mobile refrigerant recovery/recycling system

®
MOBILE
REFRIGERANT
RECOVERY/RECYCLING
SYSTEM
MODEL
AR500
AR512
SERIES
TO BE OPERATED
BY QUALIFIED
PERSONNEL ONLY!
This equipment has been certified by ITS/ETL to meet or
excees SAE J1990 and J1991 for AR512 series and
SAE J2099 and J2210 for AR500 series
OPERATION MANUAL
UNIT CONSISTS OF:
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Pro-Set® AR500/AR512
model series recovery unit
Power Cord Set
Suction Hose assembly with
service fitting for either
R-12 (AR512) or R-134a (AR500)
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Discharge Hose assembly with
Ball Valve
Magnetic Tank Thermometer
Oil Drain Hose
Operation Manual
50 lb Recovery Tank with overfill
sensor
TABLE OF CONTENTS
INTRODUCTION ...................................................................................
GENERAL SAFETY INSTRUCTIONS .....................................................
SPECIFICATIONS .................................................................................
DIRECT LIQUID OR VAPOR RECOVERY ..............................................
LIQUID PUSH-PULL RECOVERY .........................................................
ROUTINE MAINTENANCE ....................................................................
TROUBLE SHOOTING CHART ..............................................................
HELPFUL HINTS ..................................................................................
WARRANTY & CONTACT INFORMATION ............................................
2
3
4
5
5
6
7
7
8
INTRODUCTION
Thank you for purchasing the CPS® PRO-SET® AR500/AR512 model series unit. CPS is dedicated to give you the lightest, fastest and most reliable equipment to meet all your mobile
refrigerant recovery/recycling requirements. In doing this CPS has integrated its latest technolo9gy and incorporated state of the art features while improving reliability and speed.
The AR500/AR512 model series is designed for servicing mobile air conditioning systems.
Simply follow the quick start and turn it on. Follow the air purge procedure and the refrigerant has been completely recycled for future use.
The PRO-SET® AR500/AR512 model series utilizes a new valve less 1/3hp (0.75kW)
oil-less compressor.
The following are additional features:
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“On the Run” Self-CLEARING VAVLE: No need to turn the unit off when switching from
recovery to self-clearing.
On Board SUCTION and DISCHARGE gauges
Small physical size
Weighs only 10.9 kg (24 lbs)
COMFORTABLE integrated carrying handle
2
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550 psig High-pressure cutout
BUILT-IN FILTER: located under intake port. No dangling filters to damage.
FILTER CARTRIDGE can be easily cleaned or replaced
Integrated Filter Drier with Moisture Indicator
Suction and Discharge Shut off valves
HIGH EFFICIENCY rifle-fin condenser/evaporator
INDESTRUCTABLE high density polyethylene case
HEAVY DUTY powder coated aluminum chassis
MAINTENANCE FREE oil-less compressor
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Suction Oil Separator to collect and measure removed from the mobile A/C system
To help you get a good start, please continue to carefully read the balance of this
manual. This manual contains important information on the proper procedures
for operating this equipment. Please pay close attention to the safety information,
WARNING and CAUTIONS provided throughout this manual. Always remember
“SAFETY FIRST”.
Filter Drier with
Moisture Indicator
Suction Gauge and Valve
Discharge Gauge and Valve
SUCTION Port w/Filter
SELF-CLEARING Valve
DISCHARGE Port
POWER Switch
Oil Drain Port
Thermal Circuit Breaker
IEC 320 Electrical Inlet
Tank Overfill Umbilical Cord
(not on AR500E)
2
GENERAL SAFETY INSTRUCTIONS
ONLY QUALIFIED SERVICE PERSONNEL SHOULD OPERATE THIS UNIT.
MOST STATES, COUNTRIES, PROVINCES, ETC...MAY REQUIRE THE USER TO BE
LICENSED. PLEASE CHECK WITH YOUR GOVERNMENT AGENCY.
DANGER - the recovery tank contains liquid
refrigerant. Overfilling of the recovery tank
may cause a violent explosion resulting in
severe injury or even death. As a minimum
use a scale to
continuously monitor the
recovery tank weight.
