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.

Page 1

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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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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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RTI Technologies, Inc.

2. Shut Red and Blue Hose Valves.

3. Press top (ON) of rocker switch marked TEST RUN.

4. Press top (ON) of rocker switch marked RECOVER RECYCLE.

The green COMPRESSOR ON Light will illuminate and liquid refrigerant will rise in the
Charging Cy linde r Sig ht Gla ss. When the leve l is appr oximately 3 lbs, close the valve on the
refrigerant cylinder. Allow the AC800 to continue to run until the Low Side Gauge shows a
vacuum, and the green light goes out. This will empty the Blue Hose.

HINT: Heating of the cylinder of refrigerant with an RTI Heat Belt (P/N 026-80092-00) wi ll

speed the recovery process.

5. Press bottom (OFF) of rocker switch marked RECOVER RECYCLE.

6. Press bottom (OFF) of rocker switch marked TEST RUN.

... NOTE ...

The sight glass does not ind icate the amount of refrigerant recovered;

Only the amount of refrigerant available to put into the vehicle A/C System
while in the CHARGE mode of operation.

Refrigerant is processed through a Condenser by the AC800. The actual
volume of refrigerant contained in the Condenser varies from job to job due
to pressure and temperature variations.

If a known amount of refrigerant has been introduced into the AC800 it may
not all be seen in the Charging Cylinder Sight Glass. This is normal and
nothing to be concerned about. Refrigerant has not been lost.

As Purge Pressure goes up, the rate of transfer of refrigerant from the
Condenser to the Charge Cylinder goes down. As Gaug e Manifold pres s ure
goes down, the rate of transfer of refrigerant from the Condenser to the
Charge Cylinder goes down.

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Page 6

RECOVER/RECYCLE

Figure 2 Recover/Recycle

RTI Technologies, Inc.

To Recover/Recycle, refer to Figure 2 and follow these steps:

1. Attach Red and Blue Hoses to the A/C system per the vehicle manufacturer's instructions.

Note For R134a Machines

Field Service Couplings on the ends of Service Hoses are of a special design.

The valves have LEFT HAND threads which makes operation opposite to that of others.

To Close... Turn Counter-clockwise

To Open... Turn Clockwise

The valves MUST BE CLOSED before connecting or disconnecting Field Service Couplings.

2. Open Red and Blue Hose Valves.

3. Press top (ON) of rocker switch marked TEST RUN.

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RTI Technologies, Inc.

4. Press top (ON) of rocker switch marked RECOVER RECYCLE.

The AC800 will recover and recycle refrigerant from the A/C System, and then automatically
cycle off when a vacuum is sensed. This vacuum level can be seen on the Low Side Gauge.

!!!! DO NOT TURN THE AC800 OFF OR DISCONNECT HOSES !!!!

A small quantity of Liquid refrigerant will probably still remain in the A/C System. This can
be detected by observing an increasing pressure reading on the Low Side Gauge.

As pressure rises to a preset level, the AC800 will automa tically cy cle on to continue recovering
refrigerant. Allow this automatic On/Off sequence to repeat until the vacuum level remains
constant for at least 2 minutes.

Note: Press and hold th e top of the rocker sw itch marked RECOVE R OVERRIDE to

remove any residual pressure that the AC800 may not remove when used on cooler
days.

6. Close Red and Blue Hose Valves.

8. Press bottom (OFF) of rocker switch marked RECOVER RECYCLE.

8. Press bottom (OFF) of rocker switch marked TEST RUN.

INTERNAL CYLINDER FULL LIGHT:

This Light will illuminate if the Internal Charging Cylinders Fill to capacity, approximately 9 lbs.
When this occurs, the Internal Cylinder must be drained using the charging procedure outlined on
Page 12. An optional 3 0 l b DOT Refillable Cy linder equipped with an Over F ill Protection device
can be used to store the refrigerant to be charged if the recovery process is not complete. Contact
your distributor, or call Technical Support at 800-468-2321 for details.

October 6, 1999

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OIL DRAIN & AIR PURGE

Oil and Non-condensable Gas (Air) are separated fro m
the recovered refrigerant and MUST be removed
following EACH recycling procedure as follows:

Note: AC800 must be connected to power source.

