Johnson Controls YORK RECOVERY PAK LD17585 Troubleshooting guide

WATER-COOLED REFRIGERANT
RECOVERY AND RECYCLING UNITS
OPERATION & MAINTENANCE Supersedes: 50.40-OM1 (904) Form 50.40-OM1 (713)
Issue Date:
July 17, 2013
RSR UNITS
LD17583
PORTABLE
RECOVERY
PAK™
LD17585
EASYTANK™
LD17584

JOHNSON CONTROLS
2
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
This equipment is a relatively complicated apparatus.
During installation, operation maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
materials under pressure, rotating components, and
both high and low voltage. Each of these items has the
potential, if misused or handled improperly, to cause
bodily injury or death. It is the obligation and respon-
sibility of operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
operating/service personnel. It is expected that these
individuals possess independent training that will en-
able them to perform their assigned tasks properly and
safely. It is essential that, prior to performing any task
on this equipment, this individual shall have read and
understood this document and any referenced mate-
rials. This individual shall also be familiar with and
comply with all applicable governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for contin-
uous product improvement, the information contained
in this document is subject to change without notice.
Johnson Controls makes no commitment to update or
provide current information automatically to the man-
ual owner. Updated manuals, if applicable, can be ob-
tained by contacting the nearest Johnson Controls Ser-
vice office or accessing the Johnson Controls QuickLIT
website at http://cgproducts.johnsoncontrols.com.
Operating/service personnel maintain responsibility for
the applicability of these documents to the equipment.
If there is any question regarding the applicability of
these documents, the technician should verify whether
the equipment has been modified and if current litera-
ture is available from the owner of the equipment prior
to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.

JOHNSON CONTROLS
4
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 5
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION.................................................................................................................................7
Inspection – Damage – Shortage..................................................................................................................7
Safety Summary...............................................................................................................................................7
Mechanical Specifications – RSR Models........................................................................................................8
Mechanical Specifications – Portable Recovery PAK™................................................................................. 11
Mechanical Specifications – Easy Tank™......................................................................................................12
SECTION 2 - OPERATION .....................................................................................................................................13
General...........................................................................................................................................................13
Prior to Starting Refrigerant Recovery ...........................................................................................................13
Operation of Refrigerant Storage/Recycle System ........................................................................................15
Liquid Transfer – Refrigeration Unit to RSR Storage Vehicle.........................................................................15
Detection and Removal of Non-Condensible Gases......................................................................................17
Charging Refrigeration Unit with Refrigerant From RSR Unit ........................................................................18
SECTION 3 - DIAGRAMS.......................................................................................................................................23
SECTION 4 - MAINTENANCE PROCEDURES .....................................................................................................29
General...........................................................................................................................................................29
Compressor Model CFC 1000........................................................................................................................31
SECTION 5 - REPLACEMENT PARTS AND KITS ................................................................................................33
Compressor Replacement..............................................................................................................................35
Compressor Model 16799 (RST-2240, RSR-2250 & RP-2400) ..................................................................... 35
Vacuum Pump – Model CRR-1 .....................................................................................................................43
Repairing Oil Leaks .......................................................................................................................................45
Repairing Vacuum Leaks................................................................................................................................45

JOHNSON CONTROLS
6
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
LIST OF FIGURES
LIST OF TABLES
FIGURE 1 - YORK RSR System Flow Diagram......................................................................................................15
FIGURE 2 - Wiring Diagram RSR-1100V, -1600V, -1100V114, & -1600V114 ......................................................... 23
FIGURE 3 - Wiring Diagram RSR-2212 & -2222.....................................................................................................23
FIGURE 4 - Wiring Diagram Easy PAK RP-1000V, -114V & -2200 ........................................................................24
