MAHLE RTI AC800 User Manual

OPERATION

&

MAINTENANCE

MANUAL

AC800

Refrigerant Management Center

RTI Technologies, Inc.

4075 E. Market St.

P.O. Box 3099

York, PA 17402

800-468-2321

Manual P/N 035-80207-02

TABLE OF CONTENTS

AC800

Start-Up ....................................... 2

Safety Precautions ............................... 3

Filling the Charging Cylinder ....................... 5

Recover/Recycle................................. 7

Oil Drain & Air Purge ............................ 9

Deep Vacuum................................... 10

Hose Evacuation................................. 11

Charge/High Side ................................ 12

Scheduled Maintenance & Filter Maintenance ......... 14

Problems & Solutions ............................ 15

Accessory Parts List .............................. 17

Flow Diagram................................... Appendix

Circuit Diagram ................................. Appendix

CONGRATULATIONS:

You have purchased one of the finest Recovery, Recycling, and Charging Machines available!
Fill out and return the Warranty Card within 90 days to activate warranty and free lifetime
technical support.

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RTI Technologies, Inc.

START-UP INSTRUCTIONS

1) Check for any shipping damage. Place a claim with carrier if damage is discovered.

2) Complete and return the Wa rranty Card to activate Technical Support and Warranty Coverage.

Warranty claims can not be honored without this warranty card on file.

BEFORE USING THE AC800

Check for any shipping damage. Place a claim with carrier if damage is discovered.

DO NOT USE A DAMAGED UNIT.

Complete and return the Warranty Card to activate technical support serv ice and warranty coverage.

Warranty claims can not be honored without this warranty card on file.

The AC800 should not be operated or serviced by any person who has not read all the contents of
this manual. Failure to read an d comply with these instructions or any one of the limitations noted
herein can result in serious injury and/or property damage.

These general instructions describe normal operation and maintena nce situations encountered with
the AC800. The instructions should not be interpreted to anticipate every possible contingency.

It is the responsibility of the owner/user to operate the AC800 in accordance with all specific ations
and laws which may apply.

The following pages contain rules for safe operation of the AC800. Taking precedence over any
specified rule listed herein, however, is the most important rule of all:

"USE COMMON SENSE"

A few minutes spent reading these instructions can make an operator aware of dangerous practices
to avoid and precautions to take for his own safety and the safety of others.

A regular schedule of inspection of the AC800 should be established and records maintained with
special attention given to Hoses, Compressor Oil Level, Moisture Indicator, and Filters.

October 6, 1999

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RTI Technologies, Inc.

SAFETY PRECAUTIONS

! Recover, Recycle, and Charge only the refrigerants for which the machine is configured.
! Wear safety glasses and protective gloves. Refrigerant has a very low boiling point and can

cause frostbite.

! Follow the AC800 operating procedures sequentially to a void pre maturely disconnecting hoses

or opening valves which may release refrigerant to the atmosphere.

! Do not expose the AC800 to moisture or operate in wet areas.
! Use the AC800 in locations with mechanical ventilation that provides at least four air changes

per hour.

! Hoses used with the AC800 must have shutoff devices within 12 inches of the connection point

to the system being serviced to minimize the introduction of Non-condensable Gas (Air) into
the AC800 and the release of refrigerant when being disconnected.

! Disconnect power before performing any maintenance or service on the AC800.
! Avoid using an extension cord with the AC800. If necessary , use a good condition, UL listed,

3-wire grounded, #14 AWG, or larger, extension cord of the shortest possible length.

! Connect the AC800 to a properly grounded receptacle. Do not over load the circuit.
! Do not allow the AC800 to remain unattended in the Charg e Mode with power On. The Charge

Cylinder Heater will be energized creating a high pressure condition.

NEVER TURN THE CYLINDER UP-SIDE-DOWN.

DO NOT CONNECT THE AC800 TO THE LIQUID SIDE OF ANY
A/C SYSTEM WITH A CAPACITY GREATER THAN 4 LBS.

REFRIGERANT IN A/C SYSTEMS HAVING LARGER CAPACITIES
MUST BE RECOVERED FROM THE VAPOR SIDE ONLY.

NEVER CONNECT THE AC800 TO THE LIQUID PORT OF A

CYLINDER OF REFRIGERANT TO FILL THE AC800 CHARGE CYLINDER.

FAILURE TO FOLLOW THE ABOVE MAY CAUSE THE AC800 COMPRESSOR TO
FAIL AND VOID THE WARRANTY.

October 6, 1999

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RTI Technologies, Inc.

i

i CAUTION T

ii

Avoid breathing refrigerant or lubricant vapor or mist.

Exposure may irritate eyes, nose and throat.

If accidental system discharge occurs, ventilate work area before resuming service.

Additional health and safety information may be obtained from refrigerant and
lubricant manufacturers.

Special Considerations with R134a

R134a has been shown to be nonflam m abl e at am bient temperature and atm ospheric
pressure. However, tests under controlled conditions have indicated that, at pressures
above atmospheric and with air concentrations greater than 60% by volume, R134a
can form combustible mixtures.

While it is recognized that an ignition source is also required for com bustion to occur,
the presence of combustible mixtures is a potentially dangerous situation and should
be avoided.

Under no ci rcum stances should any equipment be pressure tested or leak tested with
Air/R134a mixtures. Do not use compressed air (shop air) for leak detection in
R134a systems.

October 6, 1999

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RTI Technologies, Inc.

FILLING THE CHARGING CYLINDER

A/C Systems requiring service often do not have a full charge of refrig erant. To avoid unne ce ssa ry
repositioning of hoses it is recommended that the AC800 be filled until about 3 pounds of liquid
refrigerant can be seen in the Charging Cylinder Sight Glasses. The Sight Glasses are visible
through slotted openings on the front of the AC800.

Figure 1 Filling the Cylinder

To fill the AC800 Charge Cylinder, refer to Figure 1 and follow these steps:

Note: Instructions given for R12 side only. Operation of R134a side is identical.

1. Connect the short Yellow Hose provid ed to the Rear Port of the AC800 and to the VAPOR port

of a cylinder of the correct refrigerant.

DO NOT CONNECT TO THE LIQUID VALVE.

If the cylinder has two ports, observe that the embossed marking on the cylinder knob says
VAPOR or GAS. Do not rely on color coding of the knobs on the valves.

DO NOT TURN THE CYLINDER UP-SIDE-DOWN.

INTRODUCTION OF LIQUID INTO THE AC800 MAY DAMAGE THE
COMPRESSOR AND VOID THE WARRANTY.

October 6, 1999

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