SKYE® AIR CONDITIONING SERVICE EQUIPMENT OWNERS MANUAL MODEL EP10M MULTIPLE REFRIGERANT RECOVERY SYSTEM WARNING: DO NOT MIX ANY REFRIGERANTS July 11, 2000 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 SKYE EP10M to recover any refrigerant containing more than 3% hydrocarbons (Propane, Butane, etc.). TABLE OF CONTENTS Ownership Information 2 2 Important Information, Warnings, Cautions Know Your Unit - Illustrations Machine Set Up Procedure Recovery Procedure Equipment Service and Maintenance Purge Procedure Filter Change Procedure Compressor Oil Drain & Refill Procedure Compressor Oil Level Check Procedure Compressor Oil Separator Capillary Line Service Procedure Cylinder Platform Maintenance Procedure Trouble Shooting Chart Temperature/Pressure Relationship Chart Warranty Electrical Schematic 4 5 6 7 7 7, 8 8 8, 9 9 9 9, 10 10 11 12 13 ! WARNING: 1. This equipment operates at high pressures and high voltages and, if improperly used, may cause personal injury. 2. Risk of injury - Must be operated by certified personnel. 3. Read instructions carefully before servicing. 3 4. To prevent personal injury from refrigerants, operators must wear safety glasses, gloves and protective clothing. 5. Do not operate equipment if damaged. 6. Refrigerant and oil health and safety information may be obtained from refrigerant and lubricant manufacturers. 7. Do not use this equipment in the vicinity of spilled or open containers of gasoline. 8. Safety devices require the use of authorized tanks only. 9. Service hoses must have shutoff devices within 12 inches (30 cm) of the connection point to the system being serviced to prevent accidental refrigerant loss. 10. Use this equipment in locations with mechanical ventilation that provides at least 4 air changes per hour or locate the equipment at least 18 inches above the floor. " IMPORTANT: · · · · Change filter (FD1)and compressor oil (S131-EST) every 30 hours or more often if the systems being serviced have experienced "burnout". Check compressor oil every 10 hours of operation. Compressor must not be operated unless it contains the specified 8.5 (255cc) ounces of oil. The compressor is filled initially at the factory. # CAUTION: It is important not to allow liquid to settle at any time on 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 PRESS THE OFF BUTTON when the compressor is running. Allow it to complete the evacuation and stop automatically, then press the OFF button. 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. However, if you must use an extension cord, the cord shall be AWG 16 minimum. NEW STORAGE TANKS MUST BE EVACUATED before use to remove any air and moisture. REFRIGERANTS The SKYE EP10M Refrigerant Recovery Machine may be used with R12, R22, R134a, R500, R502 and other refrigerants containing less than 3% hydrocarbons. IMPORTANT: PREVENT ACCIDENTAL REFRIGERANT LOSS % REFRIGERANT LOSSES MOSTLY OCCUR THROUGH LOOSE CONNECTIONS AND SCHRADER VALVES. CHECK YOUR FITTINGS AND CONNECTIONS PERIODICALLY. % ALWAYS CHECK THAT THE O-RINGS IN THE VALVE CAPS ARE IN GOOD ORDER AND ENSURE CAPS ARE TIGHT. % LEAK TEST FITTINGS & HOSE CONNECTIONS PERIODICALLY USING AN ELECTRONIC LEAK DETECTOR AND SOAP AND WATER. % CLOSE TANK VALVES WHEN THE MACHINE IS NOT IN USE. % WARNING: TO ELIMINATE THE RISK OF ELECTRIC SHOCK, DISCONNECT POWER BEFORE SERVICING UNIT. ELECTRICAL FAULTS MUST BE REPAIRED BY A QUALIFIED ELECTRICIAN KNOW YOUR UNIT Your SKYE EP10M is designed for vapor and liquid refrigerant RECOVERY for systems containing R12, R22, R134a, R500 & R502. Do not lay the unit on its side - This will cause loss of compressor lubrication. 4 This machine is designed for use with SKYE storage tanks with (USA131F) or without (USA131) float overfill protection devices. When tanks without floats are used, the shorting cap must be installed on the float connector at the side of the scale platform and the tank must be on the scale platform. The EP10M comes complete with: 1 x 50 lb. (23kg)Dual Valve Storage Tank 1 x Purge Hose with Quick Connect Fitting 1 x Recovered Oil Measuring Bottle 1 x Trolley Kit ESSENTIAL PRE-OPERATING PROCEDURES Before operating your SKYE machine for the first time, the following procedures must be performed. Your new machine has been factory evacuated and is ready for the refrigerant precharge. 5 SET UP PROCEDURE 1. Open the storage tank vapor port (marked vapor or gas) to vent the dry nitrogen charge (if any). 2. Using a gauge set, connect the storage tank vapor port to a vacuum pump and draw a vacuum on the tank for twenty (20) minutes. While waiting for the vacuum pump to finish, install the trolley kit on the main chassis if desired. 3. When the vacuum is complete close the tank vapor port, turn off and disconnect the vacuum pump, then place the tank on the scale platform and connect the outlet hose (factory installed) to the tank vapor port. IMPORTANT: DO NOT DISCONNECT THE OUTLET HOSE FROM THE MACHINE UNLESS REPLACING THE HOSE. 4. Using a gauge set connect a refrigerant source to the inlet port. Open the tank vapor port, connect the machine to power, press the green ON switch then open the valves on the gauge set. The switch will illuminate and the compressor will start when the pressure in the machine reaches approximately 14 PSI. Close the gauge set valves and allow the machine to stop automatically. 