R100 Oil-Less Refrigerant
Recovery Unit
Operation Manual
1
INTRODUCTION
Welcome to simple, efficient refrigerant
recovery with your new YELLOW
JACKET® Refrigerant Recovery Unit,
R100. This unit combines the latest oil-less
compressor technology with YELLOW
JACKET
quality refrigerant recovery products.
The R100 can recover refrigerant in three
different modes:
®
’s tradition as a manufacturer of
Liquid Recovery - Direct recovery of
liquid refrigerant through the recovery
unit. (Suction Valve in the “Liquid
Recovery” position.)
Vapor Recovery - Direct recovery of
vapor refrigerant through the recovery
unit. (Suction Valve in the “Vapor
Recovery” position.)
Push-Pull Liquid Recovery - Indirect
recovery of liquid by “pushing” the liquid
with high pressure refrigerant vapor.
Used when large amounts of liquid
refrigerant need to be recovered.
SPECIFICATIONS
Refrigerants: R-12, R-22, R-134a, R-404A, R-409, R-500, R-502 Hp/MP Blends
Compressor: 1 HP Reciprocating Oil-less 2-cylinder
Power Source: 110 VAC 60Hz (230 VAC 50Hz)
Amperage: Run Load Amps: 14.7 ( 3.7 )
Size: Height: 13 in
Full Load Amps: 18.4 ( 5.6 )
Locked Rotor Amps: 72.0 (18.0 )
Width: 14.75 in
Depth: 13.25 in
Weight: 48 lb.
TABLE OF CONTENTS
SECTION PAGE
Introduction 2
Specifications 2
General Safety Instructions 3
Overview of System Operation 4
Cautions & Warnings 4
Push-Pull Liquid Recovery 5
Direct (Vapor) Recovery 7
Component Location 8
Troubleshooting Information 9
Repair Parts List 11
2
GENERAL SAFETY INSTRUCTIONS
Know Your Equipment. Read and under-
stand the operation manual and labels
affixed to the unit. Learn its applications
and limitations, as well as the specific potential hazards of your equipment.
ALWAYS WEAR SAFETY GOGGLES
AND GLOVES.
Use the Correct Hoses. All hoses used
for refrigerant handling should be designated for use with the refrigerant to be
handled. Also use hoses of minimal length
with a shut-off device within 12 inches of
the end of the hose to reduce the likelihood
of refrigerant leaks to the atmosphere.
Ground All Equipment. This unit is
equipped with an approved 3-prong
grounding-type plug. Never remove the
round ground prong from the plug. Only
plug into a properly grounded receptacle.
Do not pressure test with compressed
air. Some mixtures of air and refrigerant
have been shown to be combustible at
elevated pressures.
Use the Proper Extension Cords. TO
REDUCE THE RISK OF FIRE, avoid use
of an extension cord with this unit. The
cord may overheat. If you must use an
extension cord, use the following guide for
choosing the proper extension cord:
Wire Maximum Length
18 Ga. 10 feet
16 Ga. 25 feet
14 Ga. 50 feet
12 Ga. 100 feet
Avoid Dangerous Environments.
Do not use this unit in damp locations
or expose it to rain.
This equipment should be used in a
location with mechanical ventilation
that provides at least 4 air changes
per hour. If this is not possible, it
should be located at least 18 inches
above the floor.
This equipment should not be used
near open containers or spills of
gasoline.
Disconnect Unit from Power Supply
Before Servicing. An electrical shock
hazard is present when the unit is disassembled.
Repair Damaged Parts. Do not operate
the unit with a defective part. Repair unit
to proper operating conditions.
Use Recommended Accessories. Follow
the instructions that accompany all accessories. Improper use of accessories may
damage equipment or create a hazard.
Use Caution When Connecting or Disconnecting. Improper usage may result in
refrigerant burns (frostbite). If a major
refrigerant leak occurs, proceed immediately to a well ventilated area.
Only Use the R100 with the Correct
Refrigerants. See the specifications for a
list of compatible refrigerants.
Operate the Unit within the Design Environment. The R100 was designed to
operate in a temperature range from 40°F
to 120°F. The unit should also not be operated in a wet location.
WARNING! Refrigerant, in liquid and vapor form, is a potentially hazardous material. Please consult the refrigerant manufacturer’s Material Safety Data Sheet for
addition information and adhere to the
following safety guidelines:
Avoid breathing high concentrations
of vapors.
Use with sufficient ventilation to keep
operator exposure below recommended limits, especially in enclosed
and low lying areas.
Avoid contact of liquid refrigerant with
the eyes and prolonged skin exposure.
Wear goggles and protective gloves.
Do not attempt to operate this unit
above 120°F ambient temperature.
