Water-Cooled Refrigerant Recovery and Recycling Units: Operation & Maintenance

WATER-COOLED REFRIGERANT
RECOVERY AND RECYCLING UNITS
OPERATION & MAINTENANCE Supersedes: 50.40-OM1 (904) Form 50.40-OM1 (713)
LD17585
PORTABLE
RECOVERY
PAK™
LD17584
EASYTANK™
LD17583
RSR UNITS
Issue Date:
July 17, 2013
FORM 50.40-OM1 (713)
ISSUE DATE: 07/17/2013
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During installation, operation maintenance or service, death to themselves and people at the site.
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, This document is intended for use by owner-authorized
materials under pressure, rotating components, and operating/service personnel. It is expected that these
both high and low voltage. Each of these items has the individuals possess independent training that will en-
potential, if misused or handled improperly, to cause able them to perform their assigned tasks properly and
bodily injury or death. It is the obligation and respon- safely. It is essential that, prior to performing any task
sibility of operating/service personnel to identify and on this equipment, this individual shall have read and
recognize these inherent hazards, protect themselves, understood this document and any referenced mate-
and proceed safely in completing their tasks. Failure rials. This individual shall also be familiar with and
to comply with any of these requirements could result comply with all applicable governmental standards and
in serious damage to the equipment and the property in regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation Identifies a hazard which could lead to

which will result in death or serious injury damage to the machine, damage to other
if proper care is not taken. equipment and/or environmental pollu
tion if proper care is not taken or instruc
tions and are not followed.
Indicates a potentially hazardous situa Highlights additional information useful

tion which will result in possible injuries to the technician in completing the work
or damage to equipment if proper care is being performed properly.
not taken.
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor
dance with Johnson Controls’ published specifications and must be performed only by a qualified
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.
2 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for contin- these documents, the technician should verify whether
uous product improvement, the information contained the equipment has been modified and if current litera-
in this document is subject to change without notice. ture is available from the owner of the equipment prior
Johnson Controls makes no commitment to update or to performing any work on the chiller.
provide current information automatically to the man-
ual owner. Updated manuals, if applicable, can be ob- CHANGE BARS
tained by contacting the nearest Johnson Controls Ser- Revisions made to this document are indicated with a
vice office or accessing the Johnson Controls QuickLIT line along the left or right hand column in the area the
website at http://cgproducts.johnsoncontrols.com. revision was made. These revisions are to technical in-
Operating/service personnel maintain responsibility for formation and any other changes in spelling, grammar
the applicability of these documents to the equipment. or formatting are not included.
If there is any question regarding the applicability of
JOHNSON CONTROLS 3
FORM 50.40-OM1 (713)
THIS PAGE INTENTIONALLY LEFT BLANK.
4 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION..................................................................................................................................7
Inspection – Damage – Shortage................................................................................................................... 7
Safety Summary................................................................................................................................................ 7
Mechanical Specifications – RSR Models......................................................................................................... 8
Mechanical Specifications – Portable Recovery PAK™.................................................................................. 11
Mechanical Specifications – Easy Tank™....................................................................................................... 12
SECTION 2 - OPERATION......................................................................................................................................13
General............................................................................................................................................................ 13
Prior to Starting Refrigerant Recovery............................................................................................................ 13
Operation of Refrigerant Storage/Recycle System......................................................................................... 15
Liquid Transfer – Refrigeration Unit to RSR Storage Vehicle.......................................................................... 15
Detection and Removal of Non‑Condensible Gases....................................................................................... 17
Charging Refrigeration Unit with Refrigerant From RSR Unit......................................................................... 18
SECTION 3 - DIAGRAMS........................................................................................................................................23
SECTION 4 - MAINTENANCE PROCEDURES......................................................................................................29

General............................................................................................................................................................ 29
Compressor Model CFC 1000......................................................................................................................... 31
SECTION 5 - REPLACEMENT PARTS AND KITS.................................................................................................33

Compressor Replacement............................................................................................................................... 35
Compressor Model 16799 (RST‑2240, RSR‑2250 & RP‑2400)...................................................................... 35
Vacuum Pump – Model CRR‑1 ...................................................................................................................... 43
Repairing Oil Leaks ........................................................................................................................................ 45
Repairing Vacuum Leaks................................................................................................................................ 45
JOHNSON CONTROLS 5
FORM 50.40-OM1 (713)
LIST OF FIGURES
FIGURE 1 - YORK RSR System Flow Diagram��15
FIGURE 2 - Wiring Diagram RSR-1100V, -1600V, -1100V114, & -1600V114�� 23
FIGURE 3 - Wiring Diagram RSR-2212 & -2222��23
FIGURE 4 - Wiring Diagram Easy PAK RP-1000V, -114V & -2200 ��24
FIGURE 5 - Wiring Diagram RSR-2240, -2250, -4436, -4445 & RP-2400, -3400 �� 24
FIGURE 6 - Piping Diagram RSR-1100V, -1600V, -1100V & -1600V114�� 25
FIGURE 7 - Piping Diagram RSR-2212, -2222, -2240, -4436, -4445��26
FIGURE 8 - Piping Diagram Easy-Pak RP-1000V, -114V, -2200, -2400 & -3400�� 27
FIGURE 9 - Compressor Replacement Parts – Model CFC-1000��33
FIGURE 10 - Compressor Replacement Parts – Discontinued Model 16799�� 37
FIGURE 11 - Compressor Replacement Parts – Models RA and CK�� 40
FIGURE 12 - Vacuum Pump Replacement Parts – Model CRR-1��43
FIGURE 13 - Compressor Data Sheet – Model 51VSM��46
FIGURE 14 - Compressor Dimensions – English – 51VSM��47
FIGURE 15 - Compressor Dimensions – Metric – 51VSM��47
FIGURE 16 - Compressor Parts – 51VSM��48
FIGURE 17 - Compressor Maintenance Instructions – 51VSM��50
FIGURE 18 - Photo, Compressor, Belt Driven – 51VSM��51
LIST OF TABLES
TABLE 1 - RSR Specifications – Standard��9

TABLE 2 - RSR Specifications – Metric��10
TABLE 3 - Recovery PAK Specifications (Standard and Metric)�� 11
TABLE 4 - Standard Tank Options (Standard and Metric)��12
TABLE 5 - Settings for Pressure Safety Control Switches��13
TABLE 6 - Operation Settings��16
TABLE 7 - Final Vacuum/EPA Regulatiions��17
TABLE 8 - Pressure Difference for Determining Presence of Non-Condensible Gases�� 18
TABLE 9 - Vapor Pressure – CFC-11, CFC-12, CFC-22 and CFC-500�� 18
TABLE 10 - Vapor Pressure – HCFC-123 and HFC-134a��19
TABLE 11 - Vapor Pressure – CFC-114 and CFC-502��20
TABLE 12 - Vapor Pressure (Metric (kPa) – CFC-11, CFC-12, CFC-22 and CFC-500�� 21
TABLE 13 - Vapor Pressure (Metric) – HCFC-123 and HFC-134a��21
TABLE 14 - Vapor Pressure (Metric) – CFC-114 and CFC-502��22
TABLE 15 - Compressor Replacement Parts – Model CFC-1000��34
TABLE 16 - Compressor Torque Specifications – Model CFC-1000�� 35
TABLE 17 - Compressor Piston Selective Fits��35
TABLE 18 - Torque Values for Model 16799 Compressor��36
TABLE 19 - Compressor Replacement Parts – Discontinued Model 16799�� 38
TABLE 20 - Model D799 Compressor Parts (Old Style)��39
TABLE 21 - Compressor Three Cylinder Model RA & CK – BM-99301, -99302 & -99303�� 41
TABLE 22 - Vacuum Pump Replacement Parts – Model CRR-1��44
TABLE 23 - Compressor Parts – 51VSM��49
TABLE 24 - Compressor Refrigerating Capacity – 51VSM: R134a, BTU/HR�� 51
TABLE 25 - Compressor Refrigerating Capacity – 51VSM: R22, BTU/HR�� 51
TABLE 26 - Compressor Cross Reference Chart – 51VSM��52
TABLE 27 - Compressor Specifications – 51VSM��52
TABLE 28 - SI Metric Conversion��53
6 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
SECTION 1 - INTRODUCTION 1
The YORK Refrigerant Recovery and Recycling units SAFETY SUMMARY
are designed to handle all of the major refrigerants
Installation and servicing of air conditioning equipment
used in air conditioning and refrigeration units. These
and support equipment can be hazardous because of
include R‑11, R‑114, R‑123, R‑12, R‑134a, R‑500,
system pressures and the presence of dangerous volt-
R‑502 and R‑22.
ages. Only trained and qualified service personnel
Refrigerant storage vessels are of a low pressure design should install, repair, or service such equipment.
for R‑11, R‑114 and R‑123 and a high pressure design
• When using or servicing RSR units, observe pre-
for the remaining refrigerants.
cautions in the literature, as well as those on tags
Two styles of units are available. One is a self and labels attached to the equipment.
contained “RSR”; the other is a combination of a “Por- • Follow all safety codes. Wear glasses and work
table Recovery Pak” – complete with controls – that gloves when handling refrigerants.
is used in combination with an “Easy Tank” storage
vessel complete with pressure safety controls and • Before performing service or maintenance opera-
liquid float switch. tions on this unit, turn off main power switch and
disconnect power cord. Electrical shock could
INSPECTION – DAMAGE – SHORTAGE cause personal injury.
The unit shipment should be checked on arrival to see • Only the storage cylinder, interconnecting hose
that all major pieces, boxes and crates are received. set, and filter‑driers supplied with the RST unit
The unit should be checked on the trailer or rail car may be used for hookup. Use of unspecified
when received, before unloading, for visible signs of equipment could result in operator injury and/or
damage. Any damage or signs of possible damage release of refrigerant to the atmosphere.
should be reported to the transportation company im-
mediately for their inspection. Also advise the Johnson • Avoid using an extension cord because the exten-
Controls Regional or District Office so a Johnson Con- sion cord may overheat. If it is necessary to use an
trols representative can assist in filing damage claims. extension cord, the cord shall be #10 AWG mini-
JOHNSON CONTROLS WlLL NOT BE RESPON- mum.
SIBLE FOR ANY DAMAGE IN SHIPMENT, OR AT • Do not use this equipment near spilled or open
JOB SITE, OR LOSS OF PARTS. containers of gasoline or other flammable prod-
ucts.
If damage is found, Johnson Controls must be notified
and action must be taken to prevent further damage or • This equipment should be used in a location with
deterioration of the machinery, i.e.: a slow refrigerant mechanical ventilation that provides at least four
leak exposure of internal parts to atmosphere, etc. (4) air changes per hour.
When received at the job site, all containers should be To avoid damaging the unit or the environment:
opened and contents checked against the packing list.
• The unit must be operated with the storage cylin-
Any material shortage should be reported to Johnson
der connected and valves fully open.
Controls immediately. (Refer to Shipping Damage
Claims, Form 50.15‑NM.) • Use only the hoses supplied with the unit.
• Shut off the filter‑drier valves before removing
the filter drier.
JOHNSON CONTROLS 7
FORM 50.40-OM1 (713)
SECTION 1 - iNTRODUCTION
MECHANICAL SPECIFICATIONS – RSR Heater (CFC‑11, CFC‑114 And HCFC‑123 Only

MODELS The unit has a 1000‑watt heater designed for 115V‑1 ‑
The YORK Refrigerant/Recycling System is a self‑ 50/60 power and capable of separating oil from refrig-
contained package consisting of a refrigerant compres- erant to less than 1000 ppm oil.
sor or vacuum pump, with oil separator, storage receiv-
er, heater, water-cooled condenser, filter drier and nec- Condenser
essary valves and hoses to remove, replace and distill The water-cooled condenser is a tube‑in‑tube design.
CFC and HCFC Refrigerants. All necessary controls The condenser is permanently mounted with refriger-
and safety devices are a permanent part of the system. ant lines piped to the system. 3/4‑inch hose bib con-
The complete system is portable, being mounted on nections are provided for field connection to the water
swivel casters with lock brakes. supply.
Refrigerant Compressor (High Pressure STORAGE RECEIVER

Units)
The receivers are ASME certified. Each contains inlet
The high pressure units for refrigerants CFC‑12, and outlet valves and connections.
HCFC‑22, CFC‑500, CFC‑502 and HFC‑134a feature
a reciprocating compressor that is capable of pulling Safety Devices
a vacuum to a level which is in accordance with EPA A high‑pressure switch is installed to protect the re-
requirements (See Table 7 on page 17). ceiver and compressor against over pressurization. The
relief device is per ASME specifications. Float switch
Refrigerant Vacuum Pump
cuts unit off when tank is 80% full of liquid refrigerant.
The low pressure units for refrigerants CFC‑11,
HFC‑123 and CFC‑114 utilize a vacuum pump to Filter Drier
achieve the vacuum levels required by the EPA. The filter drier is permanently mounted on the system
The term compressor will be used synonymously with so that all gas entering or leaving the receiver will be
vacuum pump throughout this document except where filtered. The filter is a replaceable core type, capable of
specific references are necessary. removing moisture to less than 50 ppm.
Controls
Oil Separator And Heater
Oil separator includes drain valve and 25 watt heater. Mounted toggle switches are used to operate the unit
and permit all safety devices to protect it.
Storage Receiver
Gauges
Several storage receiver sizes are available (See Table
1 on page 9). The vessel is a horizontal type with Unit‑mounted gauges allow the technician to monitor
two sight glasses installed to check liquid level. The suction and discharge pressure of the RSR system.
receiver is designed and stamped in accordance with
the ASME Boiler and Pressure Vessel Code. The ves-
sel is pitched toward the receiver drain to allow total
removal of liquid.
Valves And Hoses

