Robinair 178012K User Manual
Operating Manual, Model 178002K/178012K
Recovery/Recycling/Recharging Unit
For Multiple Refrigerants............................................. 1
SPN–Manual Operativo Modelo 178002K/178012K
Unidad de Recuperación/Reciclado/Recarga para
Refrigerantes Múltiples ............................................... 44
FRN–Manuel de Fonctionnement Modèle 178002K/
178012K
Unité de Récupération/Recyclage/Recharge pour
Réfrigérants Multiples ................................................. 88
DEU–Bedienungs-anleitungen178002K/178012K
Station für das Rückgewinnen/Recyclen/Füllen von
Kältemittel ................................................................... 132
ITAL–Manuale Operativo Modello 178002K/178012K
Unità di Recupero/Riciclo/Ricarica per Refrigeranti
Multipli ......................................................................... 176
LISTED
80S2
Design Certified by
Underwriters
Laboratories Inc.,®
for Compliance with
SAE J1770.
Refrigerant Recovery,
Recycling, Recharging Unit
Model: 178002K/178012K
Refrigerants: R-12, R-134a,
R-22, R-500 and R-502
WARNING
PRESSURIZED TANK CONTAINS LIQUID REFRIGERANT. OVERFILLING OF THE TANK MAY CAUSE VIOLENT
EXPLOSION AND POSSIBLE INJURY OR DEATH. Safety devices require the use of only authorized refillable refrigerant
tanks. This includes Robinair part numbers 17506 and 34750 (50-lb. tanks). Do not recover refrigerants into a non-refillable
storage container! Federal regulations require refrigerant to be transported only in containers meeting DOT spec. 4BW or
DOT spec. 4BA.
ALL HOSES MAY CONTAIN LIQUID REFRIGERANT UNDER PRESSURE. Contact with refrigerant may cause injury.
Wear proper protective equipment, including safety goggles. Disconnect hoses with extreme caution.
HIGH VOLTAGE ELECTRICITY INSIDE PANELS. RISK OF ELECTRICAL SHOCK. Disconnect power before servicing
unit. Refer to the instruction manual.
TO REDUCE THE RISK OF FIRE, avoid the use of an extension cord because the
extension cord may overheat. However, if you must use an extension cord, the cord shall be No. 14 AWG minimum and
keep the cord as short as possible. Do not use this equipment in the vicinity of spilled or open containers of gasoline or
other flammable substances.
For use in non-hazardous locations. Disconnect power before servicing.
Use this equipment in locations with mechanical ventilation that provides at least four air changes per hour or locate the
equipment at least 18 inches above the floor.
Make certain that all safety devices are functioning properly before operating the unit. Before operating, read and follow the
instructions and warnings in the operating manual.
CAUTION: SHOULD BE OPERATED BY QUALIFIED PERSONNEL. Operator must be familiar with air conditioning and
refrigeration systems, refrigerants and the dangers of pressurized components.
This equipment is not designed for any other purpose than recovering or recycling refrigerants!
Do not mix refrigerant types!
ATTENTION!
Ce réservoir sous pression contient du frigorigène liquide. S’il est surchargé, ce réservoir peut exploser et causer des
blessures ou la mort.
A utiliser dons des endroits non dangereux. Débrancher la prise de courant avant l’entretien.
ATTENTION. Débrancher avant la maintenance.
ATTENTION. Pour réduire les risques d’incendie, ne pas utiliser de cordon prolongateur de section inférieure à 14 AWG de
facon à éviter la surchauffe du cordon.
ATTENTION. Utiliser seulement du frigorigène R-12, R-134a, R-22, R-500 et R-502.
OPERATING NOTES
Drain the System Oil Separator at the end of each recovery. The display will indicate when a filter-drier and compressor oil
change are required except if you are recovering from a burn-out system. Then the filter-drier and compressor oil should
be changed at the completion of that job. When switching refrigerant types, the unit should always be self-cleared.
Non-condensables can be purged from the refillable tank during the recycling procedure. Get the temperature of the
refrigerant you are recycling from the air purge gauge. Look at the pressure-temperature chart to find what the pressure
should be at that temperature and compare it to what the air purge gauge pressure is. If the pressure on the air purge
gauge exceeds the desired pressure by more than 10 psi, open the gauge for 30 seconds, then close it and re-check the
pressure. Continue as needed during the recycling procedure.
R-134a WARNINGS!
Cross-contamination with other refrigerant types will cause severe damage to the A/C system and to service tools and
equipment. Do not mix refrigerant types through a system or in the same container!
