CHAPTER 2 THEORY OF OPERATION - Snap
Contents
1. TRANSDUCER 0 500 PSI S y OIL SOLENOID CHECK VALVE IN a Ji S1 i PURGE SOLENOID f IN i ae LIQUID 1 i _ VAPOR NOTE This section only S y present on model EEAC316 SOLENOID P LIQUID AIR 50LB RECOVERY OIL TANK FIGURE 2 5 CHARGE MODE Special Consideration During the charge mode the unit may slow down or stop charging due to pressure equalization between the Recovery Tank and the vehicle Slow Charge Condition The customer needs to close the red High panel valve start the vehicle and run the vehicle s AC system The pressure in the vehicle on the low side will drop and the unit can continue to charge The pressure in the Recovery Tank must be greater than the pressure in the vehicle to complete the charge cycle NOTE Never try to install a heater blanket on a Recovery Tank Effective 01 2002 Page 2 5 CHAPTER 2 THEORY OF OPERATION TEMPERATURE SENSOR Refer to Drawing 1 1 in Chapter 1 The temperature sensor monitors the temperature of the refrigerant in the Recovery Tank The Chart below will help you check out the temperature sen2. 3 sH PROCESS COMPRESSOR H OIL DRAIN 6 VALVE er el P t f our Vacuum Pump J N a O n BOTTLE j So PSI 3 jp 2 OIL SEPARATOR S pi OIL SOLENOID ae CHECK N CONDENSER WAIVE UY Yywq yU A 7 2 PURGE SOLENOID j Y FI Yon Wi 7 IN 3 VAPORLNE YU yy ABBV im NOTE This section only 83 present on model EEAC316 VACUUM N SOLENOID 7 LIQUID AIR 50LB RECOVERY TANK OIL FIGURE 2 1 POWER ON MODE Effective 01 2002 Page 2 1 CHAPTER 2 THEORY OF OPERATION RECYCLE MODE VEHICLE ER HIGH PORT BULKHEAD HV1 3 WAY VALVE CYCLE HV1 HV2 eee RECOVERY 1 to 2 4 to 5 NOTE This section only j IN VACUUM _ 1 to 2 4to5 present on model EEAC318 f CHARGE 8to1 6 to 4 so VENT SOLENOID FILTER DRYER 062 ORIFICE IN SUCTION z SEPARATOR amp VACUUM O SOLENOID TI HIGH PRESSURE CUTOFF SWITCH SUCTION OPENS AT 450PSI Hv2 3 WAY VALVE i 6 LOW PORT BULKHEAD z COMPRESSOR
3. VAPOR LIQUID AIR 50 LB RECOVERY TANK OIL FIGURE 2 3 PURGE MODE Effective 01 2002 NOTE This section only present on model EEAC316 S3 VACUUM N SOLENOID Page 2 3 CHAPTER 2 THEORY OF OPERATION VACUUM MODE The Vacuum Mode is initiated when the operator programs the unit to pull a vacuum from the vehicle using the ECO Xtreme When the unit is set to Vacuum Mode and both hand valves are in the gt position The unit will then turn the compressor ON Vacuum Pump for the EEAC318 Once the compressor pump starts it will pull a deep vacuum from 25 Hg to 29 Hg The pressure from the discharge side of the compressor is vented to atmosphere via S3 solenoid in the EEAC318 solenoid S3 provides a path to the Vacuum Pump During this process in the Model EEAC316 some oil from the compressor might escape but is trapped in the bottom of the Compressor Oil Separator At the end of the Vacuum cycle the Oil Solenoid S2 will open allowing the vacuum from the compressor to pull the oil back to the compressor Special Consideration In the Model EEAC318 the Vacuum Pump may require up to 60 seconds to restart if power is cycled quickly Also the Vacuum Pump will automatically shut down if it does not pull 15 Hg in 2 5 minutes This is to prevent oil loss NING DURING A VACUUM MODE THE OUTPUT OF EITHER THE COMPRESSOR EEAC316 OR THE VACUUM PUMP
