JAVAC XTR-PRO-DV Operation and maintenance manual

XTR-PRO-DV
XTR-ALTIMA A2L
LIQUID & VAPOUR REFRIGERANT RECOVERY
Safety Instructions & Operation Manual
Instructions de sécurité et notice d’utilisation
Sicherheitsanweisungen und Bedienungsanleitung
Instrucciones de seguridad y manual de funcionamiento
Istruzioni di sicurezza e manuale d’uso
EN
FE
DE
ES
IT
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Thank you for purchasing a JAVAC Refrigerant Recovery Machine.
The device combines an innovative refrigerant gas compression system with a rugged, moulded case
that is designed to oer maximum protection from damage during transit and normal handling. With
normal use and with care as prescribed in this Manual, your machine will give you years of trouble-
free operation.
SAFETY FIRST!
If you have purchased the XTR-ALTIMA A2L, the machine is designed with the inclusion of an ignition
protected low/high pressure switch, power switch, circuit breaker and a bypass switch for added
safety and convenience. The bypass switch (seen on the right side of the controls panel) allows the
operator the choice of disabling the low pressure switch from the circuit, thus enabling continuous
recovery.
When found on the machine, this international symbol is intended to alert the user to the presence
of important operating, safety and maintenance (servicing) instructions in this Manual. As used in the
Manual, it is intended to draw your attention to critical items.
IT IS IMPORTANT TO READ THIS ENTIRE MANUAL AND BE FAMILIAR WITH ITS CONTENTS
BEFORE USING THE MACHINE.
The XTR-PRO-DV and XTR-ALTIMA A2L are Recovery Machines for a broad range of refrigerants.
Recovering refrigerants into a separate storage cylinder involves a process of gas compression,
resulting in high pressures within the machine, the connecting hoses and the storage cylinder. High
pressure systems must always be treated with care and respect to prevent careless accidents.
EPA CERTIFICATION:
The JAVAC XTR-PRO-DV and XTR-ALTIMA A2L are EPA Certied machines in accordance with
Section 608 of the Clean Air Act. They have been independently tested and veried to be in
conformance with its published specications by the Air-Conditioning & Refrigeration Institute (ARI),
USA.
EN
XTR-PRO-DV
XTR-ALTIMA A2L
LIQUID & VAPOUR REFRIGERANT RECOVERY
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PRODUCT SAFETY:
These units have been designed to meet the requirements of the Standard for Refrigerant Recovery
Machines, UL1963 and AS4211.3 - 1996. In order to fully meet safety requirements, the recovery
operation must always be performed using an approved storage cylinder with a shuto switch,
which is properly connected to the unit’s Over Fill Protection circuit (available as factory option). If an
approved cylinder with overll is not available always use an approved scale to monitor the cylinders
capacity. Additionally, approved refrigerant hoses must be used which have shut-o devices within
12 inches of the ends to reduce the likelihood of refrigerant leakage to the atmosphere when
changing cylinders or setups.
RESPONSIBILITY:
Only a Qualied Technician who has been properly trained in the care and use of such equipment
and in the recovery process itself must operate the JAVAC refrigerant recovery devices. Use of this
equipment by unqualied personnel is potentially dangerous and should not be attempted.
The XTR-ALTIMA A2L is designed for most CFC, HFC, HCFC and some HFO refrigerants that have a
ammability rating of A2L or lower. It is not intended for use with A2 or A3 refrigerants such as butane
or propane. The user/technician MUST be trained or qualied for handling ammable refrigerants
of A2L classication or greater before using the machine with A2L refrigerants. Please refer to the
AIRAH ammable refrigerant safety guide or relevant regional codes of practice and legislation for
more information.
