MAHLE RTI TC2670 User Manual

OPERATION

&

MAINTENANCE

MANUAL

TC2670E & TC2670V

Refrigerant Recycling Center

RTI Technologies, Inc.

4075 E. Market St.

P.O. Box 3099

York, PA 17402 USA

717-840-0678 ext. 259

[e-mail]

Manual P/N 035-80381-00 (Revised 1999)

TABLE OF CONTENTS

TC2670

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

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

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

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

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

Vacuuming ...................................... 10

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

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

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

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

R134a Cylinder Adapter Instructions .................. 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.

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 Warranty Card to activate Technical Support and Warranty Coverage.

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

BEFORE USING THE TC2670

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 service and warranty coverage.

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

The TC2670 should not be operated or serviced by any person who has not read all the contents of this
manual. Failure to read and 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 maintenance situations encountered with the
TC2670. The instructions should not be interpreted to anticipate every possible contingency.

It is the responsibility of the owner/user to operate the TC2670 in accordance with all specifications and
laws which may apply.

The following pages contain rules for safe operation of the TC2670. 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 TC2670 should be established and records maintained with special
attention given to Hoses, Compressor Oil Level, Moisture Indicator, and Filters.

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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 TC2670 operating procedures sequentially to avoid prematurely disconnecting hoses or

opening valves which may release refrigerant to the atmosphere.

! Do not expose the TC2670 to moisture or operate in wet areas.

! Use the TC2670 in locations with mechanical ventilation that provides at least four air changes per

hour.

! Hoses used with the TC2670 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 TC2670
and the release of refrigerant when being disconnected.

! Disconnect power before performing any maintenance or service on the TC2670.

! Avoid using an extension cord with the TC2670. If necessary, use a good condition, UL listed, 3-

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

! Connect the TC2670 to a properly grounded receptacle. Do not over load the circuit.

! Do not allow the TC2670 to remain unattended in the Charge 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 TC2670 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 TC2670 TO THE LIQUID PORT OF A

CYLINDER OF REFRIGERANT TO FILL THE TC2670 CHARGE CYLINDER.

FAILURE TO FOLLOW THE ABOVE MAY CAUSE THE TC2670 COMPRESSOR TO FAIL
AND VOID THE WARRANTY.

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LL CAUTION 7

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 nonflammable at ambient temperature and atmospheric
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 combustion to occur,
the presence of combustible mixtures is a potentially dangerous situation and should
be avoided.

Under no circumstances 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.

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FILLING THE CHARGING CYLINDER

A/C Systems requiring service often do not have a full charge of refrigerant. To avoid unnecessary
repositioning of hoses it is recommended that the TC2670 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 TC2670.

Figure 1 Filling the Cylinder

To fill the TC2670 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 Low Side Blue Hose to the VAPOR port of a cylinder of the correct refrigerant. An

adapter is provided with the TC2670 for the R134a side which permits the Field Service Coupler to
be attached to the .500-16 ACME fitting on the cylinder of refrigerant (See instruction sheet in
Appendix).

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 CONNECT TO THE LIQUID VALVE.

DO NOT TURN THE CYLINDER UP-SIDE-DOWN.

INTRODUCT ION OF LIQUID INTO THE TC2670 MAY DAMAGE THE
COMPRESSOR AND VOID THE WARRANTY.

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Press top (ON) of rocker switch marked R12 POWER.

2.

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

3.

Open Low Side Gauge Manifold Valve, Blue Hose Valve and refrigerant cylinder valve.

4.

Observe the liquid refrigerant level rise in the Charging Cylinder Sight Glass and when at
approximately 3 lbs, close the valve on the refrigerant cylinder. Allow the TC2670 to continue to run
until the Low Side Gauge shows a vacuum. This will empty the Blue Hose.

HINT:

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

5.

Press bottom (OFF) of rocker switch marked R12 POWER.

6.

Close Low Side Gauge Manifold Valve and Blue Hose Valve.

7.

Heating of the cylinder of refrigerant with an RTI Heat Belt (P/N 026-80092-00) will speed
the recovery process.

... NOTE ...

The sight glass does not indicate 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 TC2670. 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 TC2670 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 Gauge Manifold pressure goes down,
the rate of transfer of refrigerant from the Condenser to the Charge Cylinder
goes down.

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RECOVER/RECYCLE

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Figure 2 Recover/Recycle

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 High and Low Gauge Valves.

3. Open Red and Blue Hose Valves.

4. Press top (ON) of rocker switch marked R12 POWER.

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

5.

The TC2670 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 TC2670 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 TC2670 will automatically cycle 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 ...

Several audible changes may be heard during the recovery and recycling process.

Refrigerant flow through check valves causes a "sizzle-type" sound.

These changing "noises" are normal and nothing to be concerned about.

Close Red and Blue Hose Valves.

6.

Close High and Low Gauge Valves.

7.

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

8.

Press bottom (OFF) of rocker switch marked R12 POWER.

8.

PURGE REQUIRED OR CYLINDER FULL LIGHT:

This Light will illuminate if either...

1) Pressure on the Purge Gauge approaches 250 psig: Go to Page 9

OR

2) The Charging Cylinder has filled to capacity: Go to Page 12

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OIL DRAIN & AIR PURGE

Oil and Non-condensable Gas (Air) are separated from the
recovered refrigerant and MUST be removed following

EACH recycling procedure as follows:

Note: TC2670 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 (located on rear of
TC2670 towards outside) 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 TC2670 will typically not remove more than a
tablespoon of oil, making replenishment unnecessary.

LEAVE THE OIL DRAIN VALVE OPEN...

