U.S. ARMY ORDNANCE SCHOOL 
FORT LEE, VIRGINIA 23801 
 

STUDENT HANDBOOK FOR SECTION 608 
TECHNICIAN CERTIFICATION 
DEC 2014 
 STUDENT HANDBOOK
FOR SECTION 608
TECHNICIAN
CERTIFICATION

FORT LEE, VIRGINIA 23801

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 Student Handbook

Name: ____________________________

Class #: _________________________

Instructor: ______________________

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TABLE OF CONTENTS

Chapter Description Pages

I. Course Contents and Student Handbook 5

II. Glossary of Terms 8

III. Important Dates 13

TOPICS

1. Refrigerants 15

2. Ozone Depletion 20

3. The Montreal Protocol 23

4. The Clean Air Act 26

5. Refrigerant Oils 31

6. Refrigeration 34

7. Recovery Systems and Units 42

8. Refrigerant Containers 46

9. Type I Systems 55

10. Type II Systems 62

11. Type III Systems 73

Appendixes

A. Pressure Temperature Chart 79

B. Pretest Sample Questions 81

C. Notes/Comments 109

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Chapter I Course Contents and Student Handbook
This course is designed to combine Video Tele Training (VTT) and self study as an
effective overall method of training.

Course Content
This course is designed to provide the training required to satisfy the United States
Environmental Protection Agency’s (EPA’s) certification requirements for Universal
Technicians as required by EPA Regulation 40 CFR Part 82, Subpart F.

This course does not provide the hands on training for the operation of different types of
equipment/devices used while performing refrigerant recovery, recycling and reclaiming.
The purpose of this course is to ensure that trainees are aware of the laws, rules and
regulations required to service the three types of systems, as well as the common core
issues.

This course does not ensure, nor is it capable of certifying, that you can perform the tasks
required to recover, recycle or reclaim refrigerants. It will be the responsibility of your
command to certify that you are able to perform the tasks.

Note: That the EPA may be sending inspectors to randomly selected locations for
regular inspections at no prearranged time. The purpose of the inspections is to ensure
that the EPA’s policy and procedures are being upheld and that all personnel who service
refrigeration systems are carrying their approved certification card.

Upon meeting EPA’s minimum standards for Technical Certification, you will receive
within 30 days of your testing date:

(1) An approved, personal, wallet size certification card.

(2) A full size certificate for your official record

Carderock Division Naval Surface Warfare Center Phila. PA will be issuing certification
cards and certificates for all persons certifying via the VTT training.

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Certification will be issued for the following:

Type I Technician: Small Appliance

A Type I Technician is a person who maintains services or repairs small appliances. This does not
include MVACs (Motor Vehicle Air Conditioners) or MVAC like systems.

Type II Technician: High and Very High Pressure Appliances

A Type II Technician is a person who maintains services or repairs high pressure or very high
pressure appliances or dispose of high pressure or very high pressure appliances. This also includes
a person who works with MVAC like appliances.

Type III Technician: Low Pressure Appliances

A Type III Technician is a person who maintains services or repairs low pressure appliances or
dispose of low pressure appliances.

Type IV Technician: Universal Technician

A Universal Technician is a person who maintains services or repairs low/high pressure systems
as defined in Type I, Type II and Type III technician descriptions.

Technicians who service all three types of systems must be certified as Universal Technicians.

Note: EPA is proposing to extend the certification requirements for technicians who work with
CFC’s and HCFC’s refrigerants to technicians who work with CFC’s and PFC’s. Technicians who
have been certified to work with CFC’s and HCFC’s would have to be retested to work with HFC’s
or PFC’s but new technicians entering the field would have to pass a test to work with CFC’s,
HCFC’s, HFC’s and/or PFC’s.

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Student Handbook

This publication is now in your custody for use while learning the Department of Defense (DOD)
Refrigerant Certification Requirements.

The purpose or this student handbook is to better allow the student to follow along with the
instructor and take notes as required.

Your instructor will direct you to particular Chapters in this guide.

This guide is yours to keep and may be referred to during and after this training session.

Presentation of Course Material

The course material is divided into Chapters and Topics, presented in a logical sequence.

The knowledge and skills you will acquire will be stated for each Chapter so that you can check
your progress.

Though provoking questions are available at the end of each chapter for your review.

Study assignments will be given in this student handbook.

The effectiveness of this Student Handbook depends upon your conscientious accomplishment of
the reading, of the reading, study and review assignments given by your instructor.

Written Test

At the end of the training the instructor or certified proctor will administer a written test consisting
of 100 multiple choice questions. The test will be divided into 4 parts with 25 questions covering
each of the three types of systems and 25 questions covering the common core issues.

The EPA has set a minimum standard of 72% achievement for each part of the test to satisfy
certification requirements. If you do not achieve the minimum standard, restudy the area(s) that
you failed and prepare to retake the test (only if you failed areas). The retest will be a different
version than the one previously taken.

Security

In the event that classified information is added to the student marked and handled in accordance
with the regulations of the latest edition of the Department of the Navy Supplement to the DOD
Information Security Program Regulation (OPNAVINST 5510.1).

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Chapter II Glossary of Terms

Glossary of Terms

The following are terms used in this book. Some may or may not be the same as what you are used
to. You must be familiar with them because they are terms that exist within the Refrigeration
Certification Training and will appear on the Certification Test.

ALKYL BENZENE: A lubricant artificially manufactured from propylene and benzene products. Most
often used with HCFC refrigerants.

APPLIANCE: Any device which contains and uses Class I (CFC) or Class II (HCFC) substance as a
refrigerant and which is used for household or commercial purposes, including any air conditioner,
refrigerator, chiller or freezer.

AHRI: American Heating and Refrigerant Institute

ASHRAE: American Society of Heating, Refrigeration and Air Conditioning Engineers

AZEOTROPIC MIXTURE: A liquid mixture of two or more substances that boils at a constant
characteristic temperature lower or higher than any of its components and that retains the same composition
in the vapor state as in the liquid state.

BTU/HR: The amount of heat measured in BTU’s per hour that is added or removed from a substance. (E.g.
1 Ton of refrigeration is equal to 12,000 BTU’s of heat removal from a substance in 1 hour).

CAA: Clean Air Act

CATARACTS: An eye disorder that can be caused by ultraviolet radiation.

CERTIFIED REFRIGERANT RECOVERY OR RECYCLING EQUIPMENT: Equipment certified by an

approved equipment testing organization to meet EPA standards.

CFCs (Chlorofluorocarbons): Non flammable, non toxic, non carcinogenic (as far as we know), non
corrosive refrigerants.

COMMERCIAL REFRIGERATION: Refrigeration appliances utilized in the retail food and cold storage
warehouse sectors. Retail food includes the refrigeration equipment found in supermarkets, convenience
stores, restaurants, naval vessels and other food service establishments. Cold storage includes the equipment
used to store meat, produce dairy products, and other perishable goods.

DE MINIMUS: Minimum quantities of refrigerant released to the atmosphere in the course of making good
faith attempts to recover and recycle or safely dispose of refrigerant.

DISPOSAL: The process leading to and including:

(1) The discharge, deposit, dumping or placing of any discarded appliance into or on any land
of water;

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 (2) The disassembly of any appliance for discharge, deposit, dumping, or placing of its
discarded component parts into or on any land or water;

(3)The disassembly of any appliance for reuse of its component parts;

DOT: The United States Department of Transportation (e.g. DOT regulations or DOT forms).

EPA: Environmental Protection Agency

FRACTIONATION: Associated with ternary type refrigerants that are leaking from an appliance. Occurs
when refrigerants of a blend leak from a system at different rates because the individual refrigerants have
different vapor pressures. The greater the difference between the boiling points of the component
refrigerants, the more severe the fractionation.

GLOBAL WARMING: A slow or gradual rising of the Earth’s temperature as a result of CFCs, HCFCs,
carbon dioxide and carbon monoxide and other substances reaching the stratosphere. These pollutants
absorb and then reflect infrared radiation back to Earth thus causing the warming trend.

HALOCARBON: Halocarbon refrigerants (including CFCs, HCFCs and HCFs) are colorless in their liquid
state and odorless as a gas. They are nonflammable, nonpoisonous, and chemically stable at the
temperatures within refrigeration systems. Each of these refrigerants contained one or more of three
halogens: chlorine, fluorine, and/or bromine.

HCFCs (Hydro chlorofluorocarbons): Second generation of refrigerants; most common is HCFC-22, the
refrigerant used in most residential HVAC equipment.

HFC (Hydrofluorocarbon): A fluorocarbon refrigerant that does not contain chlorine (the substance which
is believed to cause damage to the stratospheric ozone). A popular HFC refrigerant, HFC-134a, replaces
CFC-12 in a variety of applications. HFCs have the lowest ODP and cause no harm to the stratospheric
ozone.

HIGH PRESSURE APPLIANCE: An appliance that uses a refrigerant with a boiling point between -58 and
50 degrees Fahrenheit at atmospheric pressure (14.7PSIA). This definition includes but is not limited to
appliances using refrigerants R-12, R-22, R-114, R-500, R-134a, or R-502.

HYDROSCOPIC: A compound that has a high affinity (absorbs) to water (e.g., salt).

INDUSTRIAL PROCESS REFRIGERATION: Complex customized appliance used in the chemical,

pharmaceutical, petrochemical, and manufacturing industries. These processes also include industrial ice
machines and ice rinks.

LOW-LOSS FITTINGS: A device that is intended to establish a connection between hoses, appliances, or
recovery or recycling machines and that is designed to close automatically or to be closed manually when
disconnected, thereby minimizing the release of refrigerant from hoses, appliances, and recovery or
recycling machines.

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LOW-PRESSURE APPLIANCES: An appliance which uses a refrigerant with a boiling point above 10
degree Centigrade at atmospheric pressure (14.7 PSIA). This definition includes but is not limited to
equipment utilizing refrigerants R-11, R-113, and R-123.

MAJOR APPLIANCE: Any maintenance, service, or repair involving the removal of any or all of the
following components: compressor, condenser, evaporator or auxiliary heat exchanger coil, or when a
vacuum pump will be used for dehydration after completion of repairs.

MINOR APPLIANCE: Repairs which involve an operation on equipment which is not followed by an
evacuation to the environment (e.g. addition of refrigeration through a process port, replacement of pressure
switches, etc.).

MONTREAL PROTOCOL: International Agreement signed in September of 1987 by the United States
and 24 other nations to control the release of ozone depleting substances. The protocol contains a clause
that bans the import or export of products containing CFCs from those nations that did not sign the
agreement.

MVAC (MOTOR VEHICLE AIR CONDITIONER): An appliance that is a motor vehicle air conditioner,
used to cool the driver or passenger compartment of an off road vehicle.

OPENING AN APPLIANCE: Any service, maintenance or repair on an appliance that could reasonably be
expected to release refrigerant from the appliance to the atmosphere, unless the refrigerant was previously
recovered from the appliance.

OZONE DEPLETION: A process that takes place when CFC and HCFC refrigerants have reached the
stratosphere and have been broken down by ultraviolet radiation, separating the chlorine molecules from
the refrigerants, causing depletion of the ozone layer. This depletion permits more of the sun’s dangerous
ultraviolet rays to enter the Earth’s atmosphere.

ODP (OZONE DEPLETION POTENTIAL): A chart or scale that assigns the level or the ability of a
substance to deplete the stratospheric ozone layer, based on R-11 with an ODP value of 1.0. A measurement
of CFCs and HCFCs ability to destroy the ozone.

PAGs (Poly Alkyline Glycols): A lubricant that may be used with HFC type refrigerants. PAG type
lubricants will not mix with chlorine containing compounds (e.g. refrigerants).

POLYOLESTERS: An organic compound lubricant made through a process of synthesis of salt reaction to
acid. A synthetic lubricant may be used with HFC type refrigerants. It is not a new type lubricant and has
been used in aircraft jet engines for years for lubrication.

PROCESS STUB (Process Tube): A length of tubing that provides access to the refrigerant inside a small
appliance or room air conditioner and that can be resealed at the conclusion of repair or service. The process
stub or tube will be found on most hermetic systems and can be installed on both the low and high side of
the system. The tube is designed for soldering or clamping on some kind of access valve, generally a
Schrader type valve.

PTAC: Packaged Terminal Air Conditioner.

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RECLAIM (Refrigerant): Restore refrigerant to original chemical material specifications, verified by
sampling. Must conform to ARI-700 specifications.

RECOVER (Refrigerant): Restore refrigerant in any condition from a system and store it in an external
container without necessarily testing.

RECOVER EFFICIENCY: The percentage of refrigerant in an appliance that is recovered by recycling or

recovery equipment.

RECYCLE (Refrigerant): To clean refrigerant for reuse by oil separation and single or multiple passes
through devices, such as replaceable core filter driers, which reduce moisture, acidity, and particulate
matter.

REFRIGERANT: Any solid, liquid, or vapor that absorbs heat from another body or substance.

REFRIGERANT BLENDS: Mixtures of refrigerants which do not act as a single refrigerant by having
characteristics independent of the component refrigerants. In other words, these blends are NOT Azeotropic
mixtures. Refrigerant blends which form relatively stable and uniform mixtures are known as “near
Azeotropic mixtures.”

SELF-CONTAINED RECOVERY EQUIPMENT: Refrigerant recovery or recycling equipment that is

capable of removing the refrigerant (vapor/liquid) from an appliance without using the system components.

SERVICE APERATURE: A service valve required on all Type I or II refrigeration and air conditioning
appliances for servicing. It is generally a three way valve service valve on most larger systems with a gauge
port (mid position), as isolation position (front position) which closes off the compressor to the rest of the
system, and back position which closes off the gauge port on the valve. The service aperture may be found
on both the high and low sides of the compressor. Some smaller systems may have a factory installed access
valve (Schrader valve) in the system rather than the three way service valve.

New systems will have a Schrader valve installed in the service port of the three way valve.

SKIN CANCER: Some type of skin cancer can be directly attributed to the depletion of the ozone protective
layer. These types of skin cancer are caused by excessive amounts of ultraviolet radiation that come into
direct contact with the skin.

SMALL APPLIANCE: Any appliance that is fully manufactured, charged, and hermetically sealed in the
factory with five (5) pounds or less of refrigerant (e.g. window air conditioners and Packaged Terminal Air
Conditioners PTACs).

SYSTEM DEPENDANT RECOVERY EQUIPMENT: Refrigerant recovery equipment that requires the
assistance of components contained in an appliance or the pressure in the system to remove the refrigerant
from the appliance; normally associated with Type I appliances.

TECHNICIAN: Any person who performs maintenance, service or repair that could reasonably be expected
to release Class I or Class II substances from appliances into the atmosphere, including but not limited to
installers, contractor employees, in house service personnel, and in some cases, owners. Technician also
means any person disposing of appliances, except for small appliances.

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TEMPERATURE GLIDE: A refrigerant with several condensing and evaporative temperatures at one
pressure. Temperature glide will be found in the ternary blend type refrigerants.

TERNARY BLEND: A blend of three individual refrigerants having characteristics similar to a particular
refrigerant (e.g. ternary blend of R-22, R-152a and R-124 will have characteristics similar to R-12).

VERY HIGH PRESSURE APPLIANCE: An appliance which uses a refrigerant with a boiling point below
-58 degrees Fahrenheit at atmospheric pressure (14.7 PSIA). This definition includes but is not limited to
equipment utilizing refrigerants R-13 and R-503.

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Chapter III Important Dates

Important Dates

You must be familiar with the following dates as they exist within the Refrigeration Certification
Training and will appear on the Certification Test.

(a) Effective July 1, 1992 no person maintaining, servicing, repairing or disposing of appliances
may knowingly vent or release into the environment any Class I or Class II substance used as a
refrigerant.

De Minimis releases associated with good faith attempts to recycle or recover refrigerants are not
subject to this prohibition.

The knowing release of refrigerant subsequent to its recovery from an appliance shall be considered
a violation to this prohibition.

(b) Effective July 13, 1993 all persons opening appliances except for MVACs for maintenance,
service or repair must evacuate the refrigerant in either the entire unit or the part to be serviced (if
the latter can be isolated) to a system receiver or certified recovery or recycling machine. All
persons disposing of appliances except for small appliances, MVACs and MVAC-like appliances
must evacuate the refrigerant in the entire unit to a certified recovery or recycling machine.

(c) Effective August 12, 1993 any person opening an appliance for maintenance, service or repair
or any person disposing of appliances, must have certified to the EPA that they have acquired
certified recovery/recycling equipment and that they are complying with regulations.

