Service Manual. Models 17700/17701/17703 Recovery/Recycling/Recharging Unit For R-12 Only

Transcription

1 Service Manual Models 17700/17701/17703 Recovery/Recycling/Recharging Unit For R-12 Only Theory of Operation and Safety Precautions... 2 Component Descriptions... 3 Plumbing Diagram... 8 Pictorial Views Wiring Diagram Component Specifications Tubing Schematic Compressor Specifications and Service Troubleshooting RA19064 Replacement Main Board RA19008 Replacement Scale Diagnostic Procedures Function Test Guide Labor Rates... 38

2 ORIGINAL REVISED 12/1/94 Theory of Operation and Safety Precautions The Series recovery, recycle, evacuation and recharging units are designed to be used for R-12 type refrigerant only. These units are UL approved and meet SAE J1991 standards. These units began production in May of 1991 and were superseded to the 17700A in January of The model, serial number and manufacturing date code can be found on a white tag located on the back of the unit above the tank. DEPRESSURIZING THE UNIT 1. Close both liquid and vapor valves on the 50-lb. recovery tank. 2. Disconnect all hoses from the 50-lb. recovery tank. 3. Disconnect the red high side and blue low side hoses from a hand-held manifold gauge set. 4. Connect the blue (36"-48") liquid hose to the low side (blue handle) and the red (36") vapor hose to the high side (red handle) of a handheld manifold gauge set. 5. Connect the yellow hose (usually connected to the center port) of the hand-held manifold gauge set to the intake of your recovery unit. 6. Open both manifold valves on the hand-held manifold gauge set. 7. Plug in your recovery unit and press the Recovery Start button. 8. When the recovery light turns off (on the 17650), wait ten (10) minutes and watch the hand-held manifold gauges for a rise in pressure above zero. Repeat Steps 7 and 8 until positive pressure does not develop on the hand-held manifold gauge set. 9. Disconnect the blue (36"-48") liquid and red (36") vapor hoses from the hand-held manifold gauge set. 10. Connect the yellow (36") air purge hose and the red (96") high side hose to the hand-held manifold gauge set. 11. Open both the high and low side gauge valves on the face of the Press the Recovery Start button on the When the recovery light turns off (on the 17650), wait ten (10) minutes and watch the hand-held manifold gauges for a rise in pressure above zero. Repeat Steps 12 and 13 until positive pressure does not develop on the hand-held gauge set). WARNING! Always wear safety goggles when working with refrigerants. Contact with refrigerant can cause eye injury. Disconnect lines and hoses with extreme caution! Pressurized refrigerant may be present in lines and hoses. Always point lines and hoses away from you and anyone nearby. Always unplug the station from the power source before removing any of the shrouding or beginning any service work. To order parts please call Robinair Customer Service at Or FAX your order to All service related questions should be directed to the Robinair Technical Assistance Line at

3 REVISED ORIGINAL 12/1/94 Component Descriptions RECOVERY SIDE 1. RA17708 (2¼") RA19076 (2¾") RA17711 (2¾" 220V metric) Low Side Gauge Reads pressure and/or vacuum entering the low side hose. Note that the gauge will read pressure and/or vacuum in the low side hose with the low side valve closed. RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens. 2. RA19044 Low Side Manifold Valve Allows flow from the low side hose into the center manifold tube (suction line strainer). RA19199 Manifold Stem Repair Kit 3. RA17709 (2¼") RA19075 (2¾) RA17712 (2¾" 220V metric) High Side Gauge Reads pressure entering the high side hose. Note that the gauge will read pressure in the high side hose with the high side valve closed. RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens. 4. RA19044 High Side Manifold Valve Allows flow from the high side hose into the center manifold tube (suction line strainer). RA19199 Manifold Stem Repair Kit Suction Line Strainer Filters the refrigerant coming from the high and low side manifold valves before entering into the inlet check valve. Note that units produced after October 1993 came equipped from the factory with the strainer already installed. 6. RA17112 Inlet Check Valve Allows flow in one direction only, towards the recovery solenoid, and prevents refrigerant from escaping out of the inlet during shut down, evacuation or recycling. 7. RA19006 Recovery Solenoid This is a normally closed solenoid, designed to prevent the flow of refrigerant into the system oil separator while the unit is off or in any mode other than recovery. Note that the control voltage is 120 volts. RA19258 Solenoid Rebuild Kit 8. RA17328 Vacuum Sensor This is a normally closed sensor, designed to open when a 17" inch vacuum rating (±2") is reached in the inlet manifold. Note that this switch has orange wires attached to it. 9. RA18760 System Oil Separator This component performs three functions. Internal heat causes incoming saturated vapor to evaporate. This is important for two reasons: one, to be sure no liquid enters the compressor and, two, so the oil droplets contained in the incoming refrigerant will drop out in the separator. The third function will be discussed later Oil Drain Valve Allows the oil that has been removed from the system to be drained when the recovery process is complete. The oil removed from the system should be replaced with new oil during recharging Replacement Valve Stem Note: It is important that the oil drain procedure is done after each recovery. 38. RA17419 Oil Drain Bottle Used to measure the amount of used oil recovered from the vehicle being serviced Filter Drier Removes moisture, acid and oil from refrigerant being circulated through it during recovery and recycling Replacement Hose Gasket 12. RA17434/RA17411 Compressor Converts a low pressure/temperature entering gas into a high pressure/temperature discharge gas. Note: See Compressor Specifications and Service on page RA19067 Compressor Oil Separator Traps compressor oil that has migrated out with refrigerant while passing through the compressor. Heat is added to the incoming refrigerant to promote vaporization through a series of coils that are wrapped around the outside of the separator. The hot refrigerant contained in the coils is then allowed to cool, promoting the condensing of the refrigerant. The oil is stored in the separator until the equalization solenoid loses power and allows the oil to be returned. 3

