Instruction 2072-0400
Operation & Maintenance
Rev. 0 – March 2002
Product Leadership • Training • Service • Reliability
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Contents
MAC 2000
Table of Contents
1 Introduction ..........................................................................................................1
1.1 Glossary of Terms.....................................................................................................2
1.2 General Operating Guidelines.................................................................................2
1.3 Component Location and Description.....................................................................3
1.4 Using the Function Keys..........................................................................................7
2 Initial Set-Up.........................................................................................................9
2.1 Initial Set-Up Instructions ......................................................................................9
2.3 External Source Tank Testing...............................................................................11
3 Operation .............................................................................................................13
3.1 MAC2000 Operational Overview...........................................................................13
3.3 Recovery Mode........................................................................................................18
3.4 Vacuum Mode (Evacuation)...................................................................................19
3.5 Charge Mode...........................................................................................................20
3.6 System Flush Mode (Oil Flush).............................................................................22
3.7 Refrigerant Management System .........................................................................24
3.8 Internal Tank Manual Refill .................................................................................25
3.9 System Set Up ........................................................................................................26
3.10 Identify Refrigerant ...............................................................................................26
3.11 Check Internal Tank for Air ..................................................................................27
4 Maintenance........................................................................................................29
4.1 Changing the Filter Drier......................................................................................29
4.2 Replacing the External Source Tank ....................................................................30
4.3 Replacing the Printer Paper..................................................................................31
4.4 Replacing the Refrigerant Identifier Filter...........................................................32
5 Parts and Service ...............................................................................................33
5.2 Service Centers.......................................................................................................34
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MAC2000
SERIES: MAC2000
Refrigerant: 134a
KENT MOORE: J-055000
Air Conditioning and Refrigerant
Service Solution
WARNING
PRESSURIZED TANK CONTAINS LIQUID REFRIGERANT. OVERFILLING OF THE TANK MAY CAUSE
VIOLENT EXPLOSION AND POSSIBLE INJURY OR DEATH. Safety devices require the use of only authorized
refillable tanks. Refer to the instruction manual for tank specifications and ordering information. Do not recover
refrigerants in a non-refillable storage container! Regulations require refrigerant to be transported only in
specifically authorized containers.
ALL HOSES MAY CONTAIN LIQUID REFRIGERANT UNDER PRESSURE. Contact with refrigerant may cause
injury. Wear proper protective equipment, including safety goggles. Disconnect hoses with extreme caution.
HIGH VOLTAGE ELECTRICITY INSIDE PANELS. RISK OF ELECTRICAL SHOCK. Disconnect power before
service unit. Refer to the instruction manual.
TO REDUCE RISK OF FIRE, avoid the use of an extension cord. The extension cord may
overheat. If you must use an extension cord, the cord must be 14 AWG minimum and as short as possible. Do not
use this equipment in the vicinity of spilled or open containers of gasoline or other flammable substances.
Use this equipment in locations with mechanical ventilation that provides at least four air changes per hour or
locate the equipment at least 18 inches above the floor.
Make certain that all safety devices are functioning properly before operating the unit. Before operating, read and
follow the instructions and warnings in the manual.
CAUTION: SHOULD BE OPERATED BY QUALIFIED PERSONNEL. Technician must be familiar with air
conditioning and refrigeration systems, refrigerants and the dangers of pressurized components.
Use with the R-134a refrigerant only. This equipment is not designed for any other purpose other than recovering,
recycling and charging refrigerants. Do not mix refrigerant types.
OPERATING NOTES
Change the filter-drier when the display shows Change Filter message. Follow the instructions for the changeover.
At temperatures exceeding 120 °F / °C, wait 10 minutes between recovery jobs.
R-134a WARNINGS!
Use the MAC2000 unit only with R-134a refrigerants. Cross-contamination with other refrigerant types will cause
severe damage to the A/C systems and to service tools and equipment. Do not mix refrigerant types through a
system or in the same container.
Avoid breathing A/C refrigerant and lubricant vapor mist. Exposure may irritate eyes, nose and throat. To remove
R-134a from the system, use service equipment certified to meet the requirements of SAE-J2210 (R-134a
recycling equipment). If accidental system discharge occurs, ventilate work area before resuming service.
HFC-134a service equipment or vehicle A/C systems should not be pressured tested or leak tested with
compressed air. Some mixtures of air/HFC-134a have been shown to be combustible at elevated pressures.
These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage.
Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
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MAC2000
Introduction
1 Introduction
Important! These instructions are for qualified personnel, trained and
experienced in the handling of refrigerants. Federal and state laws
may require the licensing of refrigerant handling personnel. Failure to
follow proper operating procedures may cause personal injury and
equipment damage
The Bacharach Test System’s Mobile Air Conditioning MAC2000 is
the most advanced refrigerant management system on the market
today. It is a complete automotive A/C service tool that will identify,
recover, recycle, flush and troubleshoot automotive R-134a A/C
systems in a fully automatic manner.
A large liquid crystal diode (LCD) display screen prompts the
technician for input and displays system status. An internal 30 pound
recovery tank and electronic scale ensure convenient refrigerant
storage and accurate refrigerant management.
Upon power up, the unit performs a self-test and, if necessary, a self-
evacuation routine. The technician may then select the specific
function required for the job. During operation, the MAC2000 checks
for error conditions and alerts the technician if any exist.
The entire service procedure can be done with one hook-up to the
vehicle. A built-in refrigerant identifier checks for contaminated
refrigerant prior to recovery. Pressures are shown on the high and low
side gauges, and other operating information is shown on the screen.
