Promax RG5410A-EXTREME User's Operating Manual

USERS OPERATING MANUAL

RG5410A-EXTREME

Advanced Test Products

Lürriper Str. 62

41065 Mönchengladbach | Germany

Tel: [phone] Fax: [phone]

www.atp-europe.de ✦ [e-mail]

Advanced Test Products RG5410A-EXTREME

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) Operational procedures

A) Operating your RG5410A-EXTREME 4-6

Use of the Low Pressure Switch 6

B) Set-up procedures 7-9
C) Purging the non-condensable gases 10

IV) Diagrams

A) Part list 11
B) Refrigerant flow diagram 12
C) Wiring diagram 13

V) 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.

REV 08-2013!

This manual may not be reproduced in any way, shape or form without express written consent of

Advanced Test Products.

Advanced Test Products RG5410A-EXTREME

1

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,

3. Always think before acting. Familiarity breeds carelessness and carelessness can
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 iit should be a minimum of 14 AWG and not longer
than 25ft.
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 RG5410A-EXTREME

2

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 STORE CONTAINERS ***

Use only approved cylinders with a minimum of 41 bar working pressure that serve 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%

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3

IMPORTANT

GENERAL INFORMATION

Before operating the RG5410A-EXTREME recovery unit, read the following:

1. Always isolate large amounts of refrigerant and close off valves after use so if a leak
should develop anywhere in the system the refrigerant does not escape.

2. Storage cylinders sometimes have valves that are not properly seated when
manufactured. Keeping caps on these valves will guard against refrigerant leakage.

3. Always operate the unit on a flat level surface.

4. Your RG5410A-EXTREME has one internal high-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.

5. WARNING! Never overfill storage tanks. Overfilling may cause tanks to explode.

6. A scale must be used to avoid overfilling the storage tank.

7. Tanks and filters should be designated 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.

8. 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.

9. When you have finished recovering from the system, flush your RG5410A­EXTREME with a small amount of refrigerant oil and a small amount of clean
refrigerant to purge off any foreign substances left in the unit.

10. Always empty refrigerant from the unit into a storage tank; see Self Purge/Auto
Evacuate procedure. Liquid refrigerant left in the condenser may expand, causing
damage to components.

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4

OPERATING YOUR RG5410A-EXTREME

Connect your RG5410A-EXTREME to a 230 V outlet. Switch the main power switch to
the ON position. You should hear the fan running. Press the compressor start switch.
This "momentary" switch will start the compressor. It may be necessary, under certain
circumstances, to press this switch more than once to start the compressor.

OPERATIONAL PROCEDURES

Do not turn this valve
while unit is running.

Close input valve, turn
machine off, switch to
Purge position and re­start machine.

VAC

SENSOR

SELECT

ON

OFF

Do not turn this valve
while unit is running.

Close input valve, turn
machine off, switch to
Purge position and re­start machine.

VAC

SENSOR

SELECT

ON

OFF

NOTE: To change from Recovery mode to Purge:

Close the Input port, turn the unit off (to prevent high pressure shutoff),
switch to Purge position and restart the unit.

NORMAL RECOVERY

SELF PURGE / AUTO EVACUATE

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5

OPERATING YOUR RG5410A-EXTREME

Procedure for Normal System Recovery

1. Inspect the RG5410A-EXTREME thoroughly to insure that it is in good operating
condition.

2. Make sure all connections are correct and tight.

3. Open the liquid port of the recovery cylinder (always open valves slowly to check
hoses and connections for leaks).

4. Make sure the Recover/Purge valve is set on Recover.

5. Open the output port of the RG5410A-EXTREME.

6. Open the liquid port on the manifold gauge set; opening the liquid port will remove
the liquid from the system first, greatly reducing the recovery time (after the liquid
has been removed, open the manifold vapor port to finish evacuating the system).

7. Connect your RG5410A-EXTREME to a 230 V outlet.

a) Switch the main power switch to the ON position. You should hear the
fan running.
b) Press the compressor start switch. This "momentary" switch will start
the compressor (it may be necessary, under certain circumstances, to
press this switch more than once to start the compressor).