The unit has permanent‑mounted ball valves to allow
the unit to remove, replace, or distill refrigerant without
having to break hoses to the chiller. Eight feet of heavy
duty refrigerant hoses with flare fittings are included to
allow connection to the chiller.
8 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
Table 1 - RSR SPECIFICATIONS – STANDARD

MODEL
1
DESCRIPTION
RSR‑1100V RSR‑1600V RSR‑1100V114 RSR‑1600V114
CFC‑11 CFC‑11
Refrigerant CFC‑114 CFC‑114
HCFC‑123 HCFC‑123
Refrigerant Storage Refrigerant Lbs Refrigerant Lbs Refrigerant Lbs Refrigerant Lbs
Capacity (Lbs.): CFC‑11 1053 CFC‑11 1500
CFC‑114 1053 CFC‑114 1500
80% Full at 90° F HCFC‑123 1053 HCFC‑123 1500
Working Pressure (PSI) 50 50 50 50
Horsepower 1 1 2 2
115V‑1‑60 115V‑1‑60 115V‑1‑60 115V‑1‑60
Standard Voltages 208V‑1‑60 208V‑1‑60 208V‑1‑60 208V‑1‑60
230V‑1‑60 230V‑1‑60 230V‑1‑60 230V‑1‑60
Plugs Included Yes Yes Yes Yes
Weight (Lbs.) 700 850 700 850
L x W x H (Inches) 61 x 24 x 53 84 x 24 x 53 61 x 24 x 53 84 x 24 x 53
Wheels Included Yes Yes Yes Yes
Relief Valves (2) 1-1/4” FNPT (2) 1-1/4” FNPT (2) 1-1/4” FNPT (2) 1-1/4” FNPT
ASME Approved Yes Yes Yes Yes
MODEL
DESCRIPTION
RSR‑2212 RSR‑2222 RSR‑4436 RSR‑4445
CFC‑12, 500 & 502 CFC‑12, 500 & 502 CFC‑12, 500 & 502 CFC‑12, 500 & 502
Refrigerant HCFC‑22 HCFC‑22 HCFC‑22 HCFC‑22
HFC‑134a HFC‑134a HFC‑134a HFC‑134a
Refrigerant Lbs Refrigerant Lbs Refrigerant Lbs Refrigerant Lbs
CFC‑12 1240 CFC‑12 2166 CFC‑12 3976 CFC‑12 5684
Refrigerant Storage
HCFC‑22 1126 HCFC‑22 1966 HCFC‑22 3612 HCFC‑22 4582
Capacity (Lbs.)
80% Full at 90°F CFC‑500 970 CFC‑500 1937 CFC‑500 3503 CFC‑500 4386
CFC‑502 1170 CFC‑502 2044 CFC‑502 3752 CFC‑502 4630
HFC‑134a 1140 HFC‑134a 1992 HFC‑134a 3657 HFC‑134a 4635
Working Pressure (PSI) 50 300 300 300
Horsepower 1‑1/2 1‑1/2 10 10
115V‑1‑60 115V‑1‑60
230V‑1‑60 230V‑1‑60
Plugs Included Yes Yes 4 Prong 4 Prong
Weight (Lbs.) 1325 1600 3200 4200
L x W x H* (Inches) 84 x 24 x 53-1/8 93‑1/4 x 30 x 60-1/8 119 x 36 x 77 112 x 42 x 90
Wheels Included Yes Yes Optional Optional
Relief Valves (2) 5/8” Flare (2) 3/4” FNPT (2) 1” FNPT (2) 1” FNPT
*Wheels add 13" to overall height dimension of RSR-4436 and 4445
JOHNSON CONTROLS 9
FORM 50.40-OM1 (713)
Table 2 - RSR SPECIFICATIONS – METRIC

MODEL
DESCRIPTION
RSR‑1100V RSR‑1600V RSR‑1100V114 RSR‑1600V114
CFC‑11 CFC‑11
Refrigerant CFC‑114 CFC‑114
HCFC‑123 HCFC‑123
Refrigerant Storage Refrigerant kg Refrigerant kg Refrigerant kg Refrigerant kg
Capacity (kg) CFC‑11 478 CFC‑11 680
CFC‑114 478 CFC‑114 680
80% Full at 32° C HCFC‑123 478 HCFC‑123 680
Working Pressure (kPA) 345 345 345 345
Kilowatts 0.75 0.75 1.5 1.5
115V‑1‑60 115V‑1‑60 115V‑1‑60 115V‑1‑60
230V‑1‑60 230V‑1‑60 230V‑1‑60 230V‑1‑60
Plugs Included Yes Yes Yes Yes
Weight (kg) 318 386 318 386
L x W x H (mm) 1549 x 609 x 1386 2134 x 609 x 1346 1549 x 609 x 1346 2134 x 609 x 1346
Relief Valves (2) 1-1/4” FNPT (2) 1-1/4” FNPT (2) 1-1/4” FNPT (2) 1-1/4” FNPT
MODEL
DESCRIPTION
RSR‑2212 RSR‑2222 RSR‑4436 RSR‑4445
CFC‑12, 500 & 502 CFC‑12, 500 & 502 CFC‑12, 500 & 502 CFC‑12, 500 & 502
Refrigerant HCFC‑22 HCFC‑22 HCFC‑22 HCFC‑22
HFC‑134a HFC‑134a HFC‑134a HFC‑134a
Refrigerant kg Refrigerant kg Refrigerant kg Refrigerant kg
CFC‑12 562 CFC‑12 992 CFC‑12 1804 CFC‑12 2265
Refrigerant Storage HCFC‑22 511 HCFC‑22 900 HCFC‑22 1638 HCFC‑22 2057
Capacity (kg):
CFC‑500 440 CFC‑500 878 CFC‑500 1589 CFC‑500 1995
80% Full at 32°C
CFC‑502 531 CFC‑502 927 CFC‑502 1702 CFC‑502 2137
HFC‑134a 517 HFC‑134a 903 HFC‑134a 1659 HFC‑134a 2082
Working Pressure (kPA) 345 2069 2069 2069
Kilowatts 1.1 1.1 7.5 7.5
115V‑1‑60 115V‑1‑60
230V‑1‑60 230V‑1‑60
Plugs Included Yes Yes 4 Prong 4 Prong
Weight (kg) 601 726 1452 1905
L x W x H* (mm) 2134 x 609 x 1349 2368 x 762 x 1527 3022 x 914 x 1956 2845 x 1067 x 2286
Wheels Included Yes Yes Optional Optional
Relief Valves (2) 5/8” Flare (2) 3/4” FNPT (2) 1” FNPT (2) 1” FNPT
*Wheels add 330 mm to overall height dimension of RSR-4436 and 4445.
10 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
MECHANICAL SPECIFICATIONS – PORTABLE The condenser is permanently mounted with refriger-

RECOVERY PAK™ rant lines piped to the system. 3/4‑inch hose bib con- 1
nections are provided for field connection to the water
Valves and Hoses
supply.
The unit includes one input/one output refrigerant
valves, and two refrigerant hoses, 8’ long. Oil Separator and Heater
Oil separator includes a drain valve and 25 watt heater.
Filter
It includes replaceable, catch‑all type filters with Controls
singlecore, 48 cubic inches (786 ccm).
An on/off switch; electrical cord and plug are provided.
Refrigerant Compressor (High Pressure
Units) Safeties
The high pressure units for refrigerants CFC‑12, Unit safeties include high pressure cutoff (adjustable),
HCFC‑22, CFC‑500, CFC‑502 and HFC‑134a feature.a and vacuum cutoff (adjustable). With a YORK refrig-
reciprocating compressor that is capable of pulling a erant EasyTank™, integral safeties include heater cut-
vacuum to a level which is in accordance with EPA off (low pressure tanks only) pressure relief valve and
regulations. (See Table 7 on page 17.) a liquid level switch. The pressure relief valves meet
ASME specifications.
Refrigerant Vacuum Pump
The low pressure units for refrigerants CFC‑11, Tanks
HFC‑123 and CFC‑114 utilize a vacuum pump to Nine standard EasyTank™ receivers are available,
achieve the vacuum levels required by the EPA. from 191 to 4895 pound capacities, plus custom de-
signed receivers from 50 pound capacity and up.
The term compressor will be used synonymously with
vacuum pump throughout this document except where Features
specific references are necessary.
The unit has a solid frame construction. The unit is
Condenser equipped with four heavy duty wheels for mobility.
The water‑cooled condenser is a tube‑in‑tube design. The size and shipping weights are provided in Table 3
on page 11.
Table 3 - RECOVERY PAK SPECIFICATIONS (STANDARD AND METRIC)
MODEL
DESCRIPTION
RP‑1000V RP‑114V RP‑2200 RP‑4400
CFC‑11 CFC‑12, 500 & 502 CFC‑12, 500 & 502
Refrigerant CF-114 HCFC‑22 HCFC‑22
HCFC‑123
HFC‑134a HFC‑134a
Working PSIG 50 50 300 300
Pressure kPA 345 345 2069 2069
HP 1 2 1-1/2 10
Power
KW 0.75 1.5 1.1 7.5
115V‑1‑60 115V‑1‑60 115V‑1‑60
Standard
208V‑1‑60 208V‑1‑60 208V‑1‑60 460V‑3‑60
Voltages
230V‑1‑60 230V‑1‑60 230V‑1‑60
Plugs Included Yes Yes Yes 4 Prong
Lbs 225 225 150 850
Weight
Kg 102 102 68 385
Inches 24 x 24 x 27 24 x 24 x 27 24 x 24 x 28 57 x 29 x 66
LxWxH
mm 610 x 610 x 686 610 x 610 x 686 610 x 610 x 711 1448 x 737 x 1676
JOHNSON CONTROLS 11
FORM 50.40-OM1 (713)
Gauges Gauges
Unit mounted gauges allow the monitoring of the Sight glasses and pressure gauges are included.
suction and discharge pressure of the RSR system.
Wheels
MECHANICAL SPECIFICATIONS – EASY Standard wheels are included for tanks under 3000
TANK™ pounds (1361 kg); custom wheels available for larger
Safeties sizes.
Low‑pressure tanks use heater cutoff, pressure relief Custom Tanks

valve and refrigerant level safeties. High‑pressure
Custom‑made tanks are also available from 50 pounds
tanks use relief valves and liquid level safeties*.
(22.7 kg) storage capacity to as large as required for
*Float switch shuts off recovery unit when tank be-
both high and low pressure refrigerants. Custom com-
comes 80% full of liquid refrigerant.
ponents, controls, safeties, and wheels are available.
Rating
Optional Clean Out Port
The tanks are ASME certified. All tanks contain inlet
An ASME coded access port may be added as an op-
and outlet valves and connections (See Table 4 on page
tion. The port opening is approximately 11” x 19” (279
12).
mm x 482 mm).
Table 4 - STANDARD TANK OPTIONS (STANDARD AND METRIC)
REFRIGERANT STORAGE DIAMETER X LENGTH
APPROXIMATE
CAPACITY:
MODEL REFRIGERANT SHIPING WEIGHT
80% FULL AT 90°F (32°C)
LBS. KG INCHES MM LBS. KG
HCFC‑22 191 86.7 14-3/4 x 49 375 x 1245 68 31
CFC‑11 & 114, HFC‑123 600 272 20 x 52 508 x 1321 210 95
RT‑191 CFC‑11 & 114, HCFC‑123 1053 478 24 x 61 609 x 550 410 186
RT-300
CFC‑11 & 114, HCFC‑123 1500 680 24 x 84 609 x 2134 460 209
RT-600
CFC‑12 1240 563 24 x 84 609 x 2134 1000 454
RT-1100
RT-1600 HCFC‑22 1126 510 24 x 84 609 x 2134 1000 454
RT-2212 CFC‑500 970 440 24 x 84 609 x 2134 1000 454
CFC‑502 1170 530 24 x 84 609 x 2134 1000 454
HFC‑134a 1140 517 24 x 84 609 x 2134 1000 454
CFC‑12 2166 982 30 x 93-1/4 702 x 2368 1300 590
HCFC‑22 1966 906 30 x 93-1/4 702 x 2368 1300 590
RT‑2222 CFC‑500 1937 879 30 x 93-1/4 702 x 2368 1300 590
CFC‑502 2044 928 30 x 93-1/4 702 x 2368 1300 590
HFC‑134a 1992 904 30 x 93-1/4 702 x 2368 1300 590
CFC‑12 3976 1804 36 x 119 914 x 3022 2700 1225
HCFC‑22 3612 1639 36 x 119 914 x 3022 2700 1225
RT‑4436 CFC‑500 3503 1590 36 x 119 914 x 3022 2700 1225
CFC‑502 3752 1702 36 x 119 914 x 3022 2700 1225
HFC‑134a 3652 1748 36 x 119 914 x 3022 2700 1225
CFC‑12 4993 2265 42 x 112 1067 x 2845 3620 1642
HCFC‑22 4535 2057 42 x 112 1067 x 2845 3620 1642
RT‑4445 CFC‑500 4399 1995 42 x 112 1067 x 2845 3620 1642
CFC‑502 4712 2137 42 x 112 1067 x 2845 3620 1642
HFC‑134a 4591 2082 42 x 112 1067 x 2845 3620 1642
12 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
SECTION 2 - OPERATION
GENERAL performance of the RSR condenser and compressor for

