USER´S MANUAL
RG3000-E
Advanced Test Products Europe RG3000-E
TABLE OF CONTENTS
I) Safety precautions
A) The safe way is the only way! 1
B) Refrigerant gas recovery & containment 2
II) Important general information 3
III) Operating procedures
A) Operating your RG3000-E 4-6
B) Set-up procedures 7-9
C) Purging the non-condensable gases 10
IV) Diagrams
A) Parts list 11
B) Refrigerant flow diagram 12
C) Wiring diagram 13
V) Automatic safety pressure switch 14
VI) Care and maintenance 15
VII) Technical data 16
VIII) Helpful hints 17-19
IX) Troubleshooting 20
Design specifications and material are subject to change without notice. REV2 82011AS
This manual may not be reproduced in any way, shape or form without express writen consent of
Advanced Test Products Europe.
Advanced Test Products Europe RG3000-E
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THE SAFE WAY IS THE ONLY WAY!
NOTE! If you are not a qualified refrigerant service technician,
do not use this equipment
1. The technician should always wear goggles and gloves when working on
refrigeration systems.
2. Be sure that any room where you are working is thoroughly ventilated, especially if
a leak is suspected. Refrigerant vapor is hazardous to your health and can cause
death.
3. Always think before acting. Familiarity breeds carelessness and carelessnes scan
be harmful to your health or, worse, result in death.
4. Read the Material Safety Data Sheets (MSDS) on all compounds with which you
are likely to come in contact. Read MSDS on refrigerant and refrigerant oil. Obtain
MSDS sheets from your refrigerant supplier.
5. Never use oxygen when testing for leaks. Any oil in contact with oxygen under
pressure will form an explosive mixture.
6. Refrigerant systems are generally electrically driven and controlled. Be sure to
disconnect the unit from the power source before servicing it.
7. Always store refrigerant containers in a cool, dry place.
8. Always open service and cylinder valves slowly. This allows quick control of the flow
of gasses if there is any danger. Once it is determined that there is no danger, the
valves may be opened fully.
9. Do not mix refrigerant in a system, a tank or anywhere else. Each type of refrigerant
must have its own tank, filters, etc.
10. If moisture enters the refrigerant system, it is likely to cause considerable damage.
Keep everything connected with the refrigeration system thoroughly dry and clean.
11. To reduce the risk of fire, avoid the use of extension cords as they may overheat.If
you must use an extension cord it should be a minimum of 12 AWG and not longer
than 5m.
This equipment should be used in locations with mechanical ventilation providing at
least four air changes per hour, or the equipment should be located at least 45cm
(18”) above the floor. Do not use this equipment in the vicinity of spilled or open
containers of gasoline or any other flammable liquid.
Advanced Test Products Europe RG3000-E
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REFRIGERANT GAS
RECOVERY & CONTAINMENT
Safety comes first. Read all safety information for the safe handling of refrigerant
including the Material Safety Data Sheet provided by your refrigerant supplier. Never
operate unit in an explosive environment. Wear safety glasses and protective gloves.
Work area must be well ventilated. This unit should only be operated by a qualified
technician.
*** CAUTION: REFRIGERANT STORAGE CONTAINERS ***
Use only approved cylinders with a minimum of 41 bar working pressure that meet the
current regulations.
NOTE: Recovery cylinders are designed for different pressures. Do not exceed the
working pressure of each cylinder.
Safety codes recommend that closed tanks not be filled over 80% of volume with liquid.
The remaining 20% is called head pressure room.
NEVER TRANSPORT AN OVERFILLED CYLINDER
Refrigerant expands when it gets warm and may cause a tank to explode if overfilled.
CYLINDER TEMP. 16 °C 21 °C 38 °C 54 °C 66 °C
STARTING WITH
CYLINDER 80%
FULL BY VOLUME
SPACE OCCUPIED
BY LIQUID
STARTING WITH
CYLINDER 90%
FULL BY VOLUME
SPACE OCCUPIED
BY LIQUID
80 % 81% 83% 90% 94%
90% 92% 96% 100%
Advanced Test Products Europe RG3000-E
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IMPORTANT
GENERAL INFORMATION
Before operating the RG3000-E recovery unit, read the following:
1. Storage cylinders sometimes have valves that are not properly seated when
manufactured. Keeping caps on these valves will guard against refrigerant leakage.
