Model 34800/34801/AC900Refrigerant Management CenterCFC 12, HFC 134a Recycling Equipment ServiceManualTheory of Operation and Safety Precautions ................................... 2Component Descriptions ........................................ .......................... 3Flow Diagram Components ........................................ ..................... 6Flow Diagram ........................................ ........................................ ... 7Pictorial View - Front ........................................ ............................... 8Manifold Block Flow 9Wiring Diagram ........................................ ..................................... 10Main Board Diagram ........................................ ............................. 11Plumbing 12Display Definitions ........................................ ................................ 13Control Panel Components ........................................ .................... 13Relay Specifications ........................................ ............................... 14Relay Troubleshooting ........................................ ........................... 14Component Specifications ........................................ ...................... 15Compressor Specifications and Service ........................................ . 17Diagnostic Procedures ........................................ ............................ 24RA19210 Scale Accuracy Check and Recalibration ...................... 25Checking the Scale Accuracy ........................................ ................. 25Recalibrating the Scale ........................................ ........................... 25Setting the P-1 Pot ........................................ .................................. 25Diagnostic Procedures ........................................ ............................ 26Deep Diagnostic Functions ........................................ .................... 28Function Test ........................................ ........................................ .. 29ROBINAIR2ORIGINAL 5/9934800/34801 Service ManualTheory of Operation and Safety PrecautionsWARNINGAlways wear safety goggles when working with refrigerants. Contact withrefrigerant can cause eye injury. Disconnect lines and hoses with extremecaution! Pressurized refrigerant may be present in lines and hoses. Alwayspoint lines and hoses away from you and anyone unplug the station from the power source before removing any of theshrouding or beginning any service order parts, please FAX your order to service related questions should be directed to Robinair Series 34800/34801/AC900 recovery, recycling,evacuation, and recharging units are designed for R-12and R-134a refrigerants only. These units are ULapproved and meet SAE J-1770 units began production in March of 1999, forAC900 made prior to this date refer to previous AC900service manual. The model, serial number, andmanufacturing date code can be found on a white taglocated on the back of the unit above the THE UNITNOTE: Since the series 34800/34801/AC900 hasseparate components for each refrigerant type, it is onlynecessary to depressurize the side in need of repairs. Forthis process you will need a separate hand-held Close both the blue liquid and red vapor valves on the30 pound recovery Disconnect all hoses from the 30 pound Disconnect the red high side and blue low side hosesfrom a hand-held manifold gauge Connect the blue 36" liquid hose to the low side (bluehandle) of the hand-held manifold gauge set. Connectthe red 36" vapor hose to the high side (red handle)of the manifold gauge Connect the yellow hose attached to the center port ofthe hand-held manifold gauge set to the inlet of a7. Plug in the separate recovery unit and start itsrecovery When the hand-held gauge set shows 0 psi, stop therecovery process. Wait 10 minutes and watch thehand-held manifold gauges for a pressure rise abovezero. Repeat steps 7 and 8 until positive pressure doesnot develop on the hand-held gauge Disconnect the blue 36" liquid and red 36" vaporhoses from the hand-held manifold gauge Close the high side manifold valve on the controlpanel of the 34800/34801/AC900. Disconnect the red96" hose from the back of the unit. Connect theyellow 36" air purge hose to the low side (bluehandle) of a hand-held manifold gauge set. Connect ahose from the high side port of the machine to thehigh side of the hand-held manifold gauge the hose from the center port of thehand-held manifold set to the inlet of the separaterecovery Open both the high and low side gauge valves on thecontrol panel of the 34800/34801/AC900 and thehand-held gauge Start the recovery process on the separate When the pressure on the hand-held gauge set shows0 psi, stop the recovery process. Wait 10 minutes andwatch the hand-held manifold gauges for a pressurerise above zero. Repeat Steps 12 and 13 until positivepressure does not develop on the hand-held gauge recovery Open both manifold valves on the hand-heldmanifold gauge Service ManualORIGINAL 5/99Component Descriptions1. 18190A R-134a Low Side Coupler (blueactuator, smaller ) Allows access to the lowside of an R-134a system. RA19115 Coupler Repair Kit (front O-ring only)2. 18191A R-134a High Side Coupler (redactuator, larger ) Allows access to the highside of an R-134a system. RA19115 Coupler Repair Kit (front O-ring only)3. 62096 R-134a Low Side Hose Provides flowfrom the low side coupler to the low side port on thestation (14mm x " Acme). 17772 Hose to Coupler O-ring4. 63096 R-134a High Side Hose Provides flowfrom the high side coupler to the high side port onthe station (14mm x " Acme). 17772 Hose to Coupler O-ring5. 68296A R-12 96" Blue Quick Seal Hose Lowside service hose to the vehicle. 18180 Replacement R-12 Quick Seal O-ring 18451 45 " Flare Quick Seal Repair Kit6. 68396A R-12 96" Red Quick Seal Hose Highside service hose to the vehicle. 18180 Replacement R-12 Quick Seal O-ring 18451 45 " Flare Quick Seal Repair Kit7. 68126 36" Red R-134a Tank Hose Deliversrefrigerant being recovered or recycled to the vaporside of the R-134a storage tank. 17773 Replacement R-134a Quick Seal O-ring 40302 R-134a Quick Seal Repair Kit8. 68127 36" Blue R-134a Tank Hose Allowsflow from the liquid side of the R-134a tank to therecycling and charging solenoids. 17773 Replacement R-134a Quick Seal O-ring 40302 R-134a Quick Seal Repair Kit9. 68128 36" Yellow R-134a Tank Hose Suppliespressure from the top of the recovery tank to the airpurge control. 