OWNERS MANUAL MODEL EP-9S R12 AC SERVICE CENTER RECOVERY RECYCLING VACUUM RECHARGING WARNING - DO NOT MIX REFRIGERANTS - R12 ONLY July 11, 2000 EP9Smanb 2 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 REFRIGERANTS CONTAINING MORE THAN 3% HYDROCARBONS (Propane, Butane, etc.). 2 3 TABLE OF CONTENTS Ownership Information Important Information, Warnings & Cautions Illustrations Machine Set Up Recovery Procedure ­ Vapor & Liquid Evacuation Charging Auxiliary Recycling Non Condensable Gas Venting Temperature/Pressure Chart Equipment Service & Maintenance Purge Procedure Filter Change Procedure Compressor Oil Change Procedure Vacuum Pump Service Procedure Compressor Oil Level Check Trouble Shooting Parts Locator Warranty Electrical Schematic Flow Diagram Operating Flow Chart 2 4 5 6 7 8 8, 9 10 10 11 12 12 12, 13 13 13 14 15 16, 17 18 19 20 21 3 4 WARNING: 1. This equipment operates at high pressures and at high voltages and if improperly used may cause personal injury. 2. Must be operated by qualified and certified personnel. 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 equipment if damaged. 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 the loss of refrigerant. IMPORTANT: · Change filter (FA1) and compressor oil (S131-EST) every 30 hours. · Check the compressor oil every 10 hours. · Compressor must not be operated unless it contains the specified 8 oz. (flat side compressors) or 12 oz. (round side compressors) of oil. · Your compressor is filled initially at factory. · Change the vacuum pump oil (SA132) monthly or every 30 hours. · Close the tank valves after each machine use. · Always replace caps on inlet and outlet ports. · Routinely check your fittings for leaks. 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 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 14 minimum. NEW STORAGE TANKS MUST BE EVACUATED before use to remove any air and moisture. REFRIGERANTS The SKYE EP9S AC Service Center must only be used with R12. IMPORTANT: PREVENT ACCIDENTAL REFRIGERANT LOSS " REFRIGERATION LOSSES MOSTLY 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 ORDER AND ENSURE CAPS ARE TIGHT. " LEAK TEST FITTINGS & HOSE CONNECTIONS PERIODICALLY USING AN ELECTRONIC LEAK DETECTOR OR SOAPY WATER. " CLOSE TANK VALVES WHEN NOT IN USE. " WARNING: ELECTRICAL FAULTS MUST BE REPAIRED BY A QUALIFIED ELECTRICIAN 4 5 KNOW YOUR UNIT Your SKYE EP9S is designed for vapor and liquid Refrigerant RECOVERY, RECYCLING, VACUUM and RECHARGE of systems containing R12 ONLY. The ventilation fans run when the unit is connected to power. DO NOT LAY THE UNIT DOWN - THIS MAY CAUSE LIQUID REFRIGERANT TO SETTLE IN THE COMPRESSOR AND LOSS OF COMPRESSOR LUBRICATION. The EP-9 unit comes complete with. 1 x 96" Red service hose with ABB on one end. 1 x 96" Blue service hose with ABB on one end. 1 x Dual valve storage tank with float. 1 x Oil measuring bottle for recovered oil drain. 1 x Vapor outlet to storage tank hose with ABB one end (Attached to machine). 1 x Liquid charging/utility hose with one ABB and one quick connect fitting. EP9S MACHINE CONTROL LAYOUT 5 6 ESSENTIAL PRE-OPERATING PROCEDURES BEFORE OPERATING YOUR SKYE MACHINE FOR THE FIRST TIME, THE FOLLOWING PROCEDURES MUST BE CARRIED OUT. Your new unit is already in a vacuum. The storage tank(s) must be evacuated prior to use. Set Up Procedure: (REFER TO THE ILLUSTRATED LAYOUT ON PAGE 5.) 1. Open both the tank valves to vent the factory nitrogen charge (if any), close the LIQUID VALVE and place the tank on the scale platform. Connect the tank float lead. 2. Feed both service hoses and the power cord through the hole in the side panel. Connect the RED 96" service hose to the HIGH SIDE PORT and to the VAPOR VALVE on the storage tank. (Check tank valve handles for correct port identification - DO NOT GO BY COLOR.) 3. Connect the machine to power. 4. Turn the FUNCTION SELECTOR to the VACUUM position, open the BLUE and RED MANIFOLD VALVES and turn the VACUUM PUMP SWITCH ON. Evacuate the storage tank and machine for a minimum of 20 minutes. While evacuating remove the 2 fan shroud screws nearest the side panel hole and install the HOSE HANGER using the same screws. 5. When the vacuum is complete, turn the FUNCTION SELECTOR to the CLOSED position, CLOSE BOTH MANIFOLD VALVES and the TANK VAPOR VALVE then turn the VACUUM PUMP OFF. Disconnect the red service hose from the tank. 6. Disconnect the hose from the LOW SIDE PORT and connect it to the TANK VAPOR PORT then open the tank vapor valve. Connect the BLUE 96" service hose to LOW SIDE PORT. 7. Connect the liquid charging/utility hose to a bottle of R12 containing at least 10 lbs. of R12 and to the RECYCLE INLET PORT, open the valve on the bottle, turn it upside down for liquid and set it down in front of the machine. Press the scale keypad ON button, allow warm-up, then press the ZERO button for 2 seconds. Turn the FUNCTION SELECTOR to the RECOVER position, press the RECOVER ON button. The scale LCD will start counting up as refrigerant flows into the tank. 8. When 10 to 12 lbs. of refrigerant is in the tank, close the valve on the R12 bottle and allow the machine to stop automatically. Turn the FUNCTION SELECTOR (FS) to the CLOSED position and press the RECOVER OFF button. Remove the hose from the R12 bottle and Recycle Inlet Port then connect it to the tank liquid port and the Liquid Charging Port . If the machine is not going to be used immediately, disconnect power. YOUR MACHINE IS NOW READY FOR USE. TO RECOVER VAPOR OR LIQUID REFRIGERANT 6 7 IMPORTANT: Before recovering refrigerant with your SKYE machine, the vehicle AC system must be off. OPERATING INSTRUCTIONS: 1. Close the high side and low side manifold valves and connect the RED high side and BLUE low side service hoses to the AC system. 