4. Special Consideration At any time during the Recover Mode the unit may display High Pressure If the High Pressure light illuminates then either the red recover tank valve is turned off or the unit must be purged to release the non condensable gas Refer to the User s Manual in Appendix C for more information NOTE This section only present on model EEAC318 VEHICLE HV4 ADAPTER HIGH PORT 3 WAY VALVE j BULKHEAD 062 ORIFICE IN VENT so SOLENOID et 3 SUCTION SEPARATOR Hv2 3 WAY VALVE u T T 4 5 H OIL DRAIN 6 VALVE TRANSDUCER 0 500 PSI LOW PORT BULKHEAD LIQUID LINE CI IN OR VACUUM i SOLENOID Vacuum Pump CYCLE HV1 HV2 RECOVERY 1 to 2 4 to 5 VACUUM i to 2 4to5 CHARGE 8to1 6 to4 i MASTER FILTER DRYER _ E E HIGH PRESSURE CUTOFF SWITCH SUCTION OPENS AT 450PSI DISCHARGE PROCESS COMPRESSOR N out IN O PEUN S2 OIL SEPARATOR OIL SOLENOID CHECK CONDENSER a 7 D ST ABBV
5. PROCESS VALVE H A m Vacuum Pump F IN OIL f l xg BOTTLE f s2 S F OIL SOLENOID Sa CHECK VALVE CONDENSER E OIL DRAIN RETURN TRANSDUCER 0 500 PSI OIL SEPARATOR S1 PURGE SOLENOID DARA LIQUID LINE ABBV LIQUID VAPOR NOTE This section only VACUUM present on model EEAC316 SOLENOID VAPOR LIQUID AIR 50LB RECOVERY OIL TANK FIGURE 2 2 RECYCLE MODE During the Recycle mode the unit will pull all refrigerant from the vehicle clean it and store it in the recovery tank To start the sequence turn the unit s hand valves to the Recycle gt gt position Program the unit to recycle The Compressor starts which takes between 5 to 10 seconds Once the compressor starts refrigerant will enter the Suction Separator assembly in a liquid or vapor state but will exit in a vapor state The refrigerant will pass through the Master Filter Dryer to be dried cleaned of all moisture and processed through the compressor Refrigerant then enters the oil separator to separate the oil that is used to lubricate the compressor Refrigerant then exits the oil separato
6. COMPRESSOR The ECO Xtreme uses a rotary vane type Compressor This Compressor in model EEAC316 performs two functions one as a vacuum pump and the other as a Pressure Compressor In the Vacuum mode the Compressor pulls a deep vacuum which removes moisture and non condensable from the vehicle refrigerant system In the Recycle Mode the Compressor pulls low pressure refrigerant gas from the Oil Separator and compresses it sending it on to the condenser as a high pressure high temperature vapor During this process it is normal for a small amount of compressor oil to mix with the refrigerant leaving the Compressor The oil reservoir will separate and capture this oil and return it to the Compressor The Compressor is protected by routing 115VAC through a Klixon thermal overload device circuit breaker located under the plastic cap of the Compressor NOTE TIS RECOMMENDED TO CHANGE OIL EVERY 3 MONTHS OIL SEPARATOR The oil separator is located next to the Compressor During normal operation a small amount of oil will leave the Compressor through the discharge port This oil is captured in the oil separator Once the operation is completed and the operator turns off the unit The oil will be drawn back to the compressor via the oil return line This assures that the Compressor will always have a sufficient quantity of oil for proper operation VACUUM PUMP NOTE ONLY UNIT MODEL EEAC318 HAS A SEPARATE VACUUM PUMP MODEL EEAC316 USES THE COMPRESS
