Refrigerant Management Procedures

To comply with RINA for the class notation:

“GREEN STAR.”

Name of vessel: 45000 DWT CONRO

Name of company: HI AIR KOREA

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 Index

Introduction Page 3
RINA GREEN STAR 3 Page 3
Marpol 73/78 Page 3

Chapter 1
Refrigerant Page 3

Chapter 2
Procedure for leak detector Page 4

Chapter 3
Procedure for refrigerant recovering Page 5
Pump Down Page 5
Caution Page 6

Chapter 4
Record list
Air conditioning unit Page 6
Provision Refrigerant plant Page 7

Chapter 5
Use of different types of refrigerant Page 7

Appendix
1. Diagrammatic details of permanent refrigeration system, HVAC plant.
2. Diagrammatic details of permanent refrigeration system, Provision plant.
3. Manual for R-407C leak detector system.
4. Manual refrigerant recovery system model 1686.05.

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Introduction:
Managing the operation and maintenance of a facility’s air conditioning equipment has always been
a major responsibility. Since the annual cost of operating such systems is a major component in
both the electrical and maintenance budgets, engineering and maintenance managers should take
the necessary steps to ensure systems operate efficiently, effectively, and safely. The phase out of
ozone-depleting refrigerants has made management of chillers and refrigerants even more
important.
The air conditioning and refrigeration package shall be operated and maintained by qualified
personnel. The operators must be familiar with air conditioning and refrigeration systems,
refrigerants and pressurized components.

RINA Rules Green Star Design Pt. F, Ch.7. Sec.3 contains requirements to prevent the sea and
air pollutions.
Generally, the rules refer to applicable parts of Annex I, II, IV, V and VI of Marpol 73/78
consolidated edition 1997.
Annex I: Regulations for the Prevention of Pollution by Oil
Annex II: Regulations for the Control of Pollution by Noxious Liquid Substances in Bulk.
Annex IV: Regulations for the Prevention of Pollution by Sewage from ships.
Annex V Regulations for the Prevention of Pollution by Garbage from ships.
Annex VI Regulations for the Prevention of Air Pollution from ships.

Chapter 1
Refrigerant
Green Star Design Pt.F, Ch.7 Sec.3 chapter 2.3 Prevention of air pollution.
This plan is prepared according to above-mentioned rules and the effect on the ozone layer and
global warming potential have been considered according to The Montreal protocol on Substances
that deplete the ozone Layer.
The Refrigerant Management Procedure applies to the centralized air conditioning plant and the
provision refrigerator plan.
Domestic type stand-alone air conditioning units and refrigerators are not covered by these
requirements.
The emission criteria for refrigerants are limited to the requirements related to the properties of the
refrigerant used with respect to its ozone depleting potential (zero ozone depleting) and to its global
warming potential (ODP / GWP) as defined by the 1987 Montreal Protocol on Substances that

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Deplete the Ozone layer.
Allowed refrigerants are HFC, HFFC gases until 1 January 2020
According to RINA the refrigerants of centralized refrigeration systems are to have a global
warming potential, GWP < 2000.
When this is not possible due to assessed technical reasons (documented in a technical report),
2000 < GWP <4000 is accepted. If GWP < 4000 is used the refrigerant leakage is to be less than
10 x 2000/GWP.

For these systems R – 407C will be used. R – 407C has a GWP of 1650 and an ODP of 0.

Chapter 2
Procedure for leak detector.

A leak detection system appropriate to the applicable refrigerant shall be provided to continuously
monitor the spaces of which refrigerants may leak. Alarms shall be given in the case of leakage
detected when concentrations exceed a predetermined limit.
For the HVAC system there will be installed two sets of detectors, one in air-conditioning plant room
(enclosed area), and one near the compressor in the engine room.
For the provision room will be installed four sets of detectors, one in the engine room near the
compressor and one in each of the cold chambers.
Please see the enclosed manual for R 407C leak detector system for the way of operation and the
location of the sensors.

Annual refrigerant leakage.

Annual refrigerant leaks is to be no more than 10% of the total refrigerant charge for each system.
(If GWP < 4000 is used less than 10 x 2000/GWP)
The refrigerant leaks shall be documented in the refrigerant log-book for the refrigeration plant by
consumption figures to be recorded, whatever used for topping up due to leakage or renewal of
refrigerant during repairs or overhauls.
The refrigerant log-book shall be kept onboard and made available during periodical survey.
Procedures shall be established such that, in the event that the annual leakage exceeds the
maximum allowed, corrective actions shall be undertaken.

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Chapter 3
Procedure for refrigerant recovering.
1. The refrigerant systems shall have suitable means of isolation to allow maintenance
without releasing any bulk quantity of the refrigerant to the atmosphere. Unavoidable
minimum releases associated with recapture or recycling are acceptable provided
recovery units are installed for the evacuation of the system.
2. For refrigerant recovery, compressors shall be capable of evacuating a system charge into
a liquid receiver. Additionally, recovery units shall be provided to evacuate a system either
into existing liquid receivers or into cylinders dedicated for this purpose.

Refrigerant Recovery System

1. The refrigeration systems are inclusive of a refrigerant recovery system model 25176B,
please see the enclosed manual.
2. For refrigerant recovering the compressor has also been designed to be used for
evacuating refrigerant into condenser. (Pump down)

Pump Down
Pump down means that the refrigerant in the refrigeration system is collected temporary in the
condenser. Pump down is accomplished when the refrigerant circuit is repaired, the unit cooler is
stopped for a prolonged period or it is moved to minimize the risk due to refrigerant leakage.

How to pump down the refrigerant:

1. Supply cooling water into the condenser.
2. Open the compressor suction stop valve and condenser inlet stop valve.
3. Close the condenser liquid outlet stop valve. Open the solenoid valve in the liquid line by
hand or electrically.
4. Short circuit the terminal so that the low pressure side of the dual pressure switch will not
function.
5. Operate the compressor and draw the refrigerant on the low pressure side.
6. Stop the compressor when low pressure gauge reading becomes 0.1Bar, and leave it for a
while. When low pressure rises, once again operate the compressor until low pressure
gauge reading becomes 0.1Bar. Low pressure will not rise when this procedure is
repeated two or three times.
7. Stop the compressor and close the condenser inlet stop valve quickly, and then close the
suction stop valve.

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 8. After finishing pumping down, stop condenser water supply.

Caution:
1. If pump down continues for a long time, oil pressure may be lowered more or less,
but does not short circuit the oil pressure protection switch circuit.
2. After finishing pump down, do not forget to restore the short circuit of the terminal
on the low pressure side of the dual pressure switch.

For maintenance please see the manual for the compressor.

Chapter 4
Record list

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Chapter 5
Use of different types of refrigerant.
Where different types of refrigerants are used, measures shall be taken in order to avoid mixing
of this substance.

Moreover we refer to the enclosed documentation;

Appendix
1．Diagrammatic details of permanent refrigeration system, HVAC plant.

2．Diagrammatic details of permanent refrigeration system, Provision plant.

3．Manual for R-407C leak detector system.

4．Manual refrigerant recovery system model 1686.05.

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TECH. SPECIFICATION GAS DETECTION SYSTEM HI AIR KOREA

SCOPE OF SUPPLY FOR REFRIGERANT LEAK DETECTOR

All items will be delivered as loose parts.

Item 1

Gas Detection Monitor ............................................................ 2 set/ ship

Type : MGD- 1,2 Sensor Controller 1 Level Alarm

Item 2

Gas Detector ....................................................................... 3 sets/ ship

Type : MGD- Standard Sensor

Setting point : 300PPM

2013/7/8 Hudong-ZhongHua Shipbuilding H1695A CHARLES

MGD - Murco Gas detector / Monitor

Installation & Operation*

Content Page

1- Installation Instructions 2

2- Location Instructions 3

3- Typical Settings 3

4- Operating Instructions 3

5- Test/Function Instructions 4

6- MGD Decorative Remote Sensor Installation 4

7- Annual test 4

8- Troubleshooting 4

9- Installation and Wiring Diagrams 4

10- Mounting diagrams 4

*Technician use only

This unit must be installed by a suitably qualified technican who will install this unit in accordance with these instructions and the
standards set down in their particular industry/country. Suitably qualified operators of the unit should be aware of the regulations and
standards set down by their industry/country for the operation of this unit. These notes are only intended as a guide and the
manufacturer bears no responsibility for the installation or operation of this unit.
Failure to install and operate the unit in accordance with these instructions and with industry guidelines may cause serious injury
including death and the manufacturer will not be held responsible in this regard.

