CFC Class INTRODUCTION

INTRODUCTION
The Environmental Protection Agency (EPA) in complying with the section 608 of the Clean Air Act requires testing on legal and environmental concerns for Recovery / Recycling and use or transportation of refrigerants.

Testing Requirements
All candidates should be tested on the following. n Importance of stratospheric ozone n Theory of ozone loss n Basic Knowledge of air conditioning and refrigeration operation n Good service practices n Regulatory Requirements

November 14, 1994

This is the day that the LAW took affect. The Law states that anyone purchasing class 1 or class 2 refrigerants will require EPA certification. MVAC Section 609 Certification HVACR Section 608 Certification

HVACR Section 608 Certification Title VI

Four types of certification n Type I Small Appliance Small Equipment
n Household

Refrigerators with more then 5 lbs of refrigerant

n n n

Type II High Pressure Appliance

n Equipment n Very

Type III Low Pressure Appliance

large commercial Equipment in all above types

Universal
n Certification

Exam Breakdown
The Exam is broken into four parts you must pass all four parts to receive universal certification. Universal certification allows you to buy refrigerants that pertains to any of the Type I, II or III machines. Universal certification does not allow you to service MVAC equipment or purchase MVAC refrigerants.

Exam Breakdown
n n n

CORE
n

This portion must be passed to be certified in any type. This portion must be passed to be certified in small appliances This portion must be passed to be certified in High Pressure Equipment This portion must be passed to be certified in Low Pressure Equipment.

Type I
n

Type II
n

Type III
n

CORE

Refrigerants And Oils

Refrigerants are chemically structured as three different types.
n

CHLOROFLUOROCARBONS (CFC) HYDRO CHLOROFLUOROCARBONS (HCFC) HYDRO FLUOROCARBONS (HFC)

CHLOROFLUOROCARBONS CFC
n n

Chemical Make up
n

CHLORINE , Fluorine, and Carbon

Most harmful to environment

Chlorine destroys Ozone n Chlorine Molecule is very stable and last long in the environment.
n

n n n

Classified as Class 1 Substance. Production stopped in December 31, 1995

n

This does not mean use. R-11, R-12, R-13, R-14, R-113, R-114, R-500 and R-502

Examples of CFCs
n

n n

HYDRO CHLOROFLUOROCARBONS HCFC Chemical Make up

n

Hydrogen, CHLORINE , Fluorine, and Carbon Chlorine still destroys Ozone Chlorine Molecule is not as stable as in CFCs and does last as long in the environment. This results with less damage to the Ozone

Less harmful to environment than CFCs

n n

n n n n

Classified as Class 2 Substance. HCFCs may be used as interim replacements for CFCs. Still in Production until the year 2030
n

Acceleration may push year to 2020 R-22, R-123 and R-124

Examples of CFCs
n

HYDRO FLUOROCARBONS HFC

n n n n n n

Chemical Make up
n

Hydrogen, Fluorine, and Carbon NO Chlorine to destroy Ozone

Not harmful to environment like CFCs or HCFCs

n

Classified as Class 3 Substance. HFCs are the long term replacement for CFCs an HCFCs Still in Production Refrigerant of the future Examples of HFCs
n

HFC-134a replacement for R-12, HFC-32, HFC-152a, HFC125, HFC-143a

Compare Damage To Stratosphere

R-12 R-11 Atmospheric 100 Lifetime YRS Ozone depletion potential 0.93 45 YRS 1.0 R-22 11.8 YRS 0.05 R-134a 13.6 YRS 0.000

High Pressure / Low Pressure Refrigerants

Refrigerants can also be categorized by pressure. Refrigerants with low boiling points, operate with high pressure. Refrigerants with high boiling point operate with low pressures. R12, R-22, R-114 and R-500 are high pressure refrigerants. R-11 and R-123 are low pressure refrigerants.

R-11 High Boiling point 74.7 operates at low pressure 17.3 Hg.

R-22 low Boiling point -41.4 operates at high pressure 0.5 PSI

Refrigerant Blends
Some refrigerants are a combination of two or more refrigerants. n Blends Can be HCFC based, HFC based, or a combination of both. n HFC-based blends are long-term replacements. n HCFC-based blends are short-term replacements. n Binary blend is a blend of two different refrigerants. n Ternary Blend is a blend of three different refrigerants. Example: Popular Azeotropic binary blend mixtures. R-500 (R-12 and R-152a) R-502 (R-22 and R-115)

CFC-12 Replacement Refrigerants

n

HFC-134a will be a long-term CFC-12 replacement for high and medium temperature stationary refrigeration and air conditioning applications, and automotive air conditioning. Near-azeotropic, short-term, ternary blends manufactured by Dupont consisting of HCFC-22, HCFC-152a, and HCFC-124 with varying percentages for different temperature applications. DuPont is manufacturing these blends under the tradenames of SUVA Mp39, MP66, and Mp52.

CFC-11 Replacement Refrigerants

HCFC-123 is a short-term, retrofit and OEM refrigerant replacement for CFC-11 in Centrifugal chiller applications n Alternative for new chiller applications include HCFC-123, HFC-134a, ammonia, HCFC-22, and lithium bromide and water absorption systems. n HCFC alternatives will be short-term because of their chlorine content.
n

Near Azeotropic & Azeotropic Refrigerant Mixtures

n

Near-Azeotropic Mixtures
n

A blend which acts very similar to an azeotrope, however, it has a small volumetric composition change and temperature glide, or range of temperatures, as it evaporates and condenses.
n

Example: MP and HP series Refrigerant blends manufactured by Dupont

Azeotropic Mixtures
n

A mixture of two or more liquids, which, when mixed in precise proportion, from a compound having a boiling temperature which is independent of the boiling temperatures of the individual liquids. The same numbers of molecules vaporize at the same rate. The liquid and vapor have the same composition.
n

Example: R-502 consists of R-22 and R-115

R-500 consists of R-12 and R-152a

Refrigerant oils
n n

Refrigerant oil is used in the system to lubricate the compressor. Refrigerant oil tends to mix and travel in the system with the refrigerant. Hence, the oil must be made compatible with the refrigerant. Different refrigerants use different types of oil. Mineral Oils
n