17773 Replacement R-134a Quick Seal O-ring 40302 R-134a Quick Seal Repair Kit10. 68121A 36" Red R-12 Tank Hose Deliversrefrigerant being recovered or recycled to the vaporside of the R-12 storage tank. 18180 Replacement R-12 Quick Seal O-ring 18451 45 " Flare Quick Seal Repair Kit11. 68122A 36" Blue R-12 Tank Hose Allows flowfrom the liquid side of the R-12 tank to the recyclingand charging solenoids. 18180 Replacement R-12 Quick Seal O-ring 18451 45 1/4" Flare Quick Seal Repair Kit12. 68123A 36" Yellow R-12 Tank Hose Suppliespressure from the top of the recovery tank to the airpurge control. 18180 Replacement R-12 Quick Seal O-ring 18451 450 1/4" Flare Quick Seal Repair Kit13. RA19393 (RA19402 MacTools) R-134a HighSide Gauge - Reads pressure entering the high RA19392 (RA19403 MacTools) R-134a LowSide Gauge Reads pressure entering the lowside RA 19393 (RA19400 MacTools) R-12High Side Gauge Reads pressure entering thehigh side RA19392 (RA19401 MacTools) R-12Low Side Gauge Reads pressure entering thelow side 121238 Low and High Side Manifold ValveR-134a Assembly Allows refrigerant flow fromthe high and low side hoses to the center 121239 Low and High Side Manifold ValveR-12 Assembly Allows refrigerant flow fromthe high and low side hoses to the center RA19429 Vacuum Pump Protection Switch A normally open sensor that closes when pressuregreater than 25 psi is present in the A/C system. Ifthe pressure is less than 25 psi in the recovery mode,the display reads CH-P. In the vacuum mode, thedisplay reads U-HI if the pressure is 25 psi orgreater in the A/C system. This indicates that arecovery procedure must be performed beforeattempting a RA18752 Vacuum Sensor A normally closedsensor that sends a signal to the main board when a13" Hg vacuum has been reached on the inlet RA19258 Recovery Solenoid Rebuild Kit Anormally closed solenoid, designed to prevent theflow of refrigerant into the system oil separator whilethe unit is off or in any mode other than RA19258 Recycling Solenoid Rebuild Kit A normally closed solenoid that prevents the flow ofrefrigerant into the system oil separator when the unitis not in Recycling 5/9934800/34801 Service ManualComponent Descriptions (continued)23. RA19258 Charging Solenoid Rebuild Kit A normally closed solenoid preventing flow into theA/C system when the unit is turned off or in anymode other than RA19258 Vacuum Solenoid Rebuild Kit A normally closed solenoid designed to prevent flowto the vacuum pump during Recovery or RA15425 (RA15428 220 volt) Vacuum Pump A 6 CFM, two stage rotary vane pump designed topull moisture and air from an A/C system. 120165 Vacuum Tubing26. System Oil Separator Performs threefunctions. Internal heat evaporates the saturatedvapor, preventing liquid from entering thecompressor. Any oil droplets contained in therefrigerant drop out in the separator. The system oilseparator's third function is that it acts as a heatexchanger. RA19480 Manifold O-Ring Kit27. RA19291 Oil Drain Valve Allows the oilremoved from the system to be drained whenRecovery is complete. The same amount of oil shouldbe returned during charging. RA17419 Oil Drain Bottle28. 34724 Spin-on Filter-Drier Removes moisture,acid, and oil from the refrigerant. 40084 Replacement Filter Gasket29. RA19458 (RA19457 220 volt) Compressor Converts low pressure, low temperature incoming gasinto high pressure, high temperature discharge gas. 111043 Replacement Start Capacitor30. Compressor Oil Separator Traps compressoroil that has migrated out with refrigerant whilepassing through the compressor. The oil is stored inthe separator until the equalization solenoid losespower and allows the oil to be returned to thecompressor. RA19480 Manifold O-Ring Kit31. RA19258 (RA17578 220 volt) EqualizationSolenoid A normally closed solenoid that allowsoil trapped in the compressor oil separator to beforced back into the suction side of the compressor,equalizing pressure on the high and low side of thecompressor and pressurizing the system oil separatoras power is applied to the solenoid. Opens for 20seconds after recovery is complete. After thecompressor has run for 10 continuous minutes, thesolenoid opens for three RA19427 High Pressure Cutout A normallyclosed sensor that shuts off the unit when thedischarge pressure reaches 435 : This switch has three contacts; the outer twocontacts (numbered 1 and 3) are normally RA19326 Recovery Check Valve Allows flowin one direction only and prevents refrigerant in thetank from coming back into the unit RA19430 Automatic Expansion Valve Converts incoming liquid refrigerant into a lowpressure saturated vapor. The calibration of theexpansion valve can be checked at the oil drain witha pressure gauge. The allowable tolerance of thevalve is 30 to 40 psi during : Allow the unit to recycle 10 minutes with aminimum of 10 pounds of refrigerant in the tank beforechecking or adjusting the RA19477 (110V) RA19616 (220V) R-134a AirPurge Device After the recycling sequence hasrun for 30 seconds, a timer (programmed in the mainboard) opens the normally closed solenoid of theselected refrigerant type, allowing pressure to enterthe lower cavity of the air purge device. Whenpressure on the lower cavity exceeds pressure on theupper cavity by 7 psi or more, a valve inside thedevice opens to release the air pressure from thecavity. When the pressures come within 3 psi of eachother, the device stops RA19476, RA19623 (220V) R-12 Air PurgeDevice After the recycling sequence has run for30 seconds, a timer (programmed in the main board)opens the normally closed solenoid of the selectedrefrigerant type allowing pressure to enter the lowercavity of the air purge device. When pressure on thelower cavity exceeds pressure on the upper cavity by7 psi or more, a valve inside the device opens torelease the air pressure from the cavity. When thepressures come within 3 psi of each other, the devicestops 17105 R-12 Recovery Tank Stores refrigerantto be recycled at a later time. The tank has twovalves; the vapor valve is an open fitting to thetankand the liquid valve has a draw tube extending towithin 2 inches of the bottom of the 34705 R-134a Recovery Tank Storesrefrigerant to be recycled at a later time. The tank hastwo valves; the vapor valve is an open fitting to thetank and the liquid valve has a draw tube extendingto within 2 inches of the bottom of the Service ManualORIGINAL 5/99Component Descriptions (continued)39. 