(d) Effective November 15, 1993 no person may manufacture or import recycling or recovery
equipment for use during the maintenance, service or repair of appliances except MVACs, and no
person may manufacture or import recycling or recovery equipment for use during the disposal of
appliances except for small appliances, MVACs and MVAC-like equipment, unless the equipment
is certified according to EPA regulations.

(e) Effective November 15, 1993 no person may open an appliance for maintenance, service or
repair, and no person may dispose of appliances except for small appliances, unless such person
has certified that he/she has acquired certified recovery or recycling equipment and is complying
with the applicable requirements of this rule.

(f) Effective November 15, 1993 no person may sell or offer for sale for use as a refrigerant any
Class I or Class II substance consisting wholly or in part of used refrigerant unless the Class I or
Class II substance has been reclaimed.

(g) Effective November 15, 1993 no person reclaiming refrigerant may release more than 1.5% of
the refrigerant received by them.

(h) Effective November 15, 1993 no person may sell or distribute, or offer for sale or distribution
any appliance, except small appliances, unless such equipment is equipped with a servicing aperture
to facilitate the removal of refrigerant at servicing and disposal.

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(i) Effective November 15, 1994 no person may open an appliance except for an MVAC and no
person may dispose of an appliance except for a small appliance, unless that person has been
certified as a technician for that type of appliance.

(j) Effective November 15, 1994 no person may sell or distribute, or offer for sale or distribution
any Class I or Class II substance for use as a refrigerant to any person unless:

(1) The buyer has been certified as a Type I, Type II, Type III or Universal Technician.

(2) The buyer has been certified pursuant to 40 CFR Part 82 Subpart B.

(3) The refrigerant is sold only for eventual resale to certified technicians or to appliance
manufacturers (e.g. sold by a manufacturer to a wholesaler, sold by a technician to a
reclaimer)

(4) The refrigerant is sold to an appliance manufacturer

(5) The refrigerant is contained in an appliance

(6) The refrigerant is charged into an appliance by a certified technician during

maintenance, service or repair.

(k) Effective November 15, 1995 no person maintaining, servicing, repairing or disposing of
appliances may knowingly vent or release into the environment any alternate substance used as a
refrigerant.

(l) After 1995, the supplies of CFC refrigerant will come from recovery/recycle.

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Chapter 1 Refrigerants
Topics of Study
1. History of Refrigerants
2. Existing Refrigerants
3. Replacement Refrigerants
4. Blended Refrigerants

Topic Objectives

A. Define the terms associated with refrigerants and their applications.

B. Describe different types of refrigerants and characteristics of each.

1. History of refrigerants

Refrigeration is the process of cooling or removing heat. It is the process by which the temperature of a
substance or a given space is lowered below that of the ambient or surrounding materials. This is
accomplished by transferring heat from the substance or space being refrigerated to a colder medium, the
refrigerant. The refrigerant is subject to certain physical conditions of temperature, pressure and state to
permit absorbing heat from the substance being cooled and rejecting the absorbed heat to the atmosphere
or seawater. Knowledge of the nature and effects of heat and physical conditions affecting refrigerants are
necessary for an understanding of the operation of any refrigerant plant.

Science and industry have searched for the “perfect” refrigerant since the early 1800s. Currently,
halocarbons constitute the most common refrigerants. They contain chlorine, fluorine and/or bromine.

All technicians should have the basic understanding of the refrigeration cycle. The four basic components
of a refrigeration system are:

(a) Compressor
(b) Condenser
(c) Metering Device
(d) Evaporator

These components, together with the refrigerant, produce heat transfer and thereby cooling.

Since the development of vapor compression machines in the first part of the 19th century, refrigeration
specialists have tried different substances as refrigerants.

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By the late 1920’s, sales of household mechanical refrigeration systems rose astronomically. By applying
the same vapor compression technology, the new refrigeration industry developed the light commercial and
comfort cooling markets. However, industry still faced a big problem: all the refrigerants in use were either
flammable, toxic, or had an unbearable smell. The industry needed a good, safe, economical refrigerant
with these desirable characteristics:
 High latent heat value
 Non-toxic
 Non-flammable
 Non-corrosive to common metals and rubbers
 Environmentally acceptable
 Chemically stable
 Lubricant soluble
 Easily handled and transported
 Field system charging ability

In 1928 C.F. Kettering, a vice president of General Motors, decide that the refrigeration industry needed a
new refrigerant if they ever expected to progress. He gave the job to Thomas Midgely. Three days later,
Midgely and his associates had synthesized dichlorodifluoromethane (R-12) and demonstrated that it was
non-flammable and had unusually low toxicity. This development spawned the fluorocarbon refrigerant
industry and the rapid expansion of refrigeration and air conditioning applications.
Prior to the passage of new EPA regulations, the four most common commercial refrigerants were R-12,
R-22, R-500 and R-502, all halocarbons.
These refrigerants mix readily with the mineral lubricating oils used in compressors.
Under high temperatures they can decompose, forming poisonous gases (phosgene) and chemically
aggressive compounds (hydrofluoric and/or hydrochloric acids).
2. Existing Refrigerants
Refrigerants are special chemical mixtures, grouped under a standard numbering system and referred to by
a CFC, HCFC, HFC or R alpha-numeric indicator (e.g. CFC-11, HCFC-22, HFC-134a or R-12).
CFCs or Chlorofluorocarbon (chlorine, fluorine, carbon) CFC refrigerants are named because they contain
the elements chlorine, fluorine and carbon.
CFCs are non-flammable, non-toxic, non-carcinogenic, non-corrosive, and have extremely low boiling
points.
Three of the most common types of Navy CFCs are R-11, R-12 and R-114.
R-11 is used primarily in centrifugal shore based and some shipboard chillers, while R-114 is used in most
centrifugal shipboard chillers. R-12 is used primarily for appliances such as freezers and refrigerators,
automotive air conditioning systems and shipboard air conditioning and refrigeration plants.
CFCs are known to deplete stratospheric ozone, creating a serious health and environmental problem.
CFC refrigerants are most harmful to the stratospheric ozone and have the highest Ozone Depletion
Potential (ODP).

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HCFCs or Hydrochlorofluorocarbon (hydrogen, chlorine, fluorine and carbon)
HCFC refrigerants are named because they contain the elements hydrogen, chlorine, fluorine and carbon.

HCFCs are the refrigerants in most residential HVAC equipment.

The most common HCFC is R-22.

HCFC refrigerants are less harmful to stratospheric ozone than CFCs.

HCFCs contain hydrogen, which make them less stable after they enter the atmosphere.

HCFCs decompose at low altitudes and very little chlorine reaches the stratospheric ozone layer, thereby
minimizing ozone depletion.

Even though HCFCs are not excessively ozone depleting, they contain compounds linked with global
warming, another environmental hazard, and are regulated.

HFCs or Hydrofluorocarbon (hydrogen, fluorine and carbon)

HFC refrigerants are named because they contain the elements hydrogen, fluorine and carbon.

HFCs do not contain chlorine.

HFCs do not deplete the ozone layer.

HFCs do contribute slightly to global warming.

A popular HFC refrigerant, HFC-134a, is replacing CFC-12 in a variety of applications, although it is NOT
a “drop-in” replacement.

When charging or recovering HFC-134a, the technician should use separate hoses, gauge manifold sets,
recovery units and oil containers to avoid mixing refrigerants.

HFC-134a (also known as R-134a) provides the most promising substitute for R-12, as a fluorocarbon
without chlorine.

R-134a does not affect the ozone layer; however, its boiling point and chemical properties closely match
R-12.

Use of R-134a requires a new oil, may require a change of compressors, and possibly other system
component changes (e.g. TXV’s)

Consumers will probably experience a transition period similar to the change from leaded to unleaded
automotive gasoline, while the Navy changes from R-12 systems to systems using R-134a. Industry projects
that we will be living with R-12 systems through the turn of the century, additional motivation to developing
recovery and recycling systems. If it makes economic sense to recover and recycle R-12 in the $9 per pound
range, it makes even more sense to do the same for R-134a. No easy solutions, no drop-in replacements,
and no perfect refrigerants exist.

HFC-134a appears to be a good substitute for R-12 and R-500 in certain applications.

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However, it is less efficient than R-12, requires a new type of oil, and cannot be considered a “drop- in”
refrigerant.

3. Replacement Refrigerant

Existing Refrigerant Proposed Replacement

R-11 (CFC) R-123 (HCFC)

R-114 (CFC) R-124 (HCFC)
R-12 (CFC) R-134a (HFC)

R-22 R410A

Few test results are currently available.

According to existing test results, R-124 may be an environmentally acceptable and functionally equivalent
replacement for R-114.

No adverse toxicology findings have been reported.

R-134a

Results show that R-134a is at least safe to use as R-12.

R-134a is being considered as a replacement for R-12 in household refrigerators.

Ozone Depletion Potential of R-134a is zero because it has no chlorine.

Primarily due to lubrication requirements, R-134a, R-22, R-141b and R-125 are NOT considered suitable
“drop-in” replacements for R-12.

R-134a refrigerant charged systems should be leak checked with nitrogen after the system charge has been
properly removed.

4. Blended Refrigerants

A ternary blend of refrigerant is described as a three part mixture.

Refrigerant blends leak from a refrigeration system at different rates because the individual refrigerant
components have different vapor pressures.

Temperature Glide is the term used to describe a blend of refrigerants that have a range of boiling points or
condensing points throughout the evaporator and condenser respectively.

The proper charging method for blended refrigerants is to charge by weight into the high side of the system
as a liquid

Do not field mix refrigerants.

The significance of an Azeotropic mixture of refrigerants is that they combine and create a third refrigerant
with its own individual characteristics.

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Review

1. List six desirable characteristics of a refrigerant?

2. Prior to EPA regulations what were the four most common refrigerants?

3. Name a chlorine-free refrigerant?

4. What types of refrigerants are R-11 and R-12?

5. Name three types of refrigerant compounds and the element components of each.

6. What is an azeotropic refrigerant?

7. Which type of refrigerant is the most harmful to the stratospheric ozone layer?

8. Explain how blended refrigerants leak from a system?

9. Explain how blended refrigerants are charged to a system?

10. Explain the term “azeotropic mixture”?

11. Explain the term “temperature glide”?

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Chapter 2 Ozone Depletion

Topics of Study

1. Overview of Ozone
2. Depletion of the Stratospheric Ozone
3. Ozone Depletion and the Human Body
4. Environmental Concerns

Topic Objectives

A. Describe how CFC and HCFC molecules break down the ozone.

B. Describe the effects of ozone depletion on the human body and the environment.

1. Overview of Ozone

An international agreement with a theory postulated by Molina-Rowland in 1974 states that man-made
CFC’s and bromine released into the atmosphere have caused a depletion of ozone in the stratosphere.

The tropospheric level (ground level to 7 miles above) contains ozone as a pungent and bluish pollutant
(smog) which is a result of air contaminants exposed to the sun.

The area of the atmosphere between 7 and 30 miles above the Earth is known as the stratosphere. The
stratosphere is made of gases that help form the Earth’s protective shield.

Ozone in the stratosphere above the Earth consists of molecules containing 3 oxygen atoms (Oᴈ).

The ozone layer protects the Earth from ultraviolet radiation from the sun.

Air sampling measurements are the strongest evidence that CFCs exist in the stratosphere.

The element in refrigerants that causes ozone depletion is chlorine.

The chemical found in the upper stratosphere that indicates the ozone layer being destroyed is chlorine
monoxide.

Chlorine in the stratosphere has been determined to come primarily from CFCs rather than from natural
sources such as volcanoes, because the rise in the amount of chlorine measured in the stratosphere over
the past two decades matches the rise in the amount of fluorine, which has different natural sources than
chlorine over the same period.

It is also determined that the rise in the amount of chlorine measured in the stratosphere over the past two
decades matches the rise in CFC emissions during the same period.

Measurements over the last decade have shown that volcanoes contribute minimal quantities of chlorine to
the stratosphere as compared to CFCs.

20
2. Depletion of the Stratospheric Ozone

Depletion of the stratospheric ozone layer is a global concern and problem.

Estimates indicate that up to 100,000 ozone molecules can be destroyed by a single chlorine atom.

Unlike hydrogen chloride from volcanoes, CFCs are NOT washed out of spheres by rainfall and do NOT
dissolve or break down into components that dissolve in water.

The only fluorocarbon refrigerants that cause no harm to the stratospheric ozone are HFCs.

3. Ozone Depletion and the Human Body

Depletion or a reduction in the ozone could significantly affect the human body including cases or skin
cancer and cataracts.

Cataracts are clouds that develop on the eye and limit vision.

Effects on human health levels from ozone depletion and increased levels of ultraviolet radiation range
from increased problems in skin cancer and eye cataracts to a weakening in the immune system.

EPA estimates that without controls on CFCs, as many as 154 million additional cases and over 3 million
deaths could result from skin cancer.

EPA estimates that without controls on CFCs, as many as 18 million additional cases of cataracts could
result over the next century.

Reports indicate that people living closer to the equator have increased exposure to the sun’s ultraviolet
rays. This increased exposure weakens the body’s immune system to some diseases.

4. Environmental Concerns

Depletion or a reduction in the ozone could significantly affect the environment by affecting the growth
and reproduction of photo plankton, thereby reducing crop yields and marine life and increasing ground
level ozone.

Global warming sometimes referred to as the “greenhouse effect,” presents additional problems.

Tropospheric pollutants like CFCs, HCFCs, HFCs, carbon dioxide and carbon monoxide absorb and reflect
the Earth’s infrared radiation causing global warming.

The redirection of the Earth’s infrared radiation results in a gradual increase in the Earth’s temperature.

The effect on global warming is measured in a term known as Global Warming Potential (GWP).

A better measure has been developed by combining both the direct and indirect global warming effects of
refrigerants.

This measurement is known as the Total Equivalent Warming Impact (TEWI). TEWI can be reduced by
using alternative refrigerants.

21
1. How do CFCs and bromine affect the ozone?

2. Name the chemical found in the upper stratosphere that indicates ozone destruction?

3. What does the ozone layer protect the Earth from?

4. What evidence exists showing CFCs in the stratosphere?

5. What fluorocarbon refrigerants cause no harm to the stratospheric ozone?

6. Name the refrigeration elements that cause ozone depletion?

7. How many ozone molecules can be destroyed by a single chlorine atom?

8. Are volcanic eruptions considered contributors to the ozone depletion problem?

9. What type of problem is stratospheric ozone depletion?

10. What human health effects can result from increased exposure to ultraviolet radiation?

11. List three effects ozone depletion can have on the environment?

12. How are CFCs affected by rainfall and/or water?

22
Chapter 3 the Montreal Protocol

Topics of Study

1. Montreal Protocol Background

2. Montreal Protocol Provisions

Topic Objectives

A. State the primary purpose of the Montreal Protocol including updates and revisions.

B. Define Ozone Depletion Levels (ODPs)

1. Montreal Protocol Background

As a result of the 1974 Molina-Rowland theory, the United States banned the use of CFCs in non-essential
aerosols in 1978.

9 years later in 1987, 24 nations, including the United States, signed an agreement that is now known as the
Montreal Protocol.

The international agreement is a treaty among nations that controls production of chlorofluorocarbons,
halons and Hydrochlorofluorocarbon.

An important provision of this document was the eventual ban of the import and export of regulated CFCs
and products containing CFCs from nations NOT signing this agreement.

2. Montreal Protocol Provisions

The Montreal Protocol grouped the following CFCs in classes and groups and froze production back to
1986 levels starting in 1989.

Group I (Fully Halogenated Chlorofluorocarbons)

CFC-11
CFC-12
CFC-113
CFC-114

Group II (Halons)
Halon-1211
Halon-1301

The protocol dictated that production of Groups I and II be reduced by 20% in 1993 and by an additional
30% in 1998.

R-11, R-12, R-114 and R-500 are considered “Class I Refrigerants” by EPA. Intentionally venting these
products is unlawful.

HCFCs are considered “Class II Refrigerants”. Intentionally venting these products is unlawful.

The protocol assigned each compound an Ozone Depletion Potential (ODP) number.

23
Ozone Depletion Potential (ODP)

Compound Global Warming Potential ODP

CO2 1.0 0.0

CFC-11 4000 1.0

CFC-12 10900 0.93

CFC-113 6130 0.83

CFC-114 10040 0.71

HCFC-22 1810 0.05

HCFC-123 1320 0.016

HFC-134A 1430 0.0

HALON-1211 1801 3.0

HALON-1301 7140 10.0

HFC227EA 3660 0.0

HFC-410A 2088 0.0

HFC-404A 3922 0.0

In June 1990, 56 nations signed an agreement, known as the London Agreement that strengthened the
Montreal Protocol of 1987.