Mineral oils were used with CFC systems, however mineral oil is not as compatible with HCFC systems, and has no compatibility at all with HFC systems. Synthetic oils are used in all new HFC and HCFC systems today. Synthetic oils are not natural oils they are man made products. The names of the oils are as follows:
n n n

Synthetic oils
n

Alkylbenzene = HCFC Based systems Glycols = First oil used with HFC systems. (attracts moisture) Esters = Second Generation Lubricant used with HFC systems

Ozone Depletion
n

The Atmospheric that surrounds the earth has 3 regions.

n Troposphere
n Oxygen

= ( Ground level7 miles above earth) = ( 730 miles above earth)

(O2) located here for us to breath.

n Stratosphere
n Ozone

(03) located here to protect us as a shield from the suns ultra violet rays.

n Ionosphere
n Space

= (30-300 miles above earth)

No, Oxygen No Ozone

Transportation
Transportation evolves the switching of desired locations. n Example:
n
n When

Ozone move from the stratosphere to the troposphere it creates what we know as (smog). n When Oxygen moves from the troposphere to the stratosphere it creates the a ( thinning of ozone layer).
n

Ozone Depletion is something totally different.

n Ozone

depletion is when to much ultraviolet radiation is allowed to penetrate the troposphere.

Stratospheric Ozone
n n

Filters ultraviolet rays UV shielding earth of ultraviolet radiation. Ozone Reduction causes
n n n n

Skin Cancer Cataracts Disrupt Human Immune System Disrupt Marine Life Food Chain And Plat Life.

n n

One percent reduction of ozone results in two percent increase in UV radiation CFCs released into the troposphere reach the stratosphere and cause ozone depletion.

One chlorine atom can destroy 100,000 ozone molecules

Evidence of Ozone Depletion

Testing of the upper stratosphere has shown that chlorine monoxide is present. It has also shown levels of CFCs in the stratosphere. This means the are ozone layer is being destroyed.

Global Warming
n

The GREEN HOUSE AFFECT

n

Global warming or the green house affect takes place when the heat is trapped in the troposphere.

CFCs when compared to HCFCs and HFCs are the leading cause of the green house affect. HCFC's and HFCs have low global warming potentials. While CFCs have high global warming potentials. Compound CFC-11 CFC-12 HCFC-22 HCFC-123 HFC-134a ODP 1.0 0.93 0.05 0.016 0 GWP 1.0 3.10 0.34 0.02 0.27

Regulatory Requirements
Summary Of Dates September 16, 1987 1989 Montreal Protocol Signed by United States Omnibus Budget Reconciliation Act Levied Excise tax on the sale of CFCs EPA published (ANPRM, 55 FR 18256) Advance notice of CFC recycling program

May 1, 1990

June 29, 1990 Second Meeting of the Montreal Protocol Phase out of already regulated CFCs Ordered By year 2000 and HCFCs by 2020 and no later then 2040 November 15, 1990 Clean Air Act amendments signed calling for controlling Ozone depleting Substances 1991 Original Excise tax increased November 25, 1992 The Forth Meeting on the Montreal Protocol acceleration of the phase out is ordered. HCFCs are added to the list of chemicals controlled under the Montreal protocol. The scheduled called for the stopping of production of Halons in 1993 and CFCs after 1995 HCFCs until 2030. (Acceleration may drop to the year 2020) ( The COPENHAGEN REVISIONS)

Regulatory Requirements
Summary Of Dates July 1, 1992 May 14, 1993 June 14, 1993 November 15, 1993 November 14, 1994 November 15, 1995 December 31, 1995 Illegal to vent any CFC or HCFC Refrigerants Approximately 90 other nations signed the Montreal Protocol Leak Rate Rules become effective Rules for Recovery/ Recycling machines became Affective Only Certified technicians are permitted to buy refrigerant Illegal to vent substitutes for CFC and HCFC refrigerants. CFC production and importation stopped.

Montreal Protocol
September 16, 1987 the United States and 22 other countries signed the Montreal Protocol. n As of May 14, 1993 more then 90 nations approximately 95% of the worlds production capacity for CFCs and Halons had signed the Montreal Protocol. n The Montreal Protocol was agreement between nations to reduce the production of all ozone depleting substances.
n

Total United States CFC use by market in 1994

New Mobile Air Conditioning Other

3% 3% 13% 13% 4%

4% 6% 6% 4% 13%

Sterilant Propellant Other Lubricant Removal Electrical Cushioning Packaging Insulation Existing Equipment service New A/C Equip. Mobile A/C Service

19%

6%

6%

Section 608 Regulations of the Clean Air Act Signed Originally November 15,1990
n

n n n

n n

Requires service practices that maximize recycling of ozone- depleting compounds ( both Chlorofluorocarbons [CFCs] and Hydro chlorofluorocarbons [HCFCs] and their blends) during the servicing and disposal of air- conditioning and refrigeration equipment. Set Certification Requirements for Recycling and Recovery Equipment, Technicians, and Reclaimers. Restricts the sale of refrigerant to certified technicians. Requires persons servicing or disposing of air-conditioning and refrigeration equipment to certify to the EPA that they have acquired recycling or recovery equipment to and are complying with the LAW. Requires the repair of substantial leaks in air-conditioning and refrigeration equipment with a charge greater than 50 pounds. Establishes safe disposal requirements to ensure removal of refrigerants from goods that enter the waste stream with the charge intact. (e.g.. household appliances and automobiles.)

Prohibition of Venting
n n

Effective July 1, 1992 Section 608 of the Clean Air Act Prohibits knowingly venting ozone depleting compounds while maintaining, servicing, repairing, or disposing of air conditioning or refrigeration equipment ( Appliances). Only four types of releases are permitted under this prohibition:
n

De minims quantities of refrigerant released in the course of making good faith attempts to recapture, recycle or safely dispose of refrigerant. ( Unintentional Release) Refrigerants emitted in the course of normal operation of air conditioning such as from mechanical purging and leaks. Leaks above certain sizes must be repaired. ( Purge System) Releases of CFCs, HCFCs, HFCs and PFCs that are not used as refrigerants are permitted. ( Mixtures of nitrogen and R-22 that are used for leaking testing may be released) Small releases of refrigerant that result from purging hoses or from connecting or disconnecting hoses to charge or service appliances is permitted.