Refrigerant is recovered into and charged out of an internal storage
tank. The MAC2000 unit automatically refills this tank with
refrigerant from an external source tank as needed in order to
maintain a constant 12–15 lbs (5.45–6.82kg) of refrigerant available
for charging. One quick connection is all that’s needed to replace the
source tank when it is empty.
Other time saving features include automatic air purge, single pass
recycling, and automatic oil drain. The unit also automatically clears
refrigerant from its high- and low-side hoses after every job. A red
light on top of the unit flashes whenever a process is complete or when
the unit needs attention from the technician.
The MAC2000 is ETL listed to UL standards and meets SAE
specifications for recycled refrigerant.
Instruction 2072-0400
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Introduction
MAC2000
1.1 Glossary of Terms
A/C
A/C System
Unit
Air conditioner or air conditioning
The vehicle’s air conditioning system
The MAC2000 itself
Screen
LCD Display
Contaminated
Refrigerant that has been mixed with some
other type of refrigerant.
1.2 General Operating Guidelines
• The MAC2000 monitors the AC line voltage and disables itself if
the voltage drops below 100 VAC or rises above 135 VAC. An error
message will be displayed on screen when the line voltage is out of
tolerance. The unit must be turned OFF and then back ON to reset
the voltage monitoring circuitry. Extension cords must be a
minimum of 14 AWG and kept as short as possible.
Common causes for electrical problems include:
- Long extension cords
- Faulty, overloaded electrical circuits
- Drop lights
- Improper ground or improper polarity
• The screen shows options and gives instructions for most service
and maintenance tasks. Read the on-screen prompts and follow
their instructions.
• The MAC2000 prompts a technician to check the system oil drain
bottle on the side of the unit for recovered oil. Any system oil that is
lost is automatically drained during recovery. A technician must
measure and record the lost amount of oil in order to know how
much new oil to add during charging. Refer to the A/C system
manufacturer’s service manuals for oil specifications. Dispose of
used oil properly.
• In general, it is best to leave the MAC2000 turned ON throughout
the workday. This allows the unit time to purge itself of air and
refill the internal storage tank. Turn the unit OFF at the end of the
day.
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MAC2000
Introduction
1.3 Component Location and Description
MAC2000 Control Panel
High Side Gauge – Shows the pressure in
the high side of the vehicle’s A/C system.
Enter Key – Press to accept a value as
displayed on the screen.
Low Side Gauge – Shows the pressure in
the low side of the vehicle’s A/C system.
Weight Convert Key – Press to change
the charge amount between pounds,
pound & ounces, and kilograms. Pushing
this key allows a technician to scroll
through the different weight units.
LCD Display (Screen) – Displays all
operational, error, and maintenance
messages.
Arrow Keys – Use these keys to select
variables and adjust values such as
charge weight and vacuum time. The
Increase and Decrease keys are used to
adjust numerical values, while the Back,
Forward, Left and Right keys are used to
move between values displayed on the
screen.
Refrigerant Identifier Filter – Protects the
refrigerant identifier sensor from
contaminants.
Printer – Provides a printed record of the
functions performed by the MAC2000. The
printer can print the record of the
MAC2000’s last operation as well as other
refrigerant management data and
operational statistics.
F1 – F5 Function Keys – Use these keys to
select various modes and functions on the
MAC2000. A key’s current function is
described directly above it on the screen.
Start Key – Press to start a function.
Pause/Reset Key – Press to either pause,
reset, or abort a function and return the
display to the Main menu.
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Introduction
MAC2000
MAC2000 Front View
MAC2000 Right-Side View
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MAC2000
Introduction
MAC2000 Left-Side View
MAC2000 Back View
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Introduction
MAC2000
Closeup of MAC2000 Handle Panel
Note: The auxiliary tank ports are not used as this time.
Temperature and Velocity Data Ports
Note: The communications ports are used for software updates and
future options, and are not used during normal operation.
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MAC2000
Introduction
1.4 Using the Function Keys
The operation of each function key (F1–F5) depends on the service
operation and unit status. The display shows five labels along the
bottom of the screen pointing to the function keys below. Each label
shows the action the key will activate. To make a selection, press the
function key immediately below the arrow.
The Next menu function key takes the technician to the next set of
menu items. There will always be a menu item to take the technician
back to the main menu.
1.5 Using the Up/Down, Increase, Decrease, and
Back/Forward Arrow Keys
Pressing the Up/Down and Back/Forward keys moves the cursor on
the screen in that direction. In addition, when entering numeric data,
pressing the Increase key will increase the number, while pressing
the Decrease key will decrease the number.
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Introduction
MAC2000
Notes:
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MAC2000
Initial Set-Up
2 Initial Set-Up
2.1 Initial Set-Up Instructions
WARNING
It is extremely important to follow these instructions! Improper
setup will result in potential inaccuracies when operating the unit.
1. Un-box the MAC2000.
2. Open the accessory box that contains the rear and side tray mats,
the high- and low-side service hoses, the snap-shot transmitter,
and one spare printer paper roll.
3. Drop the mats into the side and rear storage trays.
4. Attach the blue low-side service hose to the service-hose fitting
with the blue label, and attach the red high-side service hose to the
red service fitting.
5. Attach the snap-shot transmitter to its magnetic storage plate.
6. Install an external source tank of R-134a refrigerant on the lower
shelf of the unit, below the handle. The external source tank
should be inverted so liquid refrigerant is supplied to the internal
tank. The MAC2000 can handle 30 lb (14kg) or 50 lb (23kg)
commercial tanks. Secure the tank to the unit by placing the strap
around the tank and tightening it. WARNING: Failure to
secure the source tank properly could result in injury!
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Initial Set-Up
MAC2000
7. Attach the yellow refill hose coming from behind the tank to the
source tank fitting. Open the source tank valve. To avoid the
possible of lost refrigerant, the external source tank should be
checked for leakage around the tank valve. If leakage is found,
close the valve and keep it closed at all times except during a
manual tank refill operation as described in Section 3.8.