2. Open the storage tank VAPOR port and connect the machine to power. 3. Turn the FUNCTION SELECTOR to RECOVER and press the RECOVER ON button. (Make sure the service valve is on). NOTE: If you want to measure the amount of refrigerant being recovered, press the scale keyboard ON button, wait for warm-up to complete then press and hold the zero button for 2 seconds. When the LCD reads 0 lbs. 00 oz. proceed to next step. 4. Open the low side manifold valve slowly, when the pressure on the low side manifold gauge drops below 40 PSI slowly open the high side manifold valve. The unit will operate automatically and recover and recycle all the refrigerant in the AC system. 5. When the pressure in the AC system drops to approximately 10" VACUUM, the compressor will stop. This does not mean that all the refrigerant has been recovered as there may be refrigerant trapped in the oil or in an accumulator 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. Close the low side and the high side manifold valves. If the system pressure rises during this time, allow the machine to continue the recovery process. 6. Turn the FUNCTION SELECTOR to the CLOSED position and press the RECOVER OFF button. 7. Close the storage tank VAPOR valve. 8. Drain the RECOVERED OIL into the measuring bottle by opening the OIL DRAIN VALVE. You may replace this amount of new oil back into the AC system. NOTE: If the unit stops during recovery and when you press the RECOVER ON button the CYLINDER FULL LIGHT glows, your tank is full and must be replaced. All new tanks must be evacuated before use. EVACUATION (VACUUM) PROCEDURE 7 8 1. With power connected and both service hoses connected to the AC system, turn the FUNCTION SELECTOR to the VACUUM position. 2. Turn the vacuum pump switch on. (NOTE: The vacuum pump will not start if there is pressure in the AC system or unit plumbing. If this occurs, recover the refrigerant in the system or unit plumbing and start vacuum again.) 3. Open the Low and High side manifold valves and evacuate the system for, at least, 40 minutes. 4. When the evacuation is complete, close both manifold valves, turn the FUNCTION SELECTOR to CLOSED and turn the vacuum pump off. CHARGING PROCEDURE NOTE: WHEN CHARGING DO NOT PRESS THE RECOVER ON BUTTON. POWER MUST BE CONNECTED TO THE UNIT TO OPERATE THE CHARGING SYSTEM. IMPORTANT: THE STORAGE TANK SHOULD CONTAIN AT LEAST 5 POUNDS OF REFRIGERANT TO PERFORM THE CHARGING FUNCTION. 1. Connect the BLUE and RED service hoses to the system to be charged. 2. Open the storage tank liquid valve. (NOTE: The hose from the tank liquid port must be connected to the Charging Inlet Port. 3. Turn the FUNCTION SELECTOR to the CHARGE position then turn the scale on by pressing the scale keypad ON button. The scale will beep once and a random number will appear on the LCD readout. Allow a short warm up time to ensure the scale has self calibrated. 4. Choose the desired unit of measure by pressing either the lbs key for pounds and ounces or the KG key for kilograms. (Default is lbs) The scale will beep and reset whenever the unit of measure is changed. 5. Press and hold the ZERO key for 2 seconds. The display will read 0 lbs 00 oz. Minor fluctuation in the ounce reading is normal. 6. Press the SET key until the Red LED in the corner of the key lights and the unit beeps. 7. Enter the amount to be charged by pressing the # key. To increase programming speed when charging larger amounts, press the FAST key and the # key simultaneously. Use the $ key for fine tuning if needed. 8. Press the SET key again until the Red LED goes out and the unit beeps. The LCD display will return to ZERO. 9. Press the GO/HOLD key once to begin charging; a click will be heard as the charging solenoid opens, then open the RED and BLUE manifold valves. As refrigerant flows into the system the LCD display will begin to count up indicating the weight charged. 8 9 10. When the programmed amount of refrigerant has been dispensed, the solenoid valve will close and the scale will beep. Close the manifold valves. 11. If the refrigerant tank empties before the programmed charge is reached, press the GO/HOLD key again. The solenoid will "click" closed and the unit will beep approximately once per second; the scale will retain the current reading, indicating how much refrigerant has been charged. Replace the empty cylinder and press the GO/HOLD key again, the unit will stop beeping and resume charging the system. 12. Upon completion, turn the scale off by pressing the scale keypad OFF key. 13. Refrigerant trapped in the service hoses should be recovered by going to the vapor recovery mode prior to the next service operation. WARNING: THE MAXIMUM GROSS WEIGHT THAT CAN SAFELY BE PLACED ON THE SCALE PLATFORM IS 150 LB's (68 KG). TO RECYCLE REFRIGERANT 9 10 NOTE: This machine features single pass recycling. It will clean most refrigerant as it is being recovered. This procedure may be used when refrigerant is extremely dirty or when a tank of recovered refrigerant is to be recycled. 1. Connect the BLUE SERVICE HOSE to the TANK LIQUID PORT and open both tank valves. 2. Turn the FUNCTION SELECTOR to RECOVER and press the RECOVER ON button, the g ...