7. 1 3889 3742 3602 3467 3340 3217 3099 2986 2878 2774 2675 2580 2488 2400 2316 2235 2157 2083 2011 1941 1876 1813 1752 Voltage across Probe 2 0 9878 0 9632 0 9391 0 9153 0 8919 0 8689 0 8462 0 8242 0 8023 0 7810 0 7601 0 7396 0 7195 0 7000 0 6808 0 6620 0 6436 0 6259 0 6085 0 5915 0 5748 0 5587 0 5429 0 5276 0 5127 0 4981 0 4839 0 4701 0 4567 0 4436 0 4310 0 4186 0 4064 0 3949 0 3837 0 3727 Page 2 6 Table 1 Temperature Probe function Effective 01 2002 CHAPTER 2 THEORY OF OPERATION TEMPERATURE PRESSURE CHART REFERENCE 64 F 62 68PSI 78 F 83 46PSI 92 F 108 14PSI 112 F 151 14PSI 66 F 65 42PSI 80 F 86 70PSI 94 F 111 98PSI 116 F 160 94PSI 68 F 68 26PSI 82 F 90 10PSI 96 F 115 94PSI 120 F 171 10PSI Table 2 R 134a Temperature Pressure Chart COMPONENT OPERATION SOLENOID The Solenoids are normally closed allowing flow only when power is supplied across the coil One terminal on the solenoid is wired to neutral while the other is connected to a driver delivering 115VAC hot Refer to Chapter 1 AC DC Distribution NOTE ALL SOLENOIDS ARE MARKED WITH AN ARROW A DOT OR THE WORD IN STAMPED ON THE BODY INDICATING DIRECTION OF FLOW e OIL SOLENOID Normally Closed closed in Recycle or Vacuum mode to prevent flow from the Oil Separator outlet to the Compressor inlet Opens to allow oil to return to the compressor
8. CHAPTER 2 THEORY OF OPERATION DESCRIPTION OF OPERATING CYCLES POWER ON MODE The ECO Xtreme has multiple operating modes Power On Recycle Vacuum Purge and Charge modes During the Power On Mode the unit can be set via the Hand Valves to Charge Recycle Vacuum or Off The service hoses connect to the vehicle but for the purpose of the diagram the low and high side valves are in the off position Referring to FIGURE 2 1 POWER ON MODE all Solenoids normally closed are closed and the condenser fan is running The unit s hand valves must be in the Recycle mode to allow the unit to recover and recycle the refrigerant before the compressor is activated Se CYCLE __ HVi HV2 ee N RECOVERY 1 to 2 4 to 5 NOTE This section only IN VACUUM 1to2 4to5 present on model EEAC318 f s CHARGE Bto1 6to4 No VENT VEHICLE HV SOLENOID MASTER ADAPTER HIGH PORT 3 WAY VALVE FILTER DRYER BULKHEAD 062 ORIFICE j j 1 2 i ii 3 IN SUCTION SEPARATOR HIGH PRESSURE wo S3 SUCTION CUTOFF SWITCH Hi VACUUM piscHanGe OPENS AT 450PSI 3 WAY VALVE Ty SOLENOID Low PORT amp BULKHEAD Ea r
9. EEAC318 IS VENTED TO ATMOSPHERE PERFORMING A VACUUM ON A VEHICLE THAT HAS REFRIGERANT IN THE SYSTEM WILL VENT THAT REFRIGERANT TO ATMOSPHERE F CYCLE HV1 HV2 i i N RECOVERY 1 to 2 4 to 5 NOTE This section only IN VACUUM 11 to2 14to5 present on model EEAC319 s CHARGE 8to1 6to4 fi No VENT VEHICLE HV1 SOLENOID MASTER ADAPTER HIGH PORT 3 WAY VALVE _FILTER DRYER BULKHEAD 062 ORIFICE l Tt 1 2 LL 8 SUCTION NE o l SEPARATOR l NOTE Vacuum HIGH PRESSURE Ji xc path depends SUCTION CUTOFF SWITCH 83 on Model OPENS AT 450PSI HV2 VACUUM T text DISCHARGE 3 WAY VALVE u see texi XZ LOW PORT SOLENOID BULKHEAD mn 4 SZ PROCESS COMPRESSOR H OILDRAIN 6 VALVE i 4 g a j n TRANSDUCER 0 500 PSI OIL SEPARATOR n ur X JEN AN OIL Vacuum Pump i xg I FETURN BOTTLE k Fi i Ne vA OIL SOLENOID CHECK VALVE IN IN CONDENSER z Q G wa 4h UM AA A R G S1 PURGE SOLENOID NOTE