2. Always operate the unit on a flat level surface.
3. Your RG3000-E has one internal pressure shut off switch. If the pressure inside the
system should go above 38,5 bar (550 psi), the system will automatically shut itself
off.
CAUTION
The 38,5 bar (550 psi) switch does not prevent tank overfill. If your system shuts
off on high pressure and is connected to your tank, you may have overfilled your
tank and created a very dangerous situation! Take immediate measures to relieve
any high pressure and/or tank overfill.
4. WARNING! Never overfill storage tanks. Overfilling may cause tanks to explode.
5. A scale must be used to avoid overfilling the storage tank.
6. Tanks and filters should be used for one refrigerant only. Before using a tank
previously used for another refrigerant, completely empty the tank, evacuate it,
purge the tank using dry nitrogen, and re-evacuate it.
7. Special care should be taken when recovering from a burned-out system. Use two
high acid capacity filters, in series. Alco type EK-162-F or Sporlan type C-162-F are
recommended.
8. When you have finished recovering from the system, flush your RG3000-E with a
small amount of refrigerant oil and a small amount of clean refrigerant to purge off
any foreign substances left in the unit.
9. Always empty refrigerant from the unit into a storage tank; see Purge/Auto
Evacuate procedure. Liquid refrigerant left in the condenser may expand, causing
damage to components.
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OPERATING YOUR RG3000-E
Connect your RG3000-E to a 230 V outlet and close both valves on the RG3000-E.
Open the valves to the cylinder and system and make sure no air is in the hoses, only
clean refrigerant. Open the outlet valve on the unit .Switch the main power switch to the
ON position. The fan and compressor will start running. Slowly open the inlet valve on
the unit and the refrigerant will start to move.
OPERATING PROCEDURES
NOTE: To change from Recovery mode to Purge:
If available, close the valve from the system to the inlet hose and wait untill
the LP gauge shows 0,1 bar. Then close the Inlet valve of the RG3000-E.
Turn the unit off after the unit goes in to vacuum and switch off the RG3000E. Close the outlet valve of the RG3000-E and close the valve on the
cylinder.
NORMAL RECOVERY
PURGE / AUTO EVACUATE
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OPERATING YOUR RG3000-E
Procedure for Normal System Recovery
1 Inspect the RG3000-E thoroughly to insure that it is in good operating condition.
2 Make sure all connections are correct and tight (see diagram on page 8)
3 Open the liquid valve of the recovery cylinder (always open valves slowly to check
hoses and connections for leaks).
4 Open the outlet valve of the RG3000-E.
5 Open the liquid valve on the manifold gauge set; opening the liquid valve will
remove the liquid from the system first, greatly reducing the recovery time (after the
liquid has been removed, open the manifold vapor valve to finish evacuating the
system).
6 Connect your RG3000-E to a 230 V outlet.
7 Switch the main power switch to the ON position. You should hear the
fan and compressor running.
8 Slowly open the inlet valve on the RG3000-E.
a) If the compressor starts to knock, slowly throttle back the inlet valve
until the knocking stops.
b) If the inlet valve was throttled back, it should be fully opened once the
liquid has been removed from the system (the manifold vapor valve
should also be opened at this time).
9 Run the unit until minimum required vacuum is achieved.
a) Close the manifold vapor and liquid valves.
b) Close the RG3000-E inlet valve.
c) Shut unit off and proceed with the Purge procedure on the next page.
10 Always purge the RG3000-E after each use. Failure to purge the remaining
refrigerant from the RG3000-E could result in the acidic degradation of internal
components, ultimately causing premature failure of the unit.
CAUTION
When pumping liquid, do not allow the RG3000-E to operate with the inlet valve
too far open, causing the compressor to knock. Doing so may damage the
compressor.
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OPERATING YOUR RG3000-E
Procedure for Purging Remaining Refrigerant From the RG3000-E
1. Close the valves of the system being serviced that are connected to the inlet
valve of the RG3000-E.
2. Close the inlet valve on the RG3000-E. The outlet valve should remain open.
3. Run the unit until desired vacuum is achieved.
4. Turn the RG3000-E off.
5. Close the valves on the recovery tank and the outlet valve on the RG3000-E.
6. Disconnect and store all hoses.
7. Replace the in-line filter on your RG3000-E after each time excessive contaminant
is encountered.
