MSG MS111 Test Bench for Diagnostics of Vehicle Air Conditioner Compressors User Manual

: June 8, 2024
: MSG

Table of Contents

MSG MS111 Test Bench for Diagnostics of Vehicle Air Conditioner
INTRODUCTION
PURPOSE
TECHNICAL CHARACTERSISTICS
EQUIPMENT SET
TEST BENCH DESCRIPTION
APPROPRIATE USAGE
- Preparation of the Test Bench for use
TEST BENCH MAINTENANCE
TROUBLESHOOTING GUIDE
RECYCLING
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MSG MS111 Test Bench for Diagnostics of Vehicle Air Conditioner

Compressors

INTRODUCTION

Thank you for choosing the product of MSG equipment.
The actual manual contains information on the test bench purpose, package contents, design, technical characteristics, and safe operation rules.
Read carefully this manual before putting MS111 (hereinafter “the test bench”) into operation, take special training at the equipment manufacturing facility if necessary.
As the test bench is being continuously improved, some changes made to the equipment design, package set, or firmware may not be reflected in this user manual. The test bench firmware is updateable, so its maintenance can be terminated without prior notice to users.
WARNING! The actual user manual does not contain information on how to diagnose alternators with the test bench. Follow the link MS111 Operation Manual or scan the QR-code to find this information.

PURPOSE

Test Bench MS111 is used for diagnostics of the piston, axial piston, rotor, and scroll compressors if vehicle climate systems on R134a or R1234yf.
The Test Bench performs the following operations:

Diagnostics of all types of 12/24V compressors of belt-driven vehicle air conditioners in both automatic and manual modes;
Check of electromagnetic clutches and control valves for short circuit, open circuit, and the presence of a diode both in assembly with a compressor and separately from it;
Post-maintenance run of compressors;
Pre-sale checks of new compressors-analogs;
Test report generation and printout (any external printer can be used).

TECHNICAL CHARACTERSISTICS

Main

R1234yf – 1050

V-belt / poly-V belt

Vacuum line of the unit| Yes
Refrigerant pumping out of the unit| Yes

Output parameters

| HP, bar; LP, bar;

Compr t, °С; Evpr t, °С;

PWM %.

Additional features

EQUIPMENT SET

Test Bench set includes:

Item name	Number of pcs
Test Bench MSG MS111	1
MS122 – Adapter for connecting compressors with 24V clutch	1
Set of two quick-disconnect hoses	1
MS0101 – polypropylene filter element	2
MS0102 – filter element of electromagnetic valve	2
Set of fittings to connect the compressor to the test bench	1
Clamping plates	3

MS0103 – rubber ring gasket O-02289 for sealing of interlocking parts of filter

case

TEST BENCH DESCRIPTION

The test bench consists of the following major components (Fig.1): test bench housing – 1; door for access to the power compartment – 2; mounting face – 3; control panel – 4; door for access to the service compartment – 5; swivel wheels with a brake – 6.

Figure 1 – Major components of the Test Bench
All diagnostic procedures with the tested unit are performed on the mounting face. The mounting face contains:

Compressor drive belts: V-belt and Poly-V belt.
Compressor fixing chain.
Dust cover. The diagnostic procedure is suspended when the cover is opened.
Compressor temperature sensor.
Connecting fitting for low-pressure hose.
Connecting fitting for high-pressure hose.
Compressor control valve connection terminals. Adherence to polarity is not necessary.
Compressor electromagnetic clutch connection terminals. Adherence to polarity is not necessary.

Test bench MS111

Figure 2 – Mounting face of the Test Bench
Control panel (Fig.3) includes the following elements:

Figure 3 – Control panel of the Test Bench

LP valve: low-pressure hose control.
Start button “OFF/ON”: Test Bench power on/off. Button “OFF/ON” cannot be activated when button “EMERGENCY STOP” is pressed.
Touch screen: diagnostic data display and test bench control.
Button “EMERGENCY STOP”: emergency shutdown.
HP valve: high-pressure hose control.

The back panel of the test bench (Fig.4) is equipped with a LAN port to connect the Test Bench to the Ethernet and two USB ports to connect the Wi-Fi adapter (included in the equipment set) and external printer.