10. OMPLAINT CORRECTIVE ACTION IV No Vacuum or vacuum is weak Check for debris in the Oil return solenoid or less then 25 inches NO gt Refer to Chapter 1 AC DC Model EEAC316 only Disconnect the suction side of the compressor Connect a gauge set yellow hose to the compressor Open inline hand valve on yellow hose and open low side valve on gauge set Set the unit up for a Vacuum operation Does the gauge set read 25 to 29 NO gt Disconnect oil return tube from compressor and block off compressor side Does the gauge set read 25 to 29 NO gt Replace Compressor YES gt Clean or replace Oil Solenoid Disconnect yellow hose from compressor and reconnect compressor to the input side of the master filter dryer V No vacuum or vacuum is weak Does Vacuum Pump Start or less then 25 inches NO gt Refer to Chapter 1 AC DC Model EEAC318 only i l YES gt Disconnect the suction side of the Vacuum Pump Connect a gauge set yellow hose to the compressor Open inline hand valve on yellow hose and open low side valve on gauge set Set up a vacuum operation Does the gauge set read 25 to 29 YES gt Check for leaking solenoids S4 or S3 leaking hand valves or leaking hoses fittings NO gt Check oil level in Vacuum Pump replace Vacuum Pump TROUBLESHOOTING COMPLETE Effective Page 2 10 01 2002
11. OR AS BOTH A COMPRESSOR AND A VACUUM PUMP The Vacuum Pump is used to pull a very low vacuum on a vehicle The Vacuum Pump used in the unit model EEAC318 is a self contained vender item that we do not service other than normal oil maintenance see Chapter 3 If it fails replace it The Vacuum Pump is feed 115 VAC from the Control Board via connectors J29 and 30 when a Vacuum Mode is initiated Effective 01 2002 Page 2 7 CHAPTER 2 THEORY OF OPERATION RECOVERY TANK The Recovery Tank stores up to 80 of recycled filtered and dried refrigerant It has two manual hand valves and a purge fitting located on top of the tank During the Recycle mode the refrigerant enters the tank through the valve marked VAPOR RED In the charge Dispense Refrigerant mode the refrigerant exits through the valve marked LIQUID BLUE This port has a tube which reaches the bottom of the recovery tank When using the recycle unit open both valves on the recovery tank for proper operation During the auto purge mode the non condensable gas AIR exits through the yellow hose via the purge fitting This process will release the non condensable gas out of the purge valve on the front panel of the unit For more information refer to PURGE MODE on page 2 3 LOAD CELL The Load Cell is the device that weighs the amount of the refrigerant in the tank The load cell is made of four strain gauge resistors connected in a whetstone bridge configuration The des
12. This section only present on model EEAC316 S3 VACUUM SOLENOID jf FIGURE 2 4 VACUUM MODE Effective Page 2 4 01 2002 CHAPTER 2 THEORY OF OPERATION CHARGE MODE The Charge Mode is a manual operation The operator would need to properly connect the ECO Xtreme to the vehicle and pull a vacuum before charging is performed Be sure that the blue valve on the Recovery Tank is open during the charge mode Liquid refrigerant flows from the liquid side of the Recovery Tank through the hand valves and hoses to the vehicle until the proper amount has charged Then turn the unit s hand valves to off Refer to FIGURE 2 5 CHARGE MODE CYCLE HV1 HV2 Fi Ny RECOVERY 1 to 2 4 to 5 NOTE This section only f N VACUUM 1 to 2 4to5 present on model EEAC318 f CHARGE 8to1 6 to 4 S4 Go VENT SOLENOID STER VEHICLE HV1 J MASTI ADAPTER HIGH PORT 3 WAY VALVE _ FILTER DRYER BULKHEAD 062 ORIFICE i i k 1 at 3 i IN gi SEPARATOR HIGH PRESSURE No S3 SUCTION CUTOFF SWITCH i VACUUM piscHaRGe OPENS AT 450PS1 3 WAY VALVE i Fi SOLENOID LOW PORT BULKHEAD 4 5 PROCESS COMPRESSOR H OIL DRAIN VALVE J i a j our 4 Vacuum Pump ip N N oiL O em BOTTLE QY OIL SEPARATOR
