Module 0200 EPA Section 608 Technician Certification Stationary Equipment Study Guide Third EditionApplicant Study Guide EPA Section 608 For Stationary Equipment WITH: v Quick Review Questions v Service Reminders v Helpful Illustrations v Memory Tools v Sample Test Format/Questions v Results Keyed to Manual v Internet Results v Same Day Grading Option Module: 0200 © 2000 VGI Training inment Trai le. The rights to This is an integral component of the VGI Refrigerant Containment Training Modu! tees eee by VGI Training. No part of this manual may be reproduced, distributed, displayed or sold without the written permission of VGI Training, a division of Video General inc. manual, wuccesstully best of our knowledge. contains the subject material needed to be success! DO ete tte, con cara Wada howe; reccommend feat & be ined corganciion with classroom instruction in order to give the candidate the best opportunity for passing the exam.Certification Requirements and Contents (HOW:TO LEGALLY: HANDLE REFRIGERANTS?" So ‘The Federal Government of the United States requires al refrigerant to be certified. Persons who work on stationat become certified by passing a proctored Section 608 exa three equipment categories plus Universal. individuals who open a system or container holding a controlled fy equipment oF use refrigerant designed for these systems can amination. Candidates for this exam can be certified in any of ‘A Type | technician primarily works on small appliances such as domestic refrigerators, window ait conditioners, PTACs and vending machines. (See “Study for Type | Technicians” on page 19) ‘equipment using a high pressure refrigerant such as HCFC-22. conditioners and heat pumps, supermarket refrigeration and A Type Ill technician primarily works on equipment using a low pressure refrigerant such as HCFC-123 lers. (See “Study for Type Ill Technicians” on page 31) Type Type2 A Type Il technician primarily works on: ‘The equipment includes residential air process refrigeration. (See "Study for Type Il Technicians” on page 25) Types ‘or CFC-11. The units are primarily chil Universal Any candidate passing all three of these EPA types is certified as UNIVERSAL ‘Note: To pass any EPA type, a candidate must pass a CORE section of the exam plus one of the technical types listed above. Once CORE is passed it need not be taken again and it may be used for additional EPA types. STEP 1- STEP2- STEP 3- Select the EPA Type(s) for which you wish to seek certification, answers.) Note any question that gives STEP 4- STEP 5- STEP 6- USE OF SERVICE REMINDERS ® With most of the topics you will see this sym Carefully read each topic under the section of the book for the type(s) ‘After reading a topic, try to answer the questions at the end of the section. (De not look up the you difficulty. Mf necessary, read the material again keeping in mind the questions giving you difficulty. ‘Answer the questions again until you are able to easily answer all questions. Repeat these steps for all topics for the EPA types for which you will be testing, bol. These are Service Reminders. Service Reminders are tips and facts that you need to know and will help you on the EPA exam. REMEMBER THEM HOW TO LEGALLY HANDLE REFRIGERANTS. HOW TO USE THIS STUDY GUIDE To PASS THE EPA CERTIFICATION T USE OF SERVICE REMINOERS CO STUDY FOR ALL TECHNICIANS - CORE ‘GA NTRODUCTION TOCOOUNG EQUPMIENT 2GzoNE DEPLETION GAGLEAVAR AGT NOVENTINGLAW SaePAREeUUATIONS CSNeW SERVICE PROCEDURES ‘GeSUSSTITUTE REFRIGERANTS AND OS G7 SArETy OENERAL (GaSAreTY RErRIGERANT CriINOERS 4.0 STUDY FOR TYPE | TECHNICIANS 1} EQUPUENT AND RECOVERY REQUIREMENTS. 12RECOVERY PROCEDURES. TYPE |APPUANCES. 4 Scarery With TYPEIAPPLANCES 20 STUDY FOR TYPE Il TECHNICIANS 22) EQUPUENT AND SERVICE PROCEDURES EERECOVERY PROCEDURES. TYPEIIAPPLANCES HOW TO REMEMBER THE EPACHART 23 GAFETY WH TYPE APPUANGES 3.0 STUDY FOR TYPE Ill TECHNICIANS. 2) EQUIPMENT AND RECOVERY REGUREMENTS, ‘2REDOVERY PROCEDURES” TYPE MAPPLANCES 233GarETY TH TYPE WAPPLANGES. CONGRATULATIONS GAN [USE THE INTERNET? HOW MAY OBTAIN AN EXTRA COPY OR REPLACEMENT OF MY CREDE ‘SAMPLE TEST QUESTIONS. HOW TO READ A TEMPERATURE-PRESSURE CHART est Pebavus wee2eBanReredasar ENTIAL?Core Study Material co STUDY FOR ALL TECHNICIANS - CORE ¢1 INTRODUCTION TO COOLING EQUIPMENT C1eBasic Refrigeration Circuit In a direct expansion cooling system a refrigerant liquid boils in an evaporator and absorbs heat into its boiled off vapor. The evaporator is a heat transfer component that accepts low temperature-low pressure liquid and boils it from a low temperature-high pressure liquid that has been forced through a small orifice. The small orifice (metering device) may be either of the fixed type (capillary tube) or variable (expansion valve). The liquid refrigerant is converted to a low temperature- low pressure vapor. The tubing connecting the HIGH SIDE WARM AIR OUT CONDENSER HIGH PRESSURE aud RECEIVER OPTIONAL) intake of the compressor to the evaporator is called a suction line. On its intake stroke, a ‘compressor pulls in refrigerant vapor that has been heated above its saturation temperature (superheated vapor). The compressor changes the low-pressure vapor into a high-pressure vapor. The outlet of the compressor is connected toa condenser. The condenser takes in high temperature-high pressure vapor from the compressor, cools it, and condenses it to a low temperature-high pressure liquid at the condenser outlet. (See Figure 1) LOW SIDE EVAPORATOR, & & oe Tigiiigiiit 6 Low PRESSURE uauiD ie oe Sree eT S: ) sis METERING DEVICE * vee low pressure fichreweerarure |) | Su {OW TEMPERATURE &) varor weer Coa ’ ACCUMULATOR c (OPTIONAL) ‘COMPRESSOR Figure |A manifold gauge set is used to check and set pressures within a refrigeration system. A low pressure gauge is usually on the left and is blue in color. A high pressure gauge is on the right and is usually red in color. The low side gauge is a compound gauge capable of reading both pressures above and below atmospheric Core Study Material pressure, the low pressure gauge reads in “pounds per square inch (PSIG)". For readings, below atmospheric pressure, the gauge reads in “inches of mercury (in. Hg.)". The high side gauge typically is calibrated to read pressures from 0 to 500 PSIG. The center port of the manifold is used during the evacuation, charging, pressure. For readings above atmospheric and recovery procedures. (See Figure 2) PRESSURE READINGS EVACUATION (UNIT RUNNING) “wy i 1g lf T | T VAPOR CHARGING LIQUID CHARGING (UNIT RUNNING) ¥ TOLOW SE FROM REFRIGERANT CONTANER LIQUID / VAPOR RECOVERY VAPOR RECOVERYCore Study Material ‘© Liquid refrigerant can migrate to a compressor crankcase if the compressor is the coldest location in the circuit. Low temperature means lower pressure which 4 vapor pressure. ‘ Compressors should never be started (energized) while they are in a deep vacuum or when their servic valves (discharge or suction) are closed. Operating in a deep vacuum could compressor's windings Refrigerant lines can contain contaminated oil, which must be flushed from the system. Flushing the lin with pure refrigerantis NOT a recommended practice. Prior to flushing, an oil sample should b unit has had a leak or major component failure (c sor bumout © Toconserve refrigerant supplies, find and repairleaks, and r il Cause refrigerant migration through a difference in cause damage to the faken if the Wer and recycle used refrigerants. Check Yourself What are the typical uses of the center port of a gauge set? What color are the gauges oni a manifold gauge set? What are the typical ranges of pressure measurements used on the gauges of a manifold gauge set? 1s the refrigerant leaving a condenser at a high or low pressure? Is ita liquid ora gas? 1s the refrigerant entering the expansion valve (variable metering device) a liquid or gas? Js the pressure of the refrigerant entering the compressor high orlow? Where in a refrigerant circuit does a liquid boil fo absorb heat? The refrigerant in the suction line is a gas that has been heated above its saturation. What is this condition called? 9. [Link] cause liquid refrigerant to migrate to a compressor crankcase? 10. List two conditions that can quickly damage a compressor that is starting to run. 11. What system failures require taking an oil sample? 12. Is flushing with refrigerant an acceptable tube cleaning method? 13. In addition to preventing and repairing leaks, what else should a technician do to conserve refrigerant? @NOAAoNA ©1»Dehydration Techniques After a circuit is sealed, a vacuum pump (See vacuum, the system is valved off to check for Figure 3) is used to evacuate all moisture and moisture and leaks. This valving-off isolates the non-condensables from the system's tubing and system from the vacuum pump. component passageways. A low-pressure gauge is used to measure the vacuum level. For accuracy, the vacuum gauge should be connected as far away as possible from the vacuum pump. A system should be dehydrated Until the low pressure gauge reads the appropriate deep vacuum reading and the reading does not rise when the vacuum pump is turned off. No damage will be done if a system is pulled below its recommended level. After the system has been pulled down to its proper gure 3 © Ifasystem is not evacuated fully, compressor head pressure can rise and the remaining moisture will ‘combine under heat with refrigerant and oil to form hydrofluoric and hydrochloric acids. © The speed of an evacuation depends on the size of the equipment, the ambient temperature, the su size, and the quantity of moisture in the system. : @ Increasing the temperature on the tubing and components speeds up the dehydration of the system. ® Ahigh capacity vacuum pump and short, large diameter hoses will dramatically reduce emissions, pressure drop, and evacuation/dehydration time, The hose diameter should be the size of the vacuum pump inlet connection or larger. onlineCheck Yourself CONAMALHS> What factors affect the speed of an evacuation? . How should gauge set hoses be sized for use in evacuating a system? When evacuating, what is the benefit of using short hoses with large diameters? Which connection determines the preferred size of hose used with a vacuum pump? As the capacity and suction hose size increase, what happens to the time needed for an evacuation? What purpose is served by heating a system during dehydration? Does a thorough evacuation remove ‘moisture from a system? ; What can happen to the oil in a compressor if moisture is lef in an operating system? What is the result of over-evacuating a system? Core Study Material 10. How can a system be leak checked using a low pressure gauge? ‘ 11. How close should a vacuum gauge be connected to the vacuum pump during an evacuation? 