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. To remove
R-134a from the A/C system, use service equipment certified to meet the requirements of SAE J2210 (automotive R-134a
recycling equipment). If accidental system discharge occurs, ventilate work area before resuming service.
HFC-134a service equipment or vehicle A/C systems should not be pressure tested or leak tested with compressed air.
Some mixtures of air/HFC-134a have been shown to be combustible at elevated pressures. These mixtures are potentially
dangerous and may result in fire or explosion causing injury or property damage.
Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Introduction
This manual contains important safety procedures concerning the operation,
use and maintenance of this product. Failure to follow the instructions contained in this manual may result in serious injury. If you are unable to understand any of the contents of this manual, please bring it to the attention of your
supervisor. Do not operate this equipment unless you have read and understood the contents of this manual.
TABLE OF CONTENTS
Introduction ................................................................................................ 2
Glossary of Terms ............................................................................................ 2
General Operating Guidelines ........................................................................... 3
Set-Up Instructions ....................................................................................... 4
Operating Instructions ................................................................................ 10
Recovery Procedures....................................................................................... 10
Changing Refrigerant Types ............................................................................. 12
A/C System Evacuation .................................................................................. 14
Recycling Procedures ...................................................................................... 15
Charging Procedures ...................................................................................... 16
Correcting an Incomplete Transfer ..................................................................... 17
Adding Refrigerant to the Tank ......................................................................... 18
Operating Overview .................................................................................. 20
Recovery Overview ........................................................................................ 2 0
Evacuation Overview ...................................................................................... 21
Recycling Overview ........................................................................................ 21
Charging Overview ........................................................................................ 22
Maintenance Procedures ............................................................................. 23
Changing the Vacuum Pump Oil ....................................................................... 23
Changing the Filter-Drier ................................................................................. 24
Checking the Scale Accuracy ........................................................................... 26
Calibrating the Scale ...................................................................................... 26
Checking for Leaks ......................................................................................... 27
Operating Guidelines ................................................................................. 28
Using the Control Panel ................................................................................... 28
Keypad Functions ........................................................................................... 29
Using the Digital Display ................................................................................. 29
Using the Diagnostic Mode .............................................................................. 32
Using Display Codes ...................................................................................... 34
Replacement Parts...................................................................................... 36
Flow Diagram ........................................................................................... 37
Wiring Diagram ........................................................................................ 38
Troubleshooting ........................................................................................ 39
Limited Warranty....................................................................................... 42
NOTICE: Airborne Noise Emissions
This equipment has been tested for airborne noise emission per the Council
Directive for Machinery (89/392/EEC Section 1.7.4 Instructions - Essential
Health and Safety Requirements. Sound levels do not exceed 80dB(A) actual
value.
Model 178002K/178012K Recovery/Recycling/Recharging Unit
1
Introduction
The 178002K/17802KA is a complete A/C-R service center. It recovers, recycles
and recharges a wide range of refrigerants—from existing refrigerants to new
substitutes and blends. With its multi-refrigerant capabilities, it is ideal for trucks,
buses and refrigerated trailers, as well as in-plant maintenance and other accessible
installations.
The built-in manifold means the entire service procedure can be done with just one
hook-up. A microprocessor controls the unit’s functions; evacuation time and the amount
of refrigerant to be recharged can be programmed at the beginning of the job. Prompts
lead you through programming and alert you when the filter, vacuum pump oil and
compressor oil need to be changed.
This unit is UL-listed and meets the SAE specifications for recycled refrigerant. It is also
designed to be compatible with existing service equipment and standard service procedures.
This unit is simple to operate and has many user-friendly features:
• A built-in 6 cfm vacuum pump for quick, thorough evacuation.
• An electronic scale that weighs recovered refrigerant and recharges by weight for
greatest accuracy.
• A pressure/temperature chart mounted directly above the gauges—with just
a quick glance you can tell the temperatures in the system.
• A built-in shroud that keeps the tank from falling off the platform.
• Large diameter wheels that make it easy to move the unit.
• A handy storage shelf located below the control panel to hold fittings, adapters
and other tools.
IMPORTANT! To validate your warranty, complete the warranty card attached to
your unit and return it within ten days from date of purchase.
2
GLOSSARY OF TERMS
A/C-R Air conditioning or refrigeration
A/C-R System The air conditioning or refrigeration system serviced
Unit The refrigerant recovery, recycling, recharging unit
Tank The refillable refrigerant tank
© 2000 Robinair, SPX Corporation
Introduction
GENERAL OPERATING GUIDELINES
• The voltage at the unit must be ±10% of the unit’s rated voltage. Extension cords must
be a minimum of 14 AWG and kept as short as possible.