13. ign of the Controller Board only uses the Signal to read the amount on the scale This voltage can be read on the A D U6 pin 3 to determine the amount on the scale Example Every 1 oz divided by 229 807 To determine the voltage reading with a certain amount on the scale the math would follow 40 Ibs x 16 0 oz 229 807 2 78VDC To determine the amount reading with voltage then the math would follow 2 09VDC x 229 807 16 30lbs 0 oz CUTOFF SWITCHES There is one Cutoff Switch used in this unit which is the High Pressure cutoff switch This switch works the same way as a Snap switch When the pressure reaches 450 psi the switch snaps open When the pressure decreases to 375 psi the switch then snaps closed SWITCH DEACTUATION ACTUATION HIGH 375 psi 450 psi SUCTION SEPARATOR The Suction Separator assembly is located in the front of the unit Oil removed from the vehicle s A C system is separated from the refrigerant and is accumulated in the separator bowl The purpose of the Suction Separator is to remove contaminants from the refrigerant being recovered Refrigerant can enter the Suction Separator as a vapor or liquid Any liquid entering must vaporize in order to exit through the outlet port at the top of the assembly Once the refrigerant has changed from a liquid to a vapor state the compressor will draw out the vapor The remaining oil if any will need to be purged out via the oil drain valve The amount
14. ll Unit displays High Pressure Unit will not charge liquid or charges slowly Effective 01 2002 CHAPTER 2 THEORY OF OPERATION CORRECTIVE ACTION Is the gross weight greater than 70 pounds 50lb tank 26 5lb YES gt Tank is Full Install an empty tank Perform Scale calibration Chapter 3 If unit will not calibrate Replace Controller Board or replace Load Cell Verify the unit has been purged properly and Pressure Transducer has Been Calibrated Be sure RED hand valve on tank is open and unit hand valve is set to recycle during Recycle Mode Disconnect RED hose from tank and bleed off pressure Does High Pressure Switch read shorted with an Ohm Meter NO gt Replace High Pressure Switch Reconnect the RED hose to recovery tank Perform the purge sequence Is the BLUE hand valve at the Recovery Tank Service Hoses and Front Panel valves open NO gt Open the hand valves Check to see that the Schrader core depressors in the service hoses are opening Schrader cores on the vehicle A C system Listen for pressure release when connecting to vehicle e Repair or replace as needed Does unit charge YES gt End Troubleshooting Try charging hoses if Ok check vehicle adapters at car NO gt Restriction in hose Repair as needed Turn off high side valve on gauge set and start vehicle up run vehicle compressor This is normal due to a slow charge condition Page 2 9 CHAPTER 2 THEORY OF OPERATION C
15. of oil removed will be the amount of oil that should be added back to the vehicle Refer to Appendix C Users Manual for more information PRESSURE TRANSDUCER Refer to Drawing 1 1 in Chapter 1 There is only one transducer used in this unit to monitor the pressure in the recovery tank The Purge Transducer is rated at 0 to 500 psia The transducer outputs a voltage proportional to amount of the pressure sensed Output voltage is 0 0 to 4 0 volts full scale and with a 0 5 0 1 volt zero offset Example Every 1 psi equals 8mv plus the 0 5 volt zero offset At 250 psia the output voltage is 2 5 0 1 volt Note this transducer measures absolute pressure PSIA instead of gauge pressure PSIG