4 ORIGINAL REVISED 12/1/94 Component Descriptions Note: Some units have automatic oil return controlled through the main board, when the compressor runs continuously for ten (10) minutes the main board drops power to the equalization solenoid for 3 seconds and then repowers it. 14. RA17522 Equalization Solenoid This is a normally open solenoid designed to allow oil trapped in the compressor oil separator to be forced back into the suction side of the compressor when power is dropped to the solenoid. 15. RA17072 High Pressure Cut Out This is a normally closed sensor designed to shut off the unit when discharge pressure reaches 350 psi. Note that this switch has three contacts on it, the outer two contacts (numbered 1 and 3 are normally closed) have two solid red wires connected to them. 16. RA17112 Recovery Check Valve Allows flow in one direction only. Prevents refrigerant in the tank from coming back into the unit during shut down. 9. RA18760 System Oil Separator At this point, high pressure/temperature vapor enters the separator and passes through a condensing coil to give up heat to the incoming refrigerant surrounding the coil, which causes the refrigerant in the coils to cool and condense Air Purge Well Houses the air purge device s sensing bulb and allows refrigerant to circulate around it. 18. RA17577 Moisture Indicator References the moisture content of the refrigerant being recycled. Pale yellow indicates wet and light mint green indicates dry. During recovery the moisture indicator initially fills with liquid refrigerant when recovery is started and drains out as the system being recovered empties. During recycling the moisture indicator is normally about half full of liquid refrigerant and feels warm to the touch Red (36") Vapor Tank Hose Delivers refrigerant that is being recovered or recycled to the vapor side of the 50-lb. recovery tank Replacement O-Rings Standard Hose Gasket RECYCLE SIDE Recovery Tank Stores refrigerant so that it may be recycled at a later time. The tank has two valves: one, a vapor valve which simply is an open fitting to the tank and, two, a liquid valve that has a draw tube extending to within two inches of the bottom of the tank Blue (48") Liquid Tank Hose Allows flow from the liquid side of the tank to the charging solenoid and expansion valve Replacement O-Rings Standard Hose Gasket Liquid Line Strainer Filters liquid coming in from the blue liquid hose before going to the charging solenoid or expansion valve. 23. RA17424 Automatic Expansion Valve Converts incoming liquid refrigerant into a low pressure saturated vapor. The calibration of the expansion valve can be checked at the service port with a pressure gauge. The allowable tolerance of the valve is 30 to 40 psi while recycling. Note: Allow the unit to recycle ten (10) minutes with a minimum of 10 lbs. of refrigerant in the tank before checking or adjusting pressure. 24. RA19006 Recycling Solenoid This is a normally closed solenoid designed to prevent the flow of refrigerant into the system oil separator when the unit is not running in the recycling mode. Note that the control voltage is 120 volts. RA19258 Solenoid Rebuild Kit 8. RA17328 Vacuum Sensor This is a normally closed sensor designed to open when a 17" inch vacuum rating (±2") is reached in the inlet manifold. Note that this switch has orange wires attached to it. 9. RA18760 System Oil Separator This component performs two functions. Internal heat causes incoming saturated vapor to evaporate. This is important so that no liquid enters the compressor. The second function will be discussed later. 4

5 REVISED ORIGINAL 12/1/94 Component Descriptions Oil Drain Valve Allows the oil that has been removed from the system to be drained when the recovery is complete. The oil removed from the system should be replaced with new oil during recharging Replacement Valve Stem Note: It is important that the oil drain procedure is done after each recovery. 38. RA17419 Oil Drain Bottle Used to measure the amount of used oil recovered from the vehicle being serviced Filter Drier Removes moisture, acid and oil from refrigerant being circulated through it during recovery and recycling Replacement Hose Gasket 12. RA17434/RA17411 Compressor Converts a low pressure/temperature entering gas into a high pressure/temperature discharge gas. Note: See Compressor Specifications and Service on page RA19067 Compressor Oil Separator Traps compressor oil that has migrated out with refrigerant while passing through the compressor. Heat is added to the incoming refrigerant to promote vaporization through a series of coils that are wrapped around the outside of the separator. The hot refrigerant contained in the coils is then allowed to cool, promoting the condensing of the refrigerant. The oil is stored in the separator until the equalization solenoid loses power and allows the oil to be returned. Note that some units have automatic oil return controlled through the main board. When the compressor runs continuously for ten (10) minutes, the main board drops power to the equalization solenoid for three (3) seconds and then repowers it. 14. RA17522 Equalization Solenoid This is a normally open solenoid designed to allow oil trapped in the compressor oil separator to be forced back into the suction side of the compressor when power is dropped to the solenoid. 15. RA17072 High Pressure Cut Out This is a normally closed sensor designed to shut off the unit when discharge pressure reaches 350 psi. Note that this switch has three contacts on it, the outer two contacts (numbered 1 and 3 are normally closed) have two solid red wires connected to them. 16. RA17112 Recovery Check Valve Allows flow in one direction only. Prevents refrigerant in the tank from coming back into the unit during shut down. 9. RA18760 System Oil Separator At this point high pressure/temperature vapor enters the separator and passes through a condensing coil to give up heat to the incoming refrigerant surrounding the coil, which causes the refrigerant in the coil to cool and condense Air Purge Well Houses the air purge device s sensing bulb and allows refrigerant to circulate around it. 25. RA18759 Air Purge Indicator Allows for a quick accurate method of purging air from the recovery tank while recycling. The reference bulb contained in the air purge well holds R-12 refrigerant inside itself and exerts pressure on the red indicator needle. This sealed bulbs pressure (red needle) is controlled by the temperature of the refrigerant being circulated around it. The green needle will display tank pressure at all times if the yellow supply hose is connected to the recovery tank. Note: There should be a minimum of 10 lbs. of refrigerant in the supply tank. After ten (10) minutes of recycling, the two needles should be in alignment with each other if there is no air in the tank. When air pressure is in the recovery tank, the green needle will have higher pressure than the red (sealed bulb reference pressure). 18. RA17577 Moisture Indicator References the moisture content of the refrigerant being recycled. Pale yellow indicates wet and light mint green indicates dry. During recovery the moisture indicator initially fills with liquid refrigerant when recovery is started and drains out as the system being recovered empties. During recycling the moisture indicator is normally about half full of liquid refrigerant and feels warm to the touch. 5