Do not allow refrigerants to contact
open flame. Refrigerant decomposition in a flame results in phosgene
gas. Breathing phosgene gas can be
3
GENERAL SAFETY INSTRUCTIONS, cont.
FIRST AID: If high concentrations of refrig-
erant are inhaled, immediately remove the
victim to fresh air. Call a physician or
emergency medical technician. Keep calm.
If the victim is not breathing, give artificial
respiration. If breathing is difficult, give
oxygen. Do not give epinephrine or similar
drugs.
EYE: In case of liquid contact, imme-
diately flush eyes with plenty of water.
Call a physician.
SKIN: Flush with water. Treat for
frostbite, if necessary, by gently
warming the effected area.
CAUTION! All refrigerant hoses, recovery
tanks, refrigerant lines, the R100, and other
vessels containing refrigerants should be
handled as if under high pressure.
OVERVIEW OF SYSTEM OPERATION
The 1 HP R100 offers significant flexibility
to meet your refrigerant handling needs in
a compact rugged, powder-coated case.
Careful handling of refrigerant is an
important part of servicing air-conditioning
and refrigeration equipment. Specific
regulations apply to refrigerant handling.
Familiarize yourself with these regulations.
Because the refrigerant is combined in a
large tank, every technician must be sure
which refrigerant is in each tank. Your
company procedures should help you
determine this. Mixing refrigerants can
contaminate a large volume of refrigerant.
Use care when recovering refrigerant into
a portable tank. As stated in the warnings, overfilling a tank can be extremely
dangerous. This unit is equipped with a
tank overfill sensor cord. When connected
properly to a recovery tank with a 80%
float, this device will shut off the unit when
the tank float activates (open contacts).
The R100 is designed for direct recovery
of liquid or vapor refrigerant. It can also
be used for the traditional push-pull, high
volume recovery of liquid refrigerant.
Recovery of liquid refrigerant in Vapor
Mode can damage the recovery unit compressor. If you are not sure if liquid refrigerant is present, use the Liquid Mode.
CAUTION! WARNING!
This unit should be operated by
certified personnel per 40 CFR part
82 subpart F or current equivalent.
Before operating this unit, please
read this manual thoroughly. You
must understand the procedures
outlined in this manual. Failure to
follow these procedures could void all
warranties.
Before handling refrigerants, read the
material safety data sheet (MSDS)
from the refrigerant manufacturer.
4
Inhalation of high concentration of
refrigerant vapors is harmful and may
cause heart irregularities, unconsciousness, or death. Deliberate inhalation of
refrigerants is extremely dangerous.
Death can occur without warning. Vapors
reduce oxygen available for breathing and
are heavier than air. Decomposition
products are hazardous. Liquid contact
can cause frostbite. All refrigerant
containers, equipment, and hoses contain
high pressure.
Contact with refrigerant can cause
frostbite.
TO POWER
SUPPLY
SUCTION PRESSURE
System On
High PressureTank Full
SYSTEM
SWITCH
CIRCUIT
BREAKER
SUCTION PRESSURE
O
LIQUID VAPOR PURGE RECOVER
SUCTION PORT
DISCHARGE PRESSURE
DISCHARGE PRESSURE
O
DISCHARGE PORT
Figure 1
PUSH-PULL LIQUID RECOVERY
The Push-Pull Liquid Recovery mode is
used for transferring large volumes of liquid
refrigerant. The R100 “Pulls” vapor from the
recovery cylinder and produces high
pressure discharge gas that “Pushes” liquid
out of a HVAC system into a recovery
cylinder. ( see figure 1)
Some systems may not allow push-pull
liquid recovery. If any of the following
conditions apply to your recovery job,
proceed directly to Vapor Recovery.
Equipment contains less than 8
pounds of refrigerant.
Equipment is a heat pump or other unit
with a reversing valve.
Equipment has an accumulator
between the service ports used in
liquid recovery.
Liquid refrigerant has migrated and the
location of the refrigerant is not known.
The refrigerant system does not allow
When using push-pull recovery, the
R100 will not
vacuum level in the recovered system.
Use a sight glass to determine when the
liquid is being “pushed” into the recover
tank. When liquid refrigerant is no longer
visible, switch to Vapor Recovery (see
figure 2).
The hose connections for liquid “push”
recovery are shown in the figure 1. Perform
the following steps for push-pull recovery:
1. Ensure the recovery unit System Switch
is “OFF” and the power to the system to
be serviced is also turned off.
liquid service port
hvac unit
or appliance
vapor service port
sight glass
liquid(open)
vapor(open)
recovery
tank
Charging
Scale
for a solid column of liquid refrigerant
to be formed.
recover to the required
5
PUSH-PULL LIQUID RECOVERY, cont.