FIGURE 5 - Wiring Diagram RSR-2240, -2250, -4436, -4445 & RP-2400, -3400 ..................................................24
FIGURE 6 - Piping Diagram RSR-1100V, -1600V, -1100V & -1600V114 ................................................................25
FIGURE 7 - Piping Diagram RSR-2212, -2222, -2240, -4436, -4445......................................................................26
FIGURE 8 - Piping Diagram Easy-Pak RP-1000V, -114V, -2200, -2400 & -3400 ...................................................27
FIGURE 9 - Compressor Replacement Parts – Model CFC-1000 ..........................................................................33
FIGURE 10 - Compressor Replacement Parts – Discontinued Model 16799.........................................................37
FIGURE 11 - Compressor Replacement Parts – Models RA and CK .....................................................................40
FIGURE 12 - Vacuum Pump Replacement Parts – Model CRR-1 ..........................................................................43
FIGURE 13 - Compressor Data Sheet – Model 51VSM..........................................................................................46
FIGURE 14 - Compressor Dimensions – English – 51VSM.................................................................................... 47
FIGURE 15 - Compressor Dimensions – Metric – 51VSM...................................................................................... 47
FIGURE 16 - Compressor Parts – 51VSM..............................................................................................................48
FIGURE 17 - Compressor Maintenance Instructions – 51VSM ..............................................................................50
FIGURE 18 - Photo, Compressor, Belt Driven – 51VSM.........................................................................................51
TABLE 1 - RSR Specifications – Standard ...............................................................................................................9
TABLE 2 - RSR Specifications – Metric ..................................................................................................................10
TABLE 3 - Recovery PAK Specifications (Standard and Metric) ............................................................................ 11
TABLE 4 - Standard Tank Options (Standard and Metric) ......................................................................................12
TABLE 5 - Settings for Pressure Safety Control Switches......................................................................................13
TABLE 6 - Operation Settings.................................................................................................................................16
TABLE 7 - Final Vacuum/EPA Regulatiions ............................................................................................................17
TABLE 8 - Pressure Difference for Determining Presence of Non-Condensible Gases......................................... 18
TABLE 9 - Vapor Pressure – CFC-11, CFC-12, CFC-22 and CFC-500..................................................................18
TABLE 10 - Vapor Pressure – HCFC-123 and HFC-134a ......................................................................................19
TABLE 11 - Vapor Pressure – CFC-114 and CFC-502 ...........................................................................................20
TABLE 12 - Vapor Pressure (Metric (kPa) – CFC-11, CFC-12, CFC-22 and CFC-500 ..........................................21
TABLE 13 - Vapor Pressure (Metric) – HCFC-123 and HFC-134a.........................................................................21
TABLE 14 - Vapor Pressure (Metric) – CFC-114 and CFC-502..............................................................................22
TABLE 15 - Compressor Replacement Parts – Model CFC-1000 ..........................................................................34
TABLE 16 - Compressor Torque Specifications – Model CFC-1000 ......................................................................35
TABLE 17 - Compressor Piston Selective Fits........................................................................................................35
TABLE 18 - Torque Values for Model 16799 Compressor ......................................................................................36
TABLE 19 - Compressor Replacement Parts – Discontinued Model 16799........................................................... 38
TABLE 20 - Model D799 Compressor Parts (Old Style) .........................................................................................39
TABLE 21 - Compressor Three Cylinder Model RA & CK – BM-99301, -99302 & -99303 ..................................... 41
TABLE 22 - Vacuum Pump Replacement Parts – Model CRR-1............................................................................44
TABLE 23 - Compressor Parts – 51VSM................................................................................................................49
TABLE 24 - Compressor Refrigerating Capacity – 51VSM: R134a, BTU/HR......................................................... 51
TABLE 25 - Compressor Refrigerating Capacity – 51VSM: R22, BTU/HR............................................................. 51
TABLE 26 - Compressor Cross Reference Chart – 51VSM ...................................................................................52
TABLE 27 - Compressor Specifications – 51VSM ..................................................................................................52
TABLE 28 - SI Metric Conversion ...........................................................................................................................53

JOHNSON CONTROLS 7
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
1
The YORK Refrigerant Recovery and Recycling units
are designed to handle all of the major refrigerants
used in air conditioning and refrigeration units. These
include R-11, R-114, R-123, R-12, R-134a, R-500,
R-502 and R-22.
Refrigerant storage vessels are of a low pressure design
for R-11, R-114 and R-123 and a high pressure design
for the remaining refrigerants.