the refrigerant being recovered. 2
The function of a Refrigerant Recovery/Recyling Unit
(RSR) is to remove and store refrigerant from any Prior to starting the RSR unit, the pres
machine using the refrigeration cycle and CFC or sure control must be set to the high and
HCFC refrigerants. The refrigerants must be removed low pressure values shown in Table 5 on
from the refrigerant circuit before opening any part of page 13.
the unit for maintenance or repairs. Federal law prohib-
its the venting of refrigerant to the atmosphere.
The RSR is connected to the refrigeration unit by means Check Oil Level
of hoses supplied with the RSR. The RSR compressor
develops a pressure differential between the RSR and RSR Compressor (High Pressure Units)
the refrigeration unit so that liquid refrigerant is forced The oil level should be checked in the sight glass lo-
into a storage vessel used in conjunction with the RSR. cated in the RSR compressor crankcase.
The RSR is equipped with a water cooled condenser A shortage of oil will result in the failure
that is used to condense the refrigerant vapor remain- of the RSR compressor.
ing in the refrigeration unit after the liquid refrigerant
has been removed. For this duty, the RSR compressor
pumps the remaining vapor through the condenser and
the resulting liquid refrigerant flows into the storage
vessel. The oil level should be 1/2 to 3/4 from the bottom of
the sight glass when the RSR compressor is not run-
After the refrigeration unit has been repaired, the pro- ning.
cess is reversed so that refrigerant is pumped back into
the refrigeration unit. All units, Except where Refrigerant 134a is used, come
factory charged with YORK Type “C” oil. Only this
type of oil should be used when adding oil with the ex-
PRIOR TO STARTING REFRIGERANT ception where R‑134a is used in the refrigeration unit.
RECOVERY The Ester based oil is used in conjunction with R‑134a.
Consult the manufacturer’s recommendations for oil to
Set Pressure Safety Control be used in the RSR compressor if R‑134a is used in the
A high/low pressure safety control is wired in the mo- refrigeration system.
tor control circuit. The pressure settings are adjustable
to conform to the design working pressure of the RSR It is recommended that an RSR unit be dedicated for
storage vessel and the upper limit for satisfactory use in recovering only R‑134a. Otherwise the oil in
Table 5 - SETTINGS FOR PRESSURE SAFETY CONTROL SWITCHES
CUT OUT CUT IN

REFRIGERANT
HIGH PRESSURE LOW PRESSURE HIGH PRESSURE LOW PRESSURE
PSIG KPA IN HG KPA PSIG IN HG KPA
CFC‑12/HFC‑134a 150 1034 20 68 Manual Reset 10 34
CFC‑500 180 1241 20 68 Manual Reset 10 34
CFC‑502 250 1724 20 68 Manual Reset 10 34
HCFC‑22 250 1724 20 68 Manual Reset 10 34
CFC‑11/HFC‑123 10 69 29 98 Manual Reset 20 68
CFC‑114 30 207 29 98 Manual Reset 20 68
JOHNSON CONTROLS 13
FORM 50.40-OM1 (713)
SECTION 2 - operation
the RSR compressor and oil separator will have to Filter Dryer Replacement Element
be changed when changing from other refrigerants to The RSR unit contains a filter dryer that removes
R‑134a and when changing back from R‑134a to other moisture, acids, as well as solid particles from the re-
refrigerants. frigerant that is being recovered. The filter dryer con-
See the SECTION 4 - MAINTENANCE PROCE- tains a removable element (Sporlan #RC 4864) that
DURES of this manual for the correct procedure for must be in place before the unit is used.
adding and removing oil from the RSR unit compres- The filter/dryer element must also be changed when:
sor and oil separator.
1. Changing the type of refrigerant being recov-
Check Oil Level in Vacuum Pump (Low Pressure ered.
Units)
2. When the liquid sight glass indicator shows that
The oil level in the vacuum pump should be at the mid- excessive moisture is in the refrigerant.
point of the oil level window.
3. After recovering refrigerant from a refrigeration
Unlike the high pressure units, the oil in the vacuum unit that has had a motor burnout.
pump is not the same as that used in the refrigeration
unit being serviced. A special vacuum pump oil must 4. After the RSR unit has been run for 100 hours.
be used. If the refrigeration unit, from which the refrigerant
is being recovered, has experienced a hermetic com-
Vacuum pumps are tested with DuoSeal® brand oil
pressor motor burn out, or if the liquid sight glass/
and shipped with a full charge to prevent unnecessary
moisture indicator shows excessive moisture in the
contamination. The oil acts both as a lubricant and the
refrigerant, a filter/dryer (Sporlan C‑415) should be
vacuum seal between the rotating components. An
inserted at the end of the RSR liquid refrigerant hose ,
additional supply of oil is furnished with each pump
where it connects to the refrigeration unit liquid con-
with instructions to drain and discard the oil, when it
nection.
becomes contaminated, and replace with the fresh oil.
DuoSeal oil has been especially prepared and is ideally Before the refrigeration unit is recharged, the valve
suited for use in vacuum pumps because of its desir- at the end of the liquid hose and on the refrigeration
able viscosity, low vapor pressure and chemical stabil- unit (at the opposite end of the filter dryer) should be
ity. The vacuum guarantee on all pumps applies only closed. Remove the fllter dryer and replace it with a
when Duoseal oil is used. new filter dryer with the arrow pointing in the direc-
tion of the refrigeration unit.
Oil Contamination
The arrow indicating direction of flow
The most common cause of a loss in efficiency in a should point toward the RSR unit when
vacuum pump is contamination of oil. It is caused by liquid refrigerant moves from the refrig
condensation of vapors and by foreign particles. The eration unit to the RSR storage vessel.
undesirable condensate emulsifies with the oil which
is recirculated and subjected to re‑evaporation during
the normal cycle of pump activity thus reducing the
ultimate vacuum attainable. Some foreign particles and See SECTION 4 - MAINTENANCE PROCEDURES
vapors may form sludges with the oil, impair sealing for specific instructions for changing the filter/dryer
and lubrication and cause eventual seizure. Periodic oil element.
changes are necessary to maintain efficient operation
Connecting Hoses
of the system. The required frequency of changes will
vary with the particular system. Experience with the The refrigerant hoses, furnished with the RSR unit,
process will help you determine the normal period of are connected to the evaporator and condenser of the
operation before an oil change is required. refrigeration. unit as shown in the schematic diagram
shown in Figure 1 on page 15. A third hose, used
See SECTION 4 - MAINTENANCE PROCEDURES with the portable unit only, is connected between the
for Low Pressure Units for the correct procedure to add valve on the top of the storage vessel and the refriger-
or remove oil from the vacuum pump and oil separator. ant connection on the condenser of the portable RSR
unit.
14 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
Only the dedicated storage vessel and interconnecting OPERATION OF REFRIGERANT STORAGE/
hose set supplied with the RSR unit can be used for the RECYCLE SYSTEM
hookup.
Liquid Transfer – Refrigeration Unit to RSR
Use of Unspecified Equipment Could Storage Vehicle
2
Result in Personal Injury and Release of
Refrigerant to the Atmosphere. This method is recommended for the initial phase of
refrigerant recovery. (See Figure 1 on page 15)
To bleed air from the connecting liquid refrigerant
hose:
When using the Portable Recovery Pak, it is manda-
tory that the EasyTank™, manufactured by Johnson 1. With valve 5 closed, crack valve 6 at the evapora-
Controls, be used as the storage vessel. These contain tor.
the proper pressure relief valves, liquid level float 2. Slowly open refrigerant hose connection at 5 until
switch and matching interconnecting wiring for the a very small amount of refrigerant exists at the
safety switches. In order for the Portable Recovery Pak hose connection. (Make sure unit is above 0 psig
to operate, the interconnecting safety wiring must be – if not, do not use this step.)
plugged into the matching socket.
3. Retighten hose fitting at valve 5.
Shipping Charge
To bleed air from the remaining refrigerant hose:
When the unit is shipped from the factory, a holding
charge of dry nitrogen is placed in the storage vessel 1. Close valves 1 and 2.
under a pressure of approximately 5 psig. Prior to first 2. Crack valve 7.
using the RSR unit, the pressure should be relieved to
the atmosphere and the vessel evacuated with a vacuum 3. Bleed refrigerant from hose connection at mani-
pump to a vacuum of 29 inches of mercury. Evacuate fold and retighten hose fitting as above. (Make
using gas connection (connection between valves 1 & sure unit is above 0 psig – if not, do not use this
2), open valves 1, 2, 3, & 4 during evacuation – close step.)
valve 5. (See Figure 1 on page 15)
LD01105
Figure 1 - YORK RSR SYSTEM FLOW DIAGRAM
JOHNSON CONTROLS 15
FORM 50.40-OM1 (713)
Set the valves and pumps as shown in the first column When first starting the vacuum pump on a
of Table 6 on page 16. Start the RSR unit by switch- low pressure system, the suction valve on
ing the toggle switch on the control box to the ON po- the pump should remain closed until the
sition. pump comes up to operating temperature.
If refrigerant vapor is pumped through
When the RSR unit is started, the compressor reduces the pump before the pump is warmed up,
the pressure in the storage vessel. The discharge side a large quantity of refrigerant will dis
of the compressor pressurizes the refrigeration unit solve in the oil. The dissolved refrigerant
through the connection to the condenser. The resulting will superheat and boil off violently as
pressure differential forces the liquid refrigerant from the pump approaches its operating tem
the refrigeration unit into the RSR storage vessel. perature. Excessive oil loss will result.
The transfer of liquid is complete when the level in Intake valve should be opened gradually
the RSR storage vessel, as observed through the sight to prevent sudden refrigerant rush to the
glasses, ceases to rise. Close valve 5 and move the pump and loss of oil from the pump.
RSR toggle switch to the OFF position. Proceed to the
Gas Pump Out. The vacuum pump should never be exposed to a dis-
charge pressure higher then 30 PSIG.
Table 6 - OPERATION SETTINGS
1 2 3 4 5
TO REMOVE TO REMOVE TO REMOVE TO RECHARGE CHILLER
CONTROL
LIQUID GAS FROM OIL FROM STEP 1 – GAS STEP 2 – LIQUID
FROM CHILLER CHILLER RERIGERANT OFF CHARGE
RSR SYSTEM
Valve 1 Open Closed Open Closed
1&4
Valve 2 Closed Open Closed Open
Open or
Valve 3 Open Closed Open Closed
2&3
Valve 4 Closed Open Closed Open
Valve 5 Open Closed Closed Closed Open
Compressor On On On Off On
Water to
Off On Off Off On
Condenser
Heater Off Off On Off On
CHILLER/AIR
CONDITIONER
Valve 6 Open Closed Closed Closed Open
Valve 7 Open Open Open Open Open
Chiller
Off On On On On
Water Pump Either
Condenser One
Off Off On On On
Water Pump
16 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
Gas Pump Out – Refrigeration Unit To Rsr procedure must be repeated until a pressure rise is not
Storage Vessel detected after a five minute waiting period.
After the liquid refrigerant has been removed from the Table 7 - FINAL VACUUM/EPA REGULATIIONS
refrigerant unit, as previously described, the following 2
FINAL
procedure is used to remove the remaining refrigerant DESCRIPTION VACUUM IN.
gas. HG (KPA)
HCFC-22 unit containing less than 200
0 (0)
Set the valves and pumps as shown in column 2 of Lbs. /91 kg of refrigerant
Table 6 on page 16. Start the RSR unit by turning HCFC-22 unit containing more than
10 (33.9)
the toggle switch to the ON position. 200 Lbs./91 kg of refrigerant
On units RSR‑2212, RSR‑2222 and Other high pressure units containing
10 (33.9)
RP‑2200 close compressor suction service less that 200 Lbs. /91kg of refrigerant
valve so that suction pressure does not Other high pressure units containing
15 (51)
exceed 70 psig. more than 200 Lbs./91 kg of refrigerant
Low pressure units (CFC-11, HCFC-
25* (98)
123 & CFC-114)
*=mm Hg absolute
The RSR unit draws refrigerant vapor from the re-
frigeration unit and condenses same in the RSR water DETECTION AND REMOVAL OF
cooled condenser. The liquefied refrigerant flows to NON‑CONDENSIBLE GASES
RSR storage vessel.
After the RSR unit containing the stored refrigerant
WHEN EVACUATING REFRIGERA has equalized such that the machine and stored refrig-
TION UNITS WITH LIQUID CHILLER erant are at the same temperature as the surrounding
AND/OR WATER COOLED CONDENS ambient temperature, the refrigerant can be checked
ERS — During the pumpout procedure, for non‑condensible gases. If the pressure in the stor-
while any remaining liquid refrigerant age vessel, as read on the compressor discharge gauge,
is in contact with unit water tubes, care exceeds the saturation pressure of the refrigerant at the
must be taken to prevent the unit satura ambient temperature by the amount shown in Table 8
tion pressure/temperature from dropping on page 18, there is a need to vent the non‑condens
below the freezing temperature of the ible gases from the Schraeder type valve located on the
water or brine. top of the storage vessel for a period of fifteen seconds.
The procedure should be repeated until the saturation
The operation should continue until a vacuum of the pressure in the storage vessel is within the pressure
value shown in Table 6 on page 16 exists for the range shown in Table 8 on page 18 for the given re-
specified type of refrigeration unit being evacuated. frigerant. The storage vessel and contained refrigerant
During the evacuation process, valve 6 should be allowed to equalize to ambient temperature
should remain open to evacuate the refrig between ventings.
erant hose between valves 6 and 5. When
When the refrigerant in the storage vessel reaches a
the system being evacuated reaches the
stable temperature – equal to the surrounding ambi-
aforementioned vacuum, valve 6 should
ent air temperature – the pressure in the storage ves-
be closed to seal off the hose. Valve 7
sel, read on the compressor discharge gauge, should
should be closed prior to turning the
be the same as the saturation pressure for the ambient
RSR unit off to evacuate the remaining
temperature. If the pressure reading is higher by the
refrigerant hose.
above values, or more, the storage vessel should be
After the hoses have been evacuated and valves 6 and 7 purged of non‑condensable.
closed, the RSR unit can be shut off but the hoses must
remain in place. After a waiting period of 5 minutes,
the pressure in the refrigeration unit is to be checked.
If the pressure has risen due to residual refrigerant re-
maining in the refrigeration unit, the Gas Pump Out
JOHNSON CONTROLS 17
FORM 50.40-OM1 (713)
Table 8 - PRESSURE DIFFERENCE FOR DE- Refrigerant vapor will be pulled off of the top of the refrig
TERMINING PRESENCE OF NON-CONDENSIBLE eration unit condenser, raised to a higher pressure by the
GASES RSR compressor, condensed to liquid in the RSR condenser,
DIFFERENCE BETWEEN GAUGE and then returned to the refrigeration unit as a liquid.
READING AND SATURATED
REFRIGERANT The level of liquid in the storage vessel can be observed
PRESSURE
through the sight glasses in the vessel. When the liquid has
PSIG KPA
been exhausted from the storage vessel, close valves 6 and
CFC‑11 4 27.6 7 and simultaneously shut OFF the RSR toggle switch.
CFC‑114 4 27.6
HFC‑123 4 27.6 Removal of Refrigerant from Hoses and Storage
CFC‑12 6 41.4
Vessel
HFC‑134a 6 41.4 Before removing the hoses between the RSR and the
CFC‑500 8 55.1 refrigeration unit, open valves 1 and 3 on the manifold
HCFC‑22 10 69.0 and close valves 2 and 4. Start the RSR compressor and
CFC‑502 10 69.0 open valve 7 simultaneously. Valve 5 should be open
and valve 6 closed.
CHARGING REFRIGERATION UNIT WITH
REFRIGERANT FROM RSR UNIT Run the RSR compressor until a vacuum of at least
29 in. Hg. exists in the storage vessel. At this point,
Gas Charging close valve 7 and simultaneously move the RSR toggle
When it is time to transfer the refrigerant from the RSR switch to the OFF position. Close manifold valves 1, 2,
to the refrigeration unit, the latter must first be charged 3, and 4, as well as valve 5. The hose valves can then
with gas. be closed and the hoses removed from the refrigeration
unit.
This is particularly true of refrigeration units contain-
ing liquid coolers and/or water cooled condensers. If Table 9 - VAPOR PRESSURE – CFC-11, CFC-12,
liquid refrigerant is charged in the unit when the unit CFC-22 AND CFC-500
pressure is lower than the saturation pressure equiva- TEMP. VAPOR PRESSURE*
lent to 32°F (0°C), the water tubes can freeze and burst (°F) CFC-11 CFC-12 CFC-22 CFC-500
even though water is being pumped through the tubes. ‑150 29.9 29.6 29.4
Set the water flow and valves as shown in column 4 ‑140 29.9 29.4 29.0
Table 6 on page 16. When the valves are set, refrig- ‑130 29.9 29.1 28.4
erant gas will flow into the refrigeration unit because ‑120 29.9 28.6 27.7
of the higher pressure in the RSR. The RSR compres- ‑110 29.8 28.0 26.5
sor does not have to run during gas charging. -100 29.8 27.0 25.0 26.4
When the refrigeration unit pressure is above the satu- -90 29.7 25.7 23.0 24.9
ration pressure equivalent to 32°F (0°C) (Table 8) or -80 29.6 24.1 20.2 22.9
when the pressure has equalized, close all of the valves. -70 29.4 21.8 16.6 20.3
-60 29.2 19.0 12.0 17.0
On RSR Models 1100 and 1600 and on Easy Tank™
-50 28.9 15.4 6.2 12.8
Models RT 1100 and 1600, an electric heater is in-
stalled on the bottom of the storage vessel to increase -40 28.4 11.0 0.5 7.6
the pressure of the stored refrigerant when the RSR is -35 28.1 8.4 2.6 4.6
subjected to low ambient temperatures. -30 27.8 5.4 4.9 1.2
-25 27.4 2.3 7.4 1.2
Charging with Liquid Refrigerant -20 27.0 0.6 10.2 3.2
Set the valves and pumps as indicated in column 5 of Table -15 26.5 2.4 13.2 5.4
6 on page 16. Turn the toggle switch on the RSR to the -10 26.0 4.4 16.4 7.8
ON position. -5 25.4 6.7 20.1 10.4
0 24.7 9.2 24.0 13.3
18 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
TABLE 9 - VAPOR PRESSURE – CFC-11, CFC-12, Table 10 - VAPOR PRESSURE – HCFC-123 AND
CFC-22 AND CFC-500 (CONT'D) HFC-134A
TEMP. VAPOR PRESSURE*
TEMP. VAPOR PRESSURE (PSIG)*
(°F) CFC-11 CFC-12 CFC-22 CFC-500
(°F)
2
5 23.9 11.8 28.2 16.4 HCFC-123 HFC-134A
15 22.1 17.7 37.7 23.3 -100 29.9 27.8
20 21.2 21.0 43.0 27.2 -90 29.8 26.9
25 19.9 24.6 48.8 31.4 -80 29.7 25.6
30 18.6 28.4 54.9 36.0 -70 29.6 23.8
35 17.2 32.6 61.4 40.8 -60 29.5 21.5
40 15.6 37.0 68.5 46.0 -50 29.2 18.5
45 13.9 41.7 76.0 51.6 -40 28.9 14.7
50 12.0 46.7 84.0 57.5 -30 28.5 9.8
55 10.0 52.1 92.6 63.9 -20 27.8 3.8
60 7.8 57.7 101.6 70.6 -10 27.0 1.8
65 5.4 63.8 111.2 77.8 0 26.0 6.3
70 2.8 70.2 121.4 85.3 10 24.7 11.6
75 0.0 77.0 132.2 93.4 20 23.0 18.0
80 1.5 84.2 143.6 101.9 30 20.8 25.6
85 3.2 91.8 155.7 111.0 40 18.2 34.5
90 4.9 99.8 168.4 120.4 50 15.0 44.9
95 6.8 108.2 181.8 130.5 60 11.2 56.9
100 8.8 117.2 195.9 141.1 70 6.6 70.7
105 10.9 126.6 210.7 152.2 80 1.1 86.4
110 13.1 136.4 226.4 164.0 90 2.6 104.2
115 15.6 146.8 242.7 176.3 100 6.3 124.3
120 18.3 157.7 259.9 189.2 110 10.5 146.8
125 21.0 169.1 277.9 202.8 120 15.4 171.9
130 24.0 181.0 296.8 217.0 130 21.0 199.8
135 27.1 193.5 316.6 231.8 140 27.3 230.5
140 30.4 206.6 337.2 247.4 150 34.5 264.4
145 34.0 220.3 358.9 263.7
*Vapor pressures are shown as PSIG. Screened figures are shown
150 37.7 234.6 381.5 280.7
as inches of mercury vacuum.
as inches of mercury (HG) vacuum.
JOHNSON CONTROLS 19
FORM 50.40-OM1 (713)
Table 11 - VAPOR PRESSURE – CFC-114 AND TABLE 11 - VAPOR PRESSURE – CFC-114 AND
CFC-502 CFC-502 (CONT'D)
VAPOR VAPOR VAPOR VAPOR
TEMP. PRESSURE TEMP. PRESSURE TEMP. PRESSURE TEMP. PRESSURE
(°F) (PSIG)* (°F) (PSIG)* (°F) (PSIG)* (°F) (PSIG)*
CFC-114 CFC-502 CFC-114 CFC-502
-100 29.523 -75 15.098 70 12.722 35 72.827
-80 28.994 -70 12.749 72 13.751 40 80.533
-60 27.955 -65 10.109 74 14.809 45 88.726
-40 26.073 -60 7.1539 76 15.897 50 97.425
-20 22.893 -55 3.8567 78 17.014 55 106.65
-15 21.829 -50 0.1906 85 21.172 60 116.41
-10 20.638 -49.75 0.0 90 24.384 65 126.73
-5 19.308 -48 0.6804 95 27.808 70 137.63
0 17.829 -46 1.4865 100 31.452 75 149.12
5 16.188 -44 2.3256 105 35.325 80 161.23
10 14.374 -42 3.1986 110 39.436 85 173.97
12 13.597 -40 4.1064 120 48.407 90 187.36
14 12.789 -38 5.0500 130 58.438 95 201.43
16 11.950 -36 6.0303 140 69.603 100 216.20
18 11.078 -34 7.0482 150 81.982 105 231.68
20 10.174 -32 8.1048 110 247.92
22 9.2348 -30 9.2010 115 264.92
24 8.2611 -28 10.338 120 282.72
26 7.2517 -26 11.516 125 301.35
28 6.2056 -24 12.737 130 320.85
30 5.1219 -22 14.001 135 341.25
32 3.9997 -20 15.310 140 362.60
34 2.8381 -18 16.665 145 384.95
36 1.6361 -16 18.066 150 408.37
38 0.3929 -14 19.515
38.62 0.0 -12 21.013
as inches of mercury (HG) vacuum.
40 0.4384 -10 22.560
42 1.0909 -8 24.158
44 1.7652 -6 25.808
46 2.4615 -4 27.511
48 3.1805 ‑2 20.268
50 3.9226 0 31.080
52 4.6883 2 32.948
54 5.4781 4 34.873
56 6.2924 6 36.856
58 7.1318 8 38.898
60 7.9967 10 41.001
62 8.8877 15 46.530
64 9.8053 20 52.459
66 10.750 25 58.807
68 11.722 30 65.591
20 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
Table 12 - VAPOR PRESSURE (METRIC (KPA) – TABLE 12 - VAPOR PRESSURE (METRIC (KPA) –
CFC-11, CFC-12, CFC-22 AND CFC-500 CFC-11, CFC-12, CFC-22 AND CFC-500 (CONT'D)
TEMP. VAPOR PRESSURE (KPA)* TEMP. VAPOR PRESSURE (KPA)*
(°C) CFC-11 CFC-12 CFC-22 CFC-500 (°C) CFC-11 CFC-12 CFC-22 CFC-500 2
-101 101 100 100 51.7 145 1166 1916 1398
-95 101 100 98 54.4 165 1248 2046 1496
90 101 99 96 57.2 187 1334 2183 1598
-84 101 97 94 60.0 210 1425 2325 1706
-79 101 95 90 62.8 234 1519 2475 1818
-73 100 91 85 89 65.6 260 1618 2630 1935
-67 100 87 78 84
*Vapor pressures are shown as kPa. Screened figures are
-62 100 82 68 77 shown as kPa of mercury vacuum.
-56 99 74 56 68
-51 99 64 41 58
Table 13 - VAPOR PRESSURE (METRIC) – HCFC-
-46 98 52 21 43 123 AND HFC-134A
-40 96 37 3.4 26
-37 95 28 17.9 16 TEMP. VAPOR PRESSURE (KPA)*
-34 94 18 33.8 4 (°C)

