OPERATING MANUAL
VORTEX
Refrigerant Recovery Machine
™
Vortex Operating Manual
Thank you for buying the INFICON® Vortex™ Refr igerant Recovery Machin e !
To get the best performance from your Vortex, please read this manual carefully before you start
using the recovery machine.
Safety First!
When found on the machine, this international symbol is intended to alert the user to
the presence of important operating, safety and maintenance (servicing) instructions in this
Manual. As used in the Manual, it is intended to draw your attention to critical items.
It is important to read this entire Manual and be familiar with its contents before using the machine!
The Vortex is a Recovery Machine for a broad range of refrigerants. Recovering refrigerants into a
separate storage tank involves a process of gas compre ssion, resulting in high pressures within th e
machine, the connecting hoses and the storage tank. High pressu re systems must always be treated
with care and respect to prevent careless accidents.
Responsibility
INFICON Vortex must only be operated by a Qualified Technician who has been properly
trained in the care and use of such equipment and in the recovery process itself. Use of this
equipment by unqualified personnel is potentially dangerous and should not be attempted.
Trademarks
The trademarks of the products mentioned in this manual are held by the companies that produce
them.
INFICON®, Vortex™, D-TEK™, TE K-Mate®, and Wey-TEK™ are trademarks of INFICON Inc.
All other brand and product names are trademarks or registered trademarks of their respective
companies.
The information contained in this manu al is believed to be accurate and reliable. However, INFICON
assumes no responsibility for its use and shall not be liable for any special, incidental, or
consequential damages related to the use of this product.
©2003 All rights reserved.
Reproduction or adaptation of any part of this manual without permission is unlawful.
Declaration Of Conformity
Vortex Model # 708-202-P10 is CE Certifie d.
This is to certify that this equipment, designed and manufactured by:
INFICON Inc.
Two Technology Place
East Syracuse, NY 13057 USA
Meets the essential safety requirements of the European Union and is placed on the market
accordingly. It has been construct ed in accordance with good engineering practice in safety matters
in force in the Community and does not endanger the safety of person s, domestic animals or property
when properly installed and maintained and used in applications for which it was made.
Equipment Description . . . . . . . .Vortex Refrigerant Recovery Unit
Applicable Directives. . . . . . . . . .73/23/EEC as amended by 93/68/EEC
Applicable Standards . . . . . . . . .EN 61010-1 : 2001
CE Implementation . . . . . . . . . . .June 2, 2003
Authorized Representative . . . . .Gary W. Lewis
89/336/EEC as amended by 93/68/EEC
EN 55011, Group 1, Class A : 1991
EN 50082-1 : 1992
Vice President - Quality Assurance
INFICON Inc.
Preface
Vortex Operating Manual
Table Of Contents
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Specifications, Features and Warranty. . . . . . . . . . . . . 3
2.1 Vortex Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.0 Setup and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Normal Recovery Operation . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 PURGING the Vortex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Push-Pull Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Cooling The Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Special Operating Notes. . . . . . . . . . . . . . . . . . . . . . . . . 10
4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.0 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Vortex Operating Manual
1.0 Safety Precautions
THIS EQUIPMENT MUST ALWAYS BE OPERATED BY A
QUALIFIED TECHNICIAN WHO IS FAMILIAR WITH REFRIGERANT
SYSTEMS, REFRIGERANTS, REFRIGERANT SAFETY AND LAWS
PERTAINING TO REFRIGERANT USEAGE.
READ THIS MANUAL and become familiar with the specifications
and operation of this machine prior to use.
WEAR APPROPRIATE SAFETY PROTECTION APPAREL such as
gloves, eye protection and foot prot ection when working on refrigerati on
systems.
REFRIGERANT VAPOR CAN BE HAZARDOUS AND ITS BY
PRODUCTS CAN BE LETHAL — work only in well ventilated areas. When
working indoors, ensure there is adequate airflow in the work space and
install a separate circulation fan if necessary. DO NOT WORK IN AN
ENCLOSED AREA without special safety equipment as appropriate for
the conditions.
KNOW THE PROPER SAFETY AND HANDLING REQUIREMENTS
for the Refrigerant being recovered by reviewing the Material Safety Data
Sheets (MSDS) and the Temperature - Vapor Pressure information.
PERFORM LEAK DETECTION in accordance with recommended
practice only. For best results use only a refrigerant detector such as the
INFICON D-TEK™ or TEK-Mate®. NEVER USE OXYGEN for this process
as it can become an explosive mixture in the presence of oil and
pressure.