1. Press and hold the Purge Button (below the Purge
Gauge) for 5 seconds, and then release it.

2. SLOWLY open the Oil Drain Valve (behind push
up door in front of AC800) to drain any oil which
may have been removed from the A/C System. A
cup is provided to collect the oil.

Unless the A/C System had previously been
overfilled, the AC800 will typically not remove
more than a tablespoon of oil, making replenishment
unnecessary.

LEAVE THE OIL DRAIN VALVE OPEN...

3. Read temperature on Thermometer in center of
AC800 control panel.

4. Locate the pressure (PSIG) corresponding to this
room temperature ( 0 F) in the chart on the top of the
AC800. This chart is reproduced at the right.

If the pressure indicated on the Purge Gauge is
greater than that determined from the chart:

Press and hold the Purge Button until the Purge
Gauge pressure goes down to the pressure
determined from the chart. Any Non-condensable
Gas will be vented through the Oil Drain Valve at
this time.

5. Close the Oil Drain Valve.

6. Press and hold the Purge Button for 5 seconds. This
permits any residual Non-condensable Gas to be
recirculated for reprocessing during the next recycle
procedure.

0F R12 R134a

30 42 40
32 44 42
34 46 44
36 48 46
38 50 49
40 52 51
42 54 54
44 57 56
46 59 59
48 61 61
50 64 64
52 66 67
54 69 70
56 72 72
58 74 76
60 77 78
62 80 82
64 83 85
66 85 88
68 88 92
70 92 95
72 95 97
74 98 104
76 102 107
78 105 110
80 108 114
82 112 118
84 115 123
86 118 127
88 123 130
90 127 135
92 130 140
94 135 145
96 138 148
98 143 153
100 147 157
102 150 163
104 155 167
106 160 173
108 165 180
110 168 185
112 173 190
114 178 195
116 183 200
118 188 207
120 193 213

October 6, 1999

Purge Chart

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DEEP VACUUM

If the A/C System is "opene d" for replacing components, a deep vacuum must be drawn on the
system before recharging with refrigerant. This vacuuming process removes air and moisture
introduced into the system. A Vacuum Pump in the AC800 provides this capability.

Figure 3 Deep Vacuum

To Deep Vacuum the A/C System, refer to Figure 3 and follow these steps:

1. Connect Red and Blue Hoses to the high and low sides of the A/C System.

2. Open Red and Blue Hose Valves.

3. Press top (ON) of rocker switch marked TEST RUN.

4. Press top (ON) of rocker switch marked DEEP VACUUM.

5. The Vacuum Pump will start and the AC800 will draw a vacuum.

NOTE... If pressure is sensed at the Red and Blue Hoses on the AC800, the Vacuum P u mp w i l l

not start. If this occurs, perform the recover/recycle operation described earlier.

ALSO... It may be necessary to momentarily loosen the Blue Hose to bre ak the vacuum and allow

the pump to start if its operation has been interrupted.

6. Press bottom (OFF) of rocker switch marked DEEP VACUUM.

7. Press bottom (OFF) of rocker switch marked TEST RUN.

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RTI Technologies, Inc.

HOSE EVACUATION

It's important that Air not be introduced into the A/C System during a Charging procedure. If a Deep
Vacuum procedure was performed previously, the following Hose Evacuation Procedure is not
required. If the service valv es on the hoses have been open, the following procedure must be
performed.

Figure 4 Hose Evacuation

To Evacuate Hoses, refer to Figure 4 and follow these steps:

1. Close Red and Blue Hose Valves.

2. Press top (ON) of rocker switch marked TEST RUN.

3. Press top (ON) of rocker switch marked RECOVER RECYCLE.

4. Let the AC800 run until the green COMPRESSOR ON light goes out.

Note: If the green light does not illuminate, press and hold the top of the rocker switch

marked RECOVER OVERRIDE until the Low Side Gauge indicates a vacuum.

5. Press bottom (OFF) of rocker switch marked RECOVER RECYCLE.

6. Press bottom (OFF) of rocker switch marked TEST RUN.

7. Vent any Non-condensable Gas as described in the previous section.

October 6, 1999

Page 11

CHARGE - HIGH SIDE

Figure 5 Charge - High Side

RTI Technologies, Inc.