CONTENTS
1.0 XTR-PRO-DV DUAL VOLTAGE SUPPLIMENTARY
2.0 SAFETY PRECAUTIONS
3.0 SPECIFICATIONS
4.0 FEATURES
5.0 SET UP AND OPERATION
5.1 Getting Started
5.2 Normal Recovery Operation
5.3 Purging The Recovery Machine
5.4 Push Pull Operation
5.5 Cooling The Recovery Cylinder
5.5 Special Operating Notes
5.6 Storage
6.0 APPROVED ACCESSORY ITEMS
7.0 MAINTENANCE
8.0 TROUBLE SHOOTING
9.0 SERVICE - CONSTRUCTION
10.0 RECOVERY CYLINDER SAFETY
11.0 WARRANTY
12.0 TRADE-IN AND SALES
13.0 HELP AND SUPPORT
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EN
1.0 XTR PRO-DV DUAL VOLTAGE SUPPLIMENTARY
Thank you for purchasing a JAVAC Refrigerant Recovery Machine.
1.1 The XTRC2DVUK has been designed with the inclusion of a Dual Voltage Compressor and Fan
and a Voltage selection switch for added safety and convenience. The Voltage Selection switch
allows the operator the choice of running the machine at 110 or 230 Volts.
1.2 The XTRC2DVUK is designed for most CFC’s and HFC’s, It is not intended for use with A2 or A3
refrigerant such as butane or propane. The user/technician must be trained and qualied for handling
refrigerants before using the XTRC2DVUK. Refer to your local codes of practice and legislation.
SPARE PARTS
JAVAC oer a complete range of product spares. Visit our website: javac.co.uk or contact your local
wholesaler for details.
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1.3 CAUTION: CORRECT USE OF THE DUAL VOLTAGE (UK ONLY)
This machine has been tted with a Dual Voltage compressor. It ranges between 115 and 230 Volts
50/60Hz. Please be aware that if the Voltage selecter switch is NOT in the correct position, severe
damage will be caused to this machine.
1.4 When the switch is in this position it is set for 115 Volts 50/60Hz. You will need to use a 110V 3
Pin UK Outlet Plug with an IEC Plug to the Machine.
THIS LEAD IS NOT SUPPLIED WITH THIS UNIT.
1.5 When the switch is in this position it is set for 230 Volts 50/60Hz. You will need to use a Standard
230V Outlet Plug with an IEC Plug to the machine.
THIS LEAD IS SUPPLIED WITH THIS PACKAGE.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD CAUSE DAMAGE TO THE MACHINE
AND ITS SURROUNDINGS AND SERIOUS HARM TO THE USER.
THIS WILL ALSO VOID ANY WARRANTY.
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EN
2.0 SAFETY PRECAUTIONS
2.1 THIS EQUIPMENT MUST ALWAYS BE OPERATED BY A QUALIFIED TECHNICIAN WHO
IS FAMILIAR WITH REFRIGERANT SYSTEMS, REFRIGERANTS, REFRIGERANT SAFETY AND
LOCAL REQUIREMENTS.
2.2 READ THIS MANUAL and become familiar with the specications and operation of this machine
prior to use.
2.3 WEAR APPROPRIATE SAFETY PROTECTION APPAREL such as gloves, eye protection and
foot protection when working on refrigeration systems.
2.4 REFRIGERANT VAPOUR CAN BE HAZARDOUS AND ITS BYPRODUCTS CAN BE LETHAL
- work only in well ventilated areas. When working indoors, ensure there is adequate airow in the
workspace and install a separate circulation fan if necessary. DO NOT WORK IN AN ENCLOSED
AREA without special safety equipment as appropriate for the conditions.
2.5 KNOW THE PROPER SAFETY AND HANDLING REQUIREMENTS for the refrigerant being
recovered by reviewing the Material Safety Data Sheets (MSDS) and the temperature - vapour
pressure information.
2.6 PERFORM LEAK DETECTION in accordance with recommended practice only. For best results
use only a refrigerant detector such as the JAVAC D-TEK or TEK- Mate. NEVER USE OXYGEN for
this process as it can become an explosive mixture in the presence of oil and pressure.
2.7 NEVER OVERFILL A STORAGE CONTAINER. The use of a refrigerant scale, such as the
JAVAC Pro-Charge, is required to prevent overll. OVERFILLED CYLINDERS CAN RUPTURE
EXPLOSIVELY!