USE CAUTION WHEN OPERATING. This erquipment should be
used in clean, dry areas only. Be certain the power cord and the
equipment are not placed in residual water or other potenti ally
dangerous locations.
NEVER OVERFILL A STORAGE CONTAINER. The use of a
refrigerant scale, such as the INFICON Wey-TEK™, is required to prevent
overfill. OVERFILLED TANKS CAN RUP TURE EXPLOSIVELY!
OPEN SERVICE OR CYLINDER V AL VES SLOWL Y to ensure that all
connections are tight and there is no danger.
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Vortex Operating Manual
DISCONNECT POWER before moving or servicing the INFICON
Vortex.
This unit should be opened only by a technically qualified person
who has been trained in basic electronics and refrigeration. The risk of
ELECTRIC SHOCK and exposure to HOT compressor parts is possible if
the unit is opened.
TO REDUCE THE RISK OF FIRE, EXTENSION CORDS SHOULD
NOT BE USED with this equipment as the wiring can overheat under
conditions of high current draw. If an extension cord is absolutely
necessary, its length should be as short as possible and it should
contain size 16 AWG or larger wiring.
FLAMMABLE ENVIRONMENTS ARE DANGEROUS when any
machine is used because motors and switches can generate sparks.
This equipment should be used in locati ons with mechanic al ventilation
providing at least four air changes per hour, or the equipment should be
located at least 18” above the floor. DO NOT USE THIS EQUIPMENT IN
THE VICINITY OF SPILLED OR OPEN CONTAINERS OF GASOLINE OR
ANY OTHER FLAMMABLE LIQUID.
2.0 Specifications, Features and Warranty
2.1 Vortex Specifications
Refrigerants . . . . . . . . . . R-12, R-134A, R-401C, R-500, R-401A, R-409A,
R-401B, R-22, R-502, R-407C, R-402B, R-408A,
R-407A, R-404A, R-402A, R-507, R-407B, R410A
Power . . . . . . . . . . . . . . . 230 V(ac), 50/60 Hz, 4A
Compressor:. . . . . . . . . . 1/3 HP Oilless, No inlet valve, DC Motor Drive
Cooling: . . . . . . . . . . . . . Fan driven off DC compressor motor
Protection: . . . . . . . . . . . High Pressure Switch Cutoff at 3789 kPa
Compressor motor thermally protected
Pressure . . . . . . . . . . . . . Low side design pressure 3500 kPa
High side design pressure 5500 kPa
Temperature. . . . . . . . . . Operating Range 10 to 40 °C
Case . . . . . . . . . . . . . . . . Blow-Molded, High Impact Strength
Size . . . . . . . . . . . . . . . . . 457.2 mm x 241.3 mm x 368.3 mm
Weight. . . . . . . . . . . . . . . 11.79 kg
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Vortex Operating Manual
2.2 Warranty
INFICON warrants your Vortex Refrigerant Recovery Machine to be free from
defects of materials or workmanship for one year from the date of purchase.
INFICON does not warrant any machine that has been subjected to misuse,
negligence, or accident, or has been repaired or altered by anyone other than
INFICON.
The Compressor is warranted for a period of one year by the manufacturer. To
keep this WARRANTY in force it is required that a standard filter or filter drier
be used on the Inlet Port or Hose at all times to prevent particulates from
entering the compressor. FAILURE TO USE A FILTER WILL VOID THE
COMPRESSOR WARRANTY.
INFICON’s liability is limited to machines returned to INFICON, transportation
prepaid, not later than thirty (30) days after the warranty period expires, and
which INFICON judges to have malfunctioned because of defective materials
or workmanship. INFICON’s liability is limited to, at its option, repairing or
replacing the defective machine or part.
This WARRANTY is in lieu of all other warranties, express or implied, whether
of MERCHANTABILITY or of FITNESS FOR A PARTICULAR PURPOSE or
otherwise. All such other warranties are expressly disclaimed.
INFICON shall have no liability in excess of the price paid to INFICON for the
machine plus return transportation charges prepaid. INFICON shall have no
liability for any incidental or consequential damages. All such liabilities are
EXCLUDED.
3.0 Setup and Operation
3.1 Getting Started
Only personnel who have been properly trained in the use and
operation of Refrigeration Systems, Refrigerants and Service Equipment
should operate this equipment. Failure to follow proper safety
precautions could result in personal injury or death.
Review the full contents of this Manual before attempting to use
the Vortex in actual service.
Identify the refrigerant to be recovered and prepare the Vortex for use by
installing an approved filter, hoses and optional shutoff cable per the diagram
below.
Connect the AC Power cord to a circuit that is protected by a 15 amp breaker.
