Appion G5Twin User manual

FOR REFRIGERANT RECOVERY
OPERATION MANUAL
COPYRIGHT © 2016 - APPION INC. - ALL RIGHTS RESERVED
APPIONTM AND G5TWINTM ARE TRADEMARKS OF APPION INC.
⚠ WARNING
TO REDUCE THE RISK OF INJURY OR PRODUCT
DAMAGE, READ OPERATION MANUAL PRIOR TO
OPERATING PRODUCT.
Explosion Hazard. Do NOT use with hydrocarbons. See page 4.
⚠ DANGER
www.AppionTools.com

3
Table of Contents
Warnings and Safety Information.................................................................4 - 5
Refrigerant Storage Container Safety ...............................................................6
Getting Started ..............................................................................................7
Machine Usage
G5Twin Operational Layout ..........................................................................8
Preparing for Operation................................................................................8
Standard Recovery Procedure .......................................................................9
High-Speed Direct Liquid Recovery Procedure .............................................. 10
Standard Recovery with Inline Cooling ........................................................ 11
Push Pull Recovery Procedure..................................................................... 12
Purging Non-Condensables from Recovery Cylinders .................................... 13
Changing Between Refrigerant Types .......................................................... 13
Storing the Machine Between Uses .............................................................. 13
Helpful Hints
Planning Ahead.......................................................................................... 14
Tips for Maximizing Recovery Performance ............................................. 14-17
Extension Cords and Low Voltage ................................................................ 17
Care and Maintenance
Screen Cleaning & Replacement .................................................................. 18
Planned Maintenance & Bench Test ............................................................. 18
Specications and Support
Troubleshooting Guide ............................................................................... 19
G5Twin Specications, Repair Part Kits & Accessories ................................... 20
Parts Diagram and Operational Diagrams................................................ 21-22
Manufacturers Limited Warranty................................................................. 23
Welcome to the G5Twin
Thank you for your purchase of the Appion G5Twin Refrigerant Recovery Machine. This machine was designed
to deliver fast, reliable recovery of Class III, IV and V refrigerants. Use of this machine for any other purpose is
done at your own risk.
Faster refrigerant recovery requires proper training, preparation, and operation. Working with refrigerants
under pressure also presents numerous safety risks and hazards.
To safely reach the full potential of this machine, read this manual and all safety material before use.
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED

4
Warnings and Safety Information
IMPORTANT - READ THIS MANUAL BEFORE OPERATION
This Operation Manual contains important information for protecting your safety and preventing equipment
problems. Unsafe operation could lead to serious injury or death to you or others. For best results and safe
operation, read this entire manual before operation. Keep this manual in a safe, accessible location during
operation.
⚠ WARNING
When working with refrigerants, always use the appropriate Personal Protective Equipment
(PPE), including eye and hand protection. Read all Material Safety Data Sheets (MSDS) for any compounds
that you are likely to encounter during operation. Failure to do so could lead to injury or death.
OPERATOR TRAINING, CERTIFICATION AND RESPONSIBILITY
⚠ NOTICE
This machine compresses and pumps liquid and vapor refrigerants at high pressures, which
can create dangerous conditions. This equipment is for use by technicians that are professionally trained and
certied in the safe handling of refrigerant, and safe refrigerant recovery techniques.
PERSONAL PROTECTIVE EQUIPMENT AND MSDS
HAZARD: RISK OF EXPLOSION OR FIRE
⚠ DANGER
Use of this equipment may pose certain explosion and re hazards.
WHAT CAN HAPPEN HOW TO PREVENT IT
It is possible for electrical components within the
unit to spark. If electrical sparks come into contact
with ammable vapors, they may ignite, causing re
or explosion.
Use only in well ventilated areas. In enclosed areas,
mechanical ventilation should provide at least four
air changes per hour.
Flammable/combustible gases and air may become
unknowingly ingested through leaks in hoses,
gaskets, connections or leaking seals, leading to
compression of these gases. Air and hydrocarbons,
if pumped to a tank, create an explosive mixture
that random static electricity could ignite.
Do not use in the vicinity of spilled or open
containers of gasoline, propane, butane, acetylene,
or other ammable gases.
Do not use near open sewer lines which may be
emitting sewer gases.
Flammable substances may ignite or explode when
compressed in certain situations.
Do not use this machine to pump hydrocarbons,
including blends containing butane, isobutane, or
propane. Hydrocarbons are ammable substances
and may ignite or explode when compressed in
certain situations.
Improper use of extensions cords may result in
overheating or re in the cord or machine.
Use only 12AWG or 10AWG extension cords:
- Up to 25 Feet: 12/3 UL/CSA cord
- Up to 100 Feet: 10/3 UL/CSA cord
⚠ NOTICE
Keep away from children at all times. Do not leave unattended.
⚠ NOTICE
Never defeat the safety features of this product. Do not operate with missing, broken, or
unauthorized parts. Remove broken or altered equipment from service immediately.
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED

5
Warnings and Safety Information(continued)
HAZARD: RISK TO BREATHING (ASPHYXIATION)
⚠ DANGER
Air and refrigerants pumped by this machine may pose certain breathing hazards.
WHAT CAN HAPPEN HOW TO PREVENT IT
Refrigerant vapors may be harmful or toxic when
inhaled.
Use only in well ventilated areas. In enclosed areas,
mechanical ventilation should provide at least four
air changes per hour.
Compressed air from this machine may contain
carbon monoxide or toxic refrigerant vapors.
Air from this machine should never be used to
supply air for human consumption
HAZARD: RISK FROM MOVING COMPONENTS
⚠ WARNING
This machine is equipped with a fan and motor rotating at high speeds.
WHAT CAN HAPPEN HOW TO PREVENT IT
Debris or other objects may enter the machine
housing through the air vents, causing machine
damage.
Be sure the area around the machine is free and
clear of debris before operating the machine.
Physical damage may occur to body parts, tools,
or other objects if inserted into the air vents of the
machine while it is running.
Always unplug the machine and ensure that the fan
and motor are not rotating before opening the case
or inserting any object into the machine.
Damage may occur to the machine and surrounding
objects if the machine is dropped while running.
Use caution while moving this equipment,
especially during operation.
HAZARD: RISK FROM NOISE
⚠ CAUTION
Moving components, high airow, and pumping refrigerant can all cause noise.
WHAT CAN HAPPEN HOW TO PREVENT IT
Under some conditions and duration of use, noise
from the unit may contribute to hearing loss.
Always wear certied safety equipment, including
ANSI or equivalent hearing protection.
HAZARD: RISK FROM UNATTENDED OPERATION
⚠ CAUTION
Factors aecting operation may change during the recovery process.
WHAT CAN HAPPEN HOW TO PREVENT IT
As refrigerant recovery is a dynamic process, and
oen performed in open spaces, factors aecting
the operation of the unit may change.
Always remain in attendance with the machine
while it is operating.
Remain observant to changes in environment,
refrigerant pressure and refrigerant temperature.
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED

6G5TWIN OPERATION MANUAL
⚠ WARNING
Use only DOT CFR 49 or UL-approved storage containers for recovered refrigerant.
WHAT CAN HAPPEN HOW TO PREVENT IT
Refrigerant storage containers may vent or explode
when the working pressure of the container is
exceeded.
Refrigerant storage containers are designed with
dierent working pressures. Verify that the rating
of the storage cylinder is appropriate for the
refrigerant being recovered.
For R-410a, 4BA400 and 4BW400 are appropriate rat-
ings for refrigerant storage containers.
“80% Shut O Switches,” also known as Tank
Overll Sensors and Overll Protection devices, may
fail to prevent overlling of the storage cylinder,
leading to venting or explosion.
These sensors only cut power to the recovery
machine, and do not stop the ow of refrigerant,
which may continue due to a siphon, or due to
temperature-induced migration.
Do not rely on these switches to prevent overlling.
Only a refrigerant scale can provide an active and
accurate measurement of the amount of refrigerant
in the storage container.
Do not rely on these switches to stop the ow of
refrigerant into the container. Only the valves on the
recovery machine and on the cylinder can stop the
ow of refrigerant into the container.
Refrigerant expands when heated (Diagram 1), and
storage containers may vent or explode when lled
over 80% capacity.
A refrigerant scale must be used to monitor the
amount of refrigerant in the storage container.
Be sure to close the valves on the storage container
when it has reached 80% capacity.
Filled to
80% Capacity
Filled to
90% Capacity
Diagram 1
Overlled storage containers may
explode due to liquid refrigerant
expanding when heated.
Transportation of refrigerant storage
cylinders more than 80% full is a DOT
violation.
Refrigerant Storage Container Safety
© 2016 APPION INC. - ALL RIGHTS RESERVED

7
Getting Started
⚠ CAUTION
Always use a grounded outlet that meets minimum voltage supply requirements for industrial
equipment. Do not use with portable power generators.
⚠ CAUTION
Always open valves slowly for safety, and to check for leaks.
⚠ CAUTION
The G5Twin is equipped with a 550psi (38.6 kg/cm2) pressure shut o switch to protect the
machine from damage. This does not prevent overlling of the storage container. (See Page 6)
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
CHECKING YOUR RECOVERY EQUIPMENT
ACCESSORY EQUIPMENT
Before connecting or operating the G5Twin, verify that the G5Twin will be able to operate properly:
• Check that the debris screen at the inlet tting is clean before starting every job. This screen prevents
damage to the machine that may get past the inline lter. When pumping dirty/used refrigerant, this screen
may quickly clog and slow the process when used without an inline lter.
• Verify the power source provides adequate voltage at the machine while it is running (within 10% of the
rated power). When using an extension cord, follow the sizing guidelines on Page 4.
Review the information for Care and Maintenance on Page 17 regularly to ensure optimal performance.
Additional equipment may be used to connect the G5Twin to the system you are recovering refrigerant from.
Verify operational details and safety information from the manufacturers of other equipment before use.
• . A leaking hose may cause venting of refrigerant, and may introduce atmospheric air or other
contaminants into the recovered refrigerant. Examine the gaskets on each hose to ensure they are intact,
checking for any damage or wear that may lead to leaks.
• Use the shortest length of 3/8”-diameter hoses possible on every connection. IMPORTANT: Do not use
“quick disconnect” or “auto-shuto” hoses for refrigerant recovery, as this can bring the recovery to a halt.
• Use Valve Core Removal Tools with a ball valve (such as Appion MegaFlow VCT) to remove all “Schrader”-
type access valve cores from the System access ttings. This prevents restrictions that would otherwise
limit the performance of the G5Twin and/or cause overheating of the recovery cylinder. See Page 15 for
more information.
• The recovery cylinder should have extra capacity beyond the amount you intend to recover. For maximum
recovery speeds, use a recovery cylinder that is already evacuated (500 microns or better). Note: new
recovery cylinders may not be suiciently evacuated - always verify before use.
• Check your refrigerant scale with a known weight to ensure that is operating correctly. A malfunctioning
scale may not alert you to the amount of refrigerant in the storage container.
• Examine your external manifold gauges for proper valve operation and calibration of the gauges. Contact
the manifold gauge manufacturer for instructions in this process.
• Use a new inline lter dryer as shown when pumping dirty refrigerant. Replace the lter dryer aer each
use. If the lter has exceeded its capacity, this may aect the performance of the machine.
• Use a sight glass to verify liquid ow. This can also be useful for troubleshooting purposes. Make sure that
the sight glass is in good condition and does not leak.
⚠ CAUTION