Bacharach Test Systems does not reimburse for lost refrigerant.
8. Attach the unit’s power cord to 115VAC 50/60 Hz, 15 Amp
grounded outlet. Avoid using long extension cords.
9. Set the main Power switch (located under the handle) to ON.
10. There is a brief initialization period of several seconds. The
technician will be prompted to set-up the following parameters.
(This initial set-up procedure occurs only once when a new unit is
turned on. Subsequent changes can be made using the System Set-
Up mode per Section 3.9 at any time.)
a) Set Date & Time: Press the Enter key to change the date. Use
the Left/Right and Up/Down keys to make adjustments. Press
the Enter key again to save the changes.
b) Select Language: Select the preferred Language.
c) Select Units: English or Metric (English is the Default).
d) Calibrate the Pressure Transducers: Remove high- and low-
side hoses from side of unit; then follow on-screen prompts to
calibrate the pressure sensors.
e) Set Elevation: Enter the unit’s elevation above sea level for
your location ± 500 feet.
11. The MAC2000 now automatically evacuates all air from the
internal circuit and tank, and pre-charges the tank with 12 lbs of
R-134a. This process takes approximately 15 – 20 minutes.
WARNING
Always wear eye protection when working with refrigerants.
Refrigerants can cause injury. Read and follow all warnings at the
beginning of this manual before operating this unit.
CAUTION! R-134a systems have special fittings (per SAE
specifications) to avoid cross contamination with R12 systems. Do not
attempt to adapt your unit for another refrigerant type system, or
failure will result!
12. The MAC2000 is now set-up and ready for operation.
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MAC2000
Initial Set-Up
2.2 Checking Vehicles for Possible
Contaminated Systems
Before every recovery, the MAC2000 automatically samples the
refrigerant in the vehicle’s A/C system. If the system fails the purity
level required, the unit tests a second time. In the event the system
fails a second time, the unit prompts that the hoses be disconnected
from the vehicle. Follow the on-screen prompts in order to clean out
the MAC2000.
Note: The MAC2000 must be disconnected from the vehicle before
starting the cleaning process. It is illegal to knowingly vent or allow
refrigerant to vent to the atmosphere. This illegal venting will occur if
the unit is left attached to the vehicle.
Please refer to your shop’s policy for dealing with contaminated
refrigerant.
2.3 External Source Tank Testing
The MAC2000 features an exclusive source tank refrigerant
identification process that checks the source refrigerant before it is
added to the unit’s internal tank. This testing is automatic and does
not require any action by the technician. This feature prevents
contaminated refrigerant from entering the MAC2000, thus rendering
it inoperable.
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Initial Set-Up
MAC2000
Notes:
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MAC2000
Operation
3 Operation
3.1 MAC2000 Operational Overview
The MAC2000 is an EPA-approved, ETL-listed, single-pass recycling
system. During the recovery operation, refrigerant is removed from
the vehicle and passed through an oil separator and filter drier before
entering the storage tank.
The MAC2000’s refrigerant weighing system is extremely accurate. It
has sophisticated error correction capability that minimizes incorrect
readings caused by bumps or vibration. Even with this protection,
however, the MAC2000 should be placed on level ground and out of
the way of foot traffic. Do not touch or move the unit while it is
operating!
To ensure that the displayed reading of recovered refrigerant is
accurate, the unit will perform a low side clearing routine, if
necessary, when the power is turned on. If refrigerant is sensed in the
accumulator, the screen will display “Clearing System”. This
indicates refrigerant in the accumulator is being transferred to the
storage tank.
At any time during system operation, pressing the Weight Convert
key can change the weight units. The available units are pounds only,
pounds & ounces, or kilograms.
Power Up – When power is applied, the unit performs a self-
diagnostics. When these tests are complete, the display shows “Select
mode.”
Main Data Display – (See illustration of Main Data Display in
Section 1.5 on Page 7.) Shows the date, time, ambient temperature,
RH%, AC line voltage, low- and high-side pressures, and the amount
of refrigerant available for charging. Use the function keys (F1 – F5)
to select the desired mode as described in the following paragraphs.
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Operation
MAC2000
Main Menu
Recovery
mode
Vacuum
mode
Charge
mode
Snapshot
mode
Next
menu
• Recovery mode – Recovers and recycles refrigerant from a vehicle’s
A/C system. This mode is most often used prior to opening an A/C
system to atmosphere to replace a system component.
• Vacuum mode – Removes residual air and moisture from a system
previously opened to the atmosphere. This mode also allows a
technician to verify that the A/C system will hold a vacuum for a
certain length of time.
• Charge mode – Select this mode to add refrigerant to an A/C
system; also most commonly used to “top off” the system.
• Snap-Shot mode – Monitors and records important operating
information including the high- and low-side pressures, ambient
temperatures, A/C vent temperatures, ambient humidity, and
(optionally) vent air flow velocities. This information is used to
diagnose and measure A/C performance before and after service.
• Next menu – Displays Menu 2.
Menu 2
Main
menu
System
flush
Tank
refill
System
set-up
Next
menu
• Main menu – Returns display to the Main menu.
• System flush – Removes all oil and refrigerant from an A/C system.
This mode is often used prior to retrofitting a system to R-134a.
• Tank refill – Overrides the automatic tank refill function of the
MAC2000 and transfers refrigerant from the external source tank
to the internal storage tank.
• System set-up – Sets up certain operating parameters in order for
the MAC2000 to operate correctly. The set-up information must be
entered prior to operating the MAC2000.
• Next menu – Displays Menu 3.