2.8 STORE REFRIGERANTS in a cool, dry place.
2.9 SEPARATE DIFFERENT REFRIGERANTS. Avoid mixing refrigerants by using sepa-rate storage
cylinders and lters for each type recovered.
2.10 OPEN SERVICE OR CYLINDER VALVES SLOWLY to ensure that all connections are tight and
there is no danger.
2.11 DISCONNECT POWER before moving or servicing the recovery unit. CAUTION - these units
should be opened only by a technically qualied person who has been trained in basic electronics
and refrigeration. The risk of ELECTRIC SHOCK and exposure to HOT compressor parts is possible
if the unit is opened.
2.12 WARNING - TO REDUCE THE RISK OF FIRE, EXTENSION CORDS SHOULD NOT BE USED
with this equipment as the wiring can overheat under conditions of high current draw. If an extension
cord is absolutely necessary, its length should be as short as possible and it should contain size 16
AWG (1.291 mm) or larger wiring.
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2.13 FLAMMABLE ENVIRONMENTS ARE DANGEROUS when any machine is used because
motors and switches can generate sparks. This equipment should be used in locations with
mechanical ventilation providing at least four air changes per hour, or the equipment should be
located at least 18” above the oor. DO NOT USE THIS EQUIPMENT IN THE VICINITY OF
SPILLED OR OPEN CONTAINERS OF GASOLINE OR ANY OTHER FLAMMABLE LIQUID.
2.14 MOISTURE can cause severe damage when introduced to the internal parts of a refrigeration
system. Ensure that care is exercised in the leak detection, recovery, repair and relling of a system
to prevent moisture from entering. Always use a quality high vacuum pump such as a Javac Vector
to ensure the system is totally dehydrated. An electronic total pressure gauge such as the JAVAC
Acravac should also be used to monitor the pressure.
2.15 USE CAUTION WHEN OPERATING OUTDOORS. Be certain that the power cord, the cylinder
safety cord and the unit itself are not placed in water or other potentially dangerous locations. While
these recovery machines are very safe to operate, using in environments such as hard rain or sand
and dust storms should be avoided.
2.16 CAUTION - EXERCISE CARE WHEN MOVING the equipment to prevent the risk of injury.
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3.0 SPECIFICATIONS - XTR-PRO-DV, XTR-ALTIMA A2L
EN
REF FEATURES TECHNICAL SPECIFICATIONS
3.1 Refrigerants EPA Certied to ARI 740-98 for refrigerants, R12, 134a, 22 & 410A
3.2 Safety Designed to meet UL1963, AS standards & EU equivalents
3.3 Power XTR-PRO-DV: 220/240 VAC, 50Hz, 3.6A 115VAC/50Hz, 8A
XTR-ALTIMA A2L: 220/240V VAC, 50HZ, 3.4A
3.4 Compressor 1/2 HP Oil less,AC motor drive
3.5 Cooling Fan/Motor
3.6 Protection High Pressure Switch Cuto at 3500 Kpa Compressor protected
by separate circuit breaker Cooling fan motor thermally protected
80% Cylinder Full Shuto available
3.7 Pressure Low side design pressure 1600 Kpa
High side design pressure 3500 Kpa
3.8 Temperature Operating range 100°C to 400°C
3.9 Case Blow-Moulded, High Impact Strength
3.10 Size L 390 mm X W 250 mm X H 380 mm
3.11 Weight 16 Kg (XTR-ALTIMA A2L - 14 Kg)
Perfomance for XTR-PRO-DV
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4.0 FEATURES
4.1 Designed with the highest quality components and manufactured in an ISO- 9001 Registered facility.
4.2 The JAVAC XTR-PRO-DV and XTR-ALTIMA A2L Refrigerant Recovery Machines utilize a new oil less
compressor technology that is highly tolerant of liquid and is easier to maintain since it has no Inlet Valve.