Machine Usage
8
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
PREPARING FOR OPERATION
Every recovery procedure starts with the same ve basics:
• Remove any access valve cores from the AC/R System access ttings with a Valve Core Removal Tool;
• Remove any core depressors from the hose ttings. Do not use “quick disconnect” or “auto-shuto” hose
connections for refrigerant recovery, as this can bring the recovery to a halt. Use only ball valves for low-loss.
• Use the shortest length of 3/8”-diameter hoses possible on every connection. Even with 1/4” ttings, the
larger hose diameter can deliver better performance during recovery.
• Purge the hoses of non-condensables as you connect the hoses, as needed, using best practices to minimize
any refrigerant release (aka “de minimis”). Excess non-condensables can cause tank overheating, and may
contaminate recovered refrigerant.
• Connect the G5Twin to a grounded power source for the proper voltage of the machine (115v/230v). If using
an extension cord, follow the cord sizing guidelines on Page 4.
✪For additional refrigerant recovery tips, see pages 14-17.
G5TWIN OPERATIONAL LAYOUT
Horizontal Knobs: Valves Closed Vertical Knobs: Valves Open
Diagram 2
Diagram 3

Machine Usage
STANDARD RECOVERY PROCEDURE
⚠ CAUTION
To reduce the risk of injury or product damage, read this entire operating manual, with
particular emphasis on the Safety and Preparation sections (Page 4-8), prior to operating the G5Twin.
1. Setup the G5Twin as shown in Diagram 4 (below). Make sure that all connections are tight.
A. Connect the AC/R System Liquid Port to the Manifold high side.
B. Connect the AC/R System Vapor Port to the Manifold low side.
C. Connect the Manifold Center port to the G5Twin input port.
D. Connect the G5Twin output port to the Vapor Port on the Recovery Cylinder.
Diagram 4
Recover into the Vapor Port of the Recovery
Cylinder for faster recovery.
OPTIONAL: To improve tank cooling, start
with the recovery cylinder upside down,
and ip the tank right-side up near the end
of the vapor recovery.
2. Close both valves on the Manifold Gauge Set.
3. Open both valves on the G5Twin, open the Valve Core Removal Tool ball valves at the system (if equipped),
and open the Recovery Cylinder Vapor Port.
Make sure to completely open the Recovery Cylinder valve to prevent “output restrictions” (See Tip #1).
4. Turn on the G5Twin. The compressor and fan should start.
5. Slowly open the Manifold High Side (liquid) valve.
Removing liquid rst will keep recovery time to a minimum, and improve cooling properties of the recovery
cylinder. NOTE: Overheating or slow recovery speeds may be caused by “input restrictions” (See Tip #2).
6. When all the liquid has been removed, completely open the Manifold Low Side (vapor) valve. Both sides
should now be fully open to maximize vapor ow.
7. Continue to run the G5Twin until the EPA-required vacuum is achieved.
8. Close both valves on the Manifold Gauge set.
9. Turn o the G5Twin, then close the output valve on the G5Twin.
10. Close the G5Twin input valve, close the valves on the Recovery Cylinder, and disconnect the hoses.
D
C
B
A
9G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED

Machine Usage
⚠ CAUTION
To reduce the risk of injury or product damage, read this entire operating manual, with
particular emphasis on the Safety and Preparation sections (Page 4-8), prior to operating the G5Twin.
HIGH-SPEED DIRECT LIQUID PROCEDURE
This recovery method allows for the fastest possible “direct liquid” recovery speeds. To maximize recovery
rates, be sure to follow all of the Preparing for Operation information on Page 8.
Diagram 5
This recovery method allows for
the fastest possible “direct liquid”
recovery speeds, although the
“vapor” phase of recovery may take a
little longer.
2. Close the Valve Core Removal Tool (VCRT) ball valves at both of the AC/R System Liquid and Vapor ports.
3. Open both valves on the G5Twin, and open both valves on the Recovery Cylinder.
Make sure to completely open the Recovery Cylinder valves to prevent “output restrictions” (See Tip #1).
4. Turn on the G5Twin. The compressor and fan should start.
5. Begin liquid recovery by opening both of the VCRT ball valves at the AC/R System access ports.
6. When all the liquid has been removed: close the Recovery Cylinder Vapor Valve.
7. Continue to run the G5Twin until the EPA-required vacuum is achieved.
8. Close both of the VCRT ball valves.
9. Turn o the G5Twin, then close the valves on the G5Twin.
10. Close the valves on the Recovery Cylinder and disconnect the hoses.
✪For additional refrigerant recovery tips, see pages 14-17.
AB
C
1. Setup the G5Twin as shown in Diagram 5 (below). Make sure that all connections are tight.
A. Connect the AC/R System Liquid Port to the G5Twin input port.
B. Connect the G5Twin output port to the Liquid Port on the Recovery Cylinder.
C. Connect the Cylinder Vapor Port to the AC/R System Vapor Port.
D. Connect a Compound Pressure Gauge to the AC/R System Vapor Port using a T-tting or
a side-port on a valve core removal tool.
10
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
D

