal 0,066 mbar and stops at the
end of the set vacuum time.
Recycle
During the vacuum function, the refrigerant recycle starts automatically to further
improve its purity before the recharge.
Some seconds after the vacuum stage has started, the ecu excites the EV5 and EV6
solenoid valves by opening them and starting compressor 6.
In that way, refrigerant is sucked from storage bottle 7 and is conveyed through the
filter F1, the expansion valve 3, the still/separator 4 until reaching the tank again, as it
happens in the recovery stage.
This function favours the automatic discharge of non condensable gases inside the
storage bottle.
SERVICE MANUAL
13
AC650PRO/AC690PRO ______________________________________________________________________
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
14
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
3.4 -
Vacuum test
At the end of the vacuum phase the vacuum test is started.

In this phase LOW and HIGH valves are open while EV1 solenoid valve close for the
leak test.
All other components are disabled. The system indicates a error to the operator, if the
system pressure during the vacuum test exceeds the value set by the software.
The check is carried out through the P1 transducer.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
SERVICE MANUAL
15

3.5 -
AC650PRO/AC690PRO ______________________________________________________________________
Recycle
The recycle function can be started without starting vacuum by using a special menu
function; the operation is the same as described before.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
16
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
3.6 -
Oil replenishing
After evacuating the vehicle A/C system, recovered oil has to be replaced with new oil.
The oil replenishing occurs by pressure difference.
During evacuation, both valve on the service hose T2 quick coupler and HIGH valve
remain open.
This section of the circuit is hence under vacuum; when opening EV8 solenoid valve,
the pressure difference makes new oil in the graduated bottle 1 be sucked inside the
vehicle A/C system.
After entering the amount of oil to be charged the oil is charged automatically by the
unit through the electronic scale 12.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
SERVICE MANUAL
17

3.7 -
AC650PRO/AC690PRO ______________________________________________________________________
Charge
The charge function enables to charge refrigerant inside the A/C system.
Press the charge function button and set the amount of refrigerant to be charge into
the vehicle A/C system, the ecu excites the EV3 and EV6 solenoid valves by opening
them.
The refrigerant leaves the bottle through V4 and V2 valves, passes through EV6 and
EV3 solenoid valves, the HIGH valve (in case of high side charge) and reaches the A/C
system of the car through the T2 service hose.
After charging the set amount of refrigerant, the recharging station stops the charge
automatically; the automatic stop is controlled by the ecu thanks to the signals sent by
the loading cell of the electronic scale 8.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
18
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
3.8 -
Replenishing compressor oil
During the recovery and recycle functions, a part of the recharge station compressor oil
is pulled out of compressor and has to be replenished.
This oil is separated from the refrigerant inside the still/separator 5 and then
replenished inside compressor 6.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
SERVICE MANUAL
19

3.9 -
AC650PRO/AC690PRO ______________________________________________________________________
Discharge of non condensable gases
This is an automatic function that allows to eliminate non condensable gases from the
storage tank.
During recycle and recovery pressure increases inside the storage bottle.
If non condensable gases are present the pressure increases is higher than usual thus
causing the opening of the non condensables vent valve and their purge through the
V6 valve.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
20
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
3.10 -
Dye injection
Before the charge, the A/C system can be charged with a special dye for leak detection.
By selecting the dye injection option, the software opens the solenoid valve EV9 for
some seconds, so that the dye in bottle 11 reaches the A/C system.
The opening time of the solenoid valve is set to allow the charge of the correct amount
of dye.
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
EV6
EV1
VU1
M3
12
P2
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
SERVICE MANUAL
21
AC650PRO/AC690PRO ______________________________________________________________________
4.0 -
DISPLAYED MESSAGES
4.1 -
Service messages
CHANGE OIL
Vacuum pump oil change (see chapter 7.7).
CHANGE FILTER
Change filter dryer (see chapter 7.5).
4.2 -
Error messages
HIGH PRESSURE
Out feed pressure from compressor is excessively high. Switch off the unit and wait for
about 30 minutes. If the problem persists, apply to the Technical Service.
SOFTWARE ERROR
Error in the software, apply to the Technical Service.
FULL BOTTLE
Coolant level in the bottle reached the maximum capacity level, carry out some charges
to reduce the amount of coolant inside.
SCALE RECALIBRATION
Error in scale calibration, reset it. If the error persists, apply to the Technical Service.
HIGH RECOVERY TIME
The recovery time exceeds the set safety limit. Make sure there are no leaks in the A/C
system. If no leaks are detected, apply to the Technical Service.
EMPTY SYSTEM
There is no refrigerant in the A/C system.
BOWL FULL
The oil discharge bowl is full and has to be drained.
BOWL EMPTY
The oil injection bowl is empty and has to be charged.
FULL SYSTEM
The A/C system is charged with refrigerant.
INCOMPLETE CHARGE
Excessive charge time; this proves that the pressure inside the bottle is equal to the
pressure inside the A/C system.
OIL CHARGE TIME HIGH
The A/C system is not under vacuum and the station cannot suck oil.
22
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
5.0 -
EVACUATION OF THE TOOL
Before any repair intervention, evacuate, by means of another machine, the tool from
refrigerating gas it contains. Such operation prevents the accidental outflow of gas.
To carry out this operation:
ATTENTION:
For your safety, always wear gloves when working with refrigerant.
Contact with refrigerant may injure eyes. Disconnect circuits and
hoses cautiously. Circuits and hoses may contain refrigerant under
pressure. Do not aim hoses and circuits to anyone.
Always disconnect the tool form the main supply before removing any
casing or starting any service job.
Be sure the high and low side hoses (T2 and T1) are not connected to the vehicle.
Open LOW and HIGH valves.
Carry out a recovery.
Wait for the function end.
NOTA BENE:
In case, due to the malfunction of the compressor, the recovery cannot be performed,
connect a external station to the T1 and T2 services hoses, start the recovery to open
connected SV and carry out recovery by means of the external station.
Close both liquid V2 and V4 valves and vapour V1 and V3 valves on the tank and
disconnect all hoses from the tank.
Connect the blue liquid hose to the low side of the handheld manifold set. Connect
the red vapour hose to the high side of the same manifold set. Connect the central
hose of the manifold set to the recovery inlet of another tool.
Open V1 and V2 valves.
Open both valves on the manifold set and recover refrigerant form the tool. After
recovery is completed, wait for two minutes to see whether pressure rises to the
zero. Repeat the last phase until eliminating pressure completely.
Close both valves on the manifold set and disconnect hoses form the bottle.
SERVICE MANUAL
23
AC650PRO/AC690PRO ______________________________________________________________________
6.0 -
TROUBLESHOOTING AND DEFECT ANALYSIS
This chapter presents a short description of the defect types and the components that
may cause it.
ATTENTION:
Before any type of maintenance intervention, depressurise the station
to avoid gas outflows (see chapter 5.0).
6.1 -
The station does not recover
If the compressor works:
Disconnect high and low side service hoses from the A/C system of the vehicle and
let the recovery station HIGH and LOW valves open.
If pressure on pressure gauges drops during the SELFCLEANING phase, check if