2. Connect the recovery unit, the system to
be serviced, and the recovery tank as
shown in the figure 1.
3. Open the valves on the recovery
cylinder.
4. Turn the Suction Valve to “VAPOR
RECOVERY” and the Discharge Valve to
“PURGE” position.
5. Turn the System Switch “ON.” The
Green LED should energize.
6. Monitor the sight glass. When there is
no longer significant liquid refrigerant
passing through the sight glass,
push-pull liquid recovery is complete.
Note: If the Yellow LED energizes, the
recovery tank is full.
Turn off power. Turn off both valves.
TO POWER
SUPPLY
Exchange recovery tank with an empty
one. Repeat Steps 3-6.
If the Red LED energizes, the recovery unit
is sensing a high-pressure limit. Turn off
power and check for restrictions. If tank
pressure is above 400 psig, exchange tank.
Repeat Steps 3-6.
7. Turn the Tank Vapor Valve to “OFF.”
Wait until suction pressure gauge
indicates a vacuum.
8. Perform PURGE process.
9. Disconnect Refrigerant hoses.
10.Proceed to the Vapor Recovery
procedure in this manual to remove the
remainder of the refrigerant and to
evacuate the system to the required
vacuum level.
liquid service port
(Liquid Recovery mode only)
hvac unit
or appliance
vapor service port
(Liquid or Vapor Recovery mode)
SUCTION PRESSURE
DISCHARGE PRESSURE
Tank Full
System On
High Pressure
SYSTEM
SWITCH
CIRCUIT
BREAKER
SUCTION PRESSURE
DISCHARGE PRESSURE
O
O
RECOVER
PURGE
LIQUID
VAPOR
SUCTION PORT
DISCHARGE PORT
recovery
Charging
Scale
liquid(closed)
tank
vapor(open)
Figure 2
6
VAPOR & LIQUID (DIRECT) RECOVERY
Vapor or Liquid Recovery is used to pull
refrigerant directly out of the system to be
serviced. The refrigerant is then transferred to a recovery tank.
Liquid Recovery is used when connecting
to the high pressure side of the system to
be serviced or any other service port that
liquid refrigerant is present.
Either Vapor or Liquid Recovery can be
used when connecting to the low pressure side or any other service port that
vapor refrigerant is present.
IMPORTANT: If you are not sure
whether liquid refrigerant is present,
choose Direct Liquid Mode. This mode
limits the amount of liquid refrigerant
entering the compressor. Recovery of
liquid
refrigerant in the Vapor Recov-
ery mode can damage the compressor.
If large quantities of liquid refrigerant are
expected, use the liquid push-pull
method. Push-pull will transfer liquid
refrigerant faster than direct liquid recovery.
The hose connections for vapor & liquid
recovery are shown in the figure 2. To
perform vapor or liquid recovery, please
follow the steps below:
1. Turn off power to the system to be
serviced.
2. Turn the Suction Valve to “OFF” and
the Discharge Valve to “RECOVER.”
3. Connect the recovery unit, the system
to be serviced, and the recovery tank
as shown in the figure 2. The suction
hose can be connected to the liquid
and/or vapor service ports. If you
connect to the liquid service port,
ensure you use Liquid Recovery.
Also ensure the hose to the tank is
connected to the DISCHARGE port of
the recovery unit.
4. Open the vapor valve on the recovery
cylinder.
5. Turn the discharge valve (right) to
“RECOVER” position.
6. Turn the System Switch ”ON”. The
Green LED should energize.
7. Turn the suction valve (left) to:
“VAPOR RECOVERY” for vapor recovery
from the vapor service
port.
“LIQUID RECOVERY” for liquid recovery
from the liquid service
port.
CAUTION: If unsure of the refriger-
ant’s phase, always choose
the “LIQUID RECOVERY”
position.
Note: If the Yellow LED energizes, the
recovery tank is full. Turn off power.
Turn off both valves. Exchange recovery
tank with an empty one. Repeat Steps 3-
6.
If the Red LED energizes, the recovery
unit is sensing a high-pressure limit. Turn
off power and check for restrictions. If
tank pressure is above 400 psig, exchange tank. Repeat Steps 3-6.
7. After the Suction Pressure Gauge indicates the required vacuum, turn the
discharge valve to “PURGE” to remove
the remaining refrigerant from the recovery unit.
8. When the Suction Pressure Gauge
indicates a vacuum, Turn the SUCTION VALVE to “OFF”, Turn off the
power to the recovery unit, and Disconnect the two refrigerant hoses.
Recovery and Purge Operations are now
complete. The R100 is ready for the
next job.