3. Determine the room temperature.

4. Locate the pressure (PSIG) corresponding to this room
temperature ( 0 F) in the chart on the top of the
TC2670. 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
th e 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.

RTI Technologies, Inc.

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

Purge Chart

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VACUUMING

If the A/C System is "opened" for replacing components, a vacuum must be drawn on the system before
recharging with refrigerant. This vacuuming process removes air and moisture introduced into the system.

Figure 3 Vacuum

To 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 Low and High Gauge Valves.

3. Open Red and Blue Hose Valves.

4. Press top (ON) of rocker switch marked R12 POWER.

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

6. The Pump will start and the TC2670 will draw a vacuum.

NOTE... If pressure is sensed at the Red and Blue Hoses on the TC2670, the Pump will not start. If

this occurs, perform the recover/recycle operation described earlier. It may also be necessary
to momentarily loosen the Blue Hose to break the vacuum to allow the pump to start if its
operation has been interrupted. It is normal for the TC2670 to have a 20 to 30 second
discharge when the Pump is started.

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

8. Press bottom (OFF) of rocker switch marked R12 POWER.

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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 valves 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. Open High and Low Gauge Valves.

3. Press top (ON) of rocker switch marked R12 POWER.

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

5. Let the TC2670 run until a vacuum is seen on the Low Side Gauge.

6. Turn High and Low Gauge Valves to OFF.

7. Press bottom (OFF) of rocker switch marked RECOVER/RECYCLE. All Air has now been
removed from the Hoses.

7. Press bottom (OFF) of rocker switch marked R12 POWER.

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

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CHARGE - HIGH SIDE

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Figure 5 Charge - High Side

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 high side per the vehicle manufacturer's instructions.

Note... Do not open Gauge Manifold Valves.

3. Press top (ON) of rocker switch marked R12 POWER.

4. Press top (ON) of rocker switch marked CHARGE/HIGH SIDE. The Charge Cylinder will now be
heating to develop pressure for charging.

5. Open Red and Blue Hose Valves.

6. Determine the refrigerant capacity of the A/C system 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 TC2670 charge indicator.

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

(TC2670 Liquid Level) - (A/C System Capacity) = Indicator Setting

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RTI Technologies, Inc.

EXAMPLE:

The level of liquid visible in the TC2670 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 charge of 3.2 lbs. will have been delivered

NOTE... The Sight Glasses on the Charging Cylinders have markings for both R12

and R134a. Always use the correct scale for accurate charging.

Open High Side Gauge Manifold Valve. Do not start the Vehicle's Engine. Refrigerant will flow

7.
into the high side of the A/C System. Closely monitor the liquid level as it lowers in the Charging
Cylinder Sight Glass.

Close High Gauge Valve as soon as the refrigerant level drops to the sliding indicator.

8.

Press bottom (OFF) of rocker switch marked CHARGE/HIGH SIDE.

9.

Press bottom (OFF) of rocker switch marked R12 POWER.

9.

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

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

Always close Red and Blue Hose Valves before disconnecting hoses.

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.

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SCHEDULED MAINTENANCE

BEFORE EACH USE...

Check the oil level in the Compressors DAILY before using.

The Oil Level Sight Tubes can been seen by shining a light into the bottom, middle of the side perforated
panels in the lower section of the TC2670.

The oil levels should simply be visible in the tube, not more than one inch up.

If oil is not visible or is higher than one inch in the tubes call Technical Support at 800-468-2321.

MONTHLY...

Clean the Condensers to maintain high efficiency performance of the TC2670. Disconnect power and
remove 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 TC2670.
Replace the panel before applying power to the TC2670.

FILTER MAINTENANCE

Monitor the Moisture Indicators for a color change from BLUE to PINK. When the TC2670 is new and
immediately after changing Combo Filters, the Moisture Indicators may show PINK. This is due to the
exposure to air and does not indicate inadequate filter performance.

Four Combo Filters are installed on the rear of the TC2670, two for each side.

Both Filters for one side must be changed yearly OR when the Moisture Indicator shows "Wet".

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PROBLEMS & SOLUTIONS

On rare occasion the TC2670 may seem to be performing incorrectly. Experience has shown that varying
operating conditions can affect the performance characteristics of the TC2670. The temperature of the
vehicle A/C System will affect how the TC2670 performs.

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

PROBLEM: My TC2670 worked fine all last Summer. I got it out today for the 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 summer months. Maybe the vehicle was brought 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 TC2670 will take longer to draw a vacuum. More cycles may be required to
completely recover the refrigerant.

PROBLEM: I put 5 lbs. of refrigerant into the TC2670 using the Recycle Mode. When I checked 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 Charging Cylinder. This is
normal and will explain why all refrigerant is not visible in the sight glass.

PROBLEM: I can not get the TC2670 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

TC2670 is really slow or shuts down.

SOLUTION: The auxiliary cylinder 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 TC2670.

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PROBLEM:

SOLUTION:

I turned a 30 lb. cylinder of new refrigerant upside down to fill the Charging Cylinder with
liquid. The Charging Cylinder didn't fill and now the TC2670 won't recover from an A/C
system.

The TC2670 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
TC2670 WILL OVERFILL WITH LIQUID REFRIGERANT.
THIS OVER FILLS THE SUCTION ACCUMULATOR
WITH LIQUID.

FROST ON THE OIL DRAIN ON THE REAR OF THE
TC2670 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 TC2670 as follows:

Draw a deep vacuum (25 to 29 In. Hg.) on an empty 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 TC2670 following normal recycling
procedures.

If the above 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.

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