EV3 and EV5 solenoid valves aren't supplied. If they are supplied replace the
board, if they are not supplied replace or clean solenoid valves since it means they
are leaking.
If pressure on pressure gauges does not drop, check if EV10, EV3 and EV5
solenoid valves are supplied. If they are supplied replace the faulty solenoid valve,
otherwise replace the electronic board.
NOTA BENE:
During the SELF-CLEARING phase the pressure on the manifolds does not shift since
EV3 and EV5 solenoid valves are closed.
If pressure on pressure gauges drops slowly:
Be sure the F1 mechanical filter is not obstructed (clean by compressed air).
Be sure the VU2 unidirectional valve is operating.
Be sure V1 and V3 valves are correctly open.
Be sure the pressure adjuster 3 is correctly calibrated to a 2 to 2,3 bars value,

connect a pressure gauge to the special service coupler on the adjuster.
Check the compressor 6 correct operation.
24
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
If the compressor does not work:
Check for the presence of 12 Vdc on the compressor relay coil.
Check status of fuses F2 and F3 (8 A delayed) located on the power board.
Check for the operation of compressor at the pressure of the recovery function
key. In case of malfunctioning replace the battery or the electronic board.
Check for the presence of 220 Volts on the compressor relay outlet pins. If there is
no voltage replace the defective board.
Check the value of the absorbed current if the compressor is supplied