This agreement:

 Accelerated the phase-out of CFCs, with total phase-out by the year 2000.
Reduced Methyl chloroform production of 30% in 1993, 70% in 2000, and 100% by the year 2005.

A November 1992 meeting, known as the Copenhagen Agreement, yielded a phase-out schedule for Class
II (HCFCs) and further accelerated the Protocol phase-out of Class I CFCs.

Ninety-three (93) nations signed this agreement with the primary provisions as follows:

 International funding for technology transfer.

 Freeze production of methyl bromide, an agricultural chemical, in 1995 at 1991 levels.
 Eliminate globally the use and consumption of HCFCs by the year 2030.
 Implement CFC production phase-out as of 31 December, 1995.

24
Review

1. What refrigerants have the lowest ODP?

2. Explain the Montreal Protocol Agreement.

3. What refrigerant compounds did the agreement control?

4. What chemicals are controlled by the Montreal Protocol?

5. What refrigerants have the highest ODP?

6. What is the base refrigerant for the ODP numbering system?

7. Explain Ozone Depletion Potential (ODP).

25
Chapter 4 Clean Air Act

Topics of Study

1. Clean Air Act (CAA)

2. Clean Air Act Amendments
3. Regulations and Penalties

Topic Objectives

A. Describe the Clean Air Act (CAA) including updates and amendments.

B. Describe the regulations and penalties as they apply to the CAA.

1. Clean Air Act (CAA)

The primary thrust of the CAA is to capture and ultimately eliminate the use of chlorofluorocarbons, thus
stopping damage to the stratospheric ozone layer.

The CAA requires:

 Phase-out of CFC and HCFC production;

 Prohibits venting of CFCs and HCFCs after July 1, 1992
 Requires EPA to set standards for recovery of refrigerants prior to appliance disposal.

The Department of Defense, in order to comply with both the provisions of the protocol and legislation,
issued DOD directive 6050.9 and the Navy followed suit by issuing OPNAV instruction 5090.2.

The primary provision of these documents:

 Prohibit the direct release of Ozone Depletion Substances (ODS) as of 1 July 1992;
 Phase-out non-essential and non-military uses of ozone depleting substances as soon as possible;
 Implement conservation and recycling programs;
 Conduct a survey of ODS use;
 Require annual reports on procurements, usage and inventory.

State and local governments must conform to CAA regulations.

State and local governments may invoke stricter regulations than required by the EPA.

2. Clean Air Act Amendments

In November 1990, President Bush signed the 1990 Clean Air Act Amendments. Title VI of the Act calls
for a phase-out of CFCs and HCFCs.

The primary provisions of Title VI are section 601 through 612 (excluding section 603).

Section 601 lists and defines terms necessary for all applicable parties to use when dealing with

26
Section 602 lists ozone depleting substances by Class and Group with a provision that the EPA will add to
this list any substance which is found to have an ODP of 0.2 or greater, or any substance which EPA finds
“causes or contributes significantly to harmful effects on the stratospheric ozone layer”.

Section 604 provides the phase-out schedule for production and consumption of Class I substances.

Section 605 provides the phase-out schedule for production and consumption of Class II substances.

Section 606 allows EPA to issue regulations, after notice and opportunity for public comment that would
accelerate the phase-out schedule for production and consumption of Class I and Class II substances.

Section 608, known as the National Recycling and Emissions Reduction Program, calls for the reduction
in the use and emissions of CFCs and HCFCs to the lowest achievable level and for maximizing recapturing
and recycling efforts. This section also states that, “Effective 1 July 1992, it is unlawful to knowingly vent,
or release, CFCs and HCFCs during the repair, service, maintenance or disposal of appliances or industrial
process refrigeration equipment.”

In addition, a venting prohibition for alternate refrigerants (e.g. HFC-134a) will become effective
November 15, 1995.

The prohibition permits three types of releases which are called De minim is releases:

1. Refrigerant released in the course of making good faith attempts to recapture or recycle or
safely dispose of refrigerant.

2. Leaks or emissions in the course of normal operation of air conditioning and refrigeration
equipment. The EPA requires the repair of substantial leaks (also includes purging of non-
condensable gases.

3. Mixtures of nitrogen and R-22 that are permitted as holding charges or as leak test gases,
because the ozone depleting compound is not used as a refrigerant.

Section 609 covers Motor Vehicle Air Conditioning systems

Section 610 bans non-essential products containing CFCs effective November 1992.

Section 611 requires labeling of products containing Class I or Class II substances.

Section 612 covers safe alternatives.

In addition, the EPA under Section 608 has issued 5 main requirements for recycling, emissions, reduction
and disposal of Class I and Class II substances.

1. Technicians must observe certain practices when servicing and disposing of air conditioning and
refrigeration units (the EPA defines a technician as “one who performs maintenance, service or repair to
air conditioning or refrigeration equipment that could release Class I or Class II substances into the
atmosphere”).

27
2. Certify technicians, via an EPA approved testing organization, who service and dispose or air
conditioning and refrigeration units. Limit sales of refrigerants to certification technicians.

Note: Technicians are responsible to follow and comply with all future changes in the law, once certified.

Note: Only virgin and reclaimed refrigerant can be sold.

3. Establish equipment and reclaimer certification programs so as to minimize releases or emissions and
ensure the quality of reclaimed refrigerant.

4. Require the repair of substantial leaks based on annual leak rates according to classification of
refrigerant equipment:

a) Industrial process and commercial refrigeration equipment with an annual leak rate of 35%.

b) Comfort cooling chillers and all other equipment with an annual leak rate of 15% (except small
appliances.

5. Require the proper removal and recovery of ODSs (CFCs and HCFCs) prior to disposing or dismantling
of air conditioning or refrigeration equipment.

6. Regulations and Penalties

All air conditioning and refrigeration equipment containing and/or using CFC or HCFC refrigerants are
covered by EPA regulations.

The following items could result in violation of the CAA:

1. Knowingly releasing CFC or HCFC refrigerants while conducting services, maintenance, and
repairing appliances;
2. Falsifying or failing to keep required records;
3. Failing to reach required evacuation levels before opening or disposing of appliances.

Service companies and technicians who violate the CAA provisions:

1. May lose certification;

2. May be fined;
3. May be required to appear in Federal court.

Whistle blowers who supply information that leads to a penalty against a technician who is intentionally
venting refrigerant may receive an award up to $10,000.

A fine of up to $27,500 per day, per violation may result from violations of the CAA.

EPA will issue one or more to the following to a suspected violator of the Act (contractor, building owner,
technician, etc.) that charges them with a violation:

FINDING A VIOLATION: Notification of a violation letter from the EPA that documents a violation and
places it in a file.

ADMINISTRATIVE ORDER: A stronger communication from the EPA directing compliance of the Act
or closing down the business.

28
FIELD CITATION: Tickets issued for minor violations under authority of the Clean Air Act.

ADMINISTRATIVE HEARING: a hearing called by the EPA for pursuing a violation less than $200,000
and less than 1 year old.

CIVIL/JUDICIAL COURTS: Significant violations of the Clean Air Act that will be heard by the Federal
court.

LOSS OF CERTIFICATION: Loss of technician certification.

29
Review

1. Explain the requirements of the CAA.

2. What precautions has the US taken to stop damage to the stratospheric ozone?

3. What requirements do individual state and local governments have regarding the CAA?

4. What repercussions may a service technician be subjected to for violating the CAA?

5. What constitutes a violation to the CAA?

6. Explain what fines a service technician may be subjected to for violating the CAA?

7. What equipment is controlled under the EPA CAA regulations?

30
Chapter 5 Refrigerant Oil

Topics of Study

1. Mineral Oil
2. Synthetic Oil
3. Waste Oil

Topic Objectives

A. Define the different types of oils associated with refrigerants and characteristics of each.

1. Mineral Oil

The compounds in refrigeration mineral oil can be categorized into three main groups:

 Paraffinic
 Naphthenic
 Aromatic

Refrigerant oil that has a high affinity for water is considered hygroscopic.

Note: ROC-2 (VVL-825 Type 2) is a mineral oil commonly used in Navy systems.

2. Synthetic Oil

Because of the somewhat limited solubility of mineral oils with certain refrigerants such as R-502, synthetic
oils for refrigeration applications with these refrigerants have been used successfully. Three of the most
popular synthetic oils are:

Alkyl benzenes
 Glycols
 Polyol esters (Esters)

The synthetic lubricant presently used with ternary blends containing HCFCs is Alkyl benzene.

The oils that will be employed with most of the R-134a refrigeration applications are the esters.

Different types of refrigerant oils should not be mixed.

Note: Service technicians must realize the magnitude of the refrigerant and oil transition this industry is
experiencing. Refrigerants and oils have become a complex science. There used to be “rules of thumb” to
follow that matched a certain viscosity with the temperature application.

The diversification of oils and oil additives used with today’s ozone friendly refrigerants and even
yesterday’s refrigerants rules of thumb obsolete. Education through reading current literature is one method
a technician can use to keep abreast of these new technologies changes in the industry. A technician can no
longer rely on the rule of thumb for adding oil to a system.

31
It’s important to realize that mineral oil and other types of oil cannot be mixed together.
Technicians must always refer to the manufacture’s literature for each compressor to get information on
what oil to incorporate.
3. Waste Oil
Although the EPA has recently ruled that refrigeration oils are not hazardous wastes, disposing of used oils
in a careless fashion is against the law.
The EPA specifically stated:
 That used oils may not be mixed with other wastes,
 That used oils containing CFCs be subjected to recycling and/or reclamation for further use,
 That used oils not be mixed with used oils from other sources.

32
Review

1. What are the three main groups of refrigerant mineral oil?

2. What is the synthetic oil most widely used with ternary blends?

3. Define the term “hygroscopic” when referring to refrigerant oil?

4. What type of refrigerant oil can be mixed with other oils?

33
Chapter 6 Refrigeration

Topics of Study

1. General Refrigeration
2. Recovery, Recycle, Reclaim
3. Recovery Practices
4. Leak Detection
5. Dehydration
6. Servicing Equipment
7. General Refrigeration Safety

Topic Objectives

A. Describe in detail the terms Recovery, Recycle, and Reclaim.

B. Describe the process of leak detection.

C. Describe the service equipment applicable to refrigerant servicing.

D. Describe the general refrigeration safety as associated with this training/

1. General Refrigeration

Good service practices for conserving refrigerant consist of:

 Finding and repairing leaks

 Keeping the system tight
 Recovering and recycling refrigerant

By the year 2000 it is estimated that 30% of all refrigerant used will come from reclamation.

Cooling occurs in a direct-expansion vapor-compression refrigeration system when refrigerant liquid turns
to a vapor. Refrigerant enters the compressor of a refrigeration system as a superheated low pressure vapor.
Refrigerant will migrate to a compressor’s crankcase because of a difference in vapor between the
refrigerant and the oil. The component in a refrigeration system that changes the low pressure vapor to a
high pressure vapor is the compressor. The component in a refrigeration system that changes the high
pressure vapor to a high pressure liquid is the condenser.

Refrigerant leaving the condenser of a refrigeration system is a high pressure liquid. Refrigerant entering
the metering or expansion device of a refrigeration system is a liquid.

Compound pressure gauge on the low side of a refrigeration system is measured by a PSIG and inches of
mercury pressure gauge.

A hermetic compressor must never be operated when there is a dehydration vacuums on the system.

Hermetic burn-out results in refrigerant oils being highly contaminated with acid.

34
2. Recovery, Recycle, Reclaim

It is considered a violation of the prohibition on venting to release CFC or HCFC refrigerants that contain
a mixture of nitrogen and refrigerant that resulted from adding nitrogen to a fully charged appliance for
leak checking.

CFCs will no longer be manufactured or imported into the U. S. after 31 December 1995.

1 January 1996, supplies of CFC refrigerant for equipment servicing will come from recovery and
recycling.

Unless the EPA determines that venting substitute refrigerants does not pose a threat to the environment, it
will be illegal to vent substitutes for CFC and HCFC refrigerants after November 1995.

Recovery is the process of removing refrigerant in any condition from a system and storing it in an external
container without necessarily testing or processing it in any way.

Recovery of refrigerant is necessary for:

1. Prevention of venting to the atmosphere,

2. Prevention of stratospheric ozone depletion,
3. Adequate supplies for service after bans.

All devices used for refrigerant recovery must meet EPA standards.

A “system dependant” recovery device is defined as one that captures liquid and/or vapor refrigerant WITH
the assistance of components in the air conditioning and refrigeration equipment.

A “self contained” recovery device is defined as one that can capture liquid and/or vapor refrigerant WITH-
OUT the assistance of components in the air conditioning and refrigeration equipment.

CFCs and HCFCs both must be recovered prior to opening or disposing of appliances.

Long hoses between the refrigeration system and the recovery machine will cause:

 Increased recovery time

 Increased emissions
Excessive pressure drop

Recovery during low ambient temperatures will slow the recovery process.

Recycling is the process applied to cleaning refrigerant for immediate reuse by oil separation and single or
multiple passes through moisture absorbing devices, like replaceable core filter-driers in order to reduce
moisture/acidity.

Under EPA refrigerant recycling regulations, R-114 is considered a high-pressure refrigerant” and R-123
is considered a “low-pressure refrigerant”.

Reclaim is the process that returns refrigerant to new-product specifications as determined by chemical
analysis.

35
ARI-700 is the standard to which refrigerant must be reclaimed before it can be resold.

Reclaimer Certification Title VI, section 608 details the following requirements for reclaimer certification:

Effective August 12, 1993 persons reclaiming used refrigerant for sale to a new owner must certify to the
EPA that such person will:

(a) Return refrigerant to at least the standard of purity set forth in ARI standard 700,
Specifications for Fluorocarbon Refrigerants.

(b) Verify this purity using the method set forth in ARI standard 700.

(c) Release no more than 1.5 percent of the refrigerant during the reclamation process.

(d) Dispose of wastes from the reclamation process in accordance with all applicable laws and
regulations.

In 1989, the United States Congress passed an excise tax on all Class I Group I CFCs.

This tax increased incrementally through 1997. Recycled and reclaimed refrigerant is exempt from excise
tax.

EPA has established that refrigerant recovered and/or recycled could be returned to the same system or
other system owned by the same person without restriction.

If refrigerant changes ownership, that refrigerant must be reclaimed (e.g. cleaned to the ARI standard of
purity and chemically analyzed to verify that it meets this standard).

If a reclamation facility receives a tank of mixed refrigerants, they may refuse to process the refrigerant and
return it at the owner’s expense or agree to destroy the refrigerant (typically a substantial fee is charged).

3. Recovery Practices

Only one refrigerant may be recovered into a single cylinder.

It is important not to mix refrigerants during the recovery process because the mixture may be impossible
to reclaim and because the most difficult type of contamination for a reclaiming facility to eliminate is
mixed refrigerants.

During system servicing, if a technician discovers a mixture of R-502 and R-22 in the same system, he/she
should recover the refrigerant into a separate tank.

When addressing consumer complaints concerning addition service expense due to recovery efforts, the
technician should:

 Explain that recovery is required by law,

 Explain that all professional service personnel are duty bound to adhere to law and protect
the environment,

 Explain that recovery is necessary to protect human health.

36
A refillable refrigerant cylinder must not be filled above 80% of its capacity by weight. Float devices,
electronic cutouts or weighing scales are the methods and devices currently used for monitoring the 80%
fill level in a recovery tank.

4. Leak Detection

Failure of a system to hold a vacuum after evacuation indicates a leak may exist in the system.

Whenever a system is opened for servicing or maintenance, the system filter drier should be replaced.

To determine a safe pressure for leak testing, a technician should check the nameplate data for the low-side
test-pressure.

Equipment containing more than 200 lbs. of charge is subject to a standard requiring recovery of over 99
percent of the refrigerant.

EPA has established limited exceptions to its evacuation requirements for repairs to leaky equipment and
for repairs that are not major and are not followed by an evacuation of the equipment to the environment.

“Major” repairs include those involving removal of the compressor, condenser, evaporator, or auxiliary
heat exchanger coil.

“Minor” repairs involve an operation on equipment which is not followed by an evacuation to the
environment (e.g. addition of refrigerant through a process port, replacement of pressure switches, etc.)