8. Slowly open the input port on the RG5410A-EXTREME.
a) If the compressor starts to knock, slowly throttle back the input valve
until the knocking stops.
b) If the input valve was throttled back, it should be fully opened once the
liquid has been removed from the system (the manifold vapor port
should also be opened at this time).

9. Run until minimum EPA required vacuum is achieved.
a) Close the manifold vapor and liquid ports.
b) Close the RG5410A-EXTREME input port.
c) Shut unit off and proceed with the Self Purge procedure on the next
page.

10. Always purge the RG5410A-EXTREME after each use. Failure to purge the
remaining refrigerant from the RG5410A-EXTREME could result in the acidic
degradation of internal components, ultimately causing premature failure of the unit.

CAUTION

When pumping liquid, do not allow the RG5410A-EXTREME to operate with the
input valve too far open, causing the compressor to knock. Doing so may stall the
compressor.

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6

OPERATING YOUR RG5410A-EXTREME

Procedure for Purging Remaining Refrigerant From the RG5410A-EXTREME

1. Close the ports of the system being serviced that are connected to the input
port of the RG5410A-EXTREME.

2. Close the input port on the RG5410A-EXTREME.

3. Turn off RG5410A-EXTREME.

4. Turn the Recover/Purge valve to the purge position.

5. Restart the RG5410A-EXTREME.

6. Run until desired vacuum is achieved.

7. Close the ports on the recovery tank and the RG5410A-EXTREME.

8. Turn the RG5410A-EXTREME off.

9. Return the Recover/Purge valve to the recover position.

10. Disconnect and store all hoses.

11. Replace the in-line filter on your RG5410A-EXTREME after every time excessive
contaminant is encountered.

The use of the Low Pressure Switch

The RG5410A-EXTREME is equipped with a low pressure switch which is selectable
ON/OFF (VAC SENSOR SELECT). When the low pressure switch is switched ON the
unit will automatically switch off at 0,45 bar absolute. When the Low pressure Switch is
switched OFF the unit will continue to pump down the system even when the vacuum
stage has been reached.

VAC

SENSOR

SELECT

ON

OFF

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7

RG5410A-EXTREME 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 3’0” is recommend. Always remove all unnecessary hose core
depressors and Schrader valves from port connections (using the proper valve core
tool) for maximum throughput. Deformed rubber seals and core depressors in hoses
and faulty or unnecessary Schrader 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

INPUT

OUTPUT

VAPOR

LIQUID

To start you must have a minimum of
2,5 kg of liquid refrigerant in the tank.

Throttle the output valve so that the
output pressure is 7 bar (100 psi)
greater than the input pressure, but
never more than 31,5 bar (450 psi).

Run until the tank is cold.

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8

SET-UP DIAGRAM FOR REFRIGERANT RECOVERY

This method is the fastest method for recovering vapor refrigerant.

MANIFOLD GAUGE SET

(OPTIONAL) MOISTURE

SIGHT GLASS

INPUT

OUTPUT

LIQUID

A scale must be used
to avoid overfilling the
storage tank.

SYSTEM

BEING

SERVICED

VAPOR

LIQUID

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.

SYSTEM

BEING

SERVICED

LIQUID
VAPOR

VAPOR

LIQUID
OUTPUT

OPTIONAL MOISTURE

INDICATING SIGHT GLASS

INPUT

The sight glass is used to provide a method of
determining the moisture content and quality of a
system’s refrigerant.

A scale must be
used to avoid
overfilling the
storage tank.

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OPTIONAL RECOVERY / TANK PRE OR SUB

COOLING FOR FIXED HOSE SET UP

SYSTEM

BEING

SERVICED

LIQUID
VAPOR

VAPOR

LIQUID
MANIFOLD GAUGE SET

INPUT

OUTPUT

A scale must be used
to avoid overfilling the
storage tank.

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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10

RG5410A-EXTREME 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 output 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 port 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 port 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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11

PARTS LIST RG5410A-EXTREME

Pos. Description Part No.