HCFC-123 HFC-134A
-31 93 7.8 51.0 4
-73.3 101 94
-28 91 4.1 70.3 22.1
-67.8 101 91
-26 90 16.5 91.0 37.2
-62.2 101 87
-23 88 30.3 113.1 53.8
-56.7 100 81
-21 86 46.2 138.6 71.7
-51.1 100 73
-18 84 63.4 165.5 91.7
-45.6 99 63
-15 81 81.4 194.4 113.1
-40.0 98 50
-12 78 100.6 226.2 135.8
-34.4 97 33
-9 75 122.0 259.9 160.7
-28.9 94 13
-6 72 144.8 296.5 187.5
-23.3 91 12
-4 67 170.0 336.5 216.5
-17.8 88 43
-1.1 63 196 379 248
-12.2 84 80
1.7 58 225 423 281
-6.7 78 124
4.4 53 255 472 317
-1-1 70 177
7.2 47 288 524 356
4.4 62 238
10.0 41 322 579 396
10.0 51 310
12.8 34 359 638 441
15.6 38 392
15.6 26 398 701 487
21.1 22 487
18.3 18 440 767 536
26.7 4 596
21.1 9 484 837 588
32.2 18 718
23.9 0 531 912 644
37.8 43 857
26.7 10 581 990 703
43.3 72 1012
29.4 22 633 1074 765
48.9 106 1185
32.2 34 688 1161 830
54.4 145 1378
35.0 47 746 1254 900
60.0 188 1589
37.8 61 808 1351 973
65.6 300 1823
40.6 75 873 1453 1049
43.3 90 940 1561 1131 *Vapor pressures are shown as kPa. Screened figures are
shown as kPa of mercury vacuum.
46.1 108 1012 1673 1216
JOHNSON CONTROLS 21
FORM 50.40-OM1 (713)
TABLE 14 - VAPOR PRESSURE (METRIC) – CFC--