120034 Oil Injector Assembly Controls theflow of oil from the injection bottle to the vehicle. 113025 Oil Injector Check Valve RA19141 Oil Bottle RA19478 Replacement Valve40. RA19303 (110V), RA19294 (220V), RA19097(230V) Power Cord Conducts power to the RA19047 Vacuum Pump Outlet Female socketwhere the vacuum pump power cord RA19343 Main Power Switch Controls thepower between the power cord and the main RA17416 (RA17516 220 volt) Fan Runs assoon as the MAIN POWER switch is turned on tocool the cabinet 117684 Refrigerant Selector Switch Indicates which refrigerant type the machine is RA19564 (110V), RA19618 (220V) (RA19560MacTools) Main Board Controls the unit'sfunctions, automatic or RA19445 Scale Assembly Sends a signal tothe main board for accurate weight readings and tankoverfill RA17459 (RA17324 220 volt) System Relay Energizes the compressors and vacuum pump,allowing the sensors to turn off the unit. The relayhas two sets of contacts which close when the coil RA19404 Casters 113540 Caster Screws (7 required) 109525 Caster Nuts (7 required)49. RA19405 Wheels 102755 Wheel Washers (6 required) 100723 Cotter Pin (2 required)50. 112776 Fuse Holder51. RA17416 (RA17516 220V) Fan Receives powerwhen main power is turned on. Cools internal RA19545 Manifold Block Contains recovery,recycle, recharge and equalization solenoids. Alsolocated on the block are the Hi-P sensor, vacuumsensor, vacuum pump, protection switch, expansionvalve, filter, oil and compressor oil Keypad RA19561 (RA19562 AC900) Overlaywhich contains electronic keypad. All inputs godirectly to circuit board via the ribbon. If a keypad isbad, all four keys in one row or one column will RA19282 Discharge Check Valve Allows flowin one direction only and prevents refrigerant andpressure from the tank from being equalized backinto the low side of the unit when the equalizationsolenoid opens to return compressor oil andrepressurize the system oil 5/9934800/34801 Service ManualFlow Diagram Components1. 18190A R-134a Low Side Coupler(blue actuator, smaller )2. 18191A R-134a High Side Coupler(red actuator, larger ) RA19115 Coupler Repair Kit (front O-ring only)3. 62096 R-134a Low Side Hose 17772 Hose to Coupler O-ring4. 63096 R-134a High Side Hose 17772 Hose to Coupler O-ring5. 68296A R-12 96" Blue Quick Seal Hose 18180 Replacement R-12 Quick Seal O-ring 18451 450 " Flare Quick Seal Repair Kit6. 68396A R-12 96" Red Quick Seal Hose 18180 Replacement R-12 Quick Seal O-ring 18451 450 " Flare Quick Seal Repair Kit7. 68126 36" Red R-134a Tank Hose 17773 Replacement R-134a Quick Seal O-ring 40302 R-134a Quick Seal Repair Kit8. 68127 36" Blue R-134a Tank Hose 17773 Replacement R-134a Quick Seal O-ring 40302 R-134a Quick Seal Repair Kit9. 68128 36" Yellow R-134a Tank Hose 17773 Replacement R-134a Quick Seal O-ring 40302 R-134a Quick Seal Repair Kit10. 68121A 36" Red R-12 Tank Hose 18180 Replacement R-12 Quick Seal O-ring 18451 450 " Flare Quick Seal Repair Kit11. 68122A 36" Blue R-12 Tank Hose 18180 Replacement R-12 Quick Seal O-ring 18451 450 1/4" Flare Quick Seal Repair Kit12. 68123A 36" Yellow R-12 Tank Hose 18180 Replacement R-12 Quick Seal O-ring 18451 450 1/4" Flare Quick Seal Repair Kit13. RA19393 (RA19402 MacTools) R-134a HighSide Gauge 11715 Replacement Gauge Lens14. RA19392 (RA19403 MacTools) R-134a LowSide Gauge 11715 Replacement Gauge Lens15. RA19393 2 " R-12 High Side Gauge(RA19400 MacTools) 11715 Replacement Gauge Lens16. RA19392 2 " R-12 Low Side Gauge(RA19401 Mac Tools) 11715 Replacement Gauge Lens17. 121238 R-134a High and Low Side ManifoldValves18. 121239 R-12 High and Low Side ManifoldValves19. RA19429 Vacuum Pump Protection Switch20. RA18752 Vacuum Sensor21. RA19258 Recovery Solenoid22. RA19258 Recycling Solenoid23. RA19258 Charging Solenoid24. RA19258 Vacuum Solenoid25. RA15425 (RA15428 220 volt) Vacuum Pump26. System Oil Separator27. RA19291 Oil Drain Valve28. 34724 Spin-on Filter-Drier29. RA19458 (RA19457 220 volt) Compressor30. Compressor Oil Separator31. RA19258 Equalization Solenoid32. RA19427 High Pressure Cutout33. RA19326 Recovery Check Valve34. RA19430 Expansion Valve35. RA19477 (RA19616 220v) R-134a Air Purge36. RA19476 (RA19623 220v) R-12 Air Purge37. 17105 R-12 Recovery Tank38. 34705 R-134a Recovery Tank39. 120034 Oil Injector Assembly43. RA17416 (RA17516 220v) Fan47. RA19445 Scale Assembly734800/34801 Service ManualORIGINAL 5/99Flow DiagramR-12R-134a37111012362339514136181 9332120223426325547313028432528342627313 0838557352221332324172131431439932292729 192420478ORIGINAL 5/9934800/34801 Service ManualPictorial View of Front26. System Oil Seperator28. 34724 Spin-on Filter-Drier29. RA19458 (RA19457 220v) Compressor30. Compressor Oil Seperator31. RA19258 Equalization/Oil Return Solenoid35. RA19477 (RA19616 220v) R-134a Air Purge (RA19623) 220 Volt) R-12 Air Oil Injector AssemblyINST0542262828313035315330263648 532948522948. RA17459 (RA19562 220v) System (RA17516 220 volt) Fan53. RA19545 Manifold Block54. RA19561 (RA19562 Mac Tools) Keypad*111043 Replacement Start Capcitor5439**934800/34801 Service ManualORIGINAL 5/99341933212223202425293939313528263055 Manifold Block Flow Diagram3236OR10ORIGINAL 5/9934800/34801 Service ManualWiring Diagram 34800/34801 & AC900INST05631134800/34801 Service ManualORIGINAL 5/99Main Circuit Board DiagramINST 051812ORIGINAL 5/9934800/34801 Service , 1/4" Purge Inlet , 3/8" ( ') Connector, 3/8 Purge Inlet Inlet Inlet Inlet Tube Discharge Return Oil Suction Discharge Return Oil Suction , 3/8" (10') Oil Oil DrainPlumbing Schematic1334800/34801 Service ManualORIGINAL 5/99Display DefinitionsControl Panel ComponentsCH-PLess than 24 psi at the inlet of the low side clearing routine is in vacuum pump runs specified cycle function (recovery, evacua-tion, charging or adding refrigerant) is filter-drier change is in refrigerant recovery tank is pressure in unit is above 435 to change the vacuum pump oil. To reset,press MODE and ENTER at the same time while OIL is scale is damaged, disconnected, out ofcalibration or overloaded. It cannot exceed 45pounds total is positive pressure on the vacuum MODE, then RECOVER to remove thepressure. Continue the evacuation RA19393 (Mac Tools RA19402) R-134a High SideGauge14. RA19392 (Mac Tools RA19403) R-134a Low SideGauge15. RA19393 (Mac Tools RA19400) R-12 High SideGauge16. RA19392 (Mac Tools RA19401) R-12 Low SideGaugeINST054642. RA19343 Main Power Switch44. 