Use an extension cord only when absolutely necessary to perform the service
— be sure it is the minimum length required, that it contains a safety ground
wire and that it contains wires sized 16 AWG or larger.
4
Vortex Operating Manual
Check all connections to ensure they are tight before starting the Recovery
Operation.
When recovering refrigerant, it may be necessary to throttle the Manifold
Gauge control valve(s) or the Vortex’s INLET Valve when a significant amount
of liquid is present. This is required if a loud “knocking” sound is heard from
the compressor. While the Compressor in the Vortex is tolerant of liquid, no
compressor will run on 100% liquid without damage for more than a few
minutes. In addition, a liquid “slug” can cause the High Pressure shutoff to
activate, thus adding time to the process. It is thus important to open the valves
slowly and monitor the process carefully. Should the compressor start to
“Knock”, rotate the INLET valve clockwise until the “knocking” stops. This can
also be accomplished by adjusting the Manifold Gauge valves. Exercise care
to ensure that the compressor is not damaged in this way as it will void the
warranty.
It is necessary to use a Refrigerant Scale to ensure that the tank is
not filled to more than 80% of its capacity by weight. When operating in
the NORMAL RECOVERY or PUSH-PULL mode, it is possible to overfill
the tank. Check the tank weight before transporting if you are not sure.
OVERFILLED TANKS CAN RUPTURE EXPLOSIVELY!
3.2 Normal Recovery Operation 1
Connect all cables and hoses as described in section 3.1 and as shown
in Figure 3-1 below. Ensure that they are tight and routed in such a way
that they will not interfere with the operation.
Figure 3-1 Setup Procedure For Normal Refrigerant Recovery
5
Vortex Operating Manual
2 Make sure that the hose from the Vortex to the Recovery Tank is
attached to the LIQUID PORT. Open the tank’s LIQUID PORT valve,
keeping the VAPOR port closed.
3 CLOSE the INLET valve (V1).
4 OPEN the DISCHARGE valve (V3) to its fully open position.
5 SET the PURGE/RECOVERY valve (V2) to the RECOVERY position.
6 Open the Manifold Gauge LIQUID valve slowly and verify that no leaks
are present. Extracting as much liquid as possible will speed up the
recovery process.
7 Switch ON the Vortex.
8 MONITOR the inlet pressure (LP, Low Pressure Gauge) and SLOWL Y
OPEN the Vortex’s INLET valve (V1). THROTTLE the INLET valve or
the Manifold Gauge’s Liquid and Vapor valves if too much liquid is
entering the machine.
9 When the liquid has been transferred, OPEN the INLET valve (V1) fully
to transfer the remaining VAPOR. Ensure that the Manifold Gauge
valves (liquid and vapor) are also fully opened.
10 Continue to operate until the required VACUUM has been pulled on the
system, as indicated by the LP gauge. Switch OFF the Vortex, CLOSE
the INLET (V1), and wait for 5 minutes. If the Pressure in the system,
as noted on the Manifold Gauge, rises above 0 bar, refrigerant is still
present. If this is the case, REOPEN the INLET (V1), RESTART the
Vortex, and run until the required VA CUUM is reached again . Repeat
this process until all the refrigerant is removed resulting in a fin al
reading, after the 5 minute period, of 0 bar or less.
11 IMMEDIATELY PURGE the Vortex per the procedure as described in
section 3.3 of this Manual.
3.3 PURGING the Vortex
Rotate the PURGE/RECOVER valve (V2) to the PURGE position. Rotate
1
valve V3 to OPEN. See Figure 3-2.
2 Switch the POWER ON and rotate the INLET valve (V1) slowl y to the
PURGE. Prevent flooding the compressor with liquid, do not rotate the
V1 valve quickly.
3 Observe the LP Gauge and continue to run the unit until a VACUUM of
at least -0.6 bar is achieved. Switch the POWER OFF and immediately
CLOSE the Recovery Tank’s valve. The INLET valve (V1) should be
returned to the CLOSE position. Finally close V3.
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Vortex Operating Manual
4 IMPORTANT — RETURN V2 TO RECOVERY POSITION
THE HOSE AND THE DISCHARGE PORT WILL CONTAIN A SMALL
AMOUNT OF REFRIGERANT UNDER PRESSURE. EXERCISE CARE
WHEN REMOVING THIS HOSE AND OPENING THE VALVE V3.
Figure 3-2 Setup Procedure for Purging
3.4 Push-Pull Operation
The PUSH PULL method is used to move a large amount of liquid refrigerant
from the system being serviced to the recovery tank without passing it through
the compressor. This method is only useful when more than 7 kg of liquid is
known to be in the system and it can be easily isolated. DO NOT ATTEMPT
the PUSH PULL process unless you are sure of the situation.