Two styles of units are available. One is a self
contained “RSR”; the other is a combination of a “Por-
table Recovery Pak” – complete with controls – that
is used in combination with an “Easy Tank” storage
vessel complete with pressure safety controls and
liquid float switch.
INSPECTION – DAMAGE – SHORTAGE
The unit shipment should be checked on arrival to see
that all major pieces, boxes and crates are received.
The unit should be checked on the trailer or rail car
when received, before unloading, for visible signs of
damage. Any damage or signs of possible damage
should be reported to the transportation company im-
mediately for their inspection. Also advise the Johnson
Controls Regional or District Office so a Johnson Con-
trols representative can assist in filing damage claims.
JOHNSON CONTROLS WlLL NOT BE RESPON-
SIBLE FOR ANY DAMAGE IN SHIPMENT, OR AT
JOB SITE, OR LOSS OF PARTS.
If damage is found, Johnson Controls must be notified
and action must be taken to prevent further damage or
deterioration of the machinery, i.e.: a slow refrigerant
leak exposure of internal parts to atmosphere, etc.
When received at the job site, all containers should be
opened and contents checked against the packing list.
Any material shortage should be reported to Johnson
Controls immediately. (Refer to Shipping Damage
Claims, Form 50.15-NM.)
SAFETY SUMMARY
Installation and servicing of air conditioning equipment
and support equipment can be hazardous because of
system pressures and the presence of dangerous volt-
ages. Only trained and qualified service personnel
should install, repair, or service such equipment.
• When using or servicing RSR units, observe pre-
cautions in the literature, as well as those on tags
and labels attached to the equipment.
• Follow all safety codes. Wear glasses and work
gloves when handling refrigerants.
• Before performing service or maintenance opera-
tions on this unit, turn off main power switch and
disconnect power cord. Electrical shock could
cause personal injury.
• Only the storage cylinder, interconnecting hose
set, and lter‑driers supplied with the RST unit
may be used for hookup. Use of unspecied
equipment could result in operator injury and/or
release of refrigerant to the atmosphere.
• Avoid using an extension cord because the exten-
sion cord may overheat. If it is necessary to use an
extension cord, the cord shall be #10 AWG mini-
mum.
• Do not use this equipment near spilled or open
containers of gasoline or other ammable prod-
ucts.
• This equipment should be used in a location with
mechanical ventilation that provides at least four
(4) air changes per hour.
To avoid damaging the unit or the environment:
• The unit must be operated with the storage cylin-
der connected and valves fully open.
• Use only the hoses supplied with the unit.
• Shut off the lter‑drier valves before removing
thelterdrier.
SECTION 1 - INTRODUCTION

JOHNSON CONTROLS
8
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
SECTION 1 - INTRODUCTION
MECHANICAL SPECIFICATIONS – RSR
MODELS
The YORK Refrigerant/Recycling System is a self-
contained package consisting of a refrigerant compres-
sor or vacuum pump, with oil separator, storage receiv-
er, heater, water-cooled condenser, filter drier and nec-
essary valves and hoses to remove, replace and distill
CFC and HCFC Refrigerants. All necessary controls
and safety devices are a permanent part of the system.
The complete system is portable, being mounted on
swivel casters with lock brakes.
Refrigerant Compressor (High Pressure
Units)
The high pressure units for refrigerants CFC-12,
HCFC-22, CFC-500, CFC-502 and HFC-134a feature
a reciprocating compressor that is capable of pulling
a vacuum to a level which is in accordance with EPA
requirements (See Table 7 on page 17).
Refrigerant Vacuum Pump
The low pressure units for refrigerants CFC-11,
HFC-123 and CFC-114 utilize a vacuum pump to
achieve the vacuum levels required by the EPA.
The term compressor will be used synonymously with
vacuum pump throughout this document except where
specific references are necessary.
Oil Separator And Heater
Oil separator includes drain valve and 25 watt heater.
Storage Receiver
Several storage receiver sizes are available (See Table
1 on page 9). The vessel is a horizontal type with
two sight glasses installed to check liquid level. The
receiver is designed and stamped in accordance with
the ASME Boiler and Pressure Vessel Code. The ves-
sel is pitched toward the receiver drain to allow total
removal of liquid.