12. When measuring the vacuum of a system being evacuated, the system must be isolated. What must ‘be done to the vacuum pump? c2 OZONE DEPLETION ©28Chlorine, the Refrigerants and the Ozone Layer Ozone in the stratosphere above the earth consists of molecules containing three oxygen. atoms. Although similar to oxygen in chemical makeup, ozone has few of oxygen’s properties. In the stratospheric layer of our atmosphere, ozone is vital to our health. The stability of the ozone layer and its chemical balance can be changed by the introduction of chlorine atoms. from earth. One chlorine atom, because it is, part of a chain reaction, can destroy 100,000 ozone molecules. One class of refrigerants often used in the past is the chlorofiuorocarbon group or CFC’s. They contain chlorine, fluorine, and carbon. The commonly used CFC's are CFC-11, 12, 113, and 114. The CFC’s do not dissolve in water and they do not break down into other compounds that dissolve in water. CFC’s cannot be “washed” out of the lower atmosphere, so they rise to higher altitudes where they break down, This causes the CFC’s to be a more serious problem for the health of the stratosphere. Another group of chlorine-based refrigerants are the hydrochlorofiuorocarbons or HCFC’s. They contain hydrogen, chlorine, fluorine and carbon. The commonly used HCFC's are HCFC-22 and HCFC-123, The ability of any chemical to deplete the ozone layer is called its Ozone Depletion Potential (ODP). For now, the CFC's appear to be the primary depleters. CFC-12, for example, has 20 times the ozone depleting potential of HCFC-22. (See Figure 4) [acon [san ‘Mobile Air Conditioni HCFC-22 Air Conditioning and Heat Pumps, Some Refrigeration Figure 4In addition to the pure, single compound refrigerants, there are other refrigerants called azeotropes. An azeotrope is a mixture of two ‘or more compounds (refrigerants) where the @ HFC-134a is a hydrofluorocarbon, © HFC's contain hydrogen, fluorine and carbon, © The ODP of HFC-134ais zero, © HFC’s will not damage the ozone in the stratosphere. Check Yourself What is ozone? What is Ozone Depletion Potential (ODP)? What is a CFC? Which refrigerants are CFC’s? What is an HCFC? Which refrigerants are HCFC's? ©ENOMAON™ Core Study Material mixture behaves like a single chemical (new refrigerant). The commonly used refrigerant azeotropes are R-500 and R-502. Each contain CFC's and HCFC’s. How much ozone can a chlorine atom destroy in the stratosphere? Which chemical in the CFC refrigerants does the most damage to the ozone layer? Which is more harmful to the ozone layer, a CFC or an HCFC? 10. What is it about CFC’s that make them more harmful in the stratosphere? 11. What is an HFC? 12. Which refrigerant is an HFC? 13. What is the ODP of an HFC refrigerant? 14. Which refrigerants contain chlorine? 15. What refrigerants have high ODP? 16. What refrigerants have low ODP? 17. Whatis an azeotrope refrigerant? 18. Is one of the components of R-500 a CFC? 19. Does stratospheric ozone help or hurt the work of the earth's protective shield? ©2bHealth Effects and Evidence The recent appearance of increased levels of chlorine monoxide has caused heightened fears of ozone depletion. The increase in the quantity of CFC's in the stratosphere has been measured through high altitude air sampling Increases in both chlorine and fluorine have been detected in the stratosphere. The increases in both these chemicals match the increases in emissions from CFC’s. Emissions from volcanoes have been discounted because the amount of volcano-generated chlorine Teaching the stratosphere is low. Should a weakening of the ozone layer continue, the fesults could be critical for all inhabitants of earth, ‘The ozone layer does valuable filtering work. It blocks much of the harmful ultraviolet radiation (UV-B) emitted from the sun and it helps to keep, our earth's temperatures stable. Other effects of ozone depletion are: Skin cancer and other radiation related diseases increase. Cataracts can more easily occur. Timber growth is reduced. Crop yields are lowered. Marine life and the food chains are impaired Ground level ozone is increased. Immunity against disease is reduced.Check Yourself NOMAWNS Core Study Materia, What chemical in the stratosphere tells us ozone depletion is coumnng7 How do we know the chlorine inthe stratosphere is coming fr ? How do we know CFC's get to the stratosphere : What roe does the ozone layerplayinprotecting the earin7 What are the effects on health from increased ultraviolet ra. What are the effects on the environment? Is ozone depletion a problem for the United States only or a global problem? CLEAN AIR ACT-NO VENTING LAW ©30Federal Clean Air Act The Montreal Protocol was the first treaty calling necessary regulations to implement the rulings for the reduction of the available production of in Section 608 of the Clean Air Act. In addition, CFC's. Later, the Montreal participants met many states and municipalities are creating again in London in 1980 and agreed toaddthe _their own laws to prevent and monitor the HCFC's to the schedule of production phaseout. release of CFC and HCFC based materials to The CFC’s, HCFC’s and Halons are now the atmosphere. These laws must meet the covered. In 1992 the United States ordered the requirements of the Clean Air Act and in many stoppage of all CFC production and importation _cases are stricter. after December 31, 1995. Any CFC’s used will come CFC PHASEOUT from recovery and recycling operations. Recovery of refrigerants is necessary for adequate future supplies and the prevention of stratospheric ozone depletion - due to venting refrigerant - (See Figure 5) Congress gave authority to the Environmental Protection eee ee Agency to write the = Figure 5 Check Yourself 1. Whatis the Montreal Protocol? 2. The Moire Procol cal for regulation of what chemicals? /n what date was the production and importatior ’s fume teeta ” and importation ofa F's phased out? 5. What steps are called for by the Clean Air Act? 8 Whats prohibited by the Clean AirAct? state and io 3ronty over federal z ‘and local laws have priority over federal law? Can they be less strict? To prevent damage to the ozone layer, the U.S. is making laws 's i f Ste ces honoelndo sree acs cen one can te Fes rane, By recovering refrigerant roeyeree ee so cameeye adequate supplies and prevent venting, What else does the©. Prohibition Against Venting According to the Clean Air Act, after July 1, 1992, no person installing, maintaining, repairing, or disposing of any appliance may knowingly vent or otherwise release into the environment any class | (a CFC) or class II (an HCFC) substance used as a refrigerant. The amendments called for standards to be set for recovery of all refrigerants prior to appliance service and disposal. On November 15, 1995 it became illegal to vent substitutes for CFC and HCFC refrigerants. The EPA can exempt a substitute refrigerant if it determines the refrigerant is not harmful to the ozone layer. Check Yourself Core Study Material Violations of the Clean Air Act include falsifying or failing to keep required records, failing to reach required evacuation levels, and knowingly releasing CFC or HCFC refrigerants or their substitutes. A technician may NOT add nitrogen to a charged system for the purposes of leak detection. Ina charged system, the refrigerant in the appliance must first be recovered. Pure CFC's and HCFC's, when released during leak detection, are considered a violation of the Clean Air Act. 1. The Clean Air Act phases out CFC/HCFC production and prohibits venting. What else does it require? 2. Falsifying or failing to keep required records, failing to reach required evacuation levels and knowingly releasing CFC or HCFC refrigerants, are all violations of the Clean Air Act. What activity with a substitute refrigerant is also a violation? 3. Which refrigerants must be recovered prior to opening a system? 4, What releases of a CFC and HCFC are violations of the Clean Air Act? 5. Onwhat date did it become illegal to vent CFC and HCFC refrigerants? ¢4 EPA REGULATIONS C4aGeneral The Clean Air Act amendments of 1990 defines n “appliance” as any device which contains and uses a class | or class II substance as a refrigerant and is used for household or commercial purpose. These appliances include any air conditioner, refrigerator, chiller, or freezer regardless of size. Equipment for industrial process refrigeration also falls under the term “appliance”. (See Figure 6) Low Pressure Appliance All appliances must be equipped with a service aperture or other device for 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 (process stub). Recovery devices can be divided into two main types: self-contained recovery equipment (active) and system-dependent recovery equipment (passive). A self-contained Refrigerant Types ‘This category includes appliances using CFC-11, 113, and HCFC-123. ‘This category includes appliances using CFC-12, 114, $00, 602, and HCFC-22. Figure 6 uu12 Core Study Materia, ystem-dependent recovery equipment relies solely upon the compressor in the small appliance and/or the pressure of the refrigerant in the appliance to recover the refrigerant recovery unit has its own compressor (or other transfer mechanism) to pump refrigerant out of the refrigeration system. It requires no assistance from any component in the system that is being recovered. ® All recovery and recycling machines manufactured after November 15, 1993 must be certified to meet EPA requirements © Only Section 609 certified technicians may buy CFC-12 in containers smaller than 20 pounds. Check Yourself 1. Which appliances are covered by Section 608? 2. Whatis the primary reason the EPA requires a service aperture or process stub on all appliances? 3. Who sets the regulations for recovery machines? 4. What isa “self-contained” recovery machine? 5. ISHOFC-123.a ‘low’ or *high” pressure refrigerant? 6. Is CFC-12a ‘low’ or ‘high’ pressure refrigerant? 7. What is the smallest container in which refrigerants may be sold to Section 608 certified technicians? ©4> Disposal of Equipment The final person in the disposal chain (scrap metal recycler, landfill owner, etc.) must ensure that all refrigerant has been recovered prior to disposal of any appliance. Check Yourself Persons making final disposal of appliances must either recover remaining refrigerant, or verify that refrigerant has been previously recovered. 1. What must you do to the refrigerant in an appliance before disposing of the appliance? 2. Whois responsible for removing the refrigerant from household refrigerators prior to disposal? ©4cPenalties for Violations Venting of refrigerant (and other violations of the Clean Air Act) is punishable by fines of up to $27,500 per day per violation and possible loss of technician certification. In addition, cash bounties up to $10,000 are available for individuals who report venting activities that result in a conviction in Federal Court. Check Yourself The EPA may require technicians to demonstrate their ability to perform proper procedures for recovering and/or recycling equipment. Failure to demonstrate proper procedures or failure to properly use the equipment may result in revocation of the technician's certification. 1. What is the penalty for violation of the Clean Air Act? 2. How much is the bounty for information leading to a conviction? 