yellow jacket 68940 User manual

HVAC/R REFRIGERANT ANALYZER
OPERATION MANUAL
Analyzer Part Number: 68940

Table of Contents
FOR YOUR SAFETY 3
ANALYZER WARNINGS 3
GENERAL CAUTIONS 4
WELCOME 5
1 INTRODUCTION AND OVERVIEW 6
1.1 GENERAL 6
1.2 FEATURES 7
1.3 COMPONENTS 8
68940 Base Unit 8
Low Side Vapor Sample Hose 8
High Side Liquid Sample Hose 9
AC Power Adapter 9
Control Panel 10
Back Panel Connections 10
Hard Shell Stoarage/Carrying Case 11
2 YELLOW JACKET 68940 OPERATION 12
2.1 FIRST USE 12
2.2 TURNING ON THE UNIT 12
2.3 CALIBRATION 13
2.4 VAPOR SAMPLING 14
2.5 LIQUID SAMPLING 15
2.6 VIEWING THE TEST RESULTS 15
2.7 CONTAMINATED BLEND REFRIGERANTS 16
2.8 PURE BLEND REFRIGERANTS 16
2.9 PURE BLENDS WITH INCORRECT COMPONENT RATIOS 17
2.10 MEASURING AIR 17
2.11 PRINTING THE TEST RESULTS & CHANNEL DATA 18
2.12 CHANNEL DATA MODELLING 19
3 MAINTENANCE & TROUBLESHOOTING 20
3.1 SETTING THE LCD CONTRAST 20
3.2 CHANGING THE WHITE PLASTIC SAMPLE FILTER 20
3.3 REPLACING THE BRASS SAMPLE HOSE RESTRICTOR 21
3.4 CHANGING THE PRINTER PAPER 21
3.5 SOFTWARE UPDATE 22
3.6 LOW BATTERY WARNING 23
3.7 AIR SENSOR LOW 23
3.8 ERROR MESSAGE 23
APPENDICES 24
3.9 SPARE PARTS LIST 24
3.10 APPENDIX B –SPECIFICATIONS 24
2

For Your Safety:
PLEASE READ THIS MANUAL IN ITS ENTIRETY BEFORE ATTEMPTING
INSTALLATION OR OPERATION! Attempting to operate the
YELLOW JACKET 68940 without fully understanding its features and
functions may result in unsafe conditions.
Analyzer Warnings
•REFRIGERANT BLEND WARNING: The HVAC industry is ever evolving new
refrigerants. Many of these new blends can be identified and/or profiled using the
YELLOW JACKET 68940.
•SAMPLE FILTER WARNING: Replace the sample filter of the instrument AS SOON AS
RED SPOTS OR DISCOLORATION BEGIN TO APPEAR ON THE OUTSIDE
DIAMETER OF THE WHITE ELEMENT. Failure to properly maintain and replace the
sample filter will result in severe damage or inaccurate results.
•SAMPLE INPUT WARNING: The instrument includes sampling options. One for High
Side Liquid sampling and one for Low Side Vapor Sampling. Failure to use the correct
hose configuration on the proper sample port may result in incorrect readings and/or
damage to the instrument. DO NOT attempt to introduce liquid or samples heavily laden
with oil into the Low Side sampling hose configuration. Damage caused to the
instrument due to the use of the wrong hose configuration on the wrong port will void
the warranty!
•BATTERY CHARGING WARNING: When charging the internal battery with the
supplied power supply, the power supply may become warm. If the power supply
becomes warm, unplug the immediately! When charging multiple analyzers, allow the
charger to cool between each battery.
3
3