Table 14 - VAPOR PRESSURE (METRIC) – CFC- 114 AND CFC-502 (CONT'D)
114 AND CFC-502 VAPOR VAPOR
VAPOR VAPOR TEMP. PRESSURE TEMP. PRESSURE
TEMP. PRESSURE TEMP. PRESSURE (°C) (KPA)* (°C) (KPA)*
(°C) (KPA)* (°C) (KPA)* CFC-114 CFC-502
CFC-114 CFC-502 20.0 80.8 -1.1 452
-73.3 100 -59.4 51 21.1 87.7 1.7 502
-62.2 98 -56.7 43 22.2 94.8 4.4 555
-51.1 95 -53.9 34 23.3 102.1 7.2 612
-40.0 88 -51.1 24 24.4 109.6 10 672
-28.9 78 -48.3 13 25.6 117.3 12.8 735
-26.1 74 -45.6 1 29.4 146.0 15.6 803
-23.3 70 -45.4 0 32.2 168.1 18.3 874
-20.6 65 -44.4 0 35.0 191.7 21.1 949
-17.8 60 -43.3 10 37.8 216.9 23.9 1028
-15.0 55 -42.2 16 40.6 243.6 26.7 1112
-12.2 49 -41.1 22 43.3 271.9 29.4 1200
-11.1 46 -40.0 28 48.9 333.8 32.2 1292
-10.0 43 -38.9 35 54.4 402.9 35.0 1389
-8.9 40 -37.8 42 60.0 479.9 37.8 1491
-7.8 38 -36.7 49 65.6 564.7 40.6 1597
-6.7 34 -35.6 56 43.3 1709
-5.6 31 -34.4 63 46.1 1827
-4.4 28 -33.3 71 48.9 1949
-3.3 25 -32.2 79 51.7 2078
-2.2 21 -31.1 88 54.4 2212
-1.1 17 -30.0 97 57.2 2353
0.0 14 -28.9 106 60.0 2500
1.1 10 -27.8 115 62.8 2654
2.2 6 -26.7 125 65.6 2816
3.3 1 -25.6 135
*Vapor pressures are shown as kPa. Screened figures are shown
3.7 0 -24.4 145 as kPa of mercury (HG) vacuum.
4.4 3.3 -23.3 156
5.6 7.5 -22.2 167
6.7 12.2 -21.1 178
7.8 17.0 -20.0 190
8.9 21.9 -18.9 202
10.0 27.0 -17.8 214
11.1 32.3 -16.7 227
12.2 37.8 -15.6 240
13.3 43.4 -14.4 254
14.4 49.2 -13.3 268
15.6 55.1 -12.2 283
16.7 47.5 -9.4 321
17.8 67.6 -6.7 362
18.9 74.1 -3.9 405
22 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
SECTION 3 - DIAGRAMS
LEGEND
SW-1 Switch, On-Off w/ Indicator Light (1000 Watt Heater)
SW-2 Switch, On-Off (Vacuum Pump)
HP Contact, High Pressure
HTR Heater, Refrigerant Storage Vessel (1000 Watt)
HTR Heater, Oil Separator (25 Watt)
LS Switch, Liquid Level
1-R Relay, Liquid Level Switch, w/ N.O. contact LD17563
Figure 2 - WIRING DIAGRAM RSR-1100V, -1600V, -1100V114, & -1600V114
LEGEND
SW Switch, On-Off (Compressor Motor)
HP-LP Switch, Pressure, Combination Hi-LO
1-R Relay, Float Switch, N.O. contact
2-R Relay, Motor Circuit, N.O. contact
HTR Heater, Oil Separator LD17564
Figure 3 - WIRING DIAGRAM RSR-2212 & -2222
JOHNSON CONTROLS 23
FORM 50.40-OM1 (713)
SECTION 3 - Diagrams
Johnson Controls supplies mating

"Twist-Lock" plug for field wiring
connection by customer.
(1) flex cord with special interlock plug
supplied by Johnson Controls for wiring to
customer's Pumpout vessel pressure liquid
level switch.
*Interlock Receptacle will not allow Legend

EASY-PAK Compressor to operate unless SW Switch, On-Off, Motor
liquid level switch LS is in the electrical HP-LP Switch, Pressure, Combination Hi-Lo Control
control circuit. LS Switch, Liquid Level
LSR Relay, N.O. contact
HTR Heater, Oil Separator (25 watt)
LD17565
Figure 4 - WIRING DIAGRAM EASY PAK RP-1000V, -114V & -2200
Legend
Easy-Pak Model RP-2400 is supplied with 8' SW Switch, On-Off (Compressor)
flexible cord and interlocking plug for liquid level
switch circuit on refrigerant storage tank.
HP-LP Switch, Pressure, Combination Hi-Lo Control
1-R Relay, Liquid Level, N.O. contact
M Contactor, Compressor Motor
LD17566
Figure 5 - WIRING DIAGRAM RSR-2240, -2250, -4436, -4445 & RP-2400, -3400
24 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
LD17567
LEGEND
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
1 Vacuum Pump 8 Condenser 18 HP Cutout (Tank)
2 Motor 9 Ball Valves 19 HP Cutout (Compressor)
Drive Package: Filter Dryer:: Junction Box:
10
Motor Pulley (1) Core 20 Switch-Compressor
3 Compressor Pulley 11 Moisture Indicator Switch-Heater
Belt 12 Low Pressure Vessel 21 Refrigerant Hoses
Base for Unit 13 Relief Assembly 22 Valve
4 Belt Guard 14 Sight Glass 23 Power Wire
5 Gauges 15 Casters 24 Purge Valve
6 Oil Separation 16 Heater
7 Heater 17 Float Switch
Figure 6 - PIPING DIAGRAM RSR-1100V, -1600V, -1100V & -1600V114
JOHNSON CONTROLS 25
FORM 50.40-OM1 (713)
LD17568
LEGEND
1 Compressor 8 Condenser 18 Relief Valve
2 Motor 9 Ball Valves 19 Pressure Switch
Drive Package: Filter Dryer: Junction Box:
10
Motor Pulley (1) Core 20 Switch-Compressor
3 Compressor Pulley 11 Moisture Indicator Switch-Heater
Belt 12 High Pressure Vessel 21 Refrigerant Hoses
Base for Unit 13 Relief Assembly 22 Valve
4 Belt Guard 14 Sight Glass 23 Power Wire
5 Gauges 15 Casters
6 Oil Separation 16 Purge Valve
7 Heater 17 Float Switch
Figure 7 - PIPING DIAGRAM RSR-2212, -2222, -2240, -4436, -4445
26 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
LD17569
LEGEND
1 Vacuum Pump 9 Ball Valves 17 Power Wire
2 Motor 10 Filter Dryer 18 Customer Service Valve
3 Drive Package: 11 Moisture Indicator
Belt Guard: 12 Wheels
4 Pulleys: Compressor 13 Relief Valve
Pulleys: Motor 14 Pressure Control:
5 Gauges Junction Box
6 Oil Separator 15 Switches
7 Heater Oil Separator Remote Pressure Interlock
8 Condenser 16 Refrigerant Hoses
Figure 8 - PIPING DIAGRAM EASY-PAK RP-1000V, -114V, -2200, -2400 & -3400
JOHNSON CONTROLS 27
FORM 50.40-OM1 (713)
THIS PAGE INTENTIONALLY LEFT BLANK.
28 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
SECTION 4 - MAINTENANCE PROCEDURES

GENERAL
Replacement of Filter Dryer Element belt tension must be greater than for a normal steady
load. Belt tension can be accurately determined with the
1. Unplug the RSR power cord. use of a belt tension gauge which gives a direct reading
2. Close valves 1, 2, 3 and 4 in the manifold (See of belt load as determined by the deflection. A tension
Figure 1 on page 15) and the compressor dis- of 100 Ibs. is considered to be the normal belt tension.
charge valve.
After 36 to 48 hours of operating time, the belt should
stretch to a normal operating point and a further check
4
3. Remember that the system is under pressure and
safety glasses and gloves should be worn during for proper tension should be made. Good alignment and
this operation. belt tension are important to insure long belt life, quiet
operation and to maintain top system performance.
4. Slowly turn each of the bolts, holding the end
plate on the canister, open one or two turns. Al- Pulley Alignment
low the reduction of pressure within the canister
before completely removing the end plate. A very important factor in compressor operation is cor-
rect pulley alignment. The compressor pulley must be
5. Remove the old filter core from the canister and in perfect alignment with the motor pulley and it is im-
remove the “O” ring gasket from the end plate. portant that the shaft key is in place on the shaft and the
Wipe the inside of the canister and the end plate pulley bolt drawn tight, when installing a pulley. The
clean with a clean cloth. pulley alignment may be checked by holding a 1/2”
rod –2 or 3 feet long – firmly in the V groove of the
6. Replace the “O” ring gasket with a new one after
compressor drive pulley wheel and making sure the rod
wiping it with a coating of the same type of oil
falls squarely in the motor pulley grooves. A further
being used in the compressor.
check may be made by seeing that the belt, as it goes
7. Remove the new filter/dryer element (Sporlan # from pulley to pulley, comes off the pulley grooves
RC 4864) from the hermetically sealed wrapper. perfectly straight and that there are no side‑way bends
The new element must be placed in the canis- in the belt, as it approaches or leaves the pulleys. Pul-
ter immediately since it would otherwise absorb leys and belts must be clean and free of oil.
moisture from the surrounding air.
Adding or Changing Oil (High Pressure Units)
8. Replace the end plate and bolt in place using an
alternate pattern for tightening the bolts. When the RSR is not running and the refrigerant pres-
sures have equalized, the oil should be 1/2 to 3/4 of the
9. Prior to opening the compressor discharge valve, height of the sight glass in the compressor oil sump.
crack valve number 3 of the manifold and slightly
break the flare connection in the tubing where it To add oil:
enters the compressor discharge. Allow the air to
1. Unplug the power cord.
be purged from the filter dryer and then tighten
the flare fitting and open the compressor discharge 2. Close the compressor discharge and suction
valve. valves and manifold valves 1 and 4 (See Figure
1 on page 15) and vent the pressure from the
Belts compressor. Using an oil pump, open the drain
The Refrigerant Recovery/Recyle Unit (RSR) com- valve on the compressor sump, and pump oil into
pressor drive belt should be checked frequently for the compressor until it is at the proper level.
excessive wear and tightness. If belt is in bad condition, 3. The type of oil should be the same as that used in
it should be replaced immediately. Correct belt tension the refrigeration unit being serviced.
prevents the motor pulley from slipping, keeping the
transfer unit operating at peak efficiency.
The belt tension adjustment should be made so the belt
is taut, but not too taut to create excessive bearing loads.
Due to the pulsating load created by the compressor, the
JOHNSON CONTROLS 29
FORM 50.40-OM1 (713)
To change oil: Adding or Changing Oil (Low Pressure Unit)

1. Follow steps one and two above. The procedure for the vacuum pump is essentially the
same as that for the compressor – the main excep-
2. After the refrigerant pressure has been relieved tion being the use of DuoSeal vacuum pump oil in the
to atmospheric pressure, the oil is drained from pump oil sump and in the oil separator.
the compressor oil sump through the sump drain
valve. When the oil has drained, immediately It is recommended that the vacuum pump be flushed
close the valve so that moisture and air do not en- with clean DuoSeal oil after draining the contaminated
ter the compressor. oil.
3. To remove the oil from the oil separator, the Flushing the Vacuum Pump
flanged top must be unbolted and removed. First,
After removing all the oil, close the drain and pour
however, the flared refrigerant tube connections
about four ounces of clean DuoSeal oil into the oil
must be removed from the top of the oil separator.
fill port (see exploded view drawing for your model
Be sure to only slightly open the flare fittings ini-
CAPTURE PUMP). Open the discharge port and oper-
tially to make certain the refrigerant pressure has
ate the pump for about a minute with the suction port
first been relieved. Open the valve at the bottom
alternately opened and closed to agitate and circulate
of the separator and drain the oil.
the fresh oil. Again stop the pump, drain the flushing
4. Clean the interior with a clean cloth and remove oil and force out the residue as before. The amount of
and clean the screen filter. flushing oil and the number of flushes will be deter-
mined by the extent of contamination and the color of
5. After replacing the screen filter, replace the top of
the oil. Under no circumstances should anything other
the oil separator.
than DuoSeal oil be used for flushing a CAPTURE
6. Before replacing the refrigerant and oil return pump. The higher vapor pressures of other types of oil
tubes, use a pump to pump ten fluid ounces of oil will cause difficulty later in the attainment of a vacu-
into the separator. um.
7. Connect the oil pump to the compressor oil drain Refilling the Vacuum Pump
valve – open the valve – pump ten fluid ounces
of oil into the compressor sump and close the drain After you are satisfied that the pump has been thor-
valve. oughly flushed, refill the pump by pouring new
DuoSeal oil into the refill port. Fill to the half way
8. After allowing several minutes for the oil level to point of the sight glass and start the pump with the
stabilize, check to see that the oil level is 1/2 to 3/4 suction closed. A gurgling noise is characteristic when
above the bottom of the sight glass. If not, adjust ac- high pressure air is drawn through the pump. It should
cordingly. disappear quickly as the pressure within the pump is
reduced. If gurgling continues, and the oil level drops
9. It must be emphasized that the oil used in the high
in the sight glass, add sufficient additional oil through
pressure RSR compressor is the same as that used
the oil fill port until gurgling ceases and the oil level is
in the refrigeration unit being serviced. Normally
at the half way point in the sight glass.
YORK Type C Refrigeration oil is used except in
units charged with R‑134a. An Ester base oil must The oil level should be checked again when the pump
be used with this refrigerant. reaches operating temperature. The oil separator should
10. Open the compressor suction and discharge be cleaned, as previously noted and refilled with 10
valves. And next, crack the flare fitting on the ounces
tube that connects the valve manifold to the oil
separator to purge air from the compressor and oil
separator.
11. Open the manifold valves as required for the next
recovery operation.
30 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
Compressor turn the compressor over by hand. If pressure rises