117684 Refrigerant Selector Switch53. RA19561 (RA19562 AC900) Keypad1516421444135314ORIGINAL 5/9934800/34801 Service ManualRelay SpecificationsTroubleshootingRA17459 (RA17324 220 volt) SystemRelaysThe system relay is used to energize the compressor or thevacuum pump and allow the sensors to shut the unit relay has two sets of contacts which close when thecoil is contacts 0 and 1, when energized, should have 110volts across the terminals. While voltage is applied, thecoils forms a magnetic field pulling the 2 and 4 and the 6and 8 contacts 2 and 4 and the 6 and 8 contacts have power suppliedto one terminal of the pair. When the coil is energized andsupplies power to the mating Override Ear Not Pulled In1. Check the proper voltage to the 0 and 1 contacts. Ifthere is voltage, replace the relay. If there is notvoltage, replace the main Override Ear Pulled In1. check for proper voltage from the power supplycontact to ground. If there is no voltage, check thevoltage supply check for proper voltage from the mating supplycontact to ground. If there is no voltage, replace : Use of improper extension cord size can damagecontact Service ManualORIGINAL 5/99Component SpecificationsRA18752 Vacuum SensorThe vacuum sensor is a normally closed sensor. If a 13"(+2") Hg rating is reached at the intake, the switch opensand breaks the coil contacts, shutting off the unit. The con-tacts are closed when a vacuum above 13" Hg is present inthe lower cavity. When a 13" Hg vacuum is achieved in thelower cavity, the spring contact has room to force away fromthe mating pressure in the accumulator (open the oil drain valveto be sure pressure is present), the switch should have con-tinuity. If it does not, replace the the unit is shutting off before reaching a 13" Hg vacuum,check the inlet for obstructions before replacing the High Pressure CutoutThe high pressure cutout is a normally closed sensor de-signed to shut the unit off if the discharge pressure reaches435 is detected through the orifice in the base of thesensor. In the normal setting (less than 435 psi on orifice),the 1 and 3 contacts are closed. When 435 psi is introducedto the orifice, the pressure forces up on the drive pin whichforces the center contact to disengage the 1 and 3 contactand engage the 1 and 2 contacts. When this takes place, theunit shuts off and the display reads HI-P. RA19429 Vacuum Pump ProtectionSwitchThe vacuum pump protection switch is a normally open sen-sor. If a 25 psi (+2") psi rating is reached at the intake, theswitch closes, sending a signal to the main contacts are closed when anything greater then 25 psiis present in the lower cavity. When 25 psi is achieved inthe lower cavity, the spring contact is forced into the 5/9934800/34801 Service ManualCompressor Specifications and ServiceCOMPRESSOR SPECIFICATIONSType:1/3 hp hermetic (piston type)compressorOil Capacity:10 ounces (296 milliliters)Oil Type:150 viscosity POE refrigeration oilVoltage:100-110V iunits use a RA 19458220V units use a RA19457Amperage:4-6 running amperage (100-110V)20-25 locked rotor running amperage (220V)16-19 locked rotor amperageCHECKING THE OIL1. Depressurize the Remove the compressor from the unit and place on aflat Tilt the compressor 30 degrees (see figure above). Atthis angle, there should be oil in the suction OIL1. Install a funnel in the suction fitting and pour twoounces of oil into the Start the compressor momentarily. Plug the intakefitting but leave the discharge fitting open. Thecompressor will pull oil from the funnel. Stop Check the oil level. If it is still low, add 2 ounces at atime until a proper level is and Discharge Pressure Test1. Disconnect all fittings from the Cap the intake Install a low side gauge on the suction : The fittings used on these compressors require an0-ring fitting to seal and a 120063 hose (1/4" flare o-ringX 1/2" Acme ) with an R-134a manifold Verify that the discharge fitting is Start the compressor and monitor the suctionreadings. The compressor should pull a 25" Hg ( ) vacuum. If the compressor has weak suction,check the oil level and add if necessary. If the oillevel is okay or oil was added with no improvement,replace the Disconnect the low side gauge on the dischargefitting. 7. Install a high pressure gauge on the discharge : The fittings used on these compressors require an0-ring fitting to seal and a 120063 hose (1/4" flare o-ringX 1/2" Acme ) with an R-134a manifold Verify that the intake fitting is Start the compressor and monitor the pressure forabout 4 minutes. If pressure doesn t reach at least 350psi (24 bar), replace the R-134aBrown/Black R-12Blue/White R-134aBlue Black R-12Blue/White R-134aBlue Black R-12Brown/White R-134aBrown/Black R-121734800/34801 Service ManualORIGINAL 5/99TroubleshootingUNIT WILL NOT COME OUT OF CL-L,COMPRESSOR RUNS(WILL NOT RECOVER)UNIT WILL NOT COME OUT OF CL-L,COMPRESSOR IS OFF(WILL NOT RECOVER)1. If the unit is being run through an extension cord,eliminate its Disconnect the high and low side hose from thevehicle with the gauge valves open. If the pressure onthe gauges drops while the display shows CL-L, therecovery solenoid may need to be replaced or Check the oil drain valve. Verify that it is closed andnot bleeding Install the low side hose on the oil drain with the lowside valve closed. Check the gauge. If it has positivepressure, go to Step 5. If psi is below a 20" Hgvacuum, test the vacuum sensor for continuity. Ifthere is continuity, replace the sensor. If there is nocontinuity, check the vacuum sensor wires forcontinuity. If the wires have continuity, replace themain Close the tank s liquid valve. If pressure startsdropping on the gauge and the unit starts a recoverysequence, clean and rebuild the recycling Inspect the filter for flow obstructions and check forleaks around the gasket If the equalization solenoid is receiving power,replace the circuit Check the compressor discharge and If the unit is being run through an extension cord,eliminate its Remove the shroud and look for loose Check for voltage to the coil of the compressor replay(energized). If there is no voltage, check the wiresfromt he main board to the compressor relay forcontinuity. If they have continuity, replace the If the compressor relay is energized, (receiving 110/220 volts) check for voltage from the #4 contact toground with a volt meter (it should be 110/220 volts).If there is no voltage, replace the compressor for voltage to the compressor. If there is novoltage, check the wires between the compressor andthe compressor relay for continuity. Repair or replaceas If voltage is present at the compressor, jumper