• To interrupt any procedure (other than clearing), press HOLD/CONT. Press
HOLD/CONT again to resume operation.
• The system oil should be drained at the end of every recovery or recycling procedure,
during the clearing process, or whenever oil is visible in the sight glass.
• The indicator light will tell you the state of the refrigerant coming into the unit during
recovery. ON is liquid, OFF is vapor. The light is not used for recycling since the
refrigerant coming from the tank will always be a liquid.
• Some tanks have slightly different valve configurations. Be sure to connect the red
hose to the GAS (vapor) valve and connect the blue hose to the LIQUID valve.
• To ensure that the scale readings are as accurate as possible, be sure the tank is not
touching the sides of the cart before each procedure.
• To minimize mixing of refrigerants, follow the steps in Changing Refrigerant Types
when switching between refrigerant types.
• When the unit is first turned on, the display shows either:
“134a” — Indicates R-134a automotive refrigerant using 1/2” Acme fittings.
“R12” — Indicates all other refrigerant types using 1/4” flare fittings.
“door” — Indicates the unit has been cleared; select R-12 or R-134a.
Be sure you have selected the correct refrigerant type.
• Be sure to use the correct hose set for the refrigerant type selected:
Hose Set Tank Hoses (3) System Hoses (2)
R-134a automotive 36”, 1/2” Acme with 96”, one Quick Seal
double Quick Seal with one quick coupler
R-12 automotive 36”, 1/4” flare with 96”, 1/4” flare with
double Quick Seal double Quick Seal
All other refrigerant types 36”, 1/4” flare with 96”, 1/4” flare with
single Quick Seal ball valve
• Present UL approval addresses refrigerants R-12 and R-134a. UL approval is
pending for all other refrigerants including new substitutes and blends.
Model 178002K/178012K Recovery/Recycling/Recharging Unit
3
Set-Up Instructions
Before you begin any procedure, familiarize yourself with the components
of your unit.
Lockout Box
INST0146
High Side Port
Diagram of Unit’s Components — External View
Low Side Port
Red Vapor Hose
Blue Liquid Hose
Yellow Air
Purge Hose
Tank Vapor Valve
Tank Liquid Valve
Air Purge Fitting
50 lb. (23 kg)
Unit Tank
Scale Assembly
System
Relays
Small Fan
INST0951
Diagram of Unit’s Components — Internal View
Float Chamber
Heat Exchanger
Condenser Coil
Filter-Drier
Vacuum
Pump
4
© 2000 Robinair, SPX Corporation
Sight Glass for
System Oil
Set-Up Instructions
Pressure/Temperature Chart
INST0952
Diagram of Unit’s Components — Side Views
Air Purge Gauge
Display
Main
Power
Switch
System Oil
Drain Valve
Liquid/Vapor
Indicator
Low Side
Gauge
High Side
Gauge
Keypad
Air
Purge
Valve
Low
Side
Valve
Diagram of Control Panel and Keypad
Model 178002K/178012K Recovery/Recycling/Recharging Unit
High
Side
Valve
5
Set-Up Instructions
System Oil
Separator
Return Oil
Separator
Assembly
INST0953
Diagram of Unit’s Components — Side Views
Large Fan
Compressor
Compressor
Start
Components
6
WARNING
Always wear safety goggles when working with refrigerant. Use only
authorized refillable refrigerant tanks. Disconnect hoses with extreme
caution!
All hoses may contain refrigerant under pressure. Read and follow all
warnings at the beginning of this manual before operating the unit.
© 2000 Robinair, SPX Corporation
Set-Up Instructions
Before starting the set-up procedures, open the system oil drain valve and allow the unit
to depressurize.
1. Plug the unit into a proper voltage outlet.
CAUTION! Avoid the use of an extension cord because the extension
cord may overheat. However, if you must use an extension cord, use a No.
14 AWG minimum and keep the cord length to 25 feet (7.6 meters) or less.
2. Be sure the oil drain valves on the side of the unit are in the CLOSED position.
3. Turn on the unit. The display flashes “door.” Slide the lockout panel (in the upper
left corner of the back of the unit) to expose the 1/4” flare fittings for R-12, then
press SHIFT/RESET to lock in that refrigerant type.
4. Connect the R-12 automotive hose set as follows:
• Connect the 36” red hose to the RED fitting in the lockout box.