4.3 Factory tted with a inlet particle lter which traps contaminants. This lter is easy to remove, clean or
replace in the event of restricted ow.
4.4 Inlet (Suction) and Discharge pressure gauges allow the process to be monitored from start to nish.
4.5 The unit’s lightweight and excellent balance makes it easy to transport to the job site and into dicult
locations. The handle is easy to grasp and the unit is exceptionally well balanced.
4.6 The PURGE operation can be accomplished without changing hoses.
4.7 The high impact moulded case resists damage and is designed to protect the gauges, valve knobs
and hose connection ports from incidental damage caused during operation, handling and storage.
LP Gauge HP Gauge
LP
Discharge Valve
(V3)
Discharge Port
Inlet Valve (V1)
Inlet Port with
Particle Filter
Purge / Recovery
Valve (V2)
On/O switch
Circuit breaker
Power Lead
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EN
5.0 SET UP AND OPERATION
5.1 GETTING STARTED
5.1.1 CAUTION: Only personnel who have been properly trained in the use and operation of
refrigeration systems, refrigerants and service equipment should operate this equipment. Failure to
follow proper safety precautions could result in personal injury or death.
5.1.2 CAUTION: Review the full contents of this manual before attempting to use the recovery
machine in actual service.
5.1.3 Identify the refrigerant to be recovered and prepare the recovery unit for use by installing an
approved lter, hoses and scale as per the diagram below. Refer to section 6.0 of this manual for
approved accessories.
5.1.4 Connect the AC power cord to a circuit that is protected by a circuit breaker. Use an extension
cord only when absolutely necessary to perform the service; be sure it is the minimum length
required, that it contains a safety ground wire and that it contains wires sized 16 AWG (1.291 mm) or
larger.
5.1.5 Make sure the recovery unit is set in a stable position and that it is reasonably level; observe
all safety precautions previously noted. Ensure that the fan inlet and discharge areas on both sides of
the machine are clear from obstructions.
5.1.6 Check all connections to ensure they are tight before starting the recovery operation.
5.1.7 The XTR-PRO-DV and XTR-ALTIMA A2L are liquid tolerant recovery machines. It is important
to remember to START the machine before opening the INLET valve. Should the compressor start to
‘Knock’, close the INLET valve immediately and while it is still running, slowly open the valve again.
5.1.8 Use a refrigerant scale to ensure that the cylinder is not lled to more than 80% of its capacity
by weight. When operating in the NORMAL RECOVERY or PUSH-PULL mode without the cylinder
shuto it is possible to overll the cylinder. If you are not sure, check the cylinder weight before
transporting. Refer to section 10.0 of this manual. OVERFILLED CYLINDERS CAN RUPTURE
EXPLOSIVELY!
5.2 NORMAL RECOVERY OPERATION
5.2.1 Connect all cables and hoses as described in Section 5.1 above and as shown in the diagram
below. Ensure that they are tight and routed in such a way that they will not interfere with the
operation.
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RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURG
ER
ECOVER
OPEN
V3
SET-UP PROCEDURE FOR NORMAL REFRIGERANT RECOVERY
5.2.2 Switch o the power to the unit being serviced. If the power switch is in a remote location, LOCK
it out so that no one will accidentally turn it back on.
5.2.3 Make sure that the discharge hose from the recovery unit to the Recovery Cylinder is attached
to the LIQUID PORT. If cylinder contains refrigerant, partially open liquid valve and purge hose from
recover unit discharge port end. If cylinder is empty and pre–evacuated, refer to section 5.2.4.4 and
use incoming refrigerant to purge discharge hose from cylinder port end. Open cylinder liquid valve fully
after purging hose.
5.2.4 Set the rocovery unit for RECOVERY.
5.2.4.1 OPEN DISCHARGE valve (V3) to its fully open position.
5.2.4.2 SET PURGE/RECOVERY valve (V2) to RECOVERY position.
5.2.4.3 Open the Manifold Gauge VAPOUR valve slowly and verify that no leaks are present. Open
vapour valve fully and partially open liquid valve. Do not attempt to recover 100% liquid.