Important Note
We strongly recommend the use of Robinair hoses with Quick Seals™ to avoid wasting
refrigerant because of their unique reverseable, built-in, check valve.
RA69060A - set of 3 hoses wit Quick Seals™ Red, Yellow and Blue; 152cm long.
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RG3000-E REFRIGERANT RECOVERY
ADDITIONAL INFORMATION
To achieve the deepest final vacuum, use the tank cooling method to lower the head
pressure on the recovery tank. Repeat as necessary to achieve the desired vacuum
level.
NOTE: If there is no liquid in the recovery tank, then the cooling method will not work. In
this case, use an empty tank that has been fully evacuated to achieve the final vacuum
level required.
To maximize recovery rates use the shortest possible length of 3/8” or larger hose. A
hose no longer than 90cm is recommended. Always remove all unnecessary hose core
depressors and Schraeder valves from valve connections (using the proper valve core
removal tool) for maximum flow. Deformed rubber seals and core depressors in hoses
and faulty or unnecessary Schraeder valves can restrict flow by up to 90%.
If the tank pressure exceeds 31,5 bar, use the tank cooling procedure to reduce the
tank pressure. When recovering large amounts of liquid, use the “PUSH/PULL” method
of recovery (see diagram below).
CAUTION: When using the “PUSH/PULL” method, you must use a scale to prevent
overfilling the storage tank. Once the “PUSH/PULL” siphon is started, it can continue
and overfill the storage tank even if the tank is equipped with a float level sensor. The
siphon can continue even when the machine is turned off. You must manually close the
valves on the tank and the unit to prevent overfilling the recovery tank.
SET-UP DIAGRAM FOR TANK PRE OR SUB COOLING
PROCEDURE
To start you must have a minimum of
2,5 kg of liquid refrigerant in the tank.
Throttle the outlet valve so that the
outlet pressure is 7 bar (100 psi)
greater than the inlet pressure, but
never more than 31,5 bar (450 psi).
Run the unit until the tank is cold.
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SET-UP DIAGRAM FOR REFRIGERANT RECOVERY
This method is the fastest method for recovering vapor refrigerant.
SET-UP DIAGRAM FOR “PUSH/PULL” METHOD
Push pull only works with large systems where the liquid is readily accessible. Do not
use this method on systems that contain less than 15 pounds as it may not work.
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OPTIONAL RECOVERY / TANK PRE OR SUB
COOLING FOR FIXED HOSE SET UP
Normal recovery:
Tank Vapor valve is closed.
Tank pre or sub cooling:
Tank Vapor valve is open and both Manifold Gauge Set valves are closed. Follow
above procedure.
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RG3000-E RECOVERY
Purging the non-condensable gasses from identified refrigerant in a tank
1) Allow the tank to sit undisturbed for 24 hours. (This allows the air to rise to the top).
2) Connect a manifold to the tank and read the amount of pressure in the tank by
looking at the outlet pressure gauge.
3) Determine the ambient temperature in the room.
4) Refer to a Refrigerant pressure/temperature chart. Find the temperature on the
chart and look across to the corresponding pressure for the type of refrigerant in the
tank. Determine how that relates to the reading on the gauge.
5) If the pressure reading is higher than the pressure shown on the chart, very slowly
(so as not to cause turbulence inside the tank) crack open the vapor valve. Watch
the pressure on the gauge decrease. To prevent venting, add 0,3 - 0,35 bar (4 - 5
psi) to the pressure shown on the chart. When the gauge corresponds to that
pressure, close the vapor valve valve.
6) Allow the tank to sit for 10 minutes and check the pressure again.
7) Repeat the process again if necessary.
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PARTS LIST RG3000-E
Pos. Art.-Nr. Description
Qty.
