MasterCool COMMANDER1000, COMMANDER2000, COMMANDER3000, COMMANDER1000-E, COMMANDER2000-E Instruction Manual

R134a RECOVERY/RECYCLE/RECHARGE

Operating Instructions

WARNING!!

Do not stop the recovery process. Permanent damage will occur that could void the warranty.

COMMANDER1000 (-E)
COMMANDER2000 (-E)
COMMANDER3000 (-E)

2 www.mastercool.com

3www.mastercool.com

DO NOT DISCARD

PACKING MATERIAL!

• VISUALLY INSPECT THE BOX FOR DAMAGE

• STORE WOODEN PALLET, BOX AND OTHER
PACKING MATERIAL FOR ANY FUTURE
SERVICE NEEDS*

DO NOT DISCARD

PACKING MATERIAL!

*Original packaging is required if the machine has

to be sent back to the factory or authorized service

location. If this is not available the factory will send

the proper packaging for a fee of $85.00.

4 www.mastercool.com

INTRODUCTION

This machine is ETL Laboratories approved, in compliance with SAE J2788. We are dedicated to solving
the issues surrounding the safe containment and proper management of refrigerants. Your new machine
incorporates the latest technology and state of the art features to aid you in servicing R134a air conditioning and
refrigeration systems.

NOTICE: The SAE J2788 standard has, by design made recycling machines more complex than previous models
that some End Users might be familiar with. Some noticeable changes that the End User should expect from ALL
new recycling machines are the following:

1. RECOVERY TIME: The average recovery time is approximately 30 minutes. This time is necessary to
meet the SAE J2788 standard which requires that the machine recovers at least 95% of the AC system
refrigerant and cleans the refrigerant to a minimum of 95% purity.

2. HOT WEATHER: As the ambient temperature approaches 100°F, some End Users have experienced
an increase in recovery time. This is due to the natural response of R134a when its temperature is
elevated. R134a has difficulty transforming from a gas into a liquid state at elevated temperatures. The
transformation into liquid is necessary for the machine to complete the recovery process. The End User
might notice the same effect when performing a TANK CHARGING operation. The COMMANDER series
includes a color touch screen tablet that may experience a slower processing time in extreme heat and
humidity. Avoid exposing the machine to dramatic changes in temperature or humidity.

3. COLD WEATHER: As the ambient temperature approaches 50°F, some End Users have experienced
an increase in recovery time. This is due to the natural response of R134a when its temperature is
lowered. R134a has difficulty transforming from a liquid into a vapor state at reduced temperatures. The
transformation into vapor is necessary for the machine to complete the distilling process. The End User
might notice the same effect when performing a TANK CHARGING operation. The COMMANDER series
includes a color touch screen tablet that may experience a slower processing time in extreme cold and
humidity. Avoid exposing the machine to dramatic changes in temperature or humidity.

4. SUN GLARE: Because of the way the COMMANDER color touch screen is constructed the user may
experience mirror-like screen reflectivity or screen images that are too dim to read in direct sunlight.
Whenever possible keep the color touch screen out of direct sunlight.

SAFETY SUMMARY

The following safety information is provided as guidelines to help you operate your new system under the safest
possible conditions. Any equipment that uses chemicals can be potentially dangerous to use when safety or
safe handling instructions are not known or not followed. The following safety instructions are to provide the
user with the information necessary for safe use and operation. Please read and retain these instructions for the
continued safe use of your service system.

SAFETY INFORMATION

Every craftsman respects the tools with which they work. They know that the tools represent years of constantly
improved designs and developments. The true craftsman also knows that tools are dangerous if misused or
abused. To reduce risk of discomfort, illness, or even death, read, understand, and follow the following safety
instructions. In addition, make certain that anyone else that uses this equipment understands and follows these
safety instructions as well.

READ ALL SAFETY INFORMATION CAREFULLY before attempting to install, operate, or service this equipment.
Failure to comply with these instructions could result in personal injury and/or property damage.

RETAIN THE FOLLOWING SAFETY INFORMATION FOR FUTURE REFERENCE.

Published standards on safety are available and are listed at the end of this section under ADDITIONAL SAFETY
INFORMATION.

The National Electrical Code, Occupational Safety and Health Act regulations, local industrial codes and local
inspection requirements also provide a basis for equipment installation, use, and service.

The following safety alert symbols identify important safety messages in this manual.

When you see one of the symbols shown here, be alert to the possibility of personal injury and carefully read the
message that follows.

Never fill the tank to more than 80% of maximum capacity as this will not leave an expansion chamber for

5www.mastercool.com

absorbing any pressure increases.