5.2.4.4 At this point use incoming refrigerant to purge hose.
5.2.5 Switch ON the recovery unit and verify that the compressor is operating and cooling air is
exhausting from the back of the machine.
5.2.6 MONITOR the inlet pressure (LP, Low Pressure Gauge) and SLOWLY OPEN the recovery unit
INLET valve (V1) fully. If the compressor ‘knocks’ shut V1 immediately, then close manifold liquid valve.
Open V1 while the machine is running and continue to recover in vapour phase.
5.2.7 Continue to operate until the required VACUUM has been pulled on the system (refer to Section
10.0 of this Manual), as indicated by the LP gauge. Switch OFF the recovery unit, CLOSE the INLET
(V1), and wait for 5 minutes. If the Pressure in the system, as indicated on the Manifold Gauge, rises
above 0 Kpa, refrigerant is still present. If so, RESTART Recovery Machine, REOPEN the INLET (V1) and
run until the required VACUUM is reached again. Repeat this process until all the refrigerant is removed
resulting in a nal reading of 0 Kpa or less.
5.2.8 TERMINATE the RECOVERY operation.
5.2.8.1 CLOSE Manifold Gauge Liquid and Vapor valves.
5.2.8.2 CLOSE XTR-PRO-DV INLET Valve (V1).
5.2.8.3 Switch POWER OFF.
5.2.8.4 It is a good practice to purge the Recovery Machine after each use.
Refer to section 5.3 of this manual.
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5.0 SET UP AND OPERATION continued
5.3 PURGING THE RECOVERY UNIT
5.3.1 While the recovery machine is running, rotate INLET Valve (V1) to CLOSE position.
5.3.2 Rotate PURGE/RECOVERY valve (V2) to PURGE position. Leave DISCHARGE (V3) open.
5.3.3 Slowly rotate Inlet V1 to PURGE position.
5.3.4 Observe LP gauge and continue to run the unit until a VACUUM is achieved. Switch POWER
OFF and CLOSE the recovery cylinder valve. Return INLET valve (V1) to CLOSE position and close
the V3.
5.3.5 IMPORTANT - Return V2 to RECOVERY Position.
5.3.6 CAUTION - THE DISCHARGE PORT AND HOSE WILL CONTAIN A SMALL AMOUNT OF
REFRIGERANT UNDER PRESSURE. EXERCISE CARE WHEN REMOVING THIS HOSE AND
OPENING V3 VALVE.
5.3.7 REMOVE all hoses and cables and prepare the machine and the recovery
cylinder for transport.
5.3.8 When changing refrigerants or reconnecting to a cylinder always purge the hoses and the
recovery machines ports with refrigerant, (or evacuate lines), to prevent air entering the recovery
process.
SET-UP PROCEDURE FOR PURGE
EN
RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURG
ER
ECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
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5.4 PUSH/PULL OPERATION
5.4.1 The PUSH PULL method is used to move a large amount of liquid refrigerant from the system
being serviced to the recovery cylinder without passing it through the compressor. This method is
only useful when more than 7 Kg of liquid is known to be in the system and it can be easily isolated.
DO NOT ATTEMPT the PUSH PULL process unless you are sure of the situation.
5.4.2 Connect the refrigerant hoses as shown below. Addition of a SIGHT GLASS in line between the
system being serviced and the recovery cylinder can be an important aid to determine when all the
liquid has been transferred and only vapour remains.
5.4.3 This process uses the PULL from the exhausted recovery cylinder and the Discharge PUSH
from the recovery unit to move the liquid refrigerant. Rates in excess of 5 Kg per minute can be
achieved by this procedure.
5.4.4 The SCALE is required in this process to ensure that the cylinder is not overlled. The cylinder
shuto switch, if used, would stop the compressor but could not guarantee that additional refrigerant
ow would cease because of the dynamics of the system, thus possibly overlling the cylinder.