General Cautions
•ALWAYS wear eye and skin protection when working with refrigerants. Escaping
refrigerant vapors will present a freezing danger.
•ALWAYS turn the compressor OFF before connecting the instrument to an air
conditioning system.
•ALWAYS inspect the sample hose before each use. Replace the hose if it appears
cracked, frayed, obstructed or fouled with oil.
•DO NOT direct refrigerant vapors venting from hoses towards the skin.
•DO NOT disassemble the instrument. There are no serviceable components internal to
the instrument and disassembly will void the warranty.
•ALWAYS place the Analyzer on a flat and sturdy surface.
•To reduce the risk of electrical shock, do not disassemble the instrument; do not use the
instrument in wet or damp areas.
•Some systems may contain hydrocarbons or flammable refrigerants. This analyzer is
designed with sealed heat sources and without sparking components. Ensure adequate
ventilation and always take proper precautions when working with refrigerants.
•DO NOT breathe refrigerant and lubricant vapor or mist. Exposure may irritate eyes,
nose, and throat. If accidental system discharge occurs, immediately ventilate the work
area.
•DO NOT utilize any hose assembly other than those supplied with the instrument. The
use of other hose types will introduce errors into the refrigerant analysis and instrument
calibration.
•ALWAYS verify that the refrigerant which is tested from the Low Side does not contain
or will not emit heavy loads of oil or liquid.
•NEVER admit any sample into the instrument at pressures in excess of 500 psig.
•NEVER obstruct the air intake, sample exhaust or case ventilation ports of the
instrument during use.
4
4

WELCOME
Thank you for purchasing the YELLOW JACKET 68940
Refrigerant Identifier.
The YELLOW JACKET 68940 Refrigerant Identifier is the most advanced refrigerant analyzer ever
designed for determining the purityof common gaseous refrigerants. It has many features to offer the
user,whichwillbedescribedinthismanual. Werecommendthatallpersonnel whousethisinstrument
read this manual to become more familiar with its proper operation.
For further information regarding the application, operation or spare parts, please contact the Ritchie
Engineering Co., Inc. Customer Service Department. If you have questions or comments, we would
like to hear from you.
Ritchie Engineering –YELLOW JACKET Products Division
10950 Hampshire Avenue South
Bloomington, MN 55438, USA
Tel: [phone]
Contact us: [email protected]
Visit us: www.yellowjacket.com
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5

1INTRODUCTION AND OVERVIEW
1.1 General
Contamination and mislabelling of refrigerants either in storage cylinders or air conditioning systems
can lead to component corrosion, elevated head pressures and system failures when utilized by
unsuspecting technicians. The ability of the technician to determine refrigerant type and purity is
severely hampered by the presence of air when attempting to utilize temperature-pressure relations.
The development of various substitute refrigerants further complicates the ability of a technician to
identify refrigerant purity based upon temperature-pressure relationships. The substitute refrigerant
blends can also introduce a flammability hazard to the technician and the ultimate end user of the air
conditioning system.
The YELLOW JACKET 68940 Refrigerant Analyzer provides a fast, easy and accurate means to
determine refrigerant purity in refrigerant storage cylinders or directly in air conditioning systems.
The instrument utilizes non-dispersive infrared (NDIR) technology to determine the weight
concentrations of multiple refrigerant types.Refrigerant purity is displayed on the LCD Screen and
the user must determine acceptable levels of purity based on their recovery or use standards.
The instrument is supplied complete with a ¼” Flare Vapor Sampling Hose, a High Pressure Liquid
Sample Trap Assembly, a 100-240 VAC power transformer, built in Lithium Iron Phosphate battery,
thermal printer, and all required plumbing housed within a rugged, portable, storage case.
Testing occurs when sample gas is admitted into the instrument through the supplied sampling hose
configurations and presented to the sensing device. The instrument provides the user with direct
percent by weight concentrations.
The instrument interfaces with the user via a LCD graphic display, status indicator LED’s, and push
button communication switches. Direct percent by weight concentrations of the sampled refrigerant
are provided on the display as well as user directions and prompts. An on-board printer is provided
to print an on-the-spot analysis report.
The YELLOW JACKET 68940 Refrigerant Analyzer Refrigerant Analyzer provides the refrigerant
technician with excellent knowledge of refrigerant type and purity as well as protection against
refrigerant contamination and potential flammability.
6