Machine Usage
⚠ CAUTION
To reduce the risk of injury or product damage, read this entire operating manual, with
particular emphasis on the Safety and Preparation sections (Page 4-8), prior to operating the G5Twin.
STANDARD RECOVERY WITH INLINE COOLING
This ALTERNATIVE procedure allows the user to switch between the Standard Recovery Procedure and the
High-Speed Direct Liquid Procedure during recovery, leading to reduced temperatures and back-pressure
from the recovery cylinder. This can be particularly useful with R410A and/or high ambient conditions.
Diagram 6
This method allows the user to switch
between Standard Recovery and
High-Speed Direct Liquid, which can
cool the recovery cylinder as needed.
2. Close both valves on the Manifold Gauge Set. Open both valves on the G5Twin, open both valves on the
Recovery Cylinder, and open the VCRT ball valves at the AC/R System access ports (if equipped).
Make sure to completely open the Recovery Cylinder valves to prevent “output restrictions” (See Tip #1).
3. Turn on the G5Twin. The compressor and fan should start.
4. Begin liquid recovery by opening the Manifold High Side (liquid).
5. When all the liquid has been removed: close the Recovery Cylinder Vapor Valve, open the Manifold Low
Side (vapor) valve, and the hose ball valve at the system vapor port (if equipped).
6. Continue to run the G5Twin until the EPA-required vacuum is achieved.
7. Close both valves on the Manifold Gauge set.
8. Turn o the G5Twin, then close the valves on the G5Twin.
9. Close the valves on the Recovery Cylinder and VCRT ball valves (if equipped), and disconnect the hoses.
A
B
CD
EE
1. Setup the G5Twin as shown in Diagram 6 (below). Make sure that all connections are tight.
A. Connect the AC/R System Liquid Port to the Manifold high side.
B. Connect the AC/R System Vapor Port to the Manifold low side.
C. Connect the Manifold Center port to the G5Twin input port.
D. Connect the G5Twin output port to the Liquid Port on the Recovery Cylinder.
E. Connect the Cylinder Vapor Port to the AC/R System Vapor Port, using a T-tting or
a side-port on a valve core removal tool.
11 G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED

Machine Usage
⚠ CAUTION
To reduce the risk of injury or product damage, read this entire operating manual, with
particular emphasis on the Safety and Preparation sections (Page 4-8), prior to operating the G5Twin.
PUSH/PULL RECOVERY PROCEDURE
The Push/Pull method induces a siphon from the system directly into the recovery cylinder using the G5Twin.
This method is useful for recovering large amounts of liquid from a system. This will only work on large
systems where the liquid can be accessed easily. Do not attempt this on systems that contain less than 15 lbs.
of liquid refrigerant (unless there is a receiver tank), or it may not work correctly.
⚠ CAUTION
Once the siphon starts, it can continue to fill the tank even when the machine has been
powered o. To avoid overlling, you must close all valves on the tank and system when nished.
Diagram 7
The Push/Pull recovery method induces
a siphon to move large amounts of liquid
directly from the system to the recovery
cylinder.
1. Setup the G5Twin as shown in Diagram 7 (below). Make sure that all connections are tight.
A. Connect the AC/R System Vapor Port to the G5Twin output port.
B. Connect the AC/R System Liquid Port to the Recovery Cylinder Liquid port.
C. Connect the G5Twin input port to the Recovery Cylinder Vapor port.
2. Slowly open both valves on the G5Twin.
3. Turn on the G5Twin. The compressor and fan should start.
4. Slowly open the valves on the tank and system. The liquid should now begin to be pulled out of the
system. You can monitor the progress with an inline sight glass.
Make sure to completely open the Recovery Cylinder valves to prevent “output restrictions” (See Tip #1).
5. When all the liquid has been siphoned o, turn o the G5Twin and close all the valves.
6. You can now proceed to remove the remaining refrigerant vapor using the Standard Recovery Procedure
(Page 9).
C
B
A
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G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED

13 G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
Additional Machine Usage
PURGING NON-CONDENSABLES FROM RECOVERY CYLINDERS
Inthe eventthatthe Recovery Cylinderpressureis higher thanexpected,orifthe recoveryprocessseems slower
than usual, use an external gauge (not the gauge on the G5Twin) and a Refrigerant Pressure/Temperature
chart to check for the presence of non-condensable gases in the cylinder.
You can bleed/purge non-condensables into another cylinder following this procedure:
1. The Recovery Cylinder must remain undisturbed for at least 24 hours for the non-condensables to rise to
the top of the cylinder.
2. Through a Manifold Gauge Set, connect the Recovery Cylinder Vapor Port to the Vapor Port of a second
recovery cylinder.
3. Consult a Refrigerant Pressure/Temperature chart, and check the temperature of the Recovery Cylinder to
determine what the pressure should be.
4. While the pressure is higher than the pressure on the chart, slowly open the Vapor Port to bleed o excess
pressure until it is about 5 psi (0.35 Kg/cm2) above the pressure listed on the chart.
5. Close the valves and let the cylinder stand still for 10 minutes. Repeat if necessary.
CHANGING BETWEEN REFRIGERANT TYPES
Appion refrigerant recovery machines are unique in that there is no refrigerant directly introduced into the
compressor crankcase. This allows the G5Twin to easily and eiciently clear out refrigerant at the end of the
recovery process. However, as with all recovery machines, trace refrigerant vapors may remain and should be
cleared out when switching between dierent types of refrigerant.
When you are changing between refrigerant types, any refrigerant remaining in the recovery machine
should be drawn into a deeply evacuated recovery cylinder before switching. Then, to prevent any cross-
contamination, it is recommended that a vacuum pump be connected to the output port of the G5Twin (keep
the Input Valve closed and the Output Valve open), and run the vacuum pump to completely evacuate the
machine of any trace refrigerant vapors.
STORING THE MACHINE BETWEEN USES
When storing the machine between recovery jobs, trace refrigerant vapors can continue to wear on the
internal components of the machine. If the machine is fully sealed (closed valves or port covers), storing the
machine in a hot truck can cause the trace vapors to expand and wear on the components further.
To minimize wear during storage, leave both valves on the G5Twin open. You can use port caps/covers to
protect the machine from dirt, but make sure they do not have an airtight seal.

14
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
Helpful Hints
PLAN AHEAD
It is a common belief that recovering liquid refrigerant will always be “noisy.” However, the “hammering”
or “knocking” sound associated with recovering liquid can oen be caused by output restrictions, which is
any ow restriction between the recovery machine and the interior of the recovery cylinder. If the G5Twin is
excessively noisy during liquid recovery, check for, and remove, any output restrictions.
Another common symptom of output restrictions is the recovery machine intermittently shutting o on high
pressure, but resets on its own aer the output pressure quickly drops in a short time. If the G5Twin shuts o
on high pressure but the output pressure quickly drops, check for, and remove, any output restrictions.
Prolonged pumping against output restrictions not only slows the recovery process, but the increased load
can accelerate the wear of your recovery equipment. This wear can be seen with damaged output gauges,
electrical component failure, and slower performance on the bench test (see Page 18).
Remove Output Restrictions to Maximize Recovery Performance:
To improve recovery performance, and prolong the life of your equipment, take the time to remove these
typical output restrictions before you start:
• Remove core depressors from all of the hose ttings (they block up to 50% of the ow) - See Tip #4
• DO NOT USE refrigerant charging hoses with “quick disconnect” or “auto-shuto” ttings
• Make sure that the recovery cylinder valve is completely opened
• Discard of used/worn hoses with deteriorating inner linings
Output Restrictions: Loud Recovery & High Pressure Shuto
TIP #1
In just a few years, refrigerant recovery has come a long way. At rst glance, it’s simply the process of taking
refrigerant out of a system and putting it into a storage tank. However, this simple process can rapidly become
diicult and time consuming if a few things are overlooked. What follows are some notes and guidelines that
we have learned over the years that can help you save time and make the job easier.
The rst thing you need to do is determine the quantity and type of refrigerant that is being used in the system
you are working on. Use a tank that is DOT approved for the high pressures that are present with R410a. If the
system is a burnout, you will need to use a special tank marked as containing burnout and other unidentied
gases and you must use extra ltration before recovery. This extra ltration is to protect your equipment from
corrosion caused by acids that may be present.
If the gas in the system is fairly clean or new, then you should use a clean, new tank. If the refrigerant is going
to be reclaimed, or you are going to put the refrigerant back into the system when you are done servicing
it, then you should use a tank with the same type of refrigerant in it. One note of caution: If you use many
dierent gases and you only own a single tank, you’re asking for trouble with the Environmental Protection
Agency (EPA). You should own at least one tank for every type of refrigerant that you will service, and a spare
tank for unknown gases and burned out systems.

