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CAP. 1 - INDEX
CAP. 2 - INTRODUCTION
BRAIN BEE reserves the right to bring improvements or changes to is instruments at any time
and without any notice.
It is possible for this manual to contain references or information regarding BRAIN BEE services or
products not yet on the market. Said references or information may not in any way mean that
BRAIN BEE intends to place said products or services on the market.
This publication may not be reproduced nor distributed, wholly or partially, without previous written
authorisation by BRAIN BEE (Law 22 April 1941 no.663 and following updates). Requests of
other copies of the present manual or further information must be addressed to an authorised
distributor or to a BRAIN BEE sales representative or to the email address contact@brainbee.com
All technical and sales documentation may also be found on the website: http://www.brainbee.com
BRAIN BEE is a registered trademark property of BRAIN BEE s.p.a., v. Quasimodo 4/a - 43100
Parma, Italy. Other names of products and companies mentioned in these pages may be registered
trademarks of their respective owners.
Any references to programs on use license or other BRAIN BEE products or services contained in
this publication do not mean that only said programs and/or products and/or services may be used.
In replacement to those supplied by BRAIN BEE equally functional products, programs or services
may be used that do not imply violation of BRAIN BEE intellectual property rights or other rights .
It is the user's responsibility to evaluate and verify the possibility to use other programs and/or
products and/or services, except for those expressly indicated by BRAIN BEE .
BRAIN BEE may have patents or pending patent applications relative to what is being treated in
the present publication. The supply of this publication does not imply concession of any license on
them.
2.2 SUMMARY
The present manual is intended for the assistance technician and has the objective to illustrate
clearly and coherently the use and function principles and to supply a basic guide to carry out
assistance and maintenance at the service station for air conditioning systems for vehicles with R-
134a cooling gas.
The manual chapters describe the functional groups of the CLIMA-6000 under the aspects of
structure, functioning, disassembly and assistance.
To access the service menu reserved to maintenance activities, the technician operating on the
device must know the password communicated by Brain Bee to the Assistance Centres.
________________________________________
The waste coming from the service activities must be placed in the collection points foreseen by the
enforced laws, they must not be dispersed in the environment and they must not be disposed of
with urban waste.
The present service manual must be used in context to the use and
maintenance manual of the equipment, it must be kept by the Authorised
Assistance Centre or by the Distributor of Brain Bee products and made
available to own assistance staff.
• The content of this manual was written according to the guidelines of regulation UNI
10893:2000.
• Sharing, changing, or using the present manual for own purposes is forbidden to all.
• While writing the manual, the choice was made to use clear symbols that bring attention to
precise points, in order to make consultation simpler and quicker.
• It includes all information regarding the technical aspect, functioning, equipment rest,
maintenance, spare parts and safety.
• In case of doubts regarding the correct interpretation of the instructions, refer to the
technical assistance service to obtain the necessary explanations.
The operations that represent a potentially dangerous situation for the operators
are highlighted through the symbol reported on the side.
Said operations may cause serious physical damage.
The operations that require particular attention are highlighted through the
symbol on the side.
Said operations must be carried out correctly in order to not damage things or
the surrounding environment. This symbol also highlights information which
particular attention must be paid.
The operations that require a careful reading of the indications supplied on the
use and maintenance manual are highlighted through the symbol on the side.
4.2 SYMBOLS
This paragraph described the symbology relative to safety which may be present on the exterior of
the equipment.
4.2.1 Safety
ALTERNATING CURRENT
PROTECTION GROUND
4.2.2 Marking
EC CONFORMITY SEAL
CAP. 5 - INSTALLATION
5.1 EQUIPMENT INSTALLATION
The order of the following listed steps is the one advised even if the same could be carried out in a
different order.
C/O DISTRIBUTOR HEADQUARTERS (INTERNET CONNECTION REQUIRED)
It is advised to lift the carton, connect electricity and switch on the equipment
6° Carry out Initial checking as proposed by the software according to the following points:
• Check gas scale zero
• Relative pressure zero setting according to local atmospheric pressure
• Internal tank filling (with value of at least 2 Kg until the maximum allowed by the equipment)
Initial checking, if passed, enables use of the equipment with gas.
