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Level 4

Airconditioning

Workshop Exercise

Task: Discharging an airconditioning system using the 3600 HR-220

Fluoromizer Recovery System Model 3600 HR-220 Instruction Manual (Short Version)

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Level 4

Airconditioning

Workshop Exercise

LOCATION AND DESCRIPTION OF UNIT FEATURES

1. Purge (ball) Valve

This valve determines what function the Model 3600HR performs. This valve points UP during recovery operations and DOWN for purging (and liquid pushpull operations). Opens or closes the inlet port. It is pointing UP (open) for all recovery operations and points DOWN for purging operations. See the description on the following page. When in the ON position, this switch starts the recovery operation by turning the compressor on. Opens or closes the outlet port. It points DOWN when it is open and to the LEFT when closed. Refrigerant hose connection for incoming refrigerant vapors. Refrigerant hose connection for outgoing refrigerant. Displays the outlet/discharge pressure. Displays the inlet/suction pressure of the system being evacuated. lndicates when the filter/drier is saturated with moisture. The moisture indicator is normally blue. When the moisture indicator turns red, moisture is present, indicating that the drier should be changed The filter drier removes moisture from the recovered refrigerant. See the filter maintenance section for more information. The oil separator drain valve is used to drain the oil that is collected in the oil separator. When this ball valve is opened, the oil drains into the oil drain bottle. This optional accessory connects to the recovery cylinder overfill sensor and automatically shuts the Fluoromizer unit off when the recovery cylinder reaches the 80% liquid fill limit. NOTE: If the Model 3600HR is equipped with an 80% shutoff cord, it will not work unless connected to a DOT recovery cylinder with a compatible level float switch. If the recovery cylinder does not have a float switch, a shorting cap must be installed in order to operate the system. Protects against high amperage. Located on the lelt side of the machine.

2. Inlet Port (ball) Valve 3. LCD Status Display 4. System Switch 5. Outlet Port (ball) Valve 6. Inlet Port 7. Outlet Port 8. Outlet Pressure Gauge 9. Inlet Pressure Gauge 10. Moisture Sight Glass

11. Filter Drier (on the back of the unit) 12. Oil Separator Drain (ball) Valve and Bottle (on the back of the unit) Automatic 80% Tank Full Shutoff Option (Not shown)

Compressor Circuit Breaker (not shown)

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Level 4 LCD DISPLAY MODE SYSTEM ON EXPLANATION

Airconditioning

Workshop Exercise

Indicates that the power switch is ON and the compressor is running

EVACUATION Indicates that the unit has shut down because the system being evacuated has COMPLETE reached 13" HG (the evacuation is complete). NOTE: A small amount of inlet pressure might be needed to reset the vacuum switch once the vacuum switch has been activated. This is normal. HIGH PRESSURE Indicates that there is a high pressure condition that must be corrected. The internat high pressure switch activates at 450 psi.

VAPOR RECOVERY PROCEDURES Steps: 1. Turn off all electrical or mechanical power to the refrigerant device to be evacuated. (Engine and aircondioning system off) 2. Make proper hose connections: Connect refrigerant hoses to recovery cylinder, Fluoromizer, and the refrigerant system as shown in fig. 1. Note: You must use an external filter/drier in the suction line in order to meet the conditions of the unit warranty. A scale must be used to monitor the refrigerant level in the recovery cylinder.

Fig.1 3. Place the inlet and purge valves in the RECOVERY position and the outlet valve in the OPEN position (fig. 2). Open the (DOT) recovery cylinder liquid valve.

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Level 4

Airconditioning

Workshop Exercise

Fig. 2 4. Turn the system switch to the ON position. The LED status display wilt indicate "SYSTEM ON". Note: The system fan is on whenever the system switch is in the ON position. 5. Always regulate the inlet port valve (liquid refrigerant might be present) WARNING: A "knocking" sound coming from the compressor indicates too much liquid is entering the compressor. The inlet valve must be regulated as shown in the shaded region until this knocking sound stops, otherwise compressor damage could occur. Pumping liquid when the compressor is knocking will damage the compressor and wilt reduce the compressor life and will void the compressor warranty. 6. Monitor the LCD status display. The unit wilt shut off automatically when the proper vacuum level is achieved and the status display wilt flash "EVACUATION COMPLETE".

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Level 4 SYSTEM ON

Airconditioning

Workshop Exercise

Indicates that the power switch is ON and the compressor is running.

EVACUATION Indicates that the unit has shut down because the system being COMPLETE evacuated has reached 13" HG (the evacuation is complete). Check the suction pressure to verify that the system being evacuated is down to at least 13" HG vacuum. Turn the system switch to the OFF position. Wait 5 minutes. If the inlet pressure rises above 0 psig. Repeat steps 3-6. If the inlet pressure remains below 0 psig, close all valves and disconnect the hose from the system being serviced. NOTE: A small amount of inlet pressure might be needed to reset the vacuum switch, this is normal. HIGH Indicates that there is a high pressure condition that must be corrected. PRESSURE Check for restrictions or a full recovery cylinder. Correct the problem and turn the system switch OFF to reset the system. Repeat steps 3-6.

