SKYE® AIR CONDITIONING SERVICE EQUIPMENT OWNERS MANUAL MODEL EP3 R12 Recovery/Recycling System WARNING - DO NOT MIX R12 WITH ANY OTHER REFRIGERANT. 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 EP3 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 - Vapor Recovery Procedure - Liquid Auxiliary Recycling Non Condensable Gas Venting 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 Replacement Parts List Temperature/Pressure Relationship Chart Warranty Operating Flow Chart Flow Schematic 2 4 5, 6 7 7 8 8 9 9 9 9 10 10 10 11 12 12 13 14 15 16 ! WARNING: 1. This equipment operates at high pressures and high voltages and, if improperly used, may cause personal injury. 3 2. Risk of injury - Must be operated by certified personnel. 3. Read instructions carefully before servicing. 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 (FA1)and compressor oil (S131-EST) every 30 hours Check compressor oil every 10 hours of operation. Compressor must not be operated unless it contains the specified 12 ounces(360cc) of oil. The compressor is filled initially at the factory. # CAUTION: It is important not to allow liquid to settle at any time in the Low side when the SKYE 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 STOP BUTTON when the compressor is running; allow it to evacuate the low side and cut out 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 EP3 Refrigerant Recovery and Recycling machine must only be used with R12. IMPORTANT: PREVENT ACCIDENTAL REFRIGERANT LOSS % REFRIGERANT LOSSES MOSTLY OCCUR THROUGH LOOSE CONNECTIONS AND SCHRADER VALVES. % 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 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 The SKYE EP3 meets the SAE-J1991 standard for recycled R12 refrigerant purity as tested by Underwriters Laboratories, Inc. 4 Your SKYE EP3 is designed for vapor and liquid refrigerant RECOVERY and RECYCLING for systems containing R12 only. 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 EP3 comes complete with: 1 x 50 lb. (23kg)Dual Valve Storage Tank 1 x Recovered Oil Measuring Bottle 1 x Hose Hanger 5 EP3/EP3N Series--Back View Item # 15 16 17 18 19 20 21 Description Moisture Indicator Gage, System Pressure, R12 / R-134a Hose, 24", R-12 Hose, 24", R-134a Hose, 24", R-12 Hose, 24", R-134a Belt, Nylon with Buckle Microswitch, Tank Platform Equipped Units Only Storage Tank, 50 lbs. Non-Float EP3, EP10A, EP10M Storage Tank, 50 lbs. Non-Float EP3N Storage Tank, 50 lbs. -Float EP3 Storage Tank, 50 lbs. ­Float EP3N Wheel Axle Part # SA174 / SAR150 SA124 SAR1404 SA124 SAR1404 H12 S115 USA131 USA131N USA131F USA131NF S102 S101 22 6 ESSENTIAL PRE-OPERATING PROCEDURES Before operating your SKYE machine for the first time, the following procedures must be performed. Your new machine is in a vacuum. Vacuum tank(s) before use. SET UP PROCEDURE 1. Open the storage tank vapor port (marked vapor) then locate and remove the gauge set prop rod from the storage tank cavity. 2. Remove the yellow cover from the machine and install the gauge set prop rod using the two holes on the right side frame channel then reinstall the yellow cover. 3. Connect the yellow (center) gauge set hose to the VAPOR INLET PORT on the back of the machine and hang the gauge set on the prop rod. 4. Connect the machine to power and press the green ON switch button. The button will illuminate. 5. On units equipped with a tank scale platform, press the platform down with the edge of your foot. The green ON button light will go out. 6. Continue to hold the platform down and press the green ON button. The RED tank full light will illuminate. Steps 5 & 6 confirm the tank full microswitch is operating properly. 7. On units equipped with a tank float, disconnect the float lead from the tank then press the green ON button. The RED tank full light will illuminate confirming correct float operation. YOUR MACHINE IS NOW READY FOR USE Note: This machine must be precharged with refrigerant to at least 14 PSI before the compressor will start. This can be accomplished by connecting to the vehicle AC system to be serviced or by recovering from a virgin cylinder. TO RECOVER VAPOR REFRIGERANT IMPORTANT: Before recovering refrigerant with the SKYE machine, the vehicle AC system must be off. NOTE: If the system contains more than 5 lbs. of refrigerant, use the liquid recovery procedure described in the next section. 1. Connect the unit to power and open the storage tank vapor valve. 2. Connect the YELLOW service hose to the vapor inlet port on the machine and the RED and BLUE service hoses to the AC system. 