15 G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
Helpful Hints (continued)
For the fastest recovery speeds, it is necessary to pump out the liquid rst. Using the Direct Connection
procedures in this manual, on a typical system, you should expect the “liquid recovery” stage to move the bulk
of the entire system charge as liquid - this means it should go very quickly for most of the recovery process (in
most larger systems, this could be over 90% of the refrigerant charge).
However, if you observe hot recovery cylinders, or very slow recovery aer only moving a few pounds of
refrigerant, then you likely have input restrictions. You may further conrm input restrictions by checking for
frost or condensation at each hose/port connection between the AC/R System and the recovery machine
(e.g., the system access port, or the inlet tting to the recovery machine). Input restrictions can cause liquid
refrigerant to get trapped behind the restriction, causing recovery to be slower than the expected vapor rate
(see Diagram 8), and unexpectedly adding heat
to the recovery cylinder.
What Happens With Input Restrictions:
Input restrictions will greatly slow down
refrigerant recovery by preventing the full “liquid
ow” from reaching the recovery machine. The
pressure drop caused by the recovery machine
triggers a liquid-to-vapor expansion at the point
of restriction, which drops the temperature of
the liquid refrigerant at the restriction. As the
point of restriction continues to get colder, the
vapor pressure drops, slowing the vapor ow.
Pretty soon, the recovery machine is only receiving a reduced ow of vapor that is now picking up ambient
heat and adding it to the heat of compression. All of this heat is sent along to the recovery cylinder, quickly
raising the recovery cylinder temperature.
Eorts to cool a cylinder are more eective when there is liquid refrigerant, as the liquid aids in transferring
heat through the cylinder walls to the “bucket of ice” or cooled airow. However, if contents of the tank are
mostly vapor, eorts to cool the tank (e.g., airow, ice) could be less eective than expected.
Remove Input Restrictions to Maximize Recovery Performance:
For the fastest recovery times, take the time to address these typical input restrictions before you start:
• Remove core depressors from all of the hose ttings (they block up to 50% of the ow) - See Tip #4
• DO NOT USE refrigerant charging hoses with “quick disconnect” or “auto-shuto” ttings
• Remove “Schrader”-type access valves using a Valve Core Removal Tool - See Tip #4
• Discard of used/worn hoses with deteriorating inner linings
With a full ow of liquid refrigerant, the G5Twin will quickly ll the recovery cylinder with cool liquid. Once the
liquid recovery is complete, the remaining vapor will be pumped into a cooler tank, resulting in lower nal
temperatures and faster overall recovery speeds.
Input Restrictions: Slow Recovery & Hot Recovery Cylinders
TIP #2
Diagram 8

16
Helpful Hints
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
Recovering large amounts of vapor (especially on a hot day) can increase the temperature of a recovery
cylinder, and the resulting increased back-pressure can further slow the vapor recovery process. In situations
like these, cooling the recovery cylinder and/or using an External Cooling Accessory (ECA) in a bucket of ice
water can cool o the tank and speed up the recovery process. For maximum recovery speeds, pre-cool the
recovery cylinder (and/or the ECA) by placing it in a bucket of ice water at least 30 minutes prior to beginning
the recovery process. The longer the cylinder is cooled, the better.
External Cooling Accessories Between Recovery Unit & Cylinder
TIP #3
Diagram 9
How to Make an External Cooling Accessory:
Making an ECA uses the same tools as you would use when installing an AC/R system.
You will need 10 feet of 5/16” (OD) copper tubing, and two (2) 1/4” FL Service Valves.
Connect the service valves to each end of the copper tubing with solder using
industry practices. Then, coil the tubing around a pipe or round object of at least 3”
inches in diameter, and maintaining about 1/2” spacing between each coil. Leave
about 1 foot of the copper tubing straight, and bend it upwards, so that both service
ports are pointing in the same direction, and both extend above the “coiled area,” as
in Diagram 9. Prior to using the ECA, verify pressure and vacuum tightness using the
same methods as on an AC/R system.
How to Use an External Cooling Accessory:
The ECA is about 50% submerged in water before adding
ice. Add ice on top, until the ECA is submerged below the
ice level by at least 3 inches. This will help keep the ice
water cooled as the heated vapor travels through the ECA.
Connect the ECA and hoses equipped with ball valves as
shown in Diagram 10. Submerge the ECA in a bucket of ice
water (as described above). Close the ball valve on Hose
“C”, and open the ball valves on Hose “A” and Hose “B”, as
shown in Diagram 10. Proceed with the Standard Recovery
Procedure as described on Page 9, starting from Step 2,
and continuing through Step 9 (substitute the Recovery
Cylinder Liquid Port in Step 3).
WARNING: Aer recovery is complete, the ECA and Hoses A,
B and C will contain high pressure refrigerant.
To recover the residual refrigerant from the ECA:
1. Close the G5Twin output valve, Recovery Cylinder
liquid valve, and the ball valve at the end of Hose “A”.
2. Disconnect the hoses from the G5Twin input/output.
3. Connect the hoses as shown in Diagram 11.
4. Open the G5Twin output valve, Recovery Cylinder
vapor valve, and all 3 ball valves.
5. Repeat Steps 7-10 from Page 9 to nish the recovery.
C
B
A
C
B
A
Diagram 10
Diagram 11

