Bosch Minimax-E Manuel utilisateur

USERS OPERATING MANUAL

MINIMAX-E

Advanced Test Products

Lürriper Str. 62

41065 Mönchengladbach | Germany

Tel: +49 (0)2161 59906-0 Fax: +49 (0)2161 59906-16

www.atp-europe.de  info@atp-europe.de

Advanced Test Products MINIMAX-E

TABLE OF CONTENTS

I) Safety precautions

A) The safe way is the only way! 1

B) Refrigerant gas recovery & containment 2

II) Important general information 3

III) Operational procedures

A) Operating your MINIMAX-E 4-6

Use of the Low Pressure Switch 6

B) Set-up procedures 7-9

C) Purging the non-condensable gases 10

IV) Diagrams

A) Part list 11

B) Refrigerant flow diagram 12

C) Wiring diagram 13

V) Safety pressure switch 14

VI) Care and maintenance 15

VII) Technical data 16

VIII) Helpful hints 17-19

IX) Troubleshooting 20

Design specifications and material are subject to change without notice.

REV 08-2013!

This manual may not be reproduced in any way, shape or form without express written consent of

Advanced Test Products.

Advanced Test Products MINIMAX-E

1

THE SAFE WAY IS THE ONLY WAY!

NOTE! If you are not a qualified refrigerant service technician,

do not use this equipment

1. The technician should always wear goggles and gloves when working on

refrigeration systems.

2. Be sure that any room where you are working is thoroughly ventilated,

3. Always think before acting. Familiarity breeds carelessness and carelessness can

be harmful to your health or, worse, result in death.

4. Read the Material Safety Data Sheets (MSDS) on all compounds with which you

are likely to come in contact. Read MSDS on refrigerant and refrigerant oil. Obtain

MSDS sheets from your refrigerant supplier.

5. Never use oxygen when testing for leaks. Any oil in contact with oxygen under

pressure will form an explosive mixture.

6. Refrigerant systems are generally electrically driven and controlled. Be sure to

disconnect the unit from the power source before servicing it.

7. Always store refrigerant containers in a cool, dry place.

8. Always open service and cylinder valves slowly. This allows quick control of the flow

of gasses if there is any danger. Once it is determined that there is no danger, the

valves may be opened fully.

9. Do not mix refrigerant in a system, a tank or anywhere else. Each type of refrigerant

must have its own tank, filters, etc.

10. If moisture enters the refrigerant system, it is likely to cause considerable damage.

Keep everything connected with the refrigeration system thoroughly dry and clean.

11. To reduce the risk of fire, avoid the use of extension cords as they may overheat. If

you must use an extension cord iit should be a minimum of 14 AWG and not longer

than 25ft.

This equipment should be used in locations with mechanical ventilation providing at

least four air changes per hour, or the equipment should be located at least 45cm

(18”) above the floor. Do not use this equipment in the vicinity of spilled or open

containers of gasoline or any other flammable liquid.

Advanced Test Products MINIMAX-E

2

REFRIGERANT GAS

RECOVERY & CONTAINMENT

Safety comes first. Read all safety information for the safe handling of refrigerant

including the Material Safety Data Sheet provided by your refrigerant supplier. Never

operate unit in an explosive environment. Wear safety glasses and protective gloves.

Work area must be well ventilated. This unit should only be operated by a qualified

technician.

*** CAUTION: REFRIGERANT STORE CONTAINERS ***

Use only approved cylinders with a minimum of 41 bar working pressure that serve the

current regulations.

NOTE: Recovery cylinders are designed for different pressures. Do not exceed the

working pressure of each cylinder.

Safety codes recommend that closed tanks not be filled over 80% of volume with liquid.

The remaining 20% is called head pressure room.

NEVER TRANSPORT AN OVERFILLED CYLINDER.

Refrigerant expands when it gets warm and may cause a tank to explode if overfilled.

