Appion G5 Twin User manual

FOR REFRIGERANT RECOVERY
OPERATION MANUAL
COPYRIGHT © 2022 - 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.
This unit is not rated for Explosive Environments. Do NOT use with hydrocarbons. See page 4.
It is designed to recover Class A1 and A2L refrigerants in normal or standard environments.
⚠DANGER
www.AppionTools.com
For Refrigerant Recovery
PARTS AND PRODUCT MADE IN TAIWAN,
USA, EU, SOUTH AMERICA. PRODUCT DESIGN,
ASSEMBL
Y TESTING AND QUALITY ASSURANCE
IN DENVER, COLORADO.
PATENT PENDING
SERIAL NUMBER

Table of Contents
Warnings and Safety Information................................................................ 3-5
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
Specifications and Support
Troubleshooting Guide ............................................................................. 19
G5Twin Specifications, 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.
2
G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED

3G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
Warnings and Safety Information
IMPORTANT - READ THIS MANUAL BEFORE OPERATION
This Operation Manual contains important information for 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 but not limited to 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
certified in the safe handling of refrigerant, and safe refrigerant recovery techniques.
PERSONAL PROTECTIVE EQUIPMENT AND MSDS
⚠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.
A2L REFRIGERANT SAFETY
⚠WARNING
Due to the mildly flammable nature of A2L refrigerants, it is important to ensure proper
technical training prior to recovering these refrigerants. Some jurisdictions may require special licensing or
certification before handling flammable refrigerants. Additional regulations or guidelines may be required by
your local, state, or federal agencies. Check your local occupational health and safety codes.
Proper precautions should be followed when handling or recovering A2L refrigerants.
These precautions include, but are not limited to the following:
• A temporary flammable zone should be created with a 3-meter perimeter around the work area.
• Place “No Smoking”, “Do Not Enter”, and any other appropriate warning signs in the area.
• A CO2or dry-powder type fire extinguisher should be available within the work area.
• Use a suitable flammable gas detector to monitor the air in the work area for refrigerant gas concentrations.
• Ensure adequate ventilation of the area.
• Service equipment should be connected to, and disconnected from a power source outside of the flammable
zone.
• Properly ground the recovery machine, tank, hoses, system, and other elements to prevent static buildup.
• Do not reset service equipment circuit breaker unless power has been removed from the equipment or the
area is free of ignitable concentrations.
• Disable and lock othe power to the system being serviced.
• Do not mix A2L refrigerants with air. All precautions must be taken to eliminate mixing of air with
flammable refrigerants, including monitoring the recovery cylinder for air content.
• When recovery is complete, purge the system with oxygen-free dry nitrogen (OFDN). Do not use compressed
air or oxygen.

4
G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
HAZARD: RISK OF EXPLOSION OR FIRE
⚠DANGER
Use of this equipment may pose certain explosion and fire hazards.
WHAT CAN HAPPEN HOW TO PREVENT IT
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 flammable 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 flammable substances
and may ignite or explode when compressed in
certain situations.
Improper use of extensions cords may result in
overheating or fire 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
Warnings and Safety Information(continued)
A3 REFRIGERANT DANGER
Do not use this machine to pump hydrocarbons, including A3 refrigerants.
While most refrigerant recovery machines on the market are able to pump hydrocarbon refrigerants such as
propane and butane, none of them can do so safely without creating an explosion hazard in the tank.
A significant risk inherent with the recovery of hydrocarbon refrigerants is the potential to accidentally
ingest air and pump this air into a tank with hydrocarbons. This compressed hydrocarbon and air mixture
within the tank can create an explosion hazard. The accidental ingestion of air can come from many
scenarios. These scenarios include but are not limited to faulty system components, improper system
installation, improperly purged recovery hoses, worn hose gaskets, and worn recovery machine compressor
components.
Industries that work with hydrocarbons avoid these risks by constantly venting air and hydrocarbon vapors
while transferring in a pure liquid-only state. The transfer process only stops once the liquid hydrocarbon
begins to spray out of the vent port of the receiving tank. This transfer process is the only way to make sure
no air or other non-condensables are in the receiving tank.
The procedure explained above is not possible to perform when pumping hydrocarbon vapor with a recovery
machine. Since there is no safe way to totally eliminate air being ingested during the recovery process,
pumping hydrocarbons with any recovery machine should not be done under any circumstance.
⚠DANGER