After a system charge has been recovered, pressurize the system with nitrogen to determine if any gross
leaks are present.

Nitrogen by itself will have the least damaging effect on the environment when leak checking a unit.

The following leak check devices and methods have historically good results:

Soap bubble solution

 Electronic leak detector
 Ultrasonic leak detector
 Halide torch detector

The most effective leak detection method for locating the general area of small leaks is the electronic or
ultrasonic leak detector.

Leak Check Devices for Alternative Refrigerants

Introduction of alternative refrigerants has required development of new leak detection equipment.

Most of the older technology leak detectors were designed to monitor the presence of chlorine in a
refrigerant molecule.

HFC alternate refrigerants have no chlorine.

Leak detectors designed for CFCs and HCFCs are either unable to detect some of the new HFC refrigerants
at any level, or are unable to detect them at any level low enough to meet user’s requirements.

There are five main types of leak devices that can be used for monitoring alternative refrigerant leaks:

37
 (1) Non-selective detector
(2) Halogen specific
(3) Infrared-based
(4) Fluorescent dyes
(5) Ultrasonic

5. Dehydration

The reason for refrigeration system dehydration is to remove water and water vapor.

Evacuation of a system is a suggested method of dehydration and leak detection.

Vacuum pumps are used for system dehydration and evacuation.

Vacuum pump capacity and suction line size will affect the time it takes to evacuate the system.

Using too large of a pump can cause problems by trapping water in the system, causing freezing, if a
system pressure is lowered too rapidly.

Where large amounts of moisture exist, it may be necessary to counteract freezing by raising the system
pressure with nitrogen.

If moisture is allowed to remain in an operating refrigeration system, hydrochloric and hydrofluoric acids
are likely to form.

Factors which will affect the time needed for evacuation are:

 The size of the equipment

 The ambient temperature
 The amount of moisture in the system

Heating the refrigeration system will decrease the dehydration time.

When connecting the vacuum pump to the system, the hoses used should be as short as possible, and the
diameter of the hose should be equal to or larger than the vacuum pump intake connection.

Use a vacuum pump capable of pulling a vacuum of 500 microns.

Microns are the units used to measure a deep vacuum.

Connect the system vacuum gauge as far as possible from the vacuum pump to be sure that the vacuum in
the whole system is at the required level when evacuating.

To measure the system vacuum make sure the system is isolated from the vacuum pump before measuring
the vacuum.

A system is said to be dehydrated when the vacuum indicator shows you have reached and held the required
finished vacuum.

Systems cannot be over evacuated.

6. Servicing Equipment

38
Manifold gauges:

Manifold gauge sets usually consist of a high side pressure gauge and a low side compound pressure gauge.

Generally the high side gauge will be color coded red, while the low side gauge will be coded blue.

The high pressure gauge on service manifold sets has a continuous scale, usually calibrated to read from 0
to 500 PSI.

The manifold will have three ports to connect service hoses.

The port on each end of the manifold will be used to connect to the high and low side of the system while
the center port is used for recovery, evacuation, and charging the system.

When checking system pressure to determine the performance of a refrigeration system, it’s a good idea to
use equipment such as hand shutoff valves or self-sealing hoses to minimize any release.

Process Stub:

All air conditioning and refrigeration equipment, except for small appliances and room air conditioners,
must be provided with a servicing aperture that facilitates recovery of the refrigerant.

EPA is requiring that small appliances and room air conditioners sold after November 15, 1993, be
provided with a process stub to facilitate removal of the refrigerant at servicing.

The EPA is not prohibiting the use of schrader valves on small appliances.

7. General Refrigeration Safety

The following refrigeration safety precautions should always be followed:

 Do not use oxygen to purge lines or to pressurize equipment or systems;

 Do not cut or weld any refrigeration line with refrigerant in the equipment;
 Never apply an open flame or live steam to a refrigerant cylinder.

When operating refrigerant recovery or recycling equipment, the following safety precautions should be
followed:

 Wear protective gloves

 Wear safety glasses
 Follow all safety precautions for the equipment.

Never use oxygen or compressed air to pressurize appliances to check for leaks because when mixed with
compressor oil and refrigerant they can explode.

To verify allowable equipment or system test pressure, check the design pressure on the equipment name-
plate data.

When handling and filling refrigerant cylinders, personal protective equipment (gloves, safety shoes, safety
glasses, etc.) should be worn.

39
Whenever working with any solvents, chemicals and/or refrigerants, the technician should review the
material safety data sheets.

Most refrigerant accident deaths occur from oxygen deprivation.

CFC and HCFC Refrigerants can cause asphyxia, although it is considered to be non-toxic.

Refrigerant vapors or mist in high concentration should NOT be inhaled because they may cause heart
irregularities of unconsciousness.

When pressurizing a refrigeration system with nitrogen, always charge through a pressure regulator.

A relief valve must be installed in the downstream line of the pressure regulator whenever dry nitrogen is
being used from a portable cylinder to service or install a unit.

Pressure relief valves must not be installed in series.

When corrosion build-up is found in the body of a relief valve, the valve must be replaced.

To remove ice from a sight glass or viewing glass, use an alcohol spray.

ASHRAE STD 34 classifies refrigerants according to toxicity and flammability.

ASHRAE STD 34 refrigerant safety classifies A1 as the designation being the most safe.

Higher flammability
A3
B3

Lower Flammability
A2
B2

No Flammable Propagation
A1
B1

Lower Higher
Toxicity

Most refrigerants that the Navy uses are A1 classification.

R-11, R-12, R-22, R-114, R-500, R-502 and HFC 134a are all A1 refrigerants.

ASHRAE STD 15 requires an oxygen deprivation sensor for A1 refrigerants in commercial equipment
rooms.

R-123 is a B1 refrigerant and requires a refrigerant sensor to conform with ASHRAE STD 15.

Review

40
1. How can a vacuum pump be used to leak check a system?

2. Why should vacuum hoses be as short and as large in diameter as possible?

3. What unit of measurement is used to measure a deep vacuum?

4. What documents should be reviewed before working with any chemicals?

5. Manifold high and low side gauges and hoses are color coded what colors?

6. What increments are used on the high and low gauges on a manifold set?

7. How does the technician know what type of refrigerant is being used in a system?

Chapter 7 Recovery Systems and Units

41
Topics of Study

1. Refrigerant Recovery Systems

2. Recovery Units

Topic Objectives

A. Describe the different types of refrigerant recovery systems and units.

1. Refrigerant Recovery Systems

System Dependant

System dependant type (passive type) utilizes refrigeration system components to remove refrigerants.

This type of recovery system is used only on systems with less than 15 lbs. of refrigerant and:

 May use the refrigeration system compressor;

 May use refrigeration system pressure and vacuum pump (e.g. recovery into a Whirlpool bag).

The system dependant recovery process for small appliances may capture refrigerant in a non-pressurized
container.

At least two system dependant type systems intended for small appliances use non-pressurized containers:
the Whirlpool bag and the Amana carbon absorption system.

When using system dependant recovery devices on small appliances with non-operating compressors, it is
essential to take action steps to help release trapped refrigerant from the compressor oil during refrigerant
recovery.

When recovering refrigerant into a non-pressurized container form a small appliance with an inoperative
compressor, it may be necessary to heat and strike the compressor several times and/or use a vacuum
pump (otherwise 80% recovery efficiency may not be reached).

When using a system dependant recovery device and the compressor is inoperative, it is necessary to access
both the high and low sides of the system for refrigerant recovery.

When using a system dependant recovery device and the compressor is operative, it is necessary to run the
compressor and access the high side of the system for refrigerant recovery.

System dependant recovery equipment CANNOT be used when the appliance contains over 15 lbs. of
refrigerant.

Self Contained

42
Self contained units are liquid/vapor distillation systems.

Liquid/vapor pumps with condensing units must be certified by the EPA.

Navy unit types, dimensions and weight:

ST 100a-29”H/18”W/14”D 76 lbs.
ST 1000-34”H/18”W/14”D 122 lbs.

Units will recover/recycle 0.75 to 6 lbs. of refrigerant per minute depending on the type of refrigerant and
ambient temperature.

When using a self-contained recovery device the following conditions can cause excessive pressure on the
high side.

 When the recovery tank inlet valve has not been opened
 When there is excessive air in the recovery tank

2. Recovery Units

Standard practice should include using a refrigerant leak detector to check your recovery device on a daily
basis.

Recovery systems currently available can be used with chillers up to 2,500 tons capacity.

Many systems can recover and recycle approximately 90 percent of a centrifugal chiller’s refrigerant, with
vacuum capability of an advertised 29.5” Hg Vac.

Recovery can be accomplished through either liquid or vapor removal.

It is recommended that chill water pumps be allowed to operate while recovery/recycling operations are in
progress.

Refrigerant recovery devices, if manufactured after 15 November 1993, must be equipped with low loss
fittings, which are fittings that are used to connect the recovery device to a system and which can be
manually closed or automatically close when disconnected to prevent loss of refrigerant.

Quick coupling, self sealing hoses or ball valves should be used to minimize refrigerant release when hoses
are connected or disconnected.

A standard vacuum pump can only be used as a recovery device in conjunction with a non-pressurized
container.

Note: Refrigerators built before 1950 may contain the following refrigerants and SHOULD NOT be
recovered with current recovery devices:

 Sulfur Dioxide
 Methyl Chloride
 Methyl Formate

43
Note: Current recovery devices SHOULD NOT be used to recover the following refrigerants used in small
appliances for campers or other recreational vehicles:

 Ammonia
 Hydrogen
 Water

44
Review

1. Explain the difference between a system dependant refrigerant recovery system and a self-contained
refrigerant recovery system.

2. What type of recovery system is used only on systems with less than 15 lbs. of refrigerant?

3. Explain the difference in recovery procedures when using a system dependant recovery device when
the compressor is operative and inoperative.

4. List the two types of self-contained refrigerant recovery units used by the Navy.

5. How often should you check your recovery unit for leaks?

6. How large a chiller can currently available recovery units handle?

7. What’s a good way to minimize refrigerant release when hoses are connected and/or disconnected?

8. What type of fitting is required for all refrigerant recovery units?

9. List those refrigerants that should not be recovered using current recovery devices?

45
Chapter 8 Refrigerant Containers

Topics of Study

1. Documentation and Disposal

2. Shipping and Labels
3. Commercial Refrigerant Cylinders
4. Disposable Cylinders
5. Returnable/Reusable Cylinders
6. Cylinders Used in Recovery
7. Filling Cylinders
8. Drums

Topic Objectives

A. Describe the documentation, disposal, shipping, and labeling required for refrigeration containers.

B. Describe the different types of refrigerant containers.

1. Documentation and Disposal

The Department of Transportation (DOT) regulations, 49 CFR, require the number of cylinders of each
gas be recorded on the shipping paper for Non-flammable Compressed Gases.

In addition to the major elements established in Section 608, EPA has established the following record-
keeping requirements to assist with enforcement of the CAA:

(a) A list specifying equipment certification, maintenance of testing equipment, and performance
records.

(b) Technicians servicing equipment that contains 50 pounds or more of refrigerant must provide
the owner with an invoice indicating the amount of refrigerant added to the appliance.

(c) Reclaimers are required to maintain records of names, addresses, and quantity of refrigerant
sent to them for reclamation.

(d) Contractors and other recovery and recycling equipment owners must certify that they own and
are properly using certified recovery or recycling equipment.

(e) Disposers (persons disposing of small appliances) must maintain copies of signed statements
that certify the refrigerant was recovered.

(f) Approved technician certification programs must maintain records of the names, addresses, and
test scores of persons certified, along with the date and location of the certification test.

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.

Owners/operators of air conditioning and refrigeration equipment must maintain records of servicing,
service calls and amounts of refrigerant added.

46
Owners adding their own refrigerant shall keep records of refrigerant purchased and added to equipment
each month.

Before a technician disposes of any appliance containing CFCs or HCFCs refrigerant, they must recover
the refrigerant.

To aid in complying with regulations and to aid in possible enforcement actions, a system of recording
information is recommended.

Refrigerant Recovery and Virgin Refrigerant Use Log: (Figure 1)

Each time refrigerant is used; this form should be completed, in addition to normal entries on the field
service ticket.

A Copy of this form should be maintained for each appliance containing more than 50 lbs. of refrigerant.

Under the “Safe Disposal Requirements” which is responsible for ensuring that the refrigerant has been
removed from household refrigerators before they are disposed of is the final person in the disposal chain.

The smallest container in which refrigerants may be sold to section 608 certified technicians is 20 pounds.

47
Refrigerant Recovery and Virgin Use Log

Page: of

Type of Refrigerants: Plant Number:

(Figure 1)

Date Equipment Name Refrigerants Quantity

Note: At the bottom of this form, an entry is made reflecting how many pounds of refrigerant was received
over a given time period, according to type of refrigerant.

48
 Accidental or Unintentional Venting Report:

(See Figure 2)

It is not the intention of the CAA to penalize anyone if they accidentally vent refrigerant. The law states,
“good faith effort”.

For protection, implementation of this form is recommended.

If an unintentional venting occurs, complete all the details on this form.

Completion of this form should be considered part of the service call.

Note: The EPA will not tolerate careless practices or disregard for the law, which results in venting
refrigerant.

49
Accidental or Unintentional Venting Report

(Figure 2)

Type of Refrigerant Vented:

Pounds Vented (Approx.):

Date:

Description of what happened:

Why did it happen?

What precautions have been taken to prevent future accidents/incidents?

Was anyone else aware of this situation: Yes No

If so, Whom:

Did you inform the Chief Engineer? Yes No

Operator’s Name: SSN:

(Use space below if needed to further explain repairs)

50
2. Shipping and Labels

Before shipping any used refrigerant in a cylinder, it is necessary to:

 Check that the refrigerant container meets DOT standards;

 Properly label the refrigerant container;
 Properly complete shipping paperwork.

To comply with safety requirements, only containers designated “refillable” by DOT are to be used to
transport recovered pressurized refrigerant.

When shipping refrigerant cylinders, they must be positioned upright.

Portable refillable tanks or containers used to ship CFC or HCFC refrigerants obtained with recovery
equipment must meet DOT standards.

When transporting cylinders containing used refrigerant, the Department of Transportation (DOT) requires
that you attach DOT classification tags.

DOT Requirements: Specific container labeling requirements apply for all commercial DOT regulated
hazardous materials.

The following instructions apply to non-flammable recovered refrigerants such as R-12, R-22, R-500 and
R-502 shipped in cylinders.

Note: R-11, R-113, and R-114 are not Dot regulated hazardous materials; therefore, DOT labeling and
marking requirements do not apply.

Refrigerant cylinders being returned for reclaiming must have a refrigerant label.

Labeling: Each cylinder shall display a DOT diamond (square on point) “non-flammable gas” label.

For further information on labeling, call the Stratospheric Ozone Information Hotline: (800) 296-1996 from
10:00 A.M. to 4:00 P.M. Eastern Time.

3. Commercial Refrigerant Cylinders

Refrigerant cylinders should be:

1. Free of rust and damage

2. Color coded
3. Secure

Commercial refrigerants are packaged in both disposable cylinders and reusable cylinders.

Commercial refrigerant manufacturers have voluntarily established a color coding system.

Every refrigerant cylinder must be stenciled with product, safety and warning information.

51
4. Disposable Cylinders

The Department of Transportation (DOT) has regulatory authority over all hazardous materials in
commercial transportation.

Disposable containers manufactured for CFCs are designed to Specification 39; hence, disposables are often
referred to as “DOT 39s.”

Under no conditions should a disposable cylinder be used to recover refrigerant.

Disposable cylinders are used for virgin refrigerant only.

The penalty for transporting a refilled disposable cylinder is a fine of up to $27,500 and five years
imprisonment.

When disposing of disposable cylinders the technician should:

 Assure that all refrigerant pressure in cylinder is at least 0 PSIG;
 Render the cylinders useless by puncturing cylinder;
 Recycle the metal.

5. Returnable/Reusable Cylinders

Returnable cylinders meet DOT specifications 4BA-350 or 4BW and are available in various capacities.

Returnable cylinders possess a stamp on the shoulder which generally furnishes the following information.

 Tare Weight (TW) (empty weight)

 DOT Specification Number for the cylinder
 Test Date Month and year
 Water Capacity (WC) in pounds

Reusable cylinders for refrigerants that are under pressure (above 15 PSIG) at normal ambient temperature
must be hydrostatically tested and date stamped every 5 years.