5. This unit may be equipped with a scale platform, tank float or platform/float combination for tank overfill protection. Follow the instructions below to test the overfill protection device(s). A. On units equipped with a scale platform or platform/float combination, push and hold the storage tank scale platform down and press the green ON switch. The RED tank full light will illuminate. This step confirms the scale platform microswitch is operating properly. B. On units equipped with a tank float only, disconnect the float lead from the tank connection and press the green ON switch. The RED tank full light will illuminate. This confirms that the float shut off device is functioning properly. YOUR MACHINE IS NOW READY FOR USE Note: The machine must be precharged with refrigerant to at least 14 PSI before the compressor will start. This can be accomplished by connecting to the AC system to be serviced if it is charged with refrigerant. TO RECOVER REFRIGERANT IMPORTANT: Before recovering refrigerant with the SKYE machine, the AC system must be off. NOTES: The PURGE VALVE must be open completely for the machine to perform the recovery function. 6 The sight glass on this machine is used to monitor the refrigerant input to the compressor. There should never be liquid refrigerant flowing throught the sight glass. If liquid refrigerant is detected during recovery, immediately press the OFF switch to prevent damage to the compressor. Liquid refrigerant flow through the sight glass indicates a malfunction of the flow controller mounted on the machine's inlet line. 1. Connect the unit to power, connect the outlet hose to the storage tank vapor port and open the storage tank vapor valve. 2. Connect the gauge set RED and BLUE service hoses to the AC system and the YELLOW hose to the machine inlet port. 3. Press the green ON button and slowly open the BLUE and RED gauge hand valves. The compressor will start and refrigerant will be recovered. 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 as 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 gauges remain at 0 PSI or below for at least 2 minutes with the compressor off, recovery is complete. Close the gauge set valves and press the red OFF button. 5. Drain the recovered oil into the container provided and dispose of following local, state and federal regulations. EQUIPMENT MAINTENANCE WARNING: Prior to servicing this machine refrigerant must be removed (purged) from the unit and power must be disconnected. REFRIGERANT PURGE PROCEDURE 1. Close the PURGE VALVE located on the side of the machine. 2. Connect the storage tank end of the outlet hose to the machine inlet port. 3. Connect the quick connect fitting end of the purge hose to the quick connect fitting on the side of the machine and the threaded end to the storage tank vapor port then open the storage tank vapor valve. 4. Connect the machine to power and press the green ON button. When the purge process is complete the compressor will stop automatically. Immediately disconnect the purge hose from the machine and close the tank vapor port. 5. Disconnect power from the machine. 7 YOU ARE NOW READY TO SERVICE THE UNIT FILTER CHANGE PROCEDURE 1. Remove the YELLOW front cover from the machine and locate the filter and compressor positions. 2. Remove the filter from the copper plumbing (3/8" flare fittings) and discard. 3. Replace with a new filter (FD1) and tighten fittings securely to prevent leaks. Be sure the direction of flow through the filter is correct. YOU ARE NOW READY TO CHANGE COMPRESSOR OIL COMPRESSOR OIL CHANGE PROCEDURE 1. Remove the brass seal cap from the service port on the bottom of the compressor being careful not to lose the copper washer in the cap. 2. Drain the oil into a container by tipping the unit in the direction of the port. Dispose of the oil following local, state and federal regulations. 3. Connect a short piece of hose to the port and put 8 ounces (240cc) of new compressor oil (S131-EST) into a clean container. 4. Using a gauge set, connect a vacuum pump to the oil drain port on the side of the machine, open the recovered oil drain valve and the purge valve then turn the vacuum pump on. 5. Submerge the loose end of the short hose in the new oil and allow it to drawn into the machine by the vacuum pump. When all the oil has been drawn into the machine, turn the vacuum pump off, remove the short hose from the service port, replace the service port cap securely to prevent leaks. 6. Turn the vacuum pump on and evacuate the machine for twenty (20) minutes. (While the vacuum pump is operating replace the front cover.) 7. When the vacuum is complete close the recovered oil drain valve, turn the vacuum pump off and disconnect from the machine. 8. Pressurize the machine to 14 PSI following step 4 in the set up procedure section. YOU ARE NOW READY TO RECOVER REFRIGERANT OTHER MAINTENANCE PROCEDURES COMPRESSOR OIL LEVEL CHECK 8 1. Follow the refrigerant purge procedure from page 7. 2. Disconnect power and remove the yellow front cover from the machine. 3. Locate and remove the brass cap on the compressor drain nipple. If a slight flow of oil is present, the compressor oil level is correct. If a tilt of more than five (5) degrees is required to obtain oil flow the compressor oil level is low. Change the compressor oil following the compressor oil change procedure from page 8. COMPRESSOR OIL SEPARATOR CAPILLARY LINE SERVICE If the oil return capillary line on the compressor oil separator becomes plugged follow the procedures below. 1. Follow the refrigerant purge procedure from page 7. 2. Disconnect power and remove the yellow front cover from the machine. 3. Disconnect the capillary line from the compressor only. Using compressed air, blow into the end of the capillary tube that was disconnected from the compressor. 4. Return the capillary tube to its original position, replace the front cover and remove the air from the machine using steps 4 through 8 from the compressor oil change procedure. TANK PLATFORM MICROSWITCH ADJUSTMENT This procedure requires the use of weight totaling 67 lbs. (30Kg) to depress the platform and trip the microswitch. 1. Disconnect power from machine. 2. Remove the yellow front cover from the machine. 3. Loosen the adjusting bolt locknut from the underside of the top cover of the machine and a ...