CYLINDER TEMP. 16 °C 21 °C 38 °C 54 °C 66 °C

STARTING WITH

CYLINDER 80%

FULL BY VOLUME

SPACE OCCUPIED

BY LIQUID

STARTING WITH

CYLINDER 90%

FULL BY VOLUME

SPACE OCCUPIED

BY LIQUID

80 % 81% 83% 90% 94%

90% 92% 96% 100%

Advanced Test Products MINIMAX-E

3

IMPORTANT

GENERAL INFORMATION

Before operating the MINIMAX-E recovery unit, read the following:

1. Always isolate large amounts of refrigerant and close off valves after use so if a leak

should develop anywhere in the system the refrigerant does not escape.

2. Storage cylinders sometimes have valves that are not properly seated when

manufactured. Keeping caps on these valves will guard against refrigerant leakage.

3. Always operate the unit on a flat level surface.

4. Your MINIMAX-E has one internal high-pressure shut-off switch. If the pressure

inside the system should go above 38,5 bar (550 psi), the system will automatically

shut itself off.

CAUTION

The 38,5 bar (550 psi) switch does not prevent tank overfill. If your system shuts

off on high pressure and is connected to your tank, you may have overfilled your

tank and created a very dangerous situation! Take immediate measures to relieve

any high pressure and/or tank overfill.

5. WARNING! Never overfill storage tanks. Overfilling may cause tanks to explode.

6. A scale must be used to avoid overfilling the storage tank.

7. Tanks and filters should be designated for one refrigerant only. Before using a tank

previously used for another refrigerant, completely empty the tank, evacuate it,

purge the tank using dry nitrogen, and re-evacuate it.

8. Special care should be taken when recovering from a burned-out system. Use two

high acid capacity filters, in series. Alco type EK-162-F or Sporlan type C-162-F are

recommended.

9. When you have finished recovering from the system, flush your MINIMAX-E with a

small amount of refrigerant oil and a small amount of clean refrigerant to purge off

any foreign substances left in the unit.

10. Always empty refrigerant from the unit into a storage tank; see Self Purge/Auto

Evacuate procedure. Liquid refrigerant left in the condenser may expand, causing

damage to components.

Advanced Test Products MINIMAX-E

4

OPERATING YOUR MINIMAX-E

Connect your MINIMAX-E to a 230 V outlet. Switch the main power switch to the ON

position. You should hear the fan running. Press the compressor start switch. This

"momentary" switch will start the compressor. It may be necessary, under certain

circumstances, to press this switch more than once to start the compressor.

OPERATIONAL PROCEDURES

Do not turn this valve

while unit is running.

Close input valve, turn

machine off, switch to

Purge position and re-

start machine.

S

T

A

R

T

Do not turn this valve

while unit is running.

Close input valve, turn

machine off, switch to

Purge position and re-

start machine.

S

T

A

R

T

NOTE: To change from Recovery mode to Purge:

Close the Input port, turn the unit off (to prevent high pressure shutoff),

switch to Purge position and restart the unit.

NORMAL RECOVERY

SELF PURGE / AUTO EVACUATE

Advanced Test Products MINIMAX-E

5

OPERATING YOUR MINIMAX-E

Procedure for Normal System Recovery

1. Inspect the MINIMAX-E thoroughly to insure that it is in good operating condition.

2. Make sure all connections are correct and tight.

3. Open the liquid port of the recovery cylinder (always open valves slowly to check

hoses and connections for leaks).

4. Make sure the Recover/Purge valve is set on Recover.

5. Open the output port of the MINIMAX-E.

6. Open the liquid port on the manifold gauge set; opening the liquid port will remove

the liquid from the system first, greatly reducing the recovery time (after the liquid

has been removed, open the manifold vapor port to finish evacuating the system).

7. Connect your MINIMAX-E to a 230 V outlet.

a) Switch the main power switch to the ON position. You should hear the fan

running.

b) Press the compressor start switch. This "momentary" switch will start

the compressor (it may be necessary, under certain circumstances, to

press this switch more than once to start the compressor).

8. Slowly open the input port on the MINIMAX-E.

a) If the compressor starts to knock, slowly throttle back the input valve

until the knocking stops.

b) If the input valve was throttled back, it should be fully opened once the

liquid has been removed from the system (the manifold vapor port

should also be opened at this time).