Checking may be interrupted at each of its points, if not completed it will be proposed again at every
following CLIMA machine switch on or in case one attempts to carry out the recharge operation.
If the checking is not passed, it may be necessary to proceed to equipment scale or electronic
gauge calibration; for said operation described as follows the appropriate Brain Bee SERVICE KIT is
required.
7° New oil container filling, the use of Brain Bee WARRANTY LINE consumable products is
recommended.
8° Delivery and illustration of the warranty conditions, of the EC declaration of conformity and the
use and maintenance manual to the final client.
Position the pallet on a level surface, remove the carton after having eliminated the straps that bind
it. Free the equipment from the pallet by cutting the straps that block it. Remove the unit from the
base pallet of the package by using suitable means. Once on the ground, the unit is handles on the
four wheels; brakes may be applied to the two smaller wheels.
5.1.2 Connections
In proximity of where the machine must be used, there should be a schuko type current socket
available protected by a differential switch. The nominal current voltage and absorbed power data
are indicated on the unit identification tag positioned near the turn on switch. Connect the
equipment through the supplied cable.
The equipment includes connecting pipes of about a 3 m length that when not in use must be kept in
the appropriate pipe winder with the gaskets closed.
Further views of the equipment and technical characteristics are reported in the use manual.
be carried out with the left and right keys and saved with the START key .
For subsequent changes to the contrast or the language it is possible to enter the settings pages
by switching on the equipment and keeping the start key pressed until it "beeps".
After the beep, proceed to adjusting contrast with the left and right keys and save with
5.1.4 Programming
The equipment already includes multi-language application software, it is however advised to check
that the version installed is updated compared to what is available on the website
www.brainbee.com.
PROGRAMMING the CLIMA station with the last version available on the website www.brainbee.com
at the time of installation guarantees installing of the latest versions:
• of the CLIMA machine management software and
• the vehicle database (whose use license for the specific version starts at the time of
registration).
If on the website www.brainbee.com on the internet a new version is available, this will be
transferred on the PC automatically.
Connect ACU to the PC to obtain transfer of the new version of the software on the ACU mobile
device.
To obtain updating of the clima station, connect ACU to the serial port, and switch the equipment
on again, it will be updated with the latest version.
5.1.5 Registration
To start the warranty period and to activate the automatic cycles it is necessary to carry out
REGISTRATION which foresees:
• access in the distributor reserved area on the website www.brainbee.com
• selection of the registration page CLIMA REGISTRATION
• entering the serial number of the CLIMA equipment and final client data (user)
• waiting for the counter code which will have to be entered into the equipment.
Until the counter code is entered into the equipment, it will always be requested. Print the warranty
documentation to deliver to the final client.
In the CLIMA-6000 the registration does not enable the internal vehicle database, which may be
purchased separately.
Following purchase it is necessary to carry out the enabling as described in chapter 8.2.
To start the warranty, it is necessary to carry out registration of the CLIMA station as described in
the previous point, print the warranty documents to deliver to the client from the website.
Deliver the EC Declaration of conformity document attached to the equipment to the client, it will
have to be carefully guarded by the final client.
Deliver and illustrate the use and maintenance manual attached to the equipment which will have to
be carefully guarded by the final client and made available to the operators.
It is possible to interrupt the initial check and print a report with the equipment printer in which the
checking status is reported.
Let us consider as first filling the one carried out during the initial check to the internal tank of the
equipment free of coolant gas and containing air.
Set the quantity of gas to fill (with value of at least 2 Kg until the maximum allowed by the
equipment) and follow the guided procedure on the display.
Check that the equipment piping is not connected and is positioned in the pipe winder. Start the
procedure that initially foresees the creation of vacuum in the internal tank.