SET-UP PROCEDURE FOR PUSH/PULL METHOD
RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
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15
14
EN
5.0 SET UP AND OPERATION continued
5.5 COOLING THE RECOVERY CYLINDER
5.5.1 The recovery unit can be used to PRE-cool (or SUB-cool) the recovery cylinder if the head
pressure is too high to complete the recovery process. This can occur when working with certain
refrigerants with a high vapour pressure in high ambient temperatures.
5.5.2 If the recovery process stalls out because of high head pressure, stop the recovery unit, shut
o the hose valves and recongure the setup as shown below. This can also be done before starting
the recovery process but it may have marginal long term eect. NOTE: This will only work if there is at
least 5 Kg of liquid in the recovery cylinder to develop the necessary pressure dierential required.
5.5.3 POWER ON the recovery unit and ROTATE the DISCHARGE Valve (V3) to achieve a pressure
dierential of at least 700 Kpa between the LP Gauge and the HP Gauge. KEEP THE HP BELOW
2500 Kpa on the HP Gauge to ensure that the HP Cut-O Switch will not actuate.
5.5.4 After several minutes of running, the cylinder will be cold. POWER OFF the recovery unit and
recongure the setup for NORMAL RECOVERY. Repeat as needed.
SET-UP PROCEDURE FOR SUB-COOLING METHOD
RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
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15
5.6 SPECIAL OPERATING NOTES
5.6.1 During normal operation, when the High Pressure switch activates, the machine will restart
automatically when the head pressure drops below approximately 2500 Kpa.
5.6.2 When the Optional Pressure Control Circuit is installed and when the High-Pressure switch
activates, the machine must be cycled OFF and back ON for the compressor to restart. The “High
Pressure Cut Out” signal light (red) will illuminate when activated.
5.6.3 When the optional Press Control Circuit is installed and when low pressure switch activates
on completion of recovery, the machine must be cycled OFF and back ON for compressor to restart.
Green LED will illuminate when LP is activated.
5.6.4 When optional Low-Pressure Override is installed, compressor can be restarted after LP CUT-
OUT activation by pressing the black switch. This will allow to achieve a further vacuum beyond the
LP cutout range.
5.6.5 When optional Cylinder/Tank Overll Protection Device is installed and if the CT-OFD Cable is
not connected or Cylinder/Tank is full, the yellow “Cylinder Full” signal light will be illuminated. When
this is the case, the compression will start briey if the power is cycled OFF and ON again but will not
run for more than a few seconds. This is normal operation.
5.7 STORAGE
5.7.1 When the recovery process has been completed, carefully coil the Power Cord, the Refrigerant
Hoses and the Cylinder Overll Protection Cord (if used), ensuring that no dirt or foreign material is
left in the ends or on the connectors.
5.7.2 Place the recovery unit in the service vehicle in its upright position and store the hoses and
cords nearby. Provide reasonable care to place the unit where it will not be subjected to accidental
damage due to shifting items during transit or to heavier objects being placed on its top.
5.7.3 The unit can be stored safely in temperatures of 00 - 500 C and humidity levels up to 95%
RH. When stored in conditions that are severe, the unit may need to stabilize in the range 100
- 400C before it will oer optimum operating performance. For best results, store the unit in an
environmentally controlled area when not in use.
5.7.4 Always purge and vent the machine prior to storage, close V1 & V3 and leave V2 in the
Recover Position.
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17
16
6.0 APPROVED ACCESSORY ITEMS
The XTR-PRO-DV and XTR-ALTIMA A2L Refrigerant Recovery Machines require the proper accessory
items to ensure the best performance. The following items are specically identied to ensure
safety and operational requirements are met. Check with your Wholesaler to ensure that the proper
selections have been made.
6.1 REFRIGERANT HOSES should be made with approved materials, should be as short as
possible to perform the required operations and should have shut-o devices within 300 mm of
the ends.
Approved hoses are: Refrigerant Hoses with UL Recognition and 20000 Kpa Burst Strength.