9. Run until minimum EPA required vacuum is achieved.

a) Close the manifold vapor and liquid ports.

b) Close the MINIMAX-E input port.

c) Shut unit off and proceed with the Self Purge procedure on the next

page.

10. Always purge the MINIMAX-E after each use. Failure to purge the remaining

refrigerant from the MINIMAX-E could result in the acidic degradation of internal

components, ultimately causing premature failure of the unit.

CAUTION

When pumping liquid, do not allow the MINIMAX-E to operate with the input valve

too far open, causing the compressor to knock. Doing so may stall the

compressor.

Advanced Test Products MINIMAX-E

6

OPERATING YOUR MINIMAX-E

Procedure for Purging Remaining Refrigerant From the MINIMAX-E

1. Close the ports of the system being serviced that are connected to the input

port of the MINIMAX-E.

2. Close the input port on the MINIMAX-E.

3. Turn off MINIMAX-E.

4. Turn the Recover/Purge valve to the purge position.

5. Restart the MINIMAX-E.

6. Run until desired vacuum is achieved.

7. Close the ports on the recovery tank and the MINIMAX-E.

8. Turn the MINIMAX-E off.

9. Return the Recover/Purge valve to the recover position.

10. Disconnect and store all hoses.

11. Replace the in-line filter on your MINIMAX-E after every time excessive contaminant

is encountered.

Advanced Test Products MINIMAX-E

7

MINIMAX-E REFRIGERANT RECOVERY

ADDITIONAL INFORMATION

To achieve the deepest final vacuum, use the tank cooling method to lower the head

pressure on the recovery tank. Repeat as necessary to achieve the desired vacuum

level.

NOTE: If there is no liquid in the recovery tank, then the cooling method will not work. In

this case, use an empty tank that has been fully evacuated to achieve the final vacuum

level required.

To maximize recovery rates use the shortest possible length of 3/8” or larger hose. A

hose no longer than 3’0” is recommend. Always remove all unnecessary hose core

depressors and Schrader valves from port connections (using the proper valve core

tool) for maximum throughput. Deformed rubber seals and core depressors in hoses

and faulty or unnecessary Schrader valves can restrict flow by up to 90%.

If the tank pressure exceeds 31,5 bar, use the tank cooling procedure to reduce the

tank pressure. When recovering large amounts of liquid, use the “PUSH/PULL” method

of recovery (see diagram below).

CAUTION: When using the “PUSH/PULL” method, you must use a scale to prevent

overfilling the storage tank. Once the “PUSH/PULL” siphon is started, it can continue

and overfill the storage tank even if the tank is equipped with a float level sensor. The

siphon can continue even when the machine is turned off. You must manually close the

valves on the tank and the unit to prevent overfilling the recovery tank.

SET-UP DIAGRAM FOR TANK PRE OR SUB COOLING

PROCEDURE

INPUT

OUTPUT

VAPOR

LIQUID

To start you must have a minimum of

2,5 kg of liquid refrigerant in the tank.

Throttle the output valve so that the

output pressure is 7 bar (100 psi)

greater than the input pressure, but

never more than 31,5 bar (450 psi).

Run until the tank is cold.

Advanced Test Products MINIMAX-E

8

SET-UP DIAGRAM FOR REFRIGERANT RECOVERY

This method is the fastest method for recovering vapor refrigerant.

MANIFOLD GAUGE SET

(OPTIONAL) MOISTURE

SIGHT GLASS

INPUT

OUTPUT

LIQUID

A scale must be used

to avoid overfilling the

storage tank.

SYSTEM

BEING

SERVICED

VAPOR

LIQUID

SET-UP DIAGRAM FOR “PUSH/PULL” METHOD

Push pull only works with large systems where the liquid is readily accessible. Do not

use this method on systems that contain less than 15 pounds as it may not work.

SYSTEM

BEING

SERVICED

LIQUID

VAPOR

LIQUID

OUTPUT

OPTIONAL MOISTURE

INDICATING SIGHT GLASS

INPUT

The sight glass is used to provide a method of

determining the moisture content and quality of a

system’s refrigerant.

