Recovery-Recycling of Refrigerants

Learning Element 3

Perform Recovery/Recycling of
Refrigerants

Learning Outcome

On completion of this Element you should be able to:

; Identify different types of application of recovery/recycling
; Apply operating procedures in recovery/recycling
; Apply trouble shooting of recovery/recycling operation
; Perform recovery/recycling of refrigerants
; Maintain recovery/recycling equipment

Resources

To undertake this Element you require the following resources:
• Information Sheet 5: Application of Recovery/Recycling Services
• Operation Sheet 2: Perform Recovery/Recycling Operation
• Operation Sheet 3: Troubleshooting Guide: Recovery Operation
• Service Manual: Recovery/Recycling Machine

Learning Activity Unit Recover/Recycle Refrigerants of RAC Systems
No. 3 Module Recovery/Recycling Refrigerants

Reading Activity 5

Read: Learning Outcome

Study: Information Sheet 5: Application of Recovery and Recycling Services

Optional Activity

Call Instructor: Discuss other options to attain objectives
• Ask instructor for demonstration of recovery/recycling of refrigerant and

trouble shooting

Practice Activity

Practice: Job Sheet: 4: Recovery/Recycle Refrigerant Using Van
Steenburgh Recycling Machine in Domestic Refirgeration and
Window Air Conditioner

Job Sheet 5: Recovery/Recycle Refrigerant Using Van
Steenburgh Recycling Machine in Automotive Air Conditioning
Vehicle

Ask permission from instructor

• Prepare equipment, tools and materials

• Observe safety practices

• Maintain cleanliness

Competency Assessment

Assessment: When you feel confident you can perform all the elements in
this module submit for assessment.

• Call Instructor or Assessor
• Study Assessment Guide
• See to it that all the equipment, tools and materials are available.
• Perform the activities asked in the assessment guide
• Let instructor check your work.

52

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 5 Module Recovery/Recycling Refrigerants

Application of Recovery/Recycling

I. Recover/recycling refrigerant of different systems

1. Recover/Recycling Refrigerant from a Refrigeration and Window Type Air-
conditioning Unit. It is possible to recover refrigerant from a hermetically sealed system,
which has no service valves. A line-tap valve (piercing valve) should be fitted to the system.
Procedure:
• Following the manufacturer’s instructions, and a recovery unit used to remove the
refrigerant from the unit via the line-tap as with the larger system.
• Line-tap valves should never be lea permanently in place, but removed after use if
placed on the process tube.
• It is recommended to install tap-valves on both high and low pressure side.

Note: Figure below shows a recovery unit is connected to a refrigerator with a typical
tap-valve (piercing valve). Because of the small charge of refrigerant, only vapor
recovery is needed.

Piercing Valve Core Evaporator
Tube Nut Condenser

Pierced Compressor
Tube

Refrigerant Recovery/
Outlet Port Recycling
Machine
Recovery
Tank

Scale

Refrigerant
Inlet Port

53

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 5 Module Recovery/Recycling Refrigerants

2. Recover from air-conditioning system(Liquid transfer)

Procedure
• Discharge side recoveryunit to the suction pipe on the airconditioning system
If there are available valves on the systems receiver (high pressure side) the recovery
discharge side could be connected here as well. Liquid flows now from the liquid side
of the air-conditioning system and into the cylinder.
• The recovery unit will keep the pressure inside the cylinder lower than in the air-
conditioning system and keep up the liquid flow.
Figure below shows a typical condensing unit for air-conditioning installations

OUT

54

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 5 Module Recovery/Recycling Refrigerants

3. Recovery from commercial - cold room system.

Liquid transfer procedures
• Connect the recovery cylinder’s liquid hose to the system’s outlet service valve on the
condenser/receiver.
• To monitor liquid flow, install a sight glass between the hose and cylinder.
• From the recovery unit’s inlet/suction side connect the hose to the recovery cylinder’s
vapor side (use a drier).
• Outlet/discharge side on the recovery unit goes to the system’s high pressure side at
inlet condenser or compressor high pressure stop valve.
• All systems’ service valves have to be opened, including solenoid valves.
• Run the recovery unit and keep an eye on the sight glass.
• When there is no more liquid transferred through the sight glass, this indicates there is
no more liquid refrigerant left in the system.