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MAC2000
Operation
Menu 3
Main
menu
Identify
mode
Check
tank air
Refri
data
Filter
change
• Main menu – Returns display to the Main menu.
• Identify mode – Identifies refrigerant in a vehicle’s A/C system
without having to recover the refrigerant. After the unit is finished
identifying the refrigerant the display returns to the Main menu.
• Check tank air – This option allows a technician to manually check
the internal source tank for air and other non-condensables, and
then purges the tank if too much air is present.
• Refri data – Accesses the unit’s historical refrigerant data.
• Filter change – Removes refrigerant from the filter dryer prior to
its replacement.
3.2 Diagnosing A/C System Operation
Using the Snap-Shot Mode
WARNING
Always wear eye protection and protective clothing when working
with refrigerants. Observe all warnings at the beginning of this
manual. Be sure the vehicle is in PARK before turning on the engine.
Provide adequate ventilation or pipe exhaust to outside. Vehicle
exhaust fumes can cause injury or death.
To assist in system diagnostics, the MAC2000’s Snap-Shot mode
allows a technician to monitor and record the following key operating
information from the vehicle being serviced. This data can be collected
before and after servicing to show any changes in performance of a
vehicle’s A/C system.
•
•
•
•
•
•
•
Date and Time
Ambient Temperature & Humidity
Low Side System Pressure, minimum and maximum values
High Side System Pressure, minimum and maximum values
Front Duct Temperature, minimum value
Rear Duct Temperature, minimum value
Refrigerant Identifier Results
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Operation
MAC2000
Data is collected from inside the vehicle’s passenger compartment by
means of the snap-shot transmitter (shown below). This transmitter is
powered from the vehicle’s cigarette-lighter, and wirelessly transmits
temperature (and optional air flow) data to the MAC2000.
Snap-Shot Transmitter
Red Temperature Sensor – This sensor should be used on the front
A/C vent in the vehicle. The temperature is displayed as “RED
TEMPERATURE” on the Snap-Shot mode screen.
Blue Temperature Sensor – This sensor should be used on the rear
A/C vent. The temperature is displayed as “BLUE TEMPERATURE”
on the Snap-Shot mode screen.
Anemometer (optional) – The optional Anemometer measures airflow.
This sensor can be purchased separately.
Communications Port – Used to connect the transmitter directly to
the MAC2000 via a cable (instead of transmitting data wirelessly).
This port is not normally used, and requires a cable (not included).
Enter the Snap-Shot mode as follows:
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. Press the Snapshot mode function key to select the Snap-Shot
mode.
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MAC2000
Operation
3. Follow the instructions on the screen. A technician will be
instructed to connect the high- and low-side service hoses to their
respective service ports on the vehicle’s A/C system and open the
A/C system’s service-port valves. Connect the red and blue
temperature sensors, start the vehicle, then turn the vehicle’s A/C
system to its maximum cool or re-circulating setting.
4. Press the unit’s Start key.
5. After identifying the refrigerant in the vehicle, the MAC2000
displays and updates the minimum and maximum values as
shown on the display. The snap-shot display can now be used to
monitor the performance of the vehicle’s A/C system.
6. While in the snap-shot mode, the following operations can be
performed:
Main
menu
Capture
(Print)
Reset
Recover
• Main menu – Returns display to the Main menu.
• Capture (Print) – Prints the following data:
---Snap-shot report--
Date
Time
:May 18, 2001
:PM 02:14
Low PSI :(min) 17 (max) 18
High PSI :(min) 17 (max) 18
Duct Air Flow. : (max) 0 ft/m
Blue vent. Temp.: (min) 8 F
Red vent Temp. : (min) 73 F
Ambient Temp. :
Ambient Humidity:
73 F
49 RH%
---Identifier result ---
RECOVERABLE
R134a: 99.9%
R12 : 0.0%
HC : 0.0%
R-22:
AIR:
0.0%
1.5%
---Snap-shot encrypted code---
001 Q54 L6G 028 M94 H29
• Reset Values – Resets and begins tracking new min. and max.
values.
• Recover – Starts a recovery operation.
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Operation
MAC2000
3.3 Recovery Mode
The recovery mode removes all refrigerant from the vehicle’s A/C
system and stores it in the unit’s internal storage tank. Before
recovery begins, however, there must be pressure in the hoses. This
prevents inadvertent recovery of air or other contaminants from a
leaking system. The MAC2000 will automatically sense the presence
of refrigerant and confirm that it is not contaminated before starting
the recovery process.
Begin the refrigerant recovery process as follows:
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. Press the Recovery mode function key and observe the following
message: “Hook-up the service hoses to vehicle.”
3. At this time hook up the service hoses, open the A/C system’s
service-port valves, and then press the unit’s Start key. The
refrigerant identifier will warm up, zero itself, and then display
the message “Analyzing sample, please wait . . .”
If the refrigerant is contaminated (meaning that it has somehow
been mixed with some other kind of refrigerant), the results will be
displayed along with the word “contaminated.” Note that the
unit will not allow the recovery operation to proceed when
refrigerant is contaminated.
If the refrigerant is found to meet specifications, the unit will
automatically proceed to recover the refrigerant. During the
recovery operation, refrigerant is removed from both the high and
low side of the vehicle’s A/C system. The screen will display
“Recovering refrigerant” along with showing the amount of
refrigerant being recovered.
4. When the A/C system has been recovered to a minimum vacuum of
9 inHg, the recovery process automatically stops. The following
events then occur:
•
•
•
The unit’s red light flashes and the beeper sounds, signaling
the technician that recovery is complete.
The screen reads “Recovery complete” and shows the weight
of the recovered refrigerant.
System oil is automatically drained into the oil drain bottle (see
MAC2000 Left-Side View, Page 5).