A scale must be

used to avoid

overfilling the

storage tank.

Advanced Test Products MINIMAX-E

9

OPTIONAL RECOVERY / TANK PRE OR SUB

COOLING FOR FIXED HOSE SET UP

SYSTEM

BEING

SERVICED

LIQUID

VAPOR

LIQUID

MANIFOLD GAUGE SET

INPUT

OUTPUT

A scale must be used

to avoid overfilling the

storage tank.

Normal recovery:

Tank Vapor valve is closed.

Tank pre or sub cooling:

Tank Vapor valve is open and both Manifold Gauge Set valves are closed. Follow

above procedure.

Advanced Test Products MINIMAX-E

10

MINIMAX-E RECOVERY

Purging the non-condensable gasses from identified refrigerant in a tank

1. Allow the tank to sit undisturbed for 24 hours. (This allows the air to rise to the top).

2. Connect a manifold to the tank and read the amount of pressure in the tank by

looking at the output pressure gauge.

3. Determine the ambient temperature in the room.

4. Refer to a Refrigerant pressure/temperature chart. Find the temperature on the chart

and look across to the corresponding pressure for the type of refrigerant in the tank.

Determine how that relates to the reading on the gauge.

5. If the pressure reading is higher than the pressure shown on the chart, very slowly

(so as not to cause turbulence inside the tank) crack open the vapor port valve.

Watch the pressure on the gauge decrease. To prevent venting, add 0,3 - 0,35 bar

(4 - 5 psi) to the pressure shown on the chart. When the gauge corresponds to that

pressure, close the vapor port valve.

6. Allow the tank to sit for 10 minutes and check the pressure again.

7. Repeat the process again if necessary.

Advanced Test Products MINIMAX-E

11

PARTS LIST MINIMAX-E

Pos. Description Part No.

1 Plastic case 100118

2 Fan grill 100179

3 Axial fan 100242

4 Condenser 100139

5 Compressor CP1320

6 Compressor Bracket 100207

7 Coupler CP1315

8 Bell housing CP1001

9 Motor EL1822

10 Front panel 100121

11 Manifold 700009

12 Inlet Gauge (Blue) GA1500

13 Outlet Gauge (Red) GA0800

14 Gauge Lens GA1000

15 ON/OFF Switch EL1310

16 START Switch EL1309

17 Red knob 100124

18 Black knob 100122

19 Blue knob 100123

20 Flare cap NB6501

21 Filter 100343

22 Rear Panel 105-200430-001

23 Power cord 135-200341-001

24 High Pressure switch EL2802

25 Fan Grill Inlet 100180

26 Hose 4“ 100345

Advanced Test Products MINIMAX-E

12

REFRIGERANT FLOW DIAGRAM

NOTE: A filter must always be used. Failure to use a filter will invalidate your warranty.

The use of a filter will greatly reduce the risk of damage to your MINIMAX-E by preventing foreign material from

entering the unit.

Special consideration for filtration must be given when you know you are servicing a machine that has "Burned Out".

We recommend the use of two size 162 filter driers, in line, to be used for that job and that job only.

FILTER

OUTPUT

INPUT

CONDENSER

COMPRESSOR

MOTOR

Advanced Test Products MINIMAX-E

13

Plug AC Male

Power switch

High pressure switch

Fan motor

3 pin connector for

up-grade

Start switch

1/2 HP motor

wht

grn

wht

grn

blk

brn

red

yel

blu

3

2

1

5

7

6

MINIMAX-E WIRING DIAGRAM

Advanced Test Products MINIMAX-E

14

.SAFETY PRESSURE SWITCH (WITH

MANUAL RESET FUNCTION)

The MINIMAX-E is equipped with an internal Safety Pressure Switch. If the pressure

inside the system exceeds 38,5 bar, the system is switched off automatically.

If the Safety Pressure Switch is activated automatically while filling a bottle, it may be

caused by the bottle becoming overfilled.

This is a very dangerous situation! You should take steps immediately to reduce the

overpressure and/or to eliminate the overfilling of the bottle.