1 105-201234-001 Condensor 1
2 110-ATP100179 Condensor grill 1
3 111-SPX552732 Post Grommet 8
4 111-201229-001 Motor Clamp, Left 1
5 111-201230-001 Motor Clamp Right 1
6 105-201231-001 Motor 1
7 110-201212-001 Compressor-/Motor Bracket 1
8 105-201221-001 Compressor 1
9 111-201200-001 Front Panel 1
10 105-201232-001 Manifold Assy. Low Side 1
11 105-201233-001 Manifold Assy. High Side 1
110-201201-001 Low Side Gauge only 1
110-201202-001 High Side Gauge only 1
12 145-ATPEL1310 Power Switch 1
13 140-ATPRR121917 Power Receptacle 1
14 111—ATP100419 Fuse Holder 1
15 125-201226-001 Capacitor, Motor Start 1
16 111-201241-001 Capacitor Mounting bracket 1
17 111-201228-001 Case Half, Right 1
18 145-201235-001 Fan 1
19 111-SPX550503 Grommet 8
20 111-SPX550502 Rubber froot 4
21 110-201243-001 Fan grill 1
22 110-201213-001 Coupling 1
23 110-201242-001 Inlet Tube 1
24 111-201227-001 Case Half, Left 1
25 180-201239-001 Instruction Label 1
26 180-201239-001 Nameplate Label 1
27 114-ATPNB3204 ¼“-20x1/4“ Hex Scew 2
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NOTE: A filter must always be used. Failure to use a filter will invalidate your warranty.
The use of a filter will greatly reduce the risk of damage to your RG3000
-E by preventing foreign material from
entering the unit.
Special consideration for filtration must be given when you
know you are servicing a machine that has "Burned Out".
We recommend the use of two size 162 filter driers, in line, to be used for that job and that job only.
REFRIGERANT-FLOW-DIAGRAM
FILTER
OUTPUT
INPUT
CONDENSER
COMPRESSOR
MOTOR
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RG3000-E WIRING DIAGRAMM
RG3000-E WIRING DIAGRAMM
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SAFETY PRESSURE SWITCH
(WITH AUTO RESET FUNCTION)
The RG3000-E is equipped with an internal Automatic Safety Pressure Switch. If the
pressure inside the system exceeds 38,5 bar, the system is switched off automatically.
If the Safety Pressure Switch is activated automatically while filling a bottle, it could be
caused by the bottle becoming overfilled.
This is a very dangerous situation! You should take steps immediately to reduce the
overpressure and/or to eliminate the overfilling of the bottle.
If the Safety Pressure Switch switches the unit off...
The following precautions should be taken if the Safety Pressure Switch is activated:
a) Suspected overfilling of the recovery bottle
Connect the recovery bottle to another bottle with spare capacity so that the pressure
is reduced to a safe level. This action should also reduce the pressure in the outlet line
from the RG3000-E.
b) Cause of activation of Safety Pressure Switch unknown
1) Check that the recovery bottle is not overfilled.
2) Close the system valves, recovery bottle valves and RG3000-E valves.
3) Disconnect RG3000-E from flexible hoses.
4) Disconnect RG3000-E from the power supply.
5) Open the inlet and outlet valves very slowly.
6) Investigate the reason for the failure.
Once activated, the Automatic Safety Pressure Switch will reset itself if the pressure is
reduced below 38 bar.
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CARE AND MAINTENANCE OF YOUR
RG3000-E
A filter must always be used and should be replaced frequently. Failure to use a filter
will invalidate your warranty. The use of a filter will greatly reduce the risk of damage to
your RG3000-E by preventing foreign material from entering the unit.
Special consideration for filtration must be given when you know the machine you are
servicing has "burned out". We recommend the use of two size 162 filter driers, in line,
to be used for that job and that job only. We also recommend that a clean filter be used
for every service job. Each filter should be labeled and used exclusively for one type of
refrigerant only.
Do not use this unit in the vicinity of spilled or open containers of gasoline or other
combustible liquids
Avoid the use of extension cords. If you must use an extension cord it should be a
minimum of 12 AWG and not longer than 5m. Not using an extension cord will greatly
reduce the risk of fire.
Always purge the unit of any refrigerant left after completing a service job. Refrigerant
left in the machine can expand and may cause damage to components.
If the unit is to be stored or not used for any length of time, we recommend that it be
completely evacuated of any residual refrigerant and purged with dry nitrogen.
Whenever you perform any type of maintenance work on your RG3000-E, ensure that it
is disconnected from the power supply before you begin.