(voltage reaches compressor). If the current value is 0 A or higher than 6 A, the
compressor has to be replaced.
If the FULL BOTTLE message is displayed:
Check the thank weight and drain the contents in case it is full (for instance carry
out some charges).
If the HIGH PRESSURE message is displayed:
Make sure valves V1, V2, V3 and V4 on the tank are open and hoses are
connected.
Check the high pressure gauge contacts P2. If pressure is less than 14,5 bars,
there must be continuity between pin 1 and 2 while pin 1 and 4 are open, when
14,5 bars are exceeded contacts between pin 1 and 2 open while those between
pin 1 and 4 close. If the gauge does not reflect this situation or its three pins are
shorted, replace it. If the gauge works correctly check harnessing cables or the
electronic card.
If the gauge works correctly the cause of the error message can be the obstruction
of the refrigerant flow to the tank. Check the operation of the one-direction valve
VU2 and make sure hoses are not obstructed.
If the CHANGE FILTER message is displayed:
Replace the filter and zero the counter (see special chapter).
If the message is still present after filter replacement, replace the electronic card.
SERVICE MANUAL
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AC650PRO/AC690PRO ______________________________________________________________________
The station completes the recovery but pressure on gauges does not decrease:
Make sure valve son tank V1, V2, V3 and V4 and HIGH and LOW valves are
open.
Be sure the P1 pressure transducer works correctly.
If the message RECALIBRATE THE SCALE is displayed, it means that the software,
containing a safety value to prevent the bottle filling in case of mis-calibration of the
scale, has intervened by displaying such message. In this case it is necessary:
To calibrate the scale; if the problem remains replace the loading cell or the
electronic board.
6.2 -
The station does not pull the vacuum
If the pump works but does not pull the vacuum in the A/C system of the vehicle carry
out following:
Check LOW and HIGH valves of the recharge station are open.
Check the plastic hose connected to the pump is well linked on both sides and that
it is not obstructed.
Check the correct level of oil in the vacuum pump, oil has to be even with the
reservoir sight glass on the pump side while the latter. Replace oil if necessary.
Check the pump induction is correct (the pump reaches a vacuum degree equal
0,066 mbar), if induction is good, replace the pump.
Remove the pump protection casing and make sure the supply cables are correctly
connected.
Check the EV1 and EV10 vacuum solenoid valve are live and work correctly.
If they are live replace the defective solenoid valve, if they are not live check
connection cables or replace the electronic board.
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If the message FULL SYSTEM is displayed:
Check on pressure gauges of the charge station M1 and M2 the inlet pressure, if it
exceeds 0,3 bar, carry out a recovery before pulling the vacuum.
If pressure on charge station gauges M1 and M2 is lower than 0,3 bar, check
pressure transducer P1 (see chapter 7.2).
If the problem persists replace the electronic card.
Check pressure calibration on the electronic board (see chapter 7.10).
If the vacuum pump does not work:
Check if pump is connected to the supply.
Check the status of F2 and F3 (8 A delayed) fuses on the electronic board.
Be sure there is 220 Volt voltage on the pump, if voltage is present be sure there
is not too much oil in the pump; if there is too much oil, drain some of it and
restart the pump. If it does not work replace the pump.
Be sure there are 12 Vdc on the pump relay coil; be sure are 220 V on the outlet
contacts. In case one of the two voltages is absent, replace the electronic card.
6.3 -
The station does not perform recycle
Check whether hoses are connected correctly to the tank and that valves V1, V2,
V3 and V4 are open.
Be sure the EV7 oil drain solenoid valve is not leaking.
Be sure the mechanic filter F1 are not obstructed, otherwise clean them with
compressed air.
Check the VU2 unidirectional valve correct operation.
Check the correct calibration of the pressure adjuster 3.
Make sure the refrigerant flow line is not obstructed, if necessary clean it.
If compressor does not work make sure there is supply voltage on compressor. If
there is no voltage check if supply cables and compressor relay work correctly.
SERVICE MANUAL
27
AC650PRO/AC690PRO ______________________________________________________________________
6.4 -
Non condensable gases are not discharged
Check the correct operation of the V6 automatic vent valve.
6.5 -
The station does not recycle
Make sure all hoses are connected correctly to the tank

V1, V2, V3 and V4 are open.
Make sure LOW and HIGH valves on service station are open.
Check for scale calibration.
Be sure the board accepts the set weight for the charge; if it does not accept it, be
sure the bottle contains enough coolant for the charge.
Be sure the EV6 and EV3 charge solenoid valves are live. If they are live replace
them since they are defective, if they are not live check the connection cables and
the electronic board; replace if defective.
Make sure the electronic scale is not locked.
28
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7.0 -
COMPONENTS CHECK AND MAINTENANCE
7.1 -
Pump
Technical features
Type:
Oil-bath type pump
Oil capacity:
500 cc. Approx.
Type of oil:
ROBINAIR special oil
Voltage:
230 V
Induction:
183 l/min
Vacuum:
0,066 mbar of absolute pressure equal 50 micron
To check the pump correct operation:
Make sure there is enough oil in the pump (it has to be even with the line on the
pump sight glass).
Apply on the induction port a vacuum meter to display the reached vacuum value.
Start the pump and check if it reaches a vacuum degree of 0,066 mbar equal
50 micron.
NOTA BENE:
For the good operation of the pump oil has to be replaced every 10 operating hours.
SERVICE MANUAL
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AC650PRO/AC690PRO ______________________________________________________________________
7.2 -
Pressure transducer P1
To check the transducer:
Be sure on pins 1 () and 2 (+) there are 24 Vdc of supply. If there is no voltage
check and if necessary replace the electronic card.
Be sure on pins 1 () and 3 (+ s.) there is the outlet signal. The outlet ranges from
0 Vdc to 10 Vdc.
For the transducer (SL31314) 0 bar / 10 absolute bars (-1 bar / +9 relative bars),
this means that 1,00 Vdc = 1,000 bars. If the manometers display 3 relative bars
(4 absolute bars), the voltage shall have to be 4 Vdc.
For the transducer (SL31410) 0 bar / 16 absolute bars (-1 bar / +15 relative bars),
this means that 1,00 Vdc = 1,600 bars. If the manometers display 3 relative bars
(4 absolute bars), the voltage shall have to be 2,5 Vdc.
NOTA BENE:
In case of replacement use the special glue to apply the new transducer.
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7.3 -
Safety pressure gauge P2
The pressure gauge is usually closed between contacts 1 and 2 and usually open
between contacts 1 and 4, it opens at 14,5 bar. To check the gauge:
Connect a service hose to a source tank.
Close the two valves on the storage tank.
Apply a pressure gauge to the red hose connecting the tank.
Start recovery.
When pressure reaches 14,5 bar the recovery has to stop and the message
HIGH PRESSURE has to be displayed.
Slightly discharge pressure on the tank by the valve on the tank vapour side before
resetting unit.
NOTA BENE:
In case of replacement use the special glue to apply the new gauge.
7.4 -
Expansion valve
Is calibrated to a 2 to 2,3 bars value, and keeps the valve outlet pressure constant.
To check the valve:
Connect the low side service hose to the coupler under the pressure adjuster,
through the supplied adapter.
Let the HIGH and LOW valves closed.
Start recycle function (the tank shall contain at least 4 Kg of refrigerant).
After about ten minutes, pressure should range 2 to 2,3 bar.
SERVICE MANUAL
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AC650PRO/AC690PRO ______________________________________________________________________
7.5 -
Filter dryer change
The filter dryer on this unit is conceived to trap acid and particulates and is formulated
to remove water from the refrigerant.
You must change the filter dryer to assure adequate moisture and contaminant
removal.
You can recycle up to 150 Kg of R134a. To help you know when you have reached that
point, the unit displays the warning message CHANGE FILTER thus inviting the
operator to replace the filter dryer.
To change correctly the filter dryer, follow carefully these instructions.
Connect the unit to the electrical power supplied and press the RECOVERY key.
Open the high and low pressure valves on the unit.
Wait for the end of self-cleaning.
Let the compressor operate until the pressure indicated on the manometers has
not decreased under the 0 (zero) bar value.
Press the STOP key to stop the compressor. Now all the refrigerant has been
drained from the filter and no pressure should be present.
Close the valves on the unit.
Disconnect the unit from the electrical power supply and remove the lower front
panel.
ATTENTION:
During the following phase it will be necessary to open the refrigerant
circuit of the unit. Wear goggles and gloves.
Disconnect the filter with caution and replace it with a new one. For better
tightness grease oil seals.
ATTENTION:
Check the correct positioning and the wear of grommets.
32
Set up the plastic protection again.
SERVICE MANUAL
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7.6 -
Reset counter filter dryer
After the change of the filter dryer, reset the counter.

