SKYE® AIR CONDITIONING SERVICE EQUIPMENT OWNERS MANUAL MODEL SKY8034 R134a Recovery/Recycling System WARNING - DO NOT MIX R134a WITH ANY OTHER REFRIGERANT. April 12, 2001 SKYE International Holdings, Inc. 7441 Tower Street Fort Worth, Texas 76118 Phone: (817) 595-0077 FAX: (817) 595-1106 FOR TECHNICAL SUPPORT AND CUSTOMER SERVICE, PLEASE CALL 1-800-722-SKYE (7593) RECORD YOUR EQUIPMENT DETAILS BELOW: MODEL NO. _____________________________________ SERIAL NO. _____________________________________ DATE PURCHASED _____________________________________ PURCHASED FROM _____________________________________ Thank you for choosing SKYE AC Service Equipment. With proper set up and maintenance, your equipment will provide years of trouble free service. To activate your warranty and obtain access to our free technical service, fill out and mail the enclosed warranty registration card and the EPA certification form today. Thanks Again WARNING: Know which refrigerant you are recovering. Risk of explosion - Never use your SKY8034 to recover any refrigerant containing more than 3% hydrocarbons (Propane, Butane, etc.). TABLE OF CONTENTS 2 Ownership Information Important Information, Warnings, Cautions Know Your Unit ­ Illustrations Machine Set Up Procedure Recovery Procedure Non Condensable Gas Venting Equipment Service and Maintenance Purge Procedure Filter Change Procedure Compressor Oil Drain & Refill Procedure Trouble Shooting Chart Temperature/Pressure Relationship Chart Warranty Operating Flow Chart 2 4 5 6 7 7 8 8 8 9 10 11 12 13 WARNING: 1. This equipment operates at high pressures and at high voltages. Improper use may cause personal injury. 2. This equipment must be operated by qualified and certified personnel. 3 3. Read instructions carefully before operating or servicing. 4. To prevent personal injury from refrigerants operators must wear safety glasses, gloves and protective clothing. 5. Do not operate damaged equipment. 6. Safety devices require the use of authorized refillable tanks. 7. Do not use this equipment in the vicinity of spilled or open containers of gasoline. 8. 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. 9. Service hoses must have shut off devices within 12 inches (30 cm) of the connection point to the system being serviced to prevent venting of refrigerant. IMPORTANT: · · · · · · Change the filter (FA85) and compressor oil (S131-EST) every 30 hours of recovery operation. The compressor must not be operated unless it contains the specified 8 oz. of oil. The compressor is filled initially at factory. Close the storage tank valves when the machine is not in use. Always replace caps on inlet and outlet ports. Routinely check the fittings for leaks. CAUTION: Do not to allow liquid to settle in the suction side when the compressor is not running as this may enter the compressor and cause damage next time the unit is turned on. TO PREVENT THIS, DO NOT TURN POWER OFF WHEN THE COMPRESSOR IS RUNNING; allow it to evacuate the system completely and shut off automatically, then turn power OFF. WARNING: Improper operation will void your warranty. To reduce the risk of fire, avoid the use of an extension cord because the extension cord may overheat. If you must use an extension cord, the cord must be AWG 14 minimum. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. To remove HFC 134a from the A/C system, use service equipment certified to meet the requirements of SAE J2210 (HFC 134a recycling equipment). Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. CAUTION: Do not pressure test or leak test HFC134a service equipment and/or vehicle air conditioning systems with compressed air. Some mixtures of air and HFC134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. NEW STORAGE TANKS MUST BE EVACUATED before use to remove air and moisture. REFRIGERANT: The SKY8534 A/C Service Center is for use with R134a only. IMPORTANT: PREVENT ACCIDENTAL REFRIGERANT LOSS " REFRIGERANT LOSSES OCCUR THROUGH LOOSE CONNECTIONS AND SCHRADER VALVES. CHECK YOUR FITTINGS AND VALVES. " ALWAYS CHECK THAT THE O-RINGS IN THE VALVE CAPS ARE IN GOOD CONDITION AND ENSURE CAPS ARE TIGHT. " LEAK TEST FITTINGS & HOSE CONNECTIONS PERIODICALLY USING AN ELECTRONIC LEAK DETECTOR OR SOAPY WATER. " CLOSE STORAGE TANK VALVES WHEN NOT IN USE. " WARNING: ELECTRICAL FAULTS MUST BE REPAIRED BY A QUALIFIED ELECTRICIAN. KNOW YOUR UNIT The SKY8034 meets the SAE J2210 standard for recycled R134 refrigerant purity. 