To Charge Refrigerant, refer to Figure 5 and follow these steps:

1. Perform Hose Evacuation described previously.

2. Connect Red and Blue Hoses to the A/C System per the vehicle manufacturer's instructions.

3. Determine the refriger ant capacity of the A/C sy stem to be charged. This data is usually printed
on a tag located on the accumulator or under the hood of the vehicle. Convert this quantity to
tenths of a pound for setting the AC800 charge indicator.

The following will determine where to set the indicator prior to starting the charge mode:

(AC800 Liquid Level) - (A/C System Capacity) = Indicator Setting

EXAMPLE: The level of liquid visible in the AC800 Charging Cylinder Sight Glass is 7.4 lbs.

and the A/C system capacity is 3.2 lbs. The following calculation results...

(7.4) - (3.2) = 4.2

Therefore, the sliding indicator should be set at 4.2 lbs. in this example. When the
liquid level lowers to the 4.2 lb. mark , a c harge of 3.2 lbs. will have been delivered

NOTE: The Sight Glasses on the Charging Cylinders ha ve markings for both R12 and

October 6, 1999

R134a. Always use the correct scale for accurate charging.

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RTI Technologies, Inc.

Note: Skip to step 5 if charging to an o pti onal 30 lb DOT Refillable Cylinder via the short

Yellow Hose attached to the rear port.

4. Open Red and Blue Hose Valves.

5. Press top (ON) of rocker switch marked TEST RUN.

6. Press top (ON) of rocker switch marked CHARGE HIGH SIDE. Do not start the Vehicle's
Engine. Refrigerant will flow int o the h igh side of the A/C Sy stem. Closely monitor the liquid
level as it lowers in the Charging Cylinder Sight Glass.

7. Press bottom (OFF) of ro cke r sw itch marked CHARGE HIGH SI DE as soon as the refrigerant
level drops to the sliding indicator.

8. Press bottom (OFF) of rocker switch marked TEST RUN.

The vehicle can now be started and the A/C system checked by monitoring Gauge pressures.

Always close Red and Blue Hose Valves before disconnecting hoses.

Evacuate the hoses per the preceding section "Hose Evacuation".

NOTE: All Refrigerant Recycling Machines charge Liquid, by law. The preceding is the

suggested method of charging liquid into an A/C system.

Some vehicle manufacturers may not provide a High Side connection. The above
instructions would have to be modified accordingly. Always follow the vehicle
manufacturer’s recommended service procedures.

EXTERNAL CYLINDER FULL LIGHT:

This Light will illuminate if the Externa l Charging Cy linders Fill to capac ity, approximately 25 lbs.
When this occurs, the External Cylinder must be emptied or changed.

Note: T he AC800 will be unable to charge while this light is on, or if the Yellow Over Fil l

Protection Cord is NOT connected to the 30 lb DOT Refillable Cylinder.

October 6, 1999

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SCHEDULED MAINTENANCE

BEFORE EACH USE...Check the oil leve l in the Compressor s DAILY before using. The Oil Level

Sight Glasses can been seen through slots in the front lower section of the AC800. The oil levels
should simply be visible in the glass. If oil is not visible or is above the top of the glasses c all
Technical Support at 800-468-2321.

MONTHLY...Clean the Condensers to maintain high efficiency performance of the AC800.
Disconnect pow er and r emove the lower front perforated panel and blow compressed air through the
cooling fins of the Condenser to remove any debris. Do not bend the fins on the Condenser coils.
Air flow will be restricted and cause damage to the AC800. Replace the panel before applying
power to the AC800.

FILTER MAINTENANCE

Monitor the Moisture Indicators f or a color chang e from B L UE to PI N K . W he n t he A C8 00 is new
and immediately after changing Combo Filters, the Moisture Indicators may show PINK. This is du e
to the exposure to air and does not indicate inadequate filter performance. Combo Filters (two on
each side) are located behind access panels on either side if the AC800.

The “INLET” Combo Filter (right most of the two) must be chang ed every 25 hours of operation OR
when the Moisture Indicator is Pink. Hours are indicated on the Filter Change Meter.