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MAC2000
Operation
Note: The MAC2000 will automatically restart the recovery process
if the unit senses a rise in the A/C system’s pressure.
5. After recovering the refrigerant from the A/C system, close the
service-port valves, and then remove the hoses from the vehicle.
Observe that the service hoses should remain under vacuum. This
ensures that no contaminants are introduced into the A/C system
during a recharge process.
6. The technician can now begin repairs on the A/C system.
3.4 Vacuum Mode (Evacuation)
The Vacuum mode is used to remove residual air and moisture from
the vehicle’s A/C system by pulling the system into a deep vacuum.
This mode is most often used after completing a repair that required
opening the A/C system to the atmosphere. Moisture and/or air in an
A/C system can cause erratic operation and must be removed before
recharging the system with refrigerant.
Evacuate a vehicle’s A/C system as follows:
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. Connect the high- and low-side service hoses to their respective
service ports on the vehicle’s A/C system; then open the A/C
system’s service-port valves.
3. Press the Vacuum mode function key and observe that the screen
reads “Set VACUUM TIME now.” The minimum evacuation time
is 3 minutes. To change this time, press and hold the Increase key
until the desired time is shown.
4. Press the Start key to begin the evacuation process.
Note: Before evacuation begins, the MAC2000 checks if pressure is
present in the vehicle. If pressure is sensed, the unit will display the
message: “Error: You have pressure in the hoses. You must
first recover this refrigerant before proceeding.” If this error
message appears, first abort the evacuation process by pressing the
Reset key, recover the system per Section 3.3, then restart the
evacuation process by pressing the Vacuum mode function key.
5. The evacuation process continues for the amount of time set in
Step 3. If a vacuum level of at least 27 inHg is not achieved within
the prescribed time, the evacuation process automatically
continues for a maximum of 7 minutes, or until 27 inHg is
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Operation
MAC2000
achieved. When the A/C system reaches the proper vacuum, the
unit’s red light and beeper signal evacuation is complete, and the
screen reads “Vacuum complete.” If the proper vacuum is not
achieved after 7 minutes of evacuation, the process stops, and the
technician is prompted to check for a leak.
Note: Depending on the altitude, the A/C system may not be able to
achieve 27 inHg. It is important that the altitude setting in the Set-
Up menu is correct for your location. The MAC2000 uses this
information to calculate and provide an equivalent set point for
your altitude. (For instance, at 6000 feet the equivalent set point
for your altitude pulls to 22 inHg before completing evacuation).
6. Press the Reset key to return to the Main menu.
7. The technician can now proceed to charge the system.
3.5 Charge Mode
The Charge mode is designed to add a precise amount of refrigerant to
the vehicle’s A/C system. This mode can be used to either “top off” a
system, or do a complete recharge after the system has been evacuated
or flushed. The unit has a built-in default charge amount of 2 pounds
(0.91 kg). Other charge amounts can be entered in increments of
either 0.06 pounds, 1 ounce, or 0.02 kg.
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. Press the Charge mode function key and observe that the message
“Hook-up the service hoses to vehicle” should appear. If not
already done, connect the high- and low-side service hoses to their
respective service ports on the vehicle’s A/C system, and then open
the system’s service-port valves.
Note that at the start of this step, before the service hoses are
connected, the MAC2000 first checks if the service hoses are under
a vacuum. This prevents air and other contaminants from being
introduced into the A/C system. If the message “The vehicle is
not properly evacuated” appears, perform one of the following:
•
If the refrigerant in the A/C system has just been recovered,
evacuate both the system and the service hoses per Section 3.4.
•
If the A/C system needs to be “topped off,” first ensure that the
service hoses are disconnected from the vehicle; then either
recover the hoses per Section 3.3 if they contain refrigerant, or
evacuate the hoses per Section 3.4 if they contain air.
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MAC2000
Operation
3. After entering the Charge mode, the following options are
available:
•
•
Press the Enter key to accept the 2.00 pound Default.
Press the Weight Convert key to change the “Set charge
weight” units.
•
Use the Increase or Decrease keys to set the desired charge
amount. Select the next higher value if the exact charge
amount cannot be entered. Press Enter to accept the charge
amount shown on the screen.
Note: The MAC2000 charges in one-ounce increments, regardless of
which unit of measure is selected. This means that sometimes the
exact charge amount cannot be entered. For example, the A/C
system may require a 1.03 kg charge. The MAC2000 will only allow
a setting of 1.02 kg or 1.04 kg. In this instance, always select the
next higher value. This difference is only 0.3 of an ounce, which will
not affect the vehicle’s A/C performance.
4. By default the MAC2000 charges liquid refrigerant directly into
the high side of the A/C system. A technician, however, may choose
to charge into both the high and low side by pressing the Low side
ON-OFF function key. Pressing this key toggles the low-side option
on and off. Important! Charging liquid directly into the low side of
the compressor could slug the compressor and cause permanent
damage. Check with the compressor manufacture before proceeding.
5. The screen should now show the amount of refrigerant set for
charging. Press the Start key to begin the charging process.
During the charging process, liquid refrigerant is drawn from the
unit’s internal storage tank and charged through the high side
(and optionally the low side) of the vehicle’s A/C system. The
screen will show the progress of this charging process.
Important! Do not disturb or bump the MAC2000 during charging
as any jarring movement can affect the charge accuracy.
Note: If an insufficient pressure differential exists between the tank
and the system, charging suspends and the MCR2000 goes into a
power-charge mode to increase tank pressure to complete the
charge. This normally occurs only when the unit has been in a very
cold environment prior to use.
6. When charging is complete, the red light and beeper signal that
the process is complete. The MAC2000 automatically goes into the
Snap-Shot mode, thus allowing a technician to obtain an after-
service snap-shot of important operating parameters of the A/C
system. Refer to Section 3.2 for details.