Venting prohibition on substitutes (November 1995)

n

Section 608 prohibits the venting of substitute refrigerants during the maintenance, service, repair, and disposal of air conditioning and refrigeration equipment unless the EPA determines that the release of the substance does not pose a threat to the environment. EPA is planning to cover the following substitute refrigerants under the venting prohibition of section 608:
n n

Hydrochlofluorocarbon (HFCs) Perfluorinated Compounds (PFCs)

Evacuation Requirements
July 13,1993 Technicians are required to evacuate air-conditioning and refrigeration equipment to established vacuum levels when opening the equipment. n Two different levels exist depending on the date your recycling equipment was manufactured. On or before November 15, 1993.
n

Exceptions to Evacuation Requirements

EPA has established limited exceptions to its n Requirements for 1) repairs to leaky equipment and 2) repairs that are not major and that are not followed by an evacuation of the equipment to the environment. n of the equipment to the environment. If, due to leaks, evacuation to the levels in the Table is not attainable, or would substantially contaminate the refrigerant being recovered, persons opening the appliance must: isolate leaking from non-leaking components wherever possible: evacuate nonleaking components to the levels in the Table; and evacuate leaking components to the lowest level that can be attained without substantially contaminating the refrigerant. This level cannot exceed 0 psig. n If evacuation of the equipment to the environment is not be performed when repairs are complete, and if the repair is not major, then the appliance must: be evacuated to at least 0 psig before it is opened if it is a high- or very highpressure appliance; or be pressurized to 0 psig before it is opened if it is a low pressure appliance. Methods that require subsequent purging (e.g., nitrogen) cannot be used except with appliances containing R-113.

Reclamation Requirement
The EPA has also established that refrigerant recovered and/or recycled can be returned to the same system or other systems owned by the same person without restriction. If refrigerant changes ownership, however, that refrigerant must be reclaimed

TECHNICIAN CERTIFICATION
The EPA has established a technician program for technicians who perform maintenance, service, repair, or disposal that could be reasonably expected to release refrigerants into the atmosphere. The definition of "technician" specifically includes and excludes certain activities as follows: Included: attaching and detaching hoses and gauges to and from the appliance to measure pressure within the appliance; adding refrigerant to or removing refrigerant from the appliance and any other activity that violates the integrity of the refrigerant circuit while there is refrigerant in the appliance. Excluded:
1.

1. 2.

2. 3. 4.

activities that are not reasonably expected to violate the integrity of the refrigerant circuit, such as painting the appliance, re-wiring an external electrical circuit, replacing insulation on a length of pipe, or tightening nuts and bolts on the appliance; maintenance, service, repair, or disposal of appliances that have already been evacuated in accordance with EPA requirements, unless the maintenance consists of adding refrigerant to the appliance; servicing motor vehicle air conditioners (MVACs) , which are subject to the certification requirements of the MVAC refrigerant recycling rule; and, disposing of MVACs, MVAC-like appliances, and small appliances. In addition, apprentices as defined in the glossary are exempt from certification requirements provided the apprentice is closely and continually supervised by a certified technician.

Four types of certification:

For servicing small appliances (Type I). n For servicing or disposing of high- or very highpressure appliances, except small appliances and MVACs (Type II). n For servicing or disposing of low-pressure appliances (Type III). n For servicing all types of equipment (Universal)
n

REFRIGERANT LEAKS
Owners of equipment with charges of greater than 50 pounds are required to repair leaks in the equipment when those leaks (together) would result in the loss of more than a certain percentage of the equipment's charge over a year. For the commercial and industrial process refrigeration sectors, leaks at a rate that would release 35 percent or more of the charge over a year. For all other sectors, including comfort cooling, leaks must be repaired when the appliance leaks at a rate that would release 15 percent or more of the charge over a year.

Trigger Rates For Leak Repair

The following are the leak rates for a 12 month period: Trigger rates for all appliances that have a refrigerant charge of more than 50 pounds
n n n n

commercial refrigeration Industrial process refrigeration comfort cooling all other appliances

35% 35% 15% 15%

SAFE DISPOSAL REQUIREMENTS

Under the EPA's rule, equipment that is typically dismantled on-site before disposal has to have the refrigerant recovered in accordance with EPA's requirements for servicing. However, equipment that typically enters the waste stream with the charge intact (e.g., motor vehicle air conditioners, household refrigerators/freezers, and room air conditioners) is subject to special safe disposal requirements. Under these requirements, the final person in the disposal chain is responsible for ensuring that refrigerant is recovered from equipment before the final disposal of the equipment. Technician certification is not required for individuals removing refrigerant from appliances in the waste stream. The safe disposal requirements went into effect on July 13, 1993. Equipment must be registered or certified with the EPA.

HAZARDOUS WASTE DISPOSAL

If refrigerants are recycled or reclaimed, they are not considered hazardous under federal law. In addition, used oils contaminated with CFCs are not hazardous on the condition that: They are not mixed with other waste. They are subjected to CFC recycling or reclamation They are not mixed with used oils from other sources. Used oils that contain CFCs after the CFC reclamation procedure, however, are subject to specification limits for used oil fuels if these oils are destined for burning.

REFRIGERANT SALES RESTRICTIONS

Under EPA regulations, only ceded technicians will be able to purchase CFC or HCFC refrigerants. This restriction includes blends, where one or more components of the blend is either a CFC or HCFC. Technicians who have completed an EPA approved certification program under either section 608 or section 609 are issued a certification card, and are eligible to purchase refrigerants containing CFC's or HCFC's. Effective November 14, 1994, the sale of refrigerant in any size container is restricted to technicians certified either under the program described in Technician Certification above or under EPA's motor vehicle air conditioning regulations.

