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OPERATING MANUAL
Vortex
Refrigerant Recovery Machine
®
AC
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Vortex AC Operating Manual
Thank you for buying the INFICON® Vortex® AC Refrigerant Recovery Machine!
To get the best performance from your Vortex™ AC, 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 AC is a Recovery Machine for a broad range of refrigerants. Recovering refrigerants into
a separate storage tank involves a process of gas compression, resulting in high pressures within
the machine, the connecting hoses and the storage tank. High pressure systems must always be
treated with care and respect to prevent careless accidents.
Responsibility
The INFICON Vortex AC 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®, Compass™, D-TEK™ Select, TEK-Mate®, and Wey-TEK™ are trademarks of
INFICON.
All other brand and product names are trademarks or registered trademarks of their respective
companies.
The information contained in this manual 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.
©2004 All rights reserved.
Reproduction or adaptation of any part of this manual without permission is unlawful.
Declaration Of Conformity
Vortex AC Model # 714-202-P10 is CE Certified.
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 constructed in accordance with good engineering practice in safety matters
in force in the Community and does not endanger the safety of persons, domestic animals or property
when properly installed and maintained and used in applications for which it was made.
Equipment Description . . . . . . . .Vortex AC Refrigerant Recovery Unit
Applicable Directives. . . . . . . . . .73/23/EEC as amended by 93/68/EEC
Applicable Standards . . . . . . . . .EN 61010-1: 2001
CE Implementation . . . . . . . . . . .November 1, 2004
Authorized Representative . . . . .Duane Wright
89/336/EEC as amended by 93/68/EEC
EN 55011, Group 1, Class A: 1991
EN 50082-1: 1992
Manager - Quality Assurance
INFICON Inc.
Preface
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Vortex AC Operating Manual
Table Of Contents
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 Specifications, Features and Warranty. . . . . . . . . . . . . 4
2.1 Vortex AC Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.0 Setup and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Normal Recovery Operation . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 PURGING the Vortex AC . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Push-Pull Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Cooling The Recovery Tank . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Special Operating Notes . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.0 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.2 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Vortex AC 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 protection when working on refrigeration
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™ Select, Compass™ 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 equipment should be
used in clean, dry areas only. Be certain the power cord and the
equipment are not placed in residual water or other potentially
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 RUPTURE EXPLOSIVELY!
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Vortex AC Operating Manual
OPEN SERVICE OR CYLINDER VALVES SLOWLY to ensure that all
connections are tight and there is no danger.
DISCONNECT POWER before moving or servicing the INFICON
Vortex AC.
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 locations with mechanical 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.
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Vortex AC Operating Manual
2.0 Specifications, Features and Warranty
2.1 Vortex AC 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: . . . . . . . . . . 1/2 HP Oilless, No inlet valve, AC Motor Drive
Cooling: . . . . . . . . . . . . . . Fan driven off AC 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 . . . . . . . . . . . . . . . 12.6 kg
2.2 Warranty
INFICON warrants your Vortex AC Refrigerant Recovery Machine to be free
from defects of materials or workmanship for three years 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 three years 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.
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Vortex AC Operating Manual
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 AC in actual service.
Install an approved filter on the inlet. Attach the hoses per the diagram below.
The Vortex AC has a female refrigerant flare fitting so that it may accept a filter
with male flare fittings, the hoses then attach to the filter. DO NOT USE AN
ADAPTER FITTING IN PLACE OF A FILTER AS THIS MAY CAUSE
DAMAGE TO THE VALVES AND VOID THE WARRANTY.
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.
When recovering refrigerant, it may be necessary to throttle the Manifold
Gauge control valve(s) or the Vortex AC’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 AC 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!
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Vortex AC Operating Manual
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
2 Make sure that the hose from the Vortex AC 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 AC.
8 MONITOR the inlet pressure (LP, Low Pressure Gauge) and SLOWLY
OPEN the Vortex AC’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.
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Vortex AC Operating Manual
10 Continue to operate until the required VACUUM has been pulled on the
system, as indicated by the LP gauge. Switch OFF the Vortex AC,
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 AC, and run until the required VACUUM is reached again.