1 Plastic case 111-200119-TAB

2 Fan grill 100505

3 Axial fan EL1818

4 Condenser CD1201

5 Motor 105-200446-001

6 Coupler 534483

7 Bell housing CP1001

8 Compressor 535398ASM

9 Fuse – 5x20mm 140-200347-001

10 Input gauge 534487

11 Output gauge 534488

12 Gauge lens GA1000

13 ON/OFF switch EL1310

14 Start switch EL1309

15 Blue knob 100123

16 Red knob 100124

17 Black knob 100122

18 Front panel 110-201120-001

19 Filter 100343

20 Flare cap NB6501

21 Power cord 135-200341-001

22 High Pressure switch 100339

23 Rear panel 536762

24 Select Switch 105-200396-001

25 Compressor Bracket 100207

26 Manifold 105-200808-001

27 Hose 4“ 100345

28 Fuse holder 100419

29 VAC Sensor 113726

- Check Valve 116418

- Run Capacitor 536755

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12

REFRIGERANT FLOW DIAGRAM

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 RG5410A-EXTREME 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.

INPUT

CONDENSER

COMPRESSOR

MOTOR

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13

Plug AC Male

Power switch

High pressure switch

Fan motor

3 pin connector for

up-grade

1/2 HP motor

wht

wht

brn

red

3

2

1

6

RG5410A-EXTREME WIRING

DIAGRAM

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14

SAFETY PRESSURE SWITCH (WITH

MANUAL RESET FUNCTION)

The RG5410A-EXTREME is equipped with an internal 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 whilst 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 output line
from the RG5410A-EXTREME. Proceed as normal after resetting the Safety Pressure
Switch (see below).

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 RG5410A-EXTREME valves.

3) Disconnect RG5410A-EXTREME from flexible pipes.

4) Disconnect RG5410A-EXTREME from the power supply.

5) Open the input and output valves very slowly.

6) Investigate the reason for the failure.

Once activated the Safety Pressure Switch has to be reset manually as follows:

I) Remove the black protection cover to reveal the reset button (see picture below).
II) Reset by pushing the reset button with a tool such as a screwdriver.
III) Replace the cover.

Remove this part in order to
Reset the pressure switch.

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15

CARE AND MAINTENANCE OF YOUR

RG5410A-EXTREME

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 RG5410A-EXTREME 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 14 AWG and not longer than 25 ft. 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 RG5410A-EXTREME,
insure that it is disconnected from the power supply before you begin.

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16

TECHNICAL SPECIFICATIONS

Type RG5410A-EXTREME

Application Refrigerant recovery Gas or Vapor

Suitable refrigerants R12, R22, R134A, R401A, R401B, R401C, R402A, R402B,

R404A, R406A, R407A, R407B, R407C, R407D, R408A,
R409A, R410A, R411A, R411B, R412A, R500, R502, R507,
R509

Power Source 230V / 50 Hz

Power 380 W

Dimensions 330 x 229 x 483 mm

Weight 14,5 kg

RPM´s 1437 U/min

Max. working pressure 550 p.s.i. (38,5 bar)

Fuse 5x20mm, slow blow, 8A 250V

Safety Device Safety pressure switch type P100 DA
with manual reset (550 p.s.i. / 38,5 bar)

ATTENTION

The RG5410A-EXTREME should not be used with inflammable gases
nor with gases containing ammonia.

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17

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 ports at their lowest points. If some units you’re servicing are on
maintenance contracts, you would save significant time by installing access ports at all
of the lowest points in the system, where liquid is likely to accumulate. Since most
systems don’t have these ports you need to be prepared to boil of 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 and in.