MAJOR RECORDKEEPING REQUIREMENTS

Technicians servicing appliances that contain 50 or more pounds of refrigerant must provide the owner with an invoice that indicates the amount of refrigerant added to the appliance. Technicians must also keep a copy of their proof of certification at their place of business. Owners of appliances that contain 50 or more pounds of refrigerant must keep servicing records documenting the date and type of service, as well as the quantity of refrigerant added. Wholesalers who sell CFC and HCFC refrigerants must retain invoices that indicate the name of the purchaser, the date of sale, and the quantity of refrigerant purchased. Re-claimers must maintain records of the names and addresses of persons sending them material for reclamation and the quantity of material sent to them for reclamation.

ENFORCEMENT

The EPA is authorized to assess fines of up to $25,000 per day per violation. There are also awards of up to $10,000 for persons furnishing information that leads to the conviction of a person violating provisions of the Clean Air Act.

MVAC-LIKE APPLIANCES

Some of the air conditioners that are covered by this rule are identical to motor vehicle air conditioners (MVACs), but they are not covered by the MVAC refrigerant recycling rule.

Refrigeration

Refrigeration is a term used for cooling systems such as air conditioners, ice machines, refrigerators, etc . Refrigeration is simply the process of removing heat from a place where it is not wanted to a place where the heat is unobjectionable.

REFRIGERATION CYCLE
The compressor receives low pressure, low temperature superheated vapor into its suction side and compresses it into a high temperature, high pressure superheated vapor leaving its discharge side. The refrigerant then travels to the condenser where the superheat is removed, then the latent heat is removed causing the vapor to change to a liquid. Any further heat removed is sensible heat which will leave the refrigerant Sub-cooled (sub-cooling ensures refrigerant to remain in liquid state as it passes to the metering device). This high pressure, high temperature sub-cooled liquid travels to the metering device, where there will be a pressure drop across the metering device. The refrigerant leaves the metering device a low pressure, low temperature liquid. The refrigerant now travels to the evaporator, where the refrigeration effect takes place. The evaporator receives refrigerant liquid that absorbs heat and boils into a vapor. When all of the liquid is evaporated into a vapor, and the refrigerant continues to absorb heat, the refrigerant is then superheated (superheating ensures the refrigerant remains in the vapor state). Superheated vapor then leaves the evaporator, traveling through the suction line to the compressor, where the cycle will continue.

REFRIGERATION CYCLE

Accumulator - The accumulator is located in the suction line between the evaporator and the compressor, but close to the compressor. The accumulator is designed to protect the compressor from receiving liquid (compressor is not designed to compress liquid) by trapping any liquid before it reaches the compressor. Oil Separator - The oil separator is located in the discharge line between compressor and condenser, but closer to the compressor. The oil separator is designed to prevent excessive oil loss by returning oil back to the compressor. Receiver - The receiver is located in the liquid line between the condenser and the metering device (or flow control), but close to the condenser. The receiver is designed to hold or store liquid refrigerant. Access into the receiver is provided by a King valve, which can be used for pump-down or liquid charging purposes. Filter/Drier - The filter/Drier is located in the liquid line after the receiver and before the metering device. The filter is designed to remove particulate matter from the system. The drier contains a desiccant to remove any moisture in the system. This component is called the filter/drier because it provides the two functions of filtering and removing moisture. Sight glass/Moisture indicator - The sight glass/moisture indicator is located after the filter/drier and before the metering device. As the filter /drier provide two functions so does the sight glass/moisture indicator. The sight glass is a transparent window that allows the technician to determine if refrigerant charge is low. The moisture indicator will allow the technician to determine if moisture is present in the system by observing the color of the moisture indicator dot. Heat Exchanger - The heat exchanger improves the efficiency of the refrigeration system by sub-cooling the liquid line. The heat exchanger also protects the compressor by superheating the suction line to ensure liquid does not flow into the compressor. The heat exchanger is usually located at the suction line.

Accessories

The 3 Rs
n

RECOVERY RECYCLE RECLAIM

RECOVERY
n

RECOVERY
n

To recover refrigerant means to remove refrigerant in any condition from a system without necessarily testing or processing it in any way and store it in an external container. Passive method - Passive recovery is system dependent recovery. This means the recovery process is achieved with the assistance of the components contained in the system to remove the refrigerant (i.e. pumpdown). This method can only be used with appliances that uses 15 pounds or less of refrigerant. Active method - Active recovery is recovering refrigerant by using selfcontained recovery unit. This method is the most popular method. The recovery machine does the work of removing the refrigerant with no assistance from the system components.

TWO METHODS
n

RECYCLE
Recycled refrigerant is refrigerant that is cleaned using oil separators and single or multiple passes through filter-dryers, which reduce moisture, acidity, and particulate matter. These procedures are implemented at the job site, and does not require testing to ensure quality of the refrigerant.

RECLAIM
To reclaim refrigerant means to reprocess refrigerant to meet a specific standard a d has to be tested. In some cases, refrigerant removed cannot be reused or recycled. Reclaiming is necessary if refrigerant is heavily contaminated, refrigerant quality unknown, or if recycling equipment is unavailable. Refrigerants that are badly contaminated will not be reclaimed. Badly contaminated refrigerants may include refrigerants from an acid burnout, which may be the most difficult for a reclaiming facility to eliminate. Never mix refrigerants, they will not be separated and must be destroyed. This term usually implies the use of processes or procedures available only at reprocessing or manufacturing facilities.

RECLAIMER CERTIFICATION
Reclaimers are required to return refrigerant to the purity level specified in ARI Standard 7001993 (an industry-set purity standard) and to verify using the laboratory protocol set forth in the same standard. n In addition, reclaimers must release no more than 1.5 percent of the refrigerant during the reclamation process and must dispose of wastes properly.
n

EQUIPMENT CERTIFICATION
n

Recycling and recovery equipment intended for use with airconditioning and refrigeration equipment besides small appliances must be tested under the ARI 740-1993 test protocol. Under the program, EPA requires that equipment manufactured on or after November 15, 1993, be tested by an EPA-approved testing organization to ensure that it meets EPA requirements. The EPA requires that persons servicing or disposing of airconditioning and refrigeration equipment certify to the appropriate EPA Regional Office that they have acquired (built, bought, or leased) recovery or recycling equipment and that they are complying with the applicable requirements of this rule.