To reset the counter follow carefully these instructions:
Simultaneously press the 3 and FLUSHING keys for some seconds.
The display shows the message 0000.
Digit 5555 on the keypad and press ENTER.
The functions menu is displayed.
Press the upwards cursor shifting key or the downwards cursor shifting key to
select either FILTER CHANGE and press ENTER to confirm.
The display displays a value, either in Kg or in Pounds, corresponding to the amount of

coolant that has been filtered.
Press the MULTIFUNCTION key and keep it pressed.
When the display shows 0000 release the MULTIFUNCTION key.
The display displays the functions menu again.
Press STOP to go back to the STAND-BY page.
SERVICE MANUAL
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AC650PRO/AC690PRO ______________________________________________________________________
7.7 -
Vacuum pump oil change
The oil of the vacuum pump must be changed frequently in order to assure higher
performances of the unit.
When the oil has to be changed, the display shows CHANGE OIL.
To change the oil, follow carefully these instructions:
Disconnect the unit from the power supply.
Put a beaker under the cap, open the cap and discharge the oil contained in the
vacuum pump.
When the pump is empty, screw in the cap and open the upper cap.
Fill the pump with the oil through the upper hole. Check the oil level in the pump
through the inspection glass; level has to reach the sight glass middle line.
When the pump is filled, close the upper cap.
7.8 -
Reset oil counter vacuum pump
After having changed the oil of the vacuum pump, reset the counter.
To reset the counter follow carefully these instructions:
The display shows the message 0000.
select either OIL CHANGE and press ENTER to confirm.
The display shows a value which corresponds to the working hours of the vacuum
pump.
Press the MULTIFUNCTION key and keep it pressed.
When the display shows 0000 release the MULTIFUNCTION key.
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7.9 -
Refrigerant scale calibration
Required equipment:
2 Sample weights.
After removing the rear cover, remove the container to the scale plate.
NOTA BENE:
The hoses from the internal container do not have to be disconnected. If you wish to
disconnect them, close the valves on the pipes and on the bottle.
The displays shows 0000.
Set the value 1111.
Press the ENTER key.
select either BOTTLE CALIBRATION and press ENTER to confirm.
The displays shows ZERO WEIGHT.
With the scale pan being completely empty, insert the numerical value 00.00 and
press the ENTER key.
The displays shows SAMPLE WEIGHT.
Position the sample weight on the scale plate (the suggested weight ranges
between 10 and 15 Kg).
Enter the sample weight value and press the ENTER key.
SERVICE MANUAL
35
AC650PRO/AC690PRO ______________________________________________________________________
7.10 -
Transducer calibration
The calibration is carried out on the electronic board through a simulator, since the
transducer has already been calibrated by the manufacturer.
Transducer (SL31314) 0 bar / 10 absolute bars (-1 bar / +9 relative bars)