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 airflow, 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 certified 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
© 2022 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
Overfill Sensors and Overfill Protection devices, may
fail to prevent overfilling of the storage cylinder,
leading to venting or explosion.
These sensors only cut power to the recovery
machine, and do not stop the flow of refrigerant,
which may continue due to a siphon, or due to
temperature-induced migration.
Do not rely on these switches to prevent overfilling.
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 flow of
refrigerant into the container. Only the valves on the
recovery machine and on the cylinder can stop the
flow of refrigerant into the container.
Refrigerant expands when heated (Diagram 1), and
storage containers may vent or explode when filled
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
Overfilled 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
© 2022 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 overfilling of the storage container. (See Page 6)
G5TWIN OPERATION MANUAL
© 2022 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 fitting is clean before starting every job. This screen prevents
damage to the machine that may get past the inline filter. When pumping dirty/used refrigerant, this screen
may quickly clog and slow the process when used without an inline filter.
• 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 18 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 fittings. This prevents restrictions that would otherwise
limit the performance of the G5Twin and/or cause overheating of the recovery cylinder. See Page 14 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 service gauges for proper operation and calibration of the gauges. Contact the
gauge manufacturer for instructions in this process.
• Use a new inline filter dryer as shown when pumping dirty refrigerant. Replace the filter dryer aer each
use. If the filter has exceeded its capacity, this may aect the performance of the machine.
• Use a sight glass to verify liquid flow. 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
© 2022 APPION INC. - ALL RIGHTS RESERVED
PREPARING FOR OPERATION
Every recovery procedure starts with the same six basics:
• 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.
• Check the G5Twin to make sure it is operating normally by running the 1-Minute Bench Test on Page 18.
• Remove any access valve cores from the AC/R System access fittings with a Valve Core Removal Tool;
• Remove any core depressors from the hose fittings. 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” fittings, 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.
✪For additional refrigerant recovery tips, see pages 14-17.
G5TWIN OPERATIONAL LAYOUT
Horizontal Knobs: Valves Closed
Vertical Knobs: Valves Open
Diagram 2 Diagram 3
TANK COOLING METHOD (OPTIONAL)
Refrigerant temperature and pressure may increase during the
recovery process. In some conditions, additional steps taken to cool
the tank can increase the speed and eiciency of the recovery process.
The G5Twin is equipped with a high performance fan. You can use this
fan to provide additional tank cooling while you are performing the
recovery process.
Place the Recovery Cylinder behind the G5Twin during the recovery
process, as shown in Diagram 4. This will pull cool air across the tank
surface and lower the temperature of the tank.
Diagram 4

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 3-8), prior to operating the G5Twin.
1. Setup the G5Twin as shown in Diagram 4 (below). Make sure that all connections are tight.
A. Connect a Valve Core Removal Tool to othe AC/R System Liquid Port.
B. Connect a Valve Core Removal Tool to othe AC/R System Vapor Port.
C. Connect the AC/R System Liquid Port to the Y-Connector.
D. Connect the AC/R System Vapor Port to the Y-Connector.
E. Connect the Y-Connector to the G5Twin input port.
F. 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 flip the tank right-side up near the end
of the vapor recovery.
2. Open both valves on the G5Twin and open the Recovery Cylinder Vapor Port.
Make sure to completely open the Recovery Cylinder valve to prevent “output restrictions” (See Tip #1,
Page 14).
3. Turn on the G5Twin. The compressor and fan should start.
4. Slowly open the Valve Core Removal Tool ball valve on the liquid port.
Removing liquid first 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, Page 14).
5. When all the liquid has been removed, completely open the Valve Core Removal Tool ball valve on the
vapor port. Both sides should now be fully open to maximize vapor flow.
6. Continue to run the G5Twin until the EPA-required vacuum is achieved.
7. Close both Valve Core Removal Tool ball valves.
8. Turn othe G5Twin, then close the output valve on the G5Twin.
9. Close the G5Twin input valve, close the valves on the Recovery Cylinder, and disconnect the hoses.
F
C
B
A
9G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
D
E