17
Helpful Hints (continued)
AC/R Systems are generally not designed specically for the recovery process, and this is reected in the wide
use of 1/4” access valves with “Schrader”-type valve cores. These valve cores block about 90% of the ow
through the access port, and require the use of core depressors in the hose ttings, which in turn block about
50% of the ow. When le in during the recovery process, both of these items can signicantly restrict the ow
of refrigerant, making the recovery process take up to six times longer to complete.
Use a Valve Core Removal Tool to remove these valve cores while leaving the system seal intact, as shown
in Diagram 12. These tools are available from your local wholesale distributor. Core depressors in the ends of
the hoses should be removed as well. See Page 20 for ordering info.
Use ball valves and open-ended hoses. Another common restriction is found in
charging hoses that have “Quick Disconnect, Low Loss” ttings. These ttings use
a restrictive internal check valve to limit venting when disconnecting the hose from
the system. While these may be useful in charging setups, they restrict the ow of
refrigerant, and are not ideal for use in refrigerant recovery.
Use the shortest length of 3/8” hose for fast recovery. The length and diameter
of the hose can also impact the recovery speed. Even when recovering through 1/4”
ttings, the larger diameter hose will allow for greater vapor ow, and greatly reduce
the time needed for the recovery process. See Page 20 for ordering info.
Imagine trying to drink water through a 1/4-in., 3-. long straw. Now pinch the end
closed a little bit, and you get an idea of the kind of work your recovery machine is
trying to accomplish. Using larger hoses without any restrictions will make it easier on
your machine and allow you to nish the job much quicker.
Diagram 12
EXTENSION CORDS AND LOW VOLTAGE
Recovery machines will work best when the voltage at the machine (while it is running) is about 100-105%
of the rated power (115v-122v or 230v-240v). A lower voltage can cause diiculty in starting against high
pressures. If you have low voltage source power, you may need to relieve the back pressure on the unit to
allow it to start.
Check that the voltage coming from the source outlet is adequate. Please note that the circuit could have
many other items on it e.g. light xtures, appliances, or other motors. Also, recovery equipment is used
primarily in the hot summer months when supply voltage can be at the lowest point of the year due to the
demand from A/CR equipment operating at peak conditions. These factors may cause a lower voltage and
reduced performance.
Likewise, long and thin extension cords starve the motor of necessary voltage and can cause very dangerous
overheating of the motor and extension cord. A hot, sunny rooop can also reduce the ampacity of the
extension cord. Refer to the extension cord sizing guidelines on Page 4.
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
Remove Restrictions at the Valves, Fittings & HosesTIP #4
Extension Cords and Low Voltage
TIP #5

Care and Maintenance
INLINE FILTER DRYERS
Use a new inline lter dryer on the input side of the G5Twin when pumping dirty refrigerant. Refrigerant acts
like a solvent and can collect dirt and debris when it is pumped out of a system. Failure to use an inline lter
dryer can cause damage to the compressor, and will void the warranty on your machine.
While specications may vary, most Size 032 lters will not be eective for more than 50 lbs. (22.6 Kg) of
refrigerant. Also, once refrigerant has been introduced into the inline lter, it may continue to wear down, and
may not have the same eective capacity if used across multiple jobs. Change the inline lter dryer regularly,
and consult the lter manufacturer for expected capacity. See Page 20 for ordering info.
SCREEN CLEANING AND REPLACEMENT
The G5Twin is equipped with a debris screen inside the input tting. This is the last line of defense for the
recovery machine against any debris that might make it past an inline lter. For best results it is recommended
to clean it before each use. If it becomes worn, replace it immediately.
Diagram 13
1. Unscrew Filter Cap from Input Port.
2. Remove screen from Filter Cap.
3. Clean screen and Filter Cap thoroughly. If the
screen is worn or damaged, replace it.
4. Check the O-ring that seals the Filter Cap to the
Input Port. If it is dry, apply a drop of refrigeration
oil. If it is damaged, replace it.
5. Place clean screen into Filter Cap and screw it
back onto the Input port.
PLANNED MAINTENANCE
You can use any standard refrigeration oil (mineral is ideal) to scavenge out dirt and debris, and recondition
the seals. Run the machine with no hoses connected and both valves open. Using a 1/4” port cap, ll it with
refrigeration oil and hold it up against the input port, allowing the G5Twin to suck it in. Place a towel below
the output port to catch any oil spray. This is very helpful aer recovery of burnout systems, and as regular
maintenance depending on the frequency of use.
The following test can be performed to verify that the G5Twin is operating normally:
1. Disconnect any hoses from the machine.
1-MINUTE BENCH TEST
18
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
2. With the input valve open and the output valve closed (Diagram 14),
turn the machine on.
3. Time how long it takes for the unit to pressure up and cut o. The
unit should pressure up and cut o at approximately 550 psi (38.6
Kg/cm2) in under 1 minute. Otherwise, the unit may be in need of
maintenance or repair.
Diagram 14

19
Troubleshooting Guide
⚠ WARNING
Read all safety information found in this manual and in the Material Safety Data Sheets (MSDS)
for any refrigerants used with this machine prior to performing any service on this machine.
SYMPTOM: Machine will not start, no sound when power switch turned ‘On’
CAUSE SOLUTION
Power cord not plugged in, or no power in outlet Check power cord, try dierent outlet
Machine in High Pressure Shuto See symptom below
Motor in Thermal Overload Allow motor to cool down
SYMPTOM: Machine tries to start, makes humming/buzzing sound
CAUSE SOLUTION
Low voltage at source outlet Try dierent power source outlet
Voltage drop in extension cord See Extension Cord sizing guidelines on Page 4
Too much back pressure on compressor Try starting the machine with the Input Valve closed
to reduce back pressure on compressor
SYMPTOM: Machine pumps into high pressure shuto
CAUSE SOLUTION
Valve on machine or recovery cylinder not fully
opened
Check that both valves on machine are fully open
(pointing upward);
Check that the valve on the recovery cylinder is fully
opened
Restriction in output hose
- See Tip # 1 on Page 14
Check hoses for any blockage;
Remove any core depressors
SYMPTOM: Pumps liquid slowly
CAUSE SOLUTION
Flow restrictions on input side of machine
- See Tip # 2 on Page 15
Use 3/8” hoses;
Remove “Schrader” valve cores and core depressors
Input Valve on machine not fully open Check that the blue Input Valve on machine is fully
open (pointing upward)
Trapped liquid in system
- See Tip # 2 on Page 15
Cycle system compressor for a few seconds to move
trapped liquid to another area;
Check for condensation on system, and apply heat
as needed;
Check for condensation at hose ttings, and apply
heat as needed
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED

20
Machine Specications
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
REPAIR KIT ORDERING INFORMATION
PART NO. DESCRIPTION (CONTENTS)
KTF612 Inlet Filter Fitting (1/4” Flare Fitting, 4-Pack of Inlet Filter Screens, o-ring)
KTGA00 2-Pack of 0-700 PSI Gauges
KTG515 Piston Seal Kit (seals, seal o-rings, slide rings)
KTG520 Compressor Repair Kit (valve plates, valves, springs, seals, seal o-rings, slide rings)
KTG535 Front Ball Valve Seal Replacement Kit (input/output seals, o-rings)
MODEL # G5TWIN SPECIFICATIONS
USA Dimensions & Power: International Dimensions & Power:
G5Twin UL Certied Test Results
Per ARI 740-98 - as of March 2016
* Uses high speed direct liquid mode; 8.16lb (3.7kg) with standard recovery.
** With external cooling accessory (see Page 16); R22 is 0.60lb (0.27kg) with standard recovery; R134a is 0.44 lbs (0.20 kgs) with standard
recovery.
LENGTH 349 mm
HEIGHT 262 mm
WIDTH 239 mm
WEIGHT 11 kgs
POWER 230 VAC, 50/60 Hz, 5 Amps
LENGTH 13.75 in
HEIGHT 10.3 in
WIDTH 9.4 in
WEIGHT 24 lbs
POWER 115 VAC, 60 Hz, 10 Amps
PUSH PULL
RATE
DIRECT LIQUID
RATE
VAPOR RATE FINAL
RECOVERY
VACUUM
REFRIGERANT
LOSS,
WEIGHT %
RESIDUAL
TRAPPED
REFRIGERANT
HIGH TEMP
VAPOR
RECOVERY
RATE 104F
(40C)
kg/min lb/min kg/min lb/min kg/min lb/min kPa inHg kg/min lb/min
R134a 7.20 15.87 4.60* 10.14* 0.21** 0.46** 50.53 15.00 <3 0 n/a n/a
R22 7.54 16.62 4.70 10.36 0.28 0.62 50.53 15.00 <3 0 0.28** 0.62**
R407C 7.99 17.61 5.41 11.93 0.25 0.55 50.53 15.00 <3 0 n/a n/a
R410A 9.30 20.50 7.80 17.20 0.25 0.55 50.53 15.00 <3 0 n/a n/a
RELATED ACCESSORY ORDERING INFORMATION
PART NO. DESCRIPTION (CONTENTS)
KTF032 Filter Dryer Kit (Size 032 lter, 6” adapter hose)
MGAVCR MegaFlow Valve Core Removal Tool - 5/16in.
MGAVCT MegaFlow Valve Core Removal Tool - 1/4in.
MH380006AAY MegaFlow 3/8 in. Hose - 6 . (1/4FL to 1/4FL) Yellow
MH380003AAY MegaFlow 3/8 in. Hose - 3 . (1/4FL to 1/4FL) Yellow

21
Machine Specications
# PART NO. DESCRIPTION
1 AY0050 Front Panel Assembly
2 PL7601S Front Panel Only w/Labels
3 WR9000 Power Cord - 115v US
3 WR9230 Power Cord - 230v EU
4 PL7011 Output Knob - Red
5 PL7010 Input Knob - Blue
6 KTGA00 0-700 PSI Gauge (2-Pack)
6 KTGA61 PSI & Kg/cm2Gauge (2-Pack)
7 EL5120 Power Switch
8 CT1760L Left Side Condenser
9 LB1235 Front Panel Label (Top)
10 KTF612 Inlet Filter Fitting
11 EL5030 High Pressure Switch
12 LB1205 G5Twin Side Label
13 AY0221 Case Side Panel (each)
# PART NO. DESCRIPTION
14 EL5017 Motor Start Relay - 115v
14 EL5027 Motor Start Relay - 230v
15 PL7000 Case Handle
16 AY0036 Fan Gearbox Assembly w/ Blade
17 PL7602 Case Back Panel
18 PL7625 Motor Support Bracket (each)
19 LB1201 G5Twin Warning Label - 115v
19 LB1262 G5Twin Warning Label - 230v
20 EL5000 Motor - 115v
20 EL5230 Motor - 230v
21 EL5028 Motor Start Capacitor - 115v
21 EL5034 Motor Start Capacitor - 230v
22* CA1603 Cylinder (each)
23 CT1760R Right Side Condenser
24 AY0020 Manifold Assembly
* Note: Contact Appion for compressor ordering info - See Page 20 for
repair kits
Appion reserves the right to make changes to product and specications without notice.
G5TWIN OPERATION MANUAL
© 2016 APPION INC. - ALL RIGHTS RESERVED
PARTS DIAGRAM