EQUIPMENT GRANDFATHERING
Equipment manufactured before November 15, 1993, including home-made equipment, may be grandfathered if it meets the standards in the evacuation requirement tables. Third party testing is not required for equipment manufactured before November 15, 1993, but equipment manufactured on or after that date, including home-made equipment, must be tested by a third-party

CONTAINERS
There are basically two types of containers: disposable and reusable.
n

Disposable refrigerant containers are used for virgin refrigerant. Disposable containers (Dot 39) are not to be reused under any circumstances. They are to be used and disposed of properly. Disposing of disposable cylinders is accomplished by assuring that all refrigerant is recovered and that cylinders are rendered useless, then recycling the container metal. These containers are color coded according to the type of refrigerant the container is housing.

CONTAINERS
Reusable containers are recognized
by the yellow tops and gray bottoms. These cylinders can be filled up to 80% of capacity. To ensure this capacity when transferring refrigerant to a pressurized cylinder, the safe filling level can be controlled by mechanical float devices, electronic shut-off devices and weighing the cylinder. A refrigerant label is placed on these cylinders to identify gross weight of container. When transporting cylinders containing used refrigerant, DOT requires that you attach DOT classification tags. When shipping refrigerant cylinders the position of the cylinders should always be in an upright position. Only, one refrigerant can be recovered into the same cylinder. Reusable containers for refrigerants that are under high pressure (above 15 psig) at normal ambient temperature, must be hydrostatically tested and date stamped every 5 years.

SERVICE PRACTICES

SERVICE PRACTICES
GAGE MANIFOLD

The low side compound gage and the connecting hose is usually colored blue and reads pressures above and below atmospheric. The high side gage and the connecting hose is usually colored red and reads pressures from 0 to 500 psig. The center port on a three port manifold is used for recovery, evacuation and charging.

SERVICE PRACTICES
VACUUM PUMP

REFRIGERANT OIL RECOVERY

The oil in a refrigeration system may contain large amounts of dissolved refrigerant. EPA requires a reduction in pressure before changing oil to ensure that most of the refrigerant in the oil is recovered. Pressure must be reduced to a maximum of 5 psig. pressure reduction decreases refrigerant emissions while permitting a small positive pressure to force the oil from the compressor. It is a violation to change oil at higher than 5 psig. There are two acceptable procedures for recovery of refrigerant contained in oil: Evacuate (or pressurize) the refrigeration system, or isolated portion, to a pressure no greater than 5 psig and then remove the oil. OR Drain the oil into a system receiver to be evacuated (or pressurized) to a pressure no greater than 5 psig.

EPA EVACUATION REQUIREMENTS

PLANNED LEVELS OF EVACUATION FOR APPLIANCES

LEAK DETECTORS
n

Used to detect leaks in a pressurized system. There are many different types of detectors such as halide, electronic, ultrasonic, and simply using soap bubbles. The halide leak detector uses a flame that will change colors relative to the refrigerant pulled into a tube. Electronic and ultrasonic leak detectors will detect the general area of small leaks. Soap bubbles may be used to pinpoint leaks in a system. Nitrogen can also be used to pressurize a system (trace of R-22 can be used with the nitrogen) to determine if there are any leaks in the system. In order to verify the allowable machine test pressure, check LOW SIDE design pressure on equipment name plate.

REFRIGERANT OIL
The oil in a refrigeration system may contain large amounts of dissolved refrigerant. EPA requires a reduction in pressure before changing oil to ensure that most of the refrigerant in the oil is recovered. Pressure must be reduced to a maximum of 5 psig. pressure reduction decreases refrigerant emissions while permitting a small positive pressure to force the oil from the compressor. It is a violation to change oil at higher than 5 psig. There are two acceptable procedures for recovery of refrigerant contained in oil: Evacuate (or pressurize) the refrigeration system, or isolated portion, to a pressure no greater than 5 psig and then remove the oil. OR Drain the oil into a system receiver to be evacuated (or pressurized) to a pressure no greater than 5

PLANNED LEVELS OF EVACUATION

See Chart In book

EXCEPTIONS TO EVACUATION REQUIREMENTS

The EPA has established limited exceptions to its evacuation requirements for:
n n

n n

1) repairs to leaky equipment and 2) repairs that are not major and that are not followed by an evacuation of the equipment to the environment. If, due to leaks, evacuation to the levels in the tables mentioned is not attainable, or would substantially contaminate the refrigerant being recovered, persons opening the appliance must: isolate leaking from non-leaking components wherever possible; evacuate non-leaking components to the levels in the tables mentioned; and evacuate leaking components to the lowest level that can be attained without substantially contaminating the refrigerant. This level cannot exceed 0 psig. If evacuation of the equipment to the environment is not to be performed when repairs are complete, and if the repair is not major, then the appliance must:

be evacuated to at least 0psig before it is opened if it is a high- or very high- pressure appliance; or be pressurized to 0psig before it is opened if it is a low-pressure appliance. Methods that require subsequent purging (e.g., nitrogen) cannot be used except with appliances containing R-113.

When air enters a system, moisture often enters also. Dehydration is the process of removing the moisture (water vapor). Dehydration is done by simply evacuating the system. A system is said to be dehydrated when the vacuum indicator shows you have reached and held the required finished vacuum. We need to evacuate a system to eliminate noncondensables (air) from the system at the conclusion of service. We measure a vacuum in inches of mercury. When we measure a deep vacuum we use microns because of their smaller increments. Evacuation to 500 microns is sufficient evacuation for most systems. You can never over evacuate. Factors that may affect the speed of the evacuation time are:
n n n n n n

DEHYDRATION AND EVACUATION

1. the size of equipment being evacuated 2. the ambient temperature 3. amount of moisture in system 4. the size (capacity) of vacuum pump 5. the length and diameter of hoses 6. packing the recovery vessel in ice

Dehydration is accomplished by lowing the pressure of the moisture and thereby lowing the boiling point causing the moisture to vaporize and be pulled out of the system. Use of the proper vacuum pump is very important. A vacuum pump too small may not properly dehydrate the system. Using a large vacuum pump could cause trapped water to freeze. NOTE: Failure of a system to hold a vacuum concluding the evacuation process indicates that a leak in the system may exist.