55

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 5 Module Recovery/Recycling Refrigerants

4. Recovery from mobile - air-conditioning system

Vapor transfer procedures:

Mobile air-conditioning systems are normally equipped with service valves on
compressor’s high and low pressure side. The refrigerant charge on such system is rather
small and therefore only vapor transfer is required.

• Connect the hose from the recovery unit’s suction/inlet side to the air-conditioning
system’s compressor low-pressure side and the discharge hose to the vapor valve on
the recovery cylinders.

• Run the recovery unit for 3 - 5 min.
• Connect another hose to the system’s high pressure side and complete the recovery.
• Run the recovery unit until pressure gauges read 0.6 bar. Vapor recovery

Note: See example below:

56

Information Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 5 Module Recovery/Recycling Refrigerants

a. Service valve operation

Compressor low-side or suction service valve. If valve stem is turned all the way in, it
closes off the connection from the compressor to the suction line. In this position, if valve is
removed from compressor, suction line remains sealed. If valve stem is turned out as far as
possible, it closes off the opening called the “charging and gauge port.” This makes it possible
to install compound gauge or charging line.

a. Compressor high-side service valve

The compressor high-side service valve provides a shutoff between the compressor
and the condenser. It also provides an opening for a high-pressure gauge or a gauge manifold.
With the valve closed (all the way in), it is possible to disconnect the compressor from the
condenser without any leakage of refrigerant from the condenser. When the valve stem is all
the way out, the opening for the gauge is closed.

57

Operation Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 2 Module Recovery/Recycling Refrigerants

Perform Recovery/Recycling Operation Using Van
Steenburgh Recovery/Recycling Machine

Equipment: 4. uncoded tank/cylinder
1. refrigerant identifier 5. thermometer
2. refrigerant 6. PT chart
3. unlabeled tank/cylinder 7. Operator Manual

CAUTION: Never mix refrigerants. Be sure unit is set up for the refrigerant you are
about to recover.

WARNING: Use only authorized refillable refrigerant tanks. Use of other tanks could
cause personal injury and void the warranty.

Getting started:

1 Make sure that the R/R machine is connected to proper voltage.
2 Hook the vacuum pump to both inlet and outlet fitting of R/R machine and pull a vacuum

for approximately 5-7 minutes. Make sure that the inlet and outlet valves are open. The
center switch must be in the pump out position.
3 After the evacuation of the R/R machine, unplug the machine and place the center
switch to recycle position and close inlet and outlet valves.
4 Evacuate the recovery tank for 5 minutes by hooking a vacuum pump to the vapor and
liquid valves of the cylinder.
5 The R/R machine and recovery tank is now ready to accept refrigerant.

Note: Always evacuate R/R machine and recovery tank if you will recover/recycle
another type of refrigerant

Operational procedure:
1 Plug in R/R machine to proper to proper voltage.
2 Connect hose to inlet valve of the machine and the other end to the source. Use a
gauge at the source as this will show when source is empty.
3 Attach the yellow cable to recovery tank. Connect other hose to outlet valve of the R/R
machine and the other end of the hose to the vapor port of the recovery tank.
4 Turn compressor and recycle switch on and open inlet valve half turn. If recycling
liquid regulate suction gauge pressure to 20-25 psi for 2-3 minutes, open the inlet
valve fully.
5 Open outlet valve of R/R machine. Open vapor valve of recovery tank.

58

Operation Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 2 Module Recovery/Recycling Refrigerants

6 When source is empty of liquid, turn vapor switch on. Leave on until source and R/R
machine have equalized at 3-4 psi.

7 When equalized, turn vapor switch off and unit will pump down to approximately 5"
vacuum. If additional vacuum is required, use the compressor momentary contact.

8 Pump out to clear unit by closing inlet valve, center switch to pump out and vapor
switch on and outlet valve open. Unit will pump down to 5" vacuum and shut off.

9 Turn compressor off and use the compressor momentary switch to pull R/R machine
into 10" vacuum.

10 Close the outlet valve, put center switch to recycle and turn vapor switch on. Unit will
equalize. If positive pressure remains after equalize, repeat pump out procedure.