1.2 Features
The YELLOW JACKET 68940 Refrigerant Analyzer is the MOST advanced portable instrument ever
manufactured for determining the purity of gaseous refrigerants for the HVAC-R market.
Features Include:
•Advanced ergonomic design
•Rugged rubberized hand grips
•Large graphic display with on-screen instructions
•Fast test time
•Built in printer for instant analysis report
•Built in oxygen sensor to detect presence of Air
•Vapor or Liquid Sampling ability
•Internal, rechargeable Lithium Iron Phosphate battery for cordless operation in any
location
•Hard shell carry/storage case
•USB Port for Remote Software Updates
1.3
7

YELLOW JACKET 68940 Components
Base Unit
The YELLOW JACKET 68940 Refrigerant Analyzer base unit houses the Graphic Display, Infrared
Bench, Electrical Connections, built in Lithium Iron Phosphate Battery and Printer Module. These
components require no maintenance; therefore, there are no serviceable components internal
to the instrument. Disassembly will void the warranty.
m
Low Side Vapor Sample Hose
The 6.5 foot (2 meter) Low Side Vapor Sample Hose configuration is constructed of a polyurethane
tube. A Brass Sample Hose Restrictor acts to reduce pressure at the sample connection point and
reduce the introduction of harmful oil into the machine. The maximum inlet pressure is 500 psig. The
hose is provided with an instrument inlet port mating connector on one end and a ¼” SAE female
flare coupling nut on the service end.
NOTE: The analyzer will indicate “Non-Condensable” or “Unknown Refrigerant” if the analyzer
does not receive a good sample due to obstructedflow or lack of flow. Ifthis occurs the Brass Sample
Hose Restrictor may need to be replaced.
Analyzer End
Service End
(1/4 SAE Flare Nut)
Print Door
Control Panel
Sample Filter
Air Intake Port
Brass Sample
Hose Restrictor
8

A/C Power Cord
High Side Liquid Sample Hose
The 6.5 foot (2 meter) High Side Sample Hose configuration is constructed of a polyurethane tube
with an oil reservoir. A Brass Sample Hose Restrictor acts to transform Liquid refrigerant to Vapor
at the sample connection point while the High Pressure Liquid Sample Trap Assembly collects oil
and provides a means of expulsion after the test is complete. The syringe is provided with a magnet
for attaching it to the tank, an instrument inlet port mating connector on one end and a ¼” SAE
female flare coupling nut on the service end. The maximum pressure is 500 psig.
NOTE: The analyzer will indicate “Non-Condensable” or “Unknown Refrigerant” if the analyzer
does not receive a good sample due to obstructedflow or lack of flow. If this occursthe Brass Sample
Hose Restrictor may need to be replaced.
AC Power Adapter
The YELLOW JACKET 68940 is powered via a Lithium Iron Phosphate battery. You can also power
the unit via the 90-264 VAC, 50-60 Hz power transformer. This transformer is included with each
unit and converts a standard 100-240VAC 50/60Hz wall outlet to 12VDC, 2.0A, which powers the
device. This AC Power Adapter will also charge the battery when connected to the analyzer.
NOTE: Use of any other power source may cause damage to the unit and void the warranty.
Service End
(1/4 SAE Flare Nut)
Analyzer End
High Pressure
Liquid Sample Trap
Assembly
A/C Power Converter
Brass Sample
Hose Restrictor
9

Control Panel
The Control Panel serves as the main user interface. The Control Panel features three soft key
buttons that change their function as the instrument changes modes. The current function for each
button is displayed above the Soft Key Buttons on the LCD graphic display. Red and Green LED’s
at the top of the Control Panel are used for visual status indications.
Back Panel Connections
The connections located on the back panel are illustrated below.
CAUTION: The sample outlet port should never be obstructed. Keep the sample outlet port
free and clear at all times. Do not operate near open flame.
Red LED
Green LED
Power
On/Off
Soft Keys Buttons
Sample Inlet
Sample Outlet
12DC Outlet Input
(AC Adapter)
Graphic Display
USB Port
10

Hard Shell Storage/Carrying Case
The hard shell storage/carrying case is custom fit to the YELLOW JACKET 68940. It provides
rugged protection for the instrument, as well as convenient storage for all components. The
enclosure is general purpose and is not watertight.
11