Prior to servicing the compressor: and falls with each revolution this will confirm the
discharge valve leak.
1. Make sure the power is disconnected.
4. If the discharge valves are holding then check suc-
2. Close Suction and discharge service valves. tion valves of the valve assembly.
3. Bleed refrigerant from the compressor to relieve 5. Back seat (open) the discharge service valve, with
the air from the compressor and oil separator pres- the service suction valve closed, run compressor
sure within. Pressure should be 5 psig or less prior until a vacuum of 25” (85 kPa) is reached. Failure
to opening the compressor. of a compressor to reach 25” (85 kPa) vacuum indi- 4
cates leaky suction valves. All compressors should
Servicing Compressor pump a 25” (85 kPa) vacuum against normal head
Care must be taken when servicing the compressor not pressures.
to mar, nick or scratch any of the parts. All machined
surfaces must be free of nicks or burrs to ensure a prop- COMPRESSOR MODEL CFC 1000
er fit and seating of gaskets. When replacing parts and Servicing of Shaft Seal (See Figure 9 on page
reassembly, the specified torque requirements shown 33)
in Table 16 on page 35 should not be exceeded.
Bolts should all be run in until bolt heads make contact. When servicing the shaft seal, extreme care must be
Final tightening should be in a sequence so that bolts taken when removing or installing the parts to prevent
diagonally opposite are tightened and all drawn evenly damage to the lapped surfaces and other seal parts. The
to the specified torque. portion of the shaft upon which the seal fits must be
free of scratches, burrs and dirt, and the seal housing
One of the most important factors in servicing com- cavity must be clean.
pressors is cleanliness. Extreme care should be taken
to keep foreign material from entering the compressor Removal of Seal Assembly
when it is open. All old gaskets should be replaced. 1. Remove the sheave and key from the shaft.
Any old gasket material adhering to the parts should be
carefully removed. Reusable parts should be cleaned 2. Remove the seal retainer plate bolts and gently re-
in a solvent. move the seal plate.
Checking Compressor for Performance 3. Remove the seal assembly from the shaft.
4. Clean all parts to be reused.
If the compressor appears not to perform properly, the
following checks should be made:
1. Allow the suction pressure to build up to a mini-
mum of 30 psig. Thoroughly check the compres-
sor and all refrigerant holding components for
leaks.
2. If no leaks are found, close the suction service
valve and run compressor until compressor suc-
tion pressure is 0 psig.
3. Stop compressor. Observe discharge pressure and
if it remains constant the discharge valves of the
valve assembly are holding properly. If pressure
drops more than 5 Ibs. (34.5 kPa) in one minute,
this indicates the discharge valves of the valve
assembly are leaking and should be replaced. If
in doubt as to whether the discharge valves leak,
JOHNSON CONTROLS 31
FORM 50.40-OM1 (713)
Installation of Seal Assembly Installation of Head and Valve Plate

1. Check all surfaces to make certain nicks and burrs 1. Apply a thin film of clean YORK Refrigeration
do not exist. oil on the area of the crankcase to be covered by
the cylinder gasket. Place the cylinder gasket in
2. Wash all parts of the seal assembly in clean oil of
position on the cylinder so the dowel pins in the
the same type being used in refrigeration unit be-
crankcase go through the dowel pin holes in the
ing serviced.
cylinder gasket.
3. Push the seal assembly onto the shaft. Move the
2. Apply a thin film of clean YORK Refrigeration
seal assembly in and out on the shaft to ensure a
oil to the top and bottom valve plate area to be
good seal.
covered by gaskets. Place the valve plate in posi-
4. Place a very light film of oil on the matching met- tion on the cylinder gasket so the discharge valve
al faces where the “O” ring is to be placed. Place assemblies (i.e. the smaller diameter assemblies
the “O” ring in the groove. with the retainer over the valve reed) are facing up
and the locating dowel pins go through the dowel
5. Place the seal retainer plate in position with the pol-
pin holes in the valve plate.
ished surface facing the compressor. Turn the bolts
in evenly while rotating the shaft, making sure that 3. Place the head gasket (4) in position on the valve
the clearance between the shaft and the hole in the plate (3) so the dowel pins go through the dowel
retainer plate is the same all around the circumfer- pin holes in the gasket.
ence. If clearance is not the same all around, gently
4. Apply a light film of clean YORK Refrigeration
tap the seal retainer plate until it is so. Tighten bolts
oil on the machined surface of the cylinder head
diagonally opposite to the required torque (See Ta-
which matches the head gasket. Place the head on
ble 16 on page 35).
the cylinder head gasket so the dowel pins go into
Servicing Valve Plate and Head the dowel pin holes in the head.
In removing the head, extra care should be taken not to 5. Apply a thin film of clean YORK Refrigeration
damage the sealing surfaces. oil to the service valve flanges on the head and on
the service valve flange. Place a service valve gas-
Removal of Head and Valve (See Figure 9 on ket in position on the cylinder head service valve
page 33) flanges. Place the service valve in position on the
1. Remove the four bolts (15) from cylinder head. proper service valve ports and insert the longer
bolts through the service valve mounting pads, the
The four bolts removed are longer in
head, end valve plate and in the crankcase.
length than the remaining head bolts.
6. Insert the remaining head bolts and run in all the
bolts so the bolt heads make contact. Tighten the
head and service valve bolts to the required torque,
by tightening the service bolts first. Then tighten
2. Remove the remaining bolts in the cylinder head the remaining in a sequence so bolts diagonally op-
and remove the valve plate (3), and cylinder head posite each other are evenly drawn to the specified
from the crankcase by tapping lightly under the torque.
ears which extend from the valve plate. If the head
and valve plate adhere, hold the head and tap the
valve plate ears away from the head with a soft
hammer. Do not hit or tap the head to separate the
head and valve plate because damage to the head
may result.
3. All gasket material adhering to the head, valve
plate, or cylinder, should be carefully removed in
such a manner that the machined sealing surfaces
are not scratched or nicked.
32 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
SECTION 5 - REPLACEMENT PARTS AND KITS
1. Gasket Kit BMK-683-7 contains one complete set of all

gaskets
2. Parts included inside broken lines are sold as kits per
B/M shown. [Example: BMK-680-6 would be (3) parts
only]
LD17582
Figure 9 - COMPRESSOR REPLACEMENT PARTS – MODEL CFC-1000
JOHNSON CONTROLS 33
FORM 50.40-OM1 (713)
Table 15 - COMPRESSOR REPLACEMENT PARTS – MODEL CFC-1000

REFERENCE QTY./ REFERENCE KIT
PART NAME PART NUMBER
NUMBER COMP. BMK
1 Crankcase 1 20031-17 679-1/683‑7
2 Gasket, Valve Assembly 1 30523 679‑1
3 Valve Plate Assembly 1 VP211 679 1
3a Valve Plate 1 23019 679‑1
4 Gasket, Cylinder Head 1 30563 679‑1/683‑7
5 Bolt 2 33188 679‑1
6 Washer 6 41255 679‑1
7 Suction Leaf 2 25083 679‑1
8 Discharge Leaf 4 25076 679 1
9 Retainer 2 28036 679‑1
10 Washer 2 12123 679‑1
11 Nut 2 11040 679‑1
12 Dust Shield 1 40733 665‑8
13 Cylinder Head 1 24025‑3
14 Bolt, Cylinder Head 8 10004-11
15 Bolt, Cylinder Head (Valve) 4 10049‑11
16 Gasket, Rotolock Service Valves 2 30234 683-7
18 Valve, Suction/Discharge 5/8” SAE 2 31071
19 Screw, Seal Plate 6 10112‑7
21 Seal Assembly 1 CBS-2938 665‑8
22 “O” Ring 1 5045R 665‑8/683-7
23 “O” Ring 1 30525 683‑7
24 Plate, Rear Bearing Housing 1 41268‑1
25 Snap Ring, Rear Bearing Housing 1 27022
26 Oil Sight Glass With “O” Ring 1 CBL-724
27 Plug, Oil Filter 2 5046R
28 Serial Plate 1 52575
29 Drive Screw, Serial Plate 2 3895
30 “O” Ring, Bottom Plate 1 30521 683-7
31 Bottom Plate 1 245‑46‑3
32 Snap Ring, Bottom Plate 1 27023
33 Flare Cap 1 3003
34 Ball Bearing, Front 1 26571 680‑6
35 Crankshaft 1 22540‑1 680‑6
36 Ball Bearing, Rear 1 26553 680‑6
37 Key, #6 Woodruff 1 13010
38‑40 Connecting Rod Assembly 2 Al-802 695‑1
41 Piston 2 20525‑1 695‑1
42 Piston Ring 4 35405 695-1
43 Piston Pin 2 21520 695‑1
44 Snap Ring, Piston Pin 4 27016 695‑1
45 Bolt, Flywheel 1 10004‑8
46 Washer, Flywheel 1 12011
47 Flywheel 1 25558-1
48 Mounting Foot (Suction Side) 1 57590
48 Mounting Foot (Discharge Side) 1 57590-1
49 Lock Washer 4 12116-C
50 Bolt 4 10014-C6
51 Seal Retainer 1 41324 665-8
34 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
Table 16 - COMPRESSOR TORQUE SPECIFICA- BMK680‑6 Crankshaft and Bearing Kit

TIONS – MODEL CFC-1000
BMK695‑1 Piston and Rod Kit (Standard)
CAPSCREWS AND BOLTS
TORQUE BMK695‑2 Piston and Rod Kit (.020 Oversize)
DESCRIPTION THREAD
STD. METRIC
SIZE
(KM)
BMK679‑3 Valve Plate Kit (Cad & Nickel Plated)
(FT. LBS)
Rod Cap Screw 1/4‑20 7-8 0.96–1.1 Components in the valve plate kit, seal kit, piston and
Valve Plate Screw 1/4‑28 6 0.82 rod kit and the crankshaft kit are shown within an area
Oil Filler Plug 1/8 NPT 10–15 1.38–2.0 enclosed by a line on the drawing on Figure 9 on page
Bearing Retainer 1/4‑28 6–7 0.82–0.96 33.
Seal Retainer Plate 10‑32 54–78 0.62–0.89
COMPRESSOR MODEL 16799 (RST‑2240, 5
Cylinder Head 5/16‑24 24–28 3.3–3.8
RSR‑2250 & RP‑2400)
Flywheel Capscrew 5/16‑24 24–28 3.3–3.8
Mounting Foot 3/8‑16 15–20 2.0–2.7 Shaft Seal Assembly Servicing
Rotolock Valve — 30–40 4.1–5.5 When servicing the shaft seal, extreme care must be
1 1/8‑18 taken when removing or installing the parts to prevent
Oil Sight Glass 75 10.4
UNEF damage to the lapped surfaces and other seal parts. The
Table 17 - COMPRESSOR PISTON SELECTIVE portion of the shaft upon which the seal fits must be
FITS free of scratches, burrs and dirt, and the seal housing
CLEARANCE
cavity must be clean.
SELECTIVE FITS
INCHES MM Removal Of Seal Assembly (See Figure 10 on
Piston Pin to Piston .0002/.0003 .005/.007 page 37 and Figure 11 on page 40)
Piston Pin to Rod .0002/.0003 .005/.007
1. Remove the sheave and key from the shaft.
Piston to Cylinder .0032/.0042 .081/.106
Rod to Shaft Journal .0007/.0015 .018/.038 2. Remove the seal retainer plate bolts and gently re-
move the seal plate.
COMPRESSOR REPLACEMENT
3. Remove the seal assembly from the shaft.
If the compressor fails and it is evident that the crank-
4. Clean all parts to be reused.
shaft bearings, connecting rods or pistons have been
damaged, the entire compressor should be replaced. Installation Of Seal Assembly
TWIN CYLINDER MODEL CFC1000 1. Check all surfaces to make certain nicks and burrs
do not exist.
Compressor Rotation: Either Clockwise or Counter-
clockwise. 2. Wash all parts of the seal assembly in clean YORK
Refrigeration Oil.
Listed on Table 15 on page 34 are the part numbers
and part names for each component in our belt‑driven 3. Oil shaft with refrigeration oil to allow new seal to
compressor Model CFC 1000. These part numbers and be pushed into position.
part names are indexed by reference numbers as shown 4. Put on spring holder and spring. Be sure that
in Figure 9 on page 33 which shows the layout of spring is centered in spring holder.
each part.
5. Slide the assembly along shaft just far enough to
Please note that BMK‑(number) refers to a replace- center in spring and hold spring in place. Do not
ment kit of parts as follows: compress the spring at this stage.
BMK683‑7 Gasket Kit 6. Before putting on end plate, thoroughly clean and
oil with 300 viscosity refrigeration oil on both seal-
BMK679‑1 Valve Plate Kit
ing faces. Install floating seats in end plate as fol-
BMK665‑8 Seal Kit lows:
JOHNSON CONTROLS 35
FORM 50.40-OM1 (713)
7. Make sure that the synthetic rubber seat ring is

tight against the shoulder of the floating seat,
with rounded outer edge at the rear to facilitate
insertion. The ring is assembled this way when
shipped. See that there is a 1/32” (0.79 mm) mini-
mum radius (do not chamfer) on the edge of the
cavity which holds the floating seat and seat ring.
Oil the outer surface of the seat ring with refrig-
eration oil, and push the assembly into the cavity
seating it firmly and squarely.
8. Slide end plate on shaft and press it in as far as
it will go. Do not allow it to spring out or move
backward. Tighten screws or bolts uniformly to
keep the face of the seat at right angles to shaft.
Tightening of end plate automatically sets seal in
proper position. Be sure to use the torque require-
ment specified for the seal assembly. (See Table
18 on page 36)
After seal installation is completed, rotate
the compressor by hand several times to
help seat the seal mating surface.
Table 18 - TORQUE VALUES FOR MODEL 16799