Perform oil out procedure:

The oil out procedure is very important. By performing oil out frequently, you will keep
the separated oil below the level of the chamber entry point and assure that the oil/moisture
will be purged out of the R/R machine.

1. Close inlet valve and let machine pump down and shut off.
2. Turn compressor switch off and by using the recycle/pump out switch, add 2-3 psi to

suction gauge. Do this by flipping switch to pump out position and returning to recycle
position.
3. Put a container under the oil out valve and slowly open valve.
4. When oil stops draining, close the oil out valve.

59

Operation Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 2 Module Recovery/Recycling Refrigerants

Method of Recovery/Recycling Operation Using Van
Steenburgh Recovery/Recycling Machine

Liquid Recovery Method

ALTERNATIVE CONNECTION
FOR “PUSH - PULL”

OUT

60

Operation Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 2 Module Recovery/Recycling Refrigerants

OUT

61

Operation Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No.3 Module Recovery/Recycling Refrigerants

Troubleshooting Guide: Recovery Operation

SYMPTOM CAUSE REMEDY

1. Recovery compressor • Power cord not plugged • Plug in cord, check circuit
does not start in or no power at plug for power
Recycle switch is on or
main power switch is off • Be sure recycle switch is
off and main power is on

• Tank full light is on • Change tank
• High pressure light is
• Recalibrate weight
platform

• Check valves on tank to
be sure they are open

on • Check scale calibration
• Call factory
• Bad components—start
switch, relay, • Open both tank valves
compressor, etc. • Call factory

2. Runs a short time, but • Tank valves not open
does not complete
recovery • Low oil level in
compressor

• Bad components, • Call factory
compressor, relay, etc.

3. Runs but won’t shut • Leak In vehicle system • Pressure must be present
off in manifold gauges before
• Oil drain valve not starting recovery
closed operation

• Bad components, • Close both valves
vacuum switch, etc. • Call factory

62

Operation Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 3 Module Recovery/Recycling Refrigerants

RECYCLING OPERATION

SYMPTOM CAUSE REMEDY

1. Refrigerant pump • Power cord not plugged • Plug in cord, check circuit
does not appear to in or no power at plug for power
be running
• Main power switch off • Turn on
• Tank valves not open • Open valves
• Call factory
• Faulty components,
pump, switch, etc.

2. Bubbles will not clear • Tank valves not open • Open valves
in moisture indicator
• Not enough refrigerant • Recover more refrigerant
in tank—must have 15 before recycling
Ibs. minimum

3. Moisture indicator wilt • Wet or plugged filter • Remove and replace filter
not turn green after 3 cartridge cartridge. Be sure to pull
hours of recycling a vacuum
• Not enough refrigerant
in tank—must have 15 • Recover more refrigerant
Ibs. minimum before recycling

• Faulty moisture • Remove and replace
indicator moisture indicator

63

Operation Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 3 Module Recovery/Recycling Refrigerants

Troubleshooting (VAN Steenburg Recycling Machine)

PROBLEM SOLUTION
1. Unit won’t accept refrigerant
• Check inlet ball valve
2. System “Pulls Slowly” • Check that cable is attached to recycle

3. Oil in lines cylinder
• Make sure recycle cylinder is not full
• Check valves in hoses

• Checked to ensure you are hooked to
liquid side of source

• Low ambient temperature, apply heat
to source

• Check hoses for restrictions
• Connecting hose to source to long

• Oil out operation has not been
completed on a regular basis.
Separator chamber is full and oil has
migrated though system

64

Job Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

Recovery/Recycle Refrigerant Using Van Steenburgh
Recycling Machine in Domestic Refrigeration and
Window Air Conditioner

I. Equipment, instruments, tools and material needed.

1. Equipment: 3. Tools:
• Domestic refrigeration unit • Tap line valve/piercing valve
• Window air-conditioning unit • Access valve
• VS recovery machine (VS-220) • Tubing tools
• Vacuum pump
• Oxy acetylene equipment 4. Materials:
• Appropriate refrigerant cylinder
2. Instruments: • Appropriate recovery tank

• Electronic leak detector
• Weighing scale
• Gauge manifold

A. Recovery and Recycling Procedures: Observation
Checklist
1. Prepare the required materials, equipment, instruments, tools
and personal protective equipment. YES NO N/A

2. Set-up recovery and recycling machine
Note: Pls. Refer manual of recovery and recycling machine.
3. Connect recycler to proper voltage
4. Attach hose to ¼” flare fitting labeled inlet.
5. Attach other end to the source and purge. Note: Use a gauge

at the source as this will show when source is empty.
6. Attach cable to recycle cylinder and one end of hose to ¼” flare

fitting labeled outlet. Attach other end of hose to vapor part on
cylinder.