2YELLOW JACKET 68940 OPERATION
2.1 First Use
The YELLOW JACKET 68940 has a built in Lithium Iron Phosphate battery. Prior to first use
charge the battery for a minimum of 2 hours with the included AC Power Supply.If a power
outlet is accessible you may also use the AC Power Supply to power the unit. The analyzer
will function and charge the battery while the AC Power Supply is connected.
2.2 Turning On the Unit
Press the left, soft key, ‘POWER’button. The splash screen shown in (Figure 1) will appear
followed immediately by the screen in (Figure 2). If you wish to adjust factory settings press
‘SET’and refer to section 3 Maintenance & Troubleshooting.If you do not need to adjust
the settings wait for the screen in (Figure 3) to appear. Connect the sample hose to the
analyzer and wait approximately 30 seconds for the unit to warm up. Once the analyzer warms
up you are ready for Calibration.
Figure 1
Figure 3
Figure 2
TO CHANGE
SETTINGS OR
REPLACE PAPER
ROLL PRESS
SET
CONNECT HOSE
TO ANALYZER
SOFTWARE VERSION
453- XXXX-XXXX
12

2.3 Calibration
The supplied sample hose needs to be connected to accomplish proper Calibration.
Verify the Sampling Hose assembly is connected to the analyzer and making sure it is
disconnected from any refrigerant source before Calibration. When you first turn the unit
on an Air Calibration will be required; additional Air Calibrations are only required periodically.
A reminder to perform air calibrate will appear when needed (Figure 4). Press ‘CAL’ to
calibrate the machine. When calibrating, the unit will pull fresh air into the sample cell via an
internal pump. This fresh air purges any excess refrigerant and ensures accurate test results.
Calibration requires that the sample hose is disconnected from the refrigerant cylinder or air
conditioning system and remains connected to the instrument. (Figure 5) will display while the
Air Calibration is occurring. Calibration will take approximately 130 seconds.
NOTE: In the unlikely event an ‘Air Calibration Unstable’ message is displayed as shown in
(Figure 6) verify you are in a ventilate area and there is no gas flowing near the air intake.
Once you have verified both parameters, press ‘RETRY’to complete another calibration.
Figure 5
Figure 4
AIR CALIBRATION
IS NEEDED NOW
1- DISCONNECT
HOSE FROM
SOURCE
2- PRESS CAL TO
START
OFF CAL
- CALIBRATING -
- PROGRESS -
AIR CAL UNSTABLE
CLEAR AIR INTAKE
AND VERIFY GAS
IS NOT FLOWING.
OFF RETRY
Figure 6
13
13

When the unit has completed a successful Air Calibration, the analyzer is then ready for gas
testing. The unit will display the screen shown in (Figure 7). Determine if you are Vapor
Sampling or Liquid Sampling and make sure the proper hose assembly is connected to
complete your required form of testing. Section 2.4 Vapor Sampling and 2.5 Liquid Sampling
outline proper procedure for both forms of testing.
Connect the hose to the tank or system, open the valve if connecting to a tank, and then press
‘TEST’. The YELLOW JACKET 68940 will display the screen shown in (Figure 8). Before the
test is completed the screen in (Figure 8a) will appear to indicate the test is nearly complete.
2.4 Vapor Sampling
Vapor sampling is the most common method used for identifying refrigerants using the
YELLOW JACKET 68940.It is a simple process requiring the operator to take these 4 steps:
1) Connect the Low Pressure Vapor Sampling Hose to the Low Side Vapor port
of the system or cylinder.
2) Open the low side valve of the cylinder and press ‘TEST’(Figure 7).
3) When the test is complete, close the low side valve of the cylinder and
disconnect the hose from the cylinder.
4) Disconnect the hose from the YELLOW JACKET 68940 for storage.
14
Figure 7
Figure 8
- READY -
1 –CONNECT HOSE
2 –OPEN VALVE
3 –PRESS TEST
OFF HELP TEST
- TESTING -
THIS WILL ONLY
TAKE 120 SECONDS
- PROGRESS -
ANALYZING THE
REFRIGERANT
Figure 8a