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TECHNICAL SPECIFICATIONS RG3000-E
Type RG3000-E
Application Refrigerant recovery Liquid or Vapor
Suitable Refrigerants AHRI Category III, IV & V such as:R11,R12, R13B1, R22,
R123, R134A, R141B, R401A,
R401B, R402A, R402B, R404A, R407A, R407B, R407C,
R408A, R409A, R410A, R417A, R500, R502, R503, R507,
R422A, R422D, R427A, R1234YF.
Not intended for use with Category I (e.g. R11, R123), II
(e.g. R114) nor VI (e.g. R13, R23) refrigerants.
Power Source 230V/50Hz
Power 250 W
Dimensions 310mm x 175mm x 235mm
Weight 8 kg
Rpm’s 1450 U/min
Max Working Pressure 550 p.s.i. (38,5 bar)
Safety Device Safety pressure switch
with automatic reset (550 p.s.i. / 38,5 bar)
ATTENTION
The RG3000-E should not be used with inflammable gases or with
gases containing ammonia.
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HELPFUL HINTS FOR REFRIGERANT
RECOVERY
Refrigerant recovery has come a long way in a few short years.
On the surface it’s simply the process of taking refrigerant out of a system and putting it
into a tank. However, this simple process can quickly become problematic if a few items
are overlooked. The following are some tips and pointers we’ve accumulated over the
last few years that can save you time and make the process go smoother.
First you need to identify the refrigerant type and quantity in the system you are
servicing.
If you determine it’s a burnout, you need a special tank (a tank that’s identified as
containing burnout or other unidentified gases), and you need to use extra filtration prior
to recovery.
If, on the other hand, you know the gas in the system is relatively clean or new, then a
new tank should be used. If you’re planning on putting the refrigerant back into the
same system after you have finished the service or if the refrigerant is going to be
reclaimed, then use a tank that has the same refrigerant in it. A word of caution about
the Environmental Protection Agency (EPA): If you use a variety of refrigerant gasses in
your service work - as evidenced by your refrigerant purchases - and you only own one
tank, you are asking for trouble. You would be well advised to own at least one tank for
every refrigerant type serviced, plus an extra for burnouts and other unknowns.
Planning Ahead
Knowing the quantity of refrigerant is important for planning storage requirements, as
well as planning for the actual recovery. For instance, any system with more than 5lbs.
of refrigerant is likely to have areas where the liquid can get trapped.
The key to a quick recovery procedure is to get the liquid out first, and then get the
remaining vapor out. However most systems are not “recovery friendly.” That is they
don’t have access valves at their lowest points. If some units you’re servicing are on
maintenance contracts, you would save significant time by installing access valves at all
of the lowest points in the system, where liquid is likely to accumulate. Since most
systems don’t have these valves you need to be prepared to boil off the trapped liquid
with a heat gun, when ever it’s found. An indicator of trapped liquid in a system is frost
or condensation forming on the plumbing or components where the liquid is trapped.
The trapped liquid may be in an area that is not visible. In all cases trapped liquid in a
system during recovery causes the recovery process to slow down, regardless of the
size or type of machine
If you are unable to locate the trapped liquid (but you know it’s there, because the
recovery job is taking “forever”), turn on the system compressor (if it’s operable) for a
few seconds. This will get the refrigerant moving to another part of the system.
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HOSES AND VALVES
Hoses and Schraeder valves have a large impact on recovery speed. In general, the
larger the hose, the less friction on the flow of refrigerant, the quicker the recovery time.
Many contractors are now using 3/8” lines for the inlet to the recovery machine, even if
those lines originate out of 1/4” fittings.
Schraeder valves must be removed from the connection prior to an expedient
recovery. Most wholesalers sell a tool for removing these cores, while keeping the
connection sealed. The core depressor, in the end of the hose, should also be
removed. These two items can turn a 20 minute job into one that goes on for hours. So,
be sure to remove Schraeder valves and core depressors before every recovery job.
Another hose consideration is the little rubber grommet at the end of the hose that
makes a seal with the flare fitting. We’ve seen these seals so worn and deformed that
when the hose is connected to the flare fitting the grommet virtually seals off the the
connection. This is probably never noticed in charging, because the pressure opens the
grommet, but during recovery (or with suction) the deformed grommet severely restricts
the flow of refrigerant.