65

Job Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

A. Recovery and Recycling Procedures: Observation
Checklist
7. Attach cable to recycle cylinder and one end of hose to ¼” flare
fitting labeled outlet. Attach other end of hose to vapor part on YES NO N/A
cylinder.

8. Turn compressor switch and recycle switch on and open inlet
valve. If recycling liquid regulate suction gauge pressure to 20-
25 psi, 2-3 minutes before opening the valve fully.

9. Open outlet valve and purge hose. Open vapor valve on
recycle cylinder.

10. When source is empty of liquid, turn vapor switch on. Note:
Leave on until source and recycler have equalized at 3-4 psi.

11. When equalized turn vapor switch off and unit will pump down
to approximately 5” vacuum. If additional vacuum is required
use the compressor momentary switch.

12. Pump out to clear unit by closing inlet valve, counter switch to
pump out and vapor switch on and outlet valve open. Note:
Unit will pump down to 5” vacuum and shut-off.

13. Turn compressor off and use the compressor momentary
switch to pull recycler into 10” vacuum.

14. Then close outlet valve, put center switch to recycle and turn
vapor switch on. Unit will then equalize.

Note: If positive pressures remains after equalize repeat pump out
procedure.

15. Then close outlet valve, put center switch to recycle and turn
vapor switch on. Unit will then equalize.

Note: If positive pressures remains after equalize repeat pump out
procedure.

16. Fill-up the worksheet form to complete the job.

17. Perform housekeeping.

66

Job Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 4 Module Recovery/Recycling Refrigerants

Observation
Checklist

YES NO N/A

B Maintenance (Van Steen Burgh Recycling Machine)Oil
Compressor

Note:Recycle must be of “0” psi to check oil level and to add oil to
the compressor. If oil level is below bottom of sight glass of oil
must be added.

18. Locate the valve on the front of unit labeled comp. oil

19. Attach one end of hose to fitting and other end to oil supply

20. Hold compressor momentarily switch down until a small
vacuum is indicated on suction gage.

21. By opening comp. Oil valve oil will be pulled into compressor.
Proper oil level is from bottom of the sight glass to ¼ full.

67

Job Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 5 Module Recovery/Recycling Refrigerants

Recovery/Recycle Refrigerant Using Van Steenburgh
Recycling Machine in Automotive Air-conditioning
Vehicle

I. Equipment, instruments, tools • Weighing scale
and material needed. • Gauge manifold

1. Equipment: 3. Tools:
• Domestic refrigeration unit • Tap line valve/piercing valve
• Window air-conditioning unit • Access valve
• VS recovery machine (VS-220) • Tubing tools
• Vacuum pump
• Oxy acetylene equipment 4. Materials:
• Appropriate refrigerant cylinder
2. Instruments: • Appropriate recovery tank
• Electronic leak detector

A. Recovery and Recycling Procedures: Observation
Checklist
1. Prepare the required materials, equipment, instruments, tools
and personal protective equipment. YES NO N/A

2. Ask instructor of the service manual of recovery and recycling
machine.

3. Set-up recovery and recycling machine
4. Connect recycler to proper voltage
5. Attach hose to ¼” flare fitting labeled inlet.
6. Attach other end to the source and purge. Note: Use a gauge

at the source as this will show when source is empty.
7. Attach cable to recycle cylinder and one end of hose to ¼” flare

fitting labeled outlet. Attach other end of hose to vapor part on
cylinder.

68

Job Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 5 Module Recovery/Recycling Refrigerants

A. Recovery and Recycling Procedures: Observation
Checklist
8. Turn compressor switch and recycle switch on and open inlet
valve. If recycling liquid regulate suction gauge pressure to 20- YES NO N/A
25 psi, 2-3 minutes before opening the valve fully.