2010( ASH)

Murco Ltd.
114a Georges Street Lower, Dun Laoghaire Co Dublin. Ireland,
e-mail: info@murco.ie web: www.murcogasdetection.com

1
1- MGD Installation Instructions relay, and the device to be switched to either the N/O or N/C Terminals of the
volt free relay, depending on whether a 12 Volt output is required during an
The main alarm unit and its sensor(s) should be positioned carefully to avoid alarm condition or while the system is on standby. The return from the device
mechanical damage (from moving machinery, doors, etc.) thermal extremes is connected to OV on CN9/CN11
(close to heaters) and should not be placed unprotected in direct strong
drafts/airflows and areas where water or moisture is present unless an 1.4. Voltage Free Relays.
appropriate enclosure is used.
10A @ 120/230 VAC
Avoid routing sensor cabling outside of premises, or between buildings via
overhead cables. Also, sensor wiring should be kept a minimum of 500mm Two Level Unit: One Level Unit:
from mains and telephone cables. (See section on sensor location) 1 & 2 Channel Systems: CN5: Low Level Alarm CN4
CN4: High Level Alarm
When connecting the mains and / or sensor cables ensure a second
mechanical fixing is used. Use a cable tie inside the enclosure within 25mm 4 - 6 Channel Systems: CN10: Low Level Alarm CN10
of the cable gland. CN9: High Level Alarm
CN12: Fault Reporting Relays
When power to the unit is switched on, there is a 3-minute delay before the
system activates. This allows the sensors to warm up to the correct Notes: N/O and N/C refer to contact status in standby mode.
temperature for gas detection. On a two level unit, the green light on the On a two level system, A high level alarm condition on any sensor
alarm panel comes on after the delay, indicating that the system is ready. will override a low level alarm condition on another sensor.
On a one level system the green light comes on immediately. When a unit
has been off or stored for a long time the normalising period may be longer On 4 - 6 Channel two level units, the high level relay may be set for
than 3 minutes. After the 3 minutes has expired alarms may activate. You normal or Fail-Safe operation by setting jumper JP1 on the control
may deactivate the siren until normalisation is complete. (Key switch on 2 unit printed circuit board (Refer to Installation diagram)
level units, remove link on jumper JP1 in the case of a 1 level unit)
Connect leads to terminal block for Common (COM) and N/O and/or N/C
1.1 Remove the front cover. Mount the control unit using the mounting connections as required.
holes in the base such that the sensor cable terminal blocks are at the
1.5. Mains Connection.
bottom of the unit in a convenient position (observing the above note).
Connect mains supply (using 3-core 0.75 mm, Mains Flex for 230V systems
1.2 Wiring to Remote Sensors:
or 3 wire, 18 gauge 0.823mm sq mains flex for 120V Systems) to terminal
block CN3 (on 1 & 2 channel systems), or fused terminal block mounted on
Connect sensor cable (standard 4 wire alarm cable as specified below) to
base of control unit (4 - 6 channel systems), Connections L, N and E. Ensure
sensor terminal block CN1 on control unit positions 1,2,3 & 4. Route
that earth connections to the lid and base of the enclosure are maintained.
cable through the gland to remote sensor No.1.
NOTE: Connection to mains supply must be via an approved readily
Standard Sensors:
accessible, switched and fused (2 or 5 Amp Fuse) plug and socket or
Remove lid of sensor. (To open the sensor enclosure : turn the cable gland ½
as per local wiring regulations which should be within 3 meters (10
turn anticlockwise to loosen the internal nut, depress the clip on top of the
feet) of the control unit.
enclosure and open). Connect the other end of the sensor cable to terminal
• The mains cable used should be of an approved type HAR or
block CN1 positions 1,2,3 & 4. Mount sensor box. Replace lid. Repeat above
Cenelec approved or locally approved equivalent.
sequence for remaining sensors (depending on supplied system
• If replacement of the mains fuse is required use only the
configuration.) Feed the cable through the bottom of the sensor enclosure.
appropriate type from the table below
Please ensure that connections 1 to 4 on the sensor connect to their
Control Unit Type: Fuse Rating Sensor Connection Siren /
corresponding numbers on the terminal block in the main alarm unit,
230V Systems Main Supply Fuse: Auxiallry
otherwise the system will not function correctly.
1 - 2 Channel Unit: 20mm T50mA Not Applicable Not Applicable
230V Fuse
4 - 6 Channel Unit: 20mm T160mA 20mm T250 mA 20mm T315 mA
Maximum Sensor Wiring Length: 230V Systems 230V Fuse 230V Fuse 230V Fuse
1 - 2 Channel Standard Units: 40 Metres 7/0.2mm Alarm Cable
(Max. 3.52 Ohms / Core) Control Unit Type: Fuse Rating Sensor Connection Siren /
4 - 6 Channel Standard Units: 100 Metres 7/0.2mm Alarm Cable
120V Systems Main Supply Fuse: Auxiallry
(Max. 8.8 Ohms / Core) 1 - 2 Channel Unit: 20mm T100mA Not Applicable Not Applicable
120V Fuse
Maximum Sensor Wiring Length: 120V Systems 4 - 6 Channel Unit: 20mm T315mA 20mm T250 mA 20mm T315 mA
1 - 2 Channel Units: 60.9M (200 feet) 22 gauge, stranded 4 wire 230V Fuse 120V Fuse 230V Fuse
Alarm Cable (Max 3.52 Ohms/Wire)
4 - 6 Channel Units: 152.25 Metres (500 feet) 22 gauge, stranded • The blanking plugs for cable entries should only be removed if being
4 wire Alarm Cable (Max 8.8 Ohms/Wire) replaced by cable glands
• Ensure that the live and neutral conductors take the strain before the
You may use different cables and longer distances once the ohmic resistance earth conductor.
shown is not exceeded.
2. MGD - Location Instructions

1.3 External Sounder and uncommitted 12 Volt DC output. Location of Sensors

(Applies to 4 - 6 Channel systems only)
12 volt DC Sounder (12V /150MA max) - connect positive lead to CN9/CN11
(1L/2L models) terminal marked +12V, negative to centre terminal marked
‘BUZZ’.
Sensors must be located within the appropriate wire lengths from the central
control unit.
In all cases the sensor supplied is designed for maximum sensitivity to a
particular gas.

For uncommitted 12 V DC @100mA output is obtained via CN9/CN11 Terminals
‘+12V’ and ‘0V’ This output may be wired via the volt free relays to obtain a
switching 12 volt DC output to drive an external relay or solenoid as follows:
If both the buzzer and 12V DC output are corrected correctly they should not
exceed, 250MA in total.
Connect Terminal ‘+12V’ on CN9/CN11 to the ‘COM’ terminal of the volt free
However, in certain circumstances false alarms may be caused by the
occasional presence of sufficiently high concentrations of other gaseous
impurities. If such a situation is likely to arise installers should check with our
Technical Department so that sensor (s) of suitable cross sensitivity can be
supplied. Examples of situations where such abnormalities may arise include.
• Plant room maintenance activity involving solvent or paint fumes or
refrigerant leaks.