6. Cylinders Used in Recovery

All commercial cylinders for recovering refrigerant shall have painted gray bodies and yellow tops.

Navy cylinders for recovering refrigerant shall have painted orange bodies and a yellow shoulder and top.

Storage cylinders of recovered refrigerants at normal room temperature (about 75 degrees F), in the
absence of non-condensable, will be pressurized at the following:

R-12 77 PSIG
R-22 132 PSIG
R-500 93.8 PSIG

52
7. Filling Cylinders

Never apply heat from an open flame to a refrigerant storage or recovery tank because the tank may
explode, causing serious injury to persons in the vicinity.

A heat is added to any cylinder containing liquid refrigerant, vapor pressure increases due to a higher rate
of vaporization.

When transferring refrigerant to a pressurized cylinder, the safe filling level can be determined by:

 Weight
 Mechanical float devices
 Electronic thermisters

Do not fill if the present date is more than 5 years passed the test date on the container.

The test date will be stamped on the shoulder or collar of cylinders and on the valve end chime and may
appear as follows:

A1

12 89

23

Note: This indicates the cylinder was retested in December of 1989 by re-tester number A123.

8. Graduated Charging Cylinder

When charging a graduated charging cylinder all regulated purged refrigerants must be captured and
recovered.

9. Drums

Only recovered refrigerant R-11 shall be placed into a drum that previously contained new refrigerant R-
11.

Only recovered refrigerant R-113 shall be placed into a drum that previously contained new refrigerant R-
113.

Drums shall be filled to allow a vapor space equal to at least 10% of the drum height between the top of the
liquid and the drum top.

53
1. Explain the necessary documentation for refrigerant containers.

2. How do regulations differ for virgin and recovered refrigerant containers?

3. For a technician to service a unit that contains 50 lbs or more, what must the technician provide to the
owner?

4. What records are reclaimers required to keep?

5. Explain the procedure for accidental venting.

6. Explain the shipping procedure for refrigerants.

7. When are disposable cylinders acceptable?

8. How should a disposable cylinder be scrapped?

9. What information is on the label on the shoulder of a returnable/reusable container?

10. Describe the appearance of cylinders used in refrigerant recovery.

11. Explain the procedure for filling cylinders.

54
Chapter 9 Type I Systems

Topics of Study

1. Type I Certification
2. Type I Systems
3. Recovery Requirements
4. Recovery Techniques
5. Safety

Topic Objectives

A. Identify and describe the systems and certification requirements associated with Type I Certifications.

B. Describe the recovery requirements and techniques associated with Type I systems.

C. Describe the safety requirements associated with Type I Systems.

1. Type I Certification

Technicians with Type I or Universal Certification may maintain service, dispose or repair small appliances,
except for MVACs.

This certification also applies to persons disposing of appliances, refrigerant reclaimers, and manufacturers
of appliances and recycling and recovery equipment.

After November 14, 1994, any technician servicing small appliances must be certified in refrigerant
recovery if they perform sealed system service.

After certification it is the technician’s responsibility to keep up to date on EPA regulation changes.

2. Type I Systems

Small appliances are described as products manufactured, charged and hermetically sealed in a factory with
5 pounds or less of refrigerant.

Package Terminal Air Conditioners (PTACs) may be serviced by a Type I technician, ONLY if the unit
contains 5 pounds or less of refrigerant.

3. Recovery Requirements

Effective August 12, 1993, persons using recovery equipment to recover refrigerant from a small appliance
must certify to EPA that they have equipment capable of recovering 80% of the refrigerant or achieving at
least a 4” Hg Vacuum under conditions of ARI-740.

EPA regulations require the capture of at least 80% of the refrigerant from a small appliance with a non-
operating compressor if the technician is using either the system-dependant (passive) or self-contained
(active) recovery process.

55
Effective November 14, 1994 technicians servicing small appliances must certify in refrigerant recovery if
they perform sealed system service.
Effective November 14, 1994 the sale of CFCs and HCFCs refrigerants will be restricted to technicians
certified in refrigerant recovery.
ALL recovery equipment manufactured AFTER November 15, 1993and used during maintenance, service
or repair of small appliances, MUST be certified by an EPA approved laboratory.
Small appliance recovery equipment manufactured BEFORE November 15, 1993 must be certified capable
of:
 Recovering 80 % of the refrigerant or achieving a 4” Hg Vac. Under conditions of ARI-740,
WHETHER OR NOT the compressor is operating.
Small appliance recovery equipment manufactured AFTER November 15, 1993 must be certified capable
of:
 Recovering 80 % of the refrigerant or achieving a 4” Hg Vac. Under conditions of ARI-740,
when the compressor is NOT operating;
 Recovering 90 % of the refrigerant or achieving a 4” Hg Vac. Under conditions of ARI-740,
when the compressor IS operating.
There is NO mandatory leak repair criteria for small appliances.
When servicing a small appliance for leak repair, it is NOT mandatory to repair a leak, but the technician
should do so whenever possible.
Refrigerant recovery devices manufactured after 15 November 1993 MUST be equipped with special
fittings called “low-loss fittings”
Low-loss fittings are fittings that are used to connect the recovery device to an appliance and which can be
manually closed or which closes automatically when disconnected to prevent loss of refrigerant from hoses.
All small appliances MUST be equipped with a service aperture or process stub (a straight piece of tubing
that is entered using a piercing access valve) or other device used for adding or removing refrigerant.
4. Recovery Techniques
Before beginning a refrigerant recovery procedure, it is ALWAYS necessary to identify the type of
refrigerant that is in the system.
The only way to read refrigerant pressure accurately inside a refrigerant cylinder, and to make accurate
comparison to a pressure-temperature chart, is to have stable and known pressure and temperature.
It is important to obtain an accurate pressure reading of refrigerant inside the recovery cylinder because the
reading will indicate if excessive air or other non-condensable are in the cylinder.
It is recommended that piercing valves ONLY be used on copper or aluminum tubing materials.
Solder-less type piercing valves SHOULD NOT remain installed in the refrigeration system after repairs
because they tend to leak over time.
After installing and opening a piercing valve, if the system pressure is “0,” do not begin recovery procedure.

56
When installing any type of access fitting onto a sealed system, the fitting should be leak tested BEFORE
proceeding with recovery.

To speed the recovery process and ensure that all the refrigerant has been removed from a frost-free
refrigerator, the technician should turn on the defrost heater to vaporize any trapped liquid.

On a sealed system with an operating compressor that has a completely restricted capillary tube, only one
access valve is required on the high side of the system to evacuate the refrigerant.

On a sealed system with an inoperative compressor it is recommended that low and high side access valves
be installed when recovering refrigerant to enhance the speed of recovery and to achieve required recovery
efficiency.

After recovering refrigerant from a sealed system, if nitrogen is used to pressurize or blow debris from the
system, the nitrogen may be vented to the atmosphere.

Since small amounts of CFC/HCFC refrigerants have no odor, when a pungent odor is detected during a
sealed system recovery and/or repairs, a compressor burn-out has probably occurred.

When recovering refrigerant from a system that experienced a compressor burn-out:

 The system will have to be flushed if contaminants are present.

When R-500 is recovered from an appliance, it must be recovered to its own recovery vessel that is clearly
marked to ensure that mixing of refrigerants does not occur.

5. Safety

The following are safe working practices when recovering refrigerants:

Wear safety glasses or goggles when working with any compressed gases;

 Wear butyl-lined gloves when connecting/disconnecting hoses.

When using nitrogen in repairing a sealed refrigeration system, the nitrogen tank or cylinder should always
be equipped with a regulator.

When using recovery equipment or hoses with schrader valves, it is “critical” to:

 Cap the schrader ports to prevent accidental depression of the valve core;

 Replace damaged schrader valve core to prevent leakage;

 Inspect the schrader valve core for bends.

In the event of a “large” release of R-12 or R-22 in a confined area, a Self-Contained Breathing Apparatus
(SCBA) is required.

Refrigerants (e.g. R-12, R-22, R-500, etc.) in large quantities can cause suffocation because they are
heavier than air and displace oxygen.

At high temperatures (e.g. open flames, glowing metal surfaces, etc.) R-12 and R-22 can decompose to
form:

57
 Phosgene gas

 Hydrochloric and hydrofluoric acids

Review

Practical Exercise – Supp 1a

58
1. What are Small Appliances defined as:

2. Effective 12 Aug 1993 what are the requirements for recovery equipment?

3. What is the minimum refrigerant recovery standard for equipment using either passive or system
dependent recovery for a Type I System?

4. What are the recovery requirements for recovery recycle equipment manufactured before 15
November 1993?

5. What are the recovery requirements for recovery recycle equipment manufactured after 15
November 1993?

6. What are low loss fittings?

7. Define Service Aperture or Process Tube:

59
8. Why must solder less type piercing valves not be installed in a refrigeration system for extended
periods of time?

9. Recovery/recycle equipment manufactured after November 15 1993 must remove what percentage
of the refrigerant from a system with an operating compressor.

10. What condition may be present if a pungent order is smelled?

11. What must be done when using recovery equipment or hoses using Schrader valves?

12. What device, allowing access to the system, must be installed on small appliances?

13. How can you obtain an accurate reading on a recovery cylinder?

14. What kinds of refrigerant tubing material can piercing valves be installed on?

15. What should be done to any type of access fitting on a sealed system?

16. How is refrigerant removed from a system with a completely restricted capillary tube?

60
17. How is refrigerant removed from a system with an inoperative compressor?

18. What are the safe practice procedures that should be followed when recovering refrigerants?

19. What three things must be done when a technician is using a system that utilizes Schrader valves?

20. What kind of breathing apparatus is required in the event of a large release of refrigerant in a
confined area?

21. How do refrigerants cause suffocation?

22. What chemicals do refrigerants exposed to high temperatures decompose to?

23. What are the mandatory leak repair criteria for Small Appliances?

24. What is the first thing a technician should identify prior to removing refrigerant from a system?

25. What certification does a technician need in order to service a Type I Appliance?

Chapter 10 Type II Systems

Topics of Study

1. Type II Certification

61
 2. Type II Systems
3. Leak Detection and Repair
4. Recovery Requirements
5. Recovery Techniques
6. Refrigeration
7. Safety

Topic Objectives

A. Identify and describe the systems and certification requirements associated with Type II certification.

B. Describe the recovery requirements and techniques associated with Type II systems.

C. Describe the safety requirements associated with Type II systems.

1. Type II Certification

Technicians with either Type II or Universal Certification may maintain, service, repair or dispose of high
or very high pressure appliances.

High pressure appliances are ones that operate with refrigerant having a boiling point between -58°F and
50°F atmospheric pressure (examples of high pressure appliances are ones that use R-114, R-12, or R-22
refrigerant)

Very high pressure appliances use refrigerant having a boiling point below -58°F at atmospheric pressure
(examples of very high pressure appliances are the ones that use either R-13 or R-503 refrigerant).

R-114

R-114 is listed as a high pressure refrigerant by the EPA because it has a boiling point of 38.4°F at
atmospheric pressure.

There are two types of A/C plants (high pressure appliances), open motor and hermetic.

R-12

R-12 is listed as a high pressure refrigerant by the EPA because it has a boiling point of -21.6°F at
atmospheric pressure.

R-22

R-22 is listed as a high pressure refrigerant by the EPA because it has a boiling point of -41.4°F at
atmospheric pressure.

The NAVY uses R-22 basically in O2N2 plants. The major components are basically the same as for R-
12 reciprocating plants.

After certification it is the technician’s responsibility to keep up to date with EPA regulation changes.

2. Type II Systems

A. Centrifugal Systems

62
The compressor in most R-114 systems is a single-stage centrifugal pump. Slightly superheated low
pressure gas is drawn into the impeller and discharged as a high a high pressure gas to the condenser. The
high pressure gas from the compressor passes over tubes in the condenser. Sea water passing through the
tubes removes the heat from the refrigerant and condenses it to a high pressure liquid state. The liquid
refrigerant enters the bottom of the chiller through orifice plates and covers the tubes in the chiller. Chilled
water (used to cool the ship) passes through the chiller tubes. Heat is removed from the water by the liquid
refrigerant and the liquid boils off as a low pressure gas. It is then drawn into the compressor and the cycle
starts all over again.

Excessive superheat is an indicator of a leak in a high-pressure system.

B. Reciprocating Systems

The reciprocating refrigeration cycle starts in the evaporator, where low pressure liquid refrigerant is
supplied to the evaporator by the Thermal Expansion Valve (TXV). The TXV divides the system into “high
side” and “low side.” High pressure liquid refrigerant passes through the TXV and expands at the evaporator
forming a low pressure liquid. The reduction in pressure permits the refrigerant to vaporize (boil) at a lower
temperature, absorbing heat from the water being cooled (chilled water). This evaporated low pressure
vapor refrigerant is drawn through the suction line into the compressor cylinder. The down stroke of the
piston admits a cylinder full of gas through the suction valve, compressing low pressure refrigerant gas and
vapor refrigerant flow to the condenser, where heat flows from the hot gas into the condenser sea water,
changing the refrigerant state from a high pressure gas to a high pressure liquid. This high pressure liquid
refrigerant drain into the receiver from which the high pressure liquid refrigerant is forced through the liquid
line to the TXV converting it to a low pressure liquid refrigerant, repeating the cycle.

3. Leak Detection and Repair

On an open compressor refrigeration unit that hasn’t been used for several months, the part most likely to
leak is the rotating shaft seal.

When inspecting a system thought to be leaking, look for traces of oil around flanges, fittings, and valves.

Check the operating log and the refrigerant charge level to tell if the system is losing refrigerant.

Testing with soap bubbles is used to pinpoint refrigerant leaks.

Check for leaks by checking for bubbles in the liquid line sight glass.

Many refrigeration units use an open compressor. The rotating shaft seal of this type of compressor is
likely to leak if the unit is not used for several months.

When a refrigerant trace gas becomes absolutely necessary, HCFC-22 is the refrigerant that should be used.

The plant can be shut down with the operating charge in place and leak checked using the semi-annual PMS
instruction.’

This can also be done anytime you suspect a leak.

63
Use the annual PMS check, which requires the removal of the refrigerant with a Recovery Unit (RU) or a
purge and pump out unit and pressurizing it with a mixture of nitrogen and R-22.

When a new system has been assembled (built up) and is ready for testing, it must first be pressurized with
an inert gas and leak-checked.

After installation of a field-piped split system, the unit must be pressurized with nitrogen, and then leak
checked.

A virgin refrigerant usage log must be kept for each appliance with more than 50 lbs. of refrigerant.

EPA regulations require the leaking commercial and industrial process refrigeration units must be repaired
when the leak rate exceeds 35 percent of the charge per year.

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

4. Recovery Requirements

As a commercial high-pressure refrigerant EPA requires any appliance containing 200 lbs. or more to be
pumped down to 15 inches Hg Vac before it can be opened for repairs.

Any commercial appliance containing less than 200 lbs. of a high pressure refrigerant needs to pumped
down to only 10 inches Hg.

Less than 200 Lbs. 10 inches Hg Vac.

200 Lbs. or more 15 inches Hg Vac.

Note: The Navy is applying the stricter requirement to all of its Type II systems.

1. Equipment manufactured prior to November 15, 1993:

 Small appliances must recover 80% of refrigerant charge or to 4” Hg Vac.

 High pressure system 4” Hg.

 Low pressure system 25” Hg

2. Equipment manufactured after November 15, 1993:

Small appliances must recover;
 90% of the refrigerant charge if the compressor is operable or to 4” Hg Vacuum.

64
  80% of the refrigerant charge if the compressor is inoperable or to 4” Hg Vacuum.
High Pressure system;
 10” Hg if less than 200 lbs of refrigerant
 15” Hg if more than 200 lbs of refrigerant
Low pressure system-25mm Abs.
All recycling and recovery equipment manufactured AFTER November 15, 1993 must:
 Be tested by and EPA-approved third party
 Be equipped with low-loss fittings
 Meet vacuum standards more stringent than those required for equipment manufactured
before November 15, 1993
When using recycling and recovery equipment manufactured AFTER November 15, 1993, technicians must
evacuate a system to:
15 in HG Vac. If it contains 200 lbs or more of CFC-12
10 in HG Vac. If it contains 40 lbs of R-502
When using recycling and recovery equipment manufactured BEFORE November 15, 1993, technicians
must evacuate a CFC-500 system, containing 10 lbs charge to 4 in HG Vac.
Appliances containing CFC refrigerants can be evacuated to atmospheric pressure when leaks are present
that make evacuation to the prescribed level unattainable.
After reaching the required recovery vacuum on an appliance, you should wait a few minutes to see if the
system pressure rises, indicating refrigerant in liquid form or present in the oil.
Under EPA regulations, replacement of an evaporator coil is ALWAYS considered a major repair.
5. Recovery Techniques
Changing the oil and filter is one routine maintenance task that must be performed on most refrigerant
recycling equipment.
When recovering refrigerant from a system, you can save time by removing as much refrigerant as possible
in the liquid phase.
Units with R-134a refrigerant require a special set of hoses, gauges, vacuum pump, recovery machine, and
oil containers. You cannot use the same hoses, gauges, vacuum pump, recovery machines, and oil containers
used for servicing units with CFC and HCFC refrigerants.
In order to recover liquid from a unit, you must connect one hose to the liquid line.