For the calibration of the transducer, comply with the following:
Disconnect the transducer cable from the electronic board.
Connect the simulator SL31233 to the electronic board.
Connect a tester to the simulator.
Switch On the unit.
select either PRES. CALIBRATION and press ENTER to confirm.
The displays shows ZERO CALIBRATION.
Turn the simulator potentiometer until the voltage displayed by the tester reaches
0 V.
Digit 0,000 on the keypad and press ENTER to confirm.
The displays shows WEIGHT CALIBRATION.
4,00 V.
Disconnect the simulator and reconnect the transducer.
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Calibration verification
select either INPUTS TEST and press ENTER to confirm.
Disconnect the service hoses and open the HIGH and LOW valves on the front
panel so that pressure inside the transducer reaches the atmospheric value.
Verify that the read pressure value ranges within 0,900 and 1,100 bars
(the typical value is close to 1,000 bars).
Transducer (SL31410) 0 bar / 16 absolute bars (-1 bar / +15 relative bars)
For the transducer calibration comply with the following:
Disconnect the transducer cable from the electronic board.
Connect the simulator SL31233 to the electronic board.
Connect a tester to the simulator.
Switch On the unit.
0 V.
3,00 V.
Disconnect the simulator and reconnect the transducer.
SERVICE MANUAL
37
AC650PRO/AC690PRO ______________________________________________________________________
Calibration verification
select either INPUTS TEST and press ENTER to confirm.
Disconnect the service hoses and open the HIGH and LOW valves on the front
panel so that pressure inside the transducer reaches the atmospheric value.
Verify that the read pressure value ranges within 0,900 and 1,100 bars
(the typical value is close to 1,000 bars).
In case the simulator is not available, an emergency calibration can be carried out. Such
a procedure may be applied to both transducers and ensures anyway a proper
functioning of the unit. To carry out the emergency calibration comply with the following:
Switch On the unit.
Open the HIGH and LOW valves placed on the front panel.
Start the vacuum function and hold the vacuum for 5 minutes inside the hoses
(such an operation also pulls a vacuum in the transducer).
Once the 5 minutes have elapsed stop the vacuum function, by verifying also on
the manometers that there are no leakages.
After pulling a vacuum inside the unit, stroke 0,000 on the keyboard and press
ENTER to confirm.
Disconnect the service hoses so that the pressure value in the transducer reaches
the atmospheric value.
Carry out the verification as described above.
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7.11 -
Oil replenishing scale calibration
Required equipment:
2 Sample weights.
Set the value 1111.
select either IN OIL CALIBRATION and press ENTER to confirm.
With the scale pan being completely empty (bowl disconnected), insert the
numerical value 00.00 and press the ENTER key.
between 200 and 1000 g).
NOTA BENE:
It is possible to weigh one of the bottles containing the oil and use it as sample weight.
SERVICE MANUAL
39
AC650PRO/AC690PRO ______________________________________________________________________
7.12 -
Oil purge scale calibration
Required equipment:
2 Sample weights.
Set the value 1111.
select either OUT OIL CALIBRATION and press ENTER to confirm.
With the scale pan being completely empty (bowl disconnected), insert the
numerical value 00.00 and press the ENTER key.
between 200 and 1000 g).
NOTA BENE:
It is possible to weigh one of the bottles containing the oil and use it as sample weight.
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SERVICE MANUAL
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8.0 -
TEST AND PARAMETERS SELECTION
You will find below some tests used to carry out checks and the modification of the
some setup parameters.
8.1 -
LCD test
This test allows checking the LCD and LEDs operation.
Enter the code 1515.
A menu is displayed containing the operations that may be carried out.
Press the cursor shifting key upwards or downwards to scroll the menu.
Select the DISPLAY TEST function and press ENTER to enter.
The display pixels and the LEDs are illuminated in sequence to check their correct
functioning.
8.2 -
Outputs test
This test allows checking the functioning of relays and connected components.
Select the OUTPUTS TEST function and press ENTER to enter.
As soon as the outputs test function is entered the compressor starts.
Press ENTER to shift to the next component.
SERVICE MANUAL
41
AC650PRO/AC690PRO ______________________________________________________________________
The following elements illuminate in sequence:

Compressor.
Pump.
EV1 EV2 (EV2 not used).
EV3 EV4 (EV4 not used).
EV5.
EV6.
EV7.
EV8.
EV9.
EV10.
ATTENTION:
During this operation, parts of the circuit that could be under pressure
are open. Be sure the circuit has been the depressurized
(see chapter 5.0) before continuing.
8.3 -
Inputs test
This test allows checking the electronic board digital inputs.
Select the INPUTS TEST function and press ENTER to enter.
The display shows in sequence:

Bottle weight.
IN OIL Weight (valid for AC650PRO/AC690PRO only).
OUT OIL Weight (valid for AC650PRO/AC690PRO only).
Transducer (valid for AC550PRO/AC590PRO and AC650PRO/AC690PRO only).
NOTA BENE:
Values measured by the scales relate to the net weights (total weight less preset tare).
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8.4 -
Helium test
This function enables solenoid valves EV1, EV3, EV5, EV6 to the test of production
with the HELIUM machine for leak detection.
8.5 -
Printer test
This function always performs a test print-out.
Select the PRINTER TEST function and press ENTER to print.
8.6 -
Counters
This function displays the total of operations performed by the unit.
Select the COUNTERS function and press ENTER to enter.
The display shows the history report of the recovered coolant (total amount before
installation) and the history report of the pump operating hours (total amount
since first installation).
SERVICE MANUAL
43
AC650PRO/AC690PRO ______________________________________________________________________
8.7 -
Service printing
This function allows printing a report with some data on the unit.
Select the SERVICE PRINTING function and press ENTER to print.
In the print-out report the following data are displayed:

Total of recovered coolant.
Total of working hours of the vacuum pump.
Bottle scale calibration date.
IN OIL scale calibration date (date valid for AC650PRO/AC690PRO only).
OUT OIL scale calibration date (date valid for AC650PRO/AC690PRO only).
8.8 -
Oil discharge
This function enables to open the EV7 solenoid valve and to bleed pressure from the
distiller; it is thus possible to carry out the maintenance on the EV7 solenoid valve itself.
Comply with the following procedure:
Select the OIL DISCHARGE function and press ENTER to enter.
The displays shows EV7.
Press MULTIFUNCTION to open EV7 valve.
let EV7 valve open until there is no more pressure inside the distiller.
Press STOP to close EV7 valve again and carry out the maintenance operations on
the solenoid valve itself.
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8.9 -
Parameters modification
For specific needs, some operating parameters can be modified.
ATTENTION:
The set values guarantee the correct functioning of the unit.
The modification of these parameters shall have to be carried out only
by the personnel in charge with the servicing of the A/C system being
duly authorized by the manufacturer.
Select the parameter and press ENTER to modify it.
After modifying the parameter, press ENTER to confirm.
Parameters to be modified are:
P1
Discharge system pressure. It is the absolute pressure value which, if exceeded, starts
the recovery. The default value is 1500.
P2
End of recovery pressure. It is the absolute pressure value which, if exceeded, stops
the recovery. The default value is 600.
P3
Vacuum test pressure. It is the absolute pressure value after which the vacuum test
turns out to be negative. The default value is 300.
T1
Pump oil change threshold. It is the number of hours after which the message to
change the oil pump is displayed. The default value is 10.
T2
Self-cleaning time. It is the self-cleaning time expressed in seconds. The default value is
120.
T3
Recovery maximum time, after which the function is interrupted and the display shows
the message HIGH RECOVERY TIME. The default value is 30 minutes.
SERVICE MANUAL
45
AC650PRO/AC690PRO ______________________________________________________________________
T4
Weight variations control threshold. It is the interval expressed in seconds after which
the weight stability is checked during the recovery phase. Once this time interval has
elapsed the recovery function is stopped if the weight has not varied
(AC450PRO/AC490PRO only). The default value is 60.
T5
Oil discharge time. It is the oil discharge time expressed in minutes. The default value
is 5.
T7
Preset vacuum time. The default value is 20 minutes and has been obtained as average
value of the times suggested by car manufacturers.
T8
Not used.
T9
Vacuum test time, time for the check of any pressure increase after the vacuum.
The default value is 300 seconds.
T10
Recycling plus vacuum time. It is the recycling plus vacuum function time expressed in
minutes. The default value is 10.
T13
Charge maximum time, after which the function is interrupted and the display shows
the message INCOMPLETE CHARGE. The default value is 20 minutes.
T14
Dye EV9 valve opening time. It is the opening time expressed in seconds of the EV9
solenoid valve which enables the injection of a dye dosage (AC650PRO/AC690PRO only).
The default value is 5.
T15
Oil charge maximum time, after which the function is interrupted and the display shows
the message OIL CHARGE TIME HIGH (AC650PRO/AC690PRO only).
The default value is 10 minutes.
T16
Flushing function maximum time, after which the function stops automatically and
continues. The default value is 15 minutes.
T20
Vacuum test duration for flushing. It is the vacuum test time expressed in seconds
during the flushing function. The default value is 120.
T21
EV7 valve opening time during oil discharge. It is the opening time expressed in
seconds of the EV7 solenoid valve during the oil discharge function. The default value is
180.
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W1
Filter replacement threshold. It is the value expressed in Kilograms after which the
message replace the dehydrating filter is displayed. The default value is 150.
W6
Small bottle maximum capacity. It is the value expressed in grams of the maximum
quantity of product with which the small bottle can be filled (AC450PRO/AC490PRO
only). The default value is 10000.
W8
Big bottle maximum capacity. It is the value expressed in grams of the maximum
quantity of product with which the big bottle can be filled (AC550PRO/AC590PRO and
AC650PRO/AC690PRO only). The default value is 20000.
OUTOIL2
Maximum capacity of the OUT OIL bottle, if this capacity is exceeded the message
BOTTLE FULL, DRAIN BOTTLE is displayed (AC650PRO/AC690PRO only).
The default value is 250 grams.
OUTOIL3
Not used.
PIPES CLEANING TIME
Minimum time for the cleaning of the service pipes. It is the minimum time in seconds
being necessary to empty the service pipes after the charge (AC550PRO/AC590PRO and
AC650PRO/AC690PRO only). The default value is 60.
REPORT MANAGEMENT
It is necessary to enable the data memorization function through the PC ACUSB
interface (optional). The default value is 0 (disabled).
COMPENSATION SET TO 0
It is necessary to set the compensation function to 0 (that is to disable the
compensation) during the charging phase. The default value is 0 (disabled).
BY-PASS
It is necessary to enable the by-pass function. When it is enabled it is possible to
by-pass the waiting times in the main functions of the machine through the
MULTIFUNCTION key. The default value is 0 (disabled).
ECOLD 2006
The CPU cards of 2006 may be used for the systems of 2004/2005 only by setting the
value to 0. If the value is set to 1 the card is set up for 2006 systems only.
The default value is 1.
RENAULT CONFIG.
Mode required by Renault for its chain, it modifies the waiting times between recovery
cycles by extending them. It can be enabled or disabled by selecting the relevant
option.
SERVICE MANUAL
47
AC650PRO/AC690PRO ______________________________________________________________________
BACKUP
To save station data before updating the software. For the backup follow instructions
below:
Select the function and press ENTER to enter.
Introduce a key (other than the programming key) to store data.
Confirm the cancellation of data already present on the key, if any.
At the end of the backup extract the key.
Update the software and switch off the unit.
Introduce the backup key to transfer data, hold down the MULTIFUNCTION key,
switch on the unit and release the MULTIFUNCTION key.
At the end of the operation extract the key.
NOTA BENE:
The backup phase prevents a new calibration of the unit after an update of the
software.
8.10 -
Software update
By the programming key it is possible to update the software and the unit messages.
Before updating, carry out a backup of EEPROM to prevent loosing the unit calibration
and setup parameters.
To carry out this operation follow instructions below:
Switch off the unit.
Introduce the programming key.
Introduce the backup key to transfer data, hold down the MULTIFUNCTION key,
switch on the unit and release the MULTIFUNCTION key.
At the end of programming the unit resets automatically.
Extract the programming key.
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9.0 -
DIAGRAMS
9.1 -
Flow diagram
M2
HIGH
T2
EV3
M1
EV10
LOW
EV5
P1
T1
EV9
VU3
11
EV8
M3
VU1
12
P2
EV6
EV1
F1
HP
V5
V6
VU2
5
F2
4
V1 V3
EV7
10
7
V4 V2
9
13
8
SERVICE MANUAL
49