2
 • Plant rooms in fruit ripening/storage facilities because of accidental gas
migration (bananas - ethylene, apples - carbon dioxide)
• Heavy localised exhaust fumes (carbon monoxide, dioxide, propane)
from engine driven forklifts in confined spaces or close to sensors.
A response delay is built in to the system to minimise the possibilities of false
alarms. (Two level units) or may be selected (one level units).
Machinery rooms
There is NO ABSOLUTE RULE in determining the number of sensors and their
location. However a number of simple guidelines will help to make a decision.
Sensors monitor a point as opposed to an area. If the gas leak does not reach the
sensor then no alarm will be raised. Therefore, it is extremely important to
carefully select the sensor location. Also consider ease of access for maintenance.
The size and nature of the site will help to decide which method is the most
appropriate to use. Locations requiring the most protection in a machinery or
plant room would be around compressors, pressurised storage vessels,
refrigerant cylinders or storage rooms or pipelines. Most vulnerable are valves,
gauges, flanges, joints (brazed or mechanical), filling or draining connections etc
When mechanical or natural ventilation is present mount a sensor in the airflow.
In machinery rooms where there is no discernable or strong airflow then
options are:
• Point Detection, where sensors are located as near as possible to the
most likely sources of leakage, such as the compressor, expansion
valves, mechanical joints or cable duct trenches.
• Perimeter Detection, where sensors completely surround the area or
equipment.
• With heavier than air gases such as halocarbon and hydrocarbon
refrigerants such as R404A, propane, and butane sensors should be
located near ground level
• With lighter than air gas e.g. ammonia, the sensor needs to be located
above the equipment to be monitored e.g. on a bracket or high on a wall
within 300 mm of, or on the ceiling provided there is no possibility of a
thermal layer trapped under the ceiling preventing gas reaching the
sensor. (NB. At very low temperatures, such as in a refrigerated cold
store, ammonia gas becomes heavier than air).
• With similar density or miscible gases, such as CO or CO2, sensors
should be mounted about head high – say 1.5m.
• Sensors should be positioned a little way back from any high-pressure
parts to allow gas clouds to form. Otherwise any leakage of gas is likely
to pass by in a high-speed jet and not be detected by the sensor.
• Make sure that pits, stairwells and trenches are monitored since they
may fill with stagnant pockets of gas.
• If a pressure relief vent pipe is fitted to the system, it may be a
requirement to mount a sensor to monitor this vent pipe. It should be
positioned about 2 m above the PRV to allow gas clouds to form.
• With racks or chillers pre-fitted with refrigerant sensors, these should be
mounted so as to monitor the compressors or if extract ducts are fitted
the airflow in the duct may be monitored.
Refrigerated Spaces
In refrigerated spaces sensors should be located in the return airflow to the
evaporators on a sidewall, below head high preferred, or on the ceiling, not
directly in front of an evaporator. In large rooms with multiple evaporators,
sensors should be mounted on the central line between 2 adjacent
evaporators, as turbulence will result in airflows mixing.
Chillers
In the case or small water or air-cooled enclosed chiller units mount the
sensor so as to monitor airflow to the extract fans. With larger models also
place a sensor inside the enclosure under or adjacent to the compressors
In the case of outdoor units:
• such as enclosed air-cooled chillers or the outdoor unit for VRV/VRF
systems mount the sensor so as to monitor airflow to the extract fan.
With large units also place a sensor inside the enclosure under or
adjacent to the compressors
In the case of non-enclosed outdoor units
• If there is an enclosed machinery section then locate a sensor there.
• In the case of units with enclosed compressors, mount sensors in the
enclosures
• Where you have protective or acoustic panels mount the sensor low
down under the compressors where it is protected by the panels.
3
• With air-cooled chillers or air-cooled condensers with non-enclosed
condenser sections it is difficult to effectively monitor leaks in the coil
sections. With some designs it will be possible using an airflow sensor
to monitor airflow to the start –up fans in the front or rear sections.
• If there is a possibility of refrigerant leaks into a duct or air-handling unit
install a sensor to monitor the airflow.
Weatherproof sensors should be used for unprotected outdoor applications.
Air Conditioning – Direct systems VRV/VRF
EN378 states that at least one detector shall be installed in each occupied
space being considered and the location of detectors shall be chosen in
relation to the refrigerant and they shall be located where the refrigerant from
the leak will collect. In this case refrigerants are heavier than air and detectors
should have their sensors mounted low .e.g. at less than bed height in the
case of an hotel or other similar Category Class A spaces. Ceiling or other
voids if not sealed are part of the occupied space.
In a hotel room monitoring in ceiling voids would not
strictly comply with EN378
Do’s Don’ts
• mount the in-room sensor at less than the • Do not mount sensors
normal heights of the occupants e.g in a – under mirrors
hotel room this is less than bed height - – at vanity units
between 200-500mm off the floor. – in or near bathrooms
• away from draughts and heat sources like
radiators etc.
• avoid sources of steam
For further detailed Installation tips covering most installations and equipment
types.. chillers, air cooled chillers etc see our web site www.murco.ie.
Perhaps the most important point of all is not to try and economise by
using the minimum number of sensors possible. A few extra sensors could
make all the difference if a gas leak occurs!
3- MGD - Typical settings
Gas: Refrigerant R404A Low Alarm Set Point: 100ppm
High Alarm set Point: 1000 ppm
For a particular unit please refer to the gas settings shown on the rating plate.
4- MGD- Operating Instructions
The Murco Gas Monitor having been installed in accordance with the
installation instructions is ready to monitor the chosen air space and detect
gas leaks at the pre-set level.
Each of the sensors has a green light to indicate that power is present.
To minimise false alarms, the system has a built in delay, between the arrival
of gas at the sensor unit, and an alarm occurring. For one level units this
delay is approximately 3 minutes. For two level units, this delay is 20-25
seconds before a low level alarm, and 25-30 seconds on a high level alarm.
This delay can be deactivated in a one level unit by moving the link at position
JP1 to the off position. (See technical installation drawing)
Unit Operation
Idle: Only the green light on the panel is on. No gas is present.
If the green light is off, power to the unit has been interrupted. Refer to the
troubleshooting guide.
Alarm Condition
One Level System:
One or more red lights on the panel turn on. The siren and the volt free relays
operate. This indicates that gas at one or more sensors is at a level higher
than the preset alarm point.
Two Level Systems:
Low Alarm: One of more yellow lights on the panel turn on. The sounder
operates intermittently, and the low alarm volt free relay
operates: this indicates presence of a low level of gas on one or
more sensors.
High Alarm: One or more Red Lights on the panel turn on. The sounder
operates continuously, and the High alarm volt free relay
operates: this indicates presence of a High level of gas on one
or more of the sensors.
For the purpose of system maintenance, the siren may be disabled
temporarily, on two level units, by using the key-switch. On one level units
this is achieved by setting a jumper JP1 on the control unit printed circuit
board. The location of this is shown on the Installation Drawing (Separate
drawings for 1 - 2 and 4 - 6 channel units). Remove the link to disable the
alarm
Resetting An Alarm Condition:
On one level units all of which have automatic reset no user intervention is
required. The unit will reset shortly after the gas dissipates. (All one level
systems reset automatically)
Cause: 1. Power failure (check supply)
2. Tripped circuit breaker or blown fuse on electrical supply
2. Blown fuse at the electrical supply on the controller PCB board.
3. Two Level unit only: Has unit warmed up? (This takes 3-4
minutes after power is switched on.)
Symptom: Red Light is on, but no alarm condition is active. i.e No siren and
no relay operation after 3 minutes.
Cause: 1. Make sure the siren has not been deactivated (Key switch on 2
level controllers or link on jumper JP1 on 1 level controllers
removed)
2. This indicates a wiring or sensor fault (call service provider).
If these are in order the calibration pot may have been adjusted
and may need to be reset. Check with us for instructions.

On two level units, low-level alarm conditions will reset automatically when Sensor:
the gas dissipates. High level alarm conditions require a manual reset (By Symptom: Green light on sensor is off.
pressing the reset button) Please note that a high alarm condition can only be
reset 30-60 seconds after the gas clears from around the sensors. Cause: This may indicate a wiring fault between the controller and sensor
or a sensor fault. Check power supply to the controller. Check
connections between the controller and the sensor to ensure that
5- MGD – Test / Function Instructions the wires from positions 1 to 4 on the sensor are connected to the
corresponding 1-4 on the controller. (See “Wiring Remote Sensors).
The MGD is calibrated in the factory and does not require to be calibrated on
installation. After installation the units should be bump tested. Expose the On a 4 to 6 channel unit check that the sensor fuse on the
sensors to test gas using a Murco ampoule (NH3 or CO2 etc) or test cylinder particular sensor connection position in the controller is not blown.
(appropriate to the installation) or if not available, crack open the valve of a
cigarette lighter (only for Semiconductor units) without igniting it and hold it If the fault is not cleared then the sensor has been damaged.
over the vent holes on the upper right side of the sensor. The gas is heavier than
air and should fall into the sensor. This will put the system into alarm. The red If you experience spurious alarms in the absence of a leak, contact
LED will light showing the system is in alarm. The delay will prevent the siren us for instructions and support.
sounding or relay switching for the preset delay, if delay is set.
9- Installation Diagrams
With a bump test you can see the functions of the sensor - the yellow/red led
will light, the relay and sounder will function.
1, 2 Sensor 1 Level Installation Diagram
To test the siren and or relay function, check the delay is set at zero using the
Alarm Panel
header as shown on the installation diagram and expose to gas as above.
JP1 Settings:
Mains Buzzer
Transformer 3 Minute Delay
OFF

After the gas has cleared, the red led, siren and relay will automatically reset
ON

OFF ON
on 1L Units with 2L press the reset button. JP1
Jumper
Link
CN3

Channel 1 Channel 2
Before testing the sensors on site the MGD must have been powered up and
NC
N0

4321 4321
C

allowed to stabilize. Mains

CN1 CN2
Sensor Unit

Volt Free
6- MGD Sensor - Decorative remote sensor head installation Relays 4
If you do not wish to surface mount the MGD Sensor or need to match room 3
2
1
decor, we can supply a decorative faceplate (standard: brushed stainless steel (To operate external
equipment such as a fan etc...
Or initiate plant shutdown)
to fit a 44mm double gang back box in which you can mount the sensor PCB.
(UK and Ireland). 4
3
2
1
1. If construction / decoration is still going on, fit a standard plastic blanking Sensor Unit
plate immediately you install the sensor in the back box to avoid dust or USA - 60.9 metres (200 feet) MAX.
EUROPE - 40 metres MAX.
damage to the in-room sensor. You can fit the SS vented plate when
(Please ensure that connections 1 to 4
decoration is completed. on the sensor connect to their corresponding
numbers on the terminal block in the main alarm
unit, otherwise the system will not function correctly.)
2. Cleaning: the decorative face plate should be lightly dusted – it should
not be sprayed with cleaning/polishing aerosols.
1, 2 Sensor 2 Level Installation Diagram
Alarm Panel
7- MGD Sensor - Annual Test
Mains Buzzer
Transformer
To comply with the requirements of EN378 and the F GAS regulation sensors
must be tested annually. However local regulations may specify the nature and Sensor Unit
CN5
frequency of this test. If not the Murco recommended procedure should be
CN3

Channel 1 Channel 2
followed. Contact us for details.
NC
N0

4321 4321
C

CN4 CN1 CN2 4

Mains 3
2
1
Check local regulations on calibration or testing Volt Free
Relays
requirements. High Alarm Low Alarm
4
3
(To operate external 2
After exposure to a substantial gas leak, sensor should be checked and equipment such as a fan etc...
Or initiate plant shutdown)
1
Sensor Unit
replaced if necessary.
USA - 60.9 metres (200 feet) MAX.
8 - MGD –Troubleshooting EUROPE - 40 metres MAX.