• Connect the 36” blue hose to the
BLUE fitting in the lockout box.
• Connect the 36” yellow hose to the
HIGH
LOW
YELLOW fitting in the lockout box.
• Connect the 96” red hose to the
RED
HIGH SIDE 1/4” flare fitting in the
lockout box.
• Connect the 96” blue hose to the
BLUE
YELLOW
LOW SIDE 1/4” flare fitting in the
lockout box.
INST0159
Diagram of Hose Connections — Lockout Box
CAUTION! R-134a automotive systems have
1
/2” Acme fittings (per
(R-134a shown—
R-12 same order
and colors)
SAE specifications) to avoid cross-contamination with systems using
1
/4” flare fittings. Do not attempt to adapt your unit for the other refrigerant
— system failure will result!
Important!
Because the
filter-drier has
only one access
port using a 1/4”
flare fitting, you
must initially set
up the unit for
R-12.
Model 178002K/178012K Recovery/Recycling/Recharging Unit
7
Set-Up Instructions
5. A new tank comes with a dry nitrogen charge of 5 to 10 psi to keep it clean and
dry during shipment. Purge the nitrogen charge on the R-12 (gray and yellow) tank
by opening the GAS (vapor) valve on the tank. Vent the pressure to the atmo-
sphere, then close the valve.
6. Center the unit tank on the scale platform on the back of the unit inside the tank
restraint shroud.
7. Install the filter-drier by loosening the large nut on top of the filter shell and rotating
the cap counter-clockwise. Pull the spring out and insert the filter-drier with the flat
gasket end first. Put the spring on top, and replace the cap. Torque the nut to 300
in. lbs.
8. Remove the black plastic cap from the filter-drier access fitting.
9. Connect the 96” blue low side hose from the back of the unit to the access fitting on
the cap of the filter-drier. Connect the 96” red high side hose to the air purge fitting
on the tank. Connect the 36” red hose to the red valve on the tank and open the
valve. Connect the 36” blue hose to the blue valve on the tank and open the valve.
10. Open both the low and high side valves on the control panel.
Important!
Generously lubricate the O-ring and
flat rubber gasket on the filter-drier
and the O-ring on the cap with
vacuum grease before installing.
8
INST0151
Diagram of Filter-Drier Installation
© 2000 Robinair, SPX Corporation
Set-Up Instructions
The vacuum pump is shipped without oil in the reservoir. Before starting the unit, you
must fill the pump with oil. Two 16-ounce (472 milliliters) bottles of oil are included with
your unit.
11. Remove the black plastic plug from the pump’s oil fill port. Attach the flexible spout
and cap to the bottle of oil included with your unit. This makes it easier to fill the
pump.
12. Add one-half of a bottle of vacuum pump oil to the vacuum pump.
13. Press SHIFT/RESET and ENTER at the same time, then press “VACUUM.”
The vacuum pump will start and run continuously. While the pump is running, pour
oil into the pump’s oil fill port until the level of oil is even with the line of the pump
reservoir sight glass. Replace the black plug on the oil fill port.
14. Let the pump run for about five (5) minutes to remove any air from the unit.
15. To turn off the pump, press HOLD/CONT. Then press SHIFT/RESET to exit
the diagnostics mode.
Important!
Be sure the
pump is running
when adding oil.
Do not overfill
the pump. The
approximate oil
charge is 13 oz.
(384 milliliters).
16. Disconnect the blue 96” hose from the filter housing fitting on the unit. Disconnect
the red 96” hose from the air purge fitting on the tank.
17. Connect the 36” yellow hose to the air purge fitting on the tank.
18. Replace the black cap on the filter housing fitting.
Before using a new tank, you must purge its nitrogen charge and pull it into a vacuum.
Oil Filler Tube
Pump Exhaust
Inlet
Oil Fill Port
Sight Glass
Important!
For an R-134a
tank, connect the
36" yellow hose
to the RED High
Side Service
Hose Port.
Connect the
other end to the
air purge valve
on the tank.
Diagram of Vacuum Pump Components
Model 178002K/178012K Recovery/Recycling/Recharging Unit
Oil Drain
Fitting
9
Operating Instructions
RECOVERY PROCEDURES
Always wear safety goggles when working with refrigerant. Use only
authorized refillable refrigerant tanks. Disconnect hoses with extreme
caution!
All hoses may contain refrigerant under pressure. Read and follow all
warnings at the beginning of this manual before operating the unit.
Before beginning recovery, be sure your unit is set up as described in the Set-Up
Instructions. Also be sure there is vacuum pump oil in the vacuum pump.