and is not interchangeable with older ones MASTER FILTER DRIER When vapor refrigerant passes through the Master Filter Dryer it is dried cleaned of all moisture The master filter drier is the only component that removes moisture from refrigerant The master filter drier should be changed when the filter counter Timer has reached or counts down to 0 pounds 0 ounces since the last master filter drier change The maximum amount of time for a new filter dryer is 95 pounds For more information on tracking refer to Appendix C Users Manual This filter is designed to remove moisture from R 134a refrigerants NOTE The unit is only designed to recover R134a refrigerant Effective Page 2 8 01 2002 TROUBLESHOOTING COMPLAINT Unit displays Tank Fu
16. r and flows through a check valve to allow the refrigerant to enter the condenser Refrigerant is then cooled using a fan and changed from a high pressure vapor to a high pressure liquid as it passes through the condenser The final stage captures the refrigerant in the Recovery Tank At the end of the Recover Mode the gauge set will indicate approximately 15 of vacuum The operator must turn the unit hand valves OFF The operator should monitor the low side gauge for residual pressure buildup Refer to Appendix C Users Manual for more Information NOTE fthe Recovery Tank becomes full at any time during the Recycle Mode an LED will flash and an error message will be displayed Effective Page 2 2 01 2002 PURGE MODE CHAPTER 2 THEORY OF OPERATION Since Tank Temperature is directly proportional to Tank Pressure a Temperature probe held against the Recovery Tank is used to monitor tank temperature The Temperature Sensor and Pressure Transducer are monitored before and after a Recovery If needed a Purge cycle is executed to release non condensable AIR that may have been recovered along with the refrigerant The unit monitors and releases non condensable AIR until the pressure is correct or proportional to the current tank temperature Non condensable gases are released through S1 solenoid which has a 1 32 orifice to reduce flow and ensure refrigerant is not lost This sequence will repeat until the proper pressure is established
17. sor by giving you temperature probe resistance and voltage for specific temperatures The output voltage of the temperature probe changes with temperature but is not linear The chart below shows the resistance of the probe vs temperature and output voltage when plugged into the board eC AN Oa FR WNDY O oF 32 34 36 37 39 41 43 45 46 48 50 52 54 55 57 59 61 63 64 66 68 70 72 73 75 77 79 81 82 84 86 88 90 91 93 Probe Resistance 2 32657 31036 29505 28058 26690 25396 24174 23018 21922 20886 19904 18974 18093 17258 16465 15715 15003 14327 13684 13074 12495 11944 11421 10923 10451 10000 9573 9166 8778 8409 8057 7722 7403 7099 6809 Voltage across Probe 2 1 9139 1 8908 1 8672 1 8431 1 8186 1 7937 1 7684 1 7428 1 7168 1 6906 1 6640 1 6372 1 6101 1 5828 1 5554 1 5278 1 5001 1 4723 1 4444 1 4165 1 3886 1 3607 1 3329 1 3051 1 2776 1 2500 1 2227 1 1956 1 1687 1 1420 1 1155 1 0893 1 0635 1 0379 1 0127 c 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 oF 95 97 99 100 102 104 106 108 109 111 113 115 117 118 120 122 124 126 127 129 131 133 135 136 138 140 142 144 145 147 149 151 153 154 156 158 Probe Resistance 2 6532 6268 6016 5776 5546 5327 5117 4918 4726 4543 4369 4201 404
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