(Please ensure that connections 1 to 4

on the sensor connect to their corresponding
Alarm Panel: numbers on the terminal block in the main alarm
unit, otherwise the system will not function correctly.)
Symptom: No lights displayed on panel.

4
 4, 6 Sensor 1 Level Installation Diagram 4, 6 Sensor 2 Level Installation Diagram
Tansformer Base Earth Connection Lid Earth Connection Tansformer Base Earth Connection Lid Earth Connection
Fused Terminal Block
Fused Terminal Block
Mains
Mains

Fuse = 20mm T160mA/T315mA

(230V/120V) + To Sounder (12v/150mA Max.) Fuse = 20mm T160mA/T315mA
(230V/120V) + To Sounder (12v/150mA Max.)
Uncommitted + 12V@ 100 mA Output + – –
Uncommitted + 12V@ 100 mA Output +
(Ext. Relay/Solenoid, etc.) – (Ext. Relay/Solenoid, etc.) –
Volt Fre Relays: Volt Free Relays:
Fail Safe
CN10 Alarm Output CN10 Low Alarm Output
OFF ON
CN1
Expansion CN9 JP1 ON JP1
OFF Expansion CN9 High Alarm Output
Connector Connector
HD1/HD2 Alarm Panel HD1/HD2
Alarm Panel CN12 Fault Output
CN1
CN1
4321

Repeat for Sensors 2-6

4321
As Required Repeat for Sensors 2-6
JP1 Settings: As Required
OFF ON Jumper
Max Wire Length 3 Minute Delay Max Wire Length
USA - 152.25 metres (500 feet) MAX. Link
EUROPE - 100 metres MAX. USA - 152.25 metres (500 feet) MAX.
OFF ON Jumper EUROPE - 100 metres MAX.
(Please ensure that connections 1 to 4 Link JP1 Settings:
on the sensor connect to their corresponding (Please ensure that connections 1 to 4
ON: Relay RL1 Normally Energised (De-energised
numbers on the terminal block in the main alarm on the sensor connect to their corresponding on High Alarm or Mains Failure Condition)
unit, otherwise the system will not function correctly.) numbers on the terminal block in the main alarm
unit, otherwise the system will not function correctly.) OFF: Relay RL1 Energised On Alarm
(Energised on High Alarm Condition)

Remote Sensor Remote Sensor

4 4
3 3
2 2
1 1

10 - Mounting Instructions

MGD Standard Sensor IP66 (with Splashguard)

mounting
measurements
86.0 53
122 mm
04.5
43.0
7.0

09.0

144 mm
123 mm
103.50

120

120
0.5

42 mm
O 4
8.0

mounting slots =
9mm long x 6mm wide
25.00 36.00 25.00
101 mm

use 5mm - 6mm screws

59 mm

Exd
146mm

m
50 m

90 130 151
130
160

75 m
m

138
Mounting Holes
2 x Clearance for M6

Splashguard

5 thread varies with mo

 59 mm

M42 thread
146mm

IP66 Remote Head, M42 thread, 3m Cable Mounting locations as in IP66

Exd Remote Head,

thread varies with model,
5m Cable

1”BSP thread
112.0mm

thread varies with model

PRV/IP66 Vent Pipe

Monitoring 1’’ BSP Head
3m Cable

1”BSP thread

81.50mm
Key Hole
thread varies withM42 thread
model Reset Button
13.00mm
16.00mm
Airflow Duct Mount 4,6 Sensor Controller Enclosure
Relay Expander Box
m
82.0m
Mounting locations as in IP66

Cut out in duct 260.50mm

for pitot 22mm
130.25mm

Mounting
123.0mm

O5.10mm Holes
O10.00mm

m
.0m
193
240.50mm
224.70mm

146.0
0mm

1”BSP thread
O4.60mm
1,2 Sensor ControllerScrew
Enclosure
5.0
242.50mm
Screw 260.50mm
9.0 5.0
15.5

Cable
67.70mm

X X X X X X Cable Gland
81.50mm

Holes
Holes Diameter x = 12
9.0 x = 12.7mm, PG7
15.5

50.0 X X X X X X X y = 19

50.0
10.0

10.0

Screw
4.8
Screw
4.8
77.2
15.0

15.0

77.2

12.7 74.5 12.7 12.5 5 plcs

15.0

15.0

PG 7
12.7 74.5 12.7 12.5 5 plcs

PG 7

6
TECH. SPECIFICATION REFRIGERANT RECOVERY SYSTEM HI AIR KOREA

SCOPE OF SUPPLY FOR REFRIGERANT RECOVERY

All items will be delivered as loose parts.

Item 1

Recovery unit ....................................................................... 1 set /ship

Type : 1686.05

Item 2

Charging hose with coupling ....................................................1 set /ship

Item 3

Cnnection kit ....................................................................... 1 set /ship

Item 4

Vacuum pump ......................................................................1 set /ship

Type : 1700.61

Item 5

Recovery cylinder with valve & cap ............................................. 5 bottles /ship

Type : 100kg

2013/7/26 Hudong-ZhongHua Shipbuilding H1695A CHARLES

 ROREC
ROREC

Bedienungsanleitung
Instructions for use
Instruction d’utilisation
Instrucciones de uso
Istruzioni d'uso 1686.05
Gebruiksaanwijzing
Instruções de serviço
Οδηγίες Χρήσης

www.rothenberger.com
Intro
DEUTSCH Seite 3
Bedienungsanleitung bitte lesen und aufbewaren! Nicht wegwerfen! Bei Schäden durch
Bedienungsfehler erlischt die Garntie! Technische Äanderungen vorbehalten!
ENGLISH Page 12
Please read retain these directions for use. Do not throw them away! The warranty does not cover
damage caused by incorrect use of the equipment! Subject to technical modifications.
FRANÇAIS Page 21
Lire attentivement le mode d’emploi et le ranger à un endroit s{ur! Ne pas le jetter! La garantie est
annulée lors de dommages d{us à une manipulation erronée! Sous rèserve de modificaions techniques.
ESPAÑOL. Pais de origen Página 30
¡Por favor, lea y conserve el manual de instrucciones! ¡No lo tire! ¡En caso de daños por errores de
manejo, la garantía queda sin validez! Modificaciones técnicas reservadas.
ITALIANO Pagina 39
Per favore leggere e conservare le istruzioni per l’uso! Non gettarle via! In caso di danni dovuti ad
errori nell’ uso, la garanzia si estingue! Ci si riservano modifiche tecniche.
NEDERLANDS Bladzijde 48
Lees de handleiding zorgvulding door en bewaar haar goed! Niet weggoien! Bij schade door
bedieningsfouten komt de garantieverlening te vervallen! Technische wijzgingen voorbehouden.
PORTUGUES Pagina 57
Queiram ler e guardar o manual de instruções! Não deitar fora! Em caso de avarias por utilização
incorrecta, extingue-se garantia! Reservado o direito de alterações técnicas.
EΛΛΗΝΙΚΑ σελίδα 66
Παρακαλούμε διαβάστε και κρατήστε αυτές τις οδηγίες χρήσεως. Να μην τις πετάτε! Η εγγύηση δεν καλύπτει
τις ζημιές που προκαλούνται από λανθασμένη χρήση της συσκευής! Υπόκειται σε τεχνικές τροποποιήσεις.