USING PRESSURE TEMPERATURE RELATIONSHIPS We will use water as an example for simplicity sake. Water boils at 212 degrees Fahrenheit at atmospheric pressure. Atmospheric pressure is 0 psig or 14.69 PSIA. If I wanted to boil water at less than 212 degrees F. I would have to lower the pressure of that water. If I wanted to raise the boiling point of the water, I would have to raise the pressure. The same water that boiled at 2 12 deg., will boil at 35 deg., at .204 inches of mercury absolute. This is an example of a pressure/ temperature relationship.

REFRIGERANT SAFETY
Refrigerants are not completely safe, however they can be used safely. The ideal refrigerant should be environmentally friendly, not flammable, or toxic, and be able to perform well in the refrigeration system. All fluorocarbon refrigerants are heavier than air and can cause suffocation due to lack of oxygen if exposure exceeds acceptable levels. Refrigerants are classified by ANSI/ASHRAE 34 into safety groups shown by the following matrix:

Higher Flammability Lower Flammability No Flame Propagation

A3 A2 A1 Lower Toxicity

B3 B2 B1 Higher Toxicity

ANSI/ASHRAE 34
A1 refrigerants are the safest, and B3 refrigerants are the most toxic and flammable. From A to B indicates increase in toxicity from 1 to 3 indicates increase in flammability R-123 is classified as a B1 refrigerant and needs a refrigerant sensor to detect high refrigerant exposure. R-11, R-12, R-22, R-500, R-502, and R-l34a are classified as A1 refrigerants. These refrigerants use an oxygen deprivation sensor to detect low oxygen. An oxygen alarm will be set off at 19.5 percent or more by volume. Monitoring rooms for the right amount of oxygen is required for all refrigerants. A Self-Contained Breathing Apparatus (SCBA) must be worn if a large leak has occurred. If there is no SCBA available you should ventilate the area and vacate the area as soon as possible.

ASHRAE Standard 15
ASHRAE Standard 15 is the standard for monitors, alarms, ventilation, purge venting, and breathing apparatus. Rupture disk and purges must be vented outdoors. At least one approved self-contained breathing apparatus (SCBA), suitable for the refrigerant used, shall be located outside of the room, but close to, the machinery room. A second, backup, self-contained breathing apparatus shall also be provided.

USING NITROGEN

Whenever dry nitrogen from a portable cylinder is used in service and installation practice, a relief valve inserted in the downstream line from the pressure regulator is of most importance in consideration of safety.

Safety Tips
To determine safe pressure for leak testing one should use low-side test pressure data-plate value. In order to verify the allowable machine test pressure, check design pressure on equipment nameplate. Never apply an open flame or live steam to a refrigerant cylinder. Do not cut or weld any refrigerant line while refrigerant is in the unit. Technicians should never use oxygen or compressed air to pressurize appliances to check for leaks, because when mixed with compressor oil, oxygen and compressed air can explode. Personal protective equipment (gloves, safety glasses, safety shoes, etc.) should be worn when handling and filling refrigerant cylinders.

SMALL APPLIANCES

SMALL APPLIANCES
Small appliance means products that are fully manufactured, charged, and hermetically sealed in a factory with five (5)pounds or less of refrigerant. Technicians receiving a passing grade on this small appliance examination are certified to recover refrigerant during the maintenance, service or repair of the following: refrigerators freezers designed for home use room air conditioners (including window air conditioners and packaged terminal air conditioners) packaged terminal heat pumps dehumidifiers under-the-counter ice makers vending machines drinking water coolers All appliances must be equipped with a service aperture or other device which is used when adding or removing refrigerant from the appliance. For small appliances, this service port typically is a straight piece of tubing that is entered using a piercing access valve.

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RECOVERY AND RECYCLING

Recovery equipment used during maintenance, service or repair of small appliances must be certified by an EPA-approved laboratory if manufactured after November 15, 1993.

Levels Of Evacuation for small appliances under the conditions of ARI-70-1993

Status of compressor Recovery equipment built before 11/15/1993 Recovery equipment built after 11/15/1993

80% refrigerant recovered or 4 inch of vacuum Non-operational 80% refrigerant recovered or 4 inch vacuum

Operational

90% refrigerant recovered or 4 inch vacuum 80% refrigerant recovered or 4 inch vacuum

Small Appliance Components

Compressor- Usually reciprocating hermetic or rotary hermetic 2. Condenser Usually air cooled fin tube 3. Metering Device Usually capillary tube 4. Evaporator Usually dry (direct expansion) fin tube Leak Repair When servicing a small appliance for leak repair, it is not mandatory to repair the leak but do so whenever possible.
1.

Service Aperture
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All appliances must be equipped with a service aperture or other device which is used when adding or removing refrigerant from the appliance. Small appliances may have process stubs or Schrader valves to gain access into system. When using recovev cylinders and equipment with Schrader valves, it is critical to: Inspect the Schrader valve core for bends and breakage Replace damaged Schrader valve core to prevent leakage Cap the Schrader ports to prevent accidental depression of the valve core. When installing any type of access fitting onto a sealed system the fitting should be leak tested before proceeding with recovery. It is generally recommended that piercing -type valves be used on copper or aluminum tubing materials. After in- stalling and opening a piercing access valve, if the system is 0 psig do not begin the recovery procedure. When used, solder less type piercing valves, they should not remain installed on refrigeration systems after completion of repairs because they tend to leak over time.

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HIGH PRESSURE EQUIPMENT

HIGH PRESSURE EQUIPMENT

Refrigeration machines, PTAC units, and split system air conditioning units (using R-22) are commonly the equipment used in this sector. Any equipment that contains over 5 pounds and is not low pressure equipment will fall into this category. Servicing and disposal of high pressure chillers, commercial refrigeration, commercial and residential air conditioning and heat pumps will need certification in this part.