6 ORIGINAL REVISED 12/1/94 Component Descriptions Air Purge Valve Allows the release of air from the recovery tank while open (allows the green needle to be bled to align with the red needle). If the purge process is done while recovering, refrigerant could be vented or, if left open, would allow the release of the refrigerant from the tank Replacement Valve Stem Red (36") Vapor Tank Hose Delivers refrigerant that is being recovered or recycled to the vapor side of the 50-lb. recovery tank Replacement O-Rings Standard Hose Gasket FLOW DESCRIPTION (EVACUATION) 1. RA17708 (2¼") RA19076 (2¾") RA17711 (2¾" 220V metric) Low Side Gauge Reads pressure and/or vacuum entering the low side hose. Note that the gauge will read pressure and/or vacuum in the low side hose with the low side valve closed. RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens 2. RA19044 Low Side Manifold Valve Allows flow from the low side hose into the center manifold tube (suction line strainer). RA19199 Manifold Stem Repair Kit 3. RA17709 (2¼") RA19075 (2¾) RA17712 (2¾" 220V metric) High Side Gauge Reads pressure entering the high side hose. Note that the gauge will read pressure in the high side hose with the high side valve closed. RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens 4. RA19044 High Side Manifold Valve Allows flow from the high side hose into the center manifold tube (suction line strainer). RA19199 Manifold Stem Repair Kit 27. RA17329 Vacuum Pump Protection Switch A normally open sensor designed to close if pressure greater than 25 psi is present at the vacuum solenoids. If pressure is greater than 25 psi, it will prevent the vacuum pump from starting and the vacuum solenoids from opening, and thereby prevent damage to the vacuum pump (the display reads U-HI ). The switch has two light blue wires connected to it. 28. RA19006 (x2) Vacuum Solenoids Normally closed solenoids designed to prevent flow to the vacuum pump while recovering or charging (upper solenoid) and to hold the vacuum on a system when the evacuation is complete (lower solenoid). RA19258 Solenoid Rebuild Kit 29. RA15425/RA15428 Vacuum Pump A 4 cfm, two-stage rotary vane pump designed to pull moisture and air from the system to which the unit is attached (Optional) Oil Injection Kit Controls and regulates the flow of oil from the injection bottle to the inlet manifold Installation Kit FLOW DESCRIPTION (CHARGING) Recovery Tank Stores refrigerant so that it may be charged at a later time. The tank has two valves: one, a vapor valve which simply is an open fitting to the tank and, two, a liquid valve that has a draw tube extending to within two inches of the bottom of the tank Blue (48") Liquid Tank Hose Allows flow from the liquid side of the tank to the charging solenoid and expansion valve Replacement O-Rings Standard Hose Gasket Liquid Line Strainer Filters liquid coming in from the blue liquid hose before going to the charging solenoid or expansion valve. 31. RA19006 Charging Solenoid This is a normally closed solenoid designed to prevent the flow of refrigerant into the inlet when the unit is not charging. Note that the control voltage is 120 volts. RA19258 Solenoid Rebuild Kit 2. RA19044 Low Side Manifold Valve Allows flow from the charging solenoid into the low side hose. RA19199 Manifold Stem Repair Kit 6

7 REVISED ORIGINAL 12/1/94 Component Descriptions 1. RA17708 (2¼") RA19076 (2¾") RA17711 (2¾" 220V metric) Low Side Gauge Reads pressure and/or vacuum entering the low side hose. Note that the gauge will read pressure and/or vacuum in the low side hose with the low side valve closed. RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens 4. RA19044 High Side Manifold Valve Allows flow from the charging solenoid into the high side hose. RA19199 Manifold Stem Repair Kit 3. RA17709 (2¼") RA19075 (2¾") RA17712 (2¾" 220V metric) High Side Gauge Reads pressure entering the high side hose. Note that the gauge will read pressure in the high side hose with the high side valve closed. RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens ELECTRICAL COMPONENTS 32. RA40994/RA17135 Main Power Switch Controls the power between the power cord and the main board. 33. RA17416/RA17516 Fan Activates when the Main Power switch is turned on and cools the cabinet temperature. 34. RA19064 Main Board Controls the unit s functions, either automatic or programmed. 35. RA19065 Keypad Sends controlling signals to program the main board. 27. RA17329 Vacuum Pump Protection Switch A normally open sensor designed to close if pressure greater than 25 psi is present at the vacuum solenoids. If pressure is greater than 25 psi, it will prevent the vacuum pump from starting and the vacuum solenoids from opening, and thereby prevent damage to the vacuum pump (the display reads U-HI ). The switch has two light blue wires connected to it. 8. RA17328 Vacuum Sensor A normally closed sensor designed to open when a 17" inch vacuum rating (±2") is reached in the inlet manifold. Note that this switch has orange wires attached to it. 15. RA17072 High Pressure Cut Out A normally closed sensor designed to shut off the unit when discharge pressure reaches 350 psi. Note that this switch has three contacts on it; the outer two contacts (numbered 1 and 3 are normally closed) have two solid red wires connected to them. 36. RA19008 Scale A strain gauge style, designed to send a signal to the main board for accurate weight readings during charging and recovery. 37. RA17459 System Relay Energizes the compressor and/or vacuum pump. The relay has two sets of contacts which close when the coil is energized. Note: Only one set of contacts are used in this application. If one set gets burned, the other set could be used. See page 19 for troubleshooting and wiring details. 39. RA19066 Sonalert Provides an audible tone when commands are programmed through the keypad. 7