2
 SAFETY

! WARNING
GENERAL SAFETY GUIDELINES
a) Read all safety, operating guidelines and instructions before operating this unit.
b) This recovery unit should be operated by a qualified technician only.
c) Always wear safety goggles and protective gloves when working with refrigerants to protect your skin and
eyes from refrigerant gases and refrigerant liquid. Avoid getting in touch with causticity liquid or gas.
d) Do not expose the equipment in the sun or rain.
e) Please be sure that any room where you are working is thoroughly ventilated.
f) Use ONLY authorized refillable refrigerant tanks. It requires the use of recovering tanks with a
minimum of 27.6 bar working pressure.
g) Do not overfill the storage tank. Tank is full with 80% of volume. There should be enough space
for liquid expansion---overfilling of the tank may cause a violent explosion. Must use a 80% O.F.P
storage tank or a scale to avoid over filling.
h) Do not exceed the working pressure of Recovering Tank cylinder.
i) Do not mix different refrigerants together in one tank, or they could not be separated or used.
j) Before recovering the refrigerant, the tank should achieve the vacuum level: -0.1mpa, which is for
purging non-condensable gases. Each tank was full of nitrogen when it was manufactured in the
factory, thus the nitrogen should be evacuated before the first use.
k) When the unit is not used, all the valves should be closed. Because the air or the moisture of the air
may harm the recovery result and shorten the service life of the unit.
l) When using an extension cord it should be a 12AWG minimum and no longer than 30 meters, or it
may make the voltage drop and damage the compressor.
m) A dry filter must always be used and should be replaced frequently. And each type of refrigerant must
have its own filter. For the sake of assuring the normal operation of the unit, please use the filter
specified by our company. High quality dry filters will bring high quality services.
n) Special care should be taken when recovering from a "burned-out" system. Use two high acid capacity
filters, in series. When you have finished recovering from the system, flush the unit with a small amount
of clean refrigerant and refrigerant oil to purge off any foreign substances left in the unit.
o) This unit has an internal pressure protector. If the system’s internal pressure is higher than 38.5 bars,
the system will shut-off automatically. Turn off the power switch and release some pressure, then
reset it manually. (See Exploded Drawing 16).
If the unit automatically shuts-off, please restart it after troubleshooting.
Main reason and problem solving for automatic shut-off:
1. Check the output valve, please switch to open.
2. Check the valve on cylinder, please switch to open
3. Check the connecting hose blocked or not, if yes, please replace it (make sure all valves are off).
4. Check the temperature of cylinder, the pressure will rise if the temperature is raise.
(See Page 20 cooling method).

12
 SAFETY

! WARNING
GENERAL SAFETY GUIDELINES
p) The power must be off when switching the recovery valve.
q) If the tank pressure exceeds 21 bars, use the storage tank cooling method to reduce the tank
pressure. (See Page 20 cooling method)
r) To maximize recovery rates, use the shortest possible length of 3/8" or larger hose. A hose no longer
than 0.9 meter is recommended.
s) When recovering large amounts of liquid, use the Liquid Push/Pull method. (See page 19 “System
Push/Pull method”)
t) After recovering, make sure there’s no refrigerant left in the unit. Read the Self-Purging Method
carefully. Liquid refrigerant remained may be expanded and destroy the components.
u) If the unit is to be stored or not used for any length of time, we recommend that it is completely
evacuated of any residual refrigerant and purged with dry nitrogen.
v) To avoid refrigerant losing, we suggest to use a hose with a stop valve.

13
 CONTENTS

CONTENTS
1.Specifications . ..............................................................................................................................................................................................................15
2.Parts diagram and parts list ....................................................................................................................................................................................16
3.Wiring diagram ............................................................................................................................................................................................................17
4.Operation methods ...................................................................................................................................................................................................18
5.Troubleshooting .........................................................................................................................................................................................................20
EC Declaration .................................................................................................................................................................................................................75

14
 INSTRUCTIONS FOR USE AND MAINTENANCE

1. Specifications

Cat.III: R-12, R-134a, R-401C, R-406A, R-500

Cat.IV: R-22, R-401A, R-401B, R-402B, R-407C, R-407D, R-408A, R-409A, R-411A,
Refrigerants
R-411B, R-412A, R-502, R-509, R-417A, R-422D
Cat.V: R-402A, R-404A, R-407A, R-407B, R-410A, R-507
Power Supply 220-240 VAC 50 Hz 220-240 VAC 60 Hz
Motor 1/2 HP AC four pole capacitor start capacitor running
Motor Speed 1450 RPM 1750 RPM
Current Draw 4A 4A
Compressor Type Oil Free Wind cooling Plunger type
High pressure Shut-Off 38.5 bar/3850 kPa (558 psi)
Category III IV V

Recovery Vapor 0.23 kg/min 0.25 kg/min 0.26 kg/min

rate Liquid 1.57 kg/min 1.81 kg/min 1.85 kg/min
Push/Pull 4.6 kg/min 5.57 kg/min 6.22 kg/min
Operating Temp. 0 C°-40 C°
Dimensions 490mm(L)×244(W)mm×353mm(H)
Net Weight 17 kg

15
 INSTRUCTIONS FOR USE AND MAINTENANCE

2. Parts diagram and parts list

ITEM DESCRIPTION ITEM DESCRIPTION

1 BELT 17 RUBBER FOOT
2 TOP COVER 18 BACK PANEL
3 PIN 19 AXIAL FAN
4 SIDE COVER 20 STORAGE HOPPER COVER
5 FRONT PANEL 21 STORAGE HOPPER CLAPBOARD
6 GAUGE COVER 22 CONDENSER
7 LOW PRESSURE GAUGE 23 4"HOSE
8 HIGH PRESSURE GAUGE 24 FILTER
9 KNOB 25 CAPACITOR
10 CIRCUIT BREAKER 26 SWITCH COVER
11 POWER SWITCH 27 CAPACITOR
12 PRESSURE SWITCH 28 COMPRESSOR
13 POWER SUPPLY CORD 29 COPPER PIPE KIT
14 SOCKET 30 CONTROL VALVE
15 RUBBER PLUG 31 U - DISHED PLATE
16 BASE PLATE 32 GAUGE GASKET

16
 INSTRUCTIONS FOR USE AND MAINTENANCE

3. Wiring diagram

ITEM Graphics code DESCRIPTION Remarks

1 XS Power outlet
2 SA Rocker Switches
3 FR Overload protection device
4 M1 Compressor Motor
5 M2 Axial Fan
6 SR Centrifugal switch
7 C1 Start capacitor
8 C2 Running capacitor
9 SP1 High pressure Switchgear
10 ST Motor thermal protectors

17
 INSTRUCTIONS FOR USE AND MAINTENANCE

4. Operation methods 2) If the input valve was throttled back, it

should be fully opened once the liquid has
4.1. Standard liquid/vapor recovery method
been removed from the system (the
1. Make sure the unit is in good operating
manifold gauge set vapor port should also
condition.
be opened at this time).
2. Make sure all connections are correct and tight.
9. Run until desired vacuum is achieved.
3. Open the liquid port of the storage tank.
1) Close the manifold gauge sets vapor and
4. Make sure the Recover/Purge valve is set on
liquid ports.
Recover.
2) Turn off the unit.
5. Open the output port of the unit.
3) Close the unit’s input port and proceed with
6. Open the liquid port on your manifold gauge set;
the Self-Purge Method on the next page.
opening the liquid port will remove the liquid
from the system first. After the liquid has been
removed, open the manifold vapor port to finish CAUTION: Always purge the unit after each use.
evacuating the system. Failure to purge the remaining refrigerant from
the unit could result in the acidic degradation of
internal components, ultimately causing premature
Manifold damage.
gauge set

HVAC-UNIT/APPLIANCE 4.2. Self purging method

CONTAINING REFRIGERANT
Input Procedure for purging remaining refrigerant
REFRIGERANT
Vapor
Filter RECOVERY from this unit
MACHINE
Output 1. Turn INPUT valve to CLOSE; OUTPUT valve to
Liquid OPEN, and recovery tank valve to OPEN.
Liquid
2. Turn the Recover/Purge valve to the Purge
Recovery position.
A scale must be used to avoid
tank 3. Check the connection hose, and ensure all
overfilling the recovery tank
connections are correct and tight. (Same as
7. Turn “INPUT” valve to “LIQUID” position slowly. recovery mode)
Caution: 4. Power on and get started.
--- If the power turns off after starting for some 5. Turn INPUT valve to “PURGE” slowly, and run this
reason, please try to restart, and if it does not unit until desired vacuum level is achieved or low
work, please turn input valve to “CLOSE”. Then pressure protector shuts-off automatically.
turn the power on again, press “START”to start 6. Close the ports on the recovery tank.
the compressor, and turn the INPUT valve to 7. Turn the Power-off, disconnect all hoses and dry
“LIQUID” slowly. the filter.
8. Turn Self-purging to “RECOVER” position, and both
Recover INPUT and OUTPUT valves to “CLOSE” position.
Purge
Purge
9. Finally, cover the cap on INPUT and OUTPUT
connection adaptor.
Recover
Open Open
Liq
ui
d

Purge
Close

Open Open
Liq
ui
d

Purge
8. Slowly open the input port on the unit. Close

1) If the compressor starts to knock, slowly Purge

throttle back the input valve until the
knocking stops.

