TIF MINIMAX-KT User Manual

MINIMAX

REFRIGERANT RECOVERY SYSTEM

USER’S OPERATING MANUAL

Telephone: (954) 499-5400 • Fax: (954) 499-5454 • Toll Free: (800) 327-5060

ADVANCED TEST PRODUCTS. INC • Miramar, FL

www.amprobe.com

TABLE OF CONTENTS

IMPORTANT SAFETY INFORMATION 4 OPERATING GUIDELINES 5-6

CARE AND MAINTENANCE OF YOUR MINIMAX 6 ADDITIONAL RECOVERY TANK INFORMATION 7

PURGING NON-CONDENSABLE GASES 8

HELPFUL HINTS FOR REFRIGERANT RECOVERY 9-10

OPERATING YOUR MINIMAX 11

DIAGRAM FOR REFRIGERANT RECOVERY 11 SELF PURGING YOUR MINIMAX 12 SELF PURGE/AUTO EVACUATE 12 DIAGRAM FOR “PUSH/PULL” METHOD 13

SET-UP DIAGRAM FOR TANK PRE OR SUB COOLING PROCEDURE 13 OPTIONAL RECOVERY / TANK PRE OR SUB 14

COOLING FOR FIXED HOSE SET-UP REFRIGERANT FLOW DIAGRAM 15

MINIMAX PARTS DIAGRAM/PARTS AND ACCESSORIES LIST 16 MINIMAX AND MINIMAX-KT WIRING DIAGRAMS 17

INSTALLATION OF OPTIONAL80% TANK 18 CAPACITYSENSING COMPONENTS (KIT KT-5001)

MINIMAX-KT MODEL 18 TROUBLESHOOTING YOUR MINIMAX 19 FULL ONE YEAR WARRANTY 20 ENVIRONMENTALPROTECTION AGENCY (EPA) INSTRUCTIONS 21

EPA REGIONAL OFFICES 22

m IMPORTANT SAFETY INFORMATION m

SAFETY COMES FIRST! Read all safety, operating guidelines and instructions before operating your Minimax.

1. CAUTION: ONLY A QUALIFIED TECHNICIAN SHOULD OPERATE THIS RECOVERY UNIT.

The operator must be familiar with air conditioning

and refrigeration systems, refrigerants and the dangers of pressurized components.

2. Always think before acting, familiarity breeds care-

lessness and carelessness can be harmful to your

health or, worse, result in death.

3. m WARNING Always wear safety goggles and protective gloves when working with refrigerants. Contact with refrigerant may cause injury. Disconnect hoses with extreme caution! All hoses may contain liquid refrigerant under pressure.

4. m PRESSURIZED TANK CONTAINS LIQUID REFRIGERANT. NEVER OVERFILLSTORAGE TANKS. OVERFILLING OF THE TANK MAY

CAUSE AVIOLENT EXPLOSIONAND POSSIBLE INJURY OR DEATH.DO NOT: Exceed theworking

pressure of Recovery Tank cylinder.

5.m Warning: DO NOT: Exceed the working pres-

sure of each cylinder. Recovery cylinders are designed for different pressures. Your MINIMAX is not supplied with a recovery tank, it requires the use of tanks with a minimum of 350 psi working pressure and PROMAX strongly recommends the use of 400 psi tanks.

NOTE: The use of a 400 psi tank is mandatory when recovering R-410A. See PROMAX Recovery Tanks under Parts and Accessories section on Page 16.

5. m A scale must be used to avoid overfilling the storage tank. DO NOT OVERFILL. Tank is full at

80% volume. Tank may explode if filled more than

80% due to liquid expansion.

7.Read all safety information regarding the safe handling of refrigerant and refrigerant oil, includ- ing the Material Safety Data Sheet. MSDS sheets can be obtained from your refrigerant supplier.

8. If you expect temperatures in excess of 135° F, contact the refrigerant supplier.

9. Be sure that any room where you are working is thoroughly ventilated, especially if a leak is sus pected. Refrigerant vapor is hazardous to your health and can cause death.

10. m Avoid breathingA/C refrigerant and lubrica-

tion vapor or mist. Exposure may irritate eyes, nose and throat. If accidental system discharge occurs,ventilateworkareabefore resumingservice.

11. iWARNING:TOREDUCE THE RISKOFFIRE:

• Never operate unit in an explosiveenvironment!

Do not use this equipment in the vicinity of

spilled or open containers of gasoline or any

other flammable liquid.

• When using an extension cord it should be a

3-wire, 14 AWG minimum and no longer than 25

feet.

• Use this equipment in locations with mechani-

cal ventilation that provides at least four air

changes per hour or locate the equipment at

least 18 inches above the floor.

• Never use oxygen when testing for leaks. Any

oil in contact with oxygen under pressure will

form an explosive mixture.

12. c High voltage electricity inside panels. Risk of electrical shock. Be sure to disconnect

theunitfrom thepowersourcebeforeservicing it.

13. To reduce the risk of injury, care should be taken when moving this equipment.

6. Use ONLY authorized refillable refrigerant tanks. NEVER use a standard disposable 30lb. tank (the

type of container in which virgin refrigerant is sold) to recover refrigerant.

OPERATING GUIDELINES

m Before operating the Minimax recovery unit, read

the following m

1. MINIMAX IS APPROVED FOR USE WITH THE

FOLLOWING CATEGORY III, IV and V REFRIGERANTS (Per ARI 740):

R-12, R-22, R-134A, R-401A, R-401B, R-401C, R-402A,R-402-B,R-404A,R-406A,R-407A,R-407-B, R-407C, R-407D, R-408A, R-409A, R-410A,R-411A, R-411B, R-412A, R-500, R-502, R-507 and R-509

2. A FILTER must always be used and should

replaced frequently. We recommend that a clean filter be used for every service job. Failure to use a filter will invalidate your warranty.