Connect the refrigerant hoses as shown in Figure 3-3. The addition of a
SIGHT GLASS in the line from the system being serviced to the recovery tank
is an important aid to determine when the liquid has been transferred and
vapor remains.
This process uses the PULL from the exhausted recovery tank and the
Discharge PUSH from the Vortex to move the liquid refrigerant. Rates in
excess of 7 kg per minute can be achieved by this procedure.
The SCALE is required in this process to ensure that the tank is not overfilled.
The tank shutoff switch, if used, would stop the compressor but could not
guarantee that additional refrigerant flow would cease because of the
dynamics of the system, thus possibly overfilling the tank.
7
Vortex Operating Manual
Figure 3-3 Setup Procedure for Push-Pull Method
3.5 Cooling The Recovery Tank
The Vortex can be used to PRE-cool (or SUB-cool) the recovery tank if the
head pressure is too high to complete the recovery process. This can occur
when working with certain refrigerants with a high vapor pressure when the
ambient temperature is high.
If the recovery process stalls out because of high head pressure, stop the
Vortex, shut off the hose valves and reconfigure the setup as shown in Figure
3-4. This can also be done before starting the recovery process, but it may
have marginal long term effect.
NOTE: This will only work if there is at least 2 kg of liquid in the recovery
tank to develop the necessary pressure differential required.
8
Vortex Operating Manual
Figure 3-4 Setup Procedure for Sub-Cooling Method
VAPOR
Optional Connection To System
POWER ON the Vortex and ROTATE the DISCHARGE V alve (V3) to achieve
a pressure differential of at least 6.8 bar between the LP Gauge and the HP
Gauge. KEEP THE HP BELOW 37.4 bar on the HP Gauge to ensure that the
HP Cutoff Switch will not actuate.
After several minutes of running, the tank will be cold. POWER OFF the Vortex
and reconfigure the setup for NORMAL RECOVERY. Repeat as needed.
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Vortex Operating Manual
3.6 Special Operating Notes
During normal operation, when the High Pressure switch activates the
machine will restart automatically when the head pressure drops below
approximately 28.9 bar.
4.0 Maintenance
4.1 Introduction
Your Vortex will provide many seasons of reliable service providing it is
properly maintained. The actual maintenance requirements are minimal but
important.
Keep the unit clean by wiping it down with a damp cloth to remove dirt, oils,
etc., prior to storage for the day. Standard household detergent or isop ropyl
alcohol may be used if the unit is particularly dirty — in all cases, exercise care
to prevent liquids from entering the unit. Gasoline and other solvents are to be
avoided as they can damage the Vortex’s plastic enclosure and they are
hazardous.
Ensure that the Inlet and Discharge ports are protected in transit and storage
— keep the inner diameter and the outer threads clear and clean. For best
results, keep a FILTER permanently connected to the INLET port and change
it regularly.
When performance falls off it is likely that the compressor seals require
replacing. This is normal with use and may occur after a year or two, or more
often depending upon the conditions that are prevalent during the recovery
operations. Contact your Wholesaler for assistance in selecting the proper
maintenance kit.
5.0 Troubleshooting
PROBLEM CAUSE ACTION
Unit will not start —
Compressor does not
start
10
• Power Cord not
attached
• No voltage at
receptacle
• Circuit breaker has
opened
• Discharge pressure
too high, HP Switch has
opened
• Electronics failure in
Motor
• Attach Power Cord
• Verify voltage at Job
Site
• Identify cause of
breaker activation, rectify
and reset
• Reduce pressure and
rotate V2 to Purge and
back to Recovery
• Factory service
required
Vortex Operating Manual
PROBLEM CAUSE ACTION
Compressor starts but
cuts out within a few
minutes — pressure
indication on HP gauge
is high
Compressor stops
intermittently
Unit overheats Excessive head
Recovery process too
slow
• V2 is in Purge position
and HP switch activates
• V3 not open and HP
switch activates
• Recovery tank valve
not open
• Blocked discharge
hose
• Air in system/tank
• Vapor pressure of
refrigerant in tank is
close to HP trip point
• Thermal overload
switch in compressor is
activating
pressure due to:
• High ambient
temperature
• Restricted discharge
hose
• Air in recovery tank
• Head pressure too
high
• System refrigerant
iced up
• Compressor seals are
worn
• Rotate V2 to Recovery
• Rotate V3 to open
position
• Open tank valve
• Check & clear blockage
• Bleed air from
system/tank
• Reduce tank
temperature
• Reduce amount of
liquid being pumped and
let machine cool down
before proceeding
• Reduce tank
temperature
• Check & clear
restriction
• Bleed air from tank
• Reduce tank
temperature or change
tanks
• Throttle gauge manifold
valves and V3 to reduce
pressure differential
between LP and HP
gauges
• Interrupt process to
allow ice to dissipate
• Rebuild compressor
with service kit — check
with wholesaler for
assistance
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Vortex Operating Manual
6.0 Service
6.1 General
DO NOT CHANGE any of these components as the safety of the
machine could be compromised. All service work must be performed at
an INFICON approved facility in order to maintain the safety rating and
the Warranty, if applicab le.