The “OUTLET” Combo Filter (left most of the two) must be changed every 50 hours of operation
OR when the Moisture Indicator is Pink. Hours are indicated on the Filter Change Meter.

1. Remove side Access Panel to service the Combo Filters.

2. Disconnect Flare Fittings from top and bottom of filters.

3. Remove mounting nuts, and filters.

4. Transfer filter insulation material to new filter as applicable.

5. Install new Combo Filters using hardware removed in Step 3.

6. Connect Flare Fittings to top and bottom of filters.

7. Check for leaks, repair as necessary.

8. Replace Access Panel.

October 6, 1999

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PROBLEMS & SOLUTIONS

On rare occasion the AC800 may seem to be performing incorrectly. Experience has show n that
varying operating conditions can affect the performance characteristics of the AC800. The
temperature of the vehicle A/C System will affect how the AC800 performs.

Following are typical problems with explanations of the possible cause and solution.

PROBLEM: My AC800 worked fine all last Summer. I g ot it out today fo r t he first service job

this Spring and it is very slow in evacuating the system.

SOLUTION: Today's Spring temperature may be much lower than the average temperatures

during the su mmer months. Maybe the vehicle was broug ht in from outside where
the temperature is very low.

The refrigerant in the vehicle will not be under as high a pressure at lower
temperatures and the AC800 will take longer to draw a vacuum. More cy cles may
be required to completely recover the refrigerant.

PROBLEM: I p ut 5 lbs. of refrigerant into the AC800 using the Recycle Mode. When I che cked

the sight glass on the Charging Cylinder, there was less than 5 lbs. I lost
Refrigerant. The unit must leak.

SOLUTION: Due to temperature changes, some refrigerant may condense into liquid form and

stay in tubes and other components in the circuit preceding the Charg ing Cy linder.
This is normal and will explain why all re fr ige ra nt is not visible i n t h e sight g la ss.

PROBLEM: I can not get the AC800 to draw a vacuum as indicated on the Low Side Gauge.

SOLUTION: Check Hoses for restrictions.

PROBLEM: When I try to fill the Charging Cylinder from an auxiliary cylinder of clean

refrigerant, the AC800 is really slow or shuts down.

SOLUTION: The auxiliary cy linder will cool due to the vaporization of refrigerant. This causes

the pressure to decrease.

Use a heat belt to increase the speed of recycling by the AC800.

October 6, 1999

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RTI Technologies, Inc.

PROBLEM: I turned a 30 lb. cylinder of new refrigerant upside down to fill the Charging

Cyli n d er with liquid. The Charging Cy linder didn' t fill and now the AC800 won 't
recover from an A/C system.

SOLUTION: The AC800 has been overloaded with liquid refrigerant (see Safety Precaution

Section at the beginning of this manual).

... WARNING ...

IF A CYLINDER IS TURNED UP-SIDE-DOWN, THE
AC800 WILL OVERFILL WITH LIQUID
REFRIGERANT. THIS OVER FILLS THE SUCTION
ACCUMULATOR WITH LIQUID.

FROST ON THE OIL DRAIN ON THE REAR OF THE
AC800 IS A GOOD INDICATION OF THIS
OCCURRENCE.

THIS SYMPTOM IS CAUSE FOR CONCERN AS LIQUID
REFRIGERANT WILL BE FORCED INTO THE
COMPRESSOR.

THIS CAN DESTROY THE COMPRESSOR AND WILL
VOID THE WARRANTY.

The safest method to remove the excess liquid which has collected in the Suction
Accumulator is to drain it from the Oil Drain on the back of the AC800 as follows:

Draw a deep vacuum (25 to 29 In. Hg.) on a n e m p t y cylinder and connect it to the
Oil Drain Valve. Open the cylinder valve and the Oil Drain valve.

Close the valves and disconnect the cylinder after the liquid has been drawn into the
cylinder. This refrigerant can now be recycled by the AC800 following normal
recycling procedures.

If the abo ve suggested solutions do not solve the problem, call the phone number shown on the
Serial Label on the rear of the machine and one of our technicians will help diagnose the cause.
Please have the Serial Number available for reference.

October 6, 1999

Page 16

ACCESSORY PARTS LIST

RTI Technologies, Inc.

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