3. Press the green ON button and slowly open the BLUE (low pressure) gauge hand valve. The compressor will start. 4. When the pressure on the BLUE (low pressure) gauge drops to 40 PSI, open the RED (high pressure) gauge hand valve. 5. 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 7 sensed. When the gauges remain at 0 PSI or below for at least 2 minutes recovery is complete. Close the gauge set valves and press the red OFF button. 6. Close the storage tank vapor valve. 7. Drain the recovered oil into the measuring bottle provided. You may replace this amount of new oil back into the AC system. NOTE: If the unit stops during the recovery process and the red TANK FULL light glows when the ON button is pressed, the tank is full and must be replaced. All new tanks must be evacuated prior to use. TO RECOVER LIQUID REFRIGERANT IMPORTANT: Your manifold gauge set yellow (center) hose must have a Schrader valve depresser installed or an ABB valve with a built in depresser. 1. Connect the manifold gauge set yellow (center) hose to the LIQUID inlet port on the back of the machine and open the storage tank vapor valve. 2. Connect the service hoses to the vehicle AC system and connect the machine to power. 3. Press the green ON button and open both manifold gauge set valves. The machine will control the recovery rate. 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 recovery is complete. Close the gauge set valves and press the red OFF button. 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 back into the AC system. NOTE: If the unit stops during the recovery process and the red TANK FULL light glows when the ON button is pressed, the tank is full and must be replaced. All new tanks must be evacuated prior to use. AUXILIARY RECYCLING NOTE: The storage tank must be at least 50% full for this function to be effective. 1. Connect the machine to power and press the green ON button. 2. Open the storage tank vapor valve then the liquid valve and allow the machine to run for a minimum of 3 hours. 3. When recycling is complete, close the storage tank liquid valve, allow the compressor to stop automatically then press the OFF button. DO NOT PRESS THE OFF BUTTON WHILE THE COMPRESSOR IS RUNNING. 4. Close the storage tank vapor valve. NON-CONDENSABLE GAS (NCG) VENTING PROCEDURE IMPORTANT: Allow the unit to stand for a minimum of 2 hours prior to venting NCGs. This will allow the refrigerant to stabilize and gases to separate. 8 NOTE: Perform the NCG check daily prior to operating your machine. The NCG bleed valve on the upper rear center of the machine allows manual venting of noncondensable gases that may accumulate during the recovery process. 1. With the storage tank vapor port open and the BLUE gauge valve closed, connect the BLUE (low pressure) hose from your gauge set to the NCG BLEED VALVE then open the bleed valve. 2. Compare the pressure reading on the BLUE low pressure gauge to the R12 TEMPERATURE PRESSURE RELATIONSHIP CHART on page 11. 3. If the gauge reading is 5 PSI or more higher than the pressure for that temperature, open the BLUE gauge valve and slowly bleed off pressure until the pressure reading is within 5 PSI of the correct pressure then close the NCG Bleed Valve. EQUIPMENT SERVICE AND MAINTENANCE WARNING: Before any service operation can be performed, it is necessary to purge the refrigerant from the machine system. DO NOT open unit components until all refrigerant has been purged from the system. PURGE PROCEDURE 1. Drain any recovered oil using the recovered oil drain valve on the side of the machine. 2. Remove the yellow cover from the machine, locate the Backseat Valve mounted just above the center of the compressor and remove the shaft cover. 3. Open the storage tank vapor valve, connect the machine to power and press the green ON button. 4. When the compressor stops running, immediately close the Backseat Valve (turn the shaft counter-clockwise). The valve shaft flats are 1/4" square drive. 5. Press the red OFF button, close the storage tank vapor valve 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 # FA1) includes new gasket. 1. Purge the system as described above. 2. Remove the 8 bolts from the filter housing cover, remove the cover, remove the old gasket from the machined groove then remove the old filter core from the housing. 3. Lubricate the new gasket with ESTER oil, install it in the cover groove then install the new filter core in the housing with the HOLE END DOWN. 4. Replace the filter cover on the housing and tighten the bol ...