Only when the message appears to connect the recharge tank, connect the quick coupler HP (colour
red) of the unit to an external R134a coolant gas tank using the supplied adaptor.
Open the attachment by rotating the knob clockwise. Open the valve placed on the external tank.
There are two types of source tanks: with pick-up and without pick-up.
The tanks with pick-up must remain in erect position in order to transfer the liquid coolant, for this
type of tank connect to joint L (liquid).
The tanks without pick-up only have one valve, they must then be overturned to transfer the liquid
coolant.
Fill the container, paying particular attention to the “oil care” valve.
This valve which consists in a membrane of cured silicon, it is necessary to compensate the
pressure variations inside the container and to block the inlet of humid air, thus preserving the new
oil inside.
At the end of the filling, close the container and place it back in its seat.
HYBRID FUNCTION
• by selecting this entry, one may decide to change the type of Oil to enter into the A/C
system
PRESSURE ZERO
• by selecting this entry, one may carry out zero setting of relative pressure to account for
atmospheric pressure (which depends on the altitude of the shop location).
RECHARGE MODE
• by selecting this entry, one may decide whether to enable use of the Quick Mode or Zero
Tolerance recharge method.
“Quick Mode” is the quick recharge through HP with automatic compensation of the gas
tail in the pipe. “Zero Tolerance” is the precise recharge with LP which foresees switching
on the vehicle A/C. The machine will account for said preference on condition that the
vehicle in recharge is equipped with the necessary type of attachment (HP or LP),
otherwise the choice of “Quick Mode” or “Zero Tolerance” will be carried out automatically
by the machine. The “Zero Tolerance” procedure foresees impulsive injections in the
vehicle air conditioning system through the LP side. After the injection and before the
following one, one waits for the pressure to lower to the typical system value. The
pressure threshold to set contextually to the "Zero Tolerance" option must be slightly
higher than the typical value of the system. In case the threshold is too low, the loading
procedure stop, in case the threshold is too high, the integrity of the compressor would
be compromised. Said threshold is preset to a typical value of 3 bar.
TANK HEATING
• by selecting this entry, one may decide whether to enable use of the heating strap within the
vacuum phase. (Attention, the heating strap is optional and if one intends to enable it it
must be installed first)
MULTIPASS ENABLING
• by selecting this entry, one may decide whether or not to enable the multipass function,
which enables an additional recycling, within the station itself, started in automatic when it is
switched on but not in use. This mode guarantees a more elevated level of recycled
coolant purity, benefiting the quality of the service rendered.
During the multipass there is a decrease of the counter of the dehydrator filter equal only
to 1/10 of the weight of the filtered coolant
DISPLAY CONTRAST
• by selecting this entry, it will be possible to adjust the display contrast
HOSE LENGTH
• by selecting this entry, it will be possible to enter the length of the discharge pipes, this data
affects the accuracy of the charge carried out with the Quick Mode method.
MEASURE UNIT
• by selecting this entry, it will be possible to change the measure unit relative to the
pressure (switching from Bar to Pascal)
LANGUAGE
• by selecting this entry, any language present in the database may be set. In case a language
with incomprehensible characters is chosen, one may switch directly to the language setting
RIGHT\LEFT DRIVE
• by selecting this entry, one may set the vehicle driving side on which to carry out a recharge
inside the database. Normally it is on the left, it is necessary to select the right side only
when the machine is installed in countries such as England, with different driving sides.
SWITCH ON SCREEN
• by selecting this entry, one may decide if the initial switch on screen of the unit will be the
one relative to the database or the one relative to the main menu.
STANDARD SETTINGS
• by selecting this entry, one may reset the unit's standard settings.
DATABASE ACTIVATION
• by selecting this entry, it will be possible to activate the database acquired during a following
update.
CAP. 6 - MAINTENANCE
6.1 EQUIPMENT MAINTENANCE
The interventions foreseen for periodical and preventive maintenance are listed as follows:
Necessary equipment:
• 1 Medium size Phillips screwdriver
• 1 Medium size flathead screwdriver
• 1 Hex key (10 mm)
TOP PLUG
SIGHT
GLASS
BOTTOM
PLUG
5. Fill the pump with the new oil by pouring it in the top aperture, eventually using a funnel.
Bring the new oil level in correspondence to half of the inspection device.