ELECTRICAL SHOCK HAZARDS

• To reduce the risk of electric shock, unplug the power supply cord from the outlet before
attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

• Do not operate the machine with a damaged cord or plug — replace the cord or plug
immediately. To reduce the risk of damage to electric plug and cord, disconnect the power
cord by pulling on the plug rather than the cord

An extension cord should not be used unless absolutely necessary. Use of an improper extension cord could
result in a risk of fire, electric shock and component damage. If extension cord must be used, make sure:
a. That pins on plug of extension cord are the same number, size, and shape as those on the plug on the recycler.
b. That extension cord is properly wired and in good electrical condition; and
c. That the wire size is large enough for the length of cord as specified below:

Length of cord in feet: 25 50 100 150
AWG size of cord: 16 12 10 8

MOTION HAZARDS

• Engine parts that are in motion and unexpected movement of a vehicle can injure or kill.
When working near moving engine parts, wear snug fit clothing and keep hands and fingers
away from moving parts. Keep hoses and tools clear of moving parts. Always stay clear of
moving engine parts. Hoses and tools can be thrown through the air if not kept clear of
moving engine parts.

• The unexpected movement of a vehicle can injure or kill. When working on vehicles always
set the parking brake or block the wheels.

FUME HAZARDS

• FUMES, GASES, AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS, AND DEATH! To reduce the
risk of discomfort, illness, or death, read, understand, and follow the following safety
instructions. In addition, make certain that anyone that uses the equipment understands and
follows these safety instructions as well.

• Avoid breathing A/C refrigerant and lubricant vapor mist. Exposure may irritate eyes, nose,
and throat. To remove R134a from the A/C system, use service equipment certified to meet the requirements
of SAE J2788--R134a recycling equipment. Additional health and safety information may be obtained from
refrigerant and lubricant manufacturers.

• Always perform vehicle service in a properly ventilated area. Never run an engine without proper ventilation for
its exhaust.

• Stop the recycling process if you develop momentary eye, nose, or throat irritation as this indicates inadequate
ventilation. Stop work and take necessary steps to improve ventilation in the work area.

HEAT/FREEZING HAZARDS

• When under pressure, refrigerants become liquid. When accidentally released from the liquid

state they evaporate and become gaseous. As they evaporate, they can freeze tissue very
rapidly. When these gases are breathed in, the lungs can be seriously damaged. If sufficient
quantities are taken into the lungs, death can result. If you believe you have exposed your
lungs to released refrigerant, seek immediate medical assistance.

• Refrigerants can cause frostbite and severe burns to exposed skin. Refrigerants are under pressure and
can be forcibly sprayed in all directions if carelessly handled. Avoid contact with refrigerants and always wear
protective gloves and make certain other exposed skin is properly covered.

• Refrigerants can also severely injure or cause permanent blindness to unprotected eyes. Refrigerants are
under pressure and can be forcibly sprayed in all directions if carelessly handled. Avoid contact with
refrigerants and always wear safety goggles.

6 www.mastercool.com

EXPLOSION/FLAME HAZARDS

• Never recover anything other than the approved refrigerants as specified on the machine.
Alternate refrigerants may contain flammables such as butane or propane and can explode or
cause a fire. Recovering alternate refrigerants will also void the warranty on your machine.

• For general safety reasons, at the end of the working day or in between services (when
services do not immediately follow), see to it that all valves on hoses and the machine are
closed.

ADDITIONAL SAFETY INFORMATION

For additional information concerning safety, refer to the following standards.
ANSI Standard Z87.1 — SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION ­obtainable from the American National Standards Institute, 11 West 42nd St., New York, NY 10036, Telephone
[phone], Fax [phone] - www.ansi.org

CAUTION: This equipment should be used in locations with mechanical ventilation that provides at least
four air changes per hour or the equipment should be located at least 18 inches (457 mm) above the
floor, or the equivalent.

CAUTION: Do not pressure test or leak test R134a service equipment and/or vehicle air conditioning
systems with compressed air. Some mixtures of air and R134a have been shown to be combustible at
elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health
and safety information may be obtained from refrigerant manufacturers.

ATTENTION: Technicians using this equipment must be certified under EPA Section 609 (Environmental
Protection Agency).

WARNING: There is the possibility of refrigerant contamination in the refrigerant container or the mobile
A/C system being serviced or refrigerant container. Before recycling use proper equipment such as a
refrigerant identifier, if necessary.

NOTE: Use only new refrigerant oil to replace the amount removed during the recycling process. Used oil
should be discarded per applicable federal, state, and local requirements.

The manufacturer shall not be responsible for any additional costs associated with a product failure
including, but not limited to, loss of work time, loss of refrigerant, cross contamination of refrigerant,
and unauthorized shipping and/or labor charges.

IMPORTANT: R134a systems have special fittings (per SAE specifications) to avoid cross-contamination
with R12 systems. DO NOT adapt your unit for a different refrigerant — system failure will result.

PERIODICALLY INSPECT AND MAINTAIN REFRIGERANT HOSES AND SEALS TO ENSURE THAT HOSES AND
SEALS PREVENT THE ADDITION OF EXCESS AIR, DUE TO LEAKS, DURING THE RECOVERY PROCESS, WHICH
WOULD INCREASE THE NCG LEVEL IN THE RECOVERED REFRIGERANT.

CERTIFICATION

All technicians opening the refrigeration circuit in automotive air conditioning systems must now be certified
in refrigerant recovery and recycling procedures to be in compliance with Section 609 of the Clean Air Act
Amendments of 1990. For information on certification call MACS Worldwide at [phone].