8 ORIGINAL REVISED 12/1/94 Plumbing Diagram GAS (VAPOR) LIQUID

9 REVISED ORIGINAL 12/1/94 Plumbing Diagram 1. RA17708 (2¼") RA19076 (2¾") RA17711 (2¾" 220V metric) Low Side Gauge RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens 2. RA19044 Low Side Manifold Valve RA19199 Manifold Stem Repair Kit 3. RA17709 (2¼") RA19075 (2¾") RA17712 (2¾" 220V metric) High Side Gauge RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens 4. RA19044 High Side Manifold Valve RA19199 Manifold Stem Repair Kit Suction Line Strainer 6. RA17112 Inlet Check Valve 7. RA19006 Recovery Solenoid RA19258 Solenoid Rebuild Kit 8. RA17328 Vacuum Sensor 9. RA18760 System Oil Separator Oil Drain Valve Replacement Valve Stem Filter Replacement Hose Gasket 12. RA17434/RA17411 Compressor 13. RA19067 Compressor Oil Separator 14. RA17522 Equalization Solenoid 15. RA17072 High Pressure Cut Out 16. RA17112 Recovery Check Valve Air Purge Well 18. RA17577 Moisture Indicator Red (36") Vapor Tank Hose Replacement O Rings Standard Hose Gasket Recovery Tank Blue (48") Liquid Tank Hose Replacement O Rings Standard Hose Gasket Liquid Line Strainer 23. RA17424 Automatic Expansion Valve 24. RA19006 Recycling Solenoid RA19258 Solenoid Rebuild Kit 25. RA18759 Air Purge Indicator Air Purge Valve Replacement Valve Stem 27. RA17329 Vacuum Pump Protection Switch 28. RA19006 (x2) Vacuum Solenoids RA19258 Solenoid Rebuild Kit 29. RA15425/RA15428 Vacuum Pump Oil Injection Kit (18059 Installation Kit) 31. RA19006 Charging Solenoid RA19258 Solenoid Rebuild Kit 33. RA17416/RA17516 Fan 36. RA19008 Scale 9

10 ORIGINAL REVISED 12/1/94 Pictorial Views 6. RA17112 Inlet Check Valve 7. RA19006 Recovery Solenoid RA19258 Solenoid Rebuild Kit RA18760 System Oil Separator Filter Replacement Hose Gasket 12. RA17434/RA17411 Compressor 13. RA19067 Compressor Oil Separator 14. RA17522 Equalization Solenoid Air Purge Well 23. RA17424 Automatic Expansion Valve 24. RA19006 Recycling Solenoid RA19258 Solenoid Rebuild Kit 29. RA15425/RA15428 Vacuum Pump 31. RA19006 Charging Solenoid RA19258 Solenoid Rebuild Kit 37. RA17459 System Relay Top Relay Compressor Bottom Relay Vacuum Pump 10

11 A I R P UR G E psi O I L I NHIGH LOW REVISED ORIGINAL 12/1/94 Pictorial Views 10 D R A Oil Drain Valve Replacement Valve Stem 25. RA18759 Air Purge Indicator Air Purge Valve Replacement Valve Stem 36. RA19008 Scale RA14979 Scale Platform 38. RA17419 Oil Drain Bottle 27. RA17329 Vacuum Pump Protection Switch 28. RA19006 (x2) Vacuum Solenoids RA19258 Solenoid Rebuild Kit 33. RA17416/RA17516 Fan 11

12 ORIGINAL REVISED 12/1/94 Wiring Diagram FAN J3 1 YELLOW YELLOW PURPLE PURPLE BLUE BLUE GREY GREY BROWN BROWN RED RED RED RED WHT BLK J VACUUM SOLENOID #2 BLACK WHITE RED RED ORANGE ORANGE BROWN BROWN WHITE BLACK VACUUM SOLENOID #1 VACUUM PROTECTION CUT-OUT CHARGE SOLENOID LOW PRESSURE CUT-OUT RECYCLE SOLENOID HIGH PRESSURE CUT-OUT B Y Y L E E K L L 1 3 COMPRESSOR RELAY 2 * 4 YEL RECOVERY SOLENOID W H T THERMO- PROTECTOR YEL 3 4 B 5 G COMPRESSOR 2 1 VACUUM PUMP OUTLET W W H T B L K P U R 1 3 VACUUM PUMP * 2 4 RELAY P U R MAIN POWER BLACK WHITE GREEN CAPACITOR + SONALERT - RETURN OIL SOLENOID 12

13 REVISED ORIGINAL 12/1/94 Component Specifications KG LB J7 P1 R1 C3 J1 U1 VR1 C11 R4 C10 C9 C8 R2 C7 C2 R5 C12 C13 R6 R11 U4 U3 KG LB C17 C18 L3 C19 R7 R8 R9 R10 C16 C15 R15 R16 R17 J7 1 R14 + RN1 U5 C14 J6 R12 R J2 U7 C24 1 C25 P1 U6 C26 R18 C28 VR3 C29 R19 R20 R21 R22 D6 C27 OSC1 U10 Q1 U8 C31 * MOV5 MOV3 MOV1 C30 + RL1 RL3 RL5 RL2 RL4 RL6 MOV6 MOV4 MOV2 J DIS1 U2 T1 C20 VR2 1 C21 C22 C6 + C5 C23 U9 U12 1 C33 RN2 R3 C32 U11 D5 MOV9 MOV7 RL7 NOT STUFFED RL9 RL8 RL10 MOV10 MOV8 J4 1 6 C1 F1 F2.5 AMP 1 AMP MOV11 D1 D2 D3 D4 L2 C4 ROBINAIR L J5 34 F1.5 AMP F2 1 AMP RA19064 MAIN BOARD BLANK DISPLAY HI-P WARNING 13