thethermal overload. If the compressor runs, check thecompressor amp draw. If it is drawing higher than 6amps or not running, replace the compressor. If thecompressor is cool and drawing low amperage,replace the thermal 5/9934800/34801 Service ManualTroubleshooting1. Check to be sure both tank valves are Check the tank pressure. It should not exceed 300psi. If the pressure is high, bleed the pressure down to200 psi by recycling and allowing the automatic airpurge to Check the red vapor tank hose for proper sure there is no obstruction at the tank Check the 2 amp fuse on the back of the main boardfor continuity and replace if necessary. If thereplacement fuse blows, check the compressor relayfor shorted contacts. Replace as Check the wires between the high pressure cutout andthe main board for continuity. Repair or replace Replace the high pressure cutout and retest the Reads FULL1. Check the tank weight and replace the tank if it Recalibrate the scale if Adjustment of the P-1 pots (see main board diagramfor location) may be necessary. See Setting the P1-pot" in the function test for detailed Verify that the scale is connected Reads CPL1. Verify that there is positive pressure on the unit smanifold gauges. If there is no positive pressure,connect to a vapor supply source and attemptrecovery Look for loose or broken wires in the Verify that the suction line strainer is not tubing schematic for Install the low side hose (coupler) on the oil drainwith the low side valve closed. Open the oil drainvalve. Look for a psi reading. If the pressure is below13" Hg, test the vacuum sensor for continuity. If thevacuum sensor has continuity, replace it. If it doesnot, check the vacuum sensor wires for continuity. Ifthe wires have continuity, replace the main If there is no positive pressure, verify that the inletcheck valve is operating properly. Also, verify thatthe recovery solenoid is opening and allowing and replace as WILL NOT STARTOR COMPLETE RECOVERY1934800/34801 Service ManualORIGINAL 5/99TroubleshootingDisplay Reads "CH-P"1. If there is less than 25 psi at the inlet, attemptrecovering from a positive pressure Verify that the wires that control the vacuum pumpprotection switch have If there is more than 25 psi at the inlet, verify noobstructions in the manifold valves. Then replace thevacuum pump protection If the sensor is operating properly, press CONT If the main board will not let you override, verify thatthe keypad is sending the signal. If it is, replace themain board. If it is not sending a signal, replace Reads "CH-F"1. The filter change time has elapsed. To reset the timer,refer to the operating manual for the filter If, after attempting to reset the timer, the CH-F warning does not disappear, replace the main Reads " Vacuum Program Minutes"1. If the display does not respond to keypad commands,verify that the keypad is plugged in. If the keypad isplugged in but not responding, replace the keypad. Ifthe keypad is functional, a tone sounds when a key Reads "Scale"1. Check the scale calibration and P1-pot and adjust as necessary. Refer to functioncheck for detailed Check the scale cable to be sure it is connected to themain Disconnect the scale cable from the main board andjumper the white and black leads. If the display stillreads Scale , replace the main board. If the displayclears the message Scale , replace the WILL NOT START OR COMPLETERECOVERY (continued)20ORIGINAL 5/9934800/34801 Service ManualTroubleshootingUNIT WILL NOT EVACUATE,PUMP IS RUNNINGUNIT WILL NOT EVACUATE,PUMP IS OFF1. Verify that the manifold gauge valves are Verify that the high and low side hoses (couplers) aretight at all Check the oil injector tubing for leaks and Be sure the vacuum hose is snug at both ends and notobstructed. Check the hose gaskets for Check for suction at the intake of the pump. If thereis none, replace the Remove the shroud and look for loose wires to thevacuum Check for voltage to the vacuum solenoid. If voltageis present, rebuild the solenoid or inspect for If no voltage is present, check the lead wires forcontinuity. If continuity is present, replace the Check the low side gauge for proper operation andcalibration."U HI" on Display1. Be sure pressure is present at the vacuum protectionswitch. Recover before evacuation. Unplug If U HI goes out, check for pressure at the there is none, replace the If U HI remains on, replace the main Counting Down1. Verify that the vacuum pump is plugged Check the voltage at the pump If proper voltage is present, be sure that the pump isnot overfilled with oil. If it is, drain the pump. Startand properly refill the pump. If proper voltage ispresent, replace the If proper voltage is not present, remove the shroudand look for loose Check the voltage to the vacuum pump relay there is no voltage, check the wires between thevacuum pump relay and the main board forcontinuity. If the wires are okay, replace the mainboard. If there is voltage at the vacuum pump relaycoil, replace the Check for voltage from the #4 contact to there is no voltage, replay the Service ManualORIGINAL 5/99TroubleshootingUNIT WILL NOT RECYCLE,RECYCLE PROMPT IS OFF (NO FLOW)NOTE: When the vacuum key is pressed, the unitautomatically recycles. Recycle stops when the vacuumtimer is down to three minutes. When recycle stops, thepower is dropped to the recycle solenoid. The compressorcontinues to run until the Accum Oil separator and thefilter reach a 13" Check that all recovery tank hoses are Verify that the recovery tank valves are Be sure there is a minimum of 10 pounds ofrefrigerant in the Install the low side of a manifold gauge set to the If positive pressure is present at the service port,remove the cover and look for loose wires to thevacuum sensor. If there are no loose wires, check forcontinuity on the vacuum sensor. If there is none,replace the vacuum Inspect the orange wires between the main board andthe vacuum sensor for continuity. If the wires and thevacuum sensor have continuity, jumper the orangewires Start recycling if the service port is being pulled intoa vacuum. Look for loose wires to the recyclingsolenoid and verify that 110 volts is being sent to therecycling solenoid. If there is no voltage, inspect thecontrolling wires for continuity. Replace the mainboard if the wires have Verify that you have flow through the blue tank hoseand the moisture indicator. Replace and clean If the hose or moisture indicator is not plugged,attempt to recalibrate the expansion valve. If