7
COMPONENT LOCATION AND DESCRIPTION
1. Suction Gauge - Indicates the suction
pressure of the recovery unit.
2. Power Cord - 6 foot long with grounded
plug to be connected to a grounded 110
volt AC power source. (not shown)
3. LED Status Lights- Green “on”, Yellow
“Tank Full”, Red “High Pressure Limit”
4. System Switch- -Switch for turning on
the recovery system compressor and
fan. A 15 amp circuit breaker is integrated into the switch.
5. Discharge Gauge – Indicates the
discharge pressure of the recovery unit’s
condenser.
6. Cooling Fan - This fan provides airflow
through the condenser and across the
compressor.
7. Suction Valve - Valve for selecting either liquid or vapor recovery mode. The
SUCTION port is closed when in the
“OFF” position.
8. Suction Port & Filter- Fitting for
connecting a refrigerant hose to the
system to be recovered. Filter located
under fitting. Clean or replace element.
9. Discharge Port - Fitting for connecting
a refrigerant hose to the recovery tank.
DISCHARGE port is closed when in the
“OFF” position.
10. Discharge Valve – Valve used to
select Recovery or Purge operation.
11. Circuit Breaker– 30 AMP breaker is
non-integrated.
12. Tank Overfill Sensor Cord- used to
connect to a tank float with a 3-prong
Brad Harrison. (not shown) Shorting
Cap also included
.
SUCTION PRESSURE
System On High PressureTank Full
CIRCUIT
BREAKER
SYSTEM
SWITCH
SUCTION PRESSURE
O
LIQUID
SUCTION PORT
DISCHARGE PRESSURE
DISCHARGE PRESSURE
O
RECOVER
PURGE
VAPOR
DISCHARGE PORT
8
TROUBLESHOOTING INFORMATION
Problem Possible Causes Solution
R100 compressor
and fan will not start
R100 compressor will
not start but fan runs
R100 starts but stops
after a short period
R100 trips circuit
breaker upon start up
R100 will not perform
liquid push-pull
recovery
Power cord not plugged in
Socket not energized
High Pressure Switch
activated
Tank Overfill Sensor activated
Circuit Breaker is tripped
Defective system switch
Broken or loose wire
Compressor Start relay or
capacitor defective
Compressor thermal overload
is tripped
Compressor leads are broken
or loose
Restriction in the discharge
line tripping the high pressure
switch
High differential pressure
across compressor suction
and discharge valves
System to be serviced does
not allow liquid recovery
Plug in to energized socket
Check socket for power
Check for restrictions
Check recovery tank
Turn off power to reset
Reset circuit breaker
Replace switch
Repair electrical connection
Replace the relay or capacitor
Thermal overload will automati-
cally reset
Repair compressor leads
Open valve on recovery tank
Check for other restrictions
Turn off power to reset
Turn Discharge Valve to the
PURGE position for 5 seconds.
Return valve back to
RECOVERY position.
Use Direct Recovery method
TECHNICAL SUPPORT: 800-769-8370
Call this number if you require additional information on your YELLOW JACKET
Unit.
FOR WARRANTY OR OTHER SERVICE:
Contact your YELLOW JACKET
®
Distributor
®
9
Notes:
REPAIR PARTS DIAGRAM
recovery
tank
hvac unit
or appliance
recovery
tank
10
REPAIR PARTS LIST
The following list contains the major components of the R100. To order these parts,
please contact your YELLOW JACKET
Please have the following information available when you call.
Model: R100 Serial Number: Date of Purchase:
®
Dealer.
Part Number Description
1 95248
95188
2 95215 Power Cord
3 Compressor hoses
4 95154 Compressor
5 95251 Suction Valve w/
6 95190 Capacitor
7 95233 Compressor Relay
8 95252 Foam for Handles
9 95213 Low Pressure Gauge
10 95212 High Pressure
11 95253 PC Board w/Remote
Tank Overfill Sensor
Cord Shorting Cap
(includes head)
Strainer
Gauge
LED’s
Part Number Description
12 G-95254
Y-95255
R-95256
13 95173 High Pressure
14 95206 Discharge Valve
15 95257 Fan
16 95241 Guard
17 95232 Circuit Breaker
18 95216 Rocker Switch
19 95228 Condenser
20 95163 2 psig Check
21 95247 10 psig Check
22 95258 Operation Manual
Remote LED’s
Switch
Valve
Valve
11
Recovery Division
6701 West 110th Street
Bloomington, MN 55438 USA
Email: custserv@yellowjacket.com
Web: www.yellowjacket.com
Printed in U.S.A. 04/06 FK 150834
Phone: 952-943-1333
Phone: 800-769-8370
Fax: 952-943-1605
Fax: 800-322-8684
12
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