With an air cooled condenser on the roof of a building and the evaporator on the first floor, recovery should
first occur from the liquid line entering the evaporator.
Recovering refrigerant from a system in vapor phase minimizes the loss of oil.

65
After refrigerant liquid has been recovered from the appliance, any remaining vapor is condensed
(recovered) by the recovery unit.
By packing the recovery vessel in ice, it is possible to more quickly remove the refrigerant charge from the
system.
Recovery /recycling equipment that uses hermetic compressors has the potential to overheat when drawing
deep vacuums because the motor in the equipment relies on the flow of refrigerant for cooling.
If the recovery/recycling unit you are using contains a different refrigerant than the system you are working
with, you need to first recover as mush refrigerant as possible from the recovery/recycling unit and then
change the filter and evacuate.
Recovered refrigerants contain acids, oil and moisture.
Before using a recovery unit to remove a refrigerant charge, you must:
 Check the service valve position
 Check the refrigerant unit oil level
 Evacuate the recovery unit
To minimize refrigerant release when hoses are connected and disconnected during service, quick couplers,
self-sealing hoses, or hand valves can be used.
Local municipal water supplies are the primary water source for water cooled recovery unit condensing
coils.
When the condenser is below the receiver, refrigerant should be removed from the condenser outlet.
Refrigerant should be recovered in the receiver when performing refrigerant system service on an operating
unit that has a receiver/storage tank.
If refrigerant has been recovered from an air conditioning unit and held in a refillable cylinder while the
evaporator coil was replaced, chances are the refrigerant can be charged back into the system.
6. Refrigeration
R-22 is the refrigerant most often used in residential split systems for comfort air conditioning.
For 60-ton packaged roof top air conditioning units, the easiest way to check the refrigerant used is to look
at the name plate.
Refrigerant leaving the receiver of a refrigeration system is in the high pressure liquid state.
If a system is opened for servicing, the filter drier should be replaced.

When evacuating a vapor compression system, the vacuum pump should be capable of pulling a vacuum
of 500 microns.

It is not unusual for oil foaming to occur in the compressor area of a refrigeration system.

66
The receiver directly follows the condenser in a refrigeration system that utilizes a thermal expansion valve.

The receiver is NOT part of the low side of the system.

A deep vacuum is usually measured in microns.

When under a deep vacuum a hermetic refrigeration compressor’s motor winding could be damaged if
energized.

Back seating a suction shutoff valve will close the gauge port.

On a dual compressor system, refrigerant cannot be recovered without isolating the parallel compressor
system because of an open equalization connection.

Charging of an R-12 refrigeration system with risk of freezing is begun with vapor from a vacuum level to
a pressure corresponding to the saturation pressure of the refrigerant being charged at 36 degrees F. Liquid
can then be charged.

To charge a system that has a specified charge of 80 lbs. is always a liquid charge through a liquid line
service valve.

Non-condensables in a refrigeration system result in higher discharge pressure.

The evaporation temperature or R-134a at 14.7 psia is -15 degrees F.

7. Safety

R-11, R-12, R-114, and R-134a all require equipment room oxygen deprivation sensors under ASHRAE
standard 15.

ASHRAE standard 15 states that a sensor and alarm are required for A1 refrigerants to monitor oxygen
levels.

When a discharge service valve is closed, a reciprocating compressor should not be energized.

Although nitrogen should be used to break the first vacuum when dehydrating by the multiple evacuation
method, it is too dangerous unless the nitrogen is used with a pressure regulator and relief valve.

Every refrigeration system should be protected by a pressure relief device.

Type II – Review questions

Practical Exercise – Suppl 1a
1. What kind of appliances can a person certified as a Type II technician service?

67
2. What is an indication of a leak in a high pressure system?

3. Where is an open compressor most likely to leak from?

4. Where should you look for oil on a system you suspect is leaking?

5. What is used to pinpoint refrigerant leaks?

6. Which type of refrigerant should be used as a trace gas and why?

7. What must be done to a new system that is ready for testing?

8. How do you test a newly installed field piped split system for leaks?

9. What is the annual leak rate for Commercial and Industrial Process Refrigeration Units?

10. What is the annual leak rate for Comfort Cooling Chillers?

11. An appliance containing more than 200 lbs of refrigerant must be evacuated to what level?

68
12. An appliance containing less than 200 lbs of refrigerant must be evacuated to what level?

13. What three things must recovery recycling equipment manufactured prior to November 15 1993 be
able to perform?

14. What percentage of the refrigerant must be recovered from a small appliance using recovery
recycling equipment manufactured after November 15 1993?

15. What percentage of refrigerant must be recovered from a High pressure system using equipment
manufactured after November 15 1993?

16. What three things must be done to recovery recycling equipment manufactured after 15 November
1993?

17. What are the recovery requirements for equipment manufactured after November 15 1993 for a
system containing 40 lbs of R-502?

18. What are the recovery requirements for equipment manufactured after November 15 1993 for a
system containing 200 lbs or more of CFC-12?

19. When can appliances be evacuated to atmospheric pressure?

20. What should be done after reaching the required recovery vacuum level on an appliance?

69
21. Replacing any of the following components, compressor, condenser, metering device and
evaporator is considered what type of repair?

22. What is the fastest way to recover refrigerant from a system?

23. What line must be accessed in order to recover liquid from a refrigeration system?

24. What does a unit that uses R-134a as a refrigerant require?

25. Recovering refrigerant in vapor phase minimizes the lost of?

26. What is an advantage of recovering refrigerant in the liquid phase?

27. After refrigerant has been removed from an appliance by a recovery/recycling machine what
happens to the remaining vapor?

28. What can be done to speed up refrigerant recovery from a system?

29. Recovered refrigerants may contain?

30. What three things must be done to a recovery unit before removing a refrigerant charge from a
system?

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31. What can be done to minimize refrigerant releases when hoses are connected and disconnected
during service?

32. What is the primary water source from water cooled recovery unit condensing coils?

33. Where should refrigerant be recovered from if the condenser is below the receiver?

34. Can you put refrigerant removed from a system back into the same system? If no why not?

35. How is a deep vacuum usually measured?

36. What can happen to a hermetic compressor if it is energized while under a deep vacuum?

37. Back seating a suction shutoff valves closes which port?

38. What is the result of non-condensable in a refrigeration system?

39. When should a reciprocating compressor not be energized?

40. What device must be used when using nitrogen?

71
41. What must every refrigeration system be protected by?

42. If a system is opened for servicing what must be replaced?

43. A vacuum pump should be capable of pulling a vacuum of?

44. What prevents refrigerant from being recovered on a dual compressor system?

45. Will a certified technician be notified of future changes in the law?

Chapter 11 Type III Systems

Topics of Study

1. Type III Certification

2. Type III Systems

72
 3. Leak Detection
4. Recovery Requirements
5. Recharging Techniques
6. Refrigeration
7. Safety

Topic Objectives

A. Identify and describe the systems and certification requirements associated with Type III Certification

B. Describe the recovery requirements and techniques associated with Type III systems.

C. Describe the safety requirements associated with Type III systems.

1. Type III Certification

Technicians with either Type III of Universal Certification may maintain, service, repair or dispose of low
pressure appliances.

After certification it is the technician’s responsibility to keep up to date on EPA regulation changes.

2. Type III Systems

R-11

R-11 is listed by the Environmental Protection Agency (EPA) as a low-pressure refrigerant.

Refrigerant R-11 is a colorless liquid at normal atmospheric pressures and temperatures.

Commercially there are other low-pressure refrigerants. Examples are R-123 and R-113 (R-113 has a
boiling point of 117.6°F)

Types of Centrifugal A/C plants

Refrigerant R-11 is used in the Navy on centrifugal A/C plants. There are two types of centrifugal A/C
plants:

One motor type: motor is cooled be air passing over the motor and is connected to the compressor shaft by
a flexible coupling.

Hermetic motor type: there are different designs but mainly the motor is cooled by refrigerant passing
through the motor in either vapor or liquid state.

Also the motor is connected to the compressor housing directly.

Refrigerant Flow Through the System (Cycle)

Compressor: Refrigerant vapor is drawn from the chiller and flows through the inlet vanes into the
compressor where it is compressed by the impeller and discharged into the condenser as a high pressure
refrigerant vapor.

73
Condenser: The condensed refrigerant drains into a metering device (i.e. float chamber or orifice). The
liquid refrigerant passes from the metering device into the chiller. The liquid refrigerant is distributed along
the bottom of the chiller through a baffle, repeating the cycle. The refrigerant cycle starts at the chiller. The
chilled water flowing through the chiller tubes is warmer than the refrigerant is the shell surrounding the
tubes. Heat is transferred from the chilled water to the low pressure liquid refrigerant (chilled water is then
cooled). The heat absorbed by refrigerant evaporates the liquid refrigerant in the chiller, creating a low
pressure vapor.

3. Leak Detection and Repair

Early detection and repair of leaks in low pressure systems is required or the unit will suck air and /or
moisture inside the plant, deteriorating internal components, eventually causing a failure.

A sign of leakage is an abnormally low suction pressure accompanied by a high discharge pressure in the
A/C plant.

By checking the operating log for air and non-condensable gases and checking refrigerant charge level, you
can tell if the system is losing refrigerant.

When testing for a leak in a low pressure system with nitrogen, 10 psig is the maximum test pressure.

A hydrostatic tube test kit will determine if there is a leak in the tube.

Raising the system pressure by heating with circulating hot water or heating blankets is the most effective
leak detection technique for low pressure refrigeration machines.

Place a leak detection probe through a drain valve to check gas leaks into the water box with the water
removed.

Leak test and repair the chiller to reduce refrigerant loss from a purge unit in a CFC-11 chiller.

Leak testing a low pressure refrigeration system with nitrogen in excess of 10 psig could cause the rupture
disc to fail.

A leak must be repaired within 30 days of the leak discovery.

A virgin refrigerant usage log must be kept for appliances with more than 50 lbs of refrigerant.

Specific leak rate allowed by EPA for any A/C system, such as R-11, that has more than 50 lbs of refrigerant
is less than 15% of the total charge in a year.

For example: 274 Ton R-11 system has 1,200 lbs of refrigerant and an allowable leak rate of 180 lbs a year.

Specific leak rate allowed by EPA for leaking commercial and industrial process refrigeration is 35% of
the charge per year.

Ways to leak test an A/C plant:

74
 1. Leak test using the operating charge by circulating Controlled Hot Water through the chiller
for increased pressure and leak testing efficiency.

2. Leak test after removing the operating charge, by using nitrogen or using a mixture of a trace
gas (R-22) and nitrogen to raise chiller pressure.

The following are important leak related notes:

a. Adding Nitrogen to the operating charge is prohibited.

b. Maximum chiller pressure when leak testing or charging refrigerant (for low pressure
appliances) must be 10 psig to prevent rupture disk failure.

c. R-22 is preferred over any other refrigerant as a trace gas for its low Ozone Depletion Potential
(ODP) level (0.05). Use of other refrigerant is acceptable.

Moisture most frequently enters the refrigerant system on low pressure chillers through air leaks from
gasket areas or fittings.

4. Recovery Requirements

For NAVY low pressure appliances, refrigerant needs to be recovered with a certified recovery unit (RU)
(equipment) every time a major repair is made. The guidelines are as follows:

25 in Hg Vacuum with recovery equipment manufactured BEFORE November 15, 1993

25 mm Hg abs (29 in Hg Vacuum) with recovery equipment manufactured AFTER November 15,
1993

When evacuating the refrigerant for a low pressure chiller, the recovery unit’s high pressure cut-out is set
for 10 psig.

Appliances need not be evacuated completely to the prescribed level when leaks in the appliance make
evacuation the prescribed level unattainable.

Recovery/recycling equipment does not necessarily need to be capable of handling more than one
refrigerant, according to EPA regulations.

Low-pressure appliances must be evacuated to the level of 25 mm Hg Vacuum before making major repairs
using recovery/recycling equipment manufactured BEFORE November 15, 1993.

Low-pressure appliances must be evacuated to the level of 25 mm Hg abs when using recovery/recycling
equipment manufactured AFTER November 15, 1993.

In accordance with EPA regulations, controlled hot water may be used to pressurize the system for the
purpose of opening it for non-major repair.

75
You must recover the liquid refrigerant before recovering the vapor refrigerant in a low-pressure chiller R-
11 or R-123 system refrigerant removal starts with liquid removal.

About 100 lbs of refrigerant vapor is left in an average 350 ton R-11 chiller at 0 psig pressure when all of
the R-11 liquid refrigerant has been removed.

If the pressure in a system rises from 1 mm Hg Vacuum to a level above 2.5 mm Hg vacuum during a
standing vacuum test, then according to ASHRAE Guideline 3-1990, the system should be checked for
leaks.

After reaching the required recovery vacuum on an appliance, wait for at least a few minutes to see if the
system pressure rises. This indicates that there is still refrigerant in liquid form or in the oil.

The temperature should be at 130 degrees F when removing oil from a low-pressure system so that less
refrigerant will be contained in the oil than at a lower temperature.

A rupture disk on the evaporator of a low-pressure refrigeration system relieves at 15 psig.

The system water pumps, recovery compressor, and recovery condenser water should all be turned on
during vapor removal from a refrigeration system.

A heater used with a recovery vessel aids in the quicker transfer of vapor to the chiller.

Local municipal water supplies are the primary water source for recovery unit condensing coils.

Water must be circulated through a chiller during refrigerant evacuation in order to prevent freezing of
the water.

Replacement of an evaporator is always considered “major” under EPA regulations.

5. Recharging Techniques

16.9” Hg vacuum is necessary in the shells before recharging a refrigeration system with liquid R-11.

After system servicing, refrigerant vapor is re-introduced to the refrigeration system before refrigerant
liquid because liquid charged into a deep vacuum will boil and may lower temperatures enough to freeze
water in the tubes.

You can tell that enough vapor has entered the refrigeration system and that it’s safe to charge refrigerant
liquid when the refrigerant saturation temperature reached 36 degrees F.

6. Refrigeration

Chillers that use CFC-11 and HCFC-123 require purge units because those systems operate below
atmospheric pressure.

76
The primary purpose of a purge unit on a CFC-11 chiller is to remove non-condensable gases from the
system.

The purge unit ALSO removes air from the system and returns the recycled refrigerant to the unit.

On a centrifugal unit the purge unit takes its suction from the top of the condenser.

A centrifugal chiller’s rupture disk is connected to the chiller’s evaporator.

Refrigerant is added to a centrifugal machine through the evaporator charging valve.

R-11 at a pressure of 18.1 inches Hg vacuum has a saturation temperature of 32 degrees F.

For R-123, the pressure of 20 inches of Hg vacuum corresponds to 32 degrees F.

R-11 at 14.7 PSIA will boil at approximately 74.5 degrees F.

7. Safety

An equipment room oxygen deprivation sensor is required for R-11, R-12 and R-134a under ASHRAE
standard 15.

A sensor and alarm are required for A1 refrigerants to sense oxygen deprivation under ASHRAE standard
15.

Under ASHRAE standard 34, R-123 refrigerant falls under B1 code group.

An equipment room refrigerant sensor is required for R-123 refrigerant under ASHRAE standard 15.

For low-pressure systems:

 Do not siphon refrigerant by mouth

 Do not spill liquid refrigerant on skin.

 Always use gloves and goggles when working with liquid refrigerant.

REVIEW

1. How is a hydrostatic tube test kit used?

2. What is the maximum test pressure for leak testing a low-pressure centrifugal unit with nitrogen?

77
3. What is an effective method for leak checking a charged low-pressure refrigeration unit?

4. On a CFC-11 chiller, what can be accomplished to reduce refrigerant loss from a purge unit?

5. Where would you place a leak detector probe if you were checking for leaks in the water box and the
water was removed?