9.2 -
AC650PRO/AC690PRO ______________________________________________________________________
Power card
N
220 V
10
EV1
INT
EV3
EV8
EV7
EV6
EV5
EV9
EV10
EV2
EV1
POMPA
FAN
F3
EV10 EV9 EV8 EV7 EV6 EV5 EV4
CN1
CPU
F2
COMP
F1
HP
L N T
VENTOLA
P2
EV3
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Display card
Power card
connection
CPU
9.3 -
PROGRAM
RS-232
OUT OIL PRESSURE
SERVICE MANUAL
IN OIL
Printer
serial
connection
PRN
Programming
connector
RS232-B
TANK
2 Serial
Tank scale
connection
Printer
power supply
connection
Oil injection
scale
connection
Oil purge scale
connection
Transducer
connection
51
AC650PRO/AC690PRO ______________________________________________________________________
9.4 -
Flow diagram components description
2 Vacuum pump: two-stage rotary pump with capacity 183 l/m, conceived to
remove humidity and air from A/C systems.
3 Expansion valve: measures the refrigerant flow into the tool oil separator.
The allowable tolerance of the valve is 2 - 2,3 bar. To check tolerance connect a
pressure gauge at the oil service/discharge inlet port and replenish at least 4,5 Kg
of refrigerant for 10 minutes.
4 A/C system oil separator: heat exchanger: cedes heat to the internal cylinder
thus triggering the formation of saturated vapour and the evaporation of the
accumulated refrigerating liquid, stops the refrigerant inlet into compressor and
enables refrigerant oil to deposit on the separator bottom.
5 Compressor oil separator: separates compressor oil taking it out of

compressor during the refrigerant flow. Oil is replenished in the compressor.
6 Compressor: sealed compressor with 14 cc. piston used to make refrigerant

flow. It turns low pressure and low temperature of inlet gas into high pressure and
high temperature of outlet gas.
7 Bottle: allows the storage of recovered refrigerant.
8 Scale: sends a signal to the electronic card for the accurate readings of the
weight and for the protection of the tank overfilling.
12 Oil replenishing scale: sends a signal to the electronic board of the

accurate readings of the weight and of the empty oil bottle.
13 Oil purge scale: sends a signal to the electronic card for the accurate
readings of the weight and for the protection of the oil bottle overfilling.
T1 Low side hose (" Acme 14 mm, without quick coupler): enables the
flow from the low side of an A/C system to the low side valve.
T2 High side hose(" Acme 14 mm, without quick coupler): enables the
flow from the high side of an A/C system to the high side valve.
M1 Low side pressure gauge: displays pressure and/or vacuum inside the tool
low side hose.
M2 High side pressure gauge: displays pressure and/or vacuum inside the tool
High side hose.
M3 Inside tank pressure meter: visualize the pressure into the unit storage
tank.
F1 Inlet line filter: filters refrigerant from the valve assembly before it enters the
manifold set.
F2 Filter dryer: remove humidity and filters the refrigerant flow. The average life
of the filter is of 150 Kg of recovered refrigerant.
52
SERVICE MANUAL
_____________________________________________________________________ AC650PRO/AC690PRO
VU1 Oil protection unidirectional valve: Valve that prevents the passage of
the coolant inside the measurable container 1, in case the EV8 solenoid valve
should malfunction.
VU2 Single direction discharge valve: allows the flow in one single direction
and prevents the correction of tank refrigerant and pressure into the low pressure
of the tool when oil goes back to the compressor and pressurises the oil separation
circuit.
VU3 UV dye protection unidirectional valve: Valve that prevents the passage
of the coolant inside the measurable container 11, in case the EV9 solenoid valve
should malfunction.
EV1 Vacuum solenoid valve: automatic solenoid valve usually closed preventing
the refrigerant flow in the vacuum pump when the latter is not supplied. When it is
supplied it allows the flow from the A/C system to the vacuum pump.
EV3 Passage solenoid valve: circuit sectioning