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18

HOSES AND VALVES

Hoses and Schrader valves have a large impact on recovery speed. In general, the
larger the hose, the less friction on the flow of refrigerant and the quicker the recovery
time. Many contractors are now using 3/8” lines for the input to the recovery machine,
even if those lines originate out of 1/4” fittings.
Schrader 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 Schrader 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 worm 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 port of the tank then
from the vapor port of the tank connect to the input of your recovery machine a second
tank, for storing refrigerant, should then be connected to the output 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 ports and
expressing the oil from the other. If you are going to remove the oil from the vapor port
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 output valve, you’re
effectively creating a capillary tube or an expansion device, but you need to adjust the
backpressure 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-condensable 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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20

TROUBLESHOOTING YOUR

RG5410A-EXTREME

The safe way is the only way

Read and understand all safety information contained in this manual

before servicing the unit.

Connect unit to 220 V outlet

Fan is running when power

switch is in "ON" position?

Compressor starts when

start switch is pressed

Unit pumps into high

pressure shut off?

Power supply ok?

TROUBLESHOOTING ENDS

Are your hoses tight? Do

you have leaks?

Unit pulls into a vacuum?

Is unit in high pressure shut

off?

Are valves open?

Reset button pushed?

yes

no

yes

yes

no

ye

no

yes

yesnoyes

no

j

yes

yes

C
O
N
T
A
C
T

P
R
O
M
A
X

S
E
R
V
I
C
E

BENUTZERHANDBUCH

RG5410A-EXTREME

Advanced Test Products RG5410A-EXTREME

2

INHALTSVERZEICHNIS

I) Sicherheitshinweise

A) Sicherheit ist oberstes Gebot 1
B) Kältemittelabsaugungs- und Serviceverfahren 2

II) Wichtige allgemeine Informationen 3

III) Betriebsverfahren

A) Betrieb des RG5410A-EXTREME 4-6

Gebrauch des Niederdruckschalters 6

B) Aufbau / Anschluss 7-9
C) Evakuierung der nicht kondensierbaren Gase 10

IV) Pläne und Listen

A) Teileliste 11
B) Kältemittel-Flussdiagramm 12
C) Schaltplan 13

V) Sicherheitsdruckbegrenzer (SDBK) 14

VI) Pflege und Wartung 15

VII) Technische Daten 16

VIII) Nützliche Hinweise zur Kältemittelabsaugung 17-20

IX) Störungssuche 21

X) Garantie 22

Irrtum sowie Änderungen der technischen Daten und Materialien ohne vorherige Ankündigung

vorbehalten.

Dieses Handbuch darf ohne ausdrückliche schriftliche Genehmigung von ADVANCED TEST

PRODUCTS auf keinerlei Weise und in keiner Form vervielfältigt werde.

Advanced Test Products RG5410A-EXTREME

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SICHERHEIT IST OBERSTES GEBOT

HINWEIS: Nur sachkundige, im Umgang mit Kältemitteln geschulte Personen

dürfen dieses Gerät bedienen.

1. Bei Arbeiten an Kälteanlagen sind stets Schutzbrille und Handschuhe zu tragen.

2. Die Räume, in denen das Gerät betrieben wird, müssen gut belüftet sein, vor allem

bei Verdacht auf ein Leck. Kältemitteldämpfe sind gesundheitsschädlich und
möglicherweise tödlich.

3. Zuerst denken, dann handeln! Vertrautheit mit einem Gerät verführt zu Unauf­merksamkeit, und Unaufmerksamkeit kann zu Gesundheitsschäden oder gar zum
Tode führen.

4. Lesen Sie die Sicherheitsdatenblätter sämtlicher Verbindungen durch, mit denen
Sie in Kontakt kommen können. Lesen Sie die Sicherheitsdatenblätter des Kälte­mittels und Kältemaschinenöls. Sicherheitsdatenblätter können Sie von Ihrem
Kältemittellieferanten anfordern.

5. Verwenden Sie niemals Sauerstoff zur Prüfung auf Lecks. Jede Art von Öl, die in
Kontakt mit unter Druck stehendem Sauerstoff gelangt, ergibt eine explosive
Mischung.

6. Kälteanlagen werden im allgemeinen elektrisch betrieben und gesteuert. Trennen
Sie die Anlage vor der Ausführung von Wartungsarbeiten vom Netz.