COMPRESSOR
TORQUE
DESCRIPTION
FT. LBS. KM
Head 25 – 30 3.4 – 4.1
Clamping Stud 32 – 35 4.4 – 4.8
Cylinder to Crankcase 25 – 30 3.4 – 4.1
Shaft End Plate 9 – 15 1.2 – 2.1
Seal End Plate 9 – 15 1.2 – 2.1
36 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
LD01115
Figure 10 - COMPRESSOR REPLACEMENT PARTS – DISCONTINUED MODEL 16799
JOHNSON CONTROLS 37
FORM 50.40-OM1 (713)
Table 19 - COMPRESSOR REPLACEMENT PARTS – DISCONTINUED MODEL 16799

REFERENCE PART NUMBER PART
NUMBER NAME REQUIRED NUMBER
Model 16799 compressor assy. 4 cylinder,3‑1/4” bore x 2‑1/4” stroke 16799
1 Crankcase (includes front & rear bushing) 1 16800
2 Cylinder 2 16801
3 Cylinder Head 2 16702
4 Crankshaft 1 16703*
5 Crankshaft Collar 1 16704*
727 Crankshaft Assembly 1 16705
6 Eccentric 2 16706*
7 Connecting Rod 2 16802*
8 Connecting Rod Link 2 16803*
9 Link Pin 2 16804*
10 Link Pin Retaining Ring 4 16805*
105 Eccentric and Connecting Rod Assy. 1 16806
11 Piston 4 16710
12 Wrist Pin Assembly 4 16709
13 Piston Ring 12 16711
14 Clamping Stud 2 16731
15 Lock Washer 1/2” heavy 2 30013
16 Hex Nut 1/220NF‑2 2 30012
17 Sight Glass Gasket 2 16807
18 Sight Glass 1 16811*
19 Sight Glass Retaining Ring 1 16809*
851 Sight Glass Assembly 1 16808
20 Shaft End Plate 1 16727
21 Shaft End Plate Gasket 1 16726
22 Suction Screen 2 16725
23 Service Valve Gasket 5 16728
24 Oil Fill and Drain Plug 2 16729
25 Crankcase Gasket (Model No. 16799 and D‑799) 2 16724
26 Cylinder Gasket 2 16723
27 Head Gasket 2 16722
28 Suction Reed 4 16718
29 Valve Plate 2 16712*
30 Discharge Reed 4 16713*
31 Discharge Valve Reed Retainer 4 16714*
32 Discharge Valve Spring 8 16715*
33 Discharge Valve Screw 8 16716*
34 Discharge Valve Lock Wire 4 19 Ga.*
742 Valve Plate Assembly (includes repair gaskets) 2 16717
35 Shaft Seal Spring 1 *
36 Shaft Seal Ring 1 *
37 Shaft Seal Carbon 1 *
854 Shaft Seal Assembly (includes repair gasket) 1 16999
38 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
TABLE 19 - COMPRESSOR REPLACEMENT PARTS – DISCONTINUED MODEL 16799 (CONT'D)

REFERENCE PART NUMBER PART
NUMBER NAME REQUIRED NUMBER
38 Seal End Plate Gasket 1 16720
39 Seal End Plate 1 16721
40 Head Pipe Plug 1/8” 3 16036
41 Half Union Elbow 1 16037
42 Flare Cap 1/4” 1 16730
43 Service Valve, Compressor Suction 7/8S. 2 16737
Service Valve, Compressor Discharge 7/8S. 1 16737
44 Dowel Pins 8 16034
Front Bushing ‑ Crankcase 1 16733** 5
Rear Bushing ‑ Crankcase 1 16734**
Complete Gasket Set 1 16816
Discharge Manifold Crossover Tube Assembly 1 16815
* Part cannot be ordered separately. Must be ordered as complete

Assembly.
** Must be line bored and reamed after pressing into crankcase.
All parts used in Model D799 same as Model 16799 except for the following:
Table 20 - MODEL D799 COMPRESSOR PARTS (OLD STYLE)
DETAIL PART NUMBER PART
NUMBER NAME REQUIRED NO.
1 Crankcase (includes front & rear bushing) 1 16900
2 Cylinder 2 16902
Changing the Valve Plate Assembly (See 5. Place the valve plate gasket on the cylinder head
Figure 10 on page 37 and Figure 11 on page following the outline of the cylinder head itself to
40) insure correct gasket position. Use a thin film of
1. Remove cylinder head bolts, cylinder head and refrigerant oil to make gasket adhere to cylinder
valve plate assembly from compressor. head.
2. Remove all traces of gasket material from both 6. Place the cylinder gasket on the cylinder flange
the cylinder and the cylinder head flanges. using a thin film of refrigerant oil to make gasket
adhere to the cylinder flange.
3. Thoroughly clean the cylinder head using a good
solvent as a cleaning agent. 7. Thoroughly clean the valve plate assembly with a
good solvent.
4. Thoroughly clean the top of the pistons and the
cylinder flange: The most efficient manner in 8. Place suction reeds on the cylinder dowel pins.
which to accomplish this is to bring one piston 9. Place the valve plate assembly on the cylinder us-
flush with the top of the cylinder and clean the ing the cylinder dowel pins as a guide.
top of the piston and approximately one‑half of
the cylinder flange in one operation. This process 10. Replace the cylinder head (on which the valve
should be repeated for each cylinder using a good plate gasket has already been placed—See No. 4
solvent as a cleaning agent. above) and make certain the dicharge outlet is op-
Do not allow any solvent to seep into posite the suction port on the cylinder.
crankcase oil. 11. Replace cylinder head and tighten belts, using the
torque requirement specified for the valve plate
(See Table 18 on page 36).
JOHNSON CONTROLS 39
FORM 50.40-OM1 (713)
LD03861
Figure 11 - COMPRESSOR REPLACEMENT PARTS – MODELS RA AND CK
40 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
Table 21 - COMPRESSOR THREE CYLINDER MODEL RA & CK – BM-99301, -99302 & -99303
REFERENCE PART QUANTITY/ PART REFERENCE KIT
NUMBER NUMBER COMPRESSOR NUMBER BMK–
1 Crankcase & Bearing Assembly 1 20012‑1
2 Gasket (Valve Plate) 1 30078 505‑8, 507‑2
3 Valve Plate Assembly 1 VP184 505‑8
4 Gasket (Cylinder Head) 1 30079 505‑8, 507‑2
5 Discharge Leaf 3 25046 505‑8
6 Discharge Leaf Retainer 3 28025 505‑8
7 Spacer Washer 3 12032 505‑8
8 Lock Wire 6 41097 505‑8
9 Discharge Valve Spring 3 26205 505‑8
5
10 Retainer 3 28026 505‑8
11 Discharge Valve Nut 6 11213 505‑8
12 Suction Leaf 3 25045 505‑8
13 Suction Valve Washer 3 12031 505‑8
14 Valve Screw 3 33160 505‑8
15 Discharge Valve Nut 3 11212 505‑8
16 Lockwasher 3 12307 505‑8
17 Cylinder Head 1 24016
18 Capscrew (Cylinder Head) 18 33162
19 Gasket (Adapter Plate) 1 30047 507‑2
20 Adapter Plate 1 41176
21 Capscrew 2 10020‑12
22 Gasket (Discharge S.O.V.) 1 30048 507‑2
23 Discharge S.O.V. 1 31012‑1
24 Screw 2 10012‑6
25 Connector Tube 1 34150
26 Gasket (Suction S.O.V.) 1 30047 507‑2
27 Suction S.O.V. 1 31030
28 Capscrew 2 10020‑14
29 Tee 1 60007
31 Flare Cap 3 3003
32 Suction Strainer Spring 1 26206
33 Gasket (Suction Cover Plate) 1 30016 507‑2
34 Suction Cover Plate 1 41110‑2
35 Capscrew 18 10010‑8
36 Suction Strainer Assembly 1 27508
37 Gasket (Suction Cover Plate) 1 30016 507‑2
38 Suction Cover Plate 1 41110‑1
39 Union 1 60213
40 Main Bearing 2 41099‑P1
41 Dowel Pin 2 41074
43 Capscrew 4 10010‑7
44 End Plate 1 41152
45 Gasket (End Plate) 1 30063 507‑2
JOHNSON CONTROLS 41
FORM 50.40-OM1 (713)
TABLE 21 - COMPRESSOR THREE CYLINDER MODEL RA & CK – BM-99301, -99302 & -99303 (CONT'D)
REFERENCE PART QUANTITY/ PART REFERENCE KIT:
NUMBER NUMBER COMPRESSOR NUMBER BMK–
46 Gasket (Oil Filler Plug) 1 30011 507‑2
47 Oil Filler Plug 1 40176
48 Crankcase Plug (Heater) 1 CBW2682
49 Gasket (Bottom Plate) 1 30065 507‑2
50 Bottom Plate 1 24531
52 Gasket (Sight Glass) 1 30012 625‑1, 507‑2
53 Sight Glass 1 40180 625‑1
54 Gasket (Sight Glass) 1 30013 625‑1, 507‑2
55 Thrust Washer (Sight Glass) 1 40181 625‑1
56 Retainer Nut (Sight Glass) 1 40182 625‑1
57 Seal Nut 1 11031
58 Seal Bellows Assembly 1 41151 509‑4, 509‑5
59 Seal Seat 1 41018 509‑4, 509‑5
60 Seal Ring 1 41014 509‑4, 509‑5
61 Capscrew 8 10010‑7
62 Housing Cover & Bearing Assembly 1 41099‑1 509‑4
63 Gasket (Housing Cover) 1 30060 507‑2, 509‑4
64 Seal Guard 1 41145
65 Lock Washer 2 12109
66 Machine Screw 2 10106‑C6
67 Drive Screw 2 10403C
68 Serial Plate 1 CBW2641
69 Screw 4 33251
70 Lockwasher 4 2177
71 Counterweight 2 23520‑1
72 Crankshaft 1 22518‑5 675‑7
73 Key 1 CBW2625 675‑7
74 Nut 6 11030 AI606‑1
75 Lock Washer 6 2174 AI606-1
76 Connecting Rod 3 AI606‑1
77 Rod Bolt 6 33161 AI606-1
A1604-1
78 Lockscrew 3 10030‑10 AI606-1

79 Lock Washer 3 2174 AI606‑1
80 Piston & Bushing Assembly 3 AI613 AI605
80A* Piston Bushing 6 41149 AI605
81 Piston Ring 9 41150‑1
82 Piston Pin 3 21509 AI605
83 Flywheel Locknut 1 CBW2708 675‑7
85 Flywheel 1 25531‑2
86 Rod Bearing Inserts 6 CBW2508 A1606‑1 AI604-1
Note: Only parts that can be ordered over-sized are 41150-2 .030, AI605 .030, AI613 .030 and CBW2508 .010.
42 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
VACUUM PUMP – MODEL CRR‑1 If the recovery and/or recycle system is free from leaks
and sufficient suction exists, but the discharge pressure
is insufficient, there are several sources to the problem.
Gurgling Noise A simple explanation, there is an insufficient flow of
The vacuum pump will gurgle to varying degrees un- refrigerant vapor into the vacuum pump. Check to see
der three different conditions of performance: that the tubing connecting the suction port to the chiller
is not obstructed. A low oil level or V‑belt slippage can
1. When operating at high pressure as in the begin- cause the same symptoms. If there is a leak in the oil
ning of the evacuation cycle. case of the vacuum pump, this can also cause insuffi-
2. When the oil level in the pump is low. cient discharge pressure. If none of these explanations
fit the observations, the pump may be malfunctioning
3. When a large leak is present in the system being and should be sent back to a repair facility.
evacuated. 5
SHAFT SEAL REPLACEMENT
Suction and Discharge Pressure Problems
To replace the shaft seal of a pump, drain the oil and
Leakage, oil contamination, V‑belt slippage and low remove the pump pulley and key. Remove the screws
oil level are four major causes of insufficient suction securing the old seal and pry it loose with a screw-
or discharge pressure. If the recovery and/or recycle driver or similar wedge, being careful not to mar the
system is free from leaks, and unwarranted suction surface of the pump body against which the seal fits.
problems still exist, the pump should be checked. A Discard the seal and its gasket, inspect all surfaces and
simple criterion for the condition of the vacuum pump repair any damages with a fine abrasive stone. Wipe all
is a determination of its ultimate pressure capability. If sealing areas clean and place a film of DuoSeal oil on
the suction obtainable is very poor, the pump may be both the shaft and the inside bore of the new shaft seal.
badly contaminated, low on oil or malfunctioning. On Using a new gasket, carefully slide the new seal into
the other hand, if the pressure is only slightly higher position and center it on the shaft. It is not necessary to
than the guaranteed ultimate pressure of the pump, an apply any sealant to the gasket. Tighten the mounting
oil change may be all that is required. screws uniformly and refill the pump with DuoSeal oil.
Follow instructions included in repair kit.
LD01114
Figure 12 - VACUUM PUMP REPLACEMENT PARTS – MODEL CRR-1
JOHNSON CONTROLS 43
FORM 50.40-OM1 (713)
Table 22 - VACUUM PUMP REPLACEMENT PARTS – MODEL CRR-1