you areunable to recalibrate the expansion valve, rebuild therecycling solenoid and replace the expansion If all previous attempts have failed, replace the 5/9934800/34801 Service ManualTroubleshootingUNIT WILL NOT PERFORM ANAIR PURGEUNIT WILL NOT CHARGE,NO PRESSURE ON GAUGESNOTE: The air purge only operates the first 10 minutesof recycling and then drops power to the air purgesolenoid. A minimum of six pounds of refrigerant must bein the tank for the air purge to function Verify that the recovery tank has excess air pressurein it. The only accurate way to do this is to connect ahand-held manifold gauge set to the recovery tank'sair purge fitting, check the pressure in the tank andcompare it with a temperature/pressure If excess air pressure is confirmed, verify that allrecovery tank hoses are properly connected to Slowly open the yellow hose where it attaches to theback of the unit. If the tank is allowing access and theyellow hose is unobstructed, pressure is and replace as If the yellow hose has flow, remove the front coverand verify that the exhaust port of the air purgedevice is not After recycling for at least three minutes, verify that110/220 volts is being sent to the air purge it is not getting 110/220 volts, inspect the controlwires for continuity. Repair or replace as necessary. Ifthe air purge solenoid is getting 110/220 volts, go toStep If the wires have continuity, replace the main If the solenoid is receiving 110/220 volts, remove theair purge device. Rebuild or replace as Verify that the tank's liquid valve is Verify that the manifold valves are completely openand Inspect the liquid hose for proper installation on thetank and check for crushed hose Verify that the main board has accepted the Remove the shroud and look for loose If the main board does not accept the program,replace it. Be sure the keypad is sending a programsignal before replacing. If the keypad is sending asignal, an audible tone sounds when keys are Check the voltage at the charging solenoid. If there isno voltage, check the lead wires for continuity. If thewires have continuity, replace the main board. Ifthere is proper voltage to the solenoid, replace Service ManualORIGINAL 5/99TroubleshootingUNIT WILL NOT CHARGE,PRESSURE ON GAUGES1. Verify that the unit is gaining access to the Be sure there is a minimum of six pounds ofrefrigerant in the Be sure the scale is able to move Verify that the unit is charging through both the highand low side Check for proper voltage to the charging solenoid(not an erratic voltage drop). If the voltage is okay, goto step six. If there is a problem with the voltage,replace the main Close the high side valve, start the engine and pull inthe remaining charge on the low side of the the remaining charge has been pulled from thetank, the charging solenoid closes, preventing apossible 5/9934800/34801 Service ManualPress MODE and ENTER simultaneously to enter diagnostics. Use the UP and DOWN keys to select the mode andpress ENTER to start the LB/KG mode selectENTER toggles between modes. MODE locks the chosen Diagnostic VacuumVacuum only. Mode switch may be changed between R-12 and R-134a inthis mode and a vacuum is pulled on the chosen UL Circuit AdjustmentSetting the Filter WeightDisplays weight recovered through the filter on whichever side R-12 or R-134a isselected. Mode switch may be changed between R-12 and R-134a without exiting,allowing both filter weights to be checked. Press RECOVER and RECYCLE ONLYto Audit TrailDisplays date and number of scale calibrations. Press RECOVER and RECYCLEONLY keys simultaneously to set the number of calibrations to Segment TestLights all segments of the Calibration TestChecks the scale Refrigerant WeightEstimated weight of refrigerant in the selected tank is displayed. Because tankweights vary, this can only be considered an estimate. Either tank can be selected inthis mode by moving the mode switch between R-12 and Step TestWhen this mode is entered, the display blanks. Press RECOVER and RECYCLEONLY keys simultaneously to continue. The display counts up from 001 to 015 ascorresponding outputs are cycled on and off. this test can be accelerated at any timeby pressing any key. After the step test, the display gives a code for any input that isnot in its normal state, as listed. To continue when this occurs, the input must beput into its normal state. If all inputs are in their normal state, the unit resumesnormal Codes"r12 - "CH-P" R-12 Vacuum Protection Switch"r12 - "CL-L" R-12 Low Pressure Switchr134" - "CH-P" R-134a Vacuum Protection Switchr134a - "CL-L" R-134a Low Pressure Switch"ref" - R-12/R-134a Mode SwitchF09 - Scale CalibrationSee RECALIBRATING THE SCALE for detailed - Default CodesWhen this mode is entered, the display blanks. Press RECOVER and RECYCLEONLY keys simultaneously to continue. The display shows a three-digit code thatcontrols the default oil timer, filter weight, and vacuum time. The default value forthis code is 356. The first digit represents the default vacuum time and is multipliedby 5 minutes to get the default. The second digit represents the vacuum pump oiltimer and is multiplied by 2 hrs. to get the default. The third digit represents thedefault filter weight and is multiplied by 50 lbs. to get the default. This code can bechanged by using the UP and DOWN arrow keys. The ENTER key locks in the newcode and resets the unit with the new - F99Not ProceduresAC9002534800/34801 Service ManualORIGINAL 5/99Scale Accuracy Checkand Recalibration for AC900CHECKING THE SCALE ACCURACY1. Turn on the MAIN POWER Press the MODE key until the program prompt ishighlighted on the When the screen has the program prompthighlighted, press the MODE and ENTER keyssimultaneously to enter the DIAGNOSTIC Remove all weight from both scale Using the UP and DOWN keys, toggle the display toread Press the ENTER key to turn the scale into a directreading weight : Whatever weight is on the scale when ENTER ispressed will not be shown on the display. Be pressingENTER, the unit automatically zeros the weight on thescale of the selected regfrigerant type. If you remove theweight, the display shows the change in total weight, butdoes not show a negative sign. The refrigerant selectorswitch may be changed during the procedure to checkboth the scales does not react to testing, verify that the scalesare plugged into the main THE SCALES1. Remove all weight from the scale Turn on the main power : If the unit is just being turned on, the