18
 INSTRUCTIONS FOR USE AND MAINTENANCE

4.3. Liquid push/pull method 1. Put Recover/Purge knob on Recover.

Push/pull method only works with large systems 2. Open Output valve.
where the liquid refrigerant is no less than 10 kg. 3. Open Input valve.
4. When the scale stops rising close all ports.
CAUTION: When using the "Push/pull" method, a 5. Switch off the machine.
scale must be used to avoid over filling the storage
tank, once the siphon is started, it can continue and
overfill the storage tank even if the tank is equipped
with a float level sensor. The siphon can continue
even when the machine is turned off. You must
manually close the valves on the tank and the unit to
prevent overfilling of the recovery tank.

HVAC-UNIT/APPLIANCE
CONTAINING REFRIGERANT Input

REFRIGERANT
RECOVERY
Filter MACHINE
Output

Vapor
Vapor Liquid

Recovery tank
Liquid

A scale must be used to avoid

overfilling the recovery tank Scale

19
 INSTRUCTIONS FOR USE AND MAINTENANCE

4.4. The storage cooling method 6. Throttle the Output valve of the unit so that the
Pre-work cooling procedure output pressure is 100psi greater than the input
1. To start you must have a minimum of 0.5kg of pressure, but never more than 300psi.
liquid refrigerant in the tank. 7. Run until tank is cold
2. Turn the Recover/Purge valve to the Recover
position. 4.5. Tank Cooling Procedure in the recovering process
3. Open the Vapor and Liquid valve of the storage 1. Open the vapor valve of the storage tank (it is
tank. closed while recovering).
4. Power on, and start the compressor. 2. Close the two valves of the manifold gauge set.
5. Open the Input valve and Output valve of the 3. Follow the sixth and seventh items of the
unit. Pre-work Cooling Procedure.

Manifold
gauge set

HVAC System Input

Input
Vapor Refrigerant
Refrigerant Filter
Filter recovery Output recovery
machine tank
Vapor Liquid Output
Liquid Vapor Liquid
Recovery
tank Recovery tank
A scale must be used to avoid
overfilling the recovery tank

5. Troubleshooting

PROBLEM CAUSE ACTION

Fan does not run Power supply cord not attached Voltage Attach the power supply cord.
when power Switch is is not right Check the power supply at job site.
in “ON” position The circuit breaker has cut off Press the button to reset.
The unit is in high pressure shut off Reduce pressure and then press the
button of the High Pressure Switch.
Fan runs but
Output pressure is too high Rotate Input valve to “CLOSE”, Purge
compressor does not
valve to “PURGE”, then rotate Input
start when the Start
valve back to “OPEN”, Purge valve to
Switch is in “ON”
“RECOVER”.
position
Failure in motor, or other electrical Factory service required
components
Purge valve is in “PURGE” position Rotate Purge valve to “RECOVER”
Compressor starts but
Output valve is not open and high pressure Rotate Output valve to “OPEN”
cuts off within a few
activates
minutes
Recovery tank valve is not open Open recovery tank valve
Head pressure too high Reduce tank temperature with
Recovery process too
Storage Tank Cooling Method
slow
Compressor seals are worn Factory service required
Unit does not pull out Connecting hoses are loose Tighten the connecting hoses
a vacuum Leakage in unit Factory service required

20
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 ROAIRVAC
ROTHENBERGER ROAIRVAC®

Bedienungsanleitung
Instructions for use
Instruction d’utilisation
Instrucciones de uso
Istruzioni d'uso R17006116
Instruções de serviço
R17006216
R17006316
R17006416
R17061J16
R17065J16
R17066J16
R17063J16

www.rothenberger.com
A Overview

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2
C ROAIRVAC

6
3

3
 INSTRUCTIONS FOR USE

Safety precautions Description A-B-C

1. Unit is intended for operator professionally Vacuum pump for air evacuation of closed systems
well trained, he must know refrigeration (air conditioners, tanks, etc). This equipment is
foundamentals, cooling systems, refrigerants specially designed for HVAC&R systems.
and possible damages that equipments under The Double Stage of these pump make it feasible to
pressure could cause. achieve the final vacuum level requested for these
2. Read carefully instructions in the literature, type of systems. Besides, the solenoid non-return
strict observance of procedures is main valve avoids any oil mixture due to the backflow
condition for operator safety, constant declared after a power interruption or any other process
performances and unit undamaging. interruption.
3. Wear safety glasses and gloves when handling
refrigerant; avoid contact with refrigerant, General characteristics
blindness and injuries may result to operator.
4. Keep away from flames and hot surfaces;
high temperature decomposes refrigerant 1 Gas Ballast
releasing toxic contaminants very dangerous
for environment and operator. 2 Mis Filter
5. Avoid skin contact; refrigerant has a very low
boiling temperature (approx. -18°C/-3°F) and 3 Oil level sight glass
freezing may occurs.
6. Avoid inhaling vaporized refrigerant gas; it has 4 Oil drainage plug
a narcotic effect.
7. Vacuum pump must always be suitably 5 Vacuum Gauge and Solenoid Valve integrated
earthed. 1/4”SAE connection
8. Even if the pump temperature is not expected 6
to rise a high level during use, it is advisable ON/OFF
to locate the unit so that users cannot make 7
contact with the casing, as burns may result. Cooling Fun
9. Vacuum pump is air cooled with integral fan; 8
use only where air can freely circulate. Characteristics label
10.During operations, do not vent refrigerant in 9
environment.

Material included
1 Vacuum pump
1 Cable
1 Mineral Oil bottle
1 Connector 1/4”SAE –F – 5/16”SAE –M
1 Connector 1/4”SAE –F – 3/8”SAE –M
Instrucions for use

Instruction
10 ENGLISH
 INSTRUCTIONS FOR USE

Technical Data
ROAIRVAC 1.5 ROAIRVAC 3.0 ROAIRVAC 6.0 ROAIRVAC 9.0*
230V,50-60Hz
R17006116 R17006216 R17006316 R17006416
CFM 60Hz/50Hz 1.5/1.2 3/2.5 6/5 9/8
l/min 60Hz/50Hz 42/34 85/71 170/142 255/227
HP 60Hz/50Hz 1/4 1/3 1/2 1
rpm 60Hz/50Hz 1720/1440 1720/1440 3440/2880 3440/2880
Poles 4 4 2 2
Stages 2 2 2 2
Ultimate Vacuum (micron) 25Mikron 25Mikron 25Mikron 25Mikron
Voltage 230V 230V 230V 230V
Frecuency 50/60Hz 50/60Hz 50/60Hz 50/60Hz
Connections 1/4”SAE 1/4”SAE 1/4”SAE 1/4”SAE
1/4”SAE F- 5/16”SAE M
Adaptors
1/4””SAE F-3/8””SAE M
Oil capacity (ml) 250 330 330 590
Dimensions (mmxmmxmm) 315x136x243 335x150x265 335x150x265 400x175x270
Weight (Kg) 9 10,7 11,5 17
Electrovalve (Y/N) Y Y Y Y
Gas Ballast (Y/N) Y Y Y Y
Mist filter (Y/N) Y Y Y Y
Vacuum Gauge (Y/N) Y Y Y Y
Vacuum Gauge OD (mm) 50 50 50 80
Vacuum Gauge Units mbar/Mpa mbar/Mpa mbar/Mpa mbar

ROAIRVAC 1.5J ROAIRVAC 2.5J ROAIRVAC 4.0J ROAIRVAC 6.0J*

100V,50-60Hz
R17061J16 R17065J16 R17066J16 R17063J16
CFM 60Hz/50Hz 1.5/1.3 2.5/2 4/3.5 6/5
l/min 60Hz/50Hz 42/34 71/57 113/99 170/142
HP 60Hz/50Hz 1/4 1/3 1/2 3/4
rpm 60Hz/50Hz 1720/1440 1720/1440 1720/1440 1720/1440
Poles 4 4 4 4
Stages 2 2 2 2
Ultimate Vacuum (micron) 25Mikron 25Mikron 25Mikron 25Mikron
Voltage 100V 100V 100V 100V
Frecuency 50/60Hz 50/60Hz 50/60Hz 50/60Hz
Connections 1/4”SAE 1/4”SAE 1/4”SAE 1/4”SAE
1/4”SAE F- 5/16”SAE M
Adaptors
1/4””SAE F-3/8””SAE M
Oil capacity (ml) 250 350 330 590
Dimensions (mmxmmxmm) 315x136x243 335x150x265 335x150x265 400x175x270
Weight (Kg) 9 10,5 11 17,5
Electrovalve (Y/N) Y Y Y Y
Gas Ballast (Y/N) Y Y Y Y
Mist filter (Y/N) Y Y Y Y
Vacuum Gauge (Y/N) Y Y Y Y
Vacuum Gauge OD (mm) 50 50 50 80
Vacuum Gauge Units mbar/Mpa mbar/Mpa mbar/Mpa mbar
* modells have a different design