If the Safety Pressure Switch switches the unit off...

The following precautions should be taken if the Safety Pressure Switch is activated:

a) Suspected overfilling of the recovery bottle

Connect the recovery bottle to another bottle with spare capacity so that the pressure is

reduced to a safe level. This action should also reduce the pressure in the output line

from the MINIMAX-E. Proceed as normal after resetting the Safety Pressure Switch

(see below).

b) Cause of activation of Safety Pressure Switch unknown

1) Check that the recovery bottle is not overfilled.

2) Close the system valves, recovery bottle valves and MINIMAX-E valves.

3) Disconnect MINIMAX-E from flexible pipes.

4) Disconnect MINIMAX-E from the power supply.

5) Open the input and output valves very slowly.

6) Investigate the reason for the failure.

Once activated the Safety Pressure Switch has to be reset manually as follows:

I) Remove the black protection cover to reveal the reset button (see picture below).

II) Reset by pushing the reset button with a tool such as a screwdriver.

III) Replace the cover.

Remove this part in order to

Reset the pressure switch.

Advanced Test Products MINIMAX-E

15

CARE AND MAINTENANCE OF YOUR

MINIMAX-E

A filter must always be used and should be replaced frequently. Failure to use a filter

will invalidate your warranty. The use of a filter will greatly reduce the risk of damage to

your MINIMAX-E by preventing foreign material from entering the unit.

Special consideration for filtration must be given when you know the machine you are

servicing has "burned out". We recommend the use of two size 162 filter driers, in line,

to be used for that job and that job only. We also recommend that a clean filter be used

for every service job. Each filter should be labeled and used exclusively for one type of

refrigerant only.

Do not use this unit in the vicinity of spilled or open containers of gasoline or other

combustible liquids

Avoid the use of extension cords. If you must use an extension cord it should be a

minimum of 14 AWG and not longer than 25 ft. Not using an extension cord will greatly

reduce the risk of fire.

Always purge the unit of any refrigerant left after completing a service job. Refrigerant

left in the machine can expand and may cause damage to components.

If the unit is to be stored or not used for any length of time, we recommend that it be

completely evacuated of any residual refrigerant and purged with dry nitrogen.

Whenever you perform any type of maintenance work on your MINIMAX-E, insure that it

is disconnected from the power supply before you begin.

Advanced Test Products MINIMAX-E

16

TECHNICAL SPECIFICATIONS

Type MINIMAX-E

Application Refrigerant recovery Gas or Vapor

Suitable refrigerants R12, R22, R134A, R401A, R401B, R401C, R402A, R402B,

R404A, R406A, R407A, R407B, R407C, R407D, R408A,

R409A, R410A, R411A, R411B, R412A, R500, R502, R507,

R509

Power Source 230V / 50 Hz

Power 380 W

Dimensions 250 x 222 x 406 mm

Weight 11 kg

RPM´s 1437 U/min

Max. working pressure 550 p.s.i. (38,5 bar)

Safety Device Safety pressure switch type P100 DA

with manual reset (550 p.s.i. / 38,5 bar)

ATTENTION

The MINIMAX-E should not be used with inflammable gases nor with

gases containing ammonia.

Advanced Test Products MINIMAX-E

17

HELPFUL HINTS FOR REFRIGERANT

RECOVERY

Refrigerant recovery has come a long way in a few short years.

On the surface it’s simply the process of taking refrigerant out of a system and putting it

into a tank. However, this simple process can quickly become problematic if a few items

are overlooked. The following are some tips and pointers we’ve accumulated over the

last few years that can save you time and make the process go smoother.

First you need to identify the refrigerant type and quantity in the system you are

servicing.

If you determine it’s a burnout, you need a special tank (a tank that’s identified as

containing burnout or other unidentified gases), and you need to use extra filtration prior

to recovery.