REFRIGERANTS
High pressure equipment uses refrigerant with a boiling point between -58F (-50C) and 50F (10C) at atmospheric pressure. Refrigerants 12, 22, 1 14,134a, 500 and 502 are high pressure refrigerants. Very high pressure equipment uses refrigerants with a boiling point below -58F(50C)at atmospheric pressure. Refrigerants 13 and 503 are very high pressure refrigerants. The easiest way to check the type of refrigerant a unit uses is to look at the unit name plate.

Leak Repair
The EPA requires that all appliances containing more than 50 pounds of refrigerant ( Except for Commercial and Industrial process refrigeration) be repaired when the leak rate exceeds 15 percent of the charge per year. Leaking commercial and industrial process refrigeration has to be repaired when the leak rate exceeds 35 percent of the charge per year. The only way appliances containing CFC refrigerants can be evacuated to atmospheric pressure is when the leaks in the appliance make evacuation to the prescribed level unattainable.

Recovery And Recycling

Recovery and recycling equipment manufactured after November 15, 1993: 1. Must be tested by a EPA-approved third party 2. Must meet vacuum standards more stringent than those met by equipment manufactured before November 15, 1993 3. Must be equipped with low loss fittings

Required Levels Of Evacuation For Appliances

Type of Appliance Inches of vacuum using equipment manufactured before nov.15,1993 0 psig 4 inches Hg 4 inches Hg Inches of vacuum using equipment manufactured after nov.15,1993 0 psig 10 inches Hg 10 inches Hg HCFC-22 Appliance Containing less then 200 lbs HCFC-22 Appliance Containing More then 200 lbs Other high pressure appliance containing less than 200 lbs R-12, R-500, R-502, R-114 Other high pressure appliance containing More than 200 lbs R-12, R-500, R-502, R-114

4 inches Hg

15 inches Hg

Recovery Machines
When using a recovery/recycling machine always be cognizant of the fact that these machines have the same components of any refrigeration system. Before using a recovery unit to remove charge, service valve positions and recovery unit oil level should be checked prior to evacuating recovery unit or receiver. The primary water source for a recovery unit condensing coil is local municipal water supply, make sure system has proper water flow. In general, the one routine maintenance task which must be performed on most refrigerant recycling machines is changing oil and filter dryers.

Recovery Machines
1.

2.

3.

Never recover while the system compressor is in operation, If a hermetic compressor is used, the compressor has the potential to overheat when drawing deep vacuums because the motor relies on the flow of refrigerant through the compressor for cooling. You can save time recovering the refrigerant from a system by removing as much as possible in the liquid phase. After refrigerant liquid has been recovered from the appliance, any remaining vapor should then be recovered. If an operating unit has a receiver/storage tank, and requires refrigerant system service, refrigerant should be re- covered in the receiver. Keep in mind that system-dependent (passive) recovery equipment CANNOT be used when the appliance contains over 15 pounds of refrigerant.

HIGH PRESSURE SYSTEM COMPONENTS

1. 2. 3. 4. 5.

Compressor -usually reciprocating, screw, or scroll type. Also may have hermetic, semi- hermetic, or open type housing. Condenser -usually air cooled or water cooled. Will be fin/tube, shell/ coil, or shell/ tube. Metering Device -usually thermostatic expansion valve. Evaporator -usually dry expansion or flooded. Will be fin/tube, shell/coil, or tube. Accessories -In a refrigeration system utilizing a thermal expansion valve, the component directly following the condenser is the receiver, which is on the high side of the system. The state of refrigerant leaving the receiver of a refrigeration system is high pressure liquid. The moisture-indicator sight glass used for checking the system's moisture content and refrigerant charge is the component located downstream from the receiver (If ice accumulates on sight glasses or viewing glasses, you can use an alcohol spray to remove it). The component directly following the evaporator of a refrigeration system is the accumulator which is located close to the compressor.

Leak Testing
Many refrigeration units use an open compressor. If this type unit is not used for several months the rotating shaft seal may tend to leak. In general testing with soap bubbles is the method used to pinpoint refrigerant leaks. When inspecting a hermetic system known to be leaking, you should look for traces of oil. Checking for proper superheat is another way to find a leak. Excessive superheat is an indicator of a leak in a high pressure system. Systems can also be pressurized to check for leaks. Refrigerant trace gases are used with nitrogen to pressurize a system to locate a leak using a leak detector. The trace gas (refrigerant) is used so that a leak detector can identify a leak. When a refrigerant trace gas becomes absolutely necessary, HCFC-22 should be used to identify a leak. Systems that use R-134a should be leak checked with pressurized nitrogen. Leak testing should be done prior to charging or re- charging equipment. Vacuum method of leak detection can also be used. Keep in mind that If the vacuum method is used for leak testing, when under a deep vacuum (usually measured in microns), a hermetic refrigeration compressor's motor winding could be damaged if energized.

134a Recovery
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Recovering R-134A requires special precautions. For example, if you were to provide the service work for units with R-12, R-502, and R-134a, you would need to provide a special set of hoses, gauges, vacuum pump, oil containers, and recovery machine to be used with R-134a only. THIS IS DUE TO THE USE OF DIFFERENT REFRIGERANT OILS IN 134A

Recover From The Lowest Point Possible

With an air cooled condenser on the roof of a building and the evaporator on the first floor, this system would be considered a split system, and recovery should first occur from the liquid line (with one hose connected to liquid line) entering the evaporator, because that point is he lower part of the system. Refrigerant should be removed from the condenser outlet when the condenser is below the receiver.

Charging
Charging can be done in various ways. Always check system pressures with gauges. Charging liquid is the fastest method of charging a system. Liquid charging has to be done through the high side of the system. For example, to charge a system that has a specified charge of 80 pounds you would charge liquid through the liquid-line service valve or king valve). Be aware that non-condensables in a refrigeration system will result in higher discharge pressure that may appear as a correct charge.

LOW PRESSURE EQUIPMENT

LOW PRESSURE EQUIPMENT

Low pressure equipment is the large equipment of the industry. The size of this equipment, as well as it's potential for danger to equipment, people, and the environment is of particular concern to the EPA. Low pressure equipment operates in a vacuum. Because this equipment is operating at very low pressures, there are components unique to this sector. Many technicians apply the term appliances to small appliances only, however the EPA refers to appliances for all equipment. We will stay consistent with the EPA for test purposes.