6. Once the pump is filled, close the top plug.
After replacing the oil, turn on the unit and select PUMP OIL REPLACEMENT from the
MAINTENANCE menu: press the "ZERO SETTING" key to reset the counter.
To replace the dehydrator filter, select REPLACE DEHYDRATOR FILTER from the MAINTENANCE menu:
press "ZERO SETTING" to reset the counter and to proceed with the filter replacement. Wait for execution of
the R134a gas emptying from the pipes.
DEHYDRATOR NUTS
FILTER
5. Install the new filter being careful of the position of the washers and the direction of the arrow that
points towards the fluid passage.
6. Screw the two filter connection nuts.
7. Reclose the equipment before reconnecting it to the electrical network.
Check that the contact points between the piping and the joints with quick couplers and with the
equipment do not present:
• abrasions, cracks, cuts, irreversible folds, deformations, twists.
TESTS of the piping capacity and quick couplers with upkeep tests in vacuum and in pressure.
• Close the gaskets of the quick couplers of the CLIMA-6000 equipment;
• launch the function inside the Maintenance Menu "Capacity test", check that the test is passed
successfully.
• From the Service Menu - "Manual activations", activate the "R" and "I" valves and check that the pipes
are pressured (at least 5 bar) and check that the pressure does not drop in a time slot equal to 30
minutes and that gas leaks do not occur.
19. Reassemble the solenoid valve by first mounting the piston and subsequently the block of the electrical
reel.
20. Once the solenoid valve mounting is complete, reopen the gaskets/valves of the tank
21. Reclose panel and cover, reconnect the power supply cable and turn on the machine again.
TEST IN VACUUM
Launch the function inside the Maintenance Menu "Capacity test", check that the test is passed successfully.
TEST IN VACUUM
Launch the function inside the Maintenance Menu "Capacity test", check that the test is passed successfully.
6.8 CHECK PRESENCE AND WEAR OF O-RINGS
OR2212 53.7X1.78 NBR OF THE OIL
CONTAINERS
Check the presence of the O-RING which acts as sign of the oil level on new, exhaust and tracer oil
containers. In case of signs of deterioration replace them with new ones.
In case of problems when inserting the connector on the machine joint proceed to replacing the bottle.
CAP. 7 - CALIBRATION
From the SERVICE menu select the PRESSURE CALIBRATION menu through keys and
press .
Disconnect the quick LP and HP attachments from any system and press .
Wait until the following message to open HP.
Wait for the message to connect the reference gauge contained in the service kit.
Close the quick HP attachment by rotating it counter clockwise and connect it to the gauge present
in the SERVICE KIT, open the quick HP attachment by rotating it clockwise and press .
SAFETY NOTE:
ATTENTION NOT TO POINT THE GAUGE TOWARDS ONESELF OR OTHER PEOPLE UNTIL
ONE HAS THE ABSOLUTE CERTAINTY THAT THE CONNECTION WITH THE QUICK COUPLER
IS SAFE.
OPEN THE GASKET OF THE QUICK COUPLER BY POINTING THE GAUGE TOWARDS THE
GROUND, ALWAYS KEEP THE GAUGE TOWARDS THE GROUND EXCEPT IN THE MOMENTS
IN WHICH THE GUIDED PROCEDURE REQUIRES ENTERING THE VALUE DISPLAYED ON THE
SAMPLE GAUGE.
Measure the pressure reached by the SERVICE KIT gauge and, through keys set it on the
Subsequently the equipment will execute the vacuum, at the end of which one will be asked to check
that the gauge reach -1 bar, when requested by the guided procedure press to confirm
calibration.
From the SERVICE menu select the GAS WEIGHT CALIBRATION menu through keys and
press .