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 3-8), 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,
Page 14).
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.
A
B
C
1. Setup the G5Twin as shown in Diagram 5 (below). Make sure that all connections are tight.
A. Connect a Valve Core Removal Tool to the AC/R System Liquid Port.
B. Connect a Valve Core Removal Tool to the AC/R System Vapor Port.
C. Connect the AC/R System Liquid 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.
F. Connect a Compound Pressure Gauge to the AC/R System Vapor Port using a T-fitting or
a side-port on a valve core removal tool.
10
G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
DE
F

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 3-8), 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. Open both valves on the G5Twin. Open the Valve core Removal Tool added in Step 1-G and both valves on
the Recovery Cylinder. Make sure to completely open the Recovery Cylinder valves to prevent “output
restrictions” (See Tip #1, Page 14).
3. Turn on the G5Twin. The compressor and fan should start.
4. Begin liquid recovery by slowly opening the Valve Core Removal Tool ball valve on the liquid port of the
AC/R System.
5. When all the liquid has been removed: close the Recovery Cylinder Vapor Valve, open the Valve Core
Removal Tool ball valve on the vapor port of the AC/R System.
6. Continue to run the G5Twin until the EPA-required vacuum is achieved.
7. Close both Valve Core Removal Tool ball valves.
8. Turn othe G5Twin, then close the output valve on the G5Twin.
9. Close the G5Twin input valve, close the valves on the Recovery Cylinder, and disconnect the hoses.
A
B
C
D
E
F
1. Setup the G5Twin as shown in Diagram 6 (below). Make sure that all connections are tight.
A. Connect a Valve Core Removal Tool to the AC/R System Liquid Port.
B. Connect a Valve Core Removal Tool to the AC/R System Vaport Port.
C. Connect the AC/R System Liquid Port to the Y-Connector.
D. Connect the AC/R System Vapor Port to the Y-Connector.
E. Connect the Y-Connector to the G5Twin input port.
F. Connect the G5Twin output port to the Liquid Port on the Recovery Cylinder.
G. Use a Valve Core Removal Tool to remove the valve core from the side-port of the valve core tool
on the AC/R System Vapor Port. Connect the Cylinder Vapor Port the valve core removal tool.
11 G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
G
G

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 3-8), 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 overfilling, you must close all valves on the tank and system when finished.
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 a Valve Core Removal Tool to the AC/R System Liquid Port.
B. Connect a Valve Core Removal Tool to the AC/R System Vaport Port.
C. Connect the AC/R System Vapor Port to the G5Twin output port.
D. Connect the AC/R System Liquid Port to the Recovery Cylinder Liquid port.
E. 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” (SeeTip #1,
Page 14).
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).
CB
A
12
G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
D
E

13 G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
Additional Machine Usage
PURGING NON-CONDENSABLES FROM RECOVERY CYLINDERS
Inthe eventthatthe RecoveryCylinderpressureis higherthan expected, orif therecovery process seemsslower
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.
⚠NOTICE
The US EPA only allows purging if done into a secondary cylinder. Once a recovery cylinder has
refrigerant inside, it may never be opened directly to atmosphere.

14
G5TWIN OPERATION MANUAL
© 2022 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 flow 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 fittings (they block up to 50% of the flow) - See Tip #4
• DO NOT USE refrigerant charging hoses with “quick disconnect” or “auto-shuto” fittings
• 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 first 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 first 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 unidentified
gases and you must use extra filtration before recovery. This extra filtration 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.
Input Restrictions: Slow Recovery & Hot Recovery Cylinders
TIP #2
For the fastest recovery speeds, it is necessary to pump out the liquid first. Using the Direct Connection
procedures in this manual, on a typical system, you should expect the “liquid recovery” stage to move the bulk

15 G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
Helpful Hints (continued)
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 confirm 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 fitting 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 flow” 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 flow. Pretty soon, the recovery machine is only receiving a reduced flow 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 airflow. However, if contents of the tank are
mostly vapor, eorts to cool the tank (e.g., airflow, 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 fittings (they block up to 50% of the flow) - See Tip #4
• DO NOT USE refrigerant charging hoses with “quick disconnect” or “auto-shuto” fittings
• 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 flow of liquid refrigerant, the G5Twin will quickly fill 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 final
temperatures and faster overall recovery speeds.
Diagram 8
External Cooling Accessories Between Recovery Unit & Cylinder
TIP #3
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.

