SKYE® A/C SERVICE EQUIPMENT & ACCESSORIES OWNERS MANUAL MODEL SKY8534 R134a A/C SERVICE CENTER RECOVER/RECYCLE/VACUUM/CHARGE WARNING: DO NOT MIX REFRIGERANTS April 12, 2001 SKYE® 2 A/C SERVICE EQUIPMENT & ACCESSORIES SKYE International Holdings, Inc., 7441 Tower Street, Fort Worth TX. 76118 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. With proper set up and maintenance your equipment will provide years of trouble free service. To activate your warranty, fill out and mail in the enclosed card and the EPA certification form today. Thanks Again. WARNING: KNOW WHICH REFRIGERANT YOU ARE RECOVERING. RISK OF EXPLOSION - NEVER RECOVER ANY REFRIGERANT CONTAINING MORE THAN 3% HYDROCARBONS (Propane, Butane, etc.). TABLE OF CONTENTS Ownership Information 2 2 3 Important Information, Warnings & Cautions Illustrations Machine Set Up Procedure Tank Precharge/Recharge Procedure Recovery Procedure Evacuation (Vacuum) Oil Charge Refrigerant Charging Auxiliary Recycling Non Condensable Gas (NCG) Venting Temperature/Pressure Chart Equipment Service & Maintenance Purge Procedure Filter Change Procedure Compressor Oil Drain & Refill Procedure 12 Vacuum Pump Service Procedure Trouble Shooting Chart Warranty 4 5 6 6 7 7, 8 8 8, 9 9 9 10 11 11 11 12 13 14 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. Read instructions carefully before operating or servicing. 3 4 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. Change the vacuum pump oil (SA132) at least monthly. 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 Your SKY8534 is designed for vapor and liquid refrigerant RECOVERY, RECYCLING, VACUUM and RECHARGE of systems containing R134a ONLY. 4 5 The ventilation fans run when master power is turned on. DO NOT LAY THE UNIT DOWN - THIS MAY CAUSE LIQUID REFRIGERANT TO SETTLE IN THE COMPRESSOR. The SKY8534 comes complete with. 1 x R134a Gauge set with 72" hoses and service adapters. (Part # SAR101) 1 x 30 lb. DOT dual valve storage tank with float. (Part # 276020) 2 x Oil measuring bottles for recovered oil drain and oil charge. (Part # 254010) 1 x Vapor outlet to storage tank hose with ABB valves. (Part # 256335) 1 x Liquid charging hose with ABB valves. (Part # 256335) 1 x Vacuum pump hose. (Part # 256335) 1 x Vacuum pump oil. (Part # SA132) SKY8534 MACHINE CONTROL LAYOUT CONTROL PANEL RECOVER COMPRESSOR ON VACUUM CHARGE VACUUM TANK FULL R E C O V E R VACUUM PUMP TIMER HOUR METER SKYE C H A R G E OFF PURGE VALVE MASTER POWER HOSE CONNECTIONS OUTLET TANK FLOAT POWER VACUUM PUMP TO POWER OIL DRAIN PURGE OUT RECOVERY INLET RECOVER CHARGE INLET VACUUM PUMP OIL CHARGE $ OFF $ PURGE $ $ $ VACUUM CHARGE SET UP PROCEDURE IMPORTANT: BEFORE OPERATING YOUR SKY8534 FOR THE FIRST TIME, THE FOLLOWING SET UP PROCEDURE MUST BE CARRIED OUT. Your new unit and the storage tank must be evacuated (vacuumed) prior to use. 5 6 Set Up Procedure: (REFER TO THE ILLUSTRATED LAYOUT ON PAGE 5.) 1. Open both storage tank valves to vent any factory nitrogen charge and leave them open. 2. Turn the RECOVER/PURGE VALVE to the PURGE position, place the storage tank on the scale platform and secure the retaining ring around the tank base. Connect the vapor out hose to the storage tank vapor port and the vapor out port on the machine. Connect the tank liquid hose to the storage tank liquid port and the INLET port on the machine. Connect the float lead to the tank. (NOTE: Check tank valve handles for proper port identification - DO NOT GO BY COLOR.) 3. Fill the vacuum pump to the line across the sight glass on the nose of the pump with the supplied oil. 4. Connect the machine to power and turn the MASTER POWER SWITCH on. Turn the FUNCTION SELECTOR to the VACUUM position and set the VACUUM PUMP TIMER SWITCH for a minimum of 20 minutes. While vacuuming, remove the 2 screws at the rear center of the control panel and install the gauge set mount using the same screws. 4. When the vacuum is complete turn the the FUNCTION SELECTOR to the OFF position, close the storage tank liquid valve, turn the PURGE valve to the RECOVER position and move the liquid hose from the INLET PORT to the machine CHARGE INLET PORT. YOU ARE NOW READY TO PRECHARGE THE TANK TANK PRECHARGE/RECHARGE PROCEDURE 1. Connect the ABB end of the center (yellow) gauge set hose to the machine INLET PORT. Disconnect the center (yellow) hose from the gauge set and connect it to an R134a bottle containing at least 10 lbs. of refrigerant. Open the valve on the bottle then turn it upside down for liquid. Press the MODE button on the scale keypad to select TARE WEIGHT then turn the FUNCTION SELECTOR to the RECOVER position. The machine will start recovering and the scale will start counting up as refrigerant flows into the storage tank. 7. When 10 to 12 lbs. of refrigerant is in the storage tank, close the valve on the R134a bottle and allow the machine to stop automatically. Turn the FUNCTION SELECTOR to the OFF position and turn MASTER POWER OFF. 9. Remove the yellow hose from the R134a bottle and reconnect it to the gauge set center port. YOUR MACHINE IS NOW READY FOR USE TO RECOVER VAPOR OR LIQUID REFRIGERANT IMPORTANT: Before recovering refrigerant with your SKYE machine, the vehicle A/C system must be off. OPERATING INSTRUCTIONS: 6 7 1. Close the high side and low side gauge manifold valves, connect the YELLOW gauge set hose to the machine INLET PORT then connect the (RED) high side and (BLUE) low side service hoses to the A/C system. 