14 ORIGINAL REVISED 12/1/94 RA19064 REPLACEMENT MAIN BOARD This board uses the previous basic functions with auto calibration, low side clearing, timed oil return and a 10-hour oil time change. The board can be programmed for a minimum vacuum time, oil change time and filter change time. The board automatically defaults to a 15-minute vacuum time, 10-hour oil change and 300-pound filter change. The board also has the CH-P warning, which is initiated when recovery is engaged. If there is less than five (5) psi at the inlet of the unit, this prompt will appear. Component Specifications The board can read the amount of refrigerant recovered over a period of time (week or month, depending upon how often you want to check it). To access that function, you must enter manual diagnostics and press the 3 key. The amount recovered will be displayed. To zero out the display, press the Shift/Reset and Enter keys. 36 RA19008 SCALE ASSEMBLY You can also read the amount of refrigerant in the tank by accessing diagnostics and pressing the 7 key. The following table gives the main board s default codes. Follow these steps to change the default code. 1. Turn on the unit and press the Shift/Reset and Enter keys at the same time. 2. Press The message CAL2 should display. 3. Press Enter and the current default code will display. 4. Enter the new three-digit default code and press Enter to store the code in the unit s memory. Default Code Table Code Number Vacuum Time (minutes) Filter change Amount (lbs.) Pump Oil Timer (hours)

15 F R-12 psi F R-12 psi REVISED ORIGINAL 12/1/94 Component Specifications 1 3 MANIFOLD MAIN POWER RECYCLE FILTER ROBINAIR ROBINAIR OFF ON CHG. 5 6 HOLD CONT. LOW MADE IN U.S.A. MADE IN U.S.A. HIGH VACUUM 18 CLOSED CLOSED 39 RECOVER 0 SHIFT RESET ENTER OPEN OPEN CONTROL PANEL 1. RA17708 (2¼") RA19076 (2¾") RA17711 (2¾" 220V metric) Low Side Gauge RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens 2. RA19044 Low Side Manifold Valve RA19199 Manifold Stem Repair Kit 3. RA17709 (2¼") RA19075 (2¾") RA17712 (2¾" 220V metric) High Side Gauge RA19256 (2¼") RA19257 (2¾") Replacement Gauge Lens 4. RA19044 High Side Manifold Valve RA19199 Manifold Stem Repair Kit 18. RA17577 Moisture Indicator 32. RA40994 Main Power Switch 35. RA19065 Keypad 39. RA19066 Sonalert 15

16 ORIGINAL REVISED 12/1/94 Component Specifications RECYCLE FILTER CHG. 35 ADD The recovery tank has less than 8 lbs. of refrigerant left or is beginning the add process HOLD CONT. CAL Calibrate the scale VACUUM CH-F Change the filter-drier. RECOVER 0 SHIFT RESET ENTER CH-P Less than 25 psi at inlet of machine. CL-L Low side clearing routine is in progress. CON Continuous; the vacuum pump will run continuously. CPL Complete; cycle process is finished. FIL Filter-drier change-out is in process. FULL Refrigerant tank is full. HI-P High pressure; internal unit pressure is above 350 psi. OIL Change the vacuum pump oil. To reset, press Shift/Reset and Enter at the same time while the OIL message is displayed. U-HI High pressure to vacuum pump. SCAL Scale problem; scale may be broken or disconnected, or tank weight has exceeded 80 pounds (36 kilograms). 99LB The maximum amount displayed during recovery is 99 pounds (or 99 kilograms); reset the unit. 16

17 REVISED ORIGINAL 12/1/94 Component Specifications FRONT VIEW 23 IN RECOVER RECHARGE RECYCLING IN IN TOP VIEW RA17112 Inlet Check Valve 7. RA19006 Recovery Solenoid RA19258 Solenoid Rebuild Kit 8. RA17328 Vacuum Sensor 23. RA17424 Automatic Expansion Valve 24. RA19006 Recycling Solenoid RA19258 Solenoid Rebuild Kit 27. RA17329 Vacuum Pump Protection Switch 31. RA19006 Charging Solenoid RA19258 Solenoid Rebuild Kit 17

18 ORIGINAL REVISED 12/1/94 Component Specifications 14 RA17522 N/O SOLENOID RA19067 COMPRESSOR OIL SEPERATOR 27 VACUUM PROTECTION SWITCH 9 23 AUTOMATIC EXPANSION VALVE RA18760 SYSTEM OIL SEPERATOR 18

19 REVISED ORIGINAL 12/1/94 Component Specifications YELLOW 0 1 "COMPRESSOR RELAY" * * BLACK LONG BLACK JUMPER (W/FLAG) * NO CONNECTION TERMINALS 6 & 8 EACH RELAY PURPLE 0 1 "VACUUM PUMP RELAY" RA17459 System Relay The system relay energizes the compressor and allows the sensors to shut the unit off. The relay has two sets of contacts which close when the coil is energized. Contacts 0 & 1 are the coil contacts. When energized, they should have 110 volts across the terminals. While voltage is applied, the coil forms a magnetic field pulling the 2 and 4 and the 6 and 8 contacts together. The 2 and 4 and the 6 and 8 contacts have power supplied to one terminal of the pair. When the coil is energized, it closes the contacts and supplies power to the mating contact. TROUBLESHOOTING BLACK * * SHORT BLACK JUMPER Manual override ear not pulled in. 1. Check for proper voltage to the 0 and 1 contacts. If there is proper voltage, replace the relay. If there is not proper voltage, replace the main board. Manual override ear pulled in. 1. Check for proper voltage from the power supply contact to the ground. If there is not proper voltage, check the voltage supply source. 2. Check for proper voltage from the mating supply contact to the ground. If there is not proper voltage, replace the relay. Note: Use of an improper extension cord size can damage contact points. 19

20 ORIGINAL REVISED 12/1/94 Component Specifications ORANGE WIRES 8 VACUUM SENSOR RA17328 Vacuum Sensor The vacuum sensor is a normally closed sensor. If a 17" (± 2") vacuum is reached at the intake, the switch opens and breaks the coil contacts, shutting off the unit. The contacts are closed when anything above 17" is present in the lower cavity. When 17" is achieved in the lower cavity, the spring contact has room to force away from the mating contact. TROUBLESHOOTING With pressure in the accumulator (open the oil drain valve to ensure pressure is present), the switch should have continuity. If it does not, replace the switch. If the unit is shutting off before reaching a 17" vacuum, inspect the inlet for obstructions before replacing the switch. 15 HIGH PRESSURE CUT OUT High Pressure Cut Out The high pressure cut out is a normally closed sensor designed to shut the unit off if the discharge pressure reaches 350 psi. The pressure is detected through the orifice in the base of the sensor. In the normal setting (less than 350 psi on orifice) the 1 and 3 contacts are closed. When 350 psi is introduced to the orifice, the pressure forces up on the drive pin which forces the center contact to disengage the 1 and 3 contacts and engage the 1 and 2 contacts. When this takes place, the unit shuts off and turns on the high pressure light. 20