3. What can happen ifa technician cannot demonstrate an ability to use recovery or recycling equipment?Core Study Material c4dRecovery, Recycling, and Reclaiming The recovery of refrigerant removes refrigerant Reclaiming is a complicated distillation process in any condition from a system or container for that returns recovered refrigerant to the purity of storage in an approved external container. No factory fresh refrigerant. That evel of purity is further testing or processing is necessarily done specified in ARI Standard 700. Refrigerant on the stored refrigerant. cleaned to meet this standard can be resold or used in any application. In order for refrigerant Recycling means to clean refrigerant by oil to meet the definition for “reclaimed”, the separation, non-condensable removal and refrigerant MUST be tested to meet the ARI single or multiple passes through replaceable ‘Standard 700. (See Figure 7) filter-driers to reduce moisture, acidity and particulate matter. RECOVERY RECYCLING RECLAIMING =~ = ~~. a2 om ll, e~ marae, Sa ig eo Figure 7cs NEW SERVICE PROCEDURES SLeak Detection Techniques A vacuum pump and a gaugeset are used to leak check a system and determine if the system is free of moisture and other non- condensables. The system is first pulled down to approximately 29 in. Hg. and valved off. Any leak within the evacuated appliance will cause the system pressure to eventually read 0 psig. To locate a leak on an empty system under the new EPA regulations, the system should be Core Study Materia) pressurized with an inert gas (dry nitrogen, for example). An electronic type leak detector is then used to find leaks. The electronic types include the ultrasonic style detector. One of the advantages of electronic leak detectors over other detection methods is higher sensitivity. This fact makes the electronic detector the preferred choice when checking for small leaks. ©5°Recovery Overview All recovery machines now manufactured are required to have an EPA approved certification label The speed of the recovery depends on the size of the equipment and the ambient temperature, Lower ambient conditions will increase the recovery time. Under no circumstance should different refrigerants be mixed together. No economical method exists that can separate different refrigerants that have been mixed. A reclamation facility that receives a tank of mixed refrigerant may either refuse to process the refrigerant and return it at the owners expense, or agree to destroy the refrigerant for a substantial fee. When addressing consumer complaints regarding additional service expense due to. recovery efforts, the technician needs to explain to the customer that recovery is required by law and is necessary to protect human health and the environment. Also, the technician needs to remind the customer that all professional service personnel are duty bound to follow the law and protect the environment. ‘© A potential problem when recovering liquid is that some liquid will be rapped between service valves and does not get recovered, © Ifa technician finds the refrigerant in a system has been mixed, he should recover the refrigerant into a ‘separate container.Core Study Material ©® SUBSTITUTE REFRIGERANTS AND OILS C6aAlternate Refrigerants The current replacement for CFC-12 is HFC- 134a. Currently there is not a drop-in for CFC-12 A “ternary” blend is one made by combining three different refrigerants. Because the blends are not azeotropes they can be “broken down” into refrigerants with different performance characteristics. Their pressure-versus- temperature curve, for example, is not a single discrete line. Itis a family of lines. This family is called the “temperature glide” (See Figure 8) for the blend. Because their vapor pressures can vary widely with temperature, blended refrigerants leak from a system at uneven rates PRESSURE Figure 8 © Charging blends in vapor state should be avoided ® HFC-134a refrigerant charged systems should be leak checked with Pressurized nitrogen. ® The preferred charging method for the blends is to introduce a measured charge of liquid into the high side of a system. Check Yourself 1. Whats different about any leaks in a system charged with a blended refrigerant? 2. Whatis ‘temperature glide"? 3. Whats a ternary blend? 4. How should systems using a blended refrigerant be charged? 5. Isthere a “drop-in” refrigerant for CFC-12? 6. Howdo you leak check an HFC-134a system with a partial charge (no HFC-1334a detector available)? COils The lubricants most used with HFC-134a are Another lubricant type, the alkylbenzene type, the polyolesters or “ester” based, as they are is coming into use for some ternary blends generally called. The “ester” based oils are containing HCFC's. hygroscopic, meaning they readily absorb moisture, ® Asageneral rule, different lubricants should never be mixed 15Core Study Material ©? SAFETY-GENERAL c7@Recovery Operations Arecovery should be performed on refrigerant Dry nitrogen is ce ne testing and lines before they are cut or brazed. purging refrigerant lines. nitrogen container must be equipped with a pressure regulator. Under no circumstances should oxygen, high- pressure air, or a flammable gas be used for leak testing and purging. To avoid spilling liquid refrigerant on the skin, wear butyl-lined gloves and safety glasses when operating recovery or recycling devices and when handling and refilling refrigerant cylinders. © All safety precautions for the recovery machine should be followed. Never heat refrigerant storage or recovery tank with an open flame or live steam. © Oxygen and oll when mixed can form an extremely explosive mixture. ©7Personal Safety ASHRAE STANDARD 34 The flammability and toxicity of SAFETY GROUPS the refrigerants are divided into A3 B3 two groups. The “A” group is for low toxicity and the “B” group is for high toxicity. A number following the letter indicates the flammability of the refrigerant. The refrigerants in the “A1” group have the lowest toxicity and the lowest flammability. These include CFC-11, 12, HCFC-22, HFC-134a and R-500 and 502. The higher toxicity refrigerants are the °B1” refrigerants. (See Figure 9) Figure 9 FLAMMABILTY ‘© The safety ratings and precautions to be taken for any refrigerant car jing it rial Safety Data Sheet (MSDS). Ace a ‘© High concentrations of refrigerant vapor or mist should not be inhaled irregularities or asphyxia, : Soe ‘© Oxygen deprivation is the major cause of death in refrigerant related accidents.Core Study Material Check Yourself What is a Material Safety Data Sheet? What safety classification within the ASHRAE standard is the most safe? What is caused by the inhaling of refrigerant vapor? What is the major cause of death involving refrigerant? What breathing problem can be caused by CFC-12?7 @aons © 7eEquipment Safety Equipment test pressures must not exceed the __rating are given, the low side rating should be maximum design rating listed on the unit used for pressure tests. dataplate. If both a high side and low side © Sight glasses can be cleaned with an alcohol spray © Anytime a relief valve is damaged or corroded it must replaced ® Explosions may occur from leak checking with oxygen or compressed air Check Yourself How can ice be removed from a sight glass? What must be done with a badly corroded relief valve? Where can you find the allowable test pressure on a system? Can oxygen be used to check for leaks? If not, why not? Aenea 8 SAFETY-REFRIGERANT CYLINDERS ©82Disposable Cylinders Never heat a refrigerant storage or recovery never be refilled tank with an open flame or live steam. It can result in the refrigerant in the tank decomposing When disposing of a disposable cylinder, its into a toxic material, the venting of refrigerant to __ remaining refrigerant is recovered using a the atmosphere, or the tank may explode recovery machine in a manner similar to a causing serious injury to people nearby. system recovery. For maximum safety, the container should be punctured before disposal. Disposable containers may only be used for virgin refrigerant from the factory. They may ® Before discarding a container the intemal cylinder pressure should be reduced to at least 0 psig. ‘® The metal from empty disposable cylinders should be recycled Check Yourself ‘ Whats the likely result of heating a recovery cylinder with an open flame: What is the primary purpose of a disposable cylinder’ To what internal pressure should a disposable cylinder be ete er aes? ‘Should you ever use a disposable cylinder for refrigerant recovery? To lspose ofa cylinder you should be sur all refrigerant is recovered and the cylinders no longer useable. What else should you do? ohoNs18 Core Study Material ©8>Refillable Cylinders Recovery cylinders must be Department of Transportation (DOT) approved for use as a recovery cylinder and should be colored gray with a yellow top. Never use rusted refrigerant cylinders. Refrigerant cylinders must be clean and undamaged, properly color coded, and be properly secured at all times. Check Yourself 1. Forsafety, refrigerant cylinders should not be rusted or damaged and always properly color coded. What additional step should also be taken with these cylinders? 2. Whatis the proper color code for recovery cylinders? ©-8Recovery Safety Extremely high pressures generated by ‘expanding liquid in an enclosed space (hydrostatic pressure) could cause a refrigerant tank to rupture with extreme violence. To avoid the possibility of a hydrostatic explosion, refrigerant cylinders should never be filled above ‘ 80% of the container capacity (by weight). Fill- WW limit devices, often a part of the recovery machine, vary and include floats, thermistor type sensors, and weighing scales. Figure 10 ‘© Never use refrigerant cylinders unless they have been properly tested at least once every five years. (See Figure 10) Check Yourself What is the maximum percent by weight that a cylinder may be filled? What can happen if cylinder is overfilled? List three methods for measuring the fill level ofa recovery cylinder. How often must reusable cylinders be hydrostatically tested? ONS C84 Shipping Cylinders Refillable safety tested cylinders (DOT title 49. Any time used refrigerant is transported approved) used for transport of recovered its container must be clearly labeled with a DOT pressurized refrigerant must meet the classification tag. This includes a cylinder being requirements of the Code of Federal Regulation _ transported to a reclaimer. ‘® Refrigerant cylinders should always be stored in a vertical or upright position with their valves at the top. Check Yourself Why must only refillable cylinders be used for transport? What must be affixed to a refrigerant cylinder prior to its shipment to a recial What is the purpose of a DOT classification tag? - ee What is the correct shipping position for a refrigerant cylinder? AoneType | Study Material '° STUDY FOR TYPE | TECHNICIANS 1.7P IMPORTANT: A certified Type | technician must under: stand how to use a tem iture- Pressure (T/P) chart. (Refer to T/P chart instructions on page 46.) ieee 11 EQUIPMENT AND RECOVERY REQUIREMENTS 118 Equipment Units covered by this rating are classified as “small appliances” and can be serviced only by technicians certified as Type | or Universal). A “small appliance” is defined as an appliance typically charged at the factory with five pounds orless of refrigerant. The definition specifically names the appliances covered under the “small appliance” definition. They are: refrigerators and freezers designed for home use, room air conditioners including window and packaged terminal air conditioners, packaged terminal heat pumps, dehumidifiers, under the counter ice makers, vending machines and drinking water coolers. All other appliances that use a CFC or HCFC refrigerant as a coolant are defined as an “appliance”. The type of refrigerant is not specified Service hoses must be fitted with some type of low-loss fitting (shut-off valve) on each hose to prevent the loss of refrigerant. These fittings can either be closed manually or close automatically when disconnected Figure I (See Figure 11) condensables. To check for non-condensables, All appliances must be equipped with a service a temperature and pressure comparison can be aperture or other device for adding or removing done. The pressure in the container should refrigerant from the appliance. For small read within a few degrees of the pressure appliances, this service port typically is a shown on a temperature-pressure chart. The straight piece of tubing that is entered using a test is made afer the container has been Piercing access valve. allowed to stabilize in temperature. To stabilize the container, a recommended procedure is to Before any refrigerant is reused in a Type! store the container at a temperature between appliance, it should be checked for non- 65°F and 100°F for at least 12 hours. 