2. Open the storage tank VAPOR port and connect the machine to power. 3. Turn the MASTER POWER SWITCH ON, turn the FUNCTION SELECTOR to RECOVER. The AMBER recovery light and WHITE compressor on light will illuminate. NOTE: If you want to measure to amount of refrigerant being recovered, press the scale keypad MODE button to select TARE WEIGHT before starting the recovery operation. When the LCD reads 0 lbs. 00 oz. proceed to the next step. 4. Open the BLUE and RED gauge manifold valves. The unit will operate automatically to recover/recycle the refrigerant in the A/C system. 5. When the pressure in the A/C system drops to approximately 10" VACUUM, the compressor will stop and the WHITE compressor on light will turn off. The AMBER recovery light will remain on indicating that the machine is still in the recovery mode. This does not mean that all the refrigerant has been recovered as there may be refrigerant trapped in the A/C system which will slowly evaporate. The compressor will restart automatically and recover this refrigerant. When the GAUGES remain at 0 PSI or below for at least 2 minutes recovery is complete. (Note: The compressor will cycle ON/OFF due to internal machine pressure transition while performing the 2 minute outgas check.) Close the low side and the high side manifold valves and proceed to the next step. 6. If additional operations will be performed, continue to the next function. If no further operations are to be performed at this time, turn the FUNCTION SELECTOR to the OFF position and turn MASTER POWER OFF. 7. Drain the RECOVERED OIL into the measuring bottle by turning the RECOVERED OIL DRAIN VALVE to the OIL DRAIN position. Close the valve when finished. This amount of new oil may be placed back into the A/C system. 8. Close the storage tank VAPOR valve. NOTE: If the unit stops during recovery and the RED TANK FULL light illuminates, your storage tank is full and must be replaced. All new tanks must be evacuated before use. EVACUATION (VACUUM) PROCEDURE 1. With power connected and both service hoses connected to the A/C system, turn the MASTER POWER ON and turn the FUNCTION SELECTOR to the VACUUM position. 2. Turn the VACUUM PUMP TIMER SWITCH to the desired operating time, the GREEN vacuum pump light will illuminate and the vacuum pump will turn on. (NOTE: The vacuum pump will not operate if there is pressure in the A/C system or unit plumbing. If this occurs, recover the refrigerant in the A/C system or unit plumbing and restart vacuum.) 3. Open both manifold valves and evacuate the system for the set time. (NOTE: The scale may be programmed for the charge amount at this time.) 5. When the evacuation is complete,close the gauge valves and check for vacuum leaks. 7 8 OIL CHARGE PROCEDURE IMPORTANT: THIS IS VACUUM SIDE OIL CHARGE. ONLY PUT THE AMOUNT OF OIL TO BE CHARGED IN THE BOTTLE FOR EACH JOB. ALLOW ENOUGH TIME FOR THE OIL TO CLEAR THE SERVICE HOSES BEFORE RESUMING VACUUM. 1. Put the desired amount of oil in the bottle and start the vacuum operation. 2. Allow the vacuum pump to run for 5 minutes then turn the VACUUM/OIL CHARGE valve to the CHARGE position (DO NOT TURN THE VACUUM PUMP OFF). 3. The oil will be drawn into the A/C system by the vacuum in the A/C system. IMPORTANT: ALLOW THE GAUGES TO RETURN TO 0 PSI WHICH ALLOWS ENOUGH TIME FOR THE OIL TO CLEAR THE SERVICE HOSES BEFORE RESUMING THE VACUUM OPERATION. 4. Once the oil has cleared the service hoses, turn the VACUUM/OIL CHARGE valve back to the VACUUM position and allow the pump to complete the run time. CHARGING PROCEDURE IMPORTANT: THE STORAGE TANK SHOULD CONTAIN AT LEAST 5 POUNDS OF REFRIGERANT TO PERFORM THE CHARGING FUNCTION. 1. Open the storage tank liquid valve. (NOTE: The hose from the tank liquid port must be connected to the Charging Inlet Port.) 2. The unit of measure may be selected by pressing the lbs/kg button to select pounds and ounces or kilograms (Default is lbs). The scale will reset whenever the unit of measure is changed. 3. Turn the FUNCTION SELECTOR to the CHARGE position, press the SET button then press and hold the % arrow until the desired charge amount is ...