Figure 4 –Back panel of the Test Bench

The routine maintenance of the Test Bench is essential for trouble-free enduring operation of the equipment. A service compartment of the bench (Fig.5) includes:

Vacuum pump.
Condensate tank.
Electromagnetic valve filters.
Main filter of the test bench hydraulic system.
LP and HP filling fittings.
Compressor for refrigerant pumping.

Figure 5 – Service compartment of the Test Bench

APPROPRIATE USAGE

Use the test bench as intended only (read Section 1).
WARNING! The Test Bench operates on refrigerants either R134a or R1234yf. It is strongly recommended not to use other refrigerants. Oil PAG46yf must be used for the systems on R1234yf and R134a.
Turning off the bench should be done through the interface of the service program by pressing the “Turn off the bench” button.
Use the button «EMERGENCY STOP» only if necessary to stop the diagnostic process in an emergency.
The accuracy of the compressor test depends on the amount of refrigerant in the test bench. Observe standard filling rate.
The refrigerant leak occurs every time after the replacement of a tested unit. Refrigerant deficiency in the system leads to inaccurate test results and may cause damage to the tested unit. Evacuate refrigerant from the system at the end of the working day and fill it in before you start.
In case compressor sealing gaskets lost their airtightness, air can enter the system during refrigerant pumping. Air in the system may cause diagnostics inaccuracy and damage to the tested unit.
Refill the system after the message “Too much air in the system” appears on the screen.
Automatic test mode is intended for the initial assessment of compressor performance and cannot be used for detection of such latent faults as, for example, sporadic sticking of a control valve and some others.
If any malfunction is detected during automatic testing, proceed with a manual test for accurate diagnostics of a unit.
During compressor diagnostics, wear particles normally retained by the test bench filters, can penetrate the system. These filters require periodic replacement. The test bench will signal the necessity for filter replacement.
Do not test compressors with obvious symptoms of malfunction. For example, the oil in a compressor is black and has metal shavings in it.
The use of inappropriate computer hardware or firmware will cause cancellation of the warranty (even if the computer facilities or programs were removed or deleted shortly after). Only the MSG Equipment original firmware can be used with this equipment.
To prevent the damage and the failure of the bench, do not make any modifications in the bench in your discretion. Any modifications can be effected by the official manufacturer only. Should the bench have defects contact the manufacturer or a dealer.
In case of failures in the operation of the bench, stop further operation and contact the manufacturer or sales representative.

The manufacturer is not responsible for any damage or injury to human health resulting from non-compliance with the requirements of this user manual.

Safety regulations

The Test Bench should only be used by the persons qualified to operate the test benches of certain types who received a special training in the equipment safety operation.
Before the unit dismounting from the test bench, the refrigerant should be evacuated.
Before starting any maintenance work on the bench, disconnect it from the electrical network.
The workplace should be clean, well-lit and spacious.
The use of the faulty or unearthed Test Bench is strictly prohibited.
The compressor mounting and/or dismounting should be conducted carefully to prevent its fall.
The unit with the running drive may not be left on the test bench unattended.
It is strictly forbidden to open the door of the power compartment (n. 2, Fig.1) when the test bench is connected to 400V power supply.
avoid body contact with the refrigerant, it may lead to a frostbite (R134a boiling point is -26°С, R1234yf boiling point is -30°С).
It is strongly recommended to use protective gloves and glasses.
Any refrigerant is a colorless and odorless gas which is heavier than air. Entering the atmosphere, it can cause asphyxiation or heart rhythm disorders. That is why, the Test Bench should be used in well-ventilated premises only. The available exhaust units in the room must be switched on.
Refrigerant R-1234yf is a highly flammable gas. Take extra care when working with this refrigerant.
Open flame sources are allowed nowhere near the test bench operating area. Smoking near the Test Bench is prohibited. A regular fire-extinguishing appliance is a must.
If the protective caps of the filling fittings cannot be easily unscrewed, there is a risk of injury due to the valves poor tightness.