4 Your SKY8034 is designed for vapor and liquid refrigerant RECOVERY and RECYCLING for systems containing R134a. The unit recycles the refrigerant as part of the recovery process. Do not lay the unit down - This will cause loss of compressor lubrication. The SKY8034 comes complete with: 1 x 30 lb. Dual Valve Storage Tank with Float (Part # 276020) 1 x 8 oz. Recovered Oil Measuring Bottle (Part # 254010) 1 x R134a Manifold Gauge Set with 72" Hoses (Part # SAR101) 1 x Outlet Hose (Part # 256335) CONTROL PANEL LAYOUT RECOVERY OFF/ON COMPRESSOR ON HOUR METER TANK FULL MASTER POWER HOSE CONNECTIONS FLOAT POWER VAPOR OUT OIL DRAIN $ OFF PURGE PORT PURGE VALVE PURGE $ INLET PORT RECOVER $ ESSENTIAL PRE-OPERATING PROCEDURES Before operating your SKY8034 for the first time, the following procedures must be performed. 5 SET UP PROCEDURE 1. Install the gauge set using the screws located at the upper rear center of the machine then connect the RED and BLUE service hoses to their respective connections. Do not connect the YELLOW center hose at this time. 2. Install the storage tank in the locating ring on the bottom platform and tighten the clamp ring. Connect the FLOAT LEAD to the tank then connect the short YELLOW hose to the TANK VAPOR PORT and to the VAPOR OUT PORT on the machine and OPEN the tank VAPOR VALVE. 3. Connect the YELLOW gauge set hose to the TANK LIQUID PORT and to your vacuum pump. Open the TANK LIQUID PORT and turn the vacuum pump on. Allow the vacuum pump to run for 20 minutes. 4. Close the TANK LIQUID PORT then turn the vacuum pump off. Disconnect the YELLOW hose from the TANK LIQUID PORT and the vacuum pump. Connect the ANTIBLOWBACK VALVE end of the YELLOW hose to the RECOVERY INLET PORT and the other end of the hose to a bottle of R134a. Open the valve on the R134a bottle and turn it upside down. 5. Connect the machine to power and turn the MAIN POWER SWITCH ON. Turn the RECOVERY SWITCH ON and allow the machine to recover a small amount of refrigerant. The WHITE COMPRESSOR ON LIGHT will illuminate when the compressor is running. This will precharge the unit and activate the internal pressure switches. 6. Once the precharge is complete, close the valve on the R134a bottle and allow the compressor to shut off. The WHITE COMPRESSOR ON LIGHT will shut off at this time. Disconnect the hose from the R134a bottle and connect it to the center port on the gauge set. YOUR MACHINE IS NOW READY FOR USE TO RECOVER REFRIGERANT IMPORTANT: Before recovering refrigerant with the SKYE machine, the vehicle AC system must be off. 6 1. Connect the unit to power and open the storage tank vapor valve. 2. Connect the YELLOW service hose to the inlet port on the machine and the RED and BLUE service hoses to the AC system. 3. Turn the main power switch on then turn the recovery switch on and open the BLUE and RED gauge valves. The compressor will start recovering immediately. 4. When the pressure in the AC system drops to approximately 10" VACUUM the compressor will stop. This does not mean all the refrigerant in the system has been recovered. There may be refrigerant trapped in the oil or an accumulator/drier that will slowly evaporate. The compressor will restart automatically and recover this refrigerant when the pressure rise is sensed. When the gauges remain at 0 PSI or below for at least 2 minutes, recovery is complete. Close the gauge set valves and turn the recovery switch OFF. 5. Close the storage tank vapor valve. 6. Drain the recovered oil into the measuring bottle provided. You may replace this amount of new oil into the AC system. NOTE: If the unit stops during the recovery process and the AMBER TANK FULL light glows when the recovery switch is ON, the tank is full and must be replaced. All new tanks must be evacuated prior to use. NON-CONDENSABLE GAS (NCG) VENTING PROCEDURE This machine features automatic NCG purge. It may purge at any time the power is on and the compressor is not in operation. EQUIPMENT SERVICE AND MAINTENANCE WARNING: Before any service operation can be performed, it is necessary to purge the refrigerant from the machine. DO NOT open unit components until all refrigerant has been purged from the system. 