Valves And Hoses
The unit has permanent-mounted ball valves to allow
the unit to remove, replace, or distill refrigerant without
having to break hoses to the chiller. Eight feet of heavy
duty refrigerant hoses with flare fittings are included to
allow connection to the chiller.
Heater (CFC-11, CFC-114 And HCFC-123 Only
The unit has a 1000-watt heater designed for 115V-1 -
50/60 power and capable of separating oil from refrig-
erant to less than 1000 ppm oil.
Condenser
The water-cooled condenser is a tube-in-tube design.
The condenser is permanently mounted with refriger-
ant lines piped to the system. 3/4-inch hose bib con-
nections are provided for field connection to the water
supply.
STORAGE RECEIVER
The receivers are ASME certified. Each contains inlet
and outlet valves and connections.
Safety Devices
A high-pressure switch is installed to protect the re-
ceiver and compressor against over pressurization. The
relief device is per ASME specifications. Float switch
cuts unit off when tank is 80% full of liquid refrigerant.
Filter Drier
The filter drier is permanently mounted on the system
so that all gas entering or leaving the receiver will be
filtered. The filter is a replaceable core type, capable of
removing moisture to less than 50 ppm.
Controls
Mounted toggle switches are used to operate the unit
and permit all safety devices to protect it.
Gauges
Unit-mounted gauges allow the technician to monitor
suction and discharge pressure of the RSR system.

JOHNSON CONTROLS 9
SECTION 1 - INTRODUCTION
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
1
TABLE 1 - RSR SPECIFICATIONS – STANDARD
DESCRIPTION MODEL
RSR-1100V RSR-1600V RSR-1100V114 RSR-1600V114
Refrigerant CFC-11 CFC-11 CFC-114 CFC-114
HCFC-123 HCFC-123
Refrigerant Storage
Capacity (Lbs.):
80% Full at 90° F
Refrigerant Lbs Refrigerant Lbs Refrigerant Lbs Refrigerant Lbs
CFC-11 1053 CFC-11 1500 CFC-114 1053 CFC-114 1500
HCFC-123 1053 HCFC-123 1500
Working Pressure (PSI) 50 50 50 50
Horsepower 1 1 2 2
Standard Voltages
115V-1-60 115V-1-60 115V-1-60 115V-1-60
208V-1-60 208V-1-60 208V-1-60 208V-1-60
230V-1-60 230V-1-60 230V-1-60 230V-1-60
Plugs Included Yes Yes Yes Yes
Weight (Lbs.) 700 850 700 850
L x W x H (Inches) 61 x 24 x 53 84 x 24 x 53 61 x 24 x 53 84 x 24 x 53
Wheels Included Yes Yes Yes Yes
Relief Valves (2) 1-1/4” FNPT (2) 1-1/4” FNPT (2) 1-1/4” FNPT (2) 1-1/4” FNPT
ASME Approved Yes Yes Yes Yes
DESCRIPTION MODEL
RSR-2212 RSR-2222 RSR-4436 RSR-4445
Refrigerant
CFC-12, 500 & 502 CFC-12, 500 & 502 CFC-12, 500 & 502 CFC-12, 500 & 502
HCFC-22 HCFC-22 HCFC-22 HCFC-22
HFC-134a HFC-134a HFC-134a HFC-134a
Refrigerant Storage
Capacity (Lbs.)