Preparation of the Test Bench for use

Placement location and installation
The bench is delivered packed. Release the bench from the packaging materials, remove the protective film from the display (if available). After unpacking, it is necessary to make sure that the bench is intact and does not have any damage. If damage is detected before the bench is activated, contact the manufacturer or the sales representative.
The bench has to be placed on the level floor, with the pivot wheels fixed from rotating (min. two wheels) by the activating of the brake mechanism.
The bench ensures the operation at the temperature from +18°C up to +38°C and relative air humidity from 10% up to 75%.
When installing the bench, keep the minimum space gap 0.5 m from the rear bench side – for a proper air circulation.
Considering that the Test Bench components are exposed to heating during operation, the working room should be well-ventilated. To ensure a free circulation of air, it is necessary to provide the airspace of no less than 0.5m behind the back panel of the bench and 0.3m on either side of it. Don’t block the air flow behind the Test Bench.

Refilling of the Test Bench
The Test Bench is delivered to a customer charged with refrigerant R134a for 10-15% and with a full charge of oil. To ensure the Test Bench performance, it is necessary to fill the hydraulic system up to the standard level. The required amount of the refrigerant is specified in the chart “Technical characteristics” (Item 2 of the Manual).
WARNING! Refilling of the Test Bench directly from a container with the refrigerant is strictly prohibited as it can lead to emergency situations.
WARNING! Use specialized equipment for evacuation and purification of the refrigerant R134a and system refilling. Observe the instructions set out in the corresponding User Manual.

Refilling of the hydraulic system with the refrigerant should be performed as follows:

Open the door of the service compartment (n.5, Fig.1) with a special key (included in the equipment set).
There are two fittings for refilling of the test bench hydraulic system: «Service LP» and «Service HP» (n.5, Fig.5).
Connect the filling station lines to the test bench fittings. High-pressure and low-pressure valves (n.1,5, Fig. 3) located on the control panel (Fig.3) should be in the closed position (OFF).
Pump the refrigerant out of the hydraulic system.
WARNING! It is necessary to control the amount of oil released together with the refrigerant since the same amount of it should be added when refilling.
Dehydrate the system to remove the air and moisture residues. To do this, take the filling station off into the air pumping mode. Stop pumping on reaching the pressure of -0.9 Bar.
Upon the vacuuming procedure completion, non-condensable impurities must be removed from the filling station in the following manner:
Disconnect the filling station line from the Test Bench.
Remove the non-condensed impurities through a special valve (Fig.6) as prescribed in the corresponding Manual for the filling station.
Disconnect the filling station line from the Test Bench.
Remove the non-condensed impurities through a special valve (Fig.6) as prescribed in the corresponding Manual for the filling station.
Upon completion, disconnect the filling station lines. Place protective caps on the fittings for better tightness. Close the door of the service compartment with a special key.
WARNING! In cases when R1234yf must be used in the Test Bench, the evacuation of R134a from the system is required. The evacuation time should be extended for 10 min from the rated time. To fill the bench with refrigerant R1234yf, follow the procedure described in User Manual for the filling station and the information specified above.

Connection of the cables to the Test Bench terminals
To perform the diagnostics and control of the compressor electromagnetic clutch or valve, connect either Adapter MS122 or the appropriate cables to the test bench terminals as shown in the connection diagram (Fig.7). Adherence to the electric polarity is not necessary.

Figure 7 – Connection of the cables (Adapter MS122) to the test bench terminals «Clutch» and «Valve»

TEST BENCH MAINTENANCE

The bench is designed for a long period of operation, but for the maximum period of reliable operation of the bench it is necessary to perform the following works:

Daily, at the beginning of the working day to fill the bench with coolant and pump it out at the end of the working day. It is necessary to control the amount of oil in the bench system.
If the message “Condensate tank full” appears, empty it. The procedure is described in section 6.2.
If you see the message «Replace filter» you need to replace the filter 4 fig. 5. The replacement procedure is described in section 6.3.
When you see the message «Too much air in the system» you should take the following steps:
1. Refill the refrigerant bench (see sect. 5.2.2).
2. Make sure that the requirements for the placement and installation of the bench are met, see section 5.2.1.
  Error «Too much air in the system» most often appears in cases:
- improper filling of the bench, insufficient or excessive amount of refrigerant;
- refrigerant leakage;
- air entering the system, when diagnosing not hermetic compressors;
- high indoor air temperature.

Cleaning and Care
Clean the test bench surface with neutral detergents using soft tissues or wiping cloth. Use special fiber tissue and spray to clean the display. The use of abrasives or solvents may cause failure or damage to the test bench.

Condensate draining
Drain the condensate from the tank as follows:

Disconnect the bench from the power supply.
Open the door of the service compartment (n.5 Fig.1) with a special key (included in the equipment set).
Unscrew the tank cap (n.3, Fig.8).
Disconnect the condensate level sensor (n.2 Fig.8).
Remove the tank from the test bench by pushing it upward.
Empty the tank.
Reinstall the tank, reconnect the sensor, put the tank cap on and screw it up.

Figure 8 – Removal of the condensate tank
1 – tank; 2 – connector of the condensate level sensor; 3 – tank cap

Replacement of filters in the hydraulic system of the Test Bench

Observe the actual diagram and Chart 1 for replacement of the filters:

each message «Replace filter» should be followed by replacement of the right filter element MS0101 (Fig.9);
every other replacement of the right filter element MS0101 should be followed by replacement of the left filter element MS0101;
every forth replacement of the left filter element MS0101 should be followed by replacement of both filter elements MS0102 (Fig.13);

Chart 1. Frequency of filter replacements in the Test Bench.

Figure 9 – Direction of filter cover rotation during filter replacement MS0101
WARNING! Since the compression oil is hygroscopic and absorbs moisture from the air, filter elements MS0101 and MS0102 should be reinstalled as quickly as possible.
The procedure of filter MS0101 (n.4, Fig.5, Fig.9-11) replacement is as follows:

Put both valves (HP and LP) in “OFF” position and disconnect the bench from the power supply.
Open the service compartment door (n.5, Fig.1) with a special key (included in the equipment set).
Pump the refrigerant out using a special service station for air conditioners.
Level the inside pressure of the Test Bench with the atmospheric pressure by pressing the valve of the filling port. Even a slight pressure difference will make it much more difficult to unscrew the filter cup.
turn the filter cover (n.1, Fig.10) counter-clockwise (Fig.9) with either a hook wrench or a socket wrench until the filter bowl is free.
Check the condition of O-rings (n.3, Fig.10) and replace if necessary.
Replace the filter element MS0101 (n.2 Fig. 10).
Reinstall the filter cover and screw it clockwise until tight (see Fig.9).
Close the door of the test bench service compartment (n.5 Fig.1).
Refill the Test bench with the refrigerant (Item 5.2.2).

Figure 10 – Refrigerant filter structure:
1 – filter cover; 2 – filter element MS0101; 3 – O-rings

Figure 11 – Filter element MS0101

Figure 12 – Filter element MS0102

It is recommended to replace filter elements MS0102 of electromagnetic valves together with filter elements MS0101.

Figure 13 – Direction of the cover rotation when replacing filter MS0102

Firmware update
Being connected to the Internet, with every switching on, the test bench checks for software updates. In case the bench finds the software update at company server, you’ll be offered to install the update or disregard it. To start updating, press OK, to decline – SKIP.

WARNING! It’s forbidden to switch off the bench supply to stop the updating.

TROUBLESHOOTING GUIDE

Below are the potential faults and recovery methods:

Failure symptom

|

Potential cause

|

Troubleshooting tips

---|---|---

1. Test Bench doesn’t start up.

| No connection to the power supply| Restore the supply voltage
Button «EMERGENCY STOP» is pressed|

Turn off the emergency button

Faulty power supply unit| Contact the dealer
2. Touch screen doesn’t respond the operator’s touch.|

Touch screen is damaged

|

Contact the dealer

3. Operating system doesn’t load.| Operating system failure| Contact the dealer
4. Diagnostic program doesn’t launch.| Operating system failure| Contact the dealer

5. Compressor drive doesn’t start.

| Opened protective cover or opened service compartment door; full condensate tank| Shut down the protective cover, close the service compartment door, drain the condensate.
The cable short circuit or motor winding short circuit to the ground|

Eliminate short circuit

Low power supply

| Make sure that no high- power consumers with high starting currents are nearby the Test Bench

RECYCLING

For the recycling of the bench refer to the European Directive 2202/96/EC (WEEE Directive – the directive on waste electrical and electronic equipment).
The outdated electronic devices and electrical appliances, including the cables, hardware, batteries and storage batteries shall be disposed separately from the house waste.
To dispose the waste products, exploit the available returning and collecting systems.
The appropriate disposal of the outdated devices helps to prevent harming to environment and health.

MSG equipment
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