The use of a filter will greatly reduce the risk of damage to your Minimax, by preventing foreign material from entering the unit.

2. Each filter should be labeled and used exclusively

for one type of refrigerant only.

3. Always open service and cylinder valves slowly.

This allows rapid control of the flow of gases if there is any danger. Once it is determined that there is no danger, the valves can be opened fully.

NEVER use a standarddisposable30lb.tank (the typeofcontainer in which virgin refrigerant is sold) to recover refrigerant.

9. m A scale must be used to avoid overfilling the storage tank. DO NOT OVERFILL. Tank is full at

80% volume. Tank may explode if filled more than 80%duetoliquid expansion. Below is a represen-

tative sample for R-22 refrigerant:

TANK SIZE MAX NET WEIGHT

30 lb. Tank 24 lbs. 50 lb. Tank 40 lbs.

Note: Promax strongly recommends the use of the ADS-100 Refrigerant Scale for monitoring tank

capacity.

10. Your Minimax has an Internal Pressure Shut Off

Switch. If the pressure inside the system should go above 550 psi, the system will automatically

shut itself off. Theshutoffswitch will automatically

reset itself again after the pressure drops below 300 psi.

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

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

6. Keep all connections to the refrigeration system thoroughly dry and clean. If moisture enters the refrigeration system, it is likely to cause considerable damage.

7. Promax strongly recommends the use of the optional 80% Capacity Shutoff Kit (p/n KT-5001). When installed and used with a recovery tank that has an internal float switch, the Minimax will shut

down automatically when the tank is 80% full. Your

Minimax is pre-wired from the factory for this kit.

N o t e : The Minimax is also available in model Minimax-KT, with the 80% Shutoff Kit installed direct from the factory.

8. m CAUTION: Use only authorized refillable refrigerant recovery tanks. Federal regulations require refrigerant to be transported only in containers meeting DOT spec. 4BA or 4BW.

m WARNING: The Internal Pressure Shut Off

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.

11. When recovering large amounts of liquid, use the "Push/Pull method (see diagram on page 13).

m CAUTION: When using the "Push/Pull" method,

once the "Push/Pull" siphon is started, it can continue and overfill the storage tank even if the tank is equipped with a "shut off" float sensor. The siphon can continue even after the machine is turned off. You must manually close the valves on the tank and the unit to prevent overfilling of the recovery tank.

12. Always operate the unit on a flat level surface

13. To achieve the deepest final vacuum, use the tank cooling method to lower the head pressure on the recovery tank. (See Pages 13 &14). Repeat as necessary to achieve the desired vacuum level.

OPERATING GUIDELINES - cont.

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.

14. If the tank pressure exceeds 300 psi, use the tank cooling procedure to reduce the tank pressure. (See Pages 13 & 14)

CARE AND MAINTENANCE OF YOUR MINIMAX

1. USE of a filter/dryer at the inlet is mandatory. A fil-

ter/dryer must always be used between the recovery machine and the inlet hose.

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

3. Always empty refrigerant from the MINIMAX into a

storage tank; see Self-Purge/Auto Evacuate pro-

15.To maximize recovery rates, use the shortest possible length of 3/8" or larger hose. Ahose no longer than 3 feet is recommended.

16.For maximum throughput, always remove all unnecessary hose core depressors and the Schrader valves from port connections.

17.Deformed rubber seals and core depressors in hoses and faulty or unnecessary Schrader valves can restrict flow up to 90%.

cedure on Page 12. Liquid refrigerant left in the MINIMAX’s condenser may expand, causing damage to components.

4. c Warning! Whenever you perform any type of

maintenance work on your Minimax, insure that it is disconnected from the power supply before you begin.

5. 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.

ADDITIONAL RECOVERY TANK INFORMATION

m Warning: Also read the information pertain-

ing to recovery tanks, previously listed under Safety Information and Operating Guidelines.

1. CAUTION: NEVER use a standard disposable 30lb. tank (the type of container in which virgin refrigerant is sold) to recover refrigerant. Use ONLY authorized refillable refrigerant tanks. Federal regulations require refrigerant to be trans ported only in containers meeting DOT specs. 4BW or 4BA.

2.m Warning: DO NOT: Exceed the working pres-

use of 400 psi tanks. NOTE: The use of a 400 psi tank is mandatory when recovering R-410A. See PROMAX Recovery Tanks under Parts and Accessories section on Page 16.

3. 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 and purge the tank using dry nitrogen, and then re-evacuate it.

3. Always store refrigerant containers in a cool dry place.

5. Do not mix refrigerants in a system, a tank or any where else. Each type of refrigerant must have its own tank, filter, etc.

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

7. Do not exceed 80% of tank capacity. PROMAX strongly recommends the use of the Promax ADS100 Refrigerant Scale for monitoring tank capacity. Safety codes recommend that closed tanks not be filled over 80% of volume with liquid. The remaining 20% is called head pressure room.

8. If you expect temperatures in excess of 135° F, contact the refrigerant supplier.

m NEVER TRANSPORT AN OVERFILLED CYLINDER m

Refrigerant expands when it gets warm and may cause a tank to explode if overfilled.

CYLINDER TEMPERATURE 60°F 70°F 100°F 130°F 150°F

STARTING WITH CYLINDER

80% BY VOLUME

SPACE OCCUPIED BY LIQUID 80% 81% 83% 90% 94%

STARTING WITH CYLINDER

90% BY VOLUME

SPACE OCCUPIED BY LIQUID 90% 92% 96% 100%

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