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Operation
MAC2000
7. If more refrigerant needs to be added, press the Additional Charge
function key. Otherwise, press the Done function key to exit the
Snap-Shot mode.
8. Close the service-port valves; remove the service hoses from the
vehicle; then press the Start key to recover the hoses.
Important! If the hoses are not removed from the vehicle before the
Start key is pressed, the refrigerant in the vehicle will be recovered!
9. If any oil was removed during the recovery or evacuation process,
make sure that the proper amount of oil is added back into the
vehicle’s A/C high side port in accordance with the vehicle
manufacturer’s recommendations. Add an amount of new oil equal
to the amount collected in the oil drain bottle (see MAC2000 Left-
Side View, Page 5).
3.6 System Flush Mode (Oil Flush)
The System Flush mode is designed to be used on General Motors
vehicles using their Oil Flush Adapter and Filter accessory. This
accessory is attached inline with the vehicle’s compressor and is used
to flush the A/C system with refrigerant. In this mode, refrigerant is
circulated through both the A/C system and the MAC2000 where an
oil separator removes the oil and returns oil-free refrigerant back into
the A/C system for further flushing. At the end of the cycle, the
refrigerant is completely removed from the A/C system and stored in
the unit’s internal storage tank. The flushing process can take up to
30–45 minutes to complete. Because of the variety of A/C system
configurations currently in service, the flush may bypass certain
sections of the A/C system. To ensure the complete system is flushed,
the technician may need to pinch off certain hoses to force the
refrigerant flush throughout the system.
1. Before beginning the flushing process, recover all refrigerant from
the vehicle’s A/C system per Section 3.3 Recovery Mode.
2. From the Main menu, press the Next menu function key to display
Menu 2, and then press the System flush function key to select the
System Flush mode. The unit reminds the technician to “Please
empty the purge oil bottle prior to flushing.”
3. Press Start to continue. The unit now reminds the technician to
install the inline flushing adapter and remove the orifice tube or
TXV valve before continuing.
4. If not already done, connect the high- and low-side service hoses to
their respective service ports, and ensure that the service-port
valves are open.
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MAC2000
Operation
5. Again press Start to continue. The unit now displays “Set Flush
Time.” Set the flush time by pressing and holding down the
Increase or Decrease key until the desired time is shown. Press
Start to accept the flush time shown on the screen. A minimum
flush time of 30 minutes is recommended.
Important! There must be a minimum of 12 pounds of refrigerant in
the internal storage tank in order to complete the System Flush
process. A message will be displayed if additional refrigerant needs
to be added. Add additional refrigerant by following the procedure
described in Section 3.8 Internal Tank Manual Refill.
6. Press the Start key to begin flushing. The MAC2000 begins
flushing the A/C system in the following manner:
•
•
•
The A/C system is first completely filled with refrigerant,
during which time the screen shows “Flushing – Charging.”
The system is now flushed for the time duration set in Step 5,
during which time the screen shows “Flushing system.”
After the system is flushed, all refrigerant is automatically
recovered. The screen shows “Recovering refrigerant”
during this process.
•
The flush cycle completes by draining the oil that was removed
during the flushing process into the unit’s oil drain bottle (see
MAC2000 Left-Side View, Page 5). The screen shows
“Draining oil” during this process.
Important! All oil was removed from the A/C system during the
System Flush operation. Be sure that the proper amount of oil is
added back into the vehicle’s A/C high side port in accordance with
the vehicle manufacturer’s recommendations.
7. The unit beeps and its red light flashes to indicate that the
flushing cycle is complete. The screen now reminds the technician
to remove the inline flushing adapter, and to reinstall the orifice
tube or TXV valve.
8. Evacuate and then recharge the A/C system per Sections 3.4
and 3.5.
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Operation
MAC2000
3.7 Refrigerant Management System
The MAC2000’s Refrigerant Management System tracks all aspects of
refrigeration usage, which can significantly help in the management
of an A/C repair business. In addition, the unit’s software allows a
business to meet new federal regulations requiring strict records of
refrigerant usage.
Refrigerant measurement during charging is extremely accurate. In
the recovery mode, however, accuracy is plus or minus 3 ounces based
on variations in air temperature and pressure.
Uses of the refrigerant data include:
•
•
•
•
•
Improved record keeping
Accurate determination of net profits for your business
Reduced billing errors
Minimized refrigerant loss from leaks and theft
Reduced technician errors
Enter the Refrigerant Management mode as follows:
From the Main menu, press the Next menu function key twice to
display Menu 3; then press Refri Data to select the Refrigerant
Management Mode.
The first screen displays the following information in the “Last job
refrigerant management data” screen:
• Date & time ......Date and time the job was started
• Mode .................Lists what job was performed: recovery, charging,
vacuum, or flush
• Run time ...........Time it took to complete the job
• Status ...............Describes whether the job was normally completed
or interrupted
• Recovered .........Weight of refrigerant recovered from vehicle
• Charged ............Weight of refrigerant charged into vehicle
• Added ................Weight of refrigerant transferred from the external
source tank to the internal storage tank
Pressing Next displays the following data in the “Total refrigerant
management data” screen:
• Total # Of Jobs..Total time spent doing all jobs, and number of all
jobs that were performed
• Total Recovery...Time spent doing recovery and number of times it
was performed
• Total Vacuum....Time spent doing evacuation and number of times
it was performed
• Total Charge .....Time spent charging and number of times it was
performed
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MAC2000
Operation
• Total Flush........Time spent flushing and number of times it was
performed
• Recovered .........Total amount of refrigerant recovered
• Charged ............Total amount of refrigerant charged
• Added ................Total amount of refrigerant transferred from the
external virgin tank to the internal storage tank
• Filter life left.....Weight of refrigerant that can be charged before
the Filter Dryer needs replaced
Pressing Next again displays the “Job history” screen, which
contains the history of each job performed. A technician can press the
UP and Down keys to scroll through the last 75 jobs.