ABOUT THIS MANUAL

This manual includes a SAFETY SUMMARY, MACHINE PREPARATION FOR USE, OPERATION procedures, and
MAINTENANCE instructions, for your Air Conditioning Service Center. Anyone intending to use the machine
should become familiar with ALL the information included in this manual (especially the SAFETY SUMMARY)
before attempting to use it.

Before operating this machine for the first time, perform all Setup instructions. If your new machine is not
properly prepared to perform a service, your service data could be erroneous. In order to properly perform a
complete air conditioning service, follow all procedures in the order presented. Please take the time to study
this manual before operating the machine. Then keep this manual close at hand for future reference. Please
pay close attention to the SAFETY SUMMARY and all WARNINGS and CAUTIONS provided throughout this manual.

ABOUT YOUR AIR CONDITIONING RECOVERY/RECYCLE SERVICE CENTER

Your machine incorporates a highly accurate electronic scale for determining charging weights, etc. Other

7www.mastercool.com

functions can also be performed with the electronic scale as you will discover during the operating procedures.
Either standard or metric units of measure can be selected. Your new machine has been designed specifically to
use R134a, to operate within the objectives of the Montreal Protocol.

WARRANTY

This product is warranted against any defect in materials and/or construction for a period of 1 (one) year from
the date of activation.

The machine is automatically activated upon initial startup. This activation will record the date and time your
machine is turned on and establishes the warranty. Please reference the serial number and tag number in any
warranty requests. This information can be found by pressing the >> on the middle, left side of the command
center to access the main menu, then selecting help.

The warranty consists of free-of-charge replacement or repair of defective component parts or parts considered
defective by the Manufacturer. Reference to the machine serial number must be included in any requests for
spare parts. This warranty does not cover defects arising from normal wear, incorrect or improper installation, or
phenomena not inherent to normal use and operation of the product.

NOTE: Regarding the above, the Manufacturer reminds the Customer that according to international and national
laws and regulations in force the goods are shipped at the sole risk of the latter and, unless otherwise specified
in the confirmation of order phase, the goods are shipped uninsured. The Manufacturer therefore declines any
and all responsibility in merit of CLAIMS for damages due to shipping, loading and unloading, and unpacking.

The product for which repair under guarantee is requested must be shipped to the manufacturer under the
customer’s exclusive responsibility and at the customer’s exclusive expense and risk. In order to avoid damage
during shipping for repairs, the Manufacturer’s original packing must always be used.

The manufacturer declines any and all responsibility for damage to vehicles on which recovery/recycling and
recharging are performed if said damage is the result of unskillful handling by the operator or of failure to
observe the basic safety rules set forth in the instruction manual.

The warranty will expire automatically at the end of the 12 month period or whenever one of the following
occurs: failure to perform maintenance; use of improper maintenance procedures; use of unsuitable lubricants
and/or tracer fluids; inept or improper use; repairs performed by unauthorized personnel and/or with non­original spare parts; damage caused by shocks, fires, or other accidental events.

All warranty information referenced is valid in the United States only. For information pertaining the warranty
outside of the United States, please contact your local distributor.

GENERAL INFORMATION

Machine identification information is printed on the data
plate on the rear of the machine (Figure 1). Overall machine
dimensions:
Height: 45.3” (1150 mm)
Width: 23.6” (600 mm)
Depth: 30.3” 770 mm)
Weight: 190 lb (86 kg)

Like any equipment with moving parts, the machine inevitably
produces noise. The construction system, paneling, and
special provisions adopted by the Manufacturer are such that
during work, the average noise level of the machine is less
than 70 dB (A).

NOTE: The machine is intended for indoor use only.

PRINCIPLES OF OPERATION

In a single series of operations, the machine permits
recovering and recycling refrigerant with no risk of release

Data
Plate

FIG. 1

into the environment, and also permits purging the A/C system of humidity and deposits contained in the oil.
The machine is equipped with a built-in evaporator/separator that removes oil and other impurities from the
refrigerant recovered from the A/C system and collects them in a container for that purpose. The fluid is then
filtered, recycled and returned to the tank installed in the machine. The machine also permits running certain

8 www.mastercool.com

operational and leak tests on the A/C system.

THE MACHINE

BASIC COMPONENTS (Refer to Figures 2, 3, 4 and 5.)

A. Visual Indicator Light
B. Low and High Side
Analog Gauges
C. Coupler Storage
(Hose Flush Manifold

(Commander3000 (-E))

D. Tank Filling Adapter

E. Fresh Oil Bottles

(COMMANDER2000 / 3000-E only)

F. Waste Oil Bottle
G. Cabinet Fan
H. Wheel Locks
I. Speaker
J. Low and High Side Machine Valves

K. Computer Command
Center
L. Low and High Side DOT
Tank Valves
M. 30 lb DOT Tank
N. Heater Blanket
O. Load Cell Scale

P. Vacuum Pump
Q. Vacuum Pump Vent/
Oil Fill
R. Vacuum Pump Oil
Drain
S. Filter Ball Valve
T. Filter

C

A

B

G

H

I

J

K

D

E

F

E

L

P

Q

R

S

T

M

N

O

FIG. 2 FIG. 3

FIG. 4 FIG. 5