7. Drain oil. Position the inlet and purge valves to the PURGE position (both pointing DOWN). Drain the oil by opening the oil drain valve located on the rear panel. The oil is completely drained when vapor is discharged (a "sputtering" sound wilt be heard). This should be done with the system switch in the OFF position. If the valves are turned while the unit is running, the system may shut off on either high pressure or vacuum (fig. 3).

Fig. 3 8. Proceed to Pump Down Operations. If the Fluoromizer is manually or automatically turned off before the evacuation is complete repeat steps 3-7. Note: If the circuit breaker trips, wait 10 seconds, reset citcuit breaker and go to step 3. If the compressor thermal overload trips, wait 16 to 30 miniutes before restarting

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Level 4 PUMP DOWN OPERATIONS

Airconditioning

Workshop Exercise

The Model 3600HR is equipped with a pump-down purge valve that allows the technician to pump down or evacuate the 3600HR before proceeding to the next recovery operation. This procedure not only eliminates cross contamination, but also conserves refrigerant. Follow the steps below to ensure your pump down operation is performed correctly. STEPS: 1. After recovery operations are complete and the system switch is in the OFF position: FIRST - Place the inlet valve in the PURGE position SECOND - Place the purge valve in the PURGE position THIRD - Place the outlet valve in the OPEN position as illustrated below. It is important to turn the valves in this order to ensure the compressor properly equalizes. 2. Turn the system switch to the "ON" position. The LCD status display wilt indicate "SYSTEM ON". NOTE: If the compressor fails to start, cycle the purge valve from the RECOVERY to PURGE position to reduce the pressure differente shown on the system's gauges. 3. Allow the unit to run until it shuts off automatically. The status display wilt flash "EVACUATION COMPLETE" indicating that the purge operation is complete. 4. Turn the system switch to the OFF position and turn the outlet valve to the "CLOSE" position, Close the inlet and outlet valves on the DOT recovery tank. During the pump down operation, the 3600HR's compressor pulls the entire system and discharge hose into a vacuum and discharges the gas directly out of the discharge port leaving no more than 1/4 ounce of refrigerant left the system. NOTE: If the purge valve is turned white the unit is running, it may cause the unit to shut off on either high pressure or vacuum. Therefore, it is recommended that you not turn this valve when the compressor is running.

Fig. 4

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Level 4

Airconditioning

Workshop Exercise

FILTER MAINTENANCE PROCEDURES The Model 3600HR is equipped with a high performance coalescing oil separator and filter/drier for recycling refrigerant as it is recovered. The moisture sight glas in the front of the machine indicates when the filter is no longer removing moisture from the refrigerant by turning pink. Normally this indicator is blue. 1. When the filter has reached its moisture holding capacity, the moisture indicator sight glas wilt change from blue to pink. When this occurs, it will be necessary to change the filter immediately in order to maintain the purity of the refrigerant. 2. Purge the unit as described in the "Pump Down Operations" section. Allow the system to run until it shuts off on evacuation complete (this may take 5-10 minutes). 3. Unscrew the old filter from the filter receiver by turning the filter counter-clockwise and discard the filter in a safe manner. 4. Apply a small amount of oil to the O-ring seat on the new filter cartridge. Inspect the filter threads to ensure they are clean and free of debris to prevent leak paths (dirt, paint chips etc.). 5. Tighten the new filter info the filter receiver hand tight. CAUTION: Do not over-tighten, O-ring damage could occur. 6. After installing the new filter, conduct another pump down operation on the system. This will remove air from the system. Allow the air removed from the system to discharge info the atmosphere (you do not need to discharge info a tank). Allow the system to shut itself off on "EVACUATION COMPLETE" 7. If the system does not pull info a vacuum, check the filter to ensure that the 0-ring is not damaged.

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Level 4 Trouble shooting guide Problem Fluoromizer compressor will not start LCD Status Evacuation complete High pressure

Airconditioning

Workshop Exercise

Possible cause vacuum pressure switch has been activated Check for restrictions in the discharge line. Ensure that the cylinder valves and discharge valves are open Recovery cylinder has reached 450 psi high pressure limit bad thermal overload circuit breaker is tripped No power to the fluoromizer Obstruction in fan blades defective fan system switch is off Evacuation is complete

Solution Turn fluoromizer off. Apply 1-2 psig pressurc to inlet port to reset vacuum switch. Remove restrictions in the discharge line

Replace with empty cylinder or cool cylinder with water/ice Call F.T. industries for service Reset circuit breaker Plug the fluoromizer into a 220 volt power source Remove obstruction Replace fan Turn system switch to on position Check inlet pressure, verify vacuum level is at least 10" Hg Ensure all valves are open

System on None

Fluoromizer fan will not start

System on

None Fluoromizer Evacuation starts but complete stops after a few minutes of operation

If refrigerant remains in the system, check for restrictions in the suction line Liquid valve on DOT cylinder closed or outlet valve is not open Other restriction(s) in discharge hose The unit is too hot. Thermal overlord tripped Circuit breaker tripped due to compressor stall Circuit breaker tripped due to too much pressure or liquid in the system

High pressure

Open the cylinder valves

System on None

Turn unit off. Remove restriction Let the unit cool down for 15 minutes Reduce the inlet and/or outlet pressure Purge the system and continue

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