7. Kältemittelbehälter sind stets an einem kühlen, trockenen Ort aufzubewahren.

8. Service- und Flaschenventile sind stets langsam zu öffnen. Besteht eine Gefahr,
kann der Gasfluß schnell unterbunden werden. Steht fest, daß keine Gefahr
besteht, können die Ventile vollständig geöffnet werden.

9. Unterschiedliche Kältemittel dürfen weder in Anlagen noch in Flaschen noch sons
gemischt werden. Für jedes Kältemittel ist eine eigene Flasche, ein eigener Filter
usw. erforderlich.

10. Tritt Feuchtigkeit in eine Kälteanlage ein, kann dies beträchtliche Schäden verur­sachen. Sämtliche Teile der Kälteanlage sind stets trocken und sauber zu halten.

11. Um das Risiko von Bränden zu verringern sollten Sie keine Verlängerungskabel
verwenden, da sich diese überhitzen können. Sollte es jedoch unumgänglich sein,
ein Verlängerungskabel zu verwenden, so sollte dieses ein Minimum von 14 AWG
besitzen (Querschnittsfläche Kabel: 2 mm²) und nicht länger als 7,5m sein. Dieses
Gerät darf in Räumen eingesetzt werden, bei denen durch mechanische
Lüftungsmaßnahmen mindestens vier Luftwechsel in der Stunde gewährleistet sind,
oder das Gerät muss sich mindestens 45 cm oberhalb des Bodens befinden.
Dieses Gerät darf nicht in der Nähe von verschüttetem Benzin oder offenen
Behältern mit Benzin oder anderen brennbaren Flüssigkeiten eingesetzt werden.

Advanced Test Products RG5410A-EXTREME

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RG5410A-EXTREME

KÄLTEMITTELABSAUGUNGS- UND

SERVICEVERFAHREN

Sicherheit steht an erster Stelle. Lesen Sie alle Sicherheitsinformationen zur sicheren
Handhabung von Kältemitteln sowie die Sicherheitsblätter Ihres Kältemittellieferanten
durch. Der Betrieb des Gerätes in explosionsgefährdeten Umgebungen ist unzulässig.
Tragen Sie stets Schutzbrille und Schutzhandschuhe. Das Gerät darf nur in gut
belüfteten Räumen betrieben werden. Nur sachkundige, im Umgang mit Kältemitteln
geschulte Personen dürfen dieses Gerät bedienen.

*** VORSICHT: KÄLTEMITTELFLASCHEN ***

Nur zugelassene und geprüfte, den relevanten Normen entsprechende Flaschen mit
einem zulässigen Betriebsdruck von mindestens 41 bar dürfen verwendet werden.

HINWEIS: Kältemittel- und Recyclingflaschen sind für unterschiedliche Drücke
ausgelegt. Der Arbeitsdruck der Flaschen darf nicht überschritten werden.

Die Sicherheitsvorschriften empfehlen, geschlossene Flaschen zu nicht mehr als 80%
ihres Volumens mit Flüssigkeit zu füllen. Die restlichen 20% werden als Kopfraum
bezeichnet.

DER TRANSPORT ÜBERFÜLLTER KÄLTEMITTELFLASCHEN IST UNZULÄSSIG.

Kältemittel dehnen sich bei Erwärmung aus – überfüllte Flaschen können bersten.

FLASCHENTEMP. 16 °C 21 °C 38 °C 54 °C 66 °C

AUSGANGS­FÜLLUNG
80 VOL%

FLÜSSIGKEITS­FÜLLGRAD

AUSGANGS­FÜLLUNG
90 VOL%

FLÜSSIGKEITS­FÜLLGRAD

80 % 81% 83% 90% 94%

90% 92% 96% 100%

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WICHTIGE ALLGEMEINE

INFORMATIONEN

Vor Betrieb des Absaugerätes RG5410A-EXTREME sind unbedingt folgende
Informationen durchzulesen:

1. Große Kältemittelmengen sollten isoliert werden, und nach Gebrauch sollten die

Ventile geschlossen werden, so daß im Falle eines Lecks in der Anlage kein
Kältemittel austreten kann.