1920 eo eo ¢ Type I Study Material -12Iin household reiigerators. To date there is no “drop-in” replacement HFC-134ais a replacement for CF! for CFC-12 Only CFC, HCFC, and HFC refrigerants should be r Regulations permit nitrogen and its trace refrigerant operations. Any person who opens an appliance for maintenance, S* recovery machine available at their place of business unl Repair of leaks in small appliances is not required, but lea! MVAC systems are not classified as a Type | appliance. covered with current recovery devices ‘to be vented during pressurization and purging ervice, or repair must have at least one self-contained Jess this person is working on a small appliance. ks should be repaired whenever possible. Check Yourself 1. Whatis the EPA definiton of small appliance? | EPA require the repair of leaks on small applian. 3. Wot EPA cortication ‘ype must technicians have to service any appliance that EPA calls a “small appliance”? ee 4. What service aperture may be used on small appliances? : ‘5. Whatis the name fora fitting, used to connect a recovery device to an appliance, which can close to prevent loss of refrigerant from hoses? i 6. Whatis the primary purpose for using hand valves or self-sealing hoses when using a gauge set? 7. Which refrigerants must be recovered under Section 608 of the EPA regulations? 8. Is there a "drop-in" refrigerant for CFC-12?. 9. Whatis the replacement refrigerant for CFC-12 in household refrigerators? 10. What can be determined by taking an accurate temperature and pressure of a container holding a recovered refrigerant? 11. When doing a non-condensables check, a recovery cylinder should stabilize in temperature before any readings are taken. Why? 12. Whatis the internal pressure of CFC-12 refrigerant stored at 75°F? 13. What is the exception to the rule that says that someone servicing an appliance must have at least one self-contained recovery machine available at their place of business? 14. Ammonia, hydrogen, and water can be found in the refrigerants in campers and other recreational vehicles. Should these compounds be recovered with EPA approved recovery equipment? 15. May the nitrogen used for purging or pressurizing a system be vented to the atmosphere? 1 1» Recovery Rules Passive (system dependent) recovery devices may be used to recover refrigerant from a domestic refrigerator. appliance recovery equipment manufactured after this date must be certified to be capable of recovering 90% of the refrigerant when the ‘compressor is operating or achieving a 4-inch All recovery and recycling machines manufactured after November 15, 1993 must be certified to meet EPA requirements. All recovery devices manufactured before November 15, 1993 for use with small appliances must certify to the EPA that the ‘equipment is capable of removing 80% of the refrigerant whether or not the compressor is operating or achieving a 4-inch vacuum, Small vacuum Recovery equipment manufactured after November 15, 1993 used to recover refrigerant for the purpose of disposal must be able to recover 80% of the refrigerant if the compressor is inoperative or 90% of the refrigerant if the compressor is operative.Type | Study Material © The EPA requires the certification ofall technicians who service Type | air condi equipment that uses a CFC or an HCFC as a reftigerant, If EPA regulations change after a technician becomes certified, it will be the technician's responsibility to comply with any future changes in the law. © After November 14, 1994, only technicians certified b 5 ; ni ied by an EPA approved certifying agen ited t buy refrigerant in any size container. Se eee Any regulated refrigerant released while filing a graduated charging cylinder must be recovered. tioning and refrigeration Check Yourself 1. When may a technician recover only 80% of the refrigerant in a small appliance? 2, May a technician use a passive recovery machine for recovery from a domestic refrigerator? 3. What requirements are placed on recovery machines built after November 15, 1993? 4. When using a recovery machine manufactured after November 15,1993, what percentage of the refrigerant must be recovered in a household refrigerator with an operating compressor? What percentage if the compressor is NOT operating? 5. Isa certified technician responsible for future changes in EPA regulations? 6. What type of certification is required to purchase CFC and HCFC refrigerant? 7. What must be done with any regulated refrigerant vented from a graduated charging cylinder? 12 RECOVERY PROCEDURES - TYPE | APPLIANCES 12aRecovery Basics - Type | Before any recovery is started the equipment must first be checked to be sure which refrigerant is being used. The equipment dataplate should provide this information. In theory, a vacuum pump could be used as a recovery machine....but itis highly unlikely. First, it would have to be certifiable. It would also have to be connected to a non-pressurized recovery container. Both of these possibilities are not likely. The system dependent recovery process, which captures refrigerant in a non- pressurized container, can be used on a system whose compressor is NOT operating. Ona system whose compressor |S operating, a SINGLE connection to the high side is typically used. If the system dependent recovery process is used on a system with an inoperative compressor, the recovery hoses should be connected to BOTH the high and low side fittings. This speeds up recovery, improves recovery efficiency, and may be necessary to reach required recovery levels. The recovery container must always be standing upright and be free of all non-condensables. A recovery container that is not properly evacuated or one that has an unopened inlet valve will cause excessive recovery machine discharge pressure. The recovery container should be cooled during the recovery. A recovery machine will maintain a low pressure ‘on a system as all refrigerant within it vaporizes. Compressors must be heated and struck with a rubber mallet to help free entrapped refrigerant. Defrost heaters should be turned on where possible to further speed up refrigerant release from the system oil. This is particularly true on small appliances when using system dependent Tecovery with a non-operating compressor. On an appliance that uses a captube and the captube becomes restricted, all LIQUID can be forced into the HIGH side (condenser). On these systems, system-dependent devices should only be connected to the HIGH side 21Under no c mstance should different ants be mixed together. No economical ‘od exists that can separate different refrigerants that have been mixed. A eclamation facility that receives a tank of mixed refrigerant may either refuse to proct Type I Study Material refrigerant and return it at the owners expense, or agree to destroy the refrigerant for a substantial fee. When recovering different refrigerants they must be placed in recovery vessels containing the same type of refrigerant.° ° Type | Study Material Recovery cylinders must be Department of Transportation (DOT) approved for use as a recovery cylinder and should be colored gray with a yellow top. Refillable cylinders (DOT or UL approved) used for transport of recovered pressurized refrigerant must meet the requirements of the Code of Federal Regulation ttle 49 (Parts 100-177). Any time used refrigerant is transported, its container must be clearly labeled with a DOT classification tag. Properly completed shipping paperwork should be included with a cylinder being transported to a reclaimer. ‘ Recovery devices should be checked with a refrigerant leak detector on a daily basis, Check Yourself 1. What first step must you always take before starting a recovery of refrigerant from any equipment? 2. Whatisa “system-dependent’ recovery machine? 3. Describe a system-dependent (passive) recovery process for small appliances. 4. What two conditions require that you access both the high and low side of the system for refrigerant recovery? 5. What are the benefits of accessing the low and high side access valves when recovering refrigerant from a system with an inoperative compressor? 6 How should you access the system and should you run the compressor when using a system-dependent (passive) recovery on a refrigerator with an operable compressor? 7. Which access vaive(s) should you connect to when recovering from a system with an operating ‘compressor and a completely restricted capillary tube? 8 When using a self-contained (active) recovery device, what two conditions can cause excessive pressure on the recovery machine's high side? 9. Why should defrost heaters be tumed on during a recovery from a small appliance? 10. When should entrapped refrigerant from oil be recovered? 11. What does striking the appliance compressor do during a recovery? 12. Arecovery machine should be checked daily for what? 13. Cana standard vacuum pump be used as a recovery machine? 14. Should technicians ever mix refrigerants in the field? 15. How should you recover a refrigerant that is different from the refrigerant you usually recover? 16. What can a reclaimer do with any mixed refrigerant you ship to them? 17. To ship recovered refrigerant you must label the container and complete all necessary paperwork. What else should you do? 18. What federal agency sets the standards for portable refillable tanks or containers used to ship CFC or HCFC refrigerants? 12> Recovery Precautions - Type | ‘Temporary fittings should only be installed on leak if not cared for. Schrader valves should be copper or aluminum lines and should be leak periodically checked for leaks, be replaced if tested before proceeding with recovery. damaged and capped after any service ‘Temporary fittings must be removed after the procedure. repair to prevent leaks. Schrader fittings can eo 6 Filklimit devices, often a part of the recovery machine, include floats, thermistor-type sensors, and weighing scales. Sight glasses are not currently used for fil-imit devices. To avoid spiling liquid refrigerant on the skin, wear butyL-lined gloves and safety glasses when connecting or disconnecting hoses. If system pressure reads “0 psig’ a leak is indicated and recovery procedures should not be started Ifa system is opened and a pungent odor is detected, it might mean acids are present due to a compressor burnout and a tubing flushing might be required 23Check Yourself Type | Study Material 1. Safety glasses and butyl-lined gloves should be worn for what procedures? Piercing valves are used for what purpose? On what materials are piercing valves used? What should be done to a piercing type Schrader valve after it’s installed on a charged system? Why should solderless type piercing valves be removed after completion of repairs? What does a pungent odor detected after opening a system mean? What do you do if the oil is contaminated? What system pressure would indicate a recovery should not be performed? 