Unscrew the tank, lift it and insert below it the distance clamp in order to keep it detached from the
Remove the distance clamp and re-screw the tank to the loading cell, insert the weight holder clamp
without the sample weight.
Press to acquire the signal of the cell with tank and clamp.
Rest a sample weight of at least 5 kg on the weight holder clamp and press : one will be asked
to insert the value of the weight just set on the clamp
Press keys to set the value of the sample weight and press to acquire the signal of
the cell with tank, clamp and sample weight.
Subsequently remove the sample weight and the weight holder clamp and press .
CAP. 8 - UPDATE
8.1 SOFTWARE UPDATE
To update the equipment and the relative database it is necessary to proceed to a new
programming of the equipment as described in point 5.1.4 "programming" with the serial cable
available in the Service Kit or through the ACU device (Automatic Clima Update).
Enter the "Reseller" area with the PassWord for "Service Area"
Digit the “DATABASE ACTIVATION REQUEST CODE” database activation code displayed on the
equipment screen when attempting to access to the vehicles entered in the new version of the
database.
Before confirming (green arrow) check that the e-mail is correct, otherwise contact the Brain Bee
sales office.
After confirmation you will receive an e-mail (order confirmation) which enables to obtain the code to
enter into the CLIMA equipment to activate the new database version.
Equipment
• CLIMA 8501 SERVICE KIT
• ACU - AUTOMATIC CLIMA UPDATER
Software (available in the website http://www.brainbee.itby entering the “Download” Service Area)
• Clima Update Software
• Clima 6000 Software
1 Vacuum pump
2 Compressor
3 Condensator fan
15 LP + HP pressure sensor
36 Coolant scale
37 Condensator
38 Dehydrator filter
RECOVERY
HP HP+LP LOAD
FLUSHING
Safety against the risk due to pressure of the coolant fluid inside the receiving tank is assigned to
the safety valve installed during manufacturing. In case of replacement, use of new and original
spare parts not contaminated with other substances is recommended as well as requesting the
relative declaration of conformity proving the effective test of the components in the beginning.
The assistance centre assumes responsibility for regulation assembly and for checking before new
commissioning according to the prescriptions determined by the regulation in force in the country of
use, particularly the assistance centre will have to guarantee that the assembly will ensure a perfect
capacity and that the safety components are installed appropriately so to not compromise
functioning.
Attention presence of coolant fluid under pressure, in case of disassembly of the tank or of its
components, ensure that the tank is empty and closed, the connecting pipe between tank and
manifold is empty and the connecting pipe between tank and pneumatic group is empty.
Emptying with the aid of a second CLIMA line equipment is advised.
Do not disperse gas into the environment.
Attention presence of coolant fluid under pressure, in case of disassembly of manifold or its
components ensure that the tank is closed, the connection pipe between the tank and the
manifold is empty, the LP and HP connectors are disconnected from any system and closed,
that a pipe emptying operation has been made, and the manifold has been completely emptied
(for further details see CHAP.13).
Tank gauge
LP Gauge New oil
V A I
R
DECANTER
EXPANSION SAFETY
VALVE PRESSURE
SWITCH
DISTILLATOR
IMPELLER
AND
RADIATOR
EXHAUST OIL
COMPRESSOR DEHYDRATOR
DISCHARGE
FILTER
SOLENOID VALVE
AC
NETWOR
CHASSIS
GROUND
OPTIONAL
Ordinary maintenance includes the replacement of components subject to wear, such as thermal
paper of the printer, or to use, such as: loading pipes, quick couplers and piping and solenoid valve
washers.
Extraordinary maintenance includes the replacement of other components such as, for example:
the loading cells, the vacuum pump, the pressure sensors, the printer, the keyboard, the gauges,
the safety valve and the suction unit.
In the www.brainbee.com spare parts website, the complete list is available with the relative codes
to order them.
Enter the “Service Area” with own Password received from the Brain Bee Sales Department.
Enter the "Reseller" area with the PassWord for "Service Area"
Select the area of the CLIMA product line and the model in question.