CAUTION - avoid breathing refrigerant
vapors and/or lubricant mist. Exposure may
irritate eyes, nose, throat, and skin. Please
read the manufacturers Material Safety Data
Sheet for further safety information on
refrigerants and lubricants.
DANGER - Avoid breathing refrigerant vapors
and lubricant vapor or mist. Breathing high
concentration levels may cause heart
arrhythmia, loss of consciousness, or even
cause suffocation.
CAUTION - to reduce the risk of fire, avoid
the use of extension cords thinner than
NO.14 awg. (1,5mm2) to prevent the overheating of this cord please keep length to a
minimum.
DANGER - ELECTRICAL SHOCK HAZARD - CAUTION - do not use this equipment in the
Always disconnect power source when serv- vicinity of spilled or open containers of gasoicing this equipment.
line or other flammable substances. Make
certain that all safety devices are functioning
DANGER - EXPLOSION RISK. Do not recov- properly before operating the equipment.
er flammable refrigerants.
This equipment is intended for use of one
CAUTION - all hoses may contain liquid
refrigerant at a time until the SELF-CLEARrefrigerant under pressure. Contact with
ING feature is used. Mixing of different
refrigerant may cause frostbite or other relat- refrigerants will cause your recovered supply
ed
of refrigerant to become contaminated.
injuries. Wear proper personal protective
NOTE: It is very expensive to destroy mixed
equipment such as safety goggles and or damaged refrigerants.
gloves. When disconnecting any hose,
please use extreme caution.
2
2
Direct Vapor
Direct Liquid
Push-Pull Liquid
MODELS
Compressor Type
Dimensions
Weight
Operating Temperature Range
Power Source
Power Consumption
Filtration
Shut-off Valves
Construction
Overload Protection
High Pressure Shut-off
Refrigerants
AR500J
AR500S
1/3 HP Oil-less Reciprocating Compressor
20cm (8") wide x 37cm (14.5") long x 30.5cm (12") high
10.9 kg (24 lbs.)
0°C (32°F) to 49°C (120°F )
115 VAC 50/60 Hz 1Ph
100 VAC 50/60 Hz 1Ph
220-240 VAC 50/60 Hz 1Ph
500 W
Cleanable 100-mesh screen integrated into Suction Port
Both Suction and Discharge manifold ball valves
Heavy gauge aluminum chassis with High Density Polyethylene Case
10A thermal circuit breaker
5A thermal circuit breaker
550 psig/55bar/5500kPA/5.5MPa
R-134a for AR500 series, R-12 for AR512 series,
Flow Rate
Up to .75 lb./min
Up to 3.00 lb./min
Up to 10.00 lb./min
AR500/AR512
AR500/512 SERIES SPECIFICATIONS
DIRECT VAPOR OR LIQUID RECOVERY OPERATION
1. Connect the unit as shown in Diagram 1.
Note: Connect Yellow Safety Cord to Recovery Tank.
2. Open the vapor valve on the Recovery Tank.
3. Open Discharge valve on AR unit.
4. Rotate the center valve to the “Recovery”
position.
5. Turn power switch to “ON” position.
6. Once unit has started, open the Suction valve
on the AR unit to start the refrigerant flow.
VAPOR
VA LVE
REFRIGERANT
CONT AINING
UNIT TO BE
SERVICED
SERVICE
PORT
RECOVERY
TANK
SCAL E
NOTE: If liquid refrigerant is present, a
Diagram 1
hammering sound will come from the compressor.
Use the SUCTION valve to meter or regulate the incoming refrigerant until the
hammering sound goes away. The Suction gauge will read the regulated pressure to the
compressor.
7. Monitor the suction gauge until it falls below the required vacuum level. Close the
Suction valve.
8. Rotate the center valve to the Self-Clearing position. Again monitor suction gauge.
Once the gauge reads a vacuum, close Suction valve and turn unit OFF.
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Recovery and Self-Clearing are complete.
DRAIN AND MEASURE A/C OIL FROM OIL DRAIN PORT.