If, on the other hand, you know the gas in the system is relatively clean or new, then a

new tank should be used. If you’re planning on putting the refrigerant back into the

same system after you have finished the service or if the refrigerant is going to be

reclaimed, then use a tank that has the same refrigerant in it. A word of caution about

the Environmental Protection Agency (EPA): If you use a variety of refrigerant gasses in

your service work - as evidenced by your refrigerant purchases - and you only own one

tank, you are asking for trouble. You would be well advised to own at least one tank for

every refrigerant type serviced, plus an extra for burnouts and other unknowns.

Planning Ahead

Knowing the quantity of refrigerant is important for planning storage requirements, as

well as planning for the actual recovery. For instance, any system with more than 5lbs.

of refrigerant is likely to have areas where the liquid can get trapped.

The key to a quick recovery procedure is to get the liquid out first, and then get the

remaining vapor out. However most systems are not “recovery friendly.” That is they

don’t have access ports at their lowest points. If some units you’re servicing are on

maintenance contracts, you would save significant time by installing access ports at all

of the lowest points in the system, where liquid is likely to accumulate. Since most

systems don’t have these ports you need to be prepared to boil of the trapped liquid

with a heat gun, when ever it’s found. An indicator of trapped liquid in a system is frost

or condensation forming on the plumbing or components where the liquid is trapped.

The trapped liquid may be in an area that is not visible. In all cases trapped liquid in a

system during recovery causes the recovery process to slow down, regardless of the

size or type of machine

If you are unable to locate the trapped liquid (but you know it’s there, because the

recovery job is taking “forever”), turn on the system compressor (if it’s operable) for a

few seconds. This will get the refrigerant moving to another part of the system and in.

Advanced Test Products MINIMAX-E

18

HOSES AND VALVES

Hoses and Schrader valves have a large impact on recovery speed. In general, the

larger the hose, the less friction on the flow of refrigerant and the quicker the recovery

time. Many contractors are now using 3/8” lines for the input to the recovery machine,

even if those lines originate out of 1/4” fittings.

Schrader valves must be removed from the connection prior to an expedient recovery.

Most wholesalers sell a tool for removing these cores, while keeping the

connection sealed. The core depressor, in the end of the hose, should also be removed.

These two items can turn a 20-minute job into one that goes on for hours. So, be sure to

remove Schrader valves and core depressors before every recovery job.

Another hose consideration is the little rubber grommet at the end of the hose that

makes a seal with the flare fitting. We’ve seen these seals so worm and deformed that

when the hose is connected to the flare fitting the grommet virtually seals off the the

connection. This is probably never noticed in charging, because the pressure opens the

grommet, but during recovery (or with suction) the deformed grommet severely restricts

the flow of refrigerant.

Refrigerant Recycling

Current regulations state that used refrigerant shall not be sold, or used in a different

owner’s equipment, unless the refrigerant has been laboratory analyzed and found to

meet the requirements of ARI 700 (latest edition). As a result, recycling and verifying

ARI 700 conformance isn’t economically justified in most cases. It’s still a great idea to

do as much cleaning of refrigerant going back into the same system (or owners

system) as possible. We recommend using the largest, high-acid capacity filter that are

economically feasible. Put these filters on the suction or inlet side of the recovery unit.

Change filters often.

The recovery of large amounts of liquid refrigerant can sometimes carry with it large

quantities of oil, if the system being serviced doesn’t have an adequate oil separator

installed. If this recovered refrigerant isn’t going to be liquid charged back into the same

system, you might want to separate the refrigerant from the oil in order to

measure the oil (to know how much oil to charge back into the system). However

refrigerant sent back for reclaim does not need to have the oil removed. One of the

simplest and most cost effective ways to achieve this is to use a 30 or 50 lb. tank in line

with your recovery machine. Connect the system to the liquid port of the tank then from

the vapor port of the tank connect to the input of your recovery machine a second tank,

for storing refrigerant, should then be connected to the output of the recovery machine.

If you encounter large amounts of liquid you will need to put a band heater around the

first tank.

When the recovery job is complete the oil can be removed, from the first tank, by

applying a small amount of pressure, using nitrogen, to one of the ports and

expressing the oil from the other. If you are going to remove the oil from the vapor port

you will need to turn the tank upside down. Always wear safety glasses when

performing this operation as the oil may be acidic and could cause severe burning.

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