2. Neue Kältemittelflaschen werden in einigen Fällen mit nicht richtig sitzenden Ventilen

geliefert. Kappen auf solchen Ventilen können das Austreten von Kältemittel
verhindern.

3. Das Gerät ist stets auf einer ebenen Fläche zu betreiben.

4. Das RG5410A-EXTREME ist mit einem internen Sicherheitsdruckbegrenzer

ausgerüstet. Überschreitet der Druck im System 38,5 bar, wird das System
automatisch abgeschaltet.

ACHTUNG

Auch ein Sicherheitsdruckbegrenzer (SDBK) kann die Überfüllung der Flasche
nicht verhindern. Wird das System bei hohen Drücken abgeschaltet und ist mit
einer Flasche verbunden, wurde die Flasche möglicherweise überfüllt. Dies ist ein
äußerst gefährlicher Zustand ! Maßnahmen zum Abbau des Überdrucks und/oder
zur Beseitigung der Überfüllung sind sofort zu treffen.

5. WARNUNG! Kältemittelflaschen dürfen niemals überfüllt werden. Überfüllung kann

zum Bersten der Flaschen führen.

6. Während des Absaugvorganges müssen Kältemittelflaschen gewogen werden um

ein Überfüllen der Flaschen auszuschließen.

7. Flaschen dürfen nur für jeweils ein Kältemittel verwendet werden. Bevor Sie eine

Flasche verwenden, die zuvor für ein anderes Kältemittel verwendet wurde, ist die
Flasche vollständig zu entleeren und zu evakuieren. Anschließend ist die Flasche mit
trockenem Stickstoff zu spülen und erneut zu evakuieren.

8. Bei der Absaugung einer ausgebrannten Anlage ist besondere Vorsicht geboten. In

solchen Fällen sind zwei in Serie geschaltete Filter mit hoher Säurekapazität zu
verwenden. Empfohlen werden Filter des Typs C-162-F von Sporlan. (Promax
Teil Nr. FL-1201)

9. Nach beendigter Absaugung ist das RG5410A-EXTREME mit einer geringen Menge

Kältemaschinenöl und einer geringen Menge sauberen Kältemittels zu spülen, um im
Gerät verbliebene Fremdsubstanzen zu entfernen.

10.Kältemittel ist stets aus dem Gerät in eine Flasche zu pumpen. Im Verdichter

verbleibendes Kältemittel kann sich ausdehnen und das Gerät beschädigen.

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BETRIEB DES RG5410A-EXTREME

Schließen Sie das RG5410A-EXTREME an eine 230 V-Steckdose an. Schalten Sie den
Netzschalter ein (ON-Position). Der Lüfter läuft. Drücken Sie zum Starten des
Kompressors den Kompressor-Starttaster. In manchen Fällen ist es eventuell
erforderlich, diesen Taster mehrmals zu drücken, um den Kompressor zu starten.

BETRIEBSARTEN

Das schwarze Ventil darf
bei laufendem Gerät
nicht betätigt werden.

Einlassventil schließen,
Gerät ausschalten.

In Purge-Position
schalten und Gerät
erneut starten.

Das schwarze Ventil darf
bei laufendem Gerät
nicht betätigt werden.

Einlassventil schließen,
Gerät ausschalten.

In Purge-Position
schalten und Gerät
erneut starten.

HINWEIS: Wechsel vom Absaug- zum Spülmodus:

Einlaßventil schließen, Gerät ausschalten (um Hochdruckabschaltung zu
vermeiden), auf Spülposition (PURGE) umschalten und Gerät erneut starten.

NORMALES ABSAUGEN

SELBSTSPÜLUNG / AUT. EVAKUIERUNG

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BETRIEB DES RG5410A-EXTREME

Betriebsart RECOVER: („normales Absaugen von Kältemittel“)

1. Vergewissern Sie sich, daß das RG5410A-EXTREME keine äußeren Schäden

aufweist.

2. Stellen Sie sicher, daß alle Anschlüsse und Verbindungen korrekt und fest

angeschlossen sind.