Tips: Holding down the Up or Down key speeds up scrolling.
The total screen can be cleared by entering the Set-up mode and
selecting “Clear totals?”
Job history can be cleared by entering the Set-up mode and selecting
“Clear job history?”
3.8 Internal Tank Manual Refill
When the MAC2000 remains turned ON during the day, the unit
automatically refills the internal tank with refrigerant from the
external source tank. An operator, however, can manually add
refrigerant as follows:
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. Press the Next menu function key to display Menu 2. Then press
the Tank refill function key to begin the refill process.
Note: If the tank is already filled with 12 lbs or more of refrigerant,
then the message “Tank already full” appears.
3. Press the Start key to continue. The screen will then display “The
internal tank is now being refilled.” When the internal tank is
filled, the screen displays “Tank refill complete.”
4. Press the Reset key to return to the Main menu.
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Operation
MAC2000
3.9 System Set Up
When the MAC2000 is initially turned on for the first time, the unit
automatically enters its System Set-Up mode. The unit must then be
set up by following the on-screen prompts before it can be used.
To change the data that was entered during the initial set-up process,
or to perform other functions such as clearing job history or
recalibrating the pressure transducers, re-enter the System Set-Up
mode as follows:
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. Press the Next menu function key to display Menu 2. Then press
the System set-up function key.
3. Follow the on-screen prompts to enter the following data or
perform the following procedures:
•
•
•
•
Time & Date
Language
Use Metric units (Yes or No)
Calibrate Pressure Transducers (remove service hoses from the
unit’s Service Hose Fittings and follow on-screen prompts)
Elevation above sea level
Clear error flags
Clear job totals
•
•
•
•
•
Clear job history
Print data after every job
4. Press the Reset key at any time to save the settings and return to
the Main menu.
3.10 Identify Refrigerant
Before performing any maintenance work a technician can determine
the following information about the vehicle’s refrigerant
•
Whether the refrigerant in the A/C system
can or cannot be recovered
•
•
•
•
•
% R-134a
% R-22
% R12
% Air
% HC (Hydrocarbons)
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MAC2000
Operation
Perform a refrigerant identity check as follows:
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. Press the Next menu function key twice to display Menu 3. Then
press the Identify mode function key.
3. Hook up the service hoses, open the A/C system’s service-port
valves, and then press the unit’s Start key. At this time the
refrigerant identifier will warm up, zero itself, and then display
the message “Analyzing sample, please wait . . .” When
complete, the results of the identification process will be displayed.
4. Press Reset to exit the identification screen.
5. Close service-port valves, and remove service hoses from vehicle.
6. Press Start to begin recovering the hoses. During the recovery
process the message “Clearing hoses, please wait . . .” is
displayed. After recovery is complete, the Main menu will appear.
3.11 Check Internal Tank for Air
When the MAC2000 remains turned ON during the day, air is
automatically purged from the internal storage tank. A technician,
however, can manually check and purge the internal tank of air and
any other non-condensable gases as follows:
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. Press the Next menu function key twice to display Menu 3. Then
press the Check Tank Air function key.
3. Press the Start key. The refrigerant identifier will first warm up,
zero itself, and then display the message “Analyzing sample,
please wait …” When complete, the results of the identification
process will be displayed.
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Operation
MAC2000
4. Depending on the percentage of air found in the internal tank,
perform one of the following:
•
If the display shows “Identifier result: EXCESSIVE,” then
purge the tank by first pressing the Reset key to display the
message “Would you like to purge air?” Then press the Start
key to begin purging air. When complete, the Main menu will
appear. Repeat Steps 2, 3, and 4 until the percentage of air
within the internal tank is at an acceptable level.
•
If the display shows “Identifier result: RECOVERABLE,”
then the amount of air within the tank is at an acceptable
level. Press the Reset key to display the message “Would you
like to purge air?” Then press the Reset key again to return
to the Main menu.
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MAC2000
Maintenance
4 Maintenance
Field maintenance of the MAC2000 is limited to the following:
• Changing the filter drier
• Tracking of refrigerant using the unit’s Refrigerant Management
System
• Replacing the external refrigerant source tank
• Replacing the printer paper
• Replacing the refrigerant identifier filter
All other maintenance should be performed by an authorized
Bacharach Service Center (Section 5.2).
4.1 Changing the Filter Drier
The MAC2000 has a unique filtering system that ensures the
refrigerant transferred to the storage tank is clean and moisture-free.
The filter drier must be changed periodically to ensure that the
system will work properly.
The MAC2000 will automatically indicate when the filter needs to be
changed. If the “Change Filter” message appears when the Recovery
mode is selected, it is best to complete that job before changing the
filter drier. “Change Filter” will be displayed on the screen
whenever the recovery mode is selected until the filter has been
replaced.
All refrigerant must be evacuated from the old filter before it is
removed from the unit. Follow the filter change procedures carefully
to minimize refrigerant loss and ensure only clean, moisture-free
refrigerant is transferred into the storage tank.
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Maintenance
MAC2000
Caution: The filter drier should not be changed with the MAC2000
still connected to the vehicle. Disconnect the unit by closing the vehicle’s
service-port valves and disconnecting the high- and low-side hoses from
the vehicle.
1. If not already done, plug the MAC2000 into a properly grounded
AC outlet; set the Power switch to ON; then wait until the unit
completes its self diagnostics. The screen will display “Select
mode” when ready.