They separate into two sections the hydraulic circuit.
EV5 Recovery solenoid valve: automatic solenoid valve usually closed

preventing the refrigerant flow into the oil separator if the latter is not supplied.
EV6 Recharge solenoid valve: automatic solenoid valve usually closed

preventing the refrigerant flow from the tank to the tool when the latter is not
supplied.
EV7 Oil drain solenoid valve: allows the oil of refrigerant removed form the
A/C system to be drained after recovery. It is also used as service door.
EV8 Oil replenishing solenoid valve: allows new oil to enter the A/C system for
replenishing it.
EV9 UV dye injection solenoid valve: allows the UV dye to enter in the A/C
system.
EV10 High/low pressure separation solenoid valve: It enables to carry out

the charge only from the high side during the automatic function.
Pressure transducer P1: component managing the car function and supplying
continuously the ecu with data on the A/C system pressure.
Safety pressure gauge P2: usually closed between contacts 1 and 2, opens at
14,5 bar and closes again at 11,9 bar. If in the A/C system high side pressure
exceeds 14,5 bar, the switch opens on contacts 1-2 and closes on 1-4, thus
stopping all functions.
SERVICE MANUAL
solenoid
valves.
53
AC650PRO/AC690PRO ______________________________________________________________________
10.0 -
GLOSSARY OF TERMS
Refrigerant: A refrigerant solely of the type for which the unit has been created
(ex. R134a).
A/C system: Air-conditioning system in the motor vehicle.
Unit: AC650PRO/AC690PRO equipment for the recovery, recycling, evacuation and

filling of the A/C system.
External tank: Non-refillable fresh refrigerant (ex. R134a) cylinder, used to fill
the refrigerant tank.
Refrigerant tank: The tank specifically designed for the unit.
Function: Execution of an individual function.
Recovery/Recycling: Function in which the refrigerant is recovered by an

A/C system and stored in the internal container.
Evacuation: Function in which incondensables and moisture are evacuated from

an A/C system solely by means of a vacuum pump.
Oil injection: Introduction of oil inside an A/C system for the purpose of
maintaining the amount of oil specified by the manufacturer.
Filling: Function during which refrigerant is

A/C system in the amount specified by the manufacturer.
54
introduced
into
an
SERVICE MANUAL

AC 690 Service Eng

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AC650PRO/AC690PRO

GENERAL RULES FOR MAINTENANCE

Vacuum and recycle (simultaneously)

Replenishing compressor oil

Discharge of non condensable gases

EVACUATION OF THE TOOL

TROUBLESHOOTING AND DEFECT ANALYSIS

The station does not recover

The station does not pull the vacuum

The station does not perform recycle

Non condensable gases are not discharged

The station does not recycle

COMPONENTS CHECK AND MAINTENANCE

Safety pressure gauge P2

Filter dryer change

Reset counter filter dryer

Vacuum pump oil change

Reset oil counter vacuum pump

Refrigerant scale calibration

Oil replenishing scale calibration

Oil purge scale calibration

TEST AND PARAMETERS SELECTION

Flow diagram components description

GENERAL RULES FOR MAINTENANCE

It is necessary to wear suitable protections such as goggles and gloves, the

Do not inhale refrigerating gases fumes.

Before connecting the AC650PRO/AC690PRO unit to an A/C system or to an

Extraordinary maintenance interventions have to be performed by authorised staff

Pressure of leaks of the HCF-134a service equipment or of the air conditioning

The unit has to work in a sufficiently ventilated environment.

Do not subject the AC650PRO/AC690PRO unit to dripping.

Work in environments with sufficient lighting.

1. Red hose tank

2. Yellow hose 600 mm + O'RING

3. 244 cm High side red hose

4. High side quick coupler

8. Vacuum pump oil 0,45 l

Vacuum pump oil 0,95 l

Vacuum pump oil 3,8 l

9. Piston for solenoid valve 4,5 mm

10. Tank adapting coupler

11. Tank quick coupler

12. Joints for 1/4 SAE hoses

13. O'RING 3037 14

14. AC650PRO Frontal thermoform

38. Pressure transducer (P1)

39. Check valve Kit

40. Safety pressure gauge (P2)

41. Pipes side thermoform

42. Power card

43. Union tee

44. Uncondensate discharge valve

16. Front panel

45. Cylindrical gear reducer

17. Inside tank pressure meter (M3)

46. Tank security valve

18. Low side gauge (M1)

47. Double profile for AC Robinair

19. Display card

48. AC650PRO Rear thermoform

20. High side gauge (M2)

49. 20 Kg Storage tank (7)

21. Red handle

50. Oil injection assembled bottle