6.2 RECOVERY CYLINDERS should be approved and have an appropriate pressure rating for the
refrigerant being recovered. Choose the size (normally 20 or 60 Kg) that is right for the job, and be
sure they have a cylinder full oat switch.
Approved cylinders are: Refrigerant cylinders with Brad Harrison 3 pin connectors.
6.3 FILTERS should be selected to protect the Inlet of the recovery machine from particles of
dust, metal and other foreign materials that may be present in the refrigeration system. If servicing
a system with a burned out compressor, 2 or more FILTERS in series may be necessary, and they
should be discarded immediately after use.
Approved lters are: Filters UL recognized/CSA listed for Refrigeration Service.
6.4 EXTENSION CORDS, when necessary, should be as short as possible and should contain size
16 AWG (1.291 mm) or larger conductors. This is necessary to avoid overheating during periods of
high current draw and minimize the risk of re. The longer the extension cord required at the work
site, the larger the conductor size should be particularly for runs over 10m.
6.5 CYLINDER/TANK OVER FILL DEVICE (CT - OFD), the JAVAC XTR-PRO-DV and XTR-ALTIMA
A2L have been designed to incorporate an integrated Pressure Control Circuit. The CT - OFD
upgrades the machine to a latching High-Pressure switch, (as opposed to automatic). Allows
provision for an optional factory tted Low Pressure switch, plus low voltage input, which, can be
used to connect to cylinders, which incorporate, oats, cylinder scales or timers etc.
NOTE: Because not all cylinders are available with Brad Harrison 3 pin connectors the facility will vary
depending upon the market.
EN
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17
7.0 MAINTENANCE
7.1 Your recovery machine will provide many seasons of reliable service if it is properly maintained.
The actual maintenance requirements are minimal but important.
7.2 Keep the unit clean by wiping it down with a damp cloth to remove dirt, oils, etc. Prior to storage
for the day. Standard household detergent or isopropyl alcohol may be used if the unit is particularly
dirty; in all cases, exercise care to prevent liquids from entering the unit. Gasoline and other solvents
are to be avoided as they can damage the plastic enclosure and are hazardous.
7.3 Clean inlet particle lter regularly. Discard internal lter screen if it is heavily contaminated and
replace with a new screen. Replace screen as per sketch for eciency.
7.4 Ensure that the Inlet and Discharge ports are protected and kept clean by replacing the plastic
caps after every use. For best results, keep a FILTER permanently connected to the INLET port and
change it regularly.
7.5 Change HOSES periodically as they develop leaks and a build-up of contaminants over time.
Change hoses at least once per season.
7.6 When storing the recovery machine for the season, or for long periods of time, PURGE the unit
with an inert gas such as nitrogen.
7.7 When performance falls o it is likely that the compressor seals require replacing. This is normal
with use and may occur after a year or two or more often, depending upon the conditions that are
prevalent during the recovery operations. Contact your Wholesaler for assistance in selecting the
proper maintenance kit.