For the correct display of the spare parts it is necessary to have Acrobat Reader available and the
appropriate NetSpares Plugin available for installation after download.
In case the page display is not complete, act on the zoom of own internet browser (example
Explorer).
Once the equipment has been selected from the appropriate list a .pdf file will open and the Net-
Spares functions will be available among the Acrobat Reader tools. It is advised to view the use
Before each check and/or replacement intervention of components inside the machine it is
recommended to firstly carry out the following operation:
1. Wind the 2 pipes in the supports foreseen on the side of the machine and close the gaskets
in a counter clockwise fashion.
2. Switch off the machine, remove the power supply cable and open the cover and the front
panel.
3. Close central gasket (liquid side) of the tank with service kit key
4. Reconnect the power supply cable, turn on the machine (careful not to touch terminals or
electronic cards)
5. Reach the service menu
6. Select manual activations
7. In manual activations activate OUT R, OUT I, OUT A, C, wait for the LP gauge to show a
pressure of at least - 0.4 bar,
8. Switch off the machine and remove the power supply network cable
In case of replacement of pipes equipped with o-rings use 577 loctite thread locker and replace the
internal o-ring.
In case of replacement of pipes without o-ring insert the lubricated copper washer.
If it is necessary to provide for emptying of the internal tank, it is necessary to carry out coolant
recovery with a second machine, after having interconnected the equipment with the HP pipe and
having placed the machine to empty with the open tank and an open OUT R valve.
As an alternative it is possible to disconnect the inlet to the tank on the gas side by connecting the
pipe to an external tank to fill and by activating OUT R, OUT I, OUT A, C until obtaining a tank
pressure of about -0,4 bar,
2. Slow or not possible coolant Joints fixing rubbers cut for 1. Localisation of the defects
injection. excessive locking (they relative to the rubber components
cause clogging of pipes and or dirt residue and replacement or
operational block of the cleaning.
machine, with different 2.Carry out emptying of the gas as
consequences based on the described in chap.13.2.1
position of the rubber - in 3. If yellow pipes are present, check
any case it is always and eventually replace the fixing
regarding clogging of a pipe washers placed inside the pipe
or dirt in the solenoid which connects the solenoid valve
valves). group to the tank.
3. During the recovery phase Dirt inside the Oil discharge 1.Cleaning of the solenoid valve
there is an evident coolant leak solenoid valve. OUT – S.
from the exhaust oil container. 2. Check of the washer efficiency.
The capacity test is negative.
4. Difficulty in the recovery and Closed coolant tank. 1. Open the tank valve by
recharge phase Fixing washers, broken or unscrewing it counter clockwise.
deformed, are obstructing 2.Carry out emptying of the gas as
the pipes. described in chap.13.2.1
3. Reset the normal fixing
conditions of the HP-LP gasket
washers and the HP-LP joints, both
internal and external.
4. If yellow pipes are present, check
and eventually replace the fixing
washers placed inside the pipe
which connects the solenoid valve
group to the tank.
5. During the automatic cycle it Oil loading cell out of 1. Calibration of the exhaust and
is not possible to inject and calibration or defective. new oil scales.
recover the oil. 2. Eventual replacement.
7. After the vacuum phase the This may occur when the When a vacuum time less than 20
capacity test has a negative vacuum time is too short, minutes is set, the following
result. 4-5 minutes. message appears:
“Less than 20 minutes of vacuum
do not guarantee the execution of a
correct procedure. Continue?”.
The solution is keeping to the 20
minutes vacuum time.
8. The gas scale appears Loading cell locking screw Unscrew the locking screw of the
blocked at a certain value. not sufficiently unscrewed. cell more, ensuring that it is not in
contact with the cell during use.
CAP. 15 - DIAGNOSTICS
Attention messages are codified with the code Wxxx on the window title.
Alarm messages are codified with the code Axxx on the window title.
The alarms cause the immediate stop of the procedure and do not allow to continue.