REFRIGERANTS
The two low pressure refrigerants to be concerned with are R-11 and R-123. R-1 1 is a CFC and will be replaced by HCFC-123. As of the present time HCFC-123 is the only suitable replacement for CFC-1 1. These refrigerants have similar boiling points and operating pressures. CFC-11 will boil at 74.9 degrees F at 0 PSIG or 14.7 PSIA. HCFC-123 will boil at 81.7 degrees F at 0 PSIG of 14.7 PSIA. Remember that high boiling points will result in low operating pressures. Chillers using CFC-1 1 and HCFC- 123 require purge units because these systems operate below atmospheric pressure.

REGULATORY REQUIREMENTS

EPA regulations require that all appliances containing more than 50 pounds of refrigerant (except for commercial and industrial process refrigeration) be repaired when the leak rate exceeds 15 percent of the charge per year. EPA regulations require that leaking commercial and industrial process refrigeration be repaired when the leak rate exceeds 35 percent of the charge per year.

SYSTEM COMPONENTS
Every mechanical refrigeration system will have the four basic components, from the smallest equipment to the largest equipment. The metering device used in the large low pressure systems is the orifice plates or float type metering devices. The evaporator used will be the flooded shell and tube type. The compressor will be the centrifugal type. The condenser will be water cooled shell and tube type.

Purge unit
Because CFC-1 1 and HCFC-123 operate in a vacuum (below atmospheric pressure), these machines require a purge unit, because of the potential of air and moisture entering the system. On low pressure chillers, moisture most frequently enters the refrigerant system through air leaks from gasket areas seals or fittings. The primary purpose of the purge unit on a CFC-11 or HCFC-123 chiller is to remove all non-condensables from the system. A purge unit is a device that removes air (non-condensables) from the refrigerant in a centrifugal refrigeration system during machine operation and returns recycled refrigerant to the unit. The purge unit is a small refrigeration unit that pulls non-condensables out the system. The purge unit takes its suction from the top of the condenser (non-condensables will accumulate in the condenser) and returns all condensable refrigerants back to the system. Inefficient purge units can cause excessive refrigerant loss. Leak test and repair the leak to reduce refrigerant loss from a purge unit on a CFC-11 or HCFC-123 chiller.

Purgers

Rupture disk
A centrifugal chiller needs a device to safely discard the refrigerant in the event of excessively high pressure. A rupture disk will relieve at 15 psig. The rupture disk is connected to the chiller's evaporator. Leak testing a low pressure refrigeration system with nitrogen in excess of 10 psig could cause the rupture disc to fail.

EVACUATION LEVELS FOR LOW PRESSURE EQUIPMENT

When using recovery equipment When using recovery equipment manufactured before Nov. 15,1993 25 INCHES OF MERCURY VACUUM ( 25 In. Hg vac) When using recovery equipment When using recovery equipment manufactured after Nov. 15,1993

25 Millimeters OF MERCURY ABSOLUTE (25mm Hg abs) 25 mm Hg is equal to 25,000 microns or 29 inches of mercury vacuum (29 in Hg vac.)

Using Recovery Machines

When using recovery machines keep in mind that:
1. 2.

3. 4. 5.

6.

A rupture disc on a recovery vessel for low pressure refrigerants relieves at 15 psig. CFC-11 or HCFC- 123 system refrigerant removal starts with liquid removal. An average 350 ton CFC-11 chiller at 0 psig pressure can have 100 1bs.of refrigerant left once all the CFC-1 1 liquid has been removed. A heater used on a recovery vessel can aid in the faster transfer of vapor to the chiller. Local municipal water supply is the primary water source for a recovery unit condensing coil. After reaching the required recovery vacuum on an appliance, you should wait for at least a few minutes to see if the system pressure rises, indicating that there is still refrigerant in liquid form or in the oil When evacuating the refrigerant from a low pressure chiller, the recovery unit's high pressure cut-out is set for 10 PSIG.

SERVICE PRACTICES
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Removing oil When removing oil from a low pressure system, the temperature should be 130F because less refrigerant will be contained in the oil at the higher temperature. An oil sample should be taken if recycled refrigerant has been added to the unit. Charging refrigerant Refrigerant is added to a centrifugal machine through the evaporator charging valve. When charging refrigerant, charge vapor first to avoid freeze-up. Liquid charged into deep vacuum will boil and may lower temperatures enough to freeze water in the tubes. You will determine that enough vapor has entered the refrigeration system when refrigerant saturation temperature increases to 36 degrees F. After this determination liquid refrigerant can then be charged into system. When recharging a refrigeration system with CFC-1 1, 16.9 inches of mercury vacuum is necessary in the shells before charging with liquid. Charging refrigerant liquid into a refrigeration system under a 29 inch Hg. Vacuum can cause the system water to freeze.

SERVICE PRACTICES
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Leak testing A hydrostatic tube test kit will determine if a tube leaks. Another method to check gas leaks is to place a leak detector probe into the water box through the drain valve with water removed. To determine if a system is leaking a standing pressure or standing vacuum test can be performed. According to ASHRAE Guideline 3-1990, if the pressure in a system rises from 1 mm Hg to a level above 2.5mm Hg during a standing vacuum test, the system should be checked for leaks. Charged low pressure refrigeration machines may be most efficiently leak checked by raising system pressure by heating with circulated (controlled) hot water or heating blankets. When leak testing a low pressure centrifugal with nitrogen, 10 PSIG is the maximum test pressure. Evacuation Water must be circulated through a chiller during refrigerant evacuation in order to prevent freezing of water. Increase pressure to counteract freezing with gas such as nitrogen. Always be aware that when evacuating a system, the use of a large vacuum pump could cause trapped water to freeze.

Safety Devices
Under ASHRAE standard 15 an equipment room oxygen deprivation sensor and alarm is required for A1 refrigerants such as CFC -11,12 and HFC -134a. n HCFC-123 falls under a B1 refrigerant under the code group of ASHRAE standard 34 and requires a refrigerant sensor.
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