2.5 Liquid Sampling
Liquid sampling is an option that is exclusive to the YELLOW JACKET 68940.It permits the
user to flash liquid into vapor for introduction into the analyzer. To use the liquid sampling
assembly, follow these eight steps:
1) Inspect the High Pressure Liquid Sample Trap Assembly and ensure that the
plunger is completely depressed. Assemble the High Side Liquid Sample Hose as
shown on page 1-12 of this manual.
2) Connect the appropriate end of the hose to the instrument and the opposite end
of the liquid sampling assembly to the High Side Liquid port of the system or
cylinder. Affix the High Pressure Liquid Sample Trap Assembly vertically to a
tank with the magnet.
3) Open the high side valve of the cylinder. The liquid sample will exit the tank and
flash to vapor in the hose assembly. As the liquid is flashed, the plunger on the
High Pressure Liquid Sample Trap Assembly will begin to rise and the flashed
refrigerant sample will travel into the analyzer.
4) Wait for the plunger on the High Pressure Liquid Sample Trap Assembly to
expand past the outlet port.
5) Press ‘TEST’on the Analyzer (Figure 7).
6) Upon completion of the test, close the valve on the cylinder, disconnect the hose
from the inlet of the High Pressure Liquid Sample Trap Assembly, and depress
the plunger to expel any trapped oil.
7) Inspect the hose for signs of oil and replace the Brass Sample Hose Restrictor if
necessary.
8) Disconnect the hose from the YELLOW JACKET 68940.
NOTE: Liquid sampling will likely clog the Brass Sample Hose Restrictor much faster than
Vapor Sampling. If the Restrictor becomes clogged and the analyzer continuously displays
“Non-Condensable” or “Unknown Refrigerant” readings you will need to replace the clogged
Restrictor with a new one.To avoid oil or liquid contamination from entering the analyzer, have
a designated vapor and liquid Brass Sample Hose Restrictor for each form of testing.
2.6 Viewing the Test Results
Upon completion of the test, the YELLOW JACKET 68940 will display a screen similar to that
shown in (Figure 9). Pressing the ‘MORE’ button will display the screen shown in (Figure 10).
Once you have completed your test, press ‘DONE’to return back to the ‘READY’ screen
(Figure 7) or refer to section 2.10 Print the Test Results & Channel Data to print.
15
Figure 9
Figure 10
0.0% AIR
R22
CONTAMINATED
PRINT MORE
- RESULTS -
R22 97.0%
R410A 3.0%
BACK PRINT DONE

2.7 Contaminated Refrigerants
The YELLOW JACKET 68940 includes the ability to detect and analyze the composition of
many common R400 Series refrigerants in addition to R22, R32, R134a and Hydrocarbons
(HC).In the event that the YELLOW JACKET 68940 determines that the primary refrigerant
in the system or cylinder is one of the measured refrigerants, the results will display as follows
in (Figure 11). Pressing the ‘MORE’ button will display the detail screen shown in (Figure
12). If the blend or refrigerant mixture is not recognized, the screen shown in (Figure 13) will
be displayed. Refer to section 2.10 Print the Test Results & Channel Data to print.
2.8 Pure Refrigerants
The YELLOW JACKET 68940 has the ability to identify the following refrigerants: R12,
R1234yf, R408A, R409A, R417A, R421A, R421B, R422A, R422B, R422C, R427A and
Hydrocarbons (HC). All identified refrigerants will display with “Purity Unknown” as the
analyzer cannot yield additional information regarding the composition (Figure 14). Refer to
2.12 Channel Data Modelling for additional information regarding identified Refrigerants.
The instrument can also, Identify and Analyze the component content of pure R134a, R22,
HC (Hydrocarbons), R404A, R407C and R410A. Analysis of analyzed pure blend
refrigerants will yield additional data regarding the composition of the refrigerant sample. The
YELLOW JACKET 68940 will display the blend refrigerant type as shown in (Figure 15).
Pressing the ‘MORE’ button will display the detail screen shown in (Figure 16). Refer to
section 2.10 Print the Test Results & Channel Data to print.
NOTE: Hydrocarbons (HC) encompass R600, R600A and R290 and this machine cannot
differentiate between Hydrocarbons.
16
Figure 11
Figure 12
Figure 13
0.0% AIR
R410A
CONTAMINATED
PRINT MORE
- RESULTS -
R410A 98.7%
R22 1.3%
BACK PRINT DONE
0.0% AIR
UNKNOWN
REFRIGERANT
PRINT DONE
0.0% AIR
REFRIGERANT
R12
PURITY UNKNOWN
PRINT DONE
Figure 14