FILTER
SCREEN
DIRECTION
RECOVERY UNIT
POWER
SOURCE
OPTIONAL
CONNECTION
TO SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
VAPOUR LIQUID
RECOVERY UNIT
VAPOUR
VAPOUR
LIQUID
SYSTEM
POWER
SOURCE
FILTER
CYLINDER
WITH
CT-OFD
SCALE
LIQUID
RECOVERY UNIT
LIQUID
CYLINDER
SCALE
POWER
SOURCE
RECOVERY UNIT
VAPOUR
LIQUID
LIQUID
SYSTEM
CYLINDER
WITH
CT-OFD
SCALE
POWER
SOURCE
FILTER
VALVE POSITIONS FOR PUSH/PULL METHOD
V2
L
I
Q
U
I
D
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
V1
VALVE POSITIONS DURING PURGE OPERATION
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
VALVE POSITIONS DURING SUB-COOLING METHOD
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGE RECOVER
OPEN
V3
VALVE POSITIONS DURING NORMAL RECOVERY
V2
L
I
Q
U
I
D
V1
CLOSE
OPEN CLOSEPURGE
PURGERECOVER
OPEN
V3
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19
18
8.0 TROUBLE-SHOOTING
EN
PROBLEM CAUSE ACTION
UNIT WILL NOT START
- COMPRESSOR DOES
NOT START; NO LIGHT IN
POWER SWITCH
• Power cord not attached
• No voltage at receptacle/
incorrect voltage
• Attach power cord
• Verify voltage at job site
COMPRESSOR WILL NOT
START
• Circuit breaker has opened
• Discharge pressure too high
• HP switch has opened
permanently
• Insucient pressure to close
LP switch (if tted)
• Electronics failure in Motor,
Bridge Rectier or Filter
Capacitor / Relay
• Thermal cut-out has
activated
• Identify cause of breaker
activation, rectify and reset
• Reduce pressure and rotate
V2 to purge and back to
recovery
• Reduce pressure
• Factory service required
• Check connection, hoses,
valves, gauges, system may
not contain refrigerant
• Factory service required
• Allow motor to cool. If still
not working a factory service
is required
COMPRESSOR STARTS
BUT CUTS OUT WITHIN A
FEW MINUTES; PRESSURE
INDICATION ON HP GAUGE
IS HIGH
• V2 is in purge position and
HP switch activates
• V3 not open and HP switch
activates
• Recovery cylinder valve not
open
• Blocked discharge hose
• Air in system/cylinder
• Fan not turning
• Rotate V2 to recovery
• Rotate V3 to open position
• Open cylinder valve
• Check & clear blockage
• Bleed air from system/
cylinder
• Factory service required
COMPRESSOR STOPS
INTERMITTENTLY
• Vapour pressure of
refrigerant in cylinder is close
to HP trip point
• Reduce cylinder temperature
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19
PROBLEM CAUSE ACTION
UNIT OVERHEATS Excessive head pressure
due to:
• High ambient temperature
• Restricted discharge hose
• Air in recovery cylinder
• Fan not turning
• Reduce cylinder temperature
• Check & clear restriction
• Bleed air from cylinder
• Factory service required
RECOVERY PROCESS TOO
SLOW
• Head pressure too high
• System refrigerant iced up
• Compressor seals are worn
• Inlet lter blocked
• Reduce cylinder temperature
or change cylinders
• Throttle gauge manifold
valves and V3 to reduce
pressure dierential between
LP and HP gauges
• Interrupt process to allow ice
to dissipate
• Rebuild compressor with
service kit - Check with
wholesaler for assistance
• Remove lter and clean/
replace cone screen
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21
20
9.0 SERVICE - CONSTRUCTION AND SCHEMATIC
9.1 SERVICE
9.1.1 DO NOT CHANGE any of these components as the safety of the machine could be
compromised. All service work must be performed at a JAVAC approved facility in order to maintain
the safety rating and the Warranty, if applicable.
9.1.2 Technical assistance and service information can be obtained by calling the Organisation where
you purchased the recovery machine.
NOTE: Do not return a defective unit directly to the factory. Contact your wholesaler or the
factory for assistance.
9.1.3 Spare parts and accessories (see 9.3) for your XTR-PRO-DV are available through the same
dealer from whom you purchased the unit.
9.1.4 Only technically qualied personnel who are familiar with basic electronics and refrigeration
systems should install the Pressure Control Circuit. Disassembly of the unit to rebuild the compressor
or to provide other repair work should be referred to an approved service centre as indicated above.
9.2 CONSTRUCTION
9.2.1 The JAVAC recovery machines are constructed from the highest grade materials to exacting
standards. All assembly and testing is performed in an ISO 9001 registered facility.
9.2.2 This unit is manufactured with environmentally compatible components, which can be
substantially recycled at the end of the product’s useful life. Consult your local agencies for proper
recycling.
9.2.3 The JAVAC recovery machines contain no hazardous materials.
9.3 SPARE PARTS
JAVAC oer a complete range of product spares. Visit our website: javac.co.uk or contact your local
wholesaler for details.
EN
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