2
LIQUID FLUSH OPERATION
REFRIGERANT
CONT AINING
UNIT TO BE
SERVICED
SERVICE
PORT
LIQUID
VA LVE
VAPOR
VA LVE
REFRIGERANT
SIGHT GLASS
RECOVERY
TANK
SCAL E
Diagram 2
1.
Connect the unit as shown in Diagram 2.
Note: Connect Yellow Safety Cord to Recovery Tank.
2. Open both valves on the Recovery Tank.
3. Open Discharge valve on AR unit.
4. Rotate the center valve to the “self-clearing” position.
5. Turn power switch “ON” position.
6. Once unit has started, open the Suction valve on the AR unit to start the refrigerant
flow.
7. Allow the liquid refrigerant to circulate for 10-20 minutes.
Note; If liquid refrigerant is present, a hammering sound may come from the
compressor. Use the SUCTION valve to meter or regulate the incoming refrigerant
until the hammering sound goes away. The SUCTION gauge will show the pressure
being regulated to the compressor.
8. When the flush time is complete, close the Recovery Tank liquid valve. The recovery
process will begin to remove the remaining refrigerant from the mobile A/C system.
9. Monitor the suction gauge until it falls below the required vacuum level.
10. Rotate the center valve to the SELF-CLEARING position. Again monitor suction
gauge. Once the gauge reads a vacuum, close Suction valve and turn unit OFF.
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THE FLUSHING PROCESS IS COMPLETE..
2
AIR PURGE PROCEDURE
(NON-CONDENSABLE GASES, NCG’S)
From time to time it will be necessary to purge the recovery tank of non-condensable
gases (NCG’s). The NCG’s are picked up from leaks in a/c systems, service valves left
open, etc.… The best time to check for purging is first thing in the morning before using
the unit or 30 minutes after the last recovery/recycling operation. This gives the refrigerant
time to stabilize. Read tank temperature.
PROCEDURE TO READ TANK PRESSURE:
1) Connect the suction hose from the unit’s Suction port to the liquid port of the
Recovery tank.
2) Open the Suction valve and the Tank Liquid valve. Read pressure reading on
suction gauge.
3) Use the NCG’s purge table to determine if the refrigerant in the recovery tank
needs to be purged of NCG’s.
If purging is required:
1. Open the Recovery Tank vapor valve to vent the NCG’s.
2. Once the pressure of the tank falls below the NCG Gases purge table, close the
Recovery Tank vapor valve.
Example 1:
R-134 Tank Temperature = 76 °F
R-134 Tank Pressure = 86 psig
Example 2:
R-12 Tank Temperature = 88 °F
R-12 Tank Pressure = 118 psig
Max. Pressure (from Table)=90.3 psig
No NCG purging required.
Max. Pressure (from Table)=106.5 psig
Purge NCG’s until Tank Pressure is
below 106.5 psig
CAUTION: DO NOT DISCONNECT HOSES.
THE AR500 CONTAINS HIGH PRESSURE REFRIGERANT.
When the purge process is completed, close the Recovery Tank liquid port. Connect the discharge hose from the discharge port on the unit to the Recovery Tank vapor port. Run the
unit in the Self-Clearing mode. This will clear the AR500 of any residual refrigerant. See
Direct Liquid or Vapor Recovery Operation on page 10 for further details.