1. Connect the high and low side hoses to the A/C-R system, as you would normally
connect your manifold gauge set.
2. Be sure both the high and low side valves on the control panel are open. Also be
sure both valves on the tank are open.
WARNING!
3. Plug the unit into the proper voltage outlet, and turn on the MAIN POWER
switch. The display shows either “134a” (which indicates R-134a automotive
refrigerant that uses 1/2” Acme fittings) or “R12” (which indicates all other refrigerant types that use 1/4” flare fittings).
4. Press SHIFT/RESET, then press RECOVER.
Air Purge Gauge
Display
Main
Power
Switch
Liquid/Vapor
Indicator
Low Side
Gauge
High Side
Gauge
10
Keypad
Diagram of Control Panel
Air
Purge
Valve
Low
Side
Valve
High
Side
Valve
© 2000 Robinair, SPX Corporation
Operating Instructions
The “CL-L” message shows on the display if there is pressure in the unit, and a selfclearing process of the components begins. You can press HOLD/CONT to bypass
clearing if an accurate recovery amount is not required. Otherwise, the compressor will
start and the “CL-L” message remains on the display. This process takes from 20
seconds to four minutes to complete. Once the clearing is complete, the unit automatically begins to recover refrigerant from the system. If there is no internal pressure in the
unit, refrigerant recovery begins immediately.
CAUTION! If the A/C system pressure is 25 psi or less, the message
“CH-P” appears on the display to alert you not to attempt recovery from an
empty system. Do not press HOLD/CONT to continue the recovery process
unless you know the A/C system contains refrigerant.
The display shows that the unit is in the RECOVER mode and the AUTOMATIC cycle.
You can monitor the amount of refrigerant removed from the system by watching the
display. The compressor shuts off automatically when recovery is complete (at approximately 13 inches of vacuum). The display shows the “CPL” message and then alternately
flashes the weight of refrigerant recovered.
5. To assure complete recovery of refrigerant, wait for five (5) minutes and watch the
manifold gauges for a rise in pressure above “0.” If a rise occurs, press HOLD/
CONT. Repeat as needed until the system pressure holds for two (2) minutes.
CAUTION! Drain the oil from the separator only after each recovery.
Do not completely depressurize the oil separator; immediately close the
valve when oil is completely drained in the next step. The lower right corner of the display will indicate “OIL (OUNCES)” as a reminder.
6. Be sure the oil catch bottle is empty, then slowly open the oil drain valve, and drain
the oil into the oil catch bottle. This oil was removed from the A/C system during
recovery. It must be replaced with new oil. When all the recovered oil has completely drained, immediately close the valve and record the amount of oil in the
bottle. Dispose of waste oil properly.
If the recovery tank fills completely:
• The compressor shuts off; the digital display shows the message “FULL.”
• Change the tank.
Weight Example
The A/C system is now empty. Make any repairs at this time.
Model 178002K/178012K Recovery/Recycling/Recharging Unit
11
Operating Instructions
First!
Perform
"RECOVERY
PROCEDURES"
before starting
"CHANGING
REFRIGERANT
TYPES".
Lockout Box
High Side Port
Low Side Port
Red Vapor Hose
Blue Liquid Hose
Yellow Air
Purge Hose
Tank Vapor Valve
Tank Liquid Valve
Air Purge Fitting
50 lb. (23 kg)
Unit Tank
Important!
Before changing
refrigerant types,
be sure the red
high side and
blue low side
hoses are disconnected from
the A/C system.
AUTOMATIC
INST0146
Diagram of Unit’s Components — External View
Scale Assembly
CHANGING REFRIGERANT TYPES
1. Be sure the red high side and blue low side hoses are disconnected from the A/C
system, then open the manifold and tank valves.
2. Turn on unit and close the liquid valve on the tank. Press SHIFT/RESET until the
"program" message displays. Press and hold SHIFT/RESET and then press "1" to
recycle. Unit will pull into a vacuum and shut off.
3. Turn unit on and press SHIFT/RESET until the “Clr” message appears.
4. Press HOLD/CONT to start the system oil separator clearing process.
During the system oil separator clearing process, the compressor is activated and
the “OIL” message displays. The compressor will stop while the unit equalizes
pressure and the “OIL” message will continue to display. When the unit reaches the
correct pressure, the display alternately flashes the messages “OIL” and “DRN.”
Open the system oil drain valve to drain the oil. After all oil has drained, the
12
© 2000 Robinair, SPX Corporation
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