Refrigerant Recycling
Current regulations state that used refrigerant shall not be sold, or used in a different
owner’s equipment, unless the refrigerant has been laboratory analyzed and found to
meet the requirements of ARI 700 (latest edition). As a result, recycling and verifying
ARI 700 conformance isn’t economically justified in most cases. It’s still a great idea to
do as much cleaning of refrigerant going back into the same system (or owners
system) as possible. We recommend using the largest, high-acid capacity filter that are
economically feasIble. Put these filters on the suction or inlet side of the recovery unit.
Change filters often.
The recovery of large amounts of liquid refrigerant can sometimes carry with it large
quantities of oil, if the system being serviced doesn’t have an adequate oil separator
installed. If this recovered refrigerant isn’t going to be liquid charged back into the same
system, you might want to separate the refrigerant from the oil in order to
measure the oil (to know how much oil to charge back into the system). However
refrigerant sent back for reclaim does not need to have the oil removed. One of the
simplest and most cost effective ways to achieve this is to use a 30 or 50 lb. tank in line
with your recovery machine. Connect the the system to the liquid valve of the tank then
from the vapor valve of the tank connect to the inlet of your recovery machine a second
tank, for storing refrigerant, should then be connected to the outlet of the recovery
machine. If you encounter large amounts of liquid you will need to put a band heater
around the first tank.
When the recovery job is complete the oil can be removed, from the first tank, by
applying a small amount of pressure, using nitrogen, to one of the valves and
expressing the oil from the other. If you are going to remove the oil from the vapor valve
you will need to turn the tank upside down. Always wear safety glasses when
performing this operation as the oil may be acidic and could cause severe burning.
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KEEPING THE DIRT OUT
During the recovery process your recovery machine can be exposed to debris that can,
potentially, damage it. Including brazing spatter and copper and brass slithers. Further
contamination can be introduced from the refrigerant storage tanks. To
prolong the life of your recovery machine always use an in-line filter.
Whenever you are charging a system from a recovery cylinder it is a good idea to use
an in-line filter to protect the system from contamination. Again, change your
in-line filters often.
Getting the Liquid Out (See “Push/Pull-Method”)
Push-pull is a method of removing bulk liquid from a system using the pressure
differential created by the recovery machine. Push-pull will generally not work on
smaller systems because there is no bulk liquid reservoir to create a siphon from.
Push-pull is mostly used on systems with a receiver tank or those with greater than 20
lbs. of refrigerant, or when transferring from one tank to another. The rate of liquid
transfer is very much dependent on hose size, with larger hoses providing much
better throughput.
Another trick is to chill the tank, if it’s partially filled, prior or during recovery. This
operation will lower the pressure in the storage tank and therefore speed up recovery.
There must be a minimum of 5 lbs of liquid refrigerant in the tank you wish to chill. This
operation can be performed prior to or during the recovery. See the two set up
diagrams and procedures on page 8 of this manual.
There is nothing magic here, you are simply using your recovery machine to make a
refrigerator where the tank is the evaporator. By throttling the outlet valve, you’re
effectively creating a capillary tube or an expansion device, but you need to adjust the
back pressure to suit the conditions and the refrigerant. Five to ten minutes of chilling
can produce some very dramatic tank cooling, depending on the conditions. If there are
any non condensibles in the tank this process will not work. Also the greater the
quantity of refrigerant in the tank the longer the process will take.
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TROUBLESHOOTING YOUR RG3000-E
The safe way is the only way
Read and understand all safety information
contained in this manual before servicing the
unit.
CONNECT UNIT TO
230V/50HZ POWER
SUPPLY
MOTOR RUNS WHEN
POWER SWITCH IS
TURNED ON
POWER SUPPLY
OK?
CIRCUIT BREAKER
UNIT PUMPS INTO
HIGH PRESSURE
SHUT-OFF
IS UNIT IN HIGH
PRESSURE
SHUT-OFF?
ARE VALVES
OPEN,
PRESSURE
RELEASED?
UNIT PUMPS DOWN
INTO A VACUUM?
ARE HOSE
CONNECTIONS
TIGHT, ARE
THERE LEAKS?
YES
NO
YES
YES
YES
YES
NO
NO
NO
NO
YES
TROUBLESHOOTING ENDS
CONTACT PROMAX SERVICE
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