screendefaults to display the selected refrigerant type. PressMODE until the program message is Press the MODE and ENTER keys simultaneously toenter the DIAGNOSTIC mode. Use the UP andDOWN keys to toggle the display to Press the ENTER key. The display now reads Press the RECOVER and VAC/RECYCLE keyssimultaneously. The display flashes DATE and thenshows Using the UP and DOWN keys, enter the currentmonth and year. For example, if the unit is beingcalibrated in August of 1999, enter 0-8-9-9. The display flashes r12, then displays ZEro (zero).8. Make sure nothing is on or touching the R-12 scaleplatform. Press The display flashes A1, then displays Place a certified weight, between 10 and 40 lbs., inthe center of the scale platform. Using the UP andDOWN keys, toggle to that weight on the The display flashes 134A then displays ZEro (zero).12. The display flashes A1 then read .13. Place a certified weight, between 10 and 40 pounds,in the center of the scale platform. Using the UP andDOWN keys, toggle to that weight on the display,then press ENTER. The display then shows theselected refrigerant Check the scale THE P-1 POT1. Remove all weight from the scale Turn on the MAIN POWER : If the unit is just being turned on, the screen willdefault to display the selected refrigerant type. PressMODE until the program message is Press the MODE and ENTER keys simultaneously toenter Diagnostic Mode. Use the UP and DOWN keysto toggle the display to F02 .4. Press the ENTER key. The screen will display 000 .NOTE: The zero on the left of the display is for R-12,and the zero on the right of the display is for the AC900 uses two 30 lb. tanks, the full limitshould be set at 43 Place a known weight of 43 lbs. on the R-12 zero on the left of the display should change to a 1 . The display should be reading 100 . At thispoint, adjust the R-12 P-1 pot so the full limit is set at43 lbs. Turning the P-1 pot clockwise will decreasethe amount of weight you can put on the scale beforethe zero changes to a 1 which indicates the fulllimit has been reached. Turning the P-1 potcounterclockwise will increase the amount of weightallowed before the zero changes to a 1 indicatingthat the full limit has been Repeat step 5 on the 134A : The zero on the right of the display indicates the134A full limit. Once the 134A full limit is reached, thedisplay reads 001 .26ORIGINAL 5/9934800/34801 Service ManualDiagnostic Procedures34800 and 34801All diagnostic modes mentioned here are accessed by entering the diagnostic functions menu. Press the SHIFT andENTER keys simultaneously. The unit's display prompts you for the function to run by displaying FUNC. Unlessotherwise noted, pressing RESET accepts the current settings and returns the unit to normal FUNCTIONS0 - LBS OR KG MODE SELECTIONENTER toggles the current mode. The current mode is displayedby either the lbs. or the kg. - Diagnostic VacuumThe refrigerant mode switch selects which "side" of the unit topull a diagnostic vacuum on. To exit from this routine, look forthe U-HI message or press HOLD. From either of these twostates, a RESET returns the unit to normal - Add RefrigerantThe current refrigerant mode is assumed. The process beginsimmediately upon the start of this function. Therefore, the liquidhose must already be disconnected from the correct tank andattached to the reserve tank that is being added from. The displayshows ADD briefly and then the amount of refrigerant transferredby weight. The function continues the transfer until one of thefollowing occurs: HOLD is pressed, the reserve tank is empty andpulled to a partial vacuum, or the maximum fill weight of thefunction has been reached. Under the last two conditions, thedisplay flashes between CPL and the amount of refrigeranttransferred by weight. In the HOLD condition, pressing HOLDagain resumes the - Accumulated Filter WeightDisplays total accumulated filter weight. Press the CHARGE andENTER keys simultaneously to reset the counter to - Audit TrailDisplays date of last calibration and how many calibrations havebeen performed on the scales (to a maximum of 225.) PressingCHARGE and ENTER simultaneously also returns this counterto - Segment TestThis test lights all segments of the LCD for quick indication thatthe display rountines and circuitry are functioning Service ManualORIGINAL 5/996 - Scale Calibration CheckDisplay reflects any absolute weight change on the selectedscale. Upon entry to this mode, the display briefly shows whichrefrigerant mode you are in, then displays If the refrigerantmode switch changes states, the display repeats this indicationfor the selected "side." To zero the reading, press 6 at any process is useful for adding weight to check positiveresponse and then removing weight to check negative exit, the weights will NOT be updated to reflect what wasdone to the - Refrigerant WeightDisplay indicates estimated refrigerant by weight in the selectedtank. This weight is obtained by the program by subtracting thecoded tank weight from the total weight seen by the of this variation in tank weights, this figure should onlybe used as an estimate. The refrigerant mode switch allows youto select which tank to - Unused FunctionReturns unit to normal - Gateway to Deep DiagnosticsDisplay shows four dashed lines which prompt entry of codedspecial functions. These functions directly affect large portionsof the unit's Procedures34800 and 34801 (continued)28ORIGINAL 5/9934800/34801 Service Manual DIAGNOSTIC STEP TESTPush Shift-Reset and Enter at the same timeThen push 9Then push 5Push 6 and 9 at the same time01R-134aRecycle Solenoid02R-134aRecover Solenoid03R-134aVacuum Solenoid04R-134aCharge Solenoid05R-134aAir Purge Solenoid06R-134aCompressor Relay07R-134aEqualization Solenoid08R-12Recycle SolenoidDeep Diagnostic FunctionsNOTE: Pressing the RESET key has no effect on any of these CALIBRATIONThe display briefly shows DATE, then Enter the date in the following format: press ENTER toaccept the entry. The display now briefly shows r12, followed by ZEro. Make sure there is no weight on the R12scale and press ENTER. The display now shows A1 and then Place a known weight on the R12 scale andenter the value of the weight. Press ENTER to display now briefly shows 134a, then shows ZEro. Make sure there is no weight on the R-134a scale and pressENTER The display now briefly shows A1, then Place a known weight on the R-134a scale and enter thevalue of the weight. Press ENTER to accept. The unit updates its programming