16
Helpful Hints (continued)
G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
Diagram 9
C
B
A
C
B
A
Diagram 10
Diagram 11
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 50 feet of 1/2” (OD) copper tubing, and two (2) 3/8” 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 8” inches in diameter, and maintaining about 1/8” spacing between each
coil. Leave about 2 feet of the copper tubing straight, and bend it upwards, so that
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.
Alternative: A 50 foot, 1/2in (OD) copper Immersion Wort Chiller with two (2) 3/8in
FL service valves fitted to the ends of the copper tubing can also be used in place of
making your own.
How to Use an External Cooling Accessory:
Using a 5-gallon bucket (or equivalent container), submerge
50% of the ECA in water before adding ice. Continue to add ice
until the ECA is submerged below the ice by at least 3 inches.
This will help keep the ice water cooled as the heated vapor
travels through the ECA.
Important: If the ice melts, replenish the ice as needed to maintain
maximum cooling throughout the recovery process.
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 2).
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 6-9 from Page 9 to finish the recovery.

17
Helpful Hints (continued)
AC/R Systems are generally not designed specifically for the recovery process, and this is reflected in the wide
use of 1/4” access valves with “Schrader”-type valve cores. These valve cores block about 90% of the flow
through the access port, and require the use of core depressors in the hose fittings, which in turn block about
50% of the flow. When lein during the recovery process, both of these items can significantly restrict the flow
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” fittings. These fittings 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 flow 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”
fittings, the larger diameter hose will allow for greater vapor flow, 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 finish the job much quicker.
Diagram 12
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 fixtures, 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
© 2022 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 filter 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 filter
dryer can cause damage to the compressor, and will void the warranty on your machine.
While specifications may vary, most Size 032 filters will not be eective for more than 50 lbs. (22.6 Kg) of
refrigerant. Also, once refrigerant has been introduced into the inline filter, it may continue to wear down, and
may not have the same eective capacity if used across multiple jobs. Change the inline filter dryer regularly,
and consult the filter manufacturer for expected capacity.
SCREEN CLEANING AND REPLACEMENT
The G5Twin is equipped with a debris screen inside the input fitting. This is the last line of defense for the
recovery machine against any debris that might make it past an inline filter. 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, fill 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
© 2022 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 fittings, and apply
heat as needed
G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED

USA Dimensions & Power: International Dimensions & Power:
Tested to meet ANSI 12:12.01 (Cl.1, Div.2, Gr. D T4A) Tested to meet ANSI 12:12.01 (Cl.1, Div.2, Gr.D T4A)
G5Twin UL Certified Test Results
Per ARI 740-2016 - 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.
20
Machine Specifications
G5TWIN OPERATION MANUAL
© 2022 APPION INC. - ALL RIGHTS RESERVED
REPAIR KIT ORDERING INFORMATION
PART NO. DESCRIPTION (CONTENTS)
KTGA00 2-Pack of 0-700 PSI Gauges
KTG520-R Compressor Repair Kit (valves, springs, seals, seal o-rings, slide rings)
KTG535 Front Ball Valve Seal Replacement Kit (input/output seals, o-rings)
MODEL # G5TWIN SPECIFICATIONS
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 2.91 6.41 2.56* 5.64* 0.14** 0.3** 28.54 8.42 <3 0 n/a n/a
R22 5.67 12.5 2.85 6.28 0.2 0.44 51.88 15.32 <3 0 0.28** 0.62**
R410a 4.38 9.65 2.2 4.85 0.14 0.30 56.96 16.82 <3 0 n/a n/a
R32 6.22 13.71 1.85 4.07 0.09 0.19 50.53 14.92 <3 0 n/a n/a
RELATED ACCESSORY ORDERING INFORMATION
PART NO. DESCRIPTION (CONTENTS)
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
MH380004AAY MegaFlow™ 3/8 in. Recovery Output Hose - 4 . (1/4FL to 1/4FL) Yellow
A2L Users: Please contact Appion Inc. at www.appiontools.com to get your machine serviced.
Non-A2L Users: Repair kits and parts may be ordered from Appion Inc. at www.appiontools.com.