3 4, 6. What are the critical maintenance checks done to a Schrader valve? i 8 9. 1 (0. What are the current methods used to monitor the 80% fill level in a recovery tank? 13 SAFETY WITH TYPE | APPLIANCES Be on guard for refrigerant leaks. Refrigerants are heavier than air and can replace air ina confined space leading to suffocation (asphyxiation). Oxygen starvation is the leading cause of death in accidents involving a refrigerant. A Self-Contained Breathing Apparatus (SCBA) must be worn any time one enters @ room where a large leak has occurred Ifa large leak has occurred and no SCBA is available, ventilate the space and leave the area. If a system is not evacuated fully, compressor head pressure can rise andthe remaining moisture will combine under heat with refrigerant and oil to form hydrofluoric and hydrochloric acids. Never heat a refrigerant storage or recovery tank with an open flame. It can result in the venting of refrigerant to the atmosphere or the. tank may explode causing serious injury to people nearby. Also, moisture will combine under heat with refrigerant and oil to form hydrofluoric and hydrochloric a as phosgene gas. © DOT regulations require shipping papers to show the total number of cylinders of each gas. © Refillable cylinders used for transport of recovered pressurized refrigerant must meet the requirements of the Department of Transportation (DOT). © When repairing a Type | appliance, nitrogen should be used during brazing operations. The nitrogen tank should be equipped with a regulator. Check Yourself NOMAONS and HCHC refrigerants? Why do large refrigerant leaks cause suffocation? Before entering an area of a large leak of refrigerant what apparatus must be worn? What should be done if a large leak occurs and no breathing apparatus is available? Which acids are formed when refrigerant touches sources of high heat? What safety component must be used whenever dry nitrogen is used to pressurize a system? What information does DOT require when shipping refrigerant cylinders? Which government agency sets the standards for refillable refrigerant cylinders used to transport CFCType Il Study Material 2° STUDY FOR TYPE Il TECHNICIANS 27? IMPORTANT: A certified Type II technician must understand how to use a tem} erature pressure (T/P) chart. (Refer to T/P chart instructions on page 46.) : 21 EQUIPMENT AND SERVICE PROCEDURES 21@ Equipment HCFC-22 is the most used refrigerant in this type. On some machines, a receiver is installed at the outlet of the condenser to store the low temperature-high pressure liquid until it is needed by the evaporator. They are on the high side of the system. These systems easily “load up” with moisture when opened, so filter- driers must always be replaced after a system is opened for repair. A filter-drier is installed in the liquid line to filter solid contaminants and remove moisture from the liquid refrigerant. (See basic refrigeration circuit on page 5) Equipment in this EPA type is charged with refrigerant in both vapor and liquid form. In systems above approximately 50 pounds of charge, the refrigerant should be liquid charged in the liquid state through the liquid line service valve. For many larger systems, the use of “inches of mercury” on a low pressure gauge is too crude to be used. The pressure in these systems is so near a perfect vacuum that a more precise measurement called a “micron” is used. Typically, a single adjusting stem controls the Porting of three position service valves (king valve) without Schrader fittings. Adjusting the stem changes the valve to one of three Positions: 1) refrigerant flow through a main line as well as a service (gauge) port, 2) refrigerant flow through the main line only, with the gauge port closed (this is called “backseated”) and 3) all ports closed. Under some conditions, sight glasses can “freeze over’ with ice. Should this occur, the sight glass can be cleaned with an alcohol spray. Many sight glasses include a moisture indicator to permit a check of moisture content in the circuit, In some charging operations, vapor should first be charged into the system until the saturated vapor temperature is above 32°F (approximately 33 PSIG for example, for CFC-12) An oil sample should be taken if the unit has had. a leak or major component failure (compressor burnout). IMPORTANT: With some evacuations, particularly if the vacuum pump has a high capacity, the reduction in pressure on the system can cause any moisture in the system to freeze. The frozen moisture can often be removed by increasing the pressure to allow the ice to melt. Under these conditions the system pressure must be raised with dry nitrogen only. © When evacuating these systems, a vacuum pump should be capable of pulling a vacuum of 500 microns. ‘© Oil separators are not necessary on recovery machines. ® Oilthat is heavily mixed with refrigerant will foam in the crankcase as the compressor starts. © Non-condensables in a refrigeration system result in higher discharge pressure. ® To reduce the amount of refrigerant in the lubricating oil, compressors should be equipped with heaters. 2526 Type ll Study Material Check Yourself 1. What component is always replaced after a system is opened for service? 2. What is the purpose of the moisture indicator in a sight glass? 3. What does “backseating” a suction valve do? 4. What will non-condensables do to the pressures in a refrigerant circult? 5. What causes oil foaming in a system and where does it normally occur? 6. What system failures require taking an oil sample? 7. Avvacuum pump that is too large can cause what problem? & Where is a receiver typically installed ona system? 9. What will be the boiling temperature of HFC-134a at 0 PSIG? 10. Is ita requirement that recovery machines contain an oil separator? 11. Which refrigerant is typically used on a residential split system air-conditioner? 12. Is the refrigerant leaving a receiver a liquid or a. gas? Is it at a high or low pressure? 13. What is the initial charging method of a system when the charge is specified as 70 pounds? 14. Is the receiver on the high or low side of a system? 15. What is the minimum recommended capability (measured in microns) of a vacuum pump used for evacuations? 16. What is the pressure of an CFC-12 machine at 72°F while the machine is idle? 17. What is the preferred unit of measurement for checking a deep vacuum? 18. Where is an accumulator located in a refrigeration system? 19. To prevent freezing of any moisture in a CFC-12 system, vapor should first be charged until the pressure is at what level? 20. What gas should be used during an evacuation to increase pressure to prevent freezing? 21. Whatis the purpose of a compressor heater? 22. Hows moisture remaining from an evacuation removed from the refrigerant in a system? 21> Leak Checks and Repair be a seal where the shaft enters the compressor body. Leaks at this seal can be a continuing problem. The leak detection techniques for Type II ‘equipment generally follow the same techniques used for Type | equipment. For a quick leak check of larger air conditioning systems, any stains around tubing and fittings usually Any annualized leak rate of 35% or more in indicates a leak. Because of the size of the tubing used in Type II equipment, some leaks can be pinpointed by applying a bubble solution to the joints that are suspected of leaking. If the jointis leaking, bubbles will appear at the leak. The “open type” compressor uses a motor located outside the compressor body. A disadvantage of the open type is that there must commercial refrigeration (retail food and cold storage warehouses) or industrial process equipment with 50 pounds of charge or more must be repaired. For appliances with 50 pounds of charge or more, other than industrial process equipment and commercial refrigeration, an annual leak rate of 15% or more must be repaired. ‘© In Type Il equipment, the result of a leaky system is an undercharged condition that raises superheat. ‘© Under the new EPA regulations, to locate a leak in a system prior to its charging, the system should be pressurized with an inert gas (dry nitrogen for example) with an added trace charge of refrigerant (HCFC-22 for example). HFC-13da refrigerant charged systems should be leak checked with pressurized nitrogen.Type Il Study Material Check Yourself What is the preferred method of leak checking a built-up system prior to charging? What would a technician initially look for during a visual inspection of a leaking hermetic system? What is typically indicated by excessive superheat on a high-pressure system? Which refrigerant should be used for a trace charge during leak detection? ‘How do you leak check an HFC-134a system with a partial charge (no HFC-134a detector available)? For what purpose are soap bubbles used in leak checking? Shafi seals on an open type compressor are susceptible to what failures? What leak rate is permissible on industrial and process refrigeration? What leak rate is permissible on equipment (other than industrial and process equipment) that contains ‘more than 50 pounds of refrigerant? ©ONODAONA 22 RECOVERY PROCEDURES - TYPE Il APPLIANCES. 22a Recovery Basics - Type II Before any recovery is started, the equipment must first be checked to be sure which refrigerant is being used. The equipment dataplate should provide this information. For recovery from some large systems, water- Recovering refrigerant from a system in vapor —_cooled recovery machines are used. Typically phase will minimize loss of oil. The most their water-cooled condensers are connected to important benefit of liquid recovery is that itis a nearby municipal water tap. much faster than vapor recovery. No liquid recovery is possible unless a liquid access fitting is available. One shortcoming with liquid recovery is that some vapor remains in the system and cannot be removed with the liquid recovery. A vapor recovery must be used to remove any remaining refrigerant vapor. (See Figure 12) If the recovery machine is to be used again for a different refrigerant, it must first be cleaned of all residue of the first refrigerant. The oil must be drained and replaced with © One routine maintenance task, which must be performed on most refrigerant r change the oil and fier. © The recovery container should be cooled during a recovery © Contaminated refrigerant can contain acids, oils and moisture. ing machines 27Check Yourself Type Il Study Material 1. What is the easiest way to check the type of refrigerant used in a packaged rooftop system? 2. Refrigerant will recover fastest in which phase-liquid or vapor? Se : 3. Which refrigerant line should a recovery machine be attached to in order to recover liquid refrigerant froma system? After a liquid recovery, what must be done with the vapor still in the system? Recovering in a vapor phase reduces unwanted loss of what? Ona high-pressure system recovery should the recovery cylinder! What besides filters must periodically be changed out on a recovery machir -be heated or cooled? Recovered refrigerant can contain oiland acids. Name another compound found in refrigerant? = 4. 