and returns to normal - UL CIRCUIT ADJUSTMENT (P1-pot)The P1-pots on the 34800 are located on the front of the circuit board. The pot on the left is for the R-12 scale, andthe pot on the right is for the R-134a scale. Turning the pot counter-clockwise increases the full limit. Turning thepot clockwise decreases the full limit. Enter the deep diagnostic mode by pressing 9 when the FUNC dashed lines appear on the display. Press 3 on the keypad. The display shows 000. The zero on the left is forR-12. The zero on the right is for R-134a. Since this machine uses 30lb. tanks, the full limit should be set at 43 43 lbs. is placed on the R-12 scale, the zero on the left should change to a number one (1). When the zerochanges to a one, you have reached the full limit on the R-12 a small amount of weight from the scale and watch for the number one to change back to zero. Repeat thisprocess on the R-134a scale. The only difference is that the zero on the right of the display indicates whenther ornot you have reached the full limit on the R-134a scale. This change is indicated by the change from zero to theone, then back to zero Solenoid10R-12Vacuum Solenoid11R-12Charge Solenoid12R-12Air Purge Solenoid13R-12Compressor Relay14Vacuum Pump Relay15R-12Equalization Solenoid2934800/34801 Service ManualORIGINAL 5/99Function TestRECOVERY CHECK1. Turn on the MAIN POWER Install the loose end of the low side hose (coupler) tothe oil Close the low side manifold Open the high side manifold Verify that all tank hoses are properly attached to therecovery Completely open both tank Press RECOVER. The compressor starts and the lowside gauge pulls into a 13" Hg : The unit s low side gauge pulls to a 13" Hgvacuum and starts the recovery process. Recovery isengaged when the scale reading is displayed. The low sidegauge pulls to a 13" Hg vacuum again and the unit When recovery is complete, the display shows a scaleweight, then display the CPL The low side manifold gauge builds positive pressureand a pressure transfer should be heard. This is theresult of the equalization solenoid opening andreturning oil to the compressor. If no pressure riseoccurs, the equalization solenoid and its tubing mustbe inspected for Disconnect the low side hose (coupler) from theservice port and open the low side manifold Press RECOVER. The unit recovers to 13" Hg ofvacuum and shuts & RECYCLING CHECKNOTE: The recovery tank must have at least 6 pounds ofrefrigerant in it to perform this Close the high side manifold Install the loose end of the low side hose (coupler)from a separate hand-held manifold gauge set to theservice port. Verify that the valves are closed on thehand-held manifold gauge Program a 20 minute vacuum into the main boardand start the automatic vacuum process. The vacuumpump Verify that the low side manifold valve on the unit scontrol panel is The low side gauge on the unit starts registering Within 10 seconds of the vacuum pump starting, theRECYCLE prompt appears on the display and a clickis heard. The compressor is starting and the recyclingsolenoid is being After 60 seconds of recycling, the air purge solenoidreceives 110/220 volts to open it. If air is beingpurged, the solenoid is getting 110/220 volts. In somecases, no air is present and the voltage needs to bechecked to verify the solenoid After 5 minutes, the low side gauge on the unit scontrol panel is in a 29" to 30" Hg The low side gauge on the hand-held manifold gaugeset rises to around a 30 to 40 psi reading (expansionvalve pressure). If the expansion valve setting is notin range, adjust The low side manifold gauge on the unit s controlpanel should hold a vacuum. If it does not, inspectthe hoses for Close the tank s red vapor Disconnect the tank s red vapor hose from the Using a separate manifold gauge set, verify that themanifold gauge valves are Connect the tank s red vapor hose to the high side ofthe separate manifold gauge Connect the hose from the center port of the hand-held manifold gauge set to the tank s vapor 5/9934800/34801 Service Manual17. Open the tank s red vapor valve. Do not open the redhigh side valve on the hand-held manifold gauge Use the RECYCLE ONLY function. The unit beginsrecycling and the high side manifold gauge startsincreasing The unit shuts off when the high side manifold gaugeshows a pressure of 435 psi (+20 psi). The displayshows the HI-P There is an initial drop in pressure to around 275/300psi. After the initial drop in pressure, the pressureshould hold for 3 minutes. If the pressure dropsinstantly or bleeds off steadily, the recovery checkvalve needs to be After checking for pressure loss, slowly open the highside manifold valve to equalize the unit and Once the pressure is equalized, close the tank s redvapor Close the high side manifold valve and disconnect (atthe tank end) the hose between the tank s red vaporvalve and the manifold gauge Disconnect the tank s red vapor hose from themanifold gauge Reconnect the tank s red vapor hose to the tank s redvapor Open both manifold gauge valves on the unit scontrol panel and press RECOVER. Allow the unit torecover until it automatically shuts AND SCALE CHECK1. Turn on the MAIN POWER Check the scale accuracy and recalibrate if Scale Section for detailed Install the high and low side hoses to the vapor andliquid valves of a separate reusable Program a two pound charge into the main Open both manifold gauge valves and start theautomatic charging process. The charging processstops when the programmed amount of weight hasbeen lost from the scale. The display shows the CPL Recover the refrigerant charged into the Repeat full function test for the other refrigerant typeas : To ensure a complete charge, recycle for at leastfive minutes before attempting to charge. During thisprocess the refrigerant is heated in the recovery RatesRobinair authorizes a 2 hour charge to troubleshootand complete a full function test on units that arecovered under factory warranty. This includes leaktesting. The authorized time for parts replacement is15 minutes per part. If repairs are estimated toexceed 3 hours, prior authorization from Robinair are considered to be a consumable item and, assuch, they are not covered under the factory includes parts and labor.
Model 34800/34801/AC900 Refrigerant …
Model 34800/34801/AC900 Refrigerant Management Center CFC 12, HFC 134a Recycling Equipment Service Manual Theory of Operation and Safety Precautions ..... 2
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