ENGLISH 11
 INSTRUCTIONS FOR USE
Set-up of pump before first operation
Pump is supplied without oil charge; before initial
operation, it is mandatory to fill the pump with the
recommended oil charge (see “Filling of oil”).
Filling of oil
Pump must be turned off for filling the oil and level
control.
Pump is supplied with a mineral oil bottle but
without oil charge inside the vacuum pump; before
initial operation, it is mandatory to fill the pump
with the oil up to the indicated oil level in the oil
level sight glass. Only use ROTHENBERGER oil;
different lubricants reduce performance and may
cause irreversible damage to the pump. Warranty is
void if other oil has been used.
For fill-up proceed as follows:
1. Unscrew charging plug (placed on upper part
of pump)
2. Slowly add the oil until middle of sight glass
has been reached (indicated by MAX MIN line)
3. Screw-on the plug again
To avoid excessive filling, it is suggested to only add
the oil with a graduated recipient; in that way it is
easy to check the added volume. In case of excessive
filling, it is necessary to completely empty the pump
and repeat the oil filling procedure.
WARNING: Do not pollute the environment by
spilling oil; the lubricant oil is a special waste and
must be disposed off according to relevant local law
/ guidelines in force.
Connection for evacuation
Shorter hose length or wider ID, as well as straight
path, reduce the evacuation time as the pump
will reach the desired vacuum more quickly. To
prevent backflow of lubricant from the pump into
the evacuated system in case of unexpected power
failure, a solenoid non-return valve is provided at the
suction connection.
Power Supply
Always check the power supply; it has to comply
with the data on the rating label on the pump. The
pumps’ motor is equipped with a thermal overload
protection with automatic reset and cuts off power
supply at +130°C / +266°F.
General precautions
12
The pumps’ motor must always be suitably grounded.
The pump temperature is not expected to rise to
a very high level during operation; however it is
advisable to locate the unit in such a way that no
contact can be made, as it may cause burns. When
using the pump with other equipment, it must be
ensured that the pump is fixed properly and safe to
use for the operator. Vacuum pump is air cooled by
built-in fan; only use where the air can freely circulate
and keep it away from walls or obstacles no less than
2” (5 cm). Do not cover the pump during operation.
Operation
To guarantee reliability and high level of quality,
each pump is subjected to a rigorous testing and
suitable preliminary running in before it leaves the
factory. Constant performance and long operating
life are assured by strictly observing the following
procedures:
Pump start
Before the first initial run, it is mandatory to:
1. fill the pump with the provided oil (see section
“filling of oil”).
2. Before subsequent start-ups, always check the
oil level before starting the pump. If necessary,
top-up or replace the oil.
3. before connecting the pump to the system to
be evacuated, check that there is no pressure
inside. In case of connecting the pump with
a pressurized system, the vacuum gauge may
break. The vacuum gauge measures negatives
pressures and get collapsed with positive
pressures. Warranty is void if the pump is
connected to a positive pressure.
4. connect the pump to the system to be evacuated
by the necessary equipment (quality hoses,
quality manifolds,etc). The evacuation quality
will be directly related to the way of conecction
and to the equipment quality.
In case of malfunctioning, stop the pump and call the
Service- After-Sales.
Pump stop
As the mixture of incompatible lubricants (pump
oil and compressor oil) can lead to pump failure,
installing a non-return solenoid valve at the suction
connection is required (provided). In case of frequent
on-off cycling, do not stop the pump but shut-off at
the charging hose or manifold instead.
ENGLISH
 INSTRUCTIONS FOR USE
Routine maintenance
Periodic and correct maintenance of the vacuum
pump will ensure a long operation life and constant
performance.
Lubrication
The oil provided with the pump has been specially
formulated & manufactured to lubricate vacuum
pumps; it is special as it features minimum viscosity
fluctuation when in use under a wide temperature
range. The type of lubricant supplied with the
pump allows the evacuation of systems operating
with CFC, HCFC and HFC refrigerants. Working with
ROTHENBERGER POE synthetic oil is also feasible.
Both ROTHENBERGER oil types available after order.
Volumes to be filled into the pumps are specified in
section 1.1. Replace the initial oil charge no later than
150-200 hours of operation; further replacements
should be carried out every 600 hours of correct
usage.
Oil could be polluted by other oil, humidity,
refrigerants, etc. It is mandatory to use oil in perfect
conditions to assure a perfect performance of the
pump.
Oil-change
Over-used lubrication oil damages the pumps’
mechanism; make sure to replace oil as soon as it
starts to turn cloudy. For conducting the oil-change,
ENGLISH
the pump must be switched off. For changing the oil
proceed as follows:
1. Unscrew the oil drainage plug located on the
lower part of the pump
2. Check that oil comes out completely from the
pump
3. Tightly screw the oil drainage plug back on
4. Re-fill the pump with oil (see “Filling of oil”)
WARNING: Do not pollute the environment by
spilling oil; the lubricant oil is a special waste and
must be disposed of according to relevant local law
/ guidelines in force.
Extraordinary maintenance / repair
Conduct extraordinary maintenance or repair
whenever serious faults occur such as overheating,
poor ultimate vacuum, persistent loudness / noise,
blocked pump or any other irregular functioning.
In that case, the pump needs to be disassembled,
parts need to be cleaned, repaired or replaced.
Only qualified service staff shall carry out such
maintenance or repair work; otherwise the warranty
will be void. For any information please contact our
Service-After-Sales.
Problem and Solution
13
 INSTRUCTIONS FOR USE

Problem
The pump doesn’t work
Overheating
Poor ultimate vacuum
Persistent loudness / noise
Blocked pump
Oil overconsumption
The vacuum gauge doesn’t move 1. Check that the pump sucks air in. If the pump sucks air in, it is posible
but the engine is running.
Solution
1. Check that the pump is connected to the power supply.
2. Check that the plug and cable are not damaged.
3. Check that the power supply is suitable for the pump requirements
(see the label of the pump).
4. Check that the pump is filled up with oil (see section 2.1).
5. Contact our Service-After-Sales.
1. Check that the pump is filled up with oil (see section 2.1).
2. Check that the pump is bot covered and that air could flow easily.
3. Check that the power supply is suitable for the pump requirements
(see the label of the pump).
4. Contact our Service-After-Sales.
1. Check that the pump has been working for the enough time. The
final vacuum level is directly related with the time of performance.
The time must be according to the volume to be evacuated.
2. Check that there is no leak in the connection or in the system to be
evacuated. Switch off the pump and check that the vacuum level
remains.
3. Check that all the connections and the equipment used are the
appropriate ones.
4. Contact our Service-After-Sales.
1. Check that there are not damages on the fun cover. Any impact on
this area could affect in the fun movement.
2. Check that the pump is perfectly srewed.
3. Contact our Service-After-Sales.
1. Contact our Service-After-Sales.
1. Check that the oil is ROTHENBERGER oil.
2. Check that the drainage plug is perfectly closed and there is not oil
spill.
3. Check that there is no leak in the connection or in the system to be
evacuated. Open systems increase the oil consuption.
4. Contact our Service-After-Sales.
that the vacuum gauge is damaged. If the pump doesn’t suck air in,
it is posible that the non-return solenoid valve is bloqued.
2. Contact our Service-After-Sales.

GB When its useful life is over, do not dipose or the machine

into the domestic waste, please send it to auhorised
places for recycling.