2.9 Pure Blends with Incorrect Component Ratios
The YELLOW JACKET 68940 has the ability to detect blend ratios that have been altered by
contamination. As stated in section 2.8 Pure Refrigerants, the blends that can be Identified
and Analyzed are R22, R32, R134a, Hydrocarbons (HC), R404A, R407C and R410A. If one
of the multi-component refrigerant blends has incorrect component ratios, it will display as
shown below in (Figure 17). To see the component concentrations, press the ‘MORE’ button
(Figure 18). Refer to section 2.10 Print the Test Results & Channel Data to print.
2.10 Measuring Air
The YELLOW JACKET 68940 offers the ability to measure the presence of Air independently
during every test. The built in oxygen sensor will display the percentage of Air in all Identified
or Identified and Analyzed refrigerants if there is Air in a system or cylinder. The image below
in (Figure 19) portrays how the LCD will display Air if detected. Pressing ‘MORE’ will display
the purity of the refrigerants which were detected (Figure 19a).
NOTE: Air is measured independently from refrigerant! You can have 100% pure
refrigerant with a percentage of Air in a system or tank. The presence of Air will display on
the initial results screen and on every printed test.
17
Figure 15
Figure 16
Figure 17
Figure 18
0.0% AIR
100%
R410A
MORE
- RESULTS -
COMPONENTS OF
R410A 100%
R125 50.0%
R32 50.0%
BACK PRINT DONE
0.0% AIR
COMPONENTS OF
R410A
MORE
- RESULTS -
COMPONENTS OF
R410A 100.0%
R125 60.0%
R32 40.0%
BACK PRINT DONE
9.6% AIR
R22
PRINT MORE
Figure 19
- RESULTS –
R22
100.0%
BACK PRINT DONE
Figure 19a

2.11 Printing the Test Results & Channel Data
The Test Results and Channel Data can be printed after every test is completed. Pressing
‘PRINT’ on the bottom of the screen will print the test results for all Analyzed Refrigerants. The
screen in (Figure 20)will display during printing. If printing Identified or ‘Unknown
Refrigerants", pressing ‘PRINT’ will allow you to print the Channel Data from the test. (Figure
21) will display during Channel Data printing.
Once printing is complete, carefully tear off the printout and press ‘BACK’ to return to the
previous screen. Additional printouts may be made following the same procedure. To exit the
test, press the ‘DONE’ button. (Figures 22, 23, & 24) show sample printouts for various test
results.
NOTE: Care must be taken when tearing off the printed results to leave a clean edge. Tear
the paper from RIGHT to LEFT to avoid paper jams.
Figure 22
Figure 23
Figure 24
68940
Refrigerant
Analyzer
R22 = 100.0%
AIR = 0.0%
___________
(Date)
____________
(Technician)
___________
___________
68940
Refrigerant
Analyzer
R410A = 100.0%
R125 = 50.0%
R32 = 50.0%
AIR = 0.0%
___________
(Date)
____________
(Technician)
___________
___________
68940
Refrigerant
Analyzer
NON-CONDENSABLE
___________
(Date)
____________
(Technician)
____________
__________
- PRINTING -
NOW PRINTING
RESULTS
BACK DONE
Figure 20
Figure 21
- PRINTING -
NOW PRINTING
COMPONENTS
BACK DONE