Repeat this process until all the refrigerant is removed resulting in a
final reading, after the 5 minute period, of 0 bar or less.
11 IMMEDIATELY PURGE the Vortex AC per the procedure as described
in section 3.3 of this Manual.
3.3 PURGING the Vortex AC
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) slowly 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.
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
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Vortex AC Operating Manual
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 AC 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.
Figure 3-3 Setup Procedure for Push-Pull Method
3.5 Cooling The Recovery Tank
The Vortex AC 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.
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If the recovery process stalls out because of high head pressure, stop the
Vortex AC, 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.
Figure 3-4 Setup Procedure for Sub-Cooling Method
VAPOR
Optional Connection To System
POWER ON the Vortex AC and ROTATE the DISCHARGE Valve (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
AC and reconfigure the setup for NORMAL RECOVERY. Repeat as needed.
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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
Your Vortex AC 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 isopropyl
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 AC’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
1. Power Cord not
attached
2. No voltage at
receptacle
3. Circuit breaker has
opened
4. Discharge pressure
too high, HP Switch has
opened
5. Electronics failure in
Motor
1. Attach Power Cord
2. Verify voltage at Job
Site
3. Identify cause of
breaker activation, rectify
and reset
4. Reduce pressure and
rotate V2 to Purge and
back to Recovery
5. Factory service
required
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Vortex AC 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
1. V2 is in Purge
position and HP switch
activates
2. V3 not open and HP
switch activates
3. Recovery tank valve
not open
4. Blocked discharge
hose
5. Air in system/tank
1. Vapor pressure of
refrigerant in tank is
close to HP trip point
2. Thermal overload
switch in compressor is
activating
pressure due to:
1. High ambient
temperature
2. Restricted discharge
hose
3. Air in recovery tank
1. Head pressure too
high
2. System refrigerant
iced up
3. Compressor seals
are worn
1. Rotate V2 to Recovery
2. Rotate V3 to open
position
3. Open tank valve
4. Check & clear
blockage
5. Bleed air from
system/tank
1. Reduce tank
temperature
2. Reduce amount of
liquid being pumped and
let machine cool down
before proceeding
1. Reduce tank
temperature
2. Check & clear
restriction
3. Bleed air from tank
1. Reduce tank
temperature or change
tanks
1. Throttle gauge
manifold valves and V3
to reduce pressure
differential between LP
and HP gauges
2. Interrupt process to
allow ice to dissipate
3. Rebuild compressor
with service kit — check
with wholesaler for
assistance
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Vortex AC 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 applicable.
Technical assistance and service 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 AC are available through
the same dealer from whom you purchased the unit:
Item Part #
Compressor, 230 V(ac) 714-407-P2
Motor Start Relay 060-0056
Run Capacitor, 35 μF, 370 V 043-0108
Start Capacitor, 72-87 μF, 330 V 043-0107
Circuit breaker, 125/250 V, 4 A 062-0082
Cord set, IEC plug, 230 V 068-0399
On/Off Switch 065-0261
Socket power in, IEC male 051-1359
Manifold Assembly with extensions and fittings 708-403-P1
Gauge, High Pressure for Vortex AC Model 714-202-P2 708-402-P1
Gauge, Low Pressure for Vortex AC Model 714-202-P2 708-401-P1
Gauge, High Pressure for Vortex AC Model 714-202-P10 M1002V18B -
Gauge, Low Pressure for Vortex AC Model 714-202-P10 M1002V18B -
Pressure Switch, high pressure cutout 032-0055
Condenser Assembly with tubes 708-204-G1
Case Housing - right side 714-306-P1
Case Housing - left side 714-307-P1
Strap, shoulder 708-404-P1
Cap and strap, plastic with lead 070-1107
Handle, SS tube 708-311-P1
8252PA
8253PA
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Vortex AC Operating Manual
6.2 Electrical Schematic
Figure 3-1 Electrical Schematic Diagram for 714-202-G2 & G10
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TWO TECHNOLOGY PLACE
EAST SYRACUSE, NY 13057-9714 USA
Phone: +1.800.344.3304
Fax: +1.315.437-3803
Email: reachus@inficon.com
www.inficon.com
074-403-P1B
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