21 REVISED ORIGINAL 12/1/94 Tubing Schematic HIGH SIDE LOW SIDE OIL DRAIN VALVE AIR PURGE INDICATOR AIR PURGE VALVE LOW SIDE HIGH SIDE (REF.) LEGEND COMPRESSOR (REF.) OIL DRAIN TEE UNION CHECKVALVE TUBE P/N IN RETURN OIL SEPARATOR (REF.) FILTER (REF.) OIL VACUUM PUMP (REF.) HEAT EXCHANGER (REF.) SERVICE PORT 21

22 TOP ORIGINAL REVISED 12/1/94 Component Specifications and Service INTAKE BLACK GRN COMP. ELECT. BOX SUCTION WHITE '' 30 DISCHARGE MOUNT IN UPRIGHT POSITION COMPRESSOR SPECIFICATIONS Type: Oil Capacity: Amperage: Voltage: 1/3 hp hermetic (piston type) compressor 11 oz. of 150 viscosity refrigeration oil (ester refrigeration oil) 4-6/3-5 running amperage 20-25/16-19 locked rotor amperage 110V/220V PROCEDURE FOR CHECKING OIL LEVEL 1. Depressurize the unit following the instructions on page Remove the compressor from the unit. 3. Place the compressor on flat surface. 4. Tip the compressor 30 degrees (see figure above). At this angle, there should be oil in the suction fitting. PROCEDURE FOR ADDING OIL 1. Install a hose on the suction fitting and place the loose end of the hose into a bottle containing two (2) ounces of oil. 2. Start the compressor. Plug the intake fitting with a cap, but leave the discharge open. The compressor will pull the oil from the bottle into itself. 3. Recheck the oil level. If it is still low, keep adding two (2) ounces at a time until a proper level is achieved. Be sure to check the oil level between each addition. TROUBLESHOOTING Compressor won t run. 1. Check for proper voltage to compressor (110V/ 220V). If there is no voltage, inspect the power source for defects. 2. Jumper thermal overload. If the compressor runs, take an amp draw of the compressor. If it is okay, replace the thermal overload. If it is drawing locked rotor amperage, replace the compressor. If there is no amp draw, inspect the start components and replace if necessary. Compressor runs, no suction. 1. Cap the intake fitting. 2. Install a low side gauge on the suction fitting. 3. Be sure nothing is connected to the discharge. 4. Start the compressor and monitor the suction readings (it should pull a 25" vacuum). 5. If the compressor has weak suction, check the oil level and add oil if necessary. 6. If the oil level is okay or oil was added with no improvement, replace the compressor. Compressor runs, no discharge. 1. Check the oil level and add oil if necessary. 2. Install a high pressure gauge on the discharge port. 3. Check the intake and suction fittings for obstructions. 4. Start the compressor. Pressure should build to 350 psi in about four (4) minutes. If pressure doesn t rise or reach at least 350 psi, replace the compressor. 22

23 REVISED ORIGINAL 12/1/94 Troubleshooting UNIT WILL NOT COME OUT OF CL-L COMPRESSOR RUNS UNIT WILL NOT RECOVER 1. If the unit is being run through an extension cord, eliminate it s use. 2. Disconnect the high and low side hoses from the vehicle with the gauge valves open. If the pressure on the gauges drops while the display says CL-L, the recovery solenoid needs rebuilt or cleaned. 3. Check the oil drain valve. Verify that it is closed and not bleeding through. 4. Install the low side hose on the service port with the low side valve closed. Look at the pressure reading. If the pressure is below 20", test the vacuum sensor for continuity. If the gauge has positive pressure, go to Step 5. If the vacuum sensor has continuity, replace it. If it doesn t have continuity, check the vacuum sensor wires for continuity. If the wires have continuity, replace the main board. 5. Close the liquid tank valve. If the pressure starts dropping on the gauge and starts a recovery sequence, clean and rebuild the recycling solenoid. 6. Inspect the filter for flow obstructions and leaks around the gasket area. Note that the fittings on quick disconnects should only be hand tight. Replace the gaskets if needed. When installing gaskets, be sure to lubricate them with vacuum grease or refrigerant oil if needed. 7. Verify that the equalization solenoid is receiving 110 volts from the main board. If it is not, check the solenoid s power supply wires for continuity. If they have continuity, replace the main board. 8. If the equalization solenoid is receiving power, check the equalization solenoid for bleed through to the suction side of the compressor. Replace the solenoid if it is bleeding through while receiving power. Go to Step 9 if the solenoid is functioning properly. 9. Check the compressor discharge and suction pressure (see page 22). Replace the compressor as necessary. 23