REFERENCE PART
PART NAME QUANTITY
NUMBER NUMBER
1 Pulley, Includes Setscrew, Item 2 1 41‑2074
2 Socket Head Steel Setscrew 5/16 – 18 x 3/8 1 2‑01‑9306
3 Large End Plate Cover 1 41‑0775
4 Socket Hd. Cap Screw, 1/4 – 20 x 3/4 4 2‑01‑6112
5 Intake Chamber Cover Gasket 1 41‑0234
6 Air Filter 1 41‑1692
7 Air Filter Bracket 1 41‑0663
8 Hex. Hd. Cap Screw 5/16 – 18 x 1 3 2‑01‑0316
9 Washer, Copper 5/16 ID 6 61‑8456A
10 Soc. Hd. Cap Screw 5/16 – 18 x 1 3 2‑01‑6316
11 Shaft Seal, Includes Items 3, 12 & 13 1 1401D
12 Seal Gasket 1 41‑0643
13 Fill Hd. Screw 10 – 32 x 3/8 6 2‑00‑2706
14 Hex Hd. Cap Screw, 1/4 – 20 x 3/4 10 2‑01‑0112
15 Split Lockwasher, 3/4 10 2‑63‑0193
16 Large End Plate 1 61‑8416D
17 Oil Case Gasket 1 41‑0403
19 Washer 6 41‑2363
21 Washer 1 41‑0508
22 Shaft 1 41‑1762
23 Woodruff Key 3 41‑0624
24 Retaining Ring 1 4‑06‑0754
25 Oil Case Assy. (See Note 1) 1 61‑8417D
27 Plug, Oil Fill 1 41‑2933
28 O‑Ring 1 61‑8420
29 Oil Level Window (See Note 4) 2 61‑8418
30 Male Connector 1 61‑8421
31 Copper Seal Cap 1 61‑8423
32 Short Nut 1 61‑8422
33 Drain Valve 1 41‑1734
34 Baffle Plate 1 41‑1769
35 Hex. Nut 1/4 ‑ 20 4 2‑31‑0112
36 Steel Washer, 1/4 4 2‑61‑3100
37 Headless Setscrew 2 41‑2175
38 Ring 1 41‑1760
39 Lower Exhaust Valve 4 41‑1768
40 Upper Exhaust Valve 4 41‑1779
41 Steel Washer 4 2‑61‑0000
42 Rd. Hd. Screw, 1/4 – 20 x 3/8 4 2‑01‑5106
43 Rotor 1 41‑1761
44 Vane 2 41‑1684
45 Spring Holder 2 41‑1685
46 Vane Spring 4 41‑1304
47 End Plate 1 41‑2045
44 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
TABLE 22 - VACUUM PUMP REPLACEMENT PARTS – MODEL CRR-1 (CONT'D)

REFERENCE PART
PART NAME QUANTITY
NUMBER NUMBER
48 Pressure Rls. Tube Number 2 1 41‑1005
49 Steel Ball 3/8 Dia. 1 4‑40‑1200
50 Pressure Release Valve 1 41‑0992
51 Hex Hd. Cap Screw, 5/16 – 18 x 1/4 6 2‑01‑0320
52 Pressure Rls. Tube Number 1 1 41‑0986
53 Sheet Metal Screw Number 6 x 1/4 3 2‑03‑3104
54 Thrust Disk 1 41‑1766
55 End Cap 1 41‑0672
5
*Oil Case Assembly (61-417D) includes oil case, drain valve and level window.
REPAIRING OIL LEAKS

REPAIRING VACUUM LEAKS
Location, Cause and Effect Good vacuum seals are an essential and important at-
Oil leaks may develop wherever two mating faces are tribute of a vacuum pump. A good seal is dependent
sealed with a gasket. Such seams may fail as the result upon the quality of the mating surfaces as well as the
of deterioration of the gasket material, loosening of the sealant and its preparation. The mating faces should be
screws caused by temperature variations, or improper carefully inspected for any projections or foreign par-
care as the result of previous reassembly. Typical gas- ticles which might interfere with proper mating. Slight
keted seams in a vacuum pump are located at the shaft projections such as nicks and burrs are most easily re-
seal and the mating faces of such mechanical surfaces moved by rubbing with a fine abrasive stone. The sur-
as the suction chamber cover, the oil case, and the dis- face of the mating parts may be washed with a solvent
charge chamber cover. The importance of a gasketed or alcohol after which they must be thoroughly dried.
seam is determined principally by its function. If it is
a vacuum seal, the ultimate performance of the pump
is dependent upon it. If it is an oil seal, the pump may
be operated satisfactorily for some time without loss of
function. Eventually, of course, a great loss of oil may
cause harmful damage.
Repairing Technique
Thin composition gaskets are generally used for large
irregularly shaped areas. A replacement joint of this
type should be thoroughly cleaned of all previous gas-
ket material and the mating surfaces cleaned of any
nicks.
JOHNSON CONTROLS 45
FORM 50.40-OM1 (713)
LD17570
Figure 13 - COMPRESSOR DATA SHEET – MODEL 51VSM
46 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
LD17571
Figure 14 - COMPRESSOR DIMENSIONS – ENGLISH – 51VSM
LD17576
Figure 15 - COMPRESSOR DIMENSIONS – METRIC – 51VSM
JOHNSON CONTROLS 47
FORM 50.40-OM1 (713)
LD17572
Figure 16 - COMPRESSOR PARTS – 51VSM
48 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
Table 23 - COMPRESSOR PARTS – 51VSM
LD17573
JOHNSON CONTROLS 49
FORM 50.40-OM1 (713)
LD17574
Figure 17 - COMPRESSOR MAINTENANCE INSTRUCTIONS – 51VSM
50 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
LD17577
Figure 18 - PHOTO, COMPRESSOR, BELT DRIVEN – 51VSM
Table 24 - COMPRESSOR REFRIGERATING CAPACITY – 51VSM: R134A, BTU/HR

CONDENSING TEMPERATURE 104°F
HP REQUIRED EVAPORATING TEMPERATURE °F
MODEL RPM C.INCH
H M L
H M L 50 41 32 23 14 5 -4
800 15 10 7.5 124540 101470 81620 64050 49780 37750 27820
51VSM 1000 57.91 20 15 10 155690 126850 102030 80050 62220 47190 34780
1200 20 15 10 186810 152200 122440 96080 74680 56620 41730
Table 25 - COMPRESSOR REFRIGERATING CAPACITY – 51VSM: R22, BTU/HR

EVAPORATING TEMPERATURE °F
HP
TC
MODEL RPM REQUIRED H M L
°F
H M L 41 32 23 14 5 -4 -13 -22 -31 -40
15 15 15 86 157200 130820 106690 85120 68910 53660 40650 30350 21780 14440
800 20 15 15 104 142870 113660 91440 73040 59220 43830 33010 23280 16420 11570
20 20 15 122 119390 99730 79080 63520 50650 37610 26520 18710 13180 9290
15 15 15 86 196490 163520 133380 106390 86150 67070 50820 37920 27200 18060
51VSM 1000 20 15 15 104 178600 142090 114300 91300 74030 54780 41270 29080 20480 14410
20 20 20 122 149250 124650 98840 79390 63310 47000 33140 23380 16490 11610
20 20 20 86 235770 196220 160070 127650 103380 80480 60990 45500 32630 21680
1200 25 20 20 104 214340 170520 137170 109560 88840 65740 49530 34880 24580 17310
25 25 20 122 179120 149560 118600 95260 75980 56390 39770 28020 19730 13890
JOHNSON CONTROLS 51
FORM 50.40-OM1 (713)
Table 26 - COMPRESSOR CROSS REFERENCE CHART – 51VSM

LD17578
Table 27 - COMPRESSOR SPECIFICATIONS – 51VSM

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LD17579
52 JOHNSON CONTROLS
FORM 50.40-OM1 (713)
The following factors can be used to convert from

English to the most common SI Metric values.
Table 28 - SI METRIC CONVERSION
MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT
Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW)
Power Horsepower 0.7457 Kilowatts (kW)
Flow Rate Gallons / Minute (gpm) 0.0631 Liters / Second (l/s)
Feet (ft) 0.3048 Meters (m)

Length
Inches (in) 25.4 Millimeters (mm)
Weight Pounds (lbs) 0.4538 Kilograms (kg)
Velocity Feet / Second (fps) 0.3048 Meters / Second (m/s)
Feet of Water (ft) 2.989 Kilopascals (kPa)

Pressure Drop
Pounds / Square Inch (psi) 6.895 Kilopascals (kPa)
Temperature
To convert degrees Fahrenheit (°F) to degrees Celsius
(°C), subtract 32° and multiply by 5/9 or 0.5556.
Example: (45.0°F - 32°) x 0.5556 = 27.2°C
To convert a temperature range (i.e., a range of 10°F)
from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.
Example: 10.0°F range x 0.5556 = 5.6 °C range
JOHNSON CONTROLS 53
P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2013 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 50.40-OM1 (713)
Issue Date: July 17, 2013
:Supersedes: Form 40.40-OM1 (904)

Water-Cooled Refrigerant Recovery and Recycling Units: Operation & Maintenance

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Water-Cooled Refrigerant Recovery and Recycling Units: Operation & Maintenance

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WATER-COOLED REFRIGERANT

RECOVERY AND RECYCLING UNITS

OPERATION & MAINTENANCE Supersedes: 50.40-OM1 (904) Form 50.40-OM1 (713)

Indicates a possible hazardous situation Identifies a hazard which could lead to

Indicates a potentially hazardous situa­ Highlights additional information useful

CHANGEABILITY OF THIS DOCUMENT

THIS PAGE INTENTIONALLY LEFT BLANK.

SECTION 4 - MAINTENANCE PROCEDURES......................................................................................................29

SECTION 5 - REPLACEMENT PARTS AND KITS.................................................................................................33

MECHANICAL SPECIFICATIONS – RSR Heater (CFC‑11, CFC‑114 And HCFC‑123 Only

Refrigerant Compressor (High Pressure STORAGE RECEIVER

Valves And Hoses

Table 1 - RSR SPECIFICATIONS – STANDARD

*Wheels add 13" to overall height dimension of RSR-4436 and 4445

Table 2 - RSR SPECIFICATIONS – METRIC

*Wheels add 330 mm to overall height dimension of RSR-4436 and 4445.

MECHANICAL SPECIFICATIONS – PORTABLE The condenser is permanently mounted with refriger-

Low‑pressure tanks use heater cutoff, pressure relief Custom Tanks

GENERAL performance of the RSR condenser and compressor for

Table 5 - SETTINGS FOR PRESSURE SAFETY CONTROL SWITCHES

CUT OUT CUT IN

Figure 1 - YORK RSR SYSTEM FLOW DIAGRAM

-34 94 18 33.8 4 (°C)

TABLE 14 - VAPOR PRESSURE (METRIC) – CFC--

Figure 2 - WIRING DIAGRAM RSR-1100V, -1600V, -1100V114, & -1600V114

Figure 3 - WIRING DIAGRAM RSR-2212 & -2222

Johnson Controls supplies mating

*Interlock Receptacle will not allow Legend

Figure 4 - WIRING DIAGRAM EASY PAK RP-1000V, -114V & -2200

Figure 6 - PIPING DIAGRAM RSR-1100V, -1600V, -1100V & -1600V114

Figure 7 - PIPING DIAGRAM RSR-2212, -2222, -2240, -4436, -4445

THIS PAGE INTENTIONALLY LEFT BLANK.

SECTION 4 - MAINTENANCE PROCEDURES

To change oil: Adding or Changing Oil (Low Pressure Unit)

Compressor turn the compressor over by hand. If pressure rises

Installation of Seal Assembly Installation of Head and Valve Plate

SECTION 5 - REPLACEMENT PARTS AND KITS

1. Gasket Kit BMK-683-7 contains one complete set of all

Figure 9 - COMPRESSOR REPLACEMENT PARTS – MODEL CFC-1000

Table 15 - COMPRESSOR REPLACEMENT PARTS – MODEL CFC-1000

Table 16 - COMPRESSOR TORQUE SPECIFICA- BMK680‑6 Crankshaft and Bearing Kit

7. Make sure that the synthetic rubber seat ring is

Table 18 - TORQUE VALUES FOR MODEL 16799

Figure 10 - COMPRESSOR REPLACEMENT PARTS – DISCONTINUED MODEL 16799

Table 19 - COMPRESSOR REPLACEMENT PARTS – DISCONTINUED MODEL 16799

TABLE 19 - COMPRESSOR REPLACEMENT PARTS – DISCONTINUED MODEL 16799 (CONT'D)

* Part cannot be ordered separately. Must be ordered as complete

Figure 11 - COMPRESSOR REPLACEMENT PARTS – MODELS RA AND CK

78 Lockscrew 3 10030‑10 AI606-1

Figure 12 - VACUUM PUMP REPLACEMENT PARTS – MODEL CRR-1

Table 22 - VACUUM PUMP REPLACEMENT PARTS – MODEL CRR-1

TABLE 22 - VACUUM PUMP REPLACEMENT PARTS – MODEL CRR-1 (CONT'D)

REPAIRING OIL LEAKS

Figure 13 - COMPRESSOR DATA SHEET – MODEL 51VSM

Figure 14 - COMPRESSOR DIMENSIONS – ENGLISH – 51VSM

Figure 15 - COMPRESSOR DIMENSIONS – METRIC – 51VSM

Figure 16 - COMPRESSOR PARTS – 51VSM

Table 23 - COMPRESSOR PARTS – 51VSM

Figure 17 - COMPRESSOR MAINTENANCE INSTRUCTIONS – 51VSM

Indicates a potentially hazardous situa Highlights additional information useful