3. Stellen Sie sicher, daß das „Recover/Purge“ Ventil auf Recover eingestellt ist.

4. Öffnen Sie die Ventile des zu wartenden Systems langsam.

5. Öffnen Sie das Flüssigkeitsventil der Manometerventil.

6. Stellen Sie das Einlaßventil am RG5410A-EXTREME auf die Position „Liquid“
(flüssig.

7. Stellen Sie das Auslassventil am RG5410A-EXTREME auf die Position „OPEN“
(offen.

8. Öffnen Sie das Flüssigkeitsventil der Kältemittelflasche.

9. Schließen Sie das RG5410A-EXTREME an eine 230V Spannungsquelle an.
a)Stellen Sie den Netzschalter des RG5410A-EXTREME in die Position
„ON“, dadurch wird zunächst nur der Ventilator aktiviert.
b) Drücken Sie nun den Kompressor-Starttaster um das RG5410A­EXTREME in Betrieb zu setzen.

10. Nachdem Sie sich überzeugt haben das alles ordnungsgemäß funktioniert, sollten
Sie das Einlaßventil des RG5410A-EXTREME langsam in die Stellung „OPEN“
drehen, jedoch nur soweit, dass kein lautes Schlagen (Klopfen) auftritt. Dieses
Schlagen bzw. Klopfen des Kompressors tritt nur dann auf, wenn der Verdichter
zuviel Flüssigkeit pumpt.

11. Betreiben Sie das RG5410A-EXTREME bis das erforderliche Vakuum erreicht wird.

12. Nach der Beendigung der Kältemittelabsaugung sollte auch das RG5410A­EXTREME vom Kältemittel befreit werden (siehe Funktion „Selbstentsorgung
/Purge“).

ACHTUNG

Beim Absaugen von flüssigem Kältemittel sollte das Einlaßventil nicht zu weit
geöffnet werden da es sonst zu lauten Schlägen (Klopfen) des Kompressors
kommen kann. Dieses Schlagen bzw. Klopfen des Kompressors tritt nur dann auf
wenn der Verdichter zu viel Flüssigkeit pumpt, dadurch kann der Motor
abgewürgt werden.

Advanced Test Products RG5410A-EXTREME

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BETRIEB DES RG5410A-EXTREME

Betriebsart PURGE : („Evakuierung verbliebener Kältemittelreste im RG5410A­EXTREME“)

1. Schließen Sie die Ventile des zu wartenden Systems welches am Einlaßventil des

RG5410A-EXTREME angeschlossen ist.

2. Schließen Sie das Einlaßventil am RG5410A-EXTREME (Position „CLOSED“).

3. Schalten Sie das RG5410A-EXTREME aus.

4. Stellen Sie nun das „Recover/Purge“ Ventil auf Position PURGE.

5. Starten Sie nun das RG5410A-EXTREME.

6. Betreiben Sie das RG5410A-EXTREME bis das gewünschte Vakuum erreicht ist.

7. Schließen Sie das Flüssigkeitsventil der Kältemittelflasche.

8. Schließen das Auslassventil am RG5410A-EXTREME (Position „CLOSED“).

9. Schalten Sie das RG5410A-EXTREME ab.

10. Stellen Sie nun das „Recover/Purge“ Ventil wieder auf Position RECOVER.

11. Entfernen Sie alle Zuleitungen vom RG5410A-EXTREME.

12. Wechseln Sie nach jedem Absaugen stark verschmutzter Kältemittel immer den
Einlassfilter am RG5410A-EXTREME.

Die Bedienung des

Niederdruckschalters

Das RG5410A-EXTREME ist mit einem Niederdruckschalter ausgerüstet, den man bei
Bedarf ein- bzw. ausschalten kann (ON/OFF VAC SENSOR SELECT). Bei aktiviertem
Nieder-druckschalter schaltet das Gerät bei einem Druck von 0,45 bar absolut ab. Ist
der Niederdruckschalter ausgeschaltet, saugt das Gerät auch nach Erreichen dieses
Druckniveaus kontinuierlich weiter.

VAC

SENSOR

SELECT

ON

OFF