9. Open outlet valve and purge hose. Open vapor valve on
recycle cylinder.

10. When source is empty of liquid, turn vapor switch on. Note:
Leave on until source and recycler have equalized at 3-4 psi.

11. When equalized turn vapor switch off and unit will pump down
to approximately 5” vacuum. If additional vacuum is required
use the compressor momentary switch.

12. Pump out to clear unit by closing inlet valve, counter switch to
pump out and vapor switch on and outlet valve open. Note:
Unit will pump down to 5” vacuum and shut-off.

13. Turn compressor off and use the compressor momentary
switch to pull recycler into 10” vacuum.

14. Then close outlet valve, put center switch to recycle and turn
vapor switch on. Unit will then equalize.

Note: If positive pressures remains after equalize repeat pump out
procedure.

15. Perform oil out procedure.

Note: Be sure to perform oil out procedure frequently during
recycle procedure.

16. Fill-up the worksheet form to complete the job.

17. Perform housekeeping.

69

Job Sheet Unit Recover/Recycle Refrigerants of RAC Systems
No. 5 Module Recovery/Recycling Refrigerants

Observation
Checklist

YES NO N/A

B Maintenance (Van Steen Burgh Recycling Machine)Oil
Compressor

Note:Recycle must be of “0” psi to check oil level and to add oil to
the compressor. If oil level is below bottom of sight glass of oil
must be added.

18. Locate the valve on the front of unit labeled comp. oil

19. Attach one end of hose to fitting and other end to oil supply

20. Hold compressor momentarily switch down until a small
vacuum is indicated on suction gage.

21. By opening comp. Oil valve oil will be pulled into compressor.
Proper oil level is from bottom of the sight glass to ¼ full.

70

Competency Unit Recover/Recycle Refrigerants of RAC Systems
Assessment Module Recovery/Recycling Refrigerants

NAME: Date:

COMPETENCY: Recovery/Recycling of Refrigerants TEST ATTEMPT
1ST 2ND 3RD

DIRECTIONS LEVEL OVERALL EVALUATION
ACHIEVED
• Ask instructor to assess PERFORMANCE LEVEL
your competencies of the 4
critical performance 3 CAN PERFORM THIS SKILL WIITHOUT SUPERVISION AND WITH
criteria listed below. 2 ADAPTABILITY TO PROBLEM SITUATIONS
1 CAN PERFORM THIS SKILL SATISFACTORILY WITHOUT ASSISTANCE
• You will be evaluated 0 OR SUPERVISION.
using the guide on the CAN PERFORM THIS SKILL SATISFACTORILY WITH SOME
other side ASSISTANCE & SUPERVISION
CAN PERFORM PARTS OF THIS SKILL SATISFACTORILY WITH FULL
ASSISTANCE.

CANNOT PERFORM THIS SKILL

INSTRUCTOR WILL INITIAL LEVEL ACHIEVED

PERFROMANCE STANDARD PERFORMANCE
LEVEL
1. Identify refrigerants using identifier
YES NO N/A
• Relevant data is gathered on unit to be recovered recycled
• Unit is determined whether to be subjected to refrigerant recovery/recycle.
• Apply safety measure

2. Set up equipment for recover/recycling

• Prepare, instruments, tools and accessories based on job requirements
• Set up equipment, instruments and tools according to manufacturer’s

recommendations

3. Recover/recycling refrigerants
• Observe safety measures in recovering/recycling of refrigerants
• Achieve optimum recovery/recycling of refrigerants
• Identify and label recovered refrigerant in the tank prior to recycling
• Perform refrigerant recovery/recycling according to manufacturer’s

recommendations

• Remove contaminants from the system as a result of recycling based on

instrument readings

• Operate and maintain recovery/recycling machine in accordance with

manufacturer’s recommendations

71

A Joint Project of:
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
Environmental Management Bureau
Philippine Ozone Desk
and
TECHNICAL EDUCATION AND SKILLS DEVELOPMENT AUTHORITY
National Institute for Technical Vocational Education and Training

Contracting Institution:

Department of Environment and Natural Resources
Environmental Management Bureau
Philippine Ozone Desk

Implementing Institution:

Technical Education and Skills Development Authority
National Institute for Technical Vocational Education and Training

© TESDA, 2004

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