80% Full at 90°F
Refrigerant Lbs Refrigerant Lbs Refrigerant Lbs Refrigerant Lbs
CFC-12 1240 CFC-12 2166 CFC-12 3976 CFC-12 5684
HCFC-22 1126 HCFC-22 1966 HCFC-22 3612 HCFC-22 4582
CFC-500 970 CFC-500 1937 CFC-500 3503 CFC-500 4386
CFC-502 1170 CFC-502 2044 CFC-502 3752 CFC-502 4630
HFC-134a 1140 HFC-134a 1992 HFC-134a 3657 HFC-134a 4635
Working Pressure (PSI) 50 300 300 300
Horsepower 1-1/2 1-1/2 10 10
Standard Voltages
115V-1-60 115V-1-60
460V-3-60 460V-3-60208V-1-60 208V-1-60
230V-1-60 230V-1-60
Plugs Included Yes Yes 4 Prong 4 Prong
Weight (Lbs.) 1325 1600 3200 4200
L x W x H* (Inches) 84 x 24 x 53-1/8 93-1/4 x 30 x 60-1/8 119 x 36 x 77 112 x 42 x 90
Wheels Included Yes Yes Optional Optional
Relief Valves (2) 5/8” Flare (2) 3/4” FNPT (2) 1” FNPT (2) 1” FNPT
ASME Approved Yes Yes Ye s Yes
*Wheels add 13" to overall height dimension of RSR-4436 and 4445

JOHNSON CONTROLS
10
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
SECTION 1 - INTRODUCTION
TABLE 2 - RSR SPECIFICATIONS – METRIC
DESCRIPTION MODEL
RSR-1100V RSR-1600V RSR-1100V114 RSR-1600V114
Refrigerant CFC-11 CFC-11 CFC-114 CFC-114
HCFC-123 HCFC-123
Refrigerant Storage
Capacity (kg)
80% Full at 32° C
Refrigerant kg Refrigerant kg Refrigerant kg Refrigerant kg
CFC-11 478 CFC-11 680 CFC-114 478 CFC-114 680
HCFC-123 478 HCFC-123 680
Working Pressure (kPA) 345 345 345 345
Kilowatts 0.75 0.75 1.5 1.5
Standard Voltages
115V-1-60 115V-1-60 115V-1-60 115V-1-60
208V-1-60 208V-1-60 208V-1-60 208V-1-60
230V-1-60 230V-1-60 230V-1-60 230V-1-60
Plugs Included Yes Yes Yes Yes
Weight (kg) 318 386 318 386
L x W x H (mm) 1549 x 609 x 1386 2134 x 609 x 1346 1549 x 609 x 1346 2134 x 609 x 1346
Wheels Included Yes Yes Yes Yes
Relief Valves (2) 1-1/4” FNPT (2) 1-1/4” FNPT (2) 1-1/4” FNPT (2) 1-1/4” FNPT
ASME Approved Yes Yes Yes Yes
DESCRIPTION MODEL
RSR-2212 RSR-2222 RSR-4436 RSR-4445
Refrigerant
CFC-12, 500 & 502 CFC-12, 500 & 502 CFC-12, 500 & 502 CFC-12, 500 & 502
HCFC-22 HCFC-22 HCFC-22 HCFC-22
HFC-134a HFC-134a HFC-134a HFC-134a
Refrigerant Storage
Capacity (kg):
80% Full at 32°C
Refrigerant kg Refrigerant kg Refrigerant kg Refrigerant kg
CFC-12 562 CFC-12 992 CFC-12 1804 CFC-12 2265
HCFC-22 511 HCFC-22 900 HCFC-22 1638 HCFC-22 2057
CFC-500 440 CFC-500 878 CFC-500 1589 CFC-500 1995
CFC-502 531 CFC-502 927 CFC-502 1702 CFC-502 2137
HFC-134a 517 HFC-134a 903 HFC-134a 1659 HFC-134a 2082
Working Pressure (kPA) 345 2069 2069 2069
Kilowatts 1.1 1.1 7.5 7.5
Standard Voltages
115V-1-60 115V-1-60
460V-3-60 460V-3-60208V-1-60 208V-1-60
230V-1-60 230V-1-60
Plugs Included Yes Yes 4 Prong 4 Prong
Weight (kg) 601 726 1452 1905
L x W x H* (mm) 2134 x 609 x 1349 2368 x 762 x 1527 3022 x 914 x 1956 2845 x 1067 x 2286
Wheels Included Yes Yes Optional Optional
Relief Valves (2) 5/8” Flare (2) 3/4” FNPT (2) 1” FNPT (2) 1” FNPT
ASME Approved Yes Yes Yes Yes
*Wheels add 330 mm to overall height dimension of RSR-4436 and 4445.