5 6 7. What must be done to a recovery machine when changing to a different ref t? 8. 9. 1 (0. Whatis the water source for a condensing coil on a water-cooled recovery machine? 22> Recovery Precautions - Type Il According to the new EPA rules, all hoses used with recovery machines must be fitted with some type of self-sealing fitting on each hose to prevent the loss of refrigerant when hoses are being connected and/or disconnected. Before any recovered refrigerant is reused in its original system or is transferred to another system with the same owner, it should first be checked to see that itis free of non- condensables If the recovery cylinder is full (80% max by allowable weight), it can be disconnected and an empty recovery cylinder substituted. The ‘empty recovery cylinder must be evacuated of all non-condensables before it can be used for recovery. The system must remain off with its service valves open during the recovery procedure. As much as possible, all solenoid valves should be open. Be certain the recovery machine is properly lubricated. If an evacuation of the recovery machine is necessary, it should be done prior to the recovery. Wait for the recovery machine to turn off on its low pressure control indicating most of the refrigerant has moved out of the system and into the recovery container. If refrigerant is still trapped in the system, the pressure will rise after the shut off. Wait several minutes. With some machines, the compressor will automatically turn on again and continue the recovery process. On a parallel compressor system, the equalization connection must be closed before refrigerant recovery operations are started. This will isolate the refrigerant that must be recovered from the rest of the equipment. If evacuation to the target levels is not possible because of leaks in the system or if the recovery to these levels would contaminate the refrigerant being recovered the technicians must evacuate LEAKING components to the lowest level attainable without substantially contaminating the refrigerant (This level CANNOT exceed 0 PSIG). Hermetic compressors in recovery machines are cooled by moving air over their body, flowing suction gas over their internal motors, or by a combination of these two methods. To prevent overheating the compressors internal motor, recovery machines should never be started (energized) while they are in a deep vacuum or when their service valves (discharge or suction) are closed.| HOW TO REMEMBER THE EPA CHART All Type I! and Type III technicians must evacuate to a vacuum pressure specified by EPA in its “Recovery Efficiency” chart Here js that chart HGFC-22 appliance with less than 200 ibs of charge HCEC-22 appliance with 200 Ibs or more of charge Other high pressure appliance with less than 200 lbs of charge Other high pressure appliance with 200 Ibs or more of charge Low Pressure Equipment The test candidate must know this chart and cannot carry it into the test. You may, however, quickly feconstruct this chart when you first are instructed to start your exam. You may use the blank chart | on the back of your Temperature-Pressure chart in the back of this book. Here are some easy steps to help reconstruct the chart: | start by drawing a (Gols the rect colom | chart with FOUR and write “under, | columns and FIVE "over", “under” and 2 Fows, (Remember: vover". Leave the last | 4 by 5) ‘one blank. Just i remember to start with I “under” and alternate. 7 | Label the first column © ATER Finally, eemember this | “refrigerant” (or “ref”), simple number the second column sequence: “zero-zero", “200 pound charge”, foursten”, the third column “fourteen” and “BEFORE 11/15/93” and twenty five-twenty the last column five". Enter these oh Under “AFTER 11/15/93". We ‘numbers on the chart do this for you on the Just remember the back of the T/P chart last 25s in ‘on page 48. millimeters. Start at the first < eo ATES Using blank paper, practice making the chart column. There is only : using this technique until you can easily do it. [Link] listed - ON THE DAY OF THE TEST, RECREATE ee Dae crea B8, THE CHART AS SOON AS YOU ARE GIVEN write "22", "22", other THE INSTRUCTIONS TO BEGIN THE TEST “high”, ether "high" — iy ‘A blank chart form (p. 48) is on the back of the and finally “low” TIP chart (p.47) that you may take into the test Pressure. Hi DO NOT FILL IN THIS CHART PRIOR TO YOUR TESTING SESSION 2930 Type Il Study Material system receiver/storage tank is a primary location for recovering liquid refrigerant. In most appliances, liquid refrigerant will be at the component that is at the lowest location of the system. EPA defines a “major repair” as a repair that involves removal of the compressor, evaporator, condenser or any auxiliary heat exchanger coil While system-dependent recovery devices may be used on TYPE I equipment, it must be remembered that system-dependent devices CANNOT be used on any appliance with more than 15 pounds of refrigerant. ooo ° Check Yourself 1. What access location should you use when recovering from an air cooled system with its condenser several feet above the evaporator? 2. What access location should you use when recovering from a system with its condenser below the evaporator? 3. Before using a recovery unit the technician should check service valve positions and check the recovery unit oil level? What additional step must be taken? 4. Whatis the primary purpose for using hand valves or self-sealing hoses when using a gauge set? 5. What can cause recovery equipment with a hermetic compressor to overheat when drawing a deep vacuum? 6. What is the reason for not operating a hermetic refrigeration compressor while the compressor is in a deep vacuum? What is the reason for not starting a reciprocating compressor with its discharge service valve closed? When can a ‘system-dependent” recovery device be used? What vacuum level must you reach when recovering from a system with 38 pounds of R-502 using a recovery machine manufactured in 1995? 10. What is EPA's definition of a “major repair"? 11. Priorto making a major repair, what vacuum level must you pull when using recovery equipment manufactured in 1996 on a unit with 215 pounds of CFC-12? 12. What vacuum level must you pull when using recovery equipment manufactured in 1992 when disposing of an appliance containing 12 pounds of R-500? 13. Under what circumstances may a technician recover the CFC refrigerant in an appliance to atmospheric pressure only? 14. What procedure should be performed on an empty recovery cylinder before itis used for storing recovered refrigerant? 15. What may legally be done with the refrigerant recovered from a system in order to replace a condenser coil? 16. When servicing an operating unit with a receiver, where should the recovery hoses be attached to the unit? 17. In order to recover from a system with parallel compressors, the individual compressors must be isolated. why? ©an 23 SAFETY WITH TYPE Il APPLIANCES ASHRAE Standard 15 specifies the Pressure relief devices are used to protect large requirements and use of oxygen-deprivation refrigeration systems. If more than one relief sensors in equipment machine rooms. For valve is used, they must not be installed in many rooms, refrigerant monitoring is required _series. for ALL refrigerants. © Allnitrogen tanks should be equipped with a regulator to lower outlet pressure. Check Yourself Which refrigerant(s) require an equipment room monitor per ASHRAE Standard 15? What protection is mandatory to protect a system against damage from excessive pressure? Are multiple relief valves connected in series or parallel? Why is the use of a regulator required when using dry nitrogen? AonType ill Study Material *° STUDY FOR TYPE Ill TECHNICIANS STP IMPORTANT: A certified Type Ill technician must understand how to use a temperature- pressure chart. (Refer to T/P chart instructions on page 46.) 31 EQUIPMENT AND RECOVERY REQUIREMENTS 51a Basic Systems Low-pressure chillers are typically charged with Rupture discs are used in low-pressure chillers liquid through the evaporator charging valve. To _ to relieve pressure. The rupture disc is prevent freeze-up, the initial refrigerant charge connected at the evaporator and is typically set into an evacuated system should be in vapor to open at 15 PSIG. The rupture disc is piped to state only. Adding liquid refrigerant should be the outdoors for venting. avoided until the gauge pressure when checked against a pressure temperature chart for the ‘Since water is often present in the chilled water refrigerant in use indicates a temperature above pump and water tubing, the circulating pump freezing, typically 36°F. Liquid refrigerant should be running during a recovery. This step charged into a chiller that is under a deep will prevent possible freeze-up of the water as, vacuum will drop to an extremely low pressure is reduced on the refrigerant. temperature. © Charging refrigerant liquid into a refrigeration system under 29 in. Hg. vacuum can cause the system water to freeze. © When recharging a refrigeration system with CFC-11, 16.9 in. Hg. vacuum is necessary in the shells before charging with liquid © Under some conditions sight glasses can “freeze over" with ice, Should this occur, the sight glass can be cleaned with an alcohol spray. © The lowest access point on a low pressure centrifugal air conditioners the evaporator charging valve. © Anoil sample should be taken if the unit has had a leak or major component failure (compressor burnout). Ifa system is not evacuated fully, compressor head pressure can rise. ‘© The system pressure in idle low-pressure equipment should be maintained slightly above atmospheric to prevent air accumulation, Check Yourself 4. How can ice be removed from a sight glass? 2. How high should you pressurize an idle low pressure chiller to prevent air accumulation? 3. What effect does air in a chiller have on head, pressure? 4. What system failures require taking an oil sample? 5. Why must water be circulated through a chiller during refrigerant recovery? 6 Whatis the lowest access valve on a low pressure chiller? 7. Where is a centrifugal chiller’s rupture disk attached? & Whats the typical pressure setting for a low pressure chiller's rupture disk? 9. Where is the outlet of a rupture 7 discharged? i" Eo i temperature needs to be achieved before liquid Is charged into a chiller? 