24 ORIGINAL REVISED 12/1/94 Troubleshooting UNIT WILL NOT COME OUT OF CL-L COMPRESSOR IS OFF UNIT WILL NOT RECOVER UNIT WILL NOT COMPLETE RECOVERY DISPLAY READS HI-P 1. If unit is being run through an extension cord, eliminate it s use. 2. Remove the shroud and look for loose wires. 3. Check for 110 volts to the coil of the compressor relay (energized). If there is no voltage, check the wires from the main board to the compressor relay for continuity. If they have continuity, replace the main board. 4. If the compressor relay is energized (receiving 110 volts to the coil), check for voltage from #4 contact to ground with a volt meter. There should be 110 volts. If there is no voltage, replace the compressor relay. 5. Check for voltage to the compressor. If there is no voltage, inspect the wires between the compressor and the compressor relay for continuity. Repair or replace as necessary. 6. If voltage is present at the compressor, jumper the thermal overload. If the compressor runs, check the compressor amp draw. If it is drawing higher than 6 amps or not running, replace the compressor. If the compressor is cool and drawing low amperage, replace the thermal overload. 1. Verify that both tank valves are open. 2. Check the tank pressure. It should not exceed 300 psi. If it is high, bleed the pressure down to 200 psi using the air purge. 3. Check the red vapor tank hose for proper installation. Be sure there is no obstruction at the tank fitting. 4. Check the 1-amp fuse on the back of the main board for continuity and replace if necessary. If the replacement fuse blows again, inspect the compressor relay for shorted contacts and replace as necessary. 5. Inspect the wires between the high pressure cut out and the main board for continuity. Repair or replace as necessary. 6. Inspect the recovery check valve for obstructions and replace or repair as necessary. If the check valve is okay, go to Step Replace the high pressure cut out and retest the unit. 24

25 REVISED ORIGINAL 12/1/94 Troubleshooting DISPLAY READS FULL DISPLAY READS SCALE DISPLAY READS CPL DISPLAY READS CH-P 1. Check the tank weight. If the tank is full, replace the tank. 2. Recalibrate the scale if necessary. See the scale calibration instructions on page Adjustment of the P-1 pot (located on the main board; see page 13 for location) may be necessary. Note that not all main boards have a P-1 pot; it depends on the production date of the main board. 1. Check the scale calibration and recalibrate if necessary. See the scale calibration instructions on page Check the scale s cable to be sure it is connected to the main board. If the main board has more than one scale connection, verify that the internal/external jumper is in the proper location. 3. Replace the scale if previous attempts have failed. 1. Verify that there is positive pressure on the unit s manifold gauges. If there is no positive pressure, connect to a vapor supply source and attempt recovery again. 2. Look for loose or broken wires in the unit. 3. Connect a pressure gauge to the service port and check for positive pressure. If pressure is present, go to Step 4. If there is no positive pressure, verify that the inlet check valve is operating properly. Also verify that the recovery solenoid is opening and allowing flow. Repair or replace as necessary. 4. Check the vacuum sensor for continuity. Replace if there is no continuity. 1. If there is less than 5 psi at the inlet, attempt recovering from a positive pressure source. 2. Verify that the wires that control the vacuum pump protection switch have continuity. 3. If there is more than 5 psi at the inlet, replace the vacuum pump protection switch. 4. If the sensor is operating properly, press Continue to override. 25

26 ORIGINAL REVISED 12/1/94 Troubleshooting DISPLAY READS CH-F DISPLAY READS 0.00 VACUUM PROGRAM MINUTES UNIT WILL NOT EVACUATE PUMP RUNS 1. The filter change time has elapsed. To reset the timer, press Shift/Reset and Enter at the same time while CH-F is on the display. Note that on the newer style main boards the filter changeout routine must be performed to reset the timer. 2. If the CH-F warning doesn t disappear after attempting to reset the timer, replace the main board. 1. If the display does not respond to keypad commands, verify that the keypad is plugged in. 2. If the keypad is plugged in but still not responding, replace the keypad. 3. If the keypad is functional, a tone will be heard when a key is pressed. 4. Replace the main board if commands are not being accepted. 1. Verify that the manifold gauge valves are open. 2. Verify that the high and low side hoses are tight at all fittings. 3. Verify that the vacuum hose is snug at both ends and not obstructed. Inspect hose gaskets for leaks. 4. Verify that the IsoValve (if so equipped) is in the Open position. 5. Check for suction at the intake of the vacuum pump. If there is no suction, replace the vacuum pump. 6. Remove the unit s shroud and look for loose wires to the vacuum solenoids. 7. Check for 110 volts to the vacuum solenoids. If voltage is present, rebuild the solenoids or inspect for debris. 8. If there is no voltage to the vacuum solenoids, inspect the wires between the vacuum relay for continuity. If they are okay, replace the main board. 26

27 REVISED ORIGINAL 12/1/94 Troubleshooting UNIT WILL NOT EVACUATE PUMP IS OFF U-HI ON DISPLAY TIMER COUNTING DOWN 1. Check for pressure at the vacuum pump protection switch (recover before evacuating). 2. Unplug the switch. If U-HI goes out, check for pressure at the sensor. 3. If there is no pressure at the sensor, replace the sensor. 4. If U-HI remains on the display, replace the main board. 1. Verify that the vacuum pump is plugged in. 2. If the vacuum pump is equipped with an On/Off switch, verify that it is turned on. 3. Check the voltage at the vacuum pump receptacle. 4. If there is proper voltage, check that the vacuum pump is not overfilled with oil. If it is, drain the oil from the vacuum pump. Start and refill the vacuum pump properly. If it is not overfilled, replace the vacuum pump. 5. If there is not proper voltage, remove the cover and look for loose wires. 6. Check for voltage to the coil of the vacuum pump relay, If there is no voltage, inspect the wires between the vacuum pump relay and the main board for continuity. If the wires are okay, replace the main board. 7. If voltage is present at the vacuum pump relay coil, replace the relay. 8. Check for voltage from #4 to ground. If there is no voltage, replace the relay. 27

