MAHLE RTI TC640 User Manual

OPERATION

&

MAINTENANCE

MANUAL

TC640

Refrigerant Management Center

(Convertible For Use With R12 or R134a)

RTI TECHNOLOGIES, INC.

4075 East Market Street

York, PA 17402

USA

Manual P/N 035-80412-00

TABLE OF CONTENTS

TC640

Before Using ..................................2

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

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

Recover/Recycle ................................6

Oil Drain & Air Purge ............................ 8

Vacuum ......................................9

Hose Evacuation ................................10

Charge - High Side ..............................11

Scheduled Maintenance & Filter Maintenance ..........13

Problems & Solutions ............................14

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

Schematic Diagram .............................. Appendix

CONGRATULATIONS: You have purchased one of the finest Recovery, Recycling, and

Charging Machines available at any price.

RTI Technologies, Inc.

BEFORE USING THE TC640

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

DO NOT USE A DAMAGED UNIT.
The TC640 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 TC640. The instructions should not be
interpreted to anticipate every possible contingency.

It is the responsibility of the owner/user to operate the TC640 in accordance
with all specifications and laws which may apply.

The following pages contain rules for safe operation of the TC640. 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 TC640 should be established and
records maintained with special attention given to Hoses, Compressor Oil
Level, and Filters.

September 15, 1997 Page 2

RTI Technologies, Inc.

SAFETY PRECAUTIONS

! Recover and Charge only the refrigerant 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 TC640 operating procedures sequentially to avoid prematurely

disconnecting hoses or opening valves which may release refrigerant to the
atmosphere.

! Do not expose the TC640 to moisture or operate in wet areas.
! Use the TC640 in locations with forced ventilation that provides four air

changes per hour.

! Hoses used with the TC640 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 TC640 and the release of refrigerant
when being disconnected.

! Disconnect power before performing any maintenance or service on the

TC640.

! Avoid using an extension cord with the TC640. If necessary, use a good

condition, UL listed, 3-wire grounded, #14 AWG extension cord of the
shortest possible length.

! Connect the TC640 to the proper, grounded power source of sufficient

amperage.

! Do not allow the TC640 to remain unattended in the Charge Mode with power

On.

NEVER TURN THE CYLINDER UP-SIDE-DOWN.
DO NOT CONNECT THE TC640 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 TC640 TO THE LIQUID PORT OF A
CYLINDER OF REFRIGERANT TO FILL THE TC640 CHARGE

CYLINDER.
FAILURE TO FOLLOW THE ABOVE MAY CAUSE THE TC640 COMPRESSOR TO FAIL

AND VOID THE WARRANTY.

September 15, 1997 Page 3

RTI Technologies, Inc.

L 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.

September 15, 1997 Page 4

RTI Technologies, Inc.

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 TC640
be filled until about 1.5Kg of liquid refrigerant can be seen in the Charging
Cylinder Sight Glass. The Sight Glass is visible through a slotted opening on
the front of the TC640.

Figure 1 Filling the Cylinder

To fill the TC640 Charge Cylinder, refer to Figure 1 and follow these steps:

1. Connect the Low Side Blue Hose to the VAPOR port of a cylinder of new or
recycled refrigerant. An adapter is provided with the TC640 (R134a) which
permits the Field Service Coupler to be attached to the .500 ACME fitting
on the cylinder of refrigerant.

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.
INTRODUCTION OF LIQUID INTO THE TC640 MAY DAMAGE THE

COMPRESSOR AND VOID THE WARRANTY.

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

The TC640 will recover and recycle refrigerant into the Charging Cylinder.
Observe the liquid refrigerant level rise in the Charging Cylinder Sight
Glass and when at approximately 1.5Kg close the valve on the refrigerant
cylinder. Allow the TC640 to continue running until the Low Side Gauge
shows a vacuum. This will evacuate the Blue Hose.

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

September 15, 1997 Page 5