Technical assistance and servi ce information can be obtained through your
local sales organization.
NOTE: Do not return a defective unit directly to the factory. Contact your
Wholesaler or the factory for assistance.
The following Parts and Accessories for your Vortex are available through the
same dealer from whom you purchased the unit:
Item Part #
Thomas 500 Compressor, 230 V(dc) 708-408-P1
Bridge Rectifier, 25 A, 600 V 052-0206
Capacitor Assembly, 470 µf, 400 V 600-1205-P2
Circuit breaker, 125/250 V, 4 A 062-0082
Cord set, IEC plug, 230 V 068-0399
On/Off Switch 065-0261
Manifold Assembly with extensions and fittings 708-403-P1
Gauge, High Pressure for Vortex Model 708-202-P2 708-402-P1
Gauge, Low Pressure for Vortex Model 708-202-P2 708-401-P1
Gauge, High Pressure for Vortex Model 708-202-P10 M1002V18B -
8252PA
Gauge, Low Pressure for Vortex Model 708-202-P10 M1002V18B -
8253PA
Pressure Switch, high pressure cutout 032-0055
Condenser Assembly with tubes 708-204-G1
Case Housing - right side 708-306-P1
Case Housing - left side 708-307-P1
Strap, shoulder 708-404-P1
Cap and strap, plastic with lead 070-1107
Handle, SS tube 708-311-P1
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Vortex Operating Manual
6.2 Electrical Schematic
BLUEBLACK
SW2
HI Pressure SW
Over Pressure
Switch
BLACK
CB1
12
BLACK
S1
12
Power Switch Circuit Breaker
AC Power Receptacle
TI Klixon
25PS06-0018
Sang Mao
4A Breaker
A-0710W-4A
Carling Sw
RSCA701VBB9V
123
J1
230 VAC Input
708-202-G2
Qualtek
Power Input
701W-X2/04
AC GND
230 VAC Return
BLUE
RED
RED
D1
+
M1
DC MOTOR
BRIDGE
SW1
M1 Thermal SW
A
C1
470uF 400VDC
+
-+
WHITE
-
WHITE/BLACK
WHITE/BLACK
Motor
DC Compressor
BLUE
DC Filter
Capacitor
Full Wave
Bridge
Rectifier
Safety Interlock Relay
CB1
S1
Power Switch Circuit Breaker
SW2
BLUE
HI Pressure SW
A
B
4
7
1
BLACKBLACK
6
9
3
K1
RELAY DPDT
BLACK
Sang Mao
12
4A Breaker
A-0710W-4A
BLACK
Carling Sw
12
RSCA701VBB9V
123
J1
Line Filter
AC GND
AC Power Receptacle
& Filter
230 VAC Input
230 VAC Return
BLUEBLACK
RED
TI Klixon
25PS06-0018
Magnecraft S-D
W389ACX-10/298XBXC1-240A
708-202-G10
RED
Full Wave DC Filter
Bridge Capacitor
Rectifier
6EEA2
Corcom
D1
+
M1
DC MOTOR
FB2
RED
FB1
BRIDGE
12
12
C1
+
SW1
A
34
34
470uF 400VDC
WHITE
M1 Thermal SW
-
WHITE/BLACK
Fair-Rite
2843006802
2 hole Ferrite
WHITE/BLACK
Fair-Rite
2 hole Ferrite
2843006802
-+
BLUE
WHITE/BLACK
C2
Motor
DC Compressor
Illinois Cap
224PHC850K
0.22 uF 450 VAC
Figure 6-1 Electrical Schematic Diagram for 7 08-202-G2 & G10
13
TWO TECHNOLOGY PLACE
EAST SYRACUSE, NY 13057-9714 USA
Phone: +315.434.1100
Fax: +315.437-3803
Email: reachus@inficon.com
www.inficon.com
074-386-P1B
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