2
MAXIMUM
CHART
MAXIMUMREFRIGERANT
REFRIGERANTVAPOR
VAPORPRESSURE
PRESSRE CHART
(TEMPERATURE ˚F/˚C vs. PRESSURE)
TEMPERATURE
MAXIMUM REFRIGERANT PRESSURE
˚F
˚C
R-12 psig
R-12 bar
R-12 kPa
R-12 MPa
R-134 psig
R-134a bar
R-134a kPa
32.0
0.0
40.1
2.76
276
.276
37.8
2.61
261
.261
34.0
1.1
41.7
2.88
288
.288
39.5
2.72
272
.272
36.0
2.2
43.4
2.99
299
.299
41.3
2.85
285
.285
38.0
3.3
45.2
3.12
312
.312
43.2
2.98
298
.298
40.0
4.4
46.9
3.23
323
.323
45.1
3.11
311
.311
42.0
5.6
48.8
3.37
337
.337
47.0
3.24
324
.324
44.0
6.7
50.7
3.50
350
.350
49.1
3.39
339
.339
46.0
7.8
52.7
3.63
363
.363
51.1
3.52
352
.352
48.0
8.9
54.7
3.77
377
.377
53.3
3.68
368
.368
50.0
10.0
56.7
3.91
391
.391
55.5
3.83
383
.383
52.0
11.1
58.8
4.05
405
.405
57.7
3.98
398
.398
54.0
12.2
61.0
4.21
421
.421
60.1
4.14
414
.414
56.0
13.3
63.2
4.36
436
.436
62.3
4.30
430
.430
58.0
14.4
65.4
4.51
451
.451
65.0
4.48
448
.448
60.0
15.6
67.7
4.67
467
.467
67.5
4.66
466
.466
62.0
16.7
70.1
4.83
483
.483
70.1
4.83
483
.483
64.0
17.8
72.5
5.00
500
.500
72.7
5.01
501
.501
66.0
18.9
75.0
5.17
517
.517
75.5
5.21
521
.521
68.0
20.0
77.6
5.35
535
.535
78.3
5.40
540
.540
70.0
21.1
80.2
5.53
553
.553
81.2
5.60
560
.560
72.0
22.2
82.9
5.72
572
.572
84.2
5.81
581
.581
74.0
23.3
85.6
5.90
590
.590
87.2
6.01
601
.601
76.0
24.4
88.4
6.10
610
.610
90.3
6.23
623
.623
78.0
25.6
91.3
6.30
630
.630
93.5
6.45
645
.645
80.0
26.7
94.2
6.50
650
.650
96.8
6.68
668
.668
82.0
27.8
97.2
6.70
670
.670
100.2
6.91
691
.691
84.0
28.9
100.2
6.91
691
.691
103.6
7.14
714
.714
86.0
30.0
103.3
7.12
712
.712
107.1
7.39
739
.739
88.0
31.1
106.5
7.34
734
.734
110.7
7.63
763
.763
90.0
32.2
109.8
7.57
757
.757
114.4
7.89
789
.789
92.0
33.3
113.1
7.80
780
.780
118.2
8.15
815
.815
94.0
34.4
116.5
8.03
803
.803
122.1
8.42
842
.842
96.0
35.6
120.0
8.28
828
.828
126.1
8.70
870
.870
98.0
36.7
723.5
8.52
852
.852
130.1
8.97
897
.897
100.0 37.8
127.2
8.77
877
.877
134.3
9.26
926
.926
102.0 38.9
130.9
9.03
903
.903
138.5
9.55
955
.955
104.0 40.0
134.7
9.29
929
.929
142.9
9.86
986
.986
106.0 41.1
138.5
9.55
955
.955
147.3
10.16
1016
1.016
108.0 42.2
142.4
9.83
983
.983
152.8
10.54
1054
1.054
110.0 43.3
146.4
10.10
1010
1.010
156.5
10.79
1079
1.079
112.0 44.4
150.0
10.38
1038
1.038
161.3
11.12
1112
1.112
114.0 45.6
154.7
10.67
1067
1.067
166.1
11.46
1146
1.146
116.0 47.8
158.9
10.96
1096
1.096
171.1
11.80
1180
1.180
118.0 47.8
163.2
11.26
1126
1.126
176.1
12.14
1214
1.214
120.0 48.9
167.7
11.57
1157
1.157
181.3
12.50
1250
1.250
2
R-12 MPa
ROUTINE FILTER MAINTENANCE
Filter Maintenance - the CR SERIES is equipped with a 100 mesh screen filter. This filter
should be checked periodically. A partially clogged filter will slow down the recovery rate of
this unit.
Replace the filter cartridge as follows:
1. Use a 7/8” socket or boxed end wrench to loosen the suction port as shown in Figure 1.
2. Once loose, remove the suction port- filter cartridge assembly is shown in Figure 2.
3. Either clean the current cartridge or replace with new cartridge. CRXF3
4. Inspect o-ring. Re-lubricate with compressor oil or equivalent.
5. Place filter back into suction port fitting.
6. Hand tighten this assembly back onto the CR unit.
7. Use a 7/8” socket or boxed end wrench to tighten 1/8 of a turn. DO NOT OVER TIGHTEN,
damage to the O-ring may occur.