12, To prevent freezing of water when charging a chiller, what pressure should be reached with vapor 13. What ssa aU rotiaorak bole. charged into a chiller that is holding a 29 in. Hg. vacuum? e9.1 Purge Unit The refrigerant in low-pressure equipment is typically at pressures below atmospheric. Due to the many gaskets and fittings used in this type of system, air leakage and moisture entering the system are common problems. If these are not repaired, system efficiency can be severely effected. With systems as large as most chillers, contamination is a problem. To minimize the effects of this contamination, purge cycles are almost universally used. Purging is accomplished with a purge system made up of a compressor, oil separator and purge Type Il! Study Material drum (See Figure 13). The inlet of the purge compressor is typically connected to the top of the condenser. During a purge cycle, non- condensables (with some smalll quantity of refrigerant vapor) from within the chiller are drawn off and sent to the purge drum. At the purge drum the non-condensables and reftigerant vapor are separated using distillation and the refrigerant vapor is returned to the system. High efficiency purge units remove non-condensables that contain a low: percentage of refrigerant. This feature adds greatly to the value of the purge drum in refrigerant containment. PURGE UNIT31¢Leak Detection and Repair A hydrostatic test is used to check for tubing leaks within a chiller. To prevent moisture from being drawn into the refrigerant tubing, the water circuits of the evaporator and condenser should be drained. The “open” type compressor uses a motor located outside the compressor body. The external drives of these compressors can include pulleys and drive belts, while others are driven directly by a motor (direct drive). A disadvantage of the open type is that there must be a seal where the shaft enters the compressor body. Leaks at this seal can be a continuing problem Low pressure equipment with a partial charge can be checked by increasing the refrigerant pressure using an external heat source or running hot water in the chiller tubes. When leak checking with dry nitrogen, the pressure must not exceed 10 PSIG (Excessive pressure could cause a rupture disc failure). Low pressure equipment without a charge can be leak checked using a “time to rise” test. With Check Yourself 1 What is a hydrostatic tube test kit used for? Type Ill Study Material this technique, the equipment is pulled down to a deep vacuum, usually 1-mm hg. The system is then valved off and a check is made of the stability of the vacuum. At the end of this check, the vacuum reading should not increase to more than 2.5-mm hg. (ASHRAE Standard 3- 1990) The need for purging can be reduced by leak checking and repairing any leaks on a regular schedule When leak checking a low-pressure system for leaks between the refrigerant circuits and the water circuits, the chiller barrel can be emptied of all water and a leak check can be made at the drain valve with the water off. Effective June 14, 1993, any annualized leak rate of 35% or more in commercial refrigeration or industrial process equipment with 50 pounds of charge or more must be repaired. For appliances (with 50 pounds of charge or more) other than industrial process equipment and commercial refrigeration, an annual leak. rate of 15% or more must be repaired |. Shaft seals on an open type compressor are susceptible to what failures? 2. Purge units work best when they are not needed. How can purge unit operating time be reduced? What is the maximum pressure that can be used when leak checking a low pressure chiller? What is the preferred method of leak checking a charged low pressure chiller? Where should you check for leaks between a chiller refrigerant tube and a water box? What leak rate is permissible on industrial and process refrigeration? : What leak rate is permissible on equipment other than industrial and process equipment? ‘According to ASHRAE 3-1990 what rise is permitted in vacuum level during a standing vacuum test? ). List two steps to reduce the run time of a purge unit. i Why should the water sides of the evaporator and condenser be drained before recovering refrigerant from a chiller suspected of having tube leaks? ae, 12. it is ing excessively, what problem can you ex, > ; a Wet eiscund coves ‘continuous excessive moisture collection in the purge unit of alow pressure refrigeration system? Bgeenonae 33Type Ill Study Material 32 RECOVERY PROCEDURES - TYPE Ill APPLIANCES 52a Recovery Basics - Type Ill CFC-11 or HCFC-123 system refrigerant removal starts with liquid removal (See Figure 14). One shortcoming with liquid recovery is that some vapor remains in the system and cannot be removed with the liquid recovery. A vapor recovery must be used to remove any remaining refrigerant vapor. When the removal of oil from a low-pressure system is required, the oil should be heated to 130°F because less refrigerant will be contained in the oil at the higher temperature. Vapor recovery condensers can be either air- cooled or water-cooled. Water-cooled condensers are cooled with water from the local water supply LIQUID RECOVERY USING A LIQUID PUMP. Low Pressure Appliance Liquid From Unit Figure 14 Check Yourself Awna Equalization Hose Recovered Refrigerant Container Why should oil be warmed prior to removal from a low pressure chiller? After a liquid recovery, what must be done with the vapor still in the system? Is recovery of refrigerant from a low pressure appliance typically started with liquid or vapor? Where is the connection made for the water supply used on awater cooled recovery unt?32 Recovery Procedures - Type When using the push-pull method to recover refrigerant from a low pressure chiller the recovery unit's high pressure cut-out should be set for 10 psig. (See Figure 15) During vapor removal from the refrigeration system, the system water pumps, the recovery compressor, and the recovery condenser water should all be on. ‘Once the machine cuts off on low pressure (or manually), the recovery is not necessarily complete. If refrigerant is still trapped in the system, the pressure will rise after the shut off. Wait several minutes. With some machines, the compressor will automatically turn on again and continue the recovery process. Type Ill Study Material To pressurize a system prior to a minor repair a technician can increase the refrigerant pressure using an external heat source or running hot water in the chiller tubes. If evacuation to the target levels is not possible because of leaks in the system or if the recovery to these levels would contaminate the refrigerant being recovered. Technicians must evacuate LEAKING components to the lowest level attainable without substantially contaminating the refrigerant (This level CANNOT exceed 0 PSIG). (See Recovery Efficiency on page 29) PUSH PULL RECOVERY METHOD Chiller gua * Sse Recovery| Cylinder Figure 15 aks ager us more than one type of refrigerant oR cling machines are not required to recover more: 8 ee an en ee are novetal ive ramoval of he compressor, evaporator, condenser or any auxiliary heat exchanger coll, 3536 Type Ill Study Materia) Check Yourself 7. What shoud be the maximum pressure on the discharge of @ recovery machine for fow pressure? What should be done with the water pumps during a recovery from a low pressure chiller? 2. 3. What is EPA's definition of a “major repair"? . 4. What recovery vacuum must be met on a low pressure appliance using @ machine builtin 19927 6. ity should you waita few minutes affer reaching the required recovery vacuum on an eppliance to see if ressure rises? 6. Under what ercumstances may a recovery ofan appliance be stopped without reaching the prescnbed level? 7. Isita requirement that recycling and recovery equipment be capable of handling more than one refrigerant? 8. Isitpormissible to warm the refrigerant under EPA's regulations to pressurize a low pressure system to doa non-major repair? 9. What final vacuum level is required for recovering refrigerant from a low pressure system if the technician [Link] recovery equipment manufactured BEFORE November 15, 1993? AFTER November16, 19937 2c Precautions when Recovering - Type Ill IMPORTANT: With some evacuations, The frozen moisture can often be removed by particularly if the vacuum pump has a high. increasing the pressure to allow the ice to melt. capacity, the reduction in pressure on the Under these conditions the system pressure system can cause any moisture in the system _ must be raised with dry nitrogen only. to freeze. Check Yourself 1. A vacuum pump that is too large for @ particular system can cause what problem? 2. How can you prevent moisture freezing during dehydration? 33 SAFETY WITH TYPE Ill APPLIANCES ASHRAE Standard 15 specifies the According to ASHRAE Standard 15, each requirements and use of refrigerant sensors in __ machinery room shall activate an alarm and equipment machine rooms. ASHRAE Standard mechanical ventilation system before refrigerant 18 requires equipment rooms to have refrigerant concentrations exceed the TLV-TWA (Threshold sensors for ALL refrigerant safety groups. Limit Value — Time Weighted Average). ‘© Toavoid spilling liquid refrigerant on the skin, wear butyl-lined gloves and safety glasses when connecting or disconnecting hoses. When using low-pressure refigerans, avoid siphoning refigerant by mouth The higher toxicity refrigerants are the “B41” refrigerants, The most y i is HCFC- The ate aia ig st commonly used in this group. ° ‘Some air conditioning and refrigeration systems may require more than one relief valve. If more than one relief valve is used, they must not be installed in series, Check Yourself 1. Are multiple relief valves connected in series or parallel? 2. ASHRAE standard 15 covers refrigerant level monitoring for what refrigerants? According to ASHRAE Standard 15, what s the standard for refrigerant concentration for a machine 00" Jat must not be exceeded without activating an alarm and starting ventilation in the machine room? List four safety procedures that should be followed when working i J 0 when with liquid low pressure refrigerant ‘5. What is the toxicity and flammability rating of HCFC-123, eee aaIntroduction to EPA Testing and Procedures CONGRATULATIONS At this stage you have completed your study of the certification test material and you are ready to take the test. On the following pages are samples of the actual test. Note the answer card and the instruction page opposite it. This gives you a preview of what you will need to fill out on the answer card at the beginning of the actual test. You do not need to complete any of these entries on the sample copies. Following the sample answer card page is the sample certificate. All successful candidates receive this cerfificate and a plastic laminated wallet card. This is a very sought after card and you should be proud to carry it! You will also receive a Results Report (See Figure 16) that gives you a detailed breakdown of, your test results. Note each entry has a code for the section of this manual covering the subject material for that score. This feature lets you see how you did on each topic in very great detail ‘Should you need to take some portion of the test again, you will find this information valuable to find what you might have missed on your first try Knowing you studied this manual thoroughly, you probably will not need that second try! Figure 16 CANIUSE THE INTERNET? You can use the internet for several purposes. “Seamnaren ann nets POSTON Your detailed test results will be available on the CANDIDATES net within minutes of the grading of your test. oS Only individuals with your PIN identifier can a access your results. If you choose NOT to give your PIN identifier to anyone, only you will have access to your results. To access the results site, log onto [Link] (See Figure 17). Ifyou tested with ARI, log onto [Link]. You can also use the internet to communicate with VGI, the test administrator. If you have questions, you can send an e-mail to epa@[Link]. Figure 17 37Instructions for Answer Card INSTRUCTIONS PLACE THE ANSWER CARD ON OPPOSITE PAGE. TO COMPLETE ANSWER CARD, FOLLOW THESE INSTRUCTIONS [7] Your proctor will give you this number. Enter it accurately. [2] Enter the date you are taking the exam. 7 | Ifyou use a middle initial, enter it here. 9 | Enter your city. DO NOT WRITE ON THE TEST BOOKLETSSample Answer Card 4 | 2 Se Sri 4444 : — Hilts ek fhooggogogeugaubgeueeees gees Baleala5 tiiseeedeeecdedecGaseccennsa Bi EIA te Fe gegee ae lia Pssasesescsssccecugesscces DE rile | UE EF eERRSERRSERSERTETRITRETSS i ale [ig i afb 38 g é 8 je o : EE le : 8 | Zee H i a¢ee ele Soe gis i 2o US i Se le = : 388 5 i 4 Lon i 3 == i : : £ i. q 2 3 : - i 4 i : ne 5 38 : iif cocucscgguucopuascuseenee s P Eb sssasceseesee@aeeaseqeues BE a & TE RRRERESESSERRER RRR REE RK BE a le 3) 16 39 Sarasa CanaCredentials Papsod nos Type | Bas Type i oe Type iil a 1 135 wamst Congratulations poylown Tk 76011 We ¢ : have procossod yur lat ang yout ‘attached. ence 2 7hdppit on neue = 2 canmeramsntene ee Ploase keep that in mind. Soa your daily work. HOW MAY | OBTAIN AN EXTRA COPY OR REPLACEMENT OF MY CREDENTIALS? Information about credentialing may be obtained at [Link]. com or by calling 800-886-4109.Sample Test Questions SAMPLING OF THE VARIOUS TYPES OF QUESTIONS CORE SECTION 1. The first hint that there might be a problem with depletion of ozone in the stratosphere occurred in the early: a. 1960's. b. 1970's. ©. 