14 ENGLISH
Notes

35
36
ITEM CODE QTY ITEM CODE QTY
1 R17A601 1 27 R17A627 1
2 R17A602 1 28 R17A628 2
3 R17A603 1 29 R17A629 1
4 R17A604 4 30 R17A630 1
5 R17A605 1 31 R17A631 1
6 R17A606 1 32 R17A632 1
7 R17A607 1 33 R17A633 1
8 R17A608 1 34 R17A634 1
9 R17A609 1 35 R17A635 1
10 R17A610 1 36 R17A636 1
11 R17A611 8 37 R17A637 1
12 R17A612 8 38 R17A638 2
13 R17A613 1 39 R17A639 1
14 R17A614 2 40 R17A640 1
15 R17A615 1 41 R17A641 1
16 R17A616 1 42 R17A642 4
17 R17A617 1 43 R17A643 1
18 R17A618 1 44 R17A644 1
D Spare parts - ROAIRVAC 1.5

19 R17A619 1 45 R17A645 1
20 R17A620 1 46 R17A646 1
21 R17A621 4 47 R17A647 1
22 R17A622 4 48 R17A648 4
23 R17A623 2 49 R17A649 1
24 R17A624 1 50 R17A650 1
25 R17A625 1 51 R17A651 1
26 R17A626 1 52 R17A652 1
 D
C

ITEM CODE QTY ITEM CODE QTY

1 R17B601 1 27 R17A627 1
2 R17B602 1 28 R17A628 2
3 R17B603 1 29 R17B629 1
4 R17A604 4 30 R17B630 1
5 R17B605 1 31 R17B631 1
6 R17A606 1 32 R17B632 1
7 R17B607 1 33 R17B633 1
8 R17A608 1 34 R17B634 1
9 R17A609 1 35 R17B635 1
10 R17A610 1 36 R17A636 1
11 R17A611 8 37 R17A637 1
12 R17A612 8 38 R17A638 2
13 R17B613 1 39 R17A639 1
14 R17A614 2 40 R17A640 1
15 R17B615 1 41 R17A641 1
16 R17B616 1 42 R17A642 4
17 R17B617 1 43 R17B643 1
18 R17A618 1 44 R17A644 1
E Spare parts - ROAIRVAC 3.0

19 R17A619 1 45 R17A645 1
20 R17B620 1 46 R17B646 1
21 R17A621 4 47 R17A647 1
22 R17A622 4 48 R17A648 4
23 R17A623 2 49 R17B649 1
24 R17B624 1 50 R17A650 1
25 R17B625 1 51 R17A651 1
26 R17B626 1 52 R17B652 1

37
38
ITEM CODE QTY ITEM CODE QTY
1 R17B601 1 27 R17A627 1
2 R17B602 1 28 R17A628 2
3 R17B603 1 29 R17B629 1
4 R17A604 4 30 R17B630 1
5 R17B605 1 31 R17B631 1
6 R17A606 1 32 R17B632 1
7 R17B607 1 33 R17B633 1
8 R17A608 1 34 R17B634 1
9 R17A609 1 35 R17B635 1
10 R17A610 1 36 R17A636 1
11 R17A611 8 37 R17A637 1
12 R17A612 8 38 R17A638 2
13 R17B613 1 39 R17A639 1
14 R17A614 2 40 R17A640 1
15 R17C615 1 41 R17A641 1
16 R17C616 1 42 R17A642 4
17 R17B617 1 43 R17B643 1
18 R17A618 1 44 R17A644 1
F Spare parts - ROAIRVAC 6.0

19 R17A619 1 45 R17A645 1
20 R17C620 1 46 R17B646 1
21 R17A621 4 47 R17A647 1
22 R17A622 4 48 R17A648 4
23 R17A623 2 49 R17B649 1
24 R17B624 1 50 R17A650 1
25 R17B625 1 51 R17A651 1
26 R17B626 1 52 R17B652 1
 D
G

ITEM CODE QTY ITEM CODE QTY

1 R17D601 1 24 R17D622 1
2 R17A604 4 25 R17A628 2
3 R17D602 1 26 R17D623 1
4 R17D603 1 27 R17D624 1
5 R17D604 1 28 R17D625 1
6 R17D605 1 29 R17D626 1
7 R17A623 2 30 R17D627 1
8 R17D606 1 31 R17D628 1
9 R17D607 1 32 R17D629 1
10 R17D608 1 33 R17D630 1
11 R17D609 1 34 R17D631 1
12 R17D610 1 35 R17D632 1
13 R17D611 1 36 R17D633 1
14 R17D612 1 37 R17D634 1
15 R17D613 1 38 R17A644 1
16 R17D614 1 39 R17A645 1
17 R17D615 1 40 R17A642 4
18 R17D616 1 41 R17D635 1
19 R17D617 1 42 R17D636 2
20 R17D618 1 43 R17A647 1
21 R17D619 1 44 R17D637 1
22 R17D620 1 45 R17D638 1
C Spare parts - ROAIRVAC 9.0

23 R17D621 1 46 R17D639 1

39
40
ITEM CODE QTY ITEM CODE QTY
1 R17A601 1 27 R17A627 1
2 R17A602 1 28 R17A628 2
3 R17A603 1 29 R17A629 1
4 R17A604 4 30 R17A630 1
5 R17A605 1 31 R17A631 1
6 R17A606 1 32 R17A632 1
7 R17A607 1 33 R17A633 1
8 R17E608 1 34 R17A634 1
9 R17A609 1 35 R17A635 1
10 R17A610 1 36 R17A636 1
11 R17A611 8 37 R17A637 1
12 R17A612 8 38 R17A638 2
13 R17A613 1 39 R17A639 1
14 R17A614 2 40 R17A640 1
15 R17E615 1 41 R17E641 1
16 R17E616 1 42 R17A642 4
17 R17A617 1 43 R17A643 1
18 R17A618 1 44 R17A644 1
19 R17A619 1 45 R17A645 1
H Spare parts - ROAIRVAC 1.5J

20 R17C620 1 46 R17A646 1
21 R17A621 4 47 R17A647 1
22 R17A622 4 48 R17A648 4
23 R17A623 2 49 R17A649 1
24 R17A624 1 50 R17A650 1
25 R17A625 1 51 R17E651 1
26 R17A626 1 52 R17A652 1
 D
ITEM CODE QTY ITEM CODE QTY
1 R17B601 1 27 R17A627 1
2 R17B602 1 28 R17A628 2
3 R17B603 1 29 R17B629 1
4 R17A604 4 30 R17B630 1
5 R17B605 1 31 R17B631 1
6 R17A606 1 32 R17B632 1
7 R17B607 1 33 R17B633 1
8 R17E608 1 34 R17B634 1
9 R17A609 1 35 R17B635 1
10 R17A610 1 36 R17A636 1
11 R17A611 8 37 R17A637 1
12 R17A612 8 38 R17A638 2
13 R17B613 1 39 R17A639 1
14 R17A614 2 40 R17A640 1
15 R17B615 1 41 R17E641 1
16 R17F616 1 42 R17A642 4
17 R17B617 1 43 R17B643 1
18 R17A618 1 44 R17A644 1
CI Spare parts - ROAIRVAC 2.5J

19 R17A619 1 45 R17A645 1
20 R17F620 1 46 R17B646 1
21 R17A621 4 47 R17A647 1
22 R17A622 4 48 R17A648 4
23 R17A623 2 49 R17B649 1
24 R17B624 1 50 R17A650 1
25 R17B625 1 51 R17E651 1
26 R17B626 1 52 R17B652 1

41
42
ITEM CODE QTY ITEM CODE QTY
1 R17B601 1 27 R17A627 1
2 R17B602 1 28 R17A628 2
3 R17B603 1 29 R17B629 1
4 R17A604 4 30 R17B630 1
5 R17B605 1 31 R17B631 1
6 R17A606 1 32 R17B632 1
7 R17B607 1 33 R17B633 1
8 R17E608 1 34 R17B634 1
9 R17A609 1 35 R17B635 1
10 R17A610 1 36 R17A636 1
11 R17A611 8 37 R17A637 1
12 R17A612 8 38 R17A638 2
13 R17B613 1 39 R17A639 1
14 R17A614 2 40 R17A640 1
15 R17C615 1 41 R17E641 1
16 R17G616 1 42 R17A642 4
17 R17B617 1 43 R17B643 1
18 R17A618 1 44 R17A644 1
19 R17A619 1 45 R17A645 1
J Spare parts - ROAIRVAC 4.0J

20 R17G620 1 46 R17B646 1
21 R17A621 4 47 R17A647 1
22 R17A622 4 48 R17A648 4
23 R17A623 2 49 R17B649 1
24 R17B624 1 50 R17A650 1
25 R17B625 1 51 R17E651 1
26 R17B626 1 52 R17B652 1
 D
K

ITEM CODE QTY ITEM CODE QTY

1 R17D601 1 24 R17D622 1
2 R17A604 4 25 R17A628 2
3 R17D602 1 26 R17D623 1
4 R17D603 1 27 R17H624 1
5 R17D604 1 28 R17D625 1
6 R17D605 1 29 R17D626 1
7 R17A623 2 30 R17D627 1
8 R17D606 1 31 R17D628 1
9 R17H607 1 32 R17D629 1
10 R17D608 1 33 R17D630 1
11 R17D609 1 34 R17D631 1
12 R17D610 1 35 R17D632 1
13 R17D611 1 36 R17D633 1
14 R17D612 1 37 R17D634 1
15 R17D613 1 38 R17A644 1
16 R17D614 1 39 R17A645 1
C Spare parts - ROAIRVAC 6.0J

17 R17H615 1 40 R17A642 4
18 R17D616 1 41 R17D635 1
19 R17D617 1 42 R17D636 2
20 R17D618 1 43 R17A647 1
21 R17D619 1 44 R17D637 1
22 R17D620 1 45 R17D638 1
23 R17D621 1 46 R17D639 1

43
04.09