8. Check the connection for leaks.
Figure 1
Figure 2
LIQUID FILTER DRIER MAINTENANCE
LIQUID FILTER DRIER MAINTENANCE - the AR SERIES is equipped with 16 cubic inch
filter drier with an integrated moisture indicator. This filter should be checked and replaced
periodically. This filter drier removes any moisture that maybe contained in the recovered
refrigerant.
Replace the filter drier as follows:
1. Run the unit per the RECOVERY directions on page 6, except cap
off the suction port. The suction valve should be open. It is
important to run the SELF-CLEARING portion of this procedure.
Failure to due so will leave residual refrigerant in the filter drier.
2. View the suction gauge until it shows a vacuum. Once in a vacuum
while in the SELF-CLEARING mode, the filter drier should be
emptied of all residual refrigerant removed.
Caution: Always assume the presence of high pressure
refrigerant when removing filter drier.
3. Remove filter drier by loosening the brass flare nuts on each end of
the filter drier. Pull filter drier out of the plastic holders.
Figure 3
4. Install new filter drier - ARXF2. Make sure arrow points to the right,
Figure 3.
5. Tighten brass flare nut onto each end of the new filter drier.
6. Check for leaks.
• FILTER DRIER REPLACEMENT IS COMPLETE.
2
TROUBLE SHOOTING CHART
PROBLEM: The unit will only pull down to 0 pressure or a slight vacuum.
SOLUTION: Remove refrigerant hose from Suction port. Place a cap on this port:
1. If the unit pulls a vacuum, then the low side leak is somewhere between the refrigerant
hose and the equipment being recovered.
2. If the unit does not pull a vacuum, then suspect an internal low side leak on the CR unit.
PROBLEM: The unit starts for a few minutes, then shuts-off.
SOLUTION: The high pressure switch has activated. Make sure the discharge valve is open.
Make sure the recovery tank valve(s) are open. Check for any other restrictions on the
discharge port of the unit. Correct restriction. Restart the unit.
PROBLEM: The unit does not start and the thermal circuit breaker activates.
SOLUTION: If the unit fails to start, open the suction valve and rotate the center valve to
the “Self-Clearing” position for 5-10 seconds. Then rotate back to the “RECOVERY” position. Reset circuit breaker. Push the START switch.
PROBLEM: The unit recovers at a very slow pace.
SOLUTION: Check the suction port filter. Replace or clean.
2
WARRANTY & REPAIR POLICY
CPS® Products, INC. guarantees that all products are free of manufacturing and
material defects for one year. If the equipment should fail during the guarantee
period it will be repaired or replaced (at our option) at no charge. This guarantee does not apply to equipment that have been altered, misused, or returned
solely in need of field service maintenance. This repair policy does not include
equipment that is determined to be beyond economical repair. All products
being returned for warranty repair must be accompanied by an original bill of
sale and customer contact information
CPS PRODUCTS, INC.
1010 East 31st Street, Hialeah, Florida 33013, USA
Tel: 305-687-4121, 1-800-277-3808, Fax: 305-687-3743
e-mail: [email protected] www.cpsproducts.com
CPS CANADA
4605 Crysler Ave. Niagara Falls, Ontario L2E 3V6
Tel: 905-358-3124, Fax - 905-358-7187, 1-866-629-3895,
e-mail: [email protected]
CPS PRODUCTS N.V
Krijgsbaan 241, 2070 Zwijndrecht, Belgium
Tel: (323) 281 30 40, Fax: (323) 281 65 83, www.cpsproducts.be,
e-mail: [email protected]
CPS AUSTRALIA PTY. LTD.
109 Welland Avenue, Welland, South Australia 5007
Tel: +61 8 8340 7055, Fax: +61 8 8340 7033
e-mail: [email protected]
CPS ASIA
56A Kallang Pudding Road #02-00 Singapore 349329
Tel: (65) 68461056, Fax: (65) 68461057
e-mail: [email protected]
#73-020 RevB