6. Where would moisture most likely enter a low-pressure chiller?

7. What are EPA leak rate requirements for an appliance containing more than 50 lbs of refrigerant?

8. What are EPA leak rate requirements for commercial and industrial refrigeration equipment?

9. What is the high pressure cut-out set for when evacuating refrigerant from a low-pressure chiller?

78
 PRESSURE / TEMPERATURE CHART
TEMP CFC CFC HFC HCFC HCFC HFC HFC
(OF) R12 R500 R404A R22 R123 R134A R410A
-50 15.4 6.1 28.9 18.7
-45 13.3 2.7 28.7 16.9
-40 11.0 7.9 4.3 0.5 28.4 14.8 11.6
-35 8.4 4.8 6.8 2.5 28.1 12.5 14.9
-30 5.5 1.4 11.1 4.8 27.8 9.8 18.5
-25 2.3 1.1 14.3 7.3 27.4 6.9 22.5
-20 0.6 3.1 15.7 10.1 27.0 3.7 26.9
-15 2.4 5.4 19.3 13.1 26.5 0.0 31.7
-10 4.5 7.8 23.2 16.4 26.0 1.9 36.8
-5 6.7 10.4 27.5 20.0 25.4 4.1 42.5
0 9.2 13.3 32.1 23.9 24.7 6.5 48.6
5 11.8 16.4 37.0 28.1 24.0 9.1 55.2
10 14.6 19.8 42.4 32.7 23.1 12.0 62.3
15 17.7 23.4 48.2 37.7 22.1 15.0 70.0
20 21.0 27.3 54.5 43.0 21.1 18.4 78.3
25 24.6 31.6 61.2 48.7 19.9 22.1 87.3
30 28.5 36.1 68.4 54.8 18.6 26.1 96.8
35 32.6 41.0 76.1 61.4 17.2 30.4 107.0
40 37.0 46.2 84.4 68.5 15.6 35.0 118.0
45 41.7 51.8 93.2 76.0 13 .9 40.0 130.0
50 46.7 58.7 103.0 84.0 12.0 45.3 142.0
55 52.0 64.1 113.0 92.5 10.0 51.1 155.0
60 57.7 71.0 123.0 101.6 7.7 57.3 170.0
65 68.8 78.1 135.0 111.2 5.3 63.9 185.0
70 70.2 85.8 147.0 121.4 2.6 70.9 201.0
75 77.0 93.8 159.0 132.2 0.1 78.4 217.0
80 84.2 102.5 173.0 143.6 1.6 86.4 235.0
85 91.8 111.5 187.0 155.6 3.2 94.9 254.0
90 99.8 121.2 202.0 168.4 5.0 103.9 274.0
95 108.3 131.3 218.0 181.8 6.8 113.5 295.0
100 117.2 141.9 234.0 195.9 8.9 123.6 317.0
105 126.6 153.1 252.0 210.7 11.1 134.3 340.0
110 136.4 164.9 270.0 226.3 13.4 145.6 365.0
115 146.8 177.4 289.0 242.7 15.9 157.6 391.0
120 157.7 ·190.3 310.0 259.9 18.5 170.3 418.0
125 169.1 204.0 331.0 277.9 21.3 183.6 446.0
130 181.0 218.2 353.0 296.8 24.3 197.6 476.0
135 193.5 233.2 377.0 316.5 27.4 212.4 507.0
140 206.5 248.8 401.0 337.2 30.8 227.9 539.0
145 220.3 426.0 358.8 34.4 244.3 573.0
150 234.6 453.0 381.5 38.2 261.4 608.0

Note: numbers in red indicates negative pressure

79
 Pretest Sample Questions

For DOD EPA Universal Technician Certification

Appendix (B)

Introduction

The following pages contain sample questions for each of the four areas required for Universal Technician
certification. These questions do not quote the actual test. This test is designed to give you an idea of what
to expect and also will give you an idea of how well you prepared you are for “THE TEST”.

There will be 25 questions covering each of the 4 parts of the test. To pass this test you will be required to
correctly answer 18 of the 25 questions in each of the 4 parts.

If you find that you are close to missing 7 questions in any one of the parts you should go back and do more
studying to insure that you are prepared as best as possible for the “EPA Certification Test”.

Instruction: Read each question very carefully. Be sure to read each/all of the responses. Some of the
responses will have several answers that are correct. You must select the answer that is the Best or Most
Correct.

80
 Sample Certification Test Core Questions

For questions 1 thru 4: match the dates listed below to the event listed below the answers.

Answers

a. The 1920’s b. 15 November 1990

c. 14 November 1994 d. 1 July 1992

The Event

1. The Clean Air Act (a) (b) (c) (d)

2. The Technician Certification deadline (a) (b) (c) (d)

3. Venting of CFC/HCFC refrigerants law took effect (a) (b) (c) (d)

4. Study of the Ozone began. (a) (b) (c) (d)

5. You are stationed at Herby C. Husker Air Station located in the state of Nebraska. You know that
Nebraska has a law that states “Bulk refrigerants shipped on any public transportation must be shipped
inside an air tight shipping container able to withstand 5,000 pounds of crush pressure. Which laws or
regulations must you follow when shipping used refrigerant to Denver Colorado for processing?

Note: Colorado State laws are the same as EPA laws.

a. EPA, DOD and ASAF regulations

b. Nebraska state laws

c. DOT regulations

d. all of the above

6. Which of the following is the most destructive to the ozone protective layer?

a. water soluble chlorine

b. non-water soluble chlorine

c. HCFCs such as R-22

d. evaporated sea water

7. Which of the following is an agreement that states that the United States will not import CFC type
refrigerants 1995?

a. The Clean Air Act

b. The Montreal Protocol

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 c. The Emissions Control Act

d. The Environmental Protection Agency Agreement

8. What type of technician certificate is required to service all types of refrigeration and air conditioning
systems/appliances after 14 November 1994?

a. Type I and II

b. Type I and III

c. Universal

d. Type III only because it includes Type I and Type II

9. As of 12 August 1993 all types of recovery equipment must be registered with which of the following
office or department?

a. Headquarters EPA Washington DC

b. Your EPA regional office

c. Your state EPA office

d. All of the above

10. Which of the following refrigerants does the least harm to the ozone?

a. R-114

b. R-134a

c. R-22

d. R-12

11. Which of the following refrigerants is the most harmful to the ozone?

a. HCFCs

b. HFCs

c. CFCs

d. HSFCs

12. Which of the following is a low pressure refrigerant?

a. R-11

b. R-123

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 c. R-123

d. All are low pressure

13. How many atoms will one molecule of ozone contain?

a. 1

b. 2

c. 3

d. 5

14. Refrigeration systems/appliances that use R-11, R-113 and R-123 would be classified as what type of
system and will require what type of certification for servicing?

a. High pressure…Type I

b. Low pressure…Type I

c. High pressure…Universal

d. Low pressure…Type III

15. Which of the following types of systems fall under the EPA definition for “Industrial Process
Refrigeration”?

a. Industrial ice machines and ice rinks

b. Industrial indirect expansion liquid AC chillers

c. Industrial food processing/storage plants

d. Any refrigeration system used in the process of manufacturing in anyway.

16. The loss of small amounts of refrigerant while removing service hoses is:

a. A De Minimis release of refrigerant

b. Against all EPA laws

c. Permitted until 14 November 1994

d. Both a and c are correct

For questions 17 through 22: match the EPA terms to the definitions

a. Reclaim b. Recover c. Recycle d. Small Appliance

Definitions

83
17. A manufactured hermetically sealed unit containing 5 pounds or less refrigerant charge.

a. b. c. d.

18. A refrigerant that has been cleaned and the oil separated.

a. b. c. d.

19. A refrigerant that has been reprocessed to ARI standards

a. b. c. d.

20. A refrigerant that has been removed from a system but not processed in any way.

a. b. c. d.

21. A type of system that requires a process tube or stub.

a. b. c. d.

22. Requires a Type I Technicians certificate to service.

a. b. c. d.

23. The EPA definition for “OPENING”, would apply to include all the service procedures listed
EXCEPT which one of the following:

a. The opening of a pressurized appliance.

b. The opening of an appliance that has lost its charge.

c. The opening of an appliance that has been pumped down to 1 to 5 PSIG.

d. The opening of any appliance to include opening a service valve or process tube.

24. Once recycle/recovery units have met EPA requirements it must be retested or inspected how often?

a. annually

b. two years

c. three years

d. five years

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25. Which of the following types of refrigeration appliances would it be permissible to use a passive
recovery device for evacuation?

a. a centrifugal liquid chiller air conditioner

b. a reciprocating liquid chiller air conditioner

c. a commercial walk-in refrigeration system

d. a domestic refrigerator of window AC unit

The following questions are fill in the blank.

1. What elements in refrigerants cause ozone depletion?

2. What are the effects of ozone depletion?

3. Where is good ozone located?

4. Which type of refrigerant is the most harmful?

5. What type of refrigerant does not deplete the ozone?

6. Under high temperatures, refrigerants can decompose and form?

7. How many ozone molecules are destroyed by a single chlorine atom?

8. How long is the 608 certification good for?

9. What type of refrigerant would you most likely encounter in a residential unit and why?

10. What type of refrigerant is a drop in replacement for R-12?

11. When charging or recovering R-134a, what special procedures should be followed and why?

12. What types of refrigerants do not contain chorine?

13. What three things are required by the Clean Air Act?

14. What is “DeMinimus” release of refrigerant?

15. What three types of releases are allowed by the Clean Air Act?

16. Repair of substantial leaks are based on annual leak rates. What are the leak rates for the following?

85
 Small appliances __________
Comfort cooling chillers___________
Industrial process and commercial systems____________
17. What can happen to individuals who violate the provisions of the Clean Air Act?

DEFINE THE FOLLOWING

18. Small Appliance

19. Type I Technician

20. Process Stub

21. Ternary Blend

22. Refrigerant Blends

23. Azeotropic Mixture

24. Fractionation

25. What type of oil is most commonly used with R-134a?

26. What 3 things are specifically stated by the EPA concerning used oils?

27. What is temperature glide?

28. Why are HCFC’s preferred over CFC’s?

29. What is the maximum reward that you can receive for reporting violations of the CAA?

30. When referring to oils, what is hydroscopic?

31. When does cooling occur in a direct-expansion vapor compression refrigeration system?

32. When must a hermetic compressor never be operated?

33. How do long hoses between the refrigeration system and the recovery machine affect operations?

86
34. How does low ambient temperature effect recovery?

35. What standards must reclaimed refrigerants meet?

36. Does a reclamation facility have to accept mixed refrigerants?

37. What component changes low pressure vapor to a high pressure vapor?

38. Why is recovery of refrigerants necessary(3 reasons)?

39. What three things should you tell a customer when they complain about cost due to recovery?

40. What is a self contained recovery device?

41. When will CFC refrigerants no longer be produced?

42. What is system dependant passive recovery?

43. If refrigerant changes ownership, what standards must it meet? Are there any exceptions?

44. What three methods or devices are used to monitor the 80% fill level in a recovery tank?

1. ______________________

2.______________________

3.______________________

45. Why do we perform system evacuations?

46. Can a system be over evacuated?

47. How is a deep vacuum measured?

48. If moisture is allowed to remain in a system, what can happen?

49. How is ice removed from the sight glass?

50. When pressurizing a system with nitrogen, what must you ALWAYS use?

87
 Sample Certification Test Questions Type I

1. R-134a is a drop in refrigerant for which of the following refrigerants?

a. R-12 b. R-22 c. R-502 d. none

2. What is the maximum amount of refrigerant charge that Type I appliances will hold?

a. 3 lbs b. 5 lbs c. 10 lbs d. 15 lbs

3. Which of the following appliances would not fall under Type I appliances?

a. a car air conditioner that holds 3 pounds of R-12

b. a water cooler that holds 13 ounces of R-12

c. a food freezer that holds 22 ounces of R-22

d. an ice maker charged with 12 ounces of R-12

4. While charging a graduated charging cylinder, which of the following is a true statement?

a. purging a small amount of refrigerant while filling the unit qualifies as a De Minimis
purge

b. purging refrigerant to fill the unit is lawful as long as it is less than one pound of
refrigerant

c. these types of charging station have been outlawed since 15 July 1992

d. all regulated purged refrigerant must be captured and recovered

5. All recycled R-12 cylinders for servicing Type I appliances must be color coded:

a. light blue

b. dark green

c. light green

d. none of the above

88
6. What type of service aperture will Type I appliances have when they leave the factory after
November 15, 1993:

a. none

b. a process stub

c. a 3 way service valve

d. a schrader line tap valve

ARI Standard 740 has to set the date of 15 November 1993 imposing more stringent requirements for
recovery type equipment used with Type I appliances. Answer questions 7 and 8 stating the before and
after 15 November 1993 standards stated.

Before After

7. For a system with a non-functioning compressor

a. 80% charge 4” vacuum/80% charge 4” vacuum

b. 80% charge 4” vacuum/80% charge 10” vacuum

c. 80% charge 4” vacuum/90% charge 4” vacuum

d. 80% charge 4” vacuum/100% charge 29” vacuum

8. For a system with an operational compressor

a. 80% charge 4” vacuum/80% charge 4” vacuum

b. 80% charge 4” vacuum/80% charge 10” vacuum

c. 80% charge 4” vacuum/90% charge 4” vacuum

d. 80% charge 4” vacuum/100% charge 29” vacuum

9. Which of the following statements is true concerning recovery type equipment used for Type I
appliances?

a. home made recovery/recycle units have been authorized by the EPA.

b. all recovery type equipment should have been registered with the EPA by 12 August
1993

c. passive recovery is the most common method for refrigerant recovery used for Type I
appliances.

d. answers a., b., and c. are all true statements.

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10. What is the primary difference between a system dependant (passive) recovery unit and a self
contained (active) recovery unit?

a. passive units use the appliance compressor to pump refrigerant from the appliance,
active units don’t

b. passive units do not use the appliance compressor to pump the refrigerant from the
appliance, active units don’t

c. passive units are not required to be registered with the EPA, active units are

d. active units are not required to be registered with the EPA, passive units are

11. All types of recovery/recycling units manufactured after 15 November 1993 will be required to have
which of the following?

a. a calibrated stamp or label

b. an EPA approved type of certification label

c. flexible lines that meet the new EPA specifications

d. manual triple shut-offs and triple seal isolation valves

12. Which of the following would be acceptable for finding a leak in an appliance that had lost its
charge?

a. pressurize the system with dry nitrogen and using soap bubbles to locate the leak

b. add some R-22 then pressurize the system with dry nitrogen and the testing for leaks
using a standard type leak detector.

c. pressurizing the system with compressed air and using soap bubbles to locate the
leak.

d. answers A and B are permissible, C is dangerous and should never be done

13. If you know that a domestic refrigerator has a leak in it somewhere, the current law stipulates which
of the following?

a. it does not have to be repaired

b. it must be repaired without delay

c. it must be repaired or evacuated and scrapped (salvaged)

d. it must be repaired only if the charge is R-12 a CFC type refrigerant.

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14. When scrapping a Type I system appliance, who is responsible to insure that the refrigerant charge
has been removed and disposed of, in accordance with EPA laws?

a. the owner

b. the dealer

c. the last person in the disposal chain

d. the certified service technician

15. R-12 refrigerant will no longer be manufactured for Type I appliances after:

a. Year 1990

b. Year 1995

c. Year 2000

d. Year 2020

16. Which of the following refrigerants will not damage the ozone protective layer?

a. HCHCs and HCFCs

b. HCFCs and CFCs

c. HCFCs and HFCs

d. HFC only

17. What happens when CFCs and HCFCs comes in contact with an open flame?

a. chlorine gas will be generated

b. an explosion will take place

c. hydrogen gas will be generated

d. hydrochloric/hydrofluoric acid will form

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18. When you see a refrigerant cylinder that has a gray body and a yellow top what should this indicate to
you?

a. the cylinder contains mixed refrigerants

b. the cylinder is designed to hold an inert gas

c. the cylinder is designed to hold the new refrigerant HFC 123

d. the cylinder is designed to hold and store or ship recovered refrigerant.

19. Why would you strike a compressor with several sharp blows while pulling a vacuum on an
appliance?

a. to burp it, causing the refrigerant to escape from the oil and compressor

b. to break the electrical field

c. to loosen the connection

d. to break the vacuum.