1980's. d. 1990's. 2. The prohibition against the venting of refrigerant means that, at a minimum, refrigerant must be: recovered reclaimed, recycled. all ofthe above eocs 3. What is ozone? a. Agas that is considered harmful when found atground level. b. Agas that helps form earth's protective shield in the stratosphere. ¢. gas found in many homes, sometimes call Radon, d. Bothaandb TYPE | SECTION 4, An example of a small appliance is: a split system residential air conditioner. a PTAC with 5 pounds of refrigerant. an evaporative cooler. allthe above pecs 5. A “drop-in” substitute for R-22 in a small appliance is: a. R12 b. R-134a cc. R602 d. none of the above 6. If passive recovery is used on a unit with a non-operating compressor, the recovery should be made through: both high and low sides. the high side only. the low side only. none of the above eose TYPE II SECTION 7. Overfilling a refrigerant container is extremely dangerous because of the high pressures generated. The source of thi high pressures is: ‘a._ the vapor pressure of the refrigerant. b. the discharge pressure from a recovery machine, ¢. the hydrostatic pressure of expanding liquid d._ the discharge pressure from the recovery container. 8. Recovering in the reduce oil loss. phase will a. vapor b. liquid c. initial d. final 9. In addition to the recovery of refrigerant, recovery machines can also evacuate a system of: non-condensable, oil moisture. none of the above TYPE Ill SECTION 10. Three of the refrigerants covered under the low pressure regulations of the EPA are: a. CFC-11, CFC-113 and CFC-114 b, CFC-11, CFC-113 and HCFC-123. cc, CFC-11, CFC-114 and HCFC-123. d. CFC-11, CFC-114 and CFC-502 11. A purge cycle is required on all low pressure chillers becaus a. such a chiller can operate at a pressure below atmospheric pressure, b. evacuation of all air from a chiller is not possible ¢. chillers are often opened for maintenance, d._ of the refrigerant's low boiling point. 12, The most cost-effective method of recovering refrigerant from a chiller to meet EPA requirements is to use a. liquid pump. b. vapor recovery machine. C. liquid pump followed by vapor recovery. 4. vapor recovery followed by liquid pump, 4INDEX A Accumulator location, pg. 5 ‘Active Recovery. See Recovery Machine: Self Contained Appliance Disposal, pg. 12 ASHRAE Standards 15 (Fifteen), pg. 30, 36 34 (Thirty-four), pg. 16 Azeotrope, pg. 9 c CFCs definition, pg. 8 phaseout, pg. 10 properties, pg. 8 replacement, pg. 20 types of, pg. 8 Chiller charging, pg. 31 leak checking, pg. 33 lowest access point, pg. 31 pressurization, pg. 31, 35 typical leak locations, pg. 32, 33 Chiorine-monoxide, pg.9 Clean Air Act definition, pg. 10, 11 fines and bounties, pg. 12 local and state laws, pg. 10 Compressor burnout, pg. 7, 25, 31 cooling, pg. 28 definition, pg. 5 location, pg. 5 Condenser definition, pg. 5 location, pg. 5 Crankcase heaters, pg. 25 oil foaming, pg. 25 Customer Relations, pg. 14 D Defrost Heaters, pg. 21 Disposable Cylinder disposal, pg. 17 use, pg. 17 Drop-in Refrigerant, pg. 15, 20 Index E Electronic Leak Detectors. See Leak Detection: electronic leak detectors EPA future rule changes, pg. 21 technician requirements, pg. 12 Evacuation definition, pg. 7 factors effecting speed, pg. 7 levels, pg. 20, 29 procedures, pg. 7 Evaporator definition, pg. 5 location, pg. 5 Expansion Valve, See Metering Device location, pg. 5 FE Filter-driers definition, pg. 25 location, pg. 5 replacement, pg. 25 G Graduated charging cylinder, pg. 21 H HCFC's: definition, pg. 8 properties, pg. 8 types of, pg. 8 HEC's definition, pg. 9 properties, pg. 9 types of, pg. 9 Hydrochloric acid, pg. 7, 24 Hydrofluoric acid, pg. 7, 24 Hydrostatic tube test, pg. 33 Hygroscopic, pg. 15 43L Leak Detection electronic leak detectors, pg. 14 instruments, pg. 14 pressure testing, pg. 17, 26, 33 soap bubbles, pg. 17, 26 ultrasonic leak detectors, pg. 14 using an inertgas, pg. 14, 15, 26, 33 vacuum testing, pg. 7, 14, 33 visual, pg. 26 Leak Rates, pg. 26, 33 Low-loss fitting, pg. 19, 28 M Major Repair, pg.30, 35 Manifold Gauge Set. See Manifold Hoses color, pg. 6 ranges, pg.6 use, pg. 6 Manifold Hoses. See Manifold Gauge Set connectors, pg. 19, 28 sizing, pg. 7 Material Safety Data Sheet (MSDS), pg. 16 Metering Device. See Expansion Valve location, pg. 5 Micron, pg. 25 Montreal Protocol, pg. 10 N Nitrogen recovery, pg.20 safety, pg. 16, 24, 30 use, pg. 25, 33 Non-condensables, pg.7, 25 ° ‘Oxygen Deprivation, pg, 16 Ozone benefits, pg. 9 definition, pg. 8 depletion, pg. 9 Ozone Depletion Potential (ODP), pg. 8, 9 Index P Passive Recovery. See Recovery Machine: system dependent Piercing Valves, pg. 23 Process stub, pg. 11 Pungent Odor, pg. 23 Purge Unit connections, pg. 32 definition, pg. 32 operation, pg. 32, 33 Receiver location, pg.5, 25 use, pg. 25, 30 Reclaiming, pg. 13 Recovery benefits, pg. 10 connections, pg. 27 definition, pg. 13, excluded systems, pg. 23 low ambient effects, pg. 14 speed of, pg. 27 Recovery Cylinder approval, pg. 23, 24 capacity, pg. 18 color, pg. 18, 23 cooling of, pg. 27 fill limit monitors, pg. 18, 23 hazards, pg. 18 heating of, pg. 16, 17 labeling, pg. 18 preparation, pg. 28 shipping, pg. 18, 23, 24 storage, pg. 18 testing, pg. 18 Recovery Machine availability, pg. 20 certification, pg. 12, 14, 20 high head pressure, pg. 21 high pressure cutout, pg. 35 maintenance, pg. 23, 27 recovery levels, pg.29, 35 requirements, pg. 25, 35 self contained, pg. 11, 12 system dependent connections, pg. 21 definition, pg. 12, 20, 21 inoperable compressor, pg. 21 ‘operable compressor, pg. 21 restrictions, pg. 30 water cooled, pg. 27, 34 types, pg. 11, 12, 20, 21Recovery Techniques initial step, pg. 21 liquid recovery, pg.21, 27, 30 low pressure, pg. 31, 33, 34, 35 parallel compressors, pg. 28 safety, pg. 16, 24, 36 striking compressor, pg. 21 vapor recovery, pg. 27 Recycling, pa. 13, Refrigerant charging, pg. 25, 31 conservation, pg. 7, 10 contaminants, pg. 27 flammability and toxicity, pg. 16, 36 flushing, pg. 7, 23 high pressure, pg. 14 low pressure, pg. 11 migration, pg. 7 mixing of, pg. 14, 22 personal safety asphyxiation, pg. 24 inhaling refrigerant, pg. 16 low pressure refrigerant, pg. 16, 36 safely gear, pg. 23, 24 purchasing, pg. 12, 21 relief valves, pg. 17, 30, 36 system states, pg. 5 testing, pg. 19 trapping, pg. 14 venting restrictions, pg. 11 Relief Valves, pg. 17, 30, 36 Rupture Disc location, pg. 31 pressure setting, pg. 31 s ‘Schrader Valves, pg. 23, 24 Section 608 appliances covered, pg. 11 Self Contained. See Recovery Machine: self contained Index Shaft Seals, pg. 26, 33 Sight Giasses, pg. 17, 25, 31 Small Appliance definition, pg. 19 leak repair requirements, pg. 20 recovery levels, pg. 20 types of service apertures, pg. 19 Stratospheric Ozone, pg. 8 Superheat, pg.5, 26 System refrigerant type, pg. 27 test pressures, pg. 17 System Dependent. See Recovery Machine: system dependent T Temperature Glide, pg. 15 Temperature-Pressure Chart how to use, pg. 46 Temary Blend charging, pg. 15 definition, pg. 15 leak characteristics, pg. 15 lubricants, pg. 15 Trace Gas, pg. 26 U Ultrasonic Leak Detectors. See Leak Detection ultrasonic leak detectors Ultraviolet Radiation, pg. 9 v Vacuum Pump purpose, pg. 7 requirements, pg. 25 sizing, pg. 25, 35 used for recovery, pg. 21 45How to Read a Temperature-Pressure Chart HOW TO READ A TEMPERATURE-PRESSURE CHART The “temperature-pressure chart” carried by all technicians quickly gives a corresponding pressure for a saturated refrigerant at a given temperature. It can also be used to find the temperature of a saturated refrigerant given a pressure. Several points must be remembered when using a “T/P” chart: | Both VACUUM pressures and POSITIVE pressures are on the chart. | Do not make the mistake of finding a | pressure reading from the vacuum TEMPERATURE PRESSURE CHART, section of the chart when you have a Ema eErOntOT positive pressure. i R500 In many cases, the exact pressure or 67.88 temperature you need is not on the 20.62 | chart. You can interpolate (precise 533 | guess) between the numbers to figure 79.27 out the approximate value between 3B Ee | the tw 8 fe two sets of numbers given. a5 1.7 All T/P charts have several oe1t refrigerants on them. Be certain you 28.50 are reading the column under the 148 36 30.07 105.81 || correct refrigerant. 153.21 00.60 93.51 109.14 Use Figure 18 for the following procedure: Figure 18 46Temperature-Pressure Chart TAKE THIS PAGE TO THE TEST! Note: This chart is specifically provided for use in EPA Section 608 Technician Certification Testing. No other use is intended or recommended. This chart is approved for use as a reference during the test and should be taken to the test session. TEMPERATURE-PRESSURE CHART TEMPERATURE: degrees F — PRESSURE: PSIG * = Vacuum in "Inches of Mercury" (In Ha) TEMP. R11 R12 R22 R123, R134a R500 -20 06 10.1 Sa 32 15 24 13.2 06 54 “10 45 16.5 19 78 “5 67 20.1 40 10.4 0 92 24.0 65 13.3 5 11.8 28.2 94 16.4 10 14.8 328 11.9 197 18 177 377 15.0 234 20 21.0 43.0 18.4 213 25 24.6 48.8 22.4 318 30 28.5 54.9 26.1 36.0 35 326 61.5 30.4 40.9 40 37.0 68.5 34.4 46.1 45 417 76.0 40.1 51.6 50 46.7 84.0 455 576 55 520 926 513 63.9 60 877 101.6 575 70.6 65 638 111.2 64.1 778 70 702 121.4 m2 85.4 75 0.0 70 132.2 78.8 93.5 80 15 84.2 143.6 86.8 102.0 use In approved Section 608 Cerifiation Testing programs, No othr use is authorized, The chart reas not be Gupleated reproduced in any oher manner either phetographialy or electronically Uncut th eioroasod witen permiseton ofthe copyrghtnalder. Al oer fghts er reseed TAKE THIS PAGE TO THE TEST!Recovery Requirements for EPA TAKE THIS PAGE TO THE TEST! Vacuum Levels Required by EPA BEFORE AFTER Ref Charge DO NOT WRITE ANYTHING ON THIS PAGE PRIOR TO THE TEST. YOU MAY FILL IN THIS CHART AFTER YOUR PROCTOR INSTRUCTS YOU TO BEGIN THE TEST. TAKE THIS PAGE TO THE TEST!AHRI Testing Services 1156 107th Street Arlington, TX 76011 817-640-8333 5