2. From the Main menu, press the Next menu function key to display
Menu 2.
3. Follow the on-screen prompts; then press the Start key to begin
evacuating the filter.
4. When completely evacuated, follow the on-screen prompts and
remove the old filter drier by unscrewing it counterclockwise.
Dispose of the used filter in a proper manner.
5. Lubricate the O-rings of a new filter drier with a light grease or
saliva; then hand tighten until it bottoms out.
6. Press the Reset key after the new filter has been installed. This
will remove any air that may have entered the system during the
changeover process.
4.2 Replacing the External Source Tank
The internal storage tank contains enough refrigerant for several jobs,
but it’s important to replace the external source tank soon after the
message “Source Tank empty” is displayed so that the internal
storage tank isn’t depleted during a charge operation.
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MAC2000
Maintenance
To replace the external source tank:
1. Close tank valve; remove yellow hose from tank valve; release tank
strap; then remove tank from side of unit.
2. Place a new source tank on the shelf and secure it with the tank
strap. The tank strap must be set up to supply liquid – this
usually means the tank is inverted.
3. Reconnect the yellow hose to the tank fitting; then open the tank
valve.
4. The unit’s automatic tank refill function will add refrigerant to the
internal storage vessel as the unit is used. A technician may fill it
immediately, however, by pressing the Next menu function key to
display Menu 2, and then pressing the Tank refill function key to
immediately begin filling the internal storage tank.
4.3 Replacing the Printer Paper
1. Open the printer cover by first squeezing together the cover’s two
plastic latches, and then pulling the cover forward.
2. Remove the old paper-roll core.
3. Insert the new paper roll so that it unrolls over-the-top. Then pull
out several inches of paper and position the paper so that it rests
against the paper cutter.
4. Close the printer cover.
5. Press and hold the feed button to ensure that the paper feeds
properly; then tear off the excess paper.
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Maintenance
MAC2000
4.4 Replacing the Refrigerant Identifier Filter
Caution: Visually inspect the Refrigerant Identifier Filter every day. If
it begins to turn red, replace it immediately! You risk damaging the
identifier sensor if the filter is not replaced.
The refrigerant identifier filter is located on the control panel, directly
under the Low Side pressure gauge. The filter’s function is to protect
the refrigerant identifier sensor from contaminates. When this filter
starts to develop red spots, replace the filter immediately!
1. Remove the filter from its holder; then remove the tubing from
each end.
2. Position the new filter so that its flow-arrow points in the same
direction as the flow-arrow on the control panel.
3. Attach the tubing to the new filter, and press the filter back into
its holder.
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MAC2000
Parts and Service
5 Parts and Service
5.1 Parts
Model MAC2000, 115VAC 50/60 Hz ........................................2000-4200
Model MAC2000, 220–240VAC, 50/60 Hz ...............................2000-4206
Bottle, Oil Drain........................................................................2055-0150
Filter Drier ................................................................................2037-0030
Filter, Refrigerant Identifier ....................................................2068-0010
Power Cord (for Snap-Shot Data Transmitter) .......................2066-0040
Printer........................................................................................2017-0080
Printer Paper.............................................................................2075-0060
Sensors (for Snap-Shot Data Transmitter):
Anemometer (air flow) ............................................................2064-0010
Temperature (blue) .................................................................2062-0020
Temperature (red)...................................................................2062-0010
Service Coupler – Red (High Side)...........................................2022-1240
Service Coupler – Blue (Low Side)...........................................2022-1230
Service Hose – Red (High Side)................................................2035-0170
Service Hose – Blue (Low Side)................................................2035-0180
Snap-Shot Data Transmitter....................................................2001-0001
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Parts and Service
MAC2000
5.2 Service Centers
Service and replacement parts can be obtained by contacting a Bacharach Service Center at
the following locations:
California
7281 Garden Grove Blvd.,
Suite H
Garden Grove, CA 92841
Phone: 714-895-0050
Fax: 714-895-7950
Canada
Bacharach of Canada, Inc.
151 Bentley Street Unit #6
Markham, Ontario L3R 3X9 Canada
Phone: 905-470-8985
Fax: 905-470-8963
E-mail: [email protected]
E-mail: [email protected]
Indiana
México
8618 Louisiana Place
Merrillville, IN 46410
Phone: 219-736-6178
Fax: 219-736-6269
Bacharach de México
Playa Regatas No. 473 Tercer Piso
Col. Militar Marte
Delegación Iztacalco, 08830
México D.F.
E-mail: [email protected]
México
New Jersey
Phones: 011-5255-5634-7740
7300 Industrial Park
Rte. 130, Bldg. 22
011-5255-5634-7741
011-5255-5634-7738
FAX:
Pennsauken, NJ 08110
Phone: 856-665-6176
Fax: 856-665-6661
E-mail: [email protected]
Denmark
E-mail: [email protected]
Bacharach Instruments Int'l
P.O. Box 44
Pennsylvania
39 Lindegade
DK 6070 Christiansfeld
Denmark
Phone: 011/45 74 563171
Fax: 011/45 74 563178
E-mail: [email protected]
621 Hunt Valley Circle
New Kensington, PA 15068
Phone: 724-334-5051
Fax: 724-334-5723
E-mail: [email protected]
Texas
Europe
5151 Mitchelldale, B-4
Houston, TX 77092
Phone: 713-683-8141
Fax: 713-683-9437
Bacharach Europe
Sovereign House, Queensway
Leamington Spa
Warwickshire CV31 3JR
England
E-mail: [email protected]
Phone: (01926) 338111
Fax: (01926) 338110
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World Headquarters
621 Hunt Valley Circle, New Kensington, PA 15068-7074
Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 1-800-736-4666
Printed in U.S.A.
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