20. What type of certification tests will you be required to pass in order to be certified after 14 November
1994, to service any small appliance?

a. Type I only

b. Type I plus Core

c. Type I and Type II plus Core

d. Type I plus Core or Universal

21. Which of the following would be an indication that the compressor in a small appliance has burnt up?

a. the paint has peeled off the compressor

b. the compressor is hot to the touch

c. the refrigerant has a pungent odor

d. the compressor won’t run

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22. Where will a saturated refrigerant be located in a refrigeration system while it is operating?

a. in the evaporator and the condenser

b. in the suction and discharge lines

c. in the evaporator only

d. in the liquid line only

23. What part of the refrigeration system will contain superheated vapor while the system is operating?

a. the compressor

b. the condenser and evaporator

c. the suction/discharge lines and compressor

d. all of the above

24. When is the only time it is permitted to purge the refrigerant contents of an appliance to the
atmosphere without breaking the law?

a. when there is no one around to see you do it

b. only if the lines in the system are blocked and refrigerant cannot be evacuated

c. never, it must never be done without exception

d. when the unit contains less than 20 lbs of charge

25. While operating a recovery type device, which of the following would cause excessively high
cylinder pressures?

a. oversized service hoses

b. an oversized recovery system

c. air in the storage or recovery vessel

d. all of the above would cause the same effect

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 Sample Certification Questions Type II

1. The primary difference between Type I and Type II refrigeration appliances is:

a. the refrigeration systems will have open type compressors only

b. the refrigerant charge will be greater than five pounds

c. the systems will always be remote or split systems

d. Type II systems will not have HFC type refrigerant charges

2. Which of the following type(s) of equipment will a technician NOT be able to service if he/she
possesses only a Type II Technician Certificate?

a. high pressure and very high pressure systems

b. self contained package type DX air conditioners

c. reciprocating liquid chillers with less than 200 pounds of refrigerant charge

d. automobile comfort cooling type air conditioning systems charged with CFC R-12
refrigerant only

3. How often should recovery equipment be leak checked?

a. each time it is used

b. everyday or everyday it is used

c. at least once a week even if it is not used.

d. monthly and the log must be signed and certified that it was done

4. Recovery type equipment today must be able to be used with different types of refrigerants. What is
recommended when recovering R-502 with recovery equipment that has previously recovered R-22?

a. today’s equipment requires no special servicing

b. the oil and refrigerant filters must be replaced

c. only the oil filters must be changed

d. only the oil must be changed

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5. On 15 November 1993, the standard was changed for any recovery type equipment that was built
after that date. What is the current standard for appliances with under 200 lbs of refrigerant?

a. 10” Hg

b. 15” Hg

c. 18” Hg

d. 28.9” Hg

6. The standard of 15 November 1993 also affected systems over 200 pounds. What is today’s standard
for these systems?

a. the same as systems under 200 pounds

b. 15” Hg

c. 18” Hg

d. 28.9” Hg

7. When could the requirement be waived for pulling a vacuum on a Type II system while repairing it?

a. if pulling a vacuum would cause refrigerant to be contaminated with air

b. if pulling a vacuum would require over filling the recovery vessel

c. if pulling a vacuum would cause overheating of the recovery unit causing it to burn
up

d. EPA law does not provide for any waivers for any reason for not pulling the required
standard vacuum

8. Refrigerant recovery on large Type II appliances is done in several stages to increase the speed of the
process. What is the recommended first stage to speed up refrigerant removal from the system?

a. cool the appliance with ice packs

b. remove refrigerant in a liquid state first

c. operate the appliance compressor to speed up the process

d. Heat the appliance with heat lamps to build up systems pressure to speed up
evacuation process

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9. Where should the recovery hoses be connected to a large Type II system to remove liquid refrigerant?

a. from the lowest point in the system where liquid refrigerant will settle

b. form the “king” valve on the receiver

c. from the bottom of the condenser

d. from both service valves

10. Which of the appliances are not affected by the15 November 1993 recovery standards which
established more stringent recovery requirements?

a. all Type II appliances have the same standard

b. MVAC and MVAC like appliances

c. Small appliances with less than 5 pounds charge

d. Industrial manufacturing refrigeration systems.

11. What advantage does open drive recovery systems have over hermetic type recovery systems?

a. none, actually the hermetic systems operate at higher RPMs and are capable of
achieving deeper vacuum in a shorter time

b. open type reclaimers have a large displacement capability and are able to achieve
much lower vacuums

c. open drive compressors are not subject to burn out while evacuating low volumes of
refrigerant

d. open drive compressors will permit motor slippage unlike hermetic units which have
a tendency to lock/burn up

12. What advantage to recycle units have over recovery units?

a. recycle units are able to pull deeper vacuums

b. recycle units are capable of removing acids

c. recycle units are capable of removing non-condensables from the refrigerant

d. recycle units will have safety controls not found on regular recovery units, and most
recovery units can only be used with a single refrigerant

96
13. While servicing a large commercial refrigeration system which of the following would lead you to
suspect that the system was low on refrigerant charge?

a. bubbles in the sight glass

b. frost on the suction line and accumulator

c. a compressor head that is cold to the touch

d. normal to high head pressure, suction pressure that suddenly rises and falls

14. Which of the following devices would be used to pin point a small leak?

a. a halide detector

b. an electronic leak detector

c. the use of a special soap bubble solution

d. evacuation equipment the measure pressure rise in the system to determine volume of
the leak

15. Current regulations require that if a leak exceeds 35% of the systems total charge in one year it must
be repaired. Which of the following types of equipment do this 35% leak rate pertain to?

a. commercial/industrial process refrigeration

b. large package type air conditioning systems

c. small reciprocating liquid chillers for comfort air conditioning

d. all Type II type systems

16. What is the advantage of recovering refrigerant from a Type II system as a vapor rather than a liquid?

a. it is much quicker

b. it reduces oil loss

c. it is much easier

d. all of the above

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17. What will high performance recovery type units use to speed up the process of recovery or recycling
of refrigerants?

a. water cooled condensers that use common tap water

b. special sub coolers that flash off refrigerant to keep head pressures low

c. special intercoolers that pass cool incoming vapors to come in contact with the
superheated discharge gases before they pass on to the storage cylinders or vessels.

d. none of the above

18. To replace an evaporator on an R-22 system that contains 35 pounds of refrigerant charge which of
the following procedures is the most correct procedure to follow?

a. recover the whole system charge and pull a vacuum of at least 4” Hg

b. pump the system down to 1 to 5 pounds of pressure and isolate the component from
the rest of the system before removing it

c. pump the system down to 4” Hg and isolate the evaporator from the rest of the
system then, pressurize the system to atmospheric pressure with dry nitrogen before
opening it up for replacement

d. pump the system down to 10” hg, isolate and watch to see if the pressure rises, if it
does the entire charge must be recovered prior to opening the system to remove the
evaporator

19. Why would a newly installed split air conditioner be pressurized with dry nitrogen?

a. to leak check the system

b. to purge loose particles from the lines

c. to dehydrate the system of moisture vapor

d. a, b and c are all reasons for pressurizing a newly installed system with dry nitrogen

98
20. Traces of oil on any of the component parts of a refrigeration system would indicate which of the
following?

a. the system requires a good cleaning

b. the system more than likely has a leak

c. the machine is new and still has an oil preservative on it

d. it means nothing, it is not uncommon for older systems to be covered with oil
because of the environment in most mechanical rooms

21. What is the most common type of refrigerant you would expect to find in a 5 ton PTAC unit?

a. R-123 b. R-22 c. R-134a d. R-502

22. Which of the following refrigerants would you as a service technician encounter temperature glide?

a. R-12 a CFC

b. R-22 a HCFC

c. R-502 a binary or azeotropic

d. MP-39 a blended or ternary

23. Which of the following statements are true concerning recovery/recycling equipment?

a. recovery equipment used with HFC refrigerant must not be used with other
refrigerants

b. recovery equipment used with CFC refrigerants must not be used with HCFC
refrigerants

c. recovery equipment must be overhauled and recertified every 5 years after its
purchase date

d. none of the above statements are true

24. What color are United States Government owned bulk storage cylinders used for shipping new or
virgin refrigerants?

a. red, white and blue

b. olive drab green

c. orange

d. the same color as all other refrigerant cylinders

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25. As you already know when filling a recovery or storage cylinder or vessel it should never be filled
over 80% full under normal conditions. Which of the following methods listed is NOT a proper
method to determine that a cylinder is over filled during a recovery process?

a. using an automatic electronic flow control that measures refrigerant weight

b. using an automatic liquid level sensor or float device

c. using a scale to manually measure the cylinder weight during the filling process

d. using a wrench to tap the side of the cylinder to detect the liquid level as you fill the
cylinder, stopping the filling process when the sound change is 6” below the shoulder
of the cylinder vessel

100
 Sample Certification Test Questions Type III

1. Which of the following statements are true concerning Type III Systems?

a. Type III systems include industrial process systems.

b. Type III systems are classified as low-pressure systems.

c. Type III systems are classified as high-pressure systems.

d. answers a and b are correct

2. What is the major service problem associated with low-pressure centrifugal systems?

a. air and moisture leaking into the system.

b. refrigerant leaking out of the system.

c. rupture of the diaphragm burst disk.

d. oil contamination

3. What will the high pressure cut-out be set for on a low pressure chiller?

a. 4 to 6 psig

b. 8 to 10 psig

c. 10 to 15 psig

d. 150 to 180 psig

4. Where would the lowest point be in a centrifugal air conditioner appliance that refrigerant could
settle?

a. the evaporator charging valve

b. the condenser service valve

c. the compressor cooler jacket

d. the purge unit exhaust port

101
5. What is the designed burst pressure for a rupture disk on a centrifugal chiller?

a. 5 psig b. 10 psig c. 15 psig d. 20 psig

6. Where is the rupture disk located on a centrifugal chiller

a. at the highest point in the system

b. at the lowest point in the system

c. to the chiller’s evaporator

d. the lower point of the condenser

7. The factory installed purge unit found on a centrifugal air conditioning system is designed to remove
non-condensable gases such as air and nitrogen from the system. Where does the recycled refrigerant go
after it leaves the purge unit?

a. The evaporator

b. The condenser

c. The compressor intercooler

d. The recovery service vessel

8. What purpose does a hydrostatic tube tester serve?

a. To test for water flow through the tube bundles of fugal air conditioner.

b. To test the quality of the water that flows through the tube bundles of a centrifugal air
conditioner.

c. To test for leaks.

d. There is no such item.

102
9. Why would a technician run controlled hot water through a chiller tubes?

a. To carefully raise the system refrigerant pressures to perform a leak test.

b. To wash or flush out oil or scale build up inside the tubing bundles.

c. To carefully raise system pressures to test thee high-pressure safety motor control.

d. To carefully raise the system temperatures to test the high temperature cut out control.

10. EPA regulations require when a leak exceeds 35% of the systems charge on industrial processing
refrigeration equipment in one year, it must be repaired. What is the requirement for low-pressure
appliances charged with more than 50 pounds of refrigerant?

a. 15% b. 20% c. 25% d. 30%

11. Low-pressure systems are required to have a rupture disk set to burst at 15 PSI. What should the high-
pressure cut out be set for on the recovery/recycle unit?

a. 5 psig b. 10 psig c. 12.5 psig d. 15 psig

12. What is done to prevent water in the tubing bundles from freezing when recovering refrigerant from a
centrifugal chiller?

a. Run the systems water pumps.

b. Run the system impellers.

c. Wrap the system with heating blankets.

d. Do not recover refrigerant in a liquid state.

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13. Why is it a good idea to recharge refrigerant into a centrifugal refrigeration system as a vapor rather
than a liquid when you begin the charging process with the system in a deep vacuum?

a. It isn’t, it will take three times longer to charge the system.

b. It will prevent liquid hammer on the tubing bundles.

c. It will prevent the pressure form dropping inside the recovery storage cylinder or
vessel.

d. It will prevent the water from freezing inside the tubing bundles.

14. When changing out a minor component such as a high side float valve that meters refrigerant to the
evaporator son some types of centrifugal air conditioners, which of the following procedures would be the
correct way to accomplish this task?

a. Pressurize the system with controlled hot water to atmospheric pressure before opening
it.

b. Pressurize the system with dry air to atmospheric pressure before opening.

c. Evacuate the system down to atmospheric pressure before opening it.

d. Recover all of the refrigerant in the system and pull it down to not less than 28” Hg.

15. The 15 November 1993 date established by the EPA for recovery type equipment states that before
that date recovery equipment was required to pull 25 “ Hg vacuum before major repairs could be made on
centrifugal air conditioners. What is the requirement for equipment manufactured after 15 November 1993?

a. 25” Hg vacuum c. 25 abs mm

b. 27” Hg vacuum d. 29” Hg vacuum

104
16. Where does the purge unit on a centrifugal chiller draw refrigerant from to separate the non-
condensable gases from the refrigerant?

a. From the top of the evaporator

b. From the top of the condenser

c. From the oil separator

d. From the high side float chamber

17. Refrigerants 12, 22 and 502 are all code grouped A1. What code group has ASHRAE standard 34-
grouped R-123?

a. A2 b. A3 c. B1 d. B2

18. During the recovery of refrigerant on a centrifugal air conditioner it is recommended that the oil heaters
be energized to vaporize any refrigerant trapped in the oil. What is the recommended temperature that the
oil should be heated to, to release the refrigerant?

a. 90 degrees F c. 130 degrees F

b. 100 degrees F d. 150 degrees F

19. During an evacuation procedure the service technician can run into the problem of moisture vapor
freezing, how can this problem be overcome?

a. Pressurizing the system with dry nitrogen to raise the pressure above freezing and re-
evacuating the system.

b. Pressurize the system with dry nitrogen and permit the nitrogen to absorb the moisture,
as nitrogen is an excellent desiccant.

c. Add heat to the outside of the appliance using heat pads, or lamps, controlled hot water
if it known that the leak is not from one of the two sets of tubing bundles in the system.

d. All of the above are correct procedures to help remove moisture trapped inside a system
whether frozen or not.

105
20. When pressurizing a system that was charged with R-11, a CFC type refrigerant, which of the following
is the only EPA and safety approved method?

a. Using an inert gas.

b. Injecting hot water into the system chiller tubes.

c. Pressurize with an approved HCFC refrigerant.

d. Injecting superheated dry hot steam under controlled conditions.

21. Before connecting a cylinder of dry nitrogen to a system for any reason which of the following is a
must for safety reasons?

a. Always wear protective clothing.

b. Inspect your butyl-lined gloves for leaks before putting them on.

c. Install a pressure regulator designed for nitrogen cylinders.

d. Read the toxicity-warning label and treatment instructions in case of an accident.

22. Over a prolonged period of time (years) breathing refrigerant vapors, refrigerant mists will have what
effect on the service technician’s health?

a. Heart irregularities.

b. Unconsciousness or death

c. Brain damage and lung disorders

d. None, A1 and B1 refrigerants are non-toxic.

106
23. When large volumes of nitrogen are required what is the proper method of regulating it?

a. Install more cylinders of nitrogen

b. Install extra regulators in a series manifold

c. Install extra regulators in a parallel manifold

d. Adjust the regulator to a higher pressure to increase flow

24. Besides using a pressure regulator what other device should be installed in the line when dry nitrogen
to pressurize, purge or blow out a system?

a. A pressure relief valve.

b. A high-pressure safety shut-off control.

c. None, pressure regulators have a built-in device that automatically shuts down the
valve if design pressures are exceeded.

d. None, all refrigeration systems are required by law to have some sort of pressure relief
device installed in them somewhere to prevent explosions.

25. Which of the following statements are true concerning used refrigerant oils?

a. Used refrigerant oils are not considered contaminants unless mixed with other oils.

b. Used refrigerant oils that contain acids must be processed separately from other
refrigerant oils.

c. Used refrigerant oils must not be used for heating oil unless certified to be refrigerant
free.

d. The answers a, b and c are all true and correct statements and conform to EPA
regulations.

107
 Answers
For Pretest Sample Questions
DOD EPA Universal Technician Certification
Core Type I Type II Type III
1. b d b b
2. c b d a
3. d a b b
4. a d b a
5. d d a c
6. b b b c
7. b a a a
8. c c b c
9. b d a a
10. b a b a
11. c b c b
12. d d b a
13. c a a d
14. d c c a
15. d b a c
16. a d b b
17. d d a c
18. c d d c
19. a a d d
20. b d b b
21. d c b c
22. d a d c
23. b d a c
24. c c c a
25. d c d c

108
 Appendix (C)
Notes/Comments

109
Notes/Comments

110