7 PURGE PROCEDURE 1. Drain any recovered oil using the recovered oil drain valve on the back of the machine. 2. Disconnect the short YELLOW hose from the VAPOR OUT PORT on the machine and connect it to the PURGE PORT. Turn the PURGE VALVE to the PURGE POSITION and open the tank vapor valve. 3. Disconnect the YELLOW gauge set hose from the gauge set and the machine. Connect the anti-blowback end of the YELLOW gauge set hose to the machine vapor out port and the open end to the recovery inlet port. 4. Connect the machine to power, turn the main power ON and turn the recover switch ON. 5. When the compressor stops running, turn the PURGE VALVE to the vertical position and turn the recover switch OFF. 6. Turn main power OFF and disconnect power. YOU CAN NOW SAFELY PERFORM MACHINE MAINTENANCE FILTER CHANGE PROCEDURE IMPORTANT: Filter life is 30 hours. Change the filter every 30 hours regardless of the moisture level shown on the moisture indicator. Use the hour meter mounted on the control panel to track and determine filter change intervals. NOTE: Replacement filter (part # FA85) includes new gasket. 1. Purge the system as described above. 2. Using a wrench, loosen the spin-on filter then remove it by hand. Remove the old gasket from the fitting prior to installing the new filter. 3. Lubricate the new gasket with oil, install it in the groove at the top of the new filter then install the new filter on the fitting. Tighten the filter with a wrench to prevent leakage. 4. Proceed to Compressor Oil Change Procedure. COMPRESSOR OIL CHANGE PROCEDURE 1. Purge the system if not already done. 2. Using two wrenches, remove the brass cap from the compressor oil drain port located at the center bottom of the compressor. Oil will immediately start draining from the compressor so have a container that will hold at least 8 ounces under the port. 8 3. Once the old oil is drained, connect a short hose to the compressor oil port, put 8 ounces of ESTER oil (S131EST) into a container and submerge the loose hose end of the hose in the container of oil. 4. Connect a vacuum pump to the vapor out port and turn the purge valve to the recover position. Turn the vacuum pump on and allow the vacuum to draw the new oil into the compressor. Once the new oil is in the compressor, disconnect the short hose and replace the cap on the compressor oil service port using two wrenches to tighten the cap. 5. Go to When Maintenance Is Completed. WHEN MAINTENANCE IS COMPLETED 1. Allow the vacuum pump to run for twenty minutes to evacuate the air from the machine. 2. Turn the vacuum pump off and return all hoses to their normal positions. YOU ARE NOW READY TO BEGIN NORMAL OPERATIONS TROUBLE SHOOTING CHART SYMPTOM Compressor won't run. POSSIBLE CAUSE AC system empty. AC system pressure not reaching machine. High or Low pressure switch. SOLUTION Connect to a charged system. Open gauge set valves - Check gauge set and hoses for proper operation or connection. Check switches for proper operation. Change tank. Check for proper connection. Amber light on ­ float connected. Storage tank full. Float lead connector. 9 Compressor cycles on/off rapidly. Tank vapor valve closed. Recovered oil not drained. Restricted hose connection. Filter contaminated. Contaminated element. Loose fitting or connection CALL SKYE TECHNICAL SUPPORT. Sight glass does not turn blue. Unit loses refrigerant FOR TECHNICAL DIFFICULTIES NOT COVERED OR OTHER ASSISTANCE. Open valve. Drain recovered oil. Check ABB valves/service ports for malfunction. Change filter per instruction manual. Change element or sight glass Locate leak with a leak detector or soapy water and retighten fitting as necessary. 1-800-722-7593 TEMPERATURE/PRESSURE COMPARISON CHART ºF ºC -40 -40 -35 -37 -30 -34 -25 -32 R12 PSIG KPa -11 -75.8 -8.4 -57.9 -5.5 -37.9 -2.3 -15.9 R134a PSIG KPa -14.8 -120 -12.5 -86.2 -9.9 -68.3 -6.9 -47 ...