28 ORIGINAL REVISED 12/1/94 Troubleshooting UNIT WILL NOT RECYCLE RECYCLE PROMPT IS OFF COMPRESSOR IS OFF, NO FLOW 1. Check that all recovery tank hoses are installed properly. 2. Verify that the recovery tank valves are completely open. 3. Check that there is a minimum of 10 lbs. of refrigerant in the recovery tank. 4. Install the low side of a manifold gauge set to the service port. 5. If positive pressure is present at the service port, remove the unit s cover and look for loose wires to the vacuum sensor. If there are no loose wires, check for continuity on the vacuum sensor. If there is no continuity, replace the vacuum sensor. 6. Inspect the orange wires between the main board and the vacuum sensor for continuity. If the wires and the vacuum sensor have continuity, jumper the orange wires together. 7. Start recycling if the service port is being pulled into a vacuum. Look for loose wires to the recycling solenoid and verify that 110 volts is being sent to the recycling solenoid. If there is no voltage, inspect the controlling wires for continuity. Replace the main board if the wires have continuity. 8. If the recycling solenoid is receiving 110 volts, inspect the liquid line strainer bulb (some units have the strainer installed behind the hose gasket in the liquid hose) for obstructions. Replace or clean as necessary. 9. If the strainer is not plugged, attempt recalibrating the expansion valve. If you are unable to recalibrate the expansion valve, rebuild the recycling solenoid and replace the expansion valve. 10. If all previous attempts have failed, replace the main board. 28

29 REVISED ORIGINAL 12/1/94 Troubleshooting UNIT WILL NOT RECYCLE PROMPT IS ON, NO FLOW 1. Check that all recovery tank hoses are installed properly. 2. Verify that the recovery tank valves are completely open. 3. Check that there is a minimum of 10 lbs. of refrigerant in the recovery tank. 4. Check the oil drain valve for leaks (the valve should be closed). 5. Inspect the liquid line strainer for debris. Clean or replace as necessary. 6. Install the low side of a manifold gauge set to the service port. 7. Verify that the expansion valve calibration is at 35 psi. Always check the expansion valve pressure while recycling for ten minutes with at least 10 lbs. of refrigerant in the tank. 8. Inspect the filter for flow obstructions. Ensure that the gaskets are not crushed but sealing (replacement gasket #40084). 9. Check the equalization solenoid for internal bleed through and replace if necessary. 10. If the compressor is not running, verify that 110 volts is being supplied to the compressor. If it is not receiving 110 volts, check the wiring for continuity and the system relay for proper operation. 11. If the compressor is receiving 110 volts but not running, inspect the compressor start components and check the amp draw (see page 22). Replace the compressor as necessary. 12. If the compressor is running, check the compressor suction and discharge pressures as well as the oil level. Add oil if needed. If the oil level is adequate but there is no suction or discharge pressure, replace the compressor. 29

30 ORIGINAL REVISED 12/1/94 Troubleshooting UNIT WILL NOT RECYCLE PROMPT IS ON, WITH FLOW UNIT WILL NOT CHARGE NO PRESSURE ON GAUGES 1. Verify that the recovery tank valves are completely open. 2. Check that there is a minimum of 10 lbs. of refrigerant in the recovery tank. 3. Replace the filter and recycle for a minimum of 1½ hours. 4. Replace the moisture indicator if it is not turning green. 1. Verify that the liquid tank valve is open. 2. Verify that the manifold gauge valves are completely open and unobstructed. 3. Inspect the liquid hose for proper installation on the tank and look for crushed hose gaskets. 4. Verify that the liquid line screen is unobstructed. Replace or clean as necessary. 5. Verify that the main board has accepted the charge program. 6. Remove the unit s cover and look for loose wires. 7. If the main board does not accept the program, replace the main board. Ensure that the keypad is sending a program signal before replacing it. If the keypad is sending a signal, an audible tone will be heard when the keys are pressed. 8. Check the voltage at the charging solenoid. If there is no voltage, inspect the wires for continuity. If the wires are okay, replace the main board. If 110 volts is going to the solenoid, rebuild or replace the solenoid. 30

31 REVISED ORIGINAL 12/1/94 Troubleshooting UNIT WILL NOT CHARGE PRESSURE ON GAUGES 1. Verify that the Quick Seal hose ends are engaged as well as the Schrader cores on the system. Adapters on the high and low side hoses must be used to guarantee proper access to the system. 2. Verify that a minimum of 10 lbs. of refrigerant is in the recovery tank. 3. Check that the scale is able to move freely and that the tank strap does not hinder tank movement. 4. Verify that charging is being attempted through both the high and low side hoses. 5. Check for proper voltage to the charging solenoid and see if the voltage is being erratically dropped to the charging solenoid. If the voltage is fine, go to Step 6. If the voltage is not fine, replace the main board. 6. Close the high side valve. Start the vehicle and pull the remaining charge in on the low side of the system. When the remaining charge has been pulled from the tank, the charging solenoid will close preventing a possible overcharge. 31

32 ORIGINAL REVISED 12/1/94 RA19064 Replacement Main Board The main board is used in the Series R-12 or the Series R-134A units. The boards have had several revisions since their first introduction in May of These boards can easily be identified by the six-digit part number stenciled in white lettering on the back side of the main board. FIRST GENERATION BOARD (#111367) This board performed several basic functions: Recovery automatic shut down. Display should read amount recovered. Programmable vacuum time. Programmable charge amount. Manual diagnostics: #1 starts vacuum pump #2 engages add sequence #5 turns on the entire display #6 displays scale readings SECOND GENERATION BOARD (#111961) This board performed the same basic functions, but added these features: Auto scale calibration Vacuum pump oil change timer The new auto calibration feature allows the user to easily and accurately calibrate the scale (see auto scale calibration instructions on page 34). The ten-hour timer on the oil change procedure for the vacuum pump was also added. THIRD GENERATION BOARD (#113139) This board performed all the basic functions, including auto calibration and the vacuum pump oil timer, and also added these new functions: Low side clearing Timed oil return to the compressor The low side clearing feature allows the user to receive a more accurate reading of the amount of refrigerant recovered. To do this, the board does not apply power to the recovery solenoid when the recovery key is pressed. Instead, the solenoid remains closed until the inlet tubing is in a 17" vacuum. When a vacuum is reached, the vacuum sensor opens, the main board detects that and the recovery solenoid opens. After the recovery solenoid opens, the vacuum sensor closes and the scale shows the amount of refrigerant being recovered. Before the recovery solenoid opens, the screen will display CL-L. This board also